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WÄRTSILÄ RT-FLEX96C RT-FLEX96C AND WÄRTSILÄ RT RTA96C A96C TECHNOLOGY REVIEW

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WÄRTSILÄRT-FLEX96CAND WÄRTSILÄRTA96C TECHNOLOGYREVIEW Thisisabriefguidetothetechnicalfeaturesandbenefitsof WärtsiläRT-flex96CandRTA96Clow-speedmarinedieselengines.

INTRODUCTION............................................................ ............................................................ 4 DEVELOPMENTBACKGROUND DEVELOPMENTBACKGRO UND..................................... ..................................... 6 RT-FLEX:C RT -FLEX:CONCEPTAND ONCEPTANDBENEFITS BENEFITS............................... ............................... 8 RT-FLEXCOMMO RT -FLEXCOMMON-RAILSYSTEMAPPL N-RAILSYSTEMAPPLIED................... IED................... 8 RT-FLEX:R RT -FLEX:REALIN-SERVICEFUELECONOM EALIN-SERVICEFUELECONOMY............... Y............... 10 RT-FLEX:C RT -FLEX:CLEANERINTHEENV LEANERINTHEENVIRONMENT.................. IRONMENT.................. 10 RTA96C: THETRADITIONALCAMSHAFT THETRADITIONAL CAMSHAFTARRANGEMENT............ ARRANGEMENT............ 11 ENGINESTRUCTURE.................................................. ENGINESTRUCTURE .................................................. 13 RUNNINGGEAR......................................................... 14 COMBUSTIONCHAMBER COMBUSTIONCHAM BER............................................ ............................................ 17 PISTON-RUNNINGBEHAVIOUR PISTON-RUNNINGBEHAV IOUR.................................... .................................... 17 TURBOCHARGINGANDSCAVENG TURBOCHARGING ANDSCAVENGEAIRSYSTEM EAIRSYSTEM.......... .......... 18 INSTALLATION INSTALL ATIONARRANGEMENTS ARRANGEMENTS................................. ................................. 19 WASTEHEATRECOVERY: FUELSAVINGWITHREDUCEDEMISSIONS FUELSAVING WITHREDUCEDEMISSIONS................... ................... 20











12-cylinderWärtsiläRT-flex96Cenginegiving68,640kW(93,360bhp).

INTRODUCTION TheWärtsiläRT-flex96CandRTA96Clow

FullcompliancewiththeNO Xemission

thedemandforevenhigherpoweroutputsto

speedmarinedieselengines,withapower

regulationofAnnexeVIoftheMARPOL

propelthethencominggenerationoflarger

rangeof24,000to80,080kW,aretailor

1973/78convention.

andfastercontainerships.Itfollowedina

•

madefortheeconomic,reliab madefortheecon omic,reliablepropulsionof lepropulsionof

longlineofRTA-seriesengine longlineofRT A-seriesengineswitheach switheach

large,fastcontainerliners.Theyofferclear,

TheWärtsiläRT-flex96Chasadditional

generationbringinghigherpoweroutputsto

substantialbenefits:

benefits:

caterforeverincreasingshipsizes.

•

Highpoweroutputsatoptimumshaft

•

Smokelessoperationatallrunningspeeds

speeds

•

Betterfueleconomyinthepart-loadrange

TheRTA96Cwasreadilyacceptedinthe market.Itsreliabilitywasacknowledgedvery











Output k

Output bhp

80 000 60 000

80 000

RT-flex96C RTA96C

100 000 RT-flex82T RTA82T

60 000 50 000

RT-flex82C RTA82C

40 000

RTA72U-B 40 000

RT-flex60C-B RTA62U-B

RT-flex84T-D RTA84T-D

10 000

10 000

RT-flex68-D RTA68-D

8 000

RT-flex58T-B RTA58T-B

8 000 6 000

6 000

RTA48T-B

60

70

80

90

100

RTA52U

120

140

Engine speed

PrincipalparametersofWärtsiläRT-flex96CandRTA96Cengines establishedRTA96Cengine. The14-cylinderRT-fl The14-cylinderR T-flex96Cenginese ex96Cenginesextend xtend thepowerspectrumoftheRTAseriesupto

Bore

mm

960

Stroke

mm

2500

OutputMCR,R1 OutputMCR, R1

kW/cyl

5720

bhp/cyl

7780

80,800kW(108,920bhp). 80,800kW(108,92 0bhp).Thuswithwaste Thuswithwaste heatrecoverysystemswhichcanaddupto12

Speedrange,R1-R3 Speedrange, R1-R3

rpm

102–92

percentofenginepower,RT-flex96Cengines

BMEPatR1

bar

18.6

Pmax

bar

145

canmeetthepropulsionrequirementso canmeetthepropuls ionrequirementsoflarge, flarge,

20 000

RT-flex50-B RTA50-B

20 000

integratedelectroniccontrolandthewell

30 000

4 000

rev/min











DEVELOPMENTBACKGROUND  TheRT-flexcommon TheRT -flexcommon-railtechnologyhad -railtechnologyhad

Wärtsilähasapolicyofcontinuouslyupdating

poweruptotoday’s80,080kW(108,920

itsengineprogrammeandenginedesignsto

bhp).Theincreasedpo bhp). Theincreasedpoweroutputwasmade weroutputwasmade

beenintroducedfirstintheRT-flex58T-B

adaptthemtothelatestmarketrequirements

possiblebytheverysatisfactoryservice

engine.Serviceresultswiththisengine,which

andtodeliverthebenefitsoftechnical

experiencewiththeenginesinservice.

enteredserviceinSeptember2001,were

improvements.TheWärtsiläRT-flex96Cand

Furtherimprovementsweresubsequently

excellent,clearlydemonstratingthatthenew

RTA96Cenginetypes RT A96Cenginetypesaregoodexampl aregoodexamplesof esof

achievedbytheintroductionofvariousdesign

RT-flexsystemoffers RT -flexsystemoffersdistinctiveoperational distinctiveoperational

thispolicy.

measurestoimprovepiston-runningbehaviour.

benefitswhicharenotpossiblewithcamshaft

Theseimprovementsreducewearratesof

engines.Thustheexp engines. Thustheexperiencefromthe eriencefromthe

introducedin1994,itwasbasedfullyonthe

cylinderlinersandpistonrings,extendtimes

RT-flex58T-Benginetype,theRT-flex60C

well-establishedRT well-establishe dRTA84Ctotakeadvantag A84Ctotakeadvantageof eof

betweenoverhaulsandallowreducedcylinder

enginefirstbuiltin2002,andthefull-sized

thewealthofexperienceintheoreticaldesign,

oilfeedrates.

RT-flex58Trese RT -flex58TresearchenginesinceJun archenginesinceJune1998 e1998

WhenthedesignoftheRTA96Cwas

testbedresearchandoperatingservicefrom

Amajo Am ajorst rstepf epforw orward ardwas wasach achieve ievedwh dwhen en

wereemployedinthedevelopmentofthe

theRTA84CandotherpreviousRTA-series

theRTA96CwascombinedwiththeRT-flex

engines.ThefirstRTA96Cenginesentered

electronically-controlledcommon-railtechnology

servicein1997.

forfuelinjectionandvalveactuationtocreate

testedinApril2004(eight-cylinderengine)

theRT-flex96Cengineintroducedin2003.At

andJune2004(12-cylinderengine) andJune2004 (12-cylinderengine).Th .These ese

In2000,thecylinderpoweroftheR In2000, thecylinderpoweroftheRTA96 TA96C C

RT-flex96Cengine. ThefirstRT-flex96Ceng ThefirstRT -flex96Cengineswereshop ineswereshop













WärtsiläRT-flex96C.











RT-FLEX:CONCEPTANDBENEFITS  TheWärtsiläRT TheWärts iläRT-flexsystemisthe -flexsystemistheresultofa resultofa

ofinjectorswhilecontinuingtorunonall

longprojectsincethe1980stodeveloplow

cylinders

speedmarineengineswithouttheconstraints

•

Reducedrunningcoststhroughlowerpart

imposedbymechanicaldriveoffuelinjection

loadfuelconsumptionandlongertimes

pumpsandvalveactuationpumpsbutwith

betweenoverhauls

fargreaterflexibilityinenginesettingtoreach

•

Reducedmaintenancerequirements,with

futurerequirements.The futurerequirements .Theobjectiveistodeliver objectiveistodeliver

simplersettingoftheengine. simplersettingofthee ngine.The‘as The‘as

operationalbenefitstotheshipowners.

new’runningsettingsareautomatically

TheWärtsiläRT-flex96Cisbasicallya standardWärtsilälow-speedtwo-strokemarine

maintained •

Reducedmaintenancecoststhroughprecise

dieselengine,exceptthat,insteadoftheusual

volumetricfuelinjectioncontrolleadingto

camshaftanditsgeardrive,fuelinjectionpumps,

extendabletimesbetweenoverhauls.The

exhaustvalveactuatorpumpsandreversing

common-railsystemwithitsvolumetric

servomotors,itisequippedwithacommon-rail

controlgivesexcellentbalanceinengine

systemforfuelinjection,exhaustvalveactuation

powerdevelopedbetweencylindersand

andairstarting,andfullelectroniccontrolofthese

betweencycles,withpreciseinjectiontiming

enginefunctions.

andequalisedthermalloads

Thecommon-railinjectionsystemoperates

•

withjustthesamegradesofheavyfueloilas arealreadystandardforWärtsilälow-speed

common-railhardwareincomponenttestrigs •

engines. TheRT-flexenginesofferanumberof interestingbenefitstoshipownersandoperators:

Reliabilityisgivenbylong-termtestingof Higheravailabilityowingtotheintegrated monitoringfunctions

•

Highavailabilityalsogivenbythebuilt-in redundancy,providedbytheamplecapacity

•

Smokelessoperationatallope Smokeless operationatalloperatingspeeds ratingspeeds

andduplicationinthesupplypumps,main

•

Lowersteadyrunningspeeds,intherange

deliverypipes,crank-anglesensors,electronic

of10-15percentnominalspeed, of10-15perce ntnominalspeed,obtained obtained

controlunitsandotherkeyelements.

smokelesslythroughsequentialshut-off

RailunitatthecylindertopleveloftheRT-flex96C enginewithelectroniccontrolunitsonthefrontof therailunitforgoodaccess.

RT-FLEXCOMMON-RAILSYSTEMAPPLIED  Thecommonrailforfuelinjectionisamanifold coverareseparatelycontrolledsothat,

valveactuationandstartingaircontrol.The

runningthelengthoftheengineatjustbelow

althoughtheynormallyactinunison,theycan

exhaustvalvesareoperatedinmuchthesame

thecylindercoverlevel.Thecom thecylindercoverlevel. Thecommonrailand monrailand

alsobeprogrammedtooperateseparatelyas

wayasinexistingRTAenginesbyahydraulic

otherrelatedpipeworkareneatlyarranged

necessary.

pushrodbutwiththeactuatingenergynow

beneaththetopengineplatformandreadily

ThekeyfeaturesoftheWärtsiläRT Thekeyfeaturesofthe WärtsiläRT-flex -flex

comingfromaservooilrailat200barpressure.











InsidetherailunitofanRT-flex96Cengineduringassembly.Theexhaustvalve actuator(A)ismountedontheservooilrailandtheinjectioncontrolunit(B)ison thefuelrail.Nexttothefuelrailisthesmallercontroloilrail(C)andthereturnpipe forservoandcontroloil(D).

VariousRT-flexequipme VariousRTflexequipmentonthe ntonthelowerplat lowerplatformof formofa12RT a12RT-flex96C -flex96Cengine. engine.Fromleft Fromleftto to right,theseinclude(A)thelocalenginecontrolpanel,(B)theautomaticfinefilterforservo andcontroloil,(C)thetwoelectrically-drivencontroloilpumpsand(D)thesupplyunit.











RT-FLEX: REALIN-SERVICE FUELECONOMY WhereasWärtsiläRTA-seriesengines haveexcellentfuelconsumptionin general,theRT general, theRT-flexsystemen -flexsystemenablesfurther ablesfurther improvementstobeachievedinthepart

ThenewalternativeBSFCcurveforRT-flex96CenginesgivenbyDeltaTuningcomparedwiththe ThenewalternativeBSFCcurveforRT-flex96CenginesgivenbyDeltaT uningcomparedwiththe originalBSFCcurves.AllcurvesshownareforenginescomplyingwiththeIMONOXregulation.

loadrange.Thisisbeca loadrange. Thisisbecauseofthefreedom useofthefreedom allowedbytheRT-flexsystemins allowedbytheRT -flexsysteminselecting electing optimuminjectionpressure,fuelinjection timingandexhaustvalvetimingatallengine loadsorspeeds,whileensuringefficient combustionatalltimes,evenduringdead slowrunning. Similarfreedominexhaustvalve timingallowstheRT-fl timingallowstheR T-flexsystemtokeep exsystemtokeep combustionairexcesshighbyearliervalve closingastheload/speedisreduced closingastheloa d/speedisreduced.Thi .Thisis sis notonlyadvantageousforfuelconsumption butalsolimitscomponenttemperatures, whichwouldnormallyincreaseatlowload. Lowerturbochargerefficienciesatpartload

SmokeemissionmeasurementsforRT-flex96Cenginescomparedwiththe RTA96Cengines,bothusingmarinedieseloil.

normallyresultinlowexcesscombustionair withfixedvalvetiming. Anotherimportantcontributiontofuel Anotherimportantco ntributiontofuel economyoftheRT-fl economyoftheR T-flex96Cenginesis ex96Cenginesisthe the capabilitytoadapteasilytheinjectiontiming

RT-FLEX: RT-FLEX: CLEANERINTHEENVIRONMENT CLEANERIN THEENVIRONMENT

tovariousfuelpropertieshavingapoor

Exhaustgasemissionshavebecomean

combustionbehaviour.

importantaspectofmarinedieselengine importantaspectofma rinedieselengines.Al s.Alll

RT-flexenginesneednotberestrictedby

WärtsiläRTAandRT WärtsiläRT AandRT-flexenginescom -flexenginescomplywith plywith

thecurrentstate-of-the-art.Asallsettings

theNO XemissionslimitofAnnexVIofthe

andadjustmentswithinthecombustion

MARPOL73/78conventionasstandard.

andscavengingprocessesaremade

DELTATUNING:  AFUELEFFICIENCYALTERNATIVE AFUELEFFICIENCYAL TERNATIVE 

Yettheenvironmentalbene Yetthee nvironmentalbenefitsof fitsof











12-cylinderWärtsiläRTA96Cenginegiving68,640kW.

Fuelinjectionpumpwithdoublecontrolvalves.

RTA96C: THETRADITIONALCAMSHAFT THETRAD ITIONALCAMSHAFTARRANGEMENT ARRANGEMENT TheWärtsiläRT TheWärtsilä RTA96Cretainsthetradition A96Cretainsthetraditional, al,

stableatverylowloadsand stableatverylow loadsandrotationalsh rotationalshaft aft

mechanicalcamshaftarrangementforfuel

speedsdownto15per speedsdo wnto15percentoftherate centoftherated d

injectionpumpsandvalvedrives.

speedareachieved.Valvecontrolalsohas

Thecamshaft-drivenfuelinjectionpumps areofthewell-provendouble-valvecontrolled

benefitsoflessdeteriorationoftimingover theyearsowingtolesswearandtofreedom

































Loweringthecrankshaftintothebedplate.











Pist Pi ston on,,p pis isto ton nro rod da and ndg gla land ndb box ox. .

Cros Cr ossh shea ead dpi pins nsw wit ith hgu guid ide esh shoe oes. s.











Bore-cooledpistonsfromtheunderside.













COMBUSTIONCHAMBER  Thecombustionchamberintoday’ Thecombustioncha mberintoday’sdiesel sdiesel enginehasamajorinfluenceonthee enginehasama jorinfluenceontheengine’s ngine’s

coversfromhotcorrosiveorerosiveattack.

•

Thepistonscompriseaforgedsteelcrown

reliability.Carefulattentionisnee reliability. Carefulattentionisneededforthe dedforthe

withashortskirt.Combinedjet-shakeroil

layoutofthefuelinjectionspraypatternto

coolingofthepistoncrownprovidesoptimum

sufficienthardphase •

AtWärtsilä,optimisationoffuelinje AtWärtsilä, optimisationoffuelinjection ction iscarriedoutfirstbytheuseofmodern calculationtools,suchasCFD(computerised

temperaturesonthepistoncrownwithafairly

lengthoftherunningsurface •

cylinderlinerwithoutanyinsulationor

crownsurface.Nocoatingsarenece crownsurface. Nocoatingsarenecessary. ssary.

insulatingtubes

Thecylinderlinerisalsoborecooled.Its surfacetemperaturesareoptimisedforgood

arethenconfirmedonthefirsttestengines.

piston-runningbehaviour.

•

itscomparativelyshortstroke/boreratio,and carewasneededwiththelargequantityoffuel

•

Anti-PolishingRing(APR)withdouble Anti-PolishingRing(AP R)withdouble actingscraperedgesatthetopofthe

PISTON-RUNNING BEHAVIOUR

injectedtoavoidimpingementoncomponent

Todaythetimebetween odaythetimebetweenoverhaul(TBO)of overhaul(TBO)of

surfaces.

low-speedmarinedieselenginesislargely

Thewell-provenbore-coolingprincipleis

Chromium-ceramiccoated, Chromium-ce ramiccoated,pre-profiled pre-profiled pistonringsinallpistongrooves

Themoderncalculationtoolswere rathershallowcombustionchamberowingto

Optimisedsurfacetemperaturesonthe

eventemperaturedistributionrightacrossthe

fluiddynamics)analysis. fluiddynamics)ana lysis.Thecalculatedresu Thecalculatedresults lts

invaluablewiththeRTA96Cwhichhasa

Carefulturningofthelinerrunningsurface andplateauhoningofthelineroverthefull

achievemoderatesurfacetemperaturesandto coolingperformance.Itgivesverymoderate avoidcarbondeposits.

Lineroftheappropriatematerial,with

determinedbythepiston-runningbehaviour

cylinderliner •

Increasedthicknessofchromiumlayerin thepiston-ringgrooves

•

Twobronzerubbingban wobronzerubbingbandsonshortpiston dsonshortpiston skirt

•

Load-dependentaccumulatorlubricating systemforcylinderlubrication.











TheAnti-PolishingRing(APR)forRTA96CandRT-flex96Cengineshasarevised TheAnti-PolishingRing(APR)forRTA96CandRT -flex96Cengineshasarevised geometrywithtwoedgestocleanthepistontoplandduringboththeupanddown strokesofthepiston.











Thrust Side stopper

Air cooler Location of











Turbogeneratorsetforthehigh-efficiencywasteheatrecoveryplant,with theexhaust-gaspowerturbineontheleft,thegeneratorontheright,and thesteamturbinetotherightofcentre.























SHIPREFERENCES 

Wärtsilä12RTA96C











MAINTECHNICALDAT MAINTECHNI CALDATAA  DEFINITIONS: •

•

Dimensionsandweights: Dimensionsand weights:Alldimensionsare Alldimensionsareinmillimetresanda inmillimetresandare re notbinding.Theengineweightisne notbinding. Theengineweightisnetinmetrictonnes(t), tinmetrictonnes(t),withoutoil withoutoil

MAINDATART-flex96CANDRTA96C

andwater,andisnotbinding.

Cylinderbore

R1,R2,R3,R4=powe R1,R2, R3,R4=power/speedratingsatthefourco r/speedratingsatthefourcornersofthe rnersofthe enginelayoutfield(seediagram).

•

R1=engineMaximumContinuousRating(MCR).

•

Contract-MCR(CMCR)=selectedratingpointforparticular

Pistonstroke Speed MeaneffectivepressureatR1 Pistonspeed Fuelspecification:

960mm 2500mm 92-102rpm 18.6bar 8.5m/s











Wärtsilä Switzerland Ltd P.O. Box 414, CH-8401 Winterthur, Switzerland Tel. +41 52 262 49 22 l Fax +41 52 262 07 18

l

Wärtsilä enhances the business of its customers by providing them with complete lifecycle power solutions. When creating better and environmentally compatible technologies, Wärtsilä focuses on the marine and energy markets with products and solutions as well as services. Through innovative products

/ e c fi f O s ´ k c o B / 7 0 0 2 . 1 0

Wartsila o e Rt Flex96c Rta96c Tr

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