WÄRTSILÄ 46DF User manual

Wärtsilä 46DF
PRODUCT GUIDE

© Copyright by WÄRTSILÄ FINLAND Oy
COPYRIGHT © 2019 by WÄRTSILÄ FINLAND Oy
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Introduction
This Product Guide provides data and system proposals for the early design
phase of marine engine installations. For contracted projects specific
instructions for planning the installation are always delivered. Any data and
information herein is subject to revision without notice. This 01/2019 issue
replaces all previous issues of the Wärtsilä 46DF Project Guides.
UpdatesPublishedIssue
Many updates/changes to the whole Product Guide13.05.20191/2019
New front- and backcovers for pdf version. Technical data updated. Other
minor updates.
XX.11.20163/2016
Small update to technical data04.11.20162/2016
Technical data updated09.09.20161/2016
First version of W46DF product guide03.10.20141/2014
Wärtsilä, Marine Solutions
Vaasa, May 2019
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IntroductionWärtsilä 46DF Product Guide

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Table of contents
1-11. Main Data and Outputs ............................................................................................................................
1-11.1 Maximum continuous output ...............................................................................................................
1-21.2 Output limitations in gas mode ............................................................................................................
1-51.3 Reference conditions ...........................................................................................................................
1-51.4 Operation in inclined position ..............................................................................................................
1-61.5 Dimensions and weights ......................................................................................................................
2-12. Operating Ranges ....................................................................................................................................
2-12.1 Engine operating range ........................................................................................................................
2-22.2 Loading capacity ..................................................................................................................................
2-62.3 Operation at low load and idling ..........................................................................................................
2-82.4 Low air temperature ............................................................................................................................
3-13. Technical Data ..........................................................................................................................................
3-13.1 Introduction ..........................................................................................................................................
3-13.2 Wärtsilä 6L46DF ...................................................................................................................................
3-53.3 Wärtsilä 7L46DF ...................................................................................................................................
3-93.4 Wärtsilä 8L46DF ...................................................................................................................................
3-133.5 Wärtsilä 9L46DF ...................................................................................................................................
3-173.6 Wärtsilä 12V46DF .................................................................................................................................
3-213.7 Wärtsilä 14V46DF .................................................................................................................................
3-253.8 Wärtsilä 16V46DF .................................................................................................................................
4-14. Description of the Engine ........................................................................................................................
4-14.1 Definitions .............................................................................................................................................
4-14.2 Main components and systems ...........................................................................................................
4-64.3 Cross section of the engine ..................................................................................................................
4-84.4 Overhaul intervals and expected life times ..........................................................................................
4-84.5 Engine storage .....................................................................................................................................
5-15. Piping Design, Treatment and Installation .............................................................................................
5-15.1 Pipe dimensions ...................................................................................................................................
5-25.2 Trace heating ........................................................................................................................................
5-25.3 Pressure class ......................................................................................................................................
5-35.4 Pipe class .............................................................................................................................................
5-45.5 Insulation ..............................................................................................................................................
5-45.6 Local gauges ........................................................................................................................................
5-45.7 Cleaning procedures ............................................................................................................................
5-65.8 Flexible pipe connections .....................................................................................................................
5-85.9 Clamping of pipes ................................................................................................................................
6-16. Fuel System ..............................................................................................................................................
6-16.1 Acceptable fuel characteristics ............................................................................................................
6-106.2 Operating principles .............................................................................................................................
6-116.3 Fuel gas system ...................................................................................................................................
6-236.4 Fuel oil system ......................................................................................................................................
7-17. Lubricating Oil System ............................................................................................................................
7-17.1 Lubricating oil requirements .................................................................................................................
7-37.2 Internal lubricating oil system ...............................................................................................................
7-77.3 External lubricating oil system .............................................................................................................
7-197.4 Crankcase ventilation system .............................................................................................................
7-217.5 Flushing instructions ............................................................................................................................
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Table of contentsWärtsilä 46DF Product Guide

8-18. Compressed Air System ..........................................................................................................................
8-18.1 Instrument air quality ............................................................................................................................
8-18.2 Internal compressed air system ...........................................................................................................
8-58.3 External compressed air system ..........................................................................................................
9-19. Cooling Water System .............................................................................................................................
9-19.1 Water quality ........................................................................................................................................
9-29.2 Internal cooling water system ..............................................................................................................
9-79.3 External cooling water system .............................................................................................................
10-110. Combustion Air System .........................................................................................................................
10-110.1 Engine room ventilation ......................................................................................................................
10-210.2 Combustion air system design ...........................................................................................................
11-111. Exhaust Gas System ..............................................................................................................................
11-111.1 Internal exhaust gas system ...............................................................................................................
11-411.2 Exhaust gas outlet ..............................................................................................................................
11-511.3 External exhaust gas system .............................................................................................................
12-112. Turbocharger Cleaning ..........................................................................................................................
12-212.1 Turbocharger cleaning system ...........................................................................................................
13-113. Exhaust Emissions .................................................................................................................................
13-113.1 Dual fuel engine exhaust components ...............................................................................................
13-113.2 Marine exhaust emissions legislation .................................................................................................
13-113.3 Methods to reduce exhaust emissions ..............................................................................................
14-114. Automation System ................................................................................................................................
14-114.1 Technical data and system overview .................................................................................................
14-314.2 Functions ...........................................................................................................................................
14-714.3 Alarm and monitoring signals .............................................................................................................
14-714.4 Electrical consumers ..........................................................................................................................
14-914.5 Guideline for electrical and automation system .................................................................................
15-115. Foundation ..............................................................................................................................................
15-115.1 Steel structure design ........................................................................................................................
15-115.2 Engine mounting ................................................................................................................................
16-116. Vibration and Noise ................................................................................................................................
16-116.1 External forces and couples ...............................................................................................................
16-316.2 Torque variations ................................................................................................................................
16-316.3 Mass moments of inertia ....................................................................................................................
16-416.4 Structure borne noise .........................................................................................................................
16-516.5 Air borne noise ...................................................................................................................................
16-616.6 Exhaust noise .....................................................................................................................................
17-117. Power Transmission ...............................................................................................................................
17-117.1 Flexible coupling ................................................................................................................................
17-117.2 Clutch .................................................................................................................................................
17-117.3 Shaft locking device ...........................................................................................................................
17-217.4 Input data for torsional vibration calculations ....................................................................................
18-118. Engine Room Layout ..............................................................................................................................
18-118.1 Crankshaft distances ..........................................................................................................................
18-418.2 Space requirements for maintenance ................................................................................................
18-718.3 Transportation and storage of spare parts and tools .........................................................................
18-718.4 Required deck area for service work ..................................................................................................
vi DBAD209883
Wärtsilä 46DF Product GuideTable of contents

19-119. Transport Dimensions and Weights .....................................................................................................
19-119.1 Lifting of engines ................................................................................................................................
19-219.2 Engine components ...........................................................................................................................
20-120. Product Guide Attachments ..................................................................................................................
21-121. ANNEX .....................................................................................................................................................
21-121.1 Unit conversion tables ........................................................................................................................
21-221.2 Collection of drawing symbols used in drawings ...............................................................................
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1. Main Data and Outputs
The Wärtsilä 46DF is a 4-stroke, non-reversible, turbocharged and inter-cooled dual fuel engine
with direct injection of liquid fuel and indirect injection of gas fuel. The engine can be operated
in gas mode or in diesel mode.
460 mmCylinder bore
580 mmStroke
96.4 l/cylPiston displacement
2 inlet valves and 2 exhaust valvesNumber of valves
6, 7, 8 and 9 in-line; 12, 14 and 16 in V-
form
Cylinder configuration
clockwise, counter-clockwise on requestDirection of rotation
600 rpmSpeed
11.6 m/sMean piston speed
1.1 Maximum continuous output
Table 1-1 Maximum continuous output
IMO Tier 2Cylinder configuration
bhpkW
93406870W 6L46DF
109008015W 7L46DF
124509160W 8L46DF
1401010305W 9L46DF
1868013740W 12V46DF
2179016030W 14V46DF
2491018320W 16V46DF
The mean effective pressure Pecan be calculated using the following formula:
where:
mean effective pressure [bar]Pe=
output per cylinder [kW]P =
engine speed [r/min]n =
cylinder diameter [mm]D =
length of piston stroke [mm]L =
operating cycle (4)c =
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1. Main Data and OutputsWärtsilä 46DF Product Guide

1.2 Output limitations in gas mode
1.2.1 Output limitations due to methane number
Fig 1-1 Output limitations due to methane number
Calculation Formulas for different compression ratios
if MN ≥ 80 and tbax ≤ 45 → KKNOCK = 1CR 12.7:1
if MN < 80 and/or tbax > 45 → KKNOCK = 1 -
0.017*(80 - MN) - (1 - (1 + 0.01*(45 - tbax)))
NOTE
In case of MN <80 and MN >70 derating factor could be 1%/1MN with a
penalization of efficiency.
1-2 DBAD209883
Wärtsilä 46DF Product Guide1. Main Data and Outputs

NOTE
1) Gas fuel methane number refers to the gas quality at the engine inlet. This may
differ from the average gas quality in LNG tank.
2) Compensating a low methane number gas by lowering the charge air receiver
temperature below 45 °C is not allowed.
3) Compensating a higher charge air receiver temperature than 45 °C by a high
methane number gas is not allowed.
4) The dew point shall be calculated for the specific site conditions. The minimum
charge air receiver temperature shall be above the dew point, otherwise
condensation will occur in the charge air cooler.
5) The charge air receiver temperature is approximately 5 °C higher than the charge
air coolant temperature at rated load (CAC Team to be involved for LT water
temperature info).
6) Glycol usage in cooling water according to document DAAE062266.
7) Min. suction air temperature is 5 °C.
8) High suction air temperature gives a higher air temperature after compressor,
before the charge air cooler, and therefore a higher heat output from the 1-stage
of the charge air cooler, compared to low suction air temperature.
9) Temperatures given above are max. (continuous) operating temperature at site.
For suction air temperatures 40°C, please contact Product Engineering department.
10) The permissible pressure drop in the inlet pipe before the turbocharger is max.
1kPa.
11) The total sum of exhaust gas back pressure and air inlet pressure drop is not
allowed to be higher than 5 kPa.
DBAD209883 1-3
1. Main Data and OutputsWärtsilä 46DF Product Guide

1.2.2 Output limitations due to gas feed pressure and lower
heating value
Fig 1-2 Derating of output for gas feed pressure and LHV
MJ/Nm3
2830323436KGAS
kPa a5995805645525421
3383263173093030,5
NOTE
1) Values given in m3 are valid at 0°C and 101.3 kPa.
2) The values for gas feed pressure are valid at the engine inlet i.e. after the gas
regulating unit.
3) Receiver pressure requirement is dependent on humidity. Receiver pressure
level influences on the required gas feed pressure. These values are valid for the
humidity up to 30g water/kg dry air.
4) Fuel gas feed pressure is not allowed to decrease from the level given for 36
MJ/Nm3 with LHV higher than 36 MJ/Nm3.
5) Gas fuel lower heating value refers to the gas quality at the engine inlet. This
may differ from the average gas quality in LNG tank.
6) No compensation (uprating) of the engine output is allowed, neither for gas feed
pressure higher than required in the graph above nor lower heating value above
36 MJ/Nm3.
7) If the gas pressure is lower than required, a pressure booster unit can be installed
before the gas regulating unit to ensure adequate gas pressure. If pressure arise
is not possible the engine output has to be adjusted according to above.
1-4 DBAD209883
Wärtsilä 46DF Product Guide1. Main Data and Outputs

1.3 Reference conditions
The output is available within a range of ambient conditions and coolant temperatures specified
in the chapter Technical Data. The required fuel quality for maximum output is specified in the
section Fuel characteristics. For ambient conditions or fuel qualities outside the specification,
the output may have to be reduced.
The specific fuel consumption is stated in the chapter Technical Data. The statement applies
to engines operating in ambient conditions according to ISO 15550:2002 (E).
100 kPatotal barometric pressure
25 °Cair temperature
30 %relative humidity
25 °Ccharge air coolant temperature
Correction factors for the fuel oil consumption in other ambient conditions are given in standard
ISO 15550:2002 (E).
1.4 Operation in inclined position
Max. inclination angles at which the engine will operate satisfactorily.
15.0°
●Permanent athwart ship inclinations
22.5°
●Temporary athwart ship inclinations
10.0°
●Permanent fore-and-aft inclinations
DBAD209883 1-5
1. Main Data and OutputsWärtsilä 46DF Product Guide

1.5 Dimensions and weights
Fig 1-3 In-line engines (DAAR038987)
HE3HE1LE5LE5*LE4LE3LE3*LE2LE1LE1*Engine
14303255699292460-15206170895386706L46DF
14303255699292460-15206990977396357L46DF
1430344565829246018831520781010593103108L46DF
1430344565829246018831520863011413111309L46DF
Weight [ton]WE6WE5WE3WE2WE1HE6HE5HE4Engine
102330178014801940318565026056506L46DF
118330178014801940318565026056507L46DF
130398178014801940318575526056508L46DF
146398178014801940318575526056509L46DF
* Turbocharger at driving end
All dimensions in mm. The weights are dry weights of rigidly mounted engines without flywheel.
Table 1-2 Additional weights [ton]:
9L46DF8L46DF7L46DF6L46DFItem
2222Flywheel
3.43.43.43.2Flexible mounting (without limiters)
1-6 DBAD209883
Wärtsilä 46DF Product Guide1. Main Data and Outputs

Fig 1-4 V-engines (DAAR038992)
HE3HE1LE5LE5*LE4LE3LE3*LE2LE1LE1*
Engine
16203670-430460-19217600-11036
12V46DF*
16203670684-4852043-760010375-
12V46DF
16203670684-4852043-865011425-
14V46DF
16203860689-4852347-970012687-
16V46DF
Weight [ton]WE6WE5WE3WE2WE1HE6HE5HE4
Engine
18478132251820229045556503020800
12V46DF*
18478132251820229045556503020800
12V46DF
22378132251820229045556503020800
14V46DF
23585832251820229051747503110800
16V46DF
* Turbocharger at driving end
All dimensions in mm. The weights are dry weights of rigidly mounted engines without flywheel.
Table 1-3 Additional weights [ton]:
16V46DF14V46DF12V46DFItem
1.21.21.2Flywheel
10108Flexible mounting (without limiters)
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1. Main Data and OutputsWärtsilä 46DF Product Guide

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2. Operating Ranges
2.1 Engine operating range
Running below nominal speed the load must be limited according to the diagrams in this
chapter in order to maintain engine operating parameters within acceptable limits. Operation
in the shaded area is permitted only temporarily during transients. Minimum speed is indicated
in the diagram, but project specific limitations may apply.
2.1.1 Controllable pitch propellers
An automatic load control system is required to protect the engine from overload. The load
control reduces the propeller pitch automatically, when a pre-programmed load versus speed
curve (“engine limit curve”) is exceeded, overriding the combinator curve if necessary. Engine
load is determined from measured shaft power and actual engine speed. The shaft power
meter is supplied by Wärtsilä.
The propeller efficiency is highest at design pitch. It is common practice to dimension the
propeller so that the specified ship speed is attained with design pitch, nominal engine speed
and 85% output in the specified loading condition. The power demand from a possible shaft
generator or PTO must be taken into account. The 15% margin is a provision for weather
conditions and fouling of hull and propeller. An additional engine margin can be applied for
most economical operation of the engine, or to have reserve power.
The propulsion control must also include automatic limitation of the load increase rate.
Maximum loading rates can be found later in this chapter.
DBAD209883 2-1
2. Operating RangesWärtsilä 46DF Product Guide

Fig 2-1 Operating field for CP Propeller, 1145 kW/cyl, 600 rpm
Remarks: The maximum output may have to be reduced depending on gas properties and
gas pressure. The permissible output will in such case be reduced with same percentage at
all revolution speeds.
Restrictions for low load operation to be observed.
2.2 Loading capacity
Controlled load increase is essential for highly supercharged engines, because the turbocharger
needs time to accelerate before it can deliver the required amount of air. Sufficient time to
achieve even temperature distribution in engine components must also be ensured. Dual fuel
engines operating in gas mode require precise control of the air/fuel ratio, which makes
controlled load increase absolutely decisive for proper operation on gas fuel.
The loading ramp “preheated” (see figures) can be used as the default loading rate for both
diesel and gas mode. If the control system has only one load increase ramp, then the ramp
for a preheated engine must be used. The HT-water temperature in a preheated engine must
be at least 70ºC, and the lubricating oil temperature at least 40ºC.
The loading ramp “Normal operating temperature” can be taken into use when the engine has
been operating above 30% load for 6 minutes (or the cooling water temperature after cylinders
is min. 85ºC). All engines respond equally to a change in propulsion power (or total load), also
when a recently connected engine is still uploading to even load sharing with parallel engines.
A recently connected generator shall therefore not be taken into account as “available power”
until after 6 minutes, or alternatively the available power from this generator is ramped up to
100% during 10 minutes. If the control system has only one load increase ramp, then the ramp
for a preheated engine is to be used.
2-2 DBAD209883
Wärtsilä 46DF Product Guide2. Operating Ranges

Fast load changes must be avoided during transfer from diesel to gas mode.
The “emergency” loading ramp in diesel mode can be used in critical situations, e.g. when
recovering from a fault condition to regain sufficient propulsion and steering as fast as possible.
The emergency ramp can be activated manually or according to some predefined condition,
and there shall be a visible alarm indicating that emergency loading is activated.
In applications with highly cyclic load, e.g. dynamic positioning and manoeuvring, maximum
loading and unloading capacity in gas mode (see figure 2-3) can be used in operating modes
that requires fast response. Other operating modes should have slower loading rates. If the
request is to use this curve intensively a special agreement/contract with end customer is
needed.
Maximum possible loading and unloading can also be required in other special applications.
The engine control does not limit the loading rate in gas mode (it only acts on deviation from
reference speed). If the loading rate is faster than the capacity in gas mode, the engine trips
to diesel.
Electric generators must be capable of 10% overload. The maximum engine output is 110%
in diesel mode and 100% in gas mode. Trip to diesel mode takes place automatically in case
of overload. Lower than specified methane number may result in automatic transfer to diesel
when operating close to 100% output. Load taking ability is also influenced from low methane
number. Expected variations in gas fuel quality must be taken into account to ensure that gas
operation can be maintained in normal operation.
2.2.1 Mechanical propulsion, controllable pitch propeller (CPP)
For successive loading rates and max ramp in variable speed, please contact Wartsila to have
further informations.
2.2.2 Constant speed application
Fig 2-2 Successive Loading & Unloading
The loading rates in gas mode in the diagrams above are to be applied when the gas Methane
Number is ≥ 80. For MN below 80, please contact Wartsila for further information.
DBAD209883 2-3
2. Operating RangesWärtsilä 46DF Product Guide

Unloading:
In normal operation the load should not be reduced from high load to low load (much) faster
than the load is increased. Crash stop can be recognised with a large lever movement form
ahead to astern within some seconds, which overrides normal load reduction. In the
manoeuvring range, typically below 50% load, the load can be reduced without rate limitation.
Fig 2-3 Maximum Loading and Unloading capacity in gas
2.2.2.1 Maximum instant load steps
The electrical system must be designed so that tripping of breakers can be safely handled.
This requires that the engines are protected from load steps exceeding their maximum load
acceptance capability. If fast load shedding is complicated to implement or undesired, the
instant load step capacity can be increased with a fast acting signal that requests transfer to
diesel mode.
2-4 DBAD209883
Wärtsilä 46DF Product Guide2. Operating Ranges