RECOMMENDED

OPERATING CONDITIONS
Wärtsilä VASA 12V32 Diesel Genset
GENERAL DESIGN DATA
❖ Wärtsilä VASA 12V32 diesel engine is a three-phase AC generator
rigidly mounted on a common base frame.

❖ Wärtsilä VASA 12V32 is a turbocharger inter-cooled 4-stroke

diesel engine with a direct fuel injection.

Station Nominal Output 4230 kWe

Genset Nominal Output 5100 kVA (cos θ = 0.8)

Generator Voltage 11.0 kV (士 5%)

Frequency 50 Hz

Auxiliary Voltage 220 / 380 V

RPM 750
MAIN PARTS OF A DIESEL GENSET
MAIN SYSTEMS
❖ The main systems of a power plant are:

➢ Electrical System

➢ Fuel System

➢ Lubricating Oil System

➢ Compressed Air System

➢ Cooling Water System

➢ Charge Air & Exhaust Gas System

➢ Steam Heating System

SITE CONDITIONS
❖ The equipment is designed and constructed for an output of
4230 kWe at the following maximum site conditions:

Ambient Temperature 40 °C

Engine Room Air

50 °C
Temperature

Water Temperature to Charge

45 °C
Air Cooler

Exhaust Gas Back Pressure 0.03 bar

FUEL SYSTEM
Wärtsilä VASA 12V32 Diesel Genset
FUEL SYSTEM
❖ The fuel system is divided into three main different systems:

➢ LFO Treatment System

➢ HFO Treatment System

➢ Feeding and Collecting System

❖ The engine is designed to operate on HFO (residual fuel).

FUEL OIL - CIRCUIT
FUEL OIL - PARAMETERS LIMIT
❖ Maximum viscosity of HFO should be 55 cSt at 50°C.
Viscosity of liquids can be defined as a measure of resistance to
deformation at a given rate.
It corresponds to the informal concept of thickness.

❖ Here, centistokes (cSt) is an established unit used for kinematic

viscosity. The accepted SI unit is m2/sec and 1 cSt = 10.6 m2/sec.
FUEL OIL - PARAMETERS LIMIT
❖ The diesel engine is designed and developed for continuous
operation without reduction in the rated output on fuels with
the following properties:
FUEL OIL MAXIMUM LIMITS

55 cSt / 100°C
Viscosity
730 cSt / 50°C

Density 0.991 gm/ml

Density1 1.010 gm/ml

Water (before engine) 0.3 % vol.

Water (maximum) 1.0 % vol.

Conradson Carbon
22 % mass
Residue

Asphaltenes 14 % mass

Flash Point 60 °C

Pour Point (upper

30 °C
max.)
FUEL OIL - SAMPLE REPORT OF NRL LAB
HFO SEPARATOR - PURPOSE
❖ HFO (mixture of residual and distillate) must be purified in an
efficient centrifugal separator before entering the day tank.

❖ The fuel is to be heated before centrifuging.

HFO SEPARATOR - PURPOSE
❖ Make sure that correct gravity disc is used in the separator. Never
exceed the flow rate recommended for the separator for the
grade of fuel in use.

RECOMMENDED SEPARATOR FLOW RATE

Fuel In Use

Maximum
Viscosity 10 15 25 35 45 55
(cSt / 100°C)

Approx.
Viscosity 50 90 205 350 530 730
(cSt / 500°C)

Flow Rate 60 40 30 25 20 15
HFO SEPARATOR - PURPOSE
❖ Keep the fuel temperature about 10°C above the minimum
storage temperature.

❖ An automatic viscosity controller should be installed to maintain

the viscosity of the fuel before the fuel enters the engine’s fuel
system.
LUBE OIL
Wärtsilä VASA 12V32 Diesel Genset
LUBE OIL - PRINCIPLE FUNCTIONS
❖ The lubrication system of an engine provides a supply of
lubricating oil to the various moving parts of the engine.

❖ Its main function is to enable the formation of a film of oil

between moving parts which reduces friction and wear.

❖ The lubricating oil is also used as a cleaner and in some engines

as a coolant.

❖ For Wärtsilä VASA 12V32 Diesel Engine, Shell Argina S4 40 lube

oil is used.
LUBE OIL - PRINCIPLE FUNCTIONS
❖ The principle functions of the engine lubricant are as follows:
➢ Reduces friction.

➢ Minimizes wear of engine components including corrosive

wear.
Corrosion def. - The oxidation of refined metal such that if
forms its oxide, hydro-oxide or sulphide in reaction with an
oxidant (H, O or OH).

➢ Removes heat (acts as a coolant).

➢ Protects engine components against harmful deposits.

➢ Controls any deposit formation in the lubrication system

(circulation lines, check valves, sight glasses, etc.).
LUBE OIL - CIRCUIT
LUBE OIL - CIRCUIT
❖ The shaft-driven mechanical lube oil pump, pumps the
lubricating oil towards the lube oil heat exchanger.

❖ Then it flows from the outlet line of the lube oil cooler to lube oil
filter.

❖ From the lube oil filter, it enters the engine’s lube oil system
which lubricates the following parts:

➢ Gudgeon Pin
➢ Camshaft Bearing
➢ Rocker Arm Bearing
LUBE OIL - PARAMETERS LIMIT
CRITICAL PARAMETERS
❖ The following parameters must be taken into consideration:

➢ Viscosity
➢ Alkalinity (BN Retention)
➢ Engine Cleanliness Control (Piston under the crown, in
particular)
➢ Insolubles Control
➢ Wear Protection (Oval-shaped wear of liner, in particular)
➢ Oxidation Stability
➢ Nitration
LUBE OIL - PARAMETERS LIMIT
❖ Viscosity
Shouldn’t decrease by more than 20% below the guidance value
and not rise by 25% above the guidance value at 100°C.

❖ Flash Point
Shouldn’t fall by more than 50°C below the guidance value.
Flash Point def. by ScienceDirect - The flash point is the lowest
temperature at which a volatile substance evaporates to form
an ignitable mixture with air in the presence of an igneous
source and continues to burn after the triggering source is
removed.
LUBE OIL - PARAMETERS LIMIT
❖ Water
Shouldn’t increase by more than 0.3%. Otherwise, we have to do
centrifuging or an oil change.

❖ Base Number (BN)

Minimum allowable value of a BN of a used oil is 50% of the
nominal value of a new oil i.e. 20, is the minimum permissible
value.

❖ Insolubles
An insoluble value above 1.5% calls for attention and above 2% is
not accepted.
LUBE OIL - PARAMETERS LIMIT
❖ Note: Compensate lube oil consumption by adding 10% new oil
at a time.
LUBE OIL - SAMPLE REPORT OF SHELL
LUBE OIL - SAMPLE REPORT OF NRL LAB
LUBE OIL - CHANGE INTERVALS
Change Interval
Sr. No. Auxiliary / Engine Part Oil Brand
(Rhrs)

Shell Argina
1. Engine Sump 8k or as per oil report
S4 40

2. Turning Gear Motor 6k 320 Grade

3. Governor 2k Shell Turbo T46

Mineral Oil: 0.5k Shell Turbo T46

4. Turbocharger (ABB BBC..VTR) Special Mineral Oil: 1.5k -
Synthetic Oil: 2.5k -

5. Alternator (ABB) 8k or as per oil report Shell Turbo T46

Mineral Oil: 1.5k -

6. HFO Separator
Synthetic Oil: 4k VG150

7. LO Separator 2k (D/220, D/320) D/320

8. Air Compressor 1k Shell Turbo T46

LUBE OIL - FILTERS
❖ Lube oil filters can be found on the lubricating oil pump’s
suction and discharge sides.

❖ The lube oil filter is the final barrier that prevents particulate
matter (solid impurities) from reaching the engine bearings.

❖ It is a fact that failure to maintain an adequate flow of clean

lubricating oil will lead to bearing failure and possibility of
severely damaging the crankshaft.
LO SEPARATOR - WORKING PRINCIPLE
❖ It is a purifier that separates two liquids based on their
differences in density with the use of a gravity disc to separate
solid & water and sealing water as an operator with two-holed
disc; one for water and other for lubricating oil.

❖ The time required for one (01) circulation of the total bulk oil is
about 1.5 - 6 minutes with the trend towards smaller oil volumes
and therefore shorter circulation times.

❖ For a 4-stroke diesel engine, the complete lubricating oil volume

should pass through the centrifuge system 4 - 6 times per day.

❖ Note: A compulsory service of LO separator must be carried out

during operation when the system has completed 200 Rhrs.
LO SEPARATOR - TERMINOLOGIES
❖ It is an LOPX-707 separator that follows ALCAP principle.

❖ Displacement Water
Water added to the separator bowl to displace the oil and and
ensure no oil loss at sludge discharge.

❖ Conditioning Water
Water added to the separator bowl to soften the sludge.
LO SEPARATOR - SEPARATION SEQUENCE
LO SEPARATOR - ALARMS AND FAULT IDENTIFICATION
❖ High Oil Pressure (PS41)
❖ Low Oil Pressure / Low Flow (PS42)
❖ Sludge Discharge Failure ( )
❖ Continued.. etc.
COOLING WATER SYSTEM
Wärtsilä VASA 12V32 Diesel Genset
COOLING WATER - PURPOSE
❖ To avoid unnecessary corrosion damages and operating
problems in the cooling water system of the engine.

COOLING WATER - PARAMETERS LIMITS

RAW WATER QUALITY - PARAMETERS LIMIT

Property Limit for WWCU* Use Unit

pH 6.5 - 8.5 -

Hardness max. 10 °dH (deutsche Harte)

Chlorides (Cl) max. 40 mg / litre

Sulphates (SO4) max. 100 mg / litre

COOLING WATER - SAMPLE REPORT OF
NRL LABORATORY
COOLING WATER - ANALYSIS
❖ Note: Properties that shall be checked weekly.

COOLING WATER - WEEKLY CONTROLLED ANALYSIS

WWCU* Recommended
Property Level
Unit

pH 8.0 - 11.0 -

Hardness max. 10 °dH (deutsche Harte)

Chlorides (Cl) max. 40 mg / litre

Sulphates (SO4) max. 100 mg / litre

Nitrites (NO2) 470 - 2500 ppm

COOLING WATER - ANALYSIS
❖ Note: Properties that shall be checked bi-annually.

COOLING WATER - YEARLY CONTROLLED ANALYSIS

Element Recommended Level Unit

Iron (Fe) <1 mg / litre

Calcium (Ca)
The total hardness of
°dH
(Ca+Mg) < 10
Magnesium (Mg)

Copper (Cu) <1 mg / litre

Chlorides (Cl) < 200 mg / litre

Sulphates (SO4) < 400 mg / litre

Nitrate (NO3) ≤ 50 - 200 mg / litre

COOLING WATER - ANALYSIS
❖ Caution: It is strongly recommended to change the cooling
water immediately of the Chloride (Cl) content of the water
exceeds 200 mg/litre or if the Sulphate (SO4) contents exceeds
400 mg/litre.
COOLING WATER - ADDITIVES & DOSAGE
ELECTRICAL &
CONTROL SYSTEMS
Wärtsilä VASA 12V32 Diesel Genset
ELECTRICAL & CONTROL - PURPOSE
❖ Electrical Generators are crucial machines that convert
mechanical energy into electrical energy through the principle
of electromagnetic induction.

❖ They play a vital role in various industries and applications,

providing a reliable source of power.

❖ The electrical & control systems of generators are designed to

ensure efficient operation, safe functioning and seamless
integration into power networks.
ELECTRICAL & CONTROL - PURPOSE
❖ The primary purpose of the Electrical & Control Systems in
generators is to manage and regulate the generation,
distribution and utilization of electrical power.

❖ Key objectives include:

➢ Voltage Regulation
➢ Frequency Control
➢ Synchronization Control
➢ Load Balancing
➢ Remote Monitoring and Control (DCS / SCADA)
ELECTRICAL & CONTROL - ESM
❖ The Engine Safety Module (ESM) is a crucial safety feature that
protects the engine, ensures operator’s safety and prevents
environmental hazards.

❖ By monitoring engine parameters and detecting abnormal

operating conditions, this ESM initiates a safe and controlled
shutdown of the engine safeguarding both the equipment and
the personnel involved.

❖ The following 4 major DG Set protections are covered under

ESM.
➢ Engine Over-speed (RPM) Protection
➢ Turbocharger Speed
➢ Lube Oil Pressure - Low
➢ HT Water Temperature - High
ELECTRICAL & CONTROL - VAMP 210
❖ Power Monitoring Unit (DG-I)
from Abdullah
ELECTRICAL & CONTROL - VAMP 260
❖ Generator Protection Relay (DG-I)
from Abdullah
ELECTRICAL & CONTROL - VAMP 265
❖ Generator Differential Protection (DG-I)
from Abdullah
ELECTRICAL & CONTROL - LIMITS
❖ Alarm and Shutdown limits of some additional parameters.
ELECTRICAL & CONTROL - LIMITS
❖ Alarm and Shutdown limits of some additional parameters.
STARTING SOPs Open
Wärtsilä VASA 12V32 Diesel Genset
STOPPING SOPs Open
Wärtsilä VASA 12V32 Diesel Genset
MAINTENANCE SCHEDULE Open
Wärtsilä VASA 12V32 Diesel Genset