”FAST” NOZZLE

SACLESS FUEL INJECTOR FOR

WÄRTSILÄ 2-
2-STROKE ENGINES

17. JULY 2013 ((OFFICIALLY

OFFICIALLY RELEASED
RELEASED))

1 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 FAST NOZZLE

Wärtsilä has introduced a new fuel injector technology able to

reduce emissions and fuel consumption by improving fuel
injection performance:
„FAST“
Fuel Actuated Sacless Technology

Available for new engines since end 2012, now available for
retrofit on RT-flex engines

2 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 FAST NOZZLE

FAST = Fuel Actuated Sacless Technology

• Reduced fuel operating

costs at part load operation

• Reduced maintenance cost

• Increase environmental
friendliness

3 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 FAST NOZZLE DESIGN

Original sac-hole closed by

prolonged injector needle and
adapted nozzle atomizer:

• Reduction of sac-hole
volume by ~90%

• Per cycle all fuel injected

with full injection pressure
into the cylinder leading to
improved atomization
Standard nozzle FAST nozzle

4 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 “FAST” NOZZLE: BUSINESS BENEFITS

Reduced fuel operating costs by 1%

• Fuel consumption expected to reduce by nearly
1 % at part load

Reduced maintenance costs

• Improved combustion lead to less fouling in the
exhaust gas ways and boiler, reducing
frequency of cleaning
• Less deposits in combustion chamber may
increase piston running component lifetime and
improve their behaviour

Environmental friendliness
• Reduced HC and CO emissions
• Reduced CO2 emissions at part load

5 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 EMISSIONS REDUCTION

Results from test bed measurements

(RT-flex60 & RT-flex96C)

• CO reduced by 50% in low load

and full load

• Hydrocarbon emissions
(THC=unburnt fuel) reduced by
90% at low load
-> no nozzle dripping
-> fuel consumption reduction Reduce unburnt fuel
= Fuel savings

• Smoke reduced at low load

condition – improved combustion
with less fouling

6 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 FAST NOZZLE OPERATING EXPERIENCE
Status: 30. Oct 2013

Installation No. of Max. Installed

nozzles Running
hours
8RT-flex96C 4 10200 Jan/2012

14RT-flex96C 5 5000 Dec/2012

7RT-flex60 7 9000 Dec/2011

6RT-flex50 3 5000 Nov/2012

7RT-flex82T 7 6000 Sep/2012

TOTAL 26 320.800 rhrs

7 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 FIELD TEST ON 7RT-FLEX60C

FAST nozzles after 3200..4300h field test:

• Needles clean
• No seizure marks
• Needle seat in good condition

FAST nozzles Needle after 4000h field test

8 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 FIELD TEST ON 8RT-FLEX96C

FAST nozzles after 9200 rhrs:

• Needles are clean

• Minor wear signs
• Needle seat in very good condition

12‘000 rhrs TBO is feasible

FAST nozzles Needle after 9200h operating hours

9 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 COMPONENT LIFETIME

FAST nozzles
FAST nozzles have been designed to reach higher
lifetime than today’s injection nozzles with 6’000 rhrs TBO
This is achieved by application of appropriate materials as
well as special coatings on wear surfaces
The installed FAST nozzles presently fully satisfy
expectations to reach this target.
Target TBO: 12‘000 rhrs

Combustion chamber components

Designed to reach similar combustion process as
standard reference nozzles, the heat distribution can still
change slightly. Average component temperature is on
comparable level.

10 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 INSTALLATION

The installation of the nozzle includes 2

main steps:

1. Increase the hole for the new nozzle

atomizer with larger diameter in the cover

2. Replace the nozzle front part of the fuel

injectors (installed and spare nozzles on
board)

11 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 INJECTOR PARTS REPLACEMENT

Only the front part of the Fuel Injector will

be replaced 1
• Keep main injector nozzle holder (1)
Same injector body ensure compatibility with
the injection system of either RTA or RT-flex
engine. Opening pressure to be adjusted to
FAST nozzle specific value

• Parts to be replaced
- (2) Nozzle body including valve needle
- (3) Clamping nut
- (4) Nozzle atomizer 2

- Exception: For 82 bore engines the nozzle holder need to be 3

machined to reduced length and some additional parts
required 4

12 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 CYLINDER COVER NOZZLE TIP HOLE MODIFICATION

Installation work
1. Remove cover from cylinder
2. Increase nozzle atomizer hole
- Drilling of hole
- Regrinding of hole borders on combustion
chamber side

3. Mounting of cover and new injectors

- Replace standard with FAST nozzle injector
parts. Readjust injector opening pressure
- Install injectors and put cylinder cover back in
place

Additional 82C/T: machine nozzle holder

13 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 INSTALLATION SEQUENCE OPTIONS

Time requirements:
• Complete work on one cylinder requires about 12
hours work
• Modification of all cylinders during normal
commercial operation / one port stay is therefore
not possible
• Mixing of standard and FAST nozzles on same
engine is possible

Options:
1. On board modification of covers in 2 or more port
stays (depending on no. of cylinders and length of
port stays)
2. Modification of covers on land and replace by
exchange
3. All work (except cylinder cover hole drilling) can
be executed by customer under own responsibility
14 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH
 FAST NOZZLE AVAILABILITY

Retrofit FAST nozzles can be retrofitted now on

following engines

Medium size Large size

RT-flex50 RT-flex82C, Tier2
RT-flex58T RT-flex82T
RT-flex60 RT-flex84T, Tier2
RT-flex68T, Tier2 RT-flex96C, w/o WHR

FAST for RTA engines retrofit expected for

introduction end 2013. Customer for pilot installation
welcome.

Delivery time of FAST nozzles: 4 months from time

of order

15 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 COMPLIANCE WITH IMO NOX REGULATIONS

Installation of FAST nozzles affect the NOx

emissions
• Proof of compliance required if vessel build on or after 1.
January 2000
• Amendment to the NOx technical file to be prepared
respectively

Prove of compliance will be agreed by Wärtsilä with

the respective class

Actual available approvals (July 2013)

• Germanischer Lloyd
• NK Japan

16 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

www.wartsila.com
 FAST UPGRADE FOR RT-FLEX82C AND 82T ENGINE

Modified injector parts for FAST nozzle

deeper machining New compression

Spring

Tappet guided in Bush

Distance piece with

bush

Clamping nut

FAST nozzle tip

Nozzle body
with needle

18 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH

 FAST NOZZLE BUSINESS CASE

Payback ~1years – basic package

Highlight / Introduction
• Lorem ipsum

Basic package: installation work executed by customer

12RT-flex96C (40% load), 7RT-flex82T (40% load)

Value of environmental friendliness not considered
19 © Wärtsilä March 11, 2014 Wärtsilä Service Solutions / FAST Nozzle / RH
 FAST NOZZLE BUSINESS CASE

Payback ~2 years – full package

Highlight / Introduction
• Lorem ipsum

12RT-flex96C (40% load), 7RT-flex82T (40% load)

Value of environmental friendliness not considered
20 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH
 FUEL SAVINGS AND GREEN IMAGE

Engine Solutions

Save Operating Cost

& Environment

FAST nozzle

SSUK ICC & ICM

21 © Wärtsilä 11 March 2014 Wärtsilä Service Solutions / FAST Nozzle / RH