RT-123_A3 Appendix 3 (issue 3) (Flex 82) Nov 2016...
DATA & SPECIFICATIONS 2 Stroke Engine Services Engine section
Engine type
Ref.
Date
Issue
Document no.
Page
RT-flex engines Bore sizes in cm: 82, 84 and 96
2-stroke
29.11.2016
3
RT-123_A3 Appendix 3
1(7)
Inspection and overhaul intervals Table 1 Inspection or Component
Overhaul interval1)
[RH: Running Hours]
Estimated lifetime 1), 2) [RH: Running Hours]
Maintenance methods
Comments
System Oil
3,000
Lube. Oil sample laboratory analysis.
Main lubricating oil filters (plant side)
3,000
Check filter elements - in particular for white metal particles (clean or replace filter if required). Follow manufacturer’s instructions.
Bedplate foundation bolts
12,000
Crankcase
Main bearing
Thrust bearing
Engine lifetime
Check pre-tension according to the Maintenance Manual. Visual examination, search for white metal particles from bearings and for abnormalities in general.
1,500 – 3,000 6,000
Bearing clearance measurements.
6,000
Bearing edge check by wire 3).
At indications of excessive wear or damage
90,000 Replacement if required
Bearing shell open-up inspection is only necessary if bearing clearance, crankshaft deflection, wire check, oil analysis or crankcase inspection indicates excessive wear or damage.
6,000
Bearing clearance measurements.
6,000
Check bottom drain for free passage.
At indications of excessive wear or damage
Engine Life Time Replacement if required
Thrust Bearing pads open-up inspection is only necessary if bearing clearance, oil analysis or crankcase inspection indicates excessive wear or damage.
Replacement if required
Check pre-tension: First time after one year Tie rods
Successive inspections: Random check at major overhauls or all every 30,000
Cylinder liner 4)
At each piston removal
Wärtsilä Services Switzerland Ltd
Engine lifetime
Up to 90,000
Check pre-tension according to the Maintenance Manual.
Inspect liner & establish wear in bore at every piston removal.
PO Box 414
Tel (24h):
+41 52 262 80 10
CH-8401 Winterthur Engineering Services, 2-stroke engines
Switzerland
[email protected]
Appendix DATA & SPECIFICATIONS RT-123_A3, Issue3, Page 2 / 7 Table 1, continued Inspection or Component
Lubricating quill (Pulse lubrication)
Lubricating quill (CLU-3)
Overhaul interval1)
Estimated lifetime 1), 2) [RH: Running Hours]
Comments
Maintenance methods
Check non-return valves: At each piston removal
Check function and tightness. Check function of non-return valves.
Replacement if required
Check non-return valves: At each liner removal
Check function and tightness. Check function of non-return valves.
Accumulator diaphragm: 6,000
Check diaphragm for oil leakages and replace if required.
[RH: Running Hours]
Piston rod gland
At each piston removal
36,000 (refers to rings)
Clean rings & establish wear at every piston removal. Replace rings if required.
Cylinder cover
at every piston removal
Engine lifetime
Check for cracks and dirty or damaged seat sealing faces of injection valves. Remanufacture if required.
Standard injector and FAST injector
Before starting engine after a longer engine stop 1,000 RH after replacement of injector parts
Re-confirmation of opening pressure.
6,000
Function check (opening pressure). Visual inspection of all parts. Replace parts if required. Replace the nozzle tip.
Remanufacturing
Replace or recondition the nozzle body.
Condition on board is influenced by fuel quality and treatment.
6,000
Function check (opening pressure). Visual inspection of all parts.
Replace the parts if required
18,000
Replace the nozzle tip & nozzle body.
weekly
Check pipe upstream of the valve during operation, if pipes are too hot, disassemble starting valve.
monthly
Make sure that the nut on the solenoid is tight, if necessary tighten the nut.
Up to 24,000 5)
Starting valve
Overhaul on board
Check externally for tightness
Standard injector
FAST Injector
Replacement if required
6,000
Solenoid valve; random functional check.
12,000
Remove and disassemble one starting valve, from the condition, calculate the time of overhaul for remaining valves.
18,000
Solenoid valve. engine lifetime
Starting valve.
Overhaul on board
Appendix DATA & SPECIFICATIONS RT-123_A3, Issue3, Page 3 / 7 Table 1, continued Inspection or Component
Exhaust valve spindle
Exhaust valve seat
Exhaust valve drive
Exhaust valve damper 6)
Overhaul interval1)
[RH: Running Hours]
Inspection at 18,000RH, 36,000RH and 72,000RH
Inspection at 18,000RH, 36,000RH and 72,000RH
Estimated lifetime 1), 2) [RH: Running Hours]
Comments
Maintenance methods
108,000 6)
Check condition and wear of valve spindle (if necessary regrind seat by machining). Valve plates with corrosion layer deeper than the limit given in the Maintenance Manual or seating surface ground back more than 3 mm can be remanufactured. Nimonic 80A spindles can be remanufactured up to 2 times.
Remanufacturing
72,000
Check condition and wear of valve seat (if necessary regrind seat by machining). Valves with seat surface ground back more than 3 mm or with burn scars on the inside of the seat that exceed the limit given in the Maintenance Manual must be remanufactured.
Remanufacturing
Check condition of piston seal ring, air spring, rod seal ring and guide bush. Replace parts as needed. Check condition of exhaust valve hydraulic drive parts.
Inspection at 18,000RH, 36,000RH and 72,000RH
For old designed dampers, replace with new designed damper at 20,000RH (Refer to RT-120)
18,000
Overhaul on board
Replacement if required
For new designed dampers, random check every 18,000RH. Crankshaft
Connecting rod
6,000
Engine lifetime
6,000
Bearing clearance measurements
6,000
Wire check on all bearing edges 3)
70,000 8)
Top end bearing and Bottom end bearing
Random open-up inspection. 90,000 Replacement if required
Piston head
Condition based 18,000 – 36,000
Ring grooves: 18,000 - 36,000 Crown surface: 72,000
Starting air shut-off valve
Condition based 18,000 – 36,000 30,000 – 36,000
Bearing shell open-up inspection is only necessary if bearing clearance, wire check, oil analysis or crankcase inspection indicates excessive wear or damage. Inspect condition of chromium plating and measure ring groove clearance. Check condition of piston top surface and clean oil cooling bores if needed. Recondition/rechrome if required. Measure thickness of chrome-ceramic layer.
1,500 – 2,000 Piston rings
Measure crank deflection, always after the ship grounded and after each docking
Replace piston rings based on remaining coating thickness. Engine lifetime
Clean and check seat, springs and seal rings.
Overhaul on board. Remanufacturing
Replacement
Overhaul on board
Appendix DATA & SPECIFICATIONS RT-123_A3, Issue3, Page 4 / 7 Table 1, continued Inspection or Component
Overhaul interval1)
[RH: Running Hours]
Estimated lifetime 1), 2) [RH: Running Hours]
Initial: 24,000
Servo oil pumps (Dynex)
Successive: 42,000 Servo oil pump (Bosch) Supply unit pinion bearing bushes
– Pumps with serial number < 147899: remanufacture initially at 24,000 hours. Thereafter the higher interval of 42,000 hours applies. – Pumps with serial number ≥ 147899: only exchange of pump cover on board at 24,000 hours. Remanufacture initially at 42,000 hours. Thereafter the interval of 42,000 hours applies.
42,000
Maintenance methods
Remanufacturing
Pumps with serial number ≥ 160686: remanufacture only at 42,000 hours.
60,000
Remanufacturing
90,000
Visual inspection.
Replacement if required
Inspect condition & check bearing clearances. Check for white metal pieces coming out of the bearings or in the casing.
Replacement if required
Supply unit camshaft bearings
6,000
90,000
Supply unit fuel drain pipes
6,000
Engine lifetime
Inspect fuel drain system to find clogged drain pipes. Refer to technical bulletin RT-102.
Cleaning on board.
weekly
Check the oil leakage on FOP top cover caused NRV O-ring brittle.
Replace
3,000
FOP Roller running surface check.
Cam surface can be checked together.
6,000
Random flow check of lubricating oil at every 6,000 RH according to RT180.
18,000
Remanufacturing at every 18,000 RH.
Fuel pump
Heinzmann electrical actuator StG-16 & StG-30 for FOP
Comments
Check condition of the carbon brushes and replace if required Only RT-flex82C/T & W-X82 engine.
6,000 – 12,000
Injection control unit (ICU) 9)
Remanufacturing Overhaul on board
24,000
Only ICUs on 84 and 96 bore engines built before 2010, which have not been remanufactured.
Remanufacturing
36,000
Applies to ICUs on engines built from 2010 onwards and to the already remanufactured ICUs on engines built before 2010.
Remanufacturing
Filter: 18,000 Rail valve: Monitored
Clean and check filter condition. Replace only if required.
Replacement
Check “on-time” of rail valves through flexView and replace if “on-time” > 2.6 ms.
Replacement
Control oil pump (Bucher)
60,000
Replace with a new pump.
Replacement
Control oil pump electric motor bearings
60,000
Replace ball bearings and overhaul motor.
Replacement
Servo oil rail hoses
30,000
Check condition and replace if required.
Replacement
Appendix DATA & SPECIFICATIONS RT-123_A3, Issue3, Page 5 / 7 Table 1, continued Inspection or Component
Overhaul interval1)
[RH: Running Hours] Piston and slide rod: 36,000
Exhaust valve control unit
Estimated lifetime 1), 2) [RH: Running Hours]
Comments
Engine lifetime
Random check of piston and slide rod at overhaul. Replace only if required.
Replacement
Clean and check filter condition. Replace only if required.
Replacement
Check “on-time” of rail valves through flexView and replace if “on-time” > 2.6 ms.
Replacement
Filter: 18,000 Rail valve: Monitored
Cylinder lubricating pump (Pulse lubrication)
Accumulator: every 3 months
Check gas (nitrogen) pre-charge pressure. Refill if required. Lubricating pump: 30,000
Cylinder lubricating pump (CLU-3)
According to According to instruction of pump instruction of pump manufacturer manufacturer
Intermediate fuel accumulator (IFA)
Random check for leakages
Fuel pressure control valve (PCV)
Crank Angle Sensor (belt driven at free end)
Overhaul only necessary when PCV is failing
Engine lifetime
Check pre-tension, cracks and wear of toothed belt visually: 3,000
24,000
Overhaul drive: 48,000
CAS with LEMAG increment wheel (engines with Retrofit Pulse Lubrication)
WECS-9500 Components
Overhaul on board Remanufacture IFA if required.
Remanufacturing
Perform a function check once a year. Remanufacture part if required.
Remanufacturing
Replace belt after 24,000 hours and measure run-out of the drive shaft.
Replace sensor at 48,000 hours.
Check and clean sensor lenses quarterly
Replace only if required
Check and clean wheels quarterly
Remove dirt, oil or other contamination from the slits of the increment wheels.
Replacement
Replacement of relevant parts Replacement
— Engine lifetime
Do a visual check of the cables. Replace the damaged cables and wires
quarterly WECS-9520 Components
Overhaul on board Remanufacturing
Replace ball bearings and sealing rings at overhaul. Crank angle sensor: 48,000
Maintenance methods
60,000
Replace FCM-20, ALM-20, ACM-20 modules if failing
Replacement
60,000
Replace Exh. Valve stroke sensor and TDC sensor if failing.
Replacement
60,000
Replace modules if failing.
Replacement
Appendix DATA & SPECIFICATIONS RT-123_A3, Issue3, Page 6 / 7
Notes to inspection and overhaul table 1. Intervals for inspection or overhauls and estimated lifetimes are estimates only. They are based on past experience and valid for engines fully according to currently applicable Wärtsilä Switzerland Ltd specifications. They are given for information purposes only and do not constitute any guarantee or warranty whatsoever, as the actual service life can vary considerably due to numerous conditions and influences such as but not limited to: − Environmental and operating conditions; − Heavy fuel and lubricating oil qualities; − Engine load factor; − Fuel, lubricating oil and cooling water treatment; − Overhaul according to engine manuals; − Only genuine spare parts used; − Careful and continuous engine monitoring. 2. “Estimated lifetime” refers to the life expectancy in hours under normal operating conditions before the component is removed for replacement or remanufacturing. 3. Use welding rod with the end flattened and bent at 90°. 4. The anti-polishing ring is recommended to be replaced at the liner replacement. 5. Lifetime can be achieved with remanufacturing provided that the clearance between nozzle needle and nozzle body is within specified limits. 6. Spindle lifetimes can be reached with remanufacturing. Remanufacturing of spindles must only be done at Wärtsilä workshops. 7. The current exhaust valve dampers have a tendency to suffer from cavitation and the damper can break up over a long period of time. Consequently broken parts can enter the valve drive and cause subsequent damage. Wartsila recommends replacing all dampers with the new design during the next overhaul, or anyway after 20,000 operating hours. Refer to RT-120. 8. It is recommended to open for inspection one connecting rod top end bearing and one bottom end bearing at 70,000 running hours. In case either the connecting rod top or bottom end bearing is found damaged, it is recommended to inspect other bearings of same type at the next opportunity. 9. For ICUs on 82 cm bore engines built before June 2011 refer to Technical Bulletin RT-122.
NOTE: Appendix 3 with Table 1 “Inspection and overhaul intervals” is part of the Data & Specifications bulletin RT-123.
Appendix DATA & SPECIFICATIONS RT-123_A3, Issue3, Page 7 / 7
Contacts How to contact Wärtsilä For questions about the content of this Data & Specifications bulletin, or if you need Wärtsilä assistance, services, spare parts and/or tools, please contact your nearest Wärtsilä representative.
Contact details for emergency issues Operational support For questions concerning operational issues, please send your enquiry to:
[email protected] or phone 24hrs support: +41 52 262 80 10. Field service If you need Wärtsilä Field Service, please send your enquiry to:
[email protected] or phone 24hrs support: +41 79 255 68 80. Spare parts If you need Wärtsilä spare parts and/or tools, please contact your nearest Wärtsilä representative or your key account manager.
© 2016 Wärtsilä Services Switzerland Ltd – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder. Wärtsilä Services Switzerland Ltd makes no representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or omissions for information contained herein. Information in this publication is subject to change without notice. Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as provided due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto. Any actions by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such actions will thus be at the owners/operators own cost and expense. NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.
