Rolls-Royce plc

Filton, Bristol BS34 7QE, England

Telephone: 0117 9791234
© Rolls-Royce plc 2005
Issued by Customer Information Department (MH-3)
Telephone: 0117 9797004 This document contains information which is the
Fax: 0117 9795616 property of Rolls-Royce plc. It may not be copied, or
communicated to a third party, or used for any purpose
other than that specified herein, without the prior
written consent of Rolls-Royce plc.

Marine Olympus No.

Service Bulletin SB 004(M) (Amdt 2)

Compressor Performance Recovery Cleaning and

Engine Corrosion Prevention Procedures

SB 004(M) (Amdt 2)
June 2005 Page 1 of 11
 GENERAL WARNINGS

UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER

DIRECTLY OR INDIRECTLY CREATE RISKS TO (1) THE SAFETY AND HEALTH
OF THE PERSON UNDERTAKING THE WORK OR (2) THE ENGINE AND/OR ITS
COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.

IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE

CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION
TO THE WORK ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH
RELEVANT STATUTORY, LEGAL AND INDUSTRY REQUIREMENTS TO
PROTECT THE HEALTH AND SAFETY OF THE PERSONS UNDERTAKING THE
WORK.

IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE

CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION
TO WORK ENVISAGED BY THIS DOCUMENT TO PROTECT AGAINST RISKS
TO THE ENGINE AND/OR ITS COMPONENTS WHILST THE WORK IS BEING
UNDERTAKEN.

NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE
USER FROM THEIR RESPONSIBILITY TO ENSURE THAT THE CONTROLS AND
PRECAUTIONS REFERRED TO ABOVE ARE IMPLEMENTED.

IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT,

YOU BECOME AWARE OF ANY ROLLS-ROYCE PRODUCT DESIGN-RELATED
FEATURE WHICH COULD CREATE RISK TO A PERSON UNDERTAKING WORK
OR TO THE ENGINE AND/OR ITS COMPONENTS, PLEASE CONTACT ROLLS-
ROYCE NAVAL AT BRISTOL IMMEDIATELY.

Use or disclosure of this information is subject to

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 COMPRESSOR PERFORMANCE RECOVERY CLEANING AND
ENGINE CORROSION PREVENTION PROCEDURES

1. PLANNING INFORMATION

A. Applicability
This Service Bulletin (SB) is applicable to all Marine Olympus Gas Generators. It
supersedes SBs 306, 378, 001(M) and Service Information Letter (SIL) 16
concerning Compressor Cleaning and Inhibiting. This SB has been amended to
remove reference to Castrol ICD 177 which has been renamed Techniclean GT2.

B. Safety
This SB affects the safe operation of the equipment and it is important that you
comply with its instructions.

C. Reasons
It has been found that the requirement to wash engines every 24 running hours,
for Compressor performance recovery purposes, is unnecessarily frequent.

This SB introduces a new procedure for Compressor cleaning that will increase
washing efficiency; it withdraws the ‘water-only’ wash and extends the periods
between the Compressor performance recovery washes.

This SB withdraws the use of Aqueous Based Cleaning (ABC) fluids for their
corrosion inhibiting properties and introduces changes in the procedures to make
sure the potential for corrosion during engine shutdown is minimised.

This SB incorporates all the previous documentation on Compressor cleaning

into one definitive bulletin.
D. Description
This SB introduces revised Compressor cleaning procedures using fluids
approved for marine use. For environmental reasons, ABC fluids are the
preferred alternative. In addition, this SB introduces changes to engine corrosion
protection procedures and withdraws the option of a fired wash.

E. Tooling
None.

F. Approval
The content of this Service Bulletin was approved by Rolls-Royce plc on
26th June 2005.

G. References
Maintenance Manual.

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2. MATERIAL INFORMATION

2.1 Approved Products

The following is a list of products approved for marine use. We would advise that
previously approved products should be used until stocks are exhausted. Thereafter,
the currently approved products should be used.

WARNING: OBSERVE ALL MANUFACTURERS SAFETY INSTRUCTIONS

WHEN HANDLING ANY OF THE MATERIALS LISTED IN THIS
SERVICE BULLETIN.

CAUTION: ETHYLENE GLYCOL IS THE ONLY ANTI FREEZE WHICH IS

TO BE USED WITH SOLVENT BASED CHEMICAL CLEANERS.

Material Products
Techniclean GT2
Aqueous Based Fluids:
ZOK 27

Solvent Fluids: Castrol ICE 113

Techniclean DG1

Inhibiting Fluids: Ardrox 3961

Castrol Rustilo DWX 24
Steelgard Formula 521 and 522

Anti-Freeze: Ethylene Glycol BS 2537

Methyl Alcohol BS 506
Isopropyl Alcohol BS 1595

3. SUPPLIERS

Material Supplier
Techniclean DG1 Castrol International
Techniclean GT2 Wakefield House
Castrol ICE 113 Pipers Way
Castrol Rustilo DWX 24 Swindon
Wiltshire SN3 1RE
England

Customer Service:
Tel: 0044 (0) 845 9645111
Fax: 0044 (0) 1793 486083
Web: www.castroladvantage.com
E-mail: industrialcustomerservice@castrol.com

Use or disclosure of this information is subject to

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 Material Supplier
ZOK 27 Airworthy House
Elsted
Midhurst
West Sussex GU29 0JT
England

Tel: 0044 (0) 1730 811920

Fax: 0044 (0) 1730 811930
Web: www.zok.com
E-mail: zok@zok.com

Ardrox 3961 Chemetall

Denbigh Road
Bletchley
Milton Keynes MK1 1 PB
England

Tel: 0044 (0) 1908 649333

Fax: 0044 (0) 1908 373939
Web: www.chemetall.com

Steelgard Formula 521 and Vapor-Tek Limited

522 Fairclough Street
Great Leaver
Bolton
Lancashire BL3 2AF
England

Tel: 0044 (0) 1204 521795

Fax: 0044 (0) 1204 364576
Web: www.vapor-tek.co.uk
E-mail: Information@vapor-tek.co.uk

4. ENGINE WASH PROCEDURE

4.1 Introduction

The same wash procedure is to be used for each of the following routines:

Compressor Efficiency Recovery Wash To be used to remove fouling from a

Routine (see Section 5): Compressor in order to maintain the
engine efficiency.
Engine De-Salination Wash Routine To be used to prepare an engine for a
(see Section 6): shutdown period providing protection
against aqueous corrosion.
Post-Preservation Wash Routine To be used to prepare an engine for
(see Section 7): running after the use of inhibiting oils
during long-term shutdown periods.

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4.2 Wash Procedure Operations

The wash procedure is made up of three operations:

(1) Chemical solution cleaning operation.
(2) Water rinse operation.
(3) Continued, normal use of the engine or a ‘drying-out’ run operation.
All three operations of the wash procedure are always to be used.

4.3 Wash Procedure Preparation

(1) The Gas Generator is to be shut down and allowed to cool for a minimum of 30
minutes.
(2) The Anti-icing system is to be turned OFF and the Special Service Air Bleed
(SSAB), if fitted, is to be CLOSED.
(3) The Intake and Exhaust covers (or blanks) must not be fitted until the whole
procedure is completed.
(4) Make sure the Ship’s compressed air system is available and that the Module’s
Wash System supply tank is empty and isolated.

4.4 Operation 1 - Chemical Clean

WARNINGS: WHEN HANDLING CLEANING CHEMICALS:

(1) COMPLY WITH ALL MANUFACTURERS INSTRUCTIONS
AND RECOMMENDATIONS.
(2) CONFORM TO ALL COSHH INSTRUCTIONS AND
REQUIREMENTS.
(3) COMPLY WITH ALL LOCAL PROCEDURES AND SHIP’S
STANDING ORDERS.

CAUTION: IF THE ATMOSPHERIC TEMPERATURE IS BELOW

1 DEG C, A MIXTURE OF WATER AND ANTI-FREEZE MUST BE
USED. REFER TO THE TABLE IN SECTION 8 FOR THE
PROPORTION RATIOS.

(1) Using a suitable clean container, mix the manufacturer’s recommended ratio of
chemical cleaning concentrate with a quantity of high quality drinking water, to
make a total of 27 litres (6 gallons) of cleaning solution. Make sure that the
solution is thoroughly mixed and then pour it into the Module’s Water Wash
supply tank.
Note: When the ambient temperature is above 1 deg C and ABC fluids are being
used, if facilities allow, it is recommended that the water be heated to a
temperature in the range of 60 deg C to 80 deg C, as this significantly improves
the effectiveness of the cleaning solution against organic deposits and oil
fouling. However, where solvent-based cleaners are being used or the ambient
air temperature is 1 deg C or lower and anti-freeze is being used, do not heat
the water/anti-freeze solution.

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 (2) Following local procedures, initiate a dry-motoring cycle. At the moment when
both spools reach their maximum rotating cranking speeds, operate the Wash
System for two minutes to inject the cleaning solution into the Engine Intake.
After the 40-second crank of the Starter Motor is complete, continue to inject the
cleaning solution during the engine rundown.
(3) Check that the Water Wash supply tank is empty by opening the tank drain
valve. If fluid remains in the tank, check the Wash System for correct function in
accordance with the Maintenance Manual and, if necessary, do the procedure
again.

4.5 Operation 2 - Water Rinse

(1) Allow five minutes for the wash fluid and effluent from Operation 1 to drain from
the engine and the Exhaust Volute.
(2) Open the Module and Cascade Bend drain valves to remove excess wash
residue and then close the drain valves.
(3) Refill the Water Wash supply tank with 27 litres (6 gallons) of high quality
drinking water. If the atmospheric temperature is below 1 deg C, a mixture of
water and anti-freeze must be used. Refer to Section 8.
(4) Using local procedures, initiate a dry-motoring cycle. At the moment when both
spools reach their maximum rotating cranking speeds, operate the Wash System
for two minutes to inject the rinse water into the Engine Intake. After the 40-
second crank of the Starter Motor is complete, continue to inject the rinse water
during the engine rundown.
(5) Check that the Water Wash supply tank is empty by opening the tank drain
valve. If fluid remains in the tank, check the Wash System for correct function in
accordance with the Maintenance Manual and, if necessary, do the procedure
again.

4.6 Operation 3 - Drying Out (Engine Ready for Operation)

WARNING: IT IS POSSIBLE FOR THE POWER TURBINE TO ‘BREAK-

AWAY’ DURING THIS OPERATION.

(1) Allow five minutes for the rinse water and effluent from Operation 2 to drain from
the engine and the Exhaust Volute.
(2) Open the Module and Cascade Bend drain valves to remove the excess water
from the Enclosure and then close the drain valves.
(3) If required, the engine is now ready for immediate operation but, if the engine is
to be left shut down for more than five hours, the following drying out operation
must be completed. This operation will make sure that the engine is left
completely dry and will help prevent any aqueous electrochemical corrosion
during the shut down period.

(a) Make sure the Anti-icing system is turned OFF.

(b) Start the engine and allow it to stabilise at idle speed.
(c) Run for 15 minutes at idle and then shut down the engine.

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5. COMPRESSOR EFFICIENCY RECOVERY WASH ROUTINE

5.1 General

The Compressor Efficiency Recovery Wash routine is to be used to restore the

efficiency of a Gas Generator Compressor that has deteriorated due to the fouling of
gas path surfaces. The type and rate of accumulation of fouling deposits will be
dependant primarily on the position and performance of intake separators and if any
ingestion of diesel engine exhaust is occurring.

Correct maintenance of intake filters and drain traps is essential to avoiding rapid loss
of Compressor efficiency due to fouling. Other factors that will affect the rate of
performance degradation due to Compressor fouling will be the prevailing weather
conditions and ingestion of land mass contaminants such as sand and pollen when
operating in littoral waters.

5.2 Periodicity

Nominally, the Olympus Compressor Efficiency Recovery Wash routine should be

used every 150 engine running hours.

The periodicity should be shortened if conditions are likely to result in a higher than
normal rate of fouling such as extended periods of rough weather or if there is a high
level of atmospheric pollutants.

The periodicity can be lengthened if the rate of fouling accumulation by the engine is
found to be low. Operators can contact Rolls-Royce for further guidance (refer to
Section 9).

The Compressor Efficiency Recovery Wash routine should also be carried out:
Before engine performance assessments.
Before engine health vibration surveys.
If any abnormal vibration or unusual aerodynamic transients are
experienced.

6. ENGINE DE-SALINATION WASH ROUTINE

6.1 General

The Engine De-salination Wash routine is to be used to prepare the engine for
shutdown periods by removing salt and other corrosive contaminants from the gas
path and leaving the engine dry. This will make sure the internal engine conditions will
not support widespread aqueous electrochemical corrosion. The wash routine will also
make sure surfaces are cleaned of particulate matter that will act as nucleating sites
for corrosion cells.

The wash routine is also to be used to prepare the engine before injection of
preserving oil for long-term shutdown periods.

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6.2 Periodicity

The Olympus Engine De-salination Wash routine is to be carried out when the engine
is to be left shutdown for a period in excess of one week.

The de-salination wash is to take place no more than 10 engine running hours before
the beginning of a shutdown period. To provide operators with a flexible approach, it is
appropriate to delay a Compressor Efficiency Recovery Wash routine wash for up to
50 hours to coincide with the requirement to carry out a de-salination wash.

For shutdown periods alongside in harbour in excess of one week, the engine Intake
and Exhaust covers should be used to make sure the engine remains dry. Operators
should consider carrying out a Long-term Preservation procedure to ensure the best
conditions for preventing corrosion. Refer to Section 7.

7. LONG-TERM PRESERVATION PROCEDURE

7.1 General

For engine shutdown periods in excess of three weeks, the operator must carry out a
Long-term Preservation procedure to provide an appropriate level of corrosion
protection.

A wash routine should have been carried out not more than 10 hours before carrying
out a Long-term Preservation procedure. The engine should have cooled for a
minimum of 30 minutes before carrying out the Long-term Preservation procedure.
7.2 Procedure

(1) Make sure the Water Wash supply tank is completely empty of water then add 1
ltr (1.8 pt) of inhibiting fluid into the inhibiting tank.
(2) Initiate a dry-motoring cycle and, at maximum spool speeds, inject the inhibiting
fluid. On completion, check that all of the preserving oil has been injected into
the engine. If any oil is still in the tank, check the system for correct function and
do the procedure again.
(3) On completion of the Long-term Preservation procedure, the Intake and Funnel
covers must be fitted to make sure the engine remains dry by preventing moist
sea air from circulating through the engine caused by Uptake and Downtake
differential air flows. Use of Funnel covers will also prevent rain from reaching
the Exhaust Volute and providing a source of moisture for corrosion activity.
(4) Before setting the engine to work after preserving oil has been applied, carry out
a Post-preservation Wash routine. It is recommended that the wash water is
heated to improve the oil removal. Failure to clean the oil from the engine will
result in permanent fouling due to lacquering of the gas path surfaces.
Note: When the ambient temperature is above 1 deg C and ABC fluids are being
used, if facilities allow, it is recommended that the water be heated to a
temperature in the range of 60 deg C to 80 deg C, as this significantly
improves the effectiveness of the cleaning solution against organic deposits
and oil fouling. However, where solvent-based cleaners are being used or the
ambient air temperature is 1 deg C or lower and anti-freeze is being used, do
not heat the water/anti-freeze solution.

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7.3 Long-term Preservation by De-humidification

Rolls-Royce recommend that de-humidification is used for preservation of engines, as

it is the most effective method for preventing corrosion. Use of preserving oil for long-
term preservation will not be required if a dehumidifier is used. This will enable the
operator to have an engine ready for use immediately, without the need to carry out a
post-preservation wash routine. Contact Rolls-Royce for further information.

8. PREPARATION OF WASH FLUIDS AND ANTI-FREEZE

8.1 General

Wash fluid must be prepared immediately before use and must be thoroughly pre-
mixed in a suitable clean container. The concentrate and water will not be mixed
sufficiently well by adding them separately to the Water Wash supply tank.

When adding the chemical cleaning concentrate, slowly add the fluid to water. For an
ABC / water / anti-freeze mixture, mix the water with the anti-freeze, then add the ABC
fluid. Refer to the Table in Section 8.2 for proportions.
8.2 Anti-freeze

Anti-freeze is to be used with the chemical concentrate and water for all ambient air
temperatures of 1 deg C and below in the following proportions:

Ambient Water /Anti-Freeze Water /Anti-Freeze

Temp - °C (21.5 ltr, 4.75 gal) (27 ltr, 6 gal)
Plus ABC Fluid
(5.5 ltr, 1.25 gal)
Anti-Freeze Water Anti-Freeze Water
litre gal litre gal litre gal litre gal
+1 to -5 3.2 0.7 18.4 4.1 3.9 0.9 23.1 5.1
-5 to -10 5.4 1.2 16.2 3.6 6.5 1.5 20.5 4.5
-10 to -20 7.5 1.7 14.1 3.1 9.0 2.0 18.0 4.0
-20 to -30 9.6 2.1 12.0 2.7 11.7 2.6 15.3 3.4
-30 to -40 11.9 2.6 9.7 2.1 14.2 3.2 12.8 2.8

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9. COMMUNICATION
Any queries regarding the content of this Service Bulletin are to be directed to:

Customer Support (MH-18)

Rolls-Royce Naval Marine
PO Box 3
Filton
Bristol
BS34 7QE

Telephone: 0117 906 8033

Fax: 0117 906 8045

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