Service Bulletin RTA-81

05.03.2009

Technical Information to all Owners / Operators

of Wärtsilä RTA Engines

Recommendations for the Treatment of

Temporarily Laid-up RTA Engines

Contents
1 Introduction 1
2 Preparations before stopping the
engine prior to the temporary lay-up 1
3 Preparation after stopping the engine 2
4 Repeated treatment 5
5 Measures to be taken before re-
commissioning of the engine 6
Lay-up services supplied by Wärtsilä 7

Wärtsilä Switzerland Ltd PO Box 414 Tel.: +41 52 262 23 30

Wärtsilä Schweiz AG CH-8401 Winterthur Fax: +41 52 212 71 03
Wärtsilä Suisse SA Switzerland technicalsupport.chts@wartsila.com
1 Introduction
This Service Bulletin titled “Recommendations for the treatment of
temporarily laid-up RTA engines” has been prepared to the best knowledge
and ability of its authors. However, neither Wärtsilä Switzerland Ltd nor
their employees assume any liability – under any legal aspect whatsoever –
in connection with these “Recommendations for the treatment of temporary
laid-up RTA engines”, its contents or modifications to it or in connection
with its use, including possible negligence.
The recommendations mentioned below are intended to complement the
relevant instructions included in the engine’s Operation Manual, especially
the chapter “Operation”.

2 Preparations before stopping the engine prior to the

temporary lay-up

2.1 Fuel oil

Check by analysis that the MDO on board does not contain any bacteria
which could contaminate the fuel system. Change over from HFO to MDO
sufficiently early during operation of the engine to assure that the entire fuel
system on the engine is flushed with MDO. The engine should run with pure
MDO at 70% load for at least one (1) hour.

2.2 System oil

Check with the supplier whether the system oil presently used is sufficiently
inhibited against rust. Make sure by analyses that the oil charge is fit for its
duty, i.e. contains neither water, acid nor any microbiological contamination
(limits given in chapter "Operating Media" in the Operation Manual should
not be exceeded).

2.3 Corrosion
Store a sufficient quantity of specific rust preventing engine oil like the
products listed below or similar:
SHELL ENSIS ENGINE OIL 30 or 40
VALVOLINE TECTYL 930
MOBILARMA 524

2.4 Cooling water

Check by analysis that the cooling water is still adequately inhibited (refer
to the supplier’s specifications). If not, corrective action is necessary. If the
ship is to be laid up in cold climate and if there is danger of freezing, an
antifreeze agent must be added prior to shut-down. Confirm with the

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 manufacturer that the cooling water anti-corrosion inhibitor and antifreeze
agent used are compatible with each other. Thus a sufficient quantity of
anti-freeze coolant should be taken on board.

2.5 Power
Check whether sufficient power is available for turning the engine (with
turning gear) and operating the main lub. oil pump at the same time during
the lay-up period.

3 Preparation after stopping the engine

Secure the engine as instructed in the Maintenance Manual, in chapter
“General Guidelines for Maintenance”.
The cleaner the engine is when the lay-up period begins, the more efficient
the safety measures will be.

3.1 Overhaul of all units

If actually possible, a complete overhaul of all pistons including stuffing
boxes should be carried out because the upper scraper ring group contains
combustion products which might promote corrosion. At the same time all
piston cooling stuffing boxes are to be opened and thoroughly cleaned and
after that refitted (if applicable). The cylinder cover surface facing the
combustion chamber must be cleaned of combustion residues and unburned
fuel. The same goes for the surface of the cylinder liner above the top piston
ring including the Anti Polishing Ring and its groove. By means of a brush,
coat the cleaned surfaces with rust preventing oil as mentioned under
chapter 2.3
Clean the piston underside, scavenge air receiver space and all drain-
respective collecting pipes thoroughly as possible (do not use steam
cleaning).
For vessels that are moved to the lay-up location soon after or right after
commissioning, some of the protection measures, such as overhauling
pistons, can be omitted. If the pistons are not overhauled, remove the
starting valves from the cylinder cover. Use a suitable nozzle, which sprays
the rust-prevention oil in downward as well as in the upward direction and
which can be inserted through the starting valve bores in the cylinder cover.
Spray-coat the whole combustion chamber surface (in particular top of
piston, liner wall, cylinder cover and exhaust spindle) with the above
mentioned rust protective oil. If the oil is sprayed by means of an air gun
make sure that the air does not contain water (use dried air).
The starting valves should either be refitted or the openings should be
suitably blanked off with a steel flange (draft prevention). Regarding
starting valve please also refer to chapter 3.6.

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 After that, turn the engine and spray-coat the piston rods in order to fill the
piston rod stuffing box with the rust preventing oil.

3.2 Crankcase, fuel injection pump

With the same rust preventing oil used as before, spray-coat all moving and
blank parts in the crankcase that are not covered with system oil when the
engine is turned over, in particular piston rods, camshaft assembly etc.
Close the crankcase carefully.
Spray-coat the camshaft, bearing covers, rollers, roller guides, etc. Close
housing again carefully.
Clean and spray-coat on fuel pump blocks and moving parts (springs,
pushrods, etc.) and on all outside parts of the engine which are not protected
by paint.

3.3 Prevention of condensation

Most important is the prevention of condensation inside the engine.
Maximum danger sets in when, after a long cold spell, the weather changes
to comparatively warm and wet. The prevention of any draft or “ventilation”
inside the crankcase, cylinders, turbochargers and exhaust ways is of utmost
importance.
Cover main engine’s exhaust funnel in order to prevent any moisture from
entering the engine through the gas-ways by draft or gravity. Seal exhaust
line outlet hermetically between T/C and funnel. Check exhaust manifold
for any build-up of moisture, dry-up if required.
The exhaust valves should be kept open (compressed air supply to air spring
shut-off).
Assure that the aux. blower(s) are not accidentally switched on and make
sure that the heating of the electric motors is supplied (if existing).
As a rule: Open and close the crankcase doors as much as necessary and as
less as possible. The crankcase should, if possible, be opened only during a
steady period of dry weather (not in damp, “muggy” conditions, or with fast
changing temperatures) and without the engine room fans running. A
relative humidity of 30-50% should be reached to keep the level of
corrosion low. It is highly recommended to connect a dehumidifier to the
crankcase and piston underside space. It should also be considered to
monitor the relative humidity inside the engine during the laid-up period.

3.4 Turbocharger(s)
For the protection of the turbocharger during lay-up, please refer to the
manufacturer’s instruction manual.
Open the drain valves of the silencer.
Cover the turbocharger air inlet suction filter airtight with a tarpaulin in
order to prevent air circulation through the engine.

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3.5 Cylinder lubrication
Important! The number of pulses / turns required to keep the cylinder liner
surface properly lubricated must be verified by visual inspections of the
liner surface and piston ring package from the piston underside space.

3.5.1 CLU-3 type Lubricating System

Drain cylinder lubricators and fill them with special rust-protective oil
(SHELL ENSIS ENGINE OIL 30 or similar). With the use of the
manual/emergency cylinder lubrication, turn the lubricating pump shaft by
200-300 turns in order to displace the normal cylinder oil from lubricating
lines. During this time keep the engine turning with the turning gear.

3.5.2 Retrofit Pulse and Pulse Lubricating System (RPLS / PLS)

Start main lub. oil pump and rotate engine with turning gear. Start the oil
supply pump and set the delivery pressure by means of the oil supply unit’s
pressure regulating valve, to 12-14 bar. Actuate manual cylinder lubrication.
At such low pressure (normal 50 bar), the cylinder oil will not be injected
but will flow along the liner wall. Give each cylinder approx. 100 pulses.
During this time keep the engine turning with the turning gear.
Place desiccant bags in all control boxes which contain electric equipment,
like boxes E40, E41.N.

3.6 Starting air system

All starting valves are to be removed from the cylinder cover, opened, all
parts cleaned, oiled slightly with rust-protection oil and assembled.
Thereafter, the valves can be refitted to the cylinder covers. Dismantle the
shut-off valve for starting air. All parts are to be cleaned, oiled with rust
protection oil and reassembled. Thereafter, the valve can be fitted back in
closed position.
Depending on the length of time since the starting air distributor was
overhauled and especially on ships already in service for some years, we
recommend extracting the bushes and sleeves. These parts are to be cleaned
and oiled before refitting. When extracting the valves, the air spaces of the
housing can be cleaned and oiled. The distributor control cam should also be
checked and oiled. Use protection oil sparingly.
During the lay-up period all starting and pneumatic air systems should be
depressurised, and all drains should be kept open. However, should it be
necessary to pressurise the pneumatic system, make sure that only dry air is
used.

3.7 Fuel injectors

All fuel injectors should be removed for cleaning and overhaul. After testing
with MDO, refit the injectors.

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3.8 Engines with water cooled pistons
Drain the piston cooling main- and leakage water tank. Clean the tanks.
Open the piston cooling water coolers and clean them.
Fill main tank with clean water and flush the system for several hours until
the water returning from the system becomes clean. Replace water and refill
with adequately dosed corrosion inhibitor.

3.9 Scavenge air system

Drain complete scavenge air drain piping including the condensate drain
unit.

4 Repeated treatment

4.1 Once a week

Operate the system oil pump for 20 minutes while turning the engine and
lubricate each cylinder the same way as described in chapter 3.6. However,
20 pump shaft turns respective pulses should be sufficient (check the liner
oil coverage from the piston underside).
Stop the engine in a different position each time.
Open the drain cock of the turbocharger gas outlet casing for one minute
(water check).
Operate the cooling water pump for 20 minutes.
Operate the fuel booster pumps for 20 minutes to get the MDO circulating
in the fuel system.
Move the fuel linkage by hand.

4.2 Once a month

Open the crankcase (on one side) and piston underside doors and check for
condensation and rust traces.
Open and close the main starting shut-off valve from time to time. Make
sure that the supply from the starting air bottles is depressurised.

4.3 After three months

Check for possible condensation or rust formation, particularly on thrust
bearing, gears, camshaft, cams and rollers, etc. Lift a crosshead pin and
check for signs of corrosion. Spray-coat again all parts mentioned in chapter
3.2.

4.4 After six months

Check by analysis that the cooling water is still adequately inhibited.

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5 Measures to be taken before re-commissioning of the engine
Wärtsilä Switzerland Ltd. highly recommends the attendance of a Wärtsilä
service/commissioning engineer for the re-commissioning and checking of
the engine’s safety system. Due to the long standstill, important sensors or
switches could be stuck and may not work properly anymore.

5.1 Cooling water system

Cooling water needs to be analysed and, if necessary, to be replaced and
provided with correctly dosed anti-corrosion inhibitor (refer to the supplier’s
specifications).
If an anti-freeze agent was applied to the cooling water, coolant must be
drained off and the system flushed with fresh, clean water. After that, fill the
cooling system with fresh water which is properly treated with an anti-
corrosion inhibitor.

5.2 Lubricating oil system (system oil)

The lubricating oil needs to be analysed. If required, regenerate or exchange
the oil (limits given in chapter "Operating Media" in the Operation Manual
should not be exceeded).

5.3 Electric motors

Carry out a M test on all electric motors.

5.4 Starting system

All main starting air pipes, including the main air distributing pipe on the
engine, should be blown through (the safety valves on the main starting air
pipe are to be removed before blowing-through) in order to prevent rust
from damaging the air distribution- and starting air valves.

5.5 Cylinder units

Check that all cylinders are free of water and excessive oil. Operate cylinder
lubrication as mentioned in chapter 3.6 and check flow of cylinder oil. Make
sure that the cylinder lubricator oil line is flushed and filled with the proper
cylinder lubrication oil before the engine start-up (in case the oil was
replaced with rust preventing engine oil during the lay-up period).

5.6 Turbochargers
Remove protective coverage, and refer to the manufacturer’s instruction
manual.

5.7 Before starting

The instructions as stipulated in the engine Operating Manual, chapter
“Operation”, must be followed strictly.

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Lay-up services supplied by Wärtsilä
Wärtsilä provides a wide range of lay-up services, including periodic intermediate
inspections, re-commissioning and engine start-up. Offers for customised lay-up services
can be ordered through your usual contacts in the Network Companies or directly from
Wärtsilä Switzerland.

The lay-up services from Wärtsilä are available in two ways:

Single, customised support services for different phases of ship lay-up

Technical consulting services for lay-up planning and management
Preparation, pre-inspection, overhauls and de-commissioning services
Periodic inspection, maintenance and operational services during lay-up
Lay-up ending and re-commissioning services

Lay-up management agreements

Managing all aspects of lay-up for single ships, or for an entire laid-up fleet
Lay-up services for main engine, for entire engine rooms or complete ships
Shore-based resources only, or including onboard minimal crew

The benefits of lay-up services provided by Wärtsilä are:

Competent planning, management support and project management

Minimized manning costs during long lay-up periods
Avoidance of long-term stand-still damages
Guaranteed equipment protection to ensure sustained value and reliability
Professional and trouble-free re-commissioning and start-up of engines and systems
after lay-up

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