GENERAL

INFORMATION

Wärtsilä low-speed engines RT-137

Services 2-stroke Issue 1, 26.09.2012

Maintenance concepts for Next opportunity

RT-flex components Concerned components

RT-flex components of Wärtsilä 2-stroke
engines, primarily Injection Control Units
Information to all Owners and Operators of (ICUs), Fuel Oil Pumps (FOPs) and
Wärtsilä RT-flex engines Pressure Control Valves (PCVs).

Current situation
Life-cycle maintenance costs experienced
throughout an engine’s lifetime have been
reviewed and new maintenance concepts
developed. A flexible approach is offered
to suit the maintenance philosophy of all
customers.

Solutions
This General Information bulletin provides
an overview of the maintenance concepts
available. The document should be
consulted when planning maintenance for
RT-flex components.

Note
This General Information bulletin
supersedes Service Bulletin RT-flex-06,
dated 08.02.2008, entitled “Reconditioning
of Injection Control Unit”.

Wärtsilä Switzerland Ltd. Tel (24h): +41 52 262 80 10

PO Box 414 Fax: +41 52 262 07 31
CH-8401 Winterthur technicalsupport.chts@wartsila.com
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Contents
Page
 
Introduction 2 
Available concepts for RT-flex components 2 
Recommended overhaul schedules 4 
Ordering and delivery process for remanufacturing 6 
Appendix 6 
Contacts 6 

Introduction
Note:
This General Information bulletin supersedes Service Bulletin RT-flex-06, dated
08.02.2008, entitled “Reconditioning of Injection Control Unit”.

Wärtsilä RT-flex engine technology enables more flexible and efficient engine
operation. The use of electronically controlled RT-flex components allows the
optimisation of engine performance across all engine loads and introduces fuel
consumption reductions over mechanical engines.

Wärtsilä continuously focuses on improving the total operating costs of our

engines. The maintenance costs of RT-flex components have been identified as
a focus area for these improvements. The maintenance concepts described
herein contribute substantially to the reduction of life-cycle maintenance costs
and allow for a more flexible approach to maintenance to suit the individual
needs during vessel operation.

Available concepts for RT-flex components

In order to support various requirements for the maintenance of RT-flex
components, the following flexible approaches are available for customers:

Onboard repair kits

A For continued use of RT-flex components in case of
premature failure of internal parts
Remanufactured components
B
Offered as a cost-optimised alternative to new parts with equal quality
New parts
C
For quality assured RT-flex components
RT-flex parts agreement
D
Agreements for services and parts over an agreed lifetime

Table 1
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This initial General Information bulletin release focuses on the Injection Control
Units (ICU), Fuel Oil Pumps (FOP) and Pressure Control Valves (PCV), but will
be revised over time to provide solutions for other RT-flex components as well.

A) Onboard repair kits

Should onboard repair be necessary for continued operation, Wärtsilä has
developed such kits consisting of all required internal parts to facilitate this work.

Instances where this may be of interest include cases of premature failure of

internal components of the spare parts, for example, a case of poor fuel oil
quality influencing injection equipment. Alternatively, such kits may be used to
prolong the lifetime of a component, and therefore effectively serve as a “TBO
extension kit”.

Work instructions are to be provided. Further details can be found in the following
Chapters.

Remark:
Details of the available onboard repair kits and order numbers are given in
Appendix 1.

B) Remanufactured parts
When the overhaul of a RT-flex part becomes necessary according to
maintenance schedules or condition, the purchase of remanufactured parts is
offered as a cost optimised alternative to new parts.

The details of this maintenance concept are shown in General Information

RT-119, entitled “Component remanufacturing services”.

The remanufacturing services are available in two ways:

• Exchange Parts Services
• Remanufacturing of the customer’s own component(s)

All remanufactured parts are released to the latest specification with any and all
design changes required. The repair kits are for repair purposes only.

Furthermore, all remanufactured parts fulfil the same quality standards as for new
parts and achieve the same operational lifetimes. The same warranties as for
new parts are applicable.

Note:
As the repair or overhaul of RT-flex parts onboard will be outside of any
possibilities for quality control by Wärtsilä, no warranties can be granted on these
parts after such work has been done. In order to ensure trouble-free operation,
longer lifetimes, and achievement of optimised life-cycle costs, Wärtsilä
recommends maintaining RT-flex parts only by the remanufacturing process.
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C) New OEM 1 spare parts

In cases whereby new parts are preferred, or the logistics to return used RT-flex
parts to the exchange pool is too complex, new parts remain available as an
option. In certain circumstances for components rarely sold as new, longer lead
times to a remanufactured part may be required.

D) RT-flex parts agreements

Since the release of RT-flex engines and the accompanying technology into the
market in 2001, extensive experience has been gained and the technology has
matured. The knowledge, understanding and confidence in the reliability of the
RT-flex systems are at high levels. To demonstrate the confidence of design,
Wärtsilä has moved to provide RT-flex parts agreements for customers.

The principle of such an agreement is for Wärtsilä to provide all required new
parts, remanufactured parts and onboard exchange services over an agreed
lifetime of a particular engine, e.g. 5 or 10 years.

The total costs for the agreed period are guaranteed maximum costs to be
incurred by the customer. The total lifetime costs are calculated and are charged
via a fixed annual or monthly fee. This concept provides predictability and
smoothing of costs over time and mitigates the financial risk associated with
component failure.

Such agreements are taken up on a case-by-case basis and tailored to match the
requirements of each customer. Your local Wärtsilä representative should be
contacted for more information.

Recommended overhaul schedules

The recommended Time Based Overhaul periods of all RT-flex parts are detailed
in the Data & Specifications bulletin RT-123, entitled “Inspection and overhaul
intervals”.

Further guidance for troubleshooting and gauging a component’s condition is

provided in the individual Service Bulletin for each RT-flex component.

1
Original Equipment Manufacturer
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Available Service Bulletins for RT-flex parts

Service Bulletin
RT-flex part Engine type
Number Title
Valve Control Unit
RT-92 Valve Control Unit RT-flex96C-B
(VCU)
Servo Oil Pump Dynex pump RT-flex82C
RT-103
(SOP) troubleshooting RT-flex82T
CLU4 pulse
All engines fitted
CLU4 Lubricating lubricating module:
RT-110 with PLS / RPLS
module Pressure check and
lubricating system
maintenance
Troubleshooting &
Injection Control Unit RT-flex96C-B
RT-124 maintenance on
(ICU) RT-flex84T-D
Injection control unit
Maintenance of
Pressure Control
RT-125 Pressure Control All RT-flex engines
Valve (PCV)
Valve (PCV)
Fuel oil pump RT-flex96C-B
Fuel Oil Pump (FOP) RT-130
RT-flex size IV RT-flex84T-D

Table 2

Recommended overhaul schedules when employing onboard repair kits

The repair kits are developed for the purpose of rectifying an internal failure of
RT-flex components in order to continue sailing safely.

An onboard overhaul using all repair kits cannot achieve the same quality as
remanufactured parts. The onboard repair kits are designed to cover the major
expected failures, but the combination of all kits only represents 50% of the parts
replaced in the remanufacturing process. Proper repair and reassembly will
return the RT-flex component to normal operation, but some performance
penalties may be observed.

After overhaul onboard, component efficiencies or timing can differ to those of

new or remanufactured parts and may lead to fuel consumption penalties.
Adherence to the overhaul periods as stated in the Data & Specifications bulletin
RT-123 is advised, although they may be extended with close monitoring to
optimise the lifecycle costs.

Lastly, as delivery lead times may reduce the safety benefits intended by this
offering, it is recommended that repair kits are ordered before problems are
recognised on board and held in inventory.
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Ordering and delivery process for remanufacturing

For the ordering, delivery and return process of remanufactured RT-flex parts
please refer to the General Information bulletin RT-119, entitled “Component
remanufacturing services”. This covers both exchange parts and remanufacturing
of customer’s own parts.

Appendix
• Appendix 1, RT-137_A1
Onboard repair kits information, ordering process and order numbers.

Contacts

How to contact Wärtsilä

For questions about the content of this General Information, or if you need
Wärtsilä assistance, services, spare parts and/or tools, please contact your
nearest Wärtsilä representative.
If you don’t have the contact details at hand, please follow the link “Contact us” –
“24h Services” on the Wärtsilä webpage:
www.wartsila.com

Contact details for emergency issues

Operational support
For questions concerning operational issues, please send your enquiry to:
technicalsupport.chts@wartsila.com
or phone 24hrs support: +41 52 262 80 10.

Field service
If you need Wärtsilä Field Service, please send your enquiry to:
Ch.Fieldservice@wartsila.com
or phone 24hrs support: +41 79 255 68 80.

Spare parts
If you need Wärtsilä spare parts and/or tools, please send you enquiry to:
ch.spareparts.wgls@wartsila.com
or phone 24hrs support: +41 52 262 24 02

© 2012 Wärtsilä 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 Corporation 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 in the engine, but merely as an improvement of the engine 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.