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Diesel After-Sales Service

Service Bulletin

RL 5
25.01.89

Technical Information to all the Owners


of Sulzer RL Type Diesel Engines

Reprinted 08.04.97

Water Drain from Charge


Air Receiver and Charge
Air Temperature

Contents:

Page

INTRODUCTION

1. CHARGE AIR TEMPERATURE

2. CHARGE AIR RECEIVER

3. WATER DRAIN PIPING SYSTEM 3

28.07.07.40 Printed in Switzerland

4. STORAGE / HANDLING OF
CONDENSATE

New Sulzer Diesel Ltd


Phone: (052) 262 80 10 (24hours)

Diesel After-Sales Service


Telex: 896 659 NSDL CH

PO Box 414
Telefax: (052) 213 94 83

CH-8401 Winterthur, Switzerland

INTRODUCTION
The amount of condensate from the water separator after air cooler depends mainly on the
charge air pressure, the charge air temperature and the relative humidity and temperature of
the inlet air.
When operating in humid tropical areas the condense water quantities may be up to 0.05 0.08 kg/kWh.
Accumulation of condensate in the charge air receiver has to be avoided since water in liquid
or evaporated state, swept along by the air flow can have a negative influence on the piston
running behaviour and can increase corrosive wear to piston rings and cylinder liners.
Experience gained so far, particularly on vessels running under extreme tropical conditions,
has shown that the current condensate system does not always ensure sufficient drainage.
This Service Bulletin should be kept in a separate file in the control room. The respective pages or
tables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manual or
Code Book should be copied and filed in the respective Manual or Book.

1.

CHARGE AIR TEMPERATURE

The often found practice to raise the charge air temperature after air cooler(s) in order to
avoid condensation is no longer advisable as condensation can not always be avoided with
todays highly supercharged engines.
We still recommend to operate the air coolers as follows:
- full specified cooling water flow (sea or fresh water), i.e. no throttling at part load
- sea water inlet temperature 25 - 32_C; resulting scavenge air temperature about 5 l5_C higher than cooling water inlet temperature depending on engine load
- cooling water inlet temperature for central cooling systems 25 - 36_C; resulting
scavenge air temperature about 5 - 10_C higher than cooling water inlet temperature
depending on engine load
(see also Service Instructions section 025).
As already mentioned, water contained in the scavenge air does not only have a detrimental
effect in liquid condensed form but also the vaporized or gaseous state can increase corrosive
wear to piston rings and cylinder liners. Such conditions are mainly observed when operating
in humid tropical areas and can be explained by the effect of water content in the combustion
air on the dew point temperature, as indicated in the following diagram.

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Service Bulletin RL-5

_C

1
2

4
2

Typical liner wall temp.


Dew point in cylinder
during expansion stroke
with normal cooler
operation and water
separation at ISO cond.
Same at tropical cond.

3
4
load%

Same at tropical cond. but


with elevated scavenge
temp. and thus high water
content in combustion air

From the diagram it can be seen that the operating range with liner wall temperatures above
dew point can be extended when the scavenge air temperature is lowered and the absolute
water content of the scavenge air is reduced to a minimum.

2.

CHARGE AIR RECEIVER

The following improvements may be beneficial to engines in service suffering from corrosive
wear of piston rings and cylinder liners.
It is recommended to consult the engine builder case by case.
2.1 RL 56 and 66 (enclosures RL-5/1 and /2)
At the bottom fixation for the water separators, steel plates S have to be welded-in on both
sides to prevent water from by-passing the separators by the air flow.
On RL 66 type engines only, the openings D (R = 50 mm) of the plates X have to be carefully
burnt-out to enable the condensate, which may accumulate in the respective spaces, to flow
out.
2.2 RL 76 and 90 (enclosures RL-5/3 and /4)
On both sides of the bottom fixation for the water separators, steel plates E and F have to be
welded-in to prevent water from by-passing the separators by the air flow.
Additionally steel plates G have to be welded-in.
By means of the latter, in- and outlet of the water separator reach the same level.
Same as for RL 66, openings D (R = 60 mm) of the plates X have to be carefully burnt-out.

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Service Bulletin RL-5

3.

WATER DRAIN PIPING SYSTEM (enclosure RL-5/5)

On mentioned enclosure the previous and the actually modified drainage system are
compared.
We recommend to install the automatic condense water drainage system which will ensure
sufficient cross-sectional area for proper drainage under all operating conditions (see as
well encl. RL-5/6).
Some automatic drain valves may have been supplied with a rather fine mesh filter.
This filter must be removed.
A small by-pass line permits a continuous limited flow of charge air and condense water.

4.

STORAGE / HANDLING OF CONDENSATE

As mentioned in the introduction considerable condense water quantities may have to be


dealt with.
In case of drainage to the bilge such quantities may exceed the capacity of the (dry) bilge
concept and frequently cause high level alarms. However, on no account should the drain
cocks be closed to prevent alarms.
Drainage to a tank for pumping over board via the oily water separator should be considered.

ENCLOSURES: as mentioned

New Sulzer Diesel Switzerland Ltd has issued this Service Bulletin with their best knowledge and
ability. However, New Sulzer Diesel Switzerland Ltd can not take any liability for any or all
information contained in this or any other Service Bulletin.
Changes of any nature to the form and or to the content of this or any other Service Bulletin as
published by New Sulzer Diesel Switzerland Ltd, are not permitted.
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Service Bulletin RL-5

RL 56
A-A

88.7251

B-B
A

88.7253

88.7252

Service Bulletin Enclosure RL-5/ 1

RL 66

A-A

88.7254

725
C

B-B

88.7256

88.7252

VTR 454

VTR 564

88.7255

Service Bulletin Enclosure RL-5/ 2

RL 76

A-A

C
D

88.7261

850
C

B-B

E
F

88.7259
88.7260

VTR 564

VTR 714

88.7258

Service Bulletin Enclosure RL-5/ 3

RL 90

A-A

C
D

88.7267

845

B-B

E
F

88.7268

88.7263

VTR 564

VTR 714

88 7262

Service Bulletin Enclosure RL-5/ 4

RL 56, RL 66, RL 76 AND RL 90 ENGINES


WATER DRAIN FROM CHARGE AIR RECEIVER
PREVIOUS DESIGN

Drain cock only to be shut when


washing cooler in port
Drain cock for charge air cooler
cleaning system
Drain cock
Sight glass
Throttling disc
To portable cleaning unit,
cleaning tank or bilge
To bilge or oily-water drain tank

NEW DESIGN
Level switch for receiver drainage
(high level alarm) on special request
Automatic drain valve

1 and 2 Cocks;
only shut cock 1 when washing
cooler in port

By-pass (permanently open)


Water drain from charge air receiver
1

To bilge or oily-water drain tank

To portable cleaning unit, cleaning


tank or bilge
Wash water from charge air cooler
Service Bulletin Enclosure RL-5/ 5

AUTOMATIC DRAIN VALVE

4
1
9

7
6
8
3
5
Mesh filter to be removed if fitted

Housing upper part

Float control

Joint ring (copper or soft iron)

Float control body with rotary valve

Housing lower part

Float with lever

Control valve

Fixation screw

By-pass (connection)

Service Bulletin Enclosure RL-5/ 6