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Service, Wärtsilä NSD Finland Oy Tekninen tiedote Teknisk bulletin
Engine section Engine type Ref. Date Issue Document No. Page
15 Intercooler :EWE WNSFI–S 30.11.1998 01 3215T033GB 1(2)

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(QJLQHW\SH This Technical Bulletin concerns Wärtsilä Vasa 32 engines (including
Wärtsilä Vasa 32GD engines).

*HQHUDO The charge air cooler maintains the thermal load of the diesel engine at
a correct level. This is very important for keeping fuel consumption and
operating costs at their designed values.

%DFNJURXQG An increasing pressure drop (∆p) over the charge air cooler (on the “air
side”) causes an increasing thermal load and increasing specific fuel oil
consumption (sfoc), see diagram below.
By constant measuring the ∆p over the charge air cooler, the condition of
the charge air cooler can be evaluated, and the air cooler can be cleaned or
changed to a spare air cooler without disturbing the normal operation of the
engine. 6HHLQVWUXFWLRQVRQSDJH
sfoc increase (%)


sfoc combined


sfoc due to increased
 charge air temperature

sfoc due to pressure
 drop over charge air cooler


running hours

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/HWWHUGLVWULEXWLRQ Wärtsilä NSD Service Network and owners/operators of Wärtsilä Vasa 32

engines (including Wärtsilä Vasa 32GD engines).

/HWWHUYDOLGLW\ Until further notice.

(QFORVXUH From the Wärtsilä Vasa 32 engine instruction manual:
Chapter 02, section 4, and chapter 15, page 6 and 7.
Spare parts picture 156 –18. Air cooler housing. Illustration: Measuring points.

Wärtsilä NSD Finland Oy P.O. Box 252 (Tarhaajantie 2) Telecop. +358 6 356 7355 Tel. +358 6 3270 Registered in Finland No. 465.942
Service, Vaasa FIN-65101 Vaasa, Finland Telecop. +358 6 356 7366 Telex 74251 wva fi Registered Office: Vaasa
Wärtsilä NSD Finland Oy P.O. Box 50 (Stålarminkatu 45) Telecop. +358 2 264 3279 Tel. +358 2 264 3111
Service, Turku FIN-20811 Turku, Finland Telecop. +358 2 264 3410 Telex 62640 wdfi fi
Service, Wärtsilä NSD Finland Oy Technical bulletin
Issue Document No. Page
01 3215T033GB 2(2)

,QVWUXFWLRQV The charge air cooler should be cleaned when the pressure drop has
increased by a maximum of 150 mm H2O (0.015 bar).
The Wärtsilä Vasa 32 engine has the following pressure drop values (at full
load and with a clean charge air cooler):
• For the 4R32 the ∆p value is approximately 200 mm H2O, (0.020 bar).
• For other cylinder configurations, the ∆p is approximately 300 mm H2O
(0.030 bar).

5HFRPPHQGDWLRQ It is important to clean the charge air cooler properly. The best result is
achieved with ultrasonic cleaning in a chemical bath for 24 – 36 hours. After
the ultrasonic cleaning the air cooler should be flushed with water.
• If not already installed, Wärtsilä NSD recommends equipment for
measuring the ∆p over the air coolers to be fitted to the engines.
Contact your Wärtsilä NSD service office or your service contact person at
Wärtsilä NSD Finland for more information and an equipment offer.

4 5
3UHVVXUHXQLW 1 bar = 10 mm H2O = 10 Pa (0.1 Mpa) = 750 mm Hg
FRQYHUVLRQ
 32-9701 Fuel, Lubricating Oil, Cooling Water

02.4 Chemical cleaning of charge air cooler air side

02.4.1 General

Cleaning of the air side should be done early enough to avoid accumu-
lations of soot and oil on the fins, which form a hard crust that is difficult
to remove, as well as a deposition of other crack products that form a
sulphuric acid (Compound with condensate) when left on the fins and
tubes for some time.
Generally an increase of pressure drop (∆p) over the cooler with 100
mmH2O compared to a new/clean cooler means that the cooler needs
cleaning. The pressure drop should be measured at 100 % load or at
least always at the same high load level.

02.4.2 Ultrasonic cleaning

Cleaning with ultrasonic equipment is recommended as it gives the

best cleaning result.

02.4.3 Chemical cleaning

We recommend chemical cleaning of the air side while the cooler is

removed, see section 15.5.

02.4.4 Recommended detergents

The instructions and handling guidelines provided by the manufac-

turer of the detergent in question should always be observed when
using the chemical.

02 - 19
 Fuel, Lubricating Oil, Cooling Water 32-9701

Recommended cleaning detergents

Supplier Product designation
Basol Ltd Basol 77

Clensol Ltd Industrial Clegris

Drew Ameroid Marine Division Ameroid ACC9

Ashland Chemical Company
One Drew Plaza
Boonton, NJ 07005, USA
Henkel KGaA P3-Grato 90
Düselldorf
Houseman Ltd H.D. Powder
The Priory, Burnham W.1.H.D.S phenol
Slough SL 1 7LS, UK
Nalco Chemical Company Nalfleet ACC
One Nalco Centre
Naperville, Illinois
60566 - 1024 USA
Vecom Holding BV Vecom B-85
PO Box 27
3140 AA Maassluis, Holland

02 - 20
 Turbocharging and Air Cooling 32-9801

15.5 Maintenance of charge air cooler

15.5.1 General maintenance

1 Condensate from the air is drained through a small hole/

pipe (6), Fig 15-1, at the bottom of the cooler housing, after the
insert, and at the opposite end plate of the air manifold. Examine
regularly that the pipe is open by checking the air flow when
running.

If water keeps on dripping or flowing from the draining pipe for a

longer period (unless running all the time in conditions with very high
humidity), the cooler insert may be leaky and must be dismantled
and pressure tested.

2 At longer stops, the cooler should be either completely filled

or completely empty, as a half-filled cooler increases the risk of
corrosion. If there is a risk of sinking water level in the system when
the engine is stopped, drain the cooler completely. Open the air vent
screw (3) to avoid vacuum when draining.
3 Clean and pressure test the cooler at intervals according to
chapter 04. or, if the receiver temperature cannot be held within
stipulated values, at full load.
4 Always when cleaning, check for corrosion.

15.5.2 Cleaning of air cooler

Cleaning of the water and air side heat exchange surfaces is imperative
for a long and trouble free operation of the engine and must be done at
regular intervals.
1 Remove the cooling water pipes. Loosen the cooler flange
screws and, on an in-line engine, withdraw the cooler until the
thread or the hole (7) for the lifting tool is visible. On the V-engine,
withdraw the cooler about 300 mm and fit the tool 32.84G02. Screw
on the tool by using four of the air cooler fastening screws. Then,
withdraw the cooler completely towards the tool stop. If necessary,
use screws in the two threaded extractor holes in the flange to loosen
the cooler.
2 Apply the lifting tool and lift off the cooler.

15 - 6
32-9801 Turbocharging and Air Cooling

3 Clean the air side of the cooler by immersing it in a chemi-

cal cleaning bath for at least 24 hours. Recommend cleaning deter-
gents, see section 02.4. We recommend that cleaning tank should be
equipped with perforated pipes on the bottom for the best cleaning
effect, see Fig 15-3. During cleaning steam or pressurised air should
be connected to the pipes to get a good circulation.
When cleaning is completed, the cooler should be flushed thor-
oughly by water.

Note! The use of a high pressure water jet for flushing, should be avoided
because:
- it will pack the dirt into the middle of the cooler.
- the risk of damaging the cooler fins is great.
Both of above will result in an increased pressure drop over the
cooler.

4 Clean the water side by detaching the headers (4) and (5)
from the cooler bundle and immersing the tube bundle into a
chemical cleaning bath for at least 24 hours. Upon completion,
follow the direction given for the air side.
5 Change the gaskets before reassembling the headers.
6 It is also recommended to pressure test the cooler before
mounting it on the engine.
7 Mount the cooler on the engine.
8 Vent the cooler and check the tightness when starting up.

Air cooler cleaning tank

Steam or air

Perforated pipes

Cooler insert

Fig 15-3 3215869701

15 - 7
 VASA 32 Spare Parts List 156-18
Edition A
Page 3(3)

Air Cooler Housing R32

VIEW A
156 074

156 079
156 020
A

See group 476-

156 118 156 117

156 021
156 022

156 119 156 116

156 075

Part No and Description Pcs Kg

156 020 Shield for intake bend 1

156 021 Screw 13
156 022 Spring washer 13
156 074 Screw 4
156 075 Housing for air cooler 1
156 079 Screw 4
156 116 Pipe union 2
156 117 Ball valve 2
156 118 Gasket 2
156 119 Pipe union 2
Air Cooler Measuring Points

Pipe union

Ball valve

5
When retrofitting a pipe
union (and ball valve)
a 5 mm hole must be
drilled through the cooler
housing. The hole is
drilled in the bottom
of the mid fastening
screw holes – on both
sides of the cooler.

mm H 2O