GENERAL

INFORMATION

2 Stroke Engine Services RT-137

Issue 3, 15 November 2016

Maintenance concepts for

RT-flex & W-X components
Information to all Owners and Operators of
Wärtsilä RT-flex and W-X engines
Next opportunity
Affected components
Selected components of Wärtsilä RT-flex
and W-X 2 Stroke engines primarily Fuel
Oil Pumps (FOPs), Injection Control Units
(ICUs) and Pressure Control Valves
(PCVs).
The listed components are referred to as
RT-flex components but also apply to the
W-X engines.

Current situation
Life-cycle maintenance costs experienced
throughout an engine’s lifetime are
continuously 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 / W-X components.

Note
This General Information Issue 3
supersedes General Information RT-137,
Issue 2, dated 05. July 2014.
Reasons:
Adding new engine type family.
For each RT-flex / W-X component a
separate appendix is introduced,
Appendix A1 for FOPs, Appendix A2 for
ICUs and Appendix A3 for PCVs.

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

PO Box 414
CH-8401 Winterthur technicalsupport.chts@wartsila.com
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Contents
Page
1 Introduction 2
2 Available concepts for RT-flex / W-X components 3
3 Recommended overhaul schedules 6
4 Ordering and delivery process for remanufacturing 6
5 Appendix 7
6 Contacts 7

1 Introduction
NOTE:
This General Information bulletin supersedes General Information RT-137, Issue 2,
dated 05. July 2014, due to the following reasons:
Adding new engine type family.
Update of all Appendices A1, A2 and A3.

Wärtsilä RT-flex and W-X engine technology enables more flexible and efficient engine
operation. The use of electronically controlled RT-flex and W-X components allows the
optimisation of engine performance across all engine loads and accomplishes fuel
consumption reduction compared to mechanically controlled engines.

Wärtsilä continuously focuses on reducing the total operating costs of our engines. The
maintenance costs of RT-flex and W-X 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 maintenance approach to suit the individual needs during vessel operation.
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2 Available concepts for RT-flex / W-X components

NOTE:
For detailed information consult:
- Appendix A1 for Fuel Oil Pumps (FOP)
- Appendix A2 for Injection control unit (ICU)
- Appendix A3 for Pressure Control Valve (PCV)

In order to support various requirements for the maintenance of RT-flex / W-X

components, the following flexible approaches are available:

Table 1

On-board Repair Kits

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

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

2.1 On-board Repair Kits (A)

NOTE 1:
Details of the available On-board Repair Kits and order numbers are given in Appendix
A1, A2 and A3.

NOTE 2:
As the repair or overhaul of RT-flex / W-X components onboard will be outside of any
possibilities for quality control by Wärtsilä, no warranties can be granted on these
components 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 components only by the remanufacturing process.

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

In order to properly install the repair kits, Wärtsilä prepared Instructions for each of the
On-board Repair Kit. The Instruction will be delivered with the ordered kit. The repair
kits are for repair purposes only.

2.2 Remanufactured components (B)

When an overhaul of a RT-flex / W-X components becomes necessary according to
maintenance schedules or condition, the purchase of remanufactured components is
offered as a cost optimised alternative to new components.

The details of this maintenance concept are shown in the Bulletin General Information
RT-119, entitled “Remanufacturing services”.

The Remanufacturing services are available in two different ways:

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

All remanufactured components are released to the latest specification with any and all
design changes required.

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

2.3 New OEM1 spare parts (C)

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

1
Original Equipment Manufacturer
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2.4 RT-flex / W-X parts agreements (D)

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

The principle of such an agreement is for Wärtsilä to provide all required new parts,
remanufactured components 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.
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3 Recommended overhaul schedules

The recommended Time Based Overhaul periods of all RT-flex / W-X components are
detailed in the Data & Specifications Bulletin RT-123, entitled “Inspection and overhaul
intervals” including the Appendix of the Bulletin RT-123.

3.1 Recommended overhaul schedules when employing On-board Repair Kits

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

An onboard overhaul using all repair kits cannot achieve the same quality as
remanufactured components. The On-board 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 / W-X 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 components 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.

4 Ordering and delivery process for remanufacturing

For the ordering, delivery and return process of remanufactured RT-flex and W-X
components please refer to the General Information Bulletin RT-119, entitled
“Component remanufacturing services”. This covers both, exchange components and
remanufacturing of customer’s own components.
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5 Appendix
Appendix 1, RT-137_A1
On-board Repair Kits for Fuel Oil Pump (FOP), information and order numbers.
Appendix 2, RT-137_A2
On-board Repair Kits for Injection Control Unit (ICU), information and order
numbers.
Appendix 3, RT-137_A3
On-board Repair Kits for Pressure Control Valve (PCV), information and order
numbers.

6 Contacts
6.1 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.

6.2 Contact details for emergency issues

6.2.1 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.

6.2.2 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.

6.2.3 Spare parts

If you need Wärtsilä spare parts and/or tools, please contact your nearest Wärtsilä
representative or your key account manager.

© 2016 Wärtsilä Services 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 Services
Switzerland Ltd 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 of the product, but merely as an improvement of the product 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.