Service Bulletin RTA-58

15.10.02
Technical Information to all Owners / Operators of
Sulzer RTA “-C and -T Series” Engines

Cleaning of Scavenge Air Cooler

During Operation and at Standstill

Contents: Page

1. Introduction 1

2. General 1

3. Operating Instructions 1

4. Air Side Cleaning of the SAC in 2

Service

5. Cleaning of the Scavenge Air Pre- 5

stage Coolers on Engine Types
RTA96C/C-B and RTA84T-D with
Charging Module at Engine Stand-
still

6. Service Bulletins Published for 6

Large Bore RTA–Type Engines
28. 84.71.40 Printed in Switzerland

Wärtsilä Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22

Wärtsilä Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17
Wärtsilä Suisse SA Switzerland E–mail: mail–ch@wartsila.com
1. INTRODUCTION

This Service Bulletin informs you about the cleaning of the scavenge air cooler(s) during operation of
the engine. It has to be clearly stated that all the instructions given in our Maintenance Manuals as well
as in the Operating Manuals concerning cleaning of the scavenge air coolers are superseded by the
instruction given in this Service Bulletin.
The RTA “-C Series” comprises the following engine types in this Service Bulletin:
RTA84C, RTA84CU, RTA96C, RTA96C-B
The RTA “-T Series” comprises the following engine types in this Service Bulletin:
RTA84T, RTA84T-B, RTA84T-D

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.

2. GENERAL
A scavenge air cooler (SAC for short) is installed after each exhaust gas turbocharger whose purpose
is to cool the compressed and thereby heated scavenge air before it gets to the cylinders via water
separator and scavenge air receiver. The standard cooler is a single-stage multi-pass cooler. The
cooling water flows through the cooler in four to six water passes in the opposite direction to the air
flow, depending on the cooler size. It enters the cooler at ’KE’(see Fig. A on page No. 3), flows
through it in various directions, and leaves at ’KA’(see Fig. A on page No. 3). The temperature
difference water / scavenge air is thus distributed equally along the whole cooler.

3. OPERATING INSTRUCTIONS
As accumulated air in the cooling water system of the scavenge air cooler can lead to operating
troubles on the engine and to damage of the SAC, proper functioning of the SAC venting must be
ensured. The scavenge air cooler temperature must be checked periodically in accordance with
Operating Data Sheet 0250–1.
Should an alarm be triggered in operation by level switch 20 (see Fig. B on page No. 4) for the
condensate drain unit 18, it must be investigated whether the water is condensate water or scavenge
air cooling water. Should the latter be the case, then the cooler must be dismantled and repaired (see
Maintenance Manual 6509–2 and 6606-2). Please refer also to page No.5 (Drain System).
To prevent damage to the SAC, the correct cooling water flow must be maintained in operation. The
flow of cooling water must not be throttled at partial load nor during manoeuvring.

Note: The butterfly valves at the cooling water inlet and outlet pipes must not be used for controlling
the flow rate, otherwise the water separators (plastic) could be damaged due to too high
scavenge air temperatures at higher loads.
Concerning operation with a defective scavenge air cooler, recommendations can be found in
0550–1.
As a guide to proper functioning of the SAC, the temperature difference between scavenge air outlet
and cooling water inlet at the SAC can be taken as a basis. The two temperature values have to be
checked periodically. If the difference increases while engine load and cooling water flow remain
unchanged, it is a sign of increasing fouling of the SAC.

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If the fouling is on the water side of the SAC, the scavenge air temperature increases.
If the fouling is on the air side, the pressure difference (∆p) of the scavenge air through the SAC
increases. This does not show the full effect of the fouling because an increased resistance also causes
a reduced air throughput from the turbocharger (pay attention to limiting values). More detailed
indications for the monitoring of the SAC in operation are given in the Operating Manual 0250–1/A1.
Higher scavenge air temperature and reduced air flows both lead to increased thermal loading of the
engine and to higher exhaust gas temperatures.

4. AIR SIDE CLEANING OF THE SAC IN SERVICE (ENGINE IN OPERATION)

The equipment necessary for air side cleaning of the SAC is installed on the engine (see Fig. ’A’).

4.1. Cleaning Intervals

To achieve an optimum cleaning effect of the SAC, carry out the cooler cleaning always after cleaning
the compressor of the turbocharger. The degree of contamination of the SAC depends to a major
extent on the condition of the intake air (too much dust entering through the engine room ventilation
and oil mist in the engine room), as well as on the maintenance and the type of the suction filters.
Experience will show whether the time intervals can be extended.

4.2. Cleaning Procedure

The cleaning should be carried out with the engine operating in the lower load range, i.e. the scavenge
air temperature before air cooler should not exceed 100 C (measured at the diffusor just after TC), as
otherwise too much of the cleaning agent will vaporize.
The following parameters can also be used to make sure that the temperature of the scavenge air after
turbocharger is not too high, this in case that there is no thermometer installed as mentioned above.
Engine parameters: psc
0.8 bar

4.3. Cleaning in Tropical Areas

Air cooler cleaning in tropical areas should be avoided if possible. In tropical areas the amount of
water which is carried by the scavenge air can be very high. In this case the cleaning agent will be
diluted too much and the cleaning effect lost.

Note: If the cleaning agent and the wash-water have to be collected because of environmental
protection, this can be carried out by opening ball cock 22 (Fig. B page No. 4) during the
cleaning procedure. Close ball cock 22 again after the cleaning procedure has been finished.
As dirt loosened from the cooling fins might collect in the water separator elements or in the
scavenge air receiver 4, they must occasionally be checked and cleaned out (see Maintenance
Manual).

4.4. Cleaning Agent

For air cooler cleaning, only products from reputable firms, which are in accordance with the
regulations for Safety at Sea, should be utilized. Their instructions concerning mixing ratio etc. have
to be followed in detail. The water and the cleaning agent have to be mixed together before they are
filled into the container of the cleaning system.

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 4.5. Without cleaning of SAC and TC Blower Side
Since a few years on many vessels there is no more cleaning of the SAC applied. Instead of cleaning
the SAC and the TC blower side , an additional felt on the top of the coarse air inlet filter is installed.
Based on the increase of ∆p e.g. to max. 100 mm WG or discolouration of the filter mat, the felt will be
changed and the dirt can be washed out. With this simple method the pressure drop over the air cooler
on the air side can be kept constant for a very long period of time.
A combination of both i.e. washing in much longer periods and felt installation may extend the time of
visible increase of pressure drop accross the SAC.

A ⇒ Prepare the specified quantity of water and cleaning

PLANT ENGINE
agent in a separate container.
Attention: For safety reasons always fill in the water
8 5 first and then start giving the cleaning agent into the wa-
Fresh Water ter. (Content of bottle max. 32 liters).
FW ⇒ Reduce the engine power to the mentioned values.
10
DL
Compressed air and fresh water must be available at
Compressed Air 14 shut-off valves 9 and 10.
7 6 12
⇒ Open venting valve 11 and ball cock 12.
11
9 ⇒ Fill the specified quantity of water and cleaning agent
1 mixed before together (see paragraph ’Cleaning
4 3 2 16 agent’) into the container 1 (max. 32 liters) through
filling funnel 14.

13 ⇒ Close ball cock 12 and venting valve 11.

⇒ Open shut-off valve 9 and ball cock 13 on the contai-
ner 1, by which the content is sprayed through the
spray nozzles 16 within about 1 minute.
⇒ Open ball cock 17 and drain the cleaning fluid. (*)
⇒ Close shut-off valve 9 and ball cock 13.
15
⇒
009.226/01
Open shut-off valve 11 till container 1 is vented.
KE KA 17 ⇒ Close ball cock 17. (*)
⇒ Fill the container 1 by opening the valves 12 and 10 after
about 10 minutes with clean Water, but add no cleaning
agent.
⇒ Repeat the points which are printed in bold type.

End of the cleaning process.

Note: (*) Only for engine types RTA96C/C-B and RTA84T-D

Key to illustration A
1 Container 12 Ball cock
2 Pre–stage SAC * 13 Ball cock
3 Scavenge air cooler 14 Filling funnel
4 Receiver 15 Distributing pipe
5 Fresh water distributing pipe 16 Spray nozzles
6 Compressed air distributing pipe 17 Ball cock *
7 Shut–off valve
8 Shut–off valve FW Fresh water 2.5 bar
9 Shut–off valve DL Compressed air from board system 7 – 8 bar
10 Shut–off valve KE Cooling water inlet
11 Venting valve KA Cooling water outlet

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 5 8 ENGINE PLANT
B
Fresh Water
FW

10 6 7

12 DL
Compressed Air
11
9
1
4
13

23
21
20

18

22
19
24

009.286/01
OW WE EL WE

Key to Illustration: B’ Arrangement of washing water system on the engine

1 Container 18 Condensate drain unit

5 Fresh-water distributing pipe 19 Throttling disc
6 Compressed air distributing pipe 20 Level switch
7 Shut-off valve 21 Wash-water drain *
8 Shut-off valve 22 Ball cock
9 Shut-off valve 23 SAC drain
10 Shut-off valve 24 Venting unit
11 Venting valve
12 Ball cock EL Vent
13 Ball cock FW Fresh water 2.5 bar
DL Compressed air from board system 7–8 bar
OW Drain to sludge water tank (containing oil)
WE Drain to bilge water tank

Note: * Only for RTA 96C/C-B and RTA84T-D engines

4/6 Service Bulletin RTA–58

5. CLEANING OF THE SCAVENGE AIR PRE-STAGE COOLERS ON ENGINE
TYPES RTA96C/C-B AND RTA84T-D WITH CHARGING MODULE AT ENGINE
STANDSTILL

On the above mentioned engine types the cleaning of the pre-stage scavenge air coolers should be
done with the engine at standstill. To carry out the cleaning a high pressure cleaning unit should be
available. Trough the openings in the charge air module the pre-stage cooler can get cleaned by the
high pressure gun of the mobile high pressure cleaning unit. Thereby care has to be taken that the
pressure is limited to 75 - 80 bar, in order not to damage the cooling fins.
In case the pre-stage cooler can not be cleaned anymore with a high pressure cleaning device the
pre-stage of the air cooler has to be removed from the engine and can be cleaned in an ultrasonic bath.

Pressure limited to 75  80 bar

Wärtsilä Switzerland Ltd has issued this Service Bulletin with their best knowledge and ability.
However, Wärtsilä 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 Wärtsilä Switzerland Ltd, are not permitted.

5/6 Service Bulletin RTA–58

6. SERVICE BULLETINS PUBLISHED FOR LARGE BORE RTA–TYPE ENGINES

We have so far published the following Service Bulletins which are valid for Large Bore RTA–Type Engines
(RTA 48T to RTA 96C):
RTA–1 dated 01.03.88 Recommendation Concerning Piston Running Behaviour
RTA–2 dated 05.10.88 Water Drain from Charge Air Receiver and Charge Air Temperature
RTA–3.4 dated 30.03.98 Fuel Injection Nozzles
RTA–4 dated 20.11.89 Oil Damping for Short Tie Rods
RTA–8 dated 15.06.92 RTA–Cylinder Liners and Reinforced Water Guide Jackets
RTA–9 dated 20.07.92 Cylinder Cover with Erosion / Corrosion Resistant Cladding
RTA–10 dated 28.10.92 RTA ”–8 Series” Engines / Piston Skirt in Two Parts
RTA–11.2 dated 11.05.2001 Fuel Injection Pump Regulating Linkage
RTA–14 dated 30.11.93 System Oil Care and Maintenance
RTA–15 dated 10.02.94 Elastic Studs on RTA-Type Engines
RTA–16.1 dated 20.02.98 Retrofit for Piston Rod Stuffing Boxes for RTA ”-8 Series” Engines
RTA–17.1 dated 28.02.95 Circulation Valve to Fuel Injection Valve
RTA–18.2 dated 14.06.2002 Running-in of Cylinder Liners and Piston Rings
RTA–19 dated 28.10.94 Oil Supply Monitoring for Geislinger Torsional Vibration Damper
RTA–20 dated 30.11.94 Rotational Safety Studs for Roller Guide of Fuel Pump and
Exhaust Valve Actuator
RTA–21 dated 10.04.95 Improvement of Starting Behaviour (For engines with
DENIS–1 and DENIS–5 Control Systems only!)
RTA–22.1 dated 28.11.96 Waisted Bolts for Piston Crown Spraying Plate of RTA 84C,
84CU, 84M and 84T Type Engines
RTA–24.2 dated 18.05.99 VTR..4 Turbochargers After Sales Service Information issued by ABB
RTA–26 dated 03.01.96 Loss of Material on Piston Crowns due to High Temperature
Corrosion and Erosion (Watercooled Pistons)
RTA–27 dated 26.04.96 Plastic Water Separator
RTA–28 dated 31.05.96 Improvement of the Engine Control System
RTA–29 dated 21.10.96 Improved Oil Supply to the Integrated Axial Detuner
equipped with Internal Oil Supply Line
RTA–30 dated 27.11.96 Improvement of starting behaviour on RTA engines equipped
with Type PGA200 and PGA EG200 Woodward Governors
RTA–31 dated 23.01.97 Alphabetical Index of Topics of Service Bulletins
RTA–33 dated 11.04.97 Crank Pin Bearing Shell
RTA–34 dated 28.11.97 Fuel Injection System Modification and Maintenance
RTA–35.1 dated 07.06.2001 Retrofit for Piston Rod Stuffing Boxes for RTA ”-2 and -2U Series” Engines
RTA–36.1 dated 08.06.2001 Reconditioning of Piston Rods of RTA “-2 Series” Engines
RTA–37.1 dated 11.06.2001 Reconditioning of Piston Rods of RTA “-8 Series” Engines
RTA–38 dated 26.02.98 Piston Crown Loss of Material on Combustion Side
RTA–39 dated 31.03.98 Overhaul and Reconditioning of Pistons
RTA–42.1 dated 14.03.2002 Templates for Exhaust Valve Seat and Spindle
RTA–43.1 dated 09.01.2002 Piston Rings
RTA–44 dated 26.02.99 Tightening Instructions for the Plunger Guide Nipple
RTA–45 dated 03.06.99 Tightening Instructions for Screws and Waisted Studs
RTA–46 dated 17.06.99 Cracks in Columns
RTA–47 dated 28.06.99 Draining of Fuel Oil Pipes; Modification to Shut-off Valves of Fuel Pipes and
Drain Plug of Fuel Pump Block
RTA–48 dated 20.09.99 Instruction for Replacement of NOx Relevant Components on IMO
Compliant Sulzer RTA Engines
RTA–49 dated 08.10.99 Gearing for Auxiliary Drives Z 42800
RTA–50 dated 10.01.2000 Leakage Oil Collector in Air Spring System
RTA–51 dated 21.08.2000 Deflagration in Engine Scavenge System and Exhaust Manifold
RTA–52 dated 22.09.2000 Water Separator on RTA – Type Engines
RTA–53 dated 12.06.2001 Variable Injection Timing and Fuel Quality Setting
RTA–54 dated 18.07.2001 Electronic Variable Injection Timing Troubles and Remedies
RTA–55 dated 31.10.2001 Exhaust Valve Seat and Exhaust Valve Spindle
RTA–56 dated 26.02.2002 Indicator Valves
RTA–57 dated 20.06.2002 Improved Starting Behaviour with Quick Venting Valves
RTA–58 dated 15.10.2002 Cleaning of Scavenge Air Cooler During Operation and at Standstill
Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contact your local
Wärtsilä representative for your copy.

6/6 Service Bulletin RTA–58