TECHNICAL

BULLETIN

Wärtsilä 2-stroke RT-157

Technical Services Issue 1, 06 November 2013

Piston running behaviour

For your information

Information to all Owners and Operators of Concerned components

Wärtsilä RTA82T and RT-flex82T engines Pulse feed cylinder liners of Wärtsilä
RTA82T and RT-flex82T engines.

Current situation
These days most Wärtsilä 2-stroke diesel
engines are operated at continuous low
load (below 60% CMCR).

Problem
Running diesel engines at low loads might
lead to cold corrosion of the cylinder liners.

Solutions
To reduce the risk of cold corrosion
Wärtsilä recommends:
• Adapt the lubricating oil Base Number
(BN) to the piston underside residual
BN.
• Increase of cylinder liner wall
temperature by installation of cylinder
liner cooling bore insulation and
increase of cylinder cooling water outlet
temperature.
• Modify the load program,
• Adjustment of the cylinder lubricating oil
feed rate curve and dosage correction
factors.
Details to these recommendations are
described in this Technical Bulletin.

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

PO Box 414
CH-8401 Winterthur [email protected]
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Contents
Page
1 Introduction 2
2 Recommendations 2
2.1 Choice of cylinder lubricating oil 2
2.2 Blending on Board 3
2.3 Cylinder cooling water outlet temperature 3
2.4 Modified load program 4
2.5 Feed rate curve, dosage correction factor adjustment 7
2.6 Insulation of cooling bores in cylinder liners 8
2.7 Lubricating oil grooves 9
2.8 References to other related documents 11
3 Contacts 12
3.1 How to contact Wärtsilä 12
3.2 Contact details for emergency issues 12

1 Introduction
This Technical Bulletin is intended for customers operating Wärtsilä RTA82T and
RT-flex82T 2-stroke engines mainly at continuous low load (below 60% CMCR and
down to extreme low loads). To prevent possible piston running problems at low load
operation, recommendations and countermeasures are summarised to improve the
piston running behaviour.
Latest service experience showed that the choice of high BN cylinder oils is of utmost
importance to secure satisfactory piston running condition.

2 Recommendations
The following solutions and advice are recommended to be implemented in order to
limit the adverse effects on the piston running behaviour during continuous low load
operation.

2.1 Choice of cylinder lubricating oil

One of the most effective countermeasures in case of cylinder liner corrosion with
excessive wear rates is to adapt the lubricant Base Number (BN) in correspondence
with the residual BN found in the piston underside drain oil analysis.

Specially in challenging running conditions with a high sulphur fuel and continuous low
load operation, the use of high BN lubricants (BN higher than 70) showed an improved
cylinder liner condition. The high BN lubricants neutralise the sulphuric acid formed in
the combustion chamber and reduce the deposits with a higher detergency effect.
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2.2 Blending on Board

The main purposes of cylinder lubricating oil are:

• Building an optimal oil film between the cylinder liner and the piston rings.
• Neutralisation of sulphuric acid formed during combustion.
• Detergent and dispersant property in order to keep the piston, piston rings and
cylinder liner free from deposits.

The traditional way of dealing with operational conditions that increase the risk for cold
corrosion or other adverse piston running conditions is increasing the cylinder oil feed
rate. As the cylinder oil consumption is a significant part of the engine’s operational
costs, Wärtsilä has introduced the Blending on Board (BOB) system. Rather than being
bound to one or two cylinder oils with fixed base numbers (BN) and the need for
increasing the cylinder oil feed rate, the BOB system allows for matching the BN to the
actual fuel sulphur content and operating conditions such as slow steaming. BOB
consists of a blending unit and an oil analyser. The unit blends an additive package
using the main engine system oil as base oil. This offers the possibility to blend the
cylinder oil with a BN ranging from 40 up to 120 as circumstances may require. The
feed rate remains at an optimum level.

For more information please contact your nearest Wärtsilä representative.

Additional information about BOB was published in the Wärtsilä Technical Journal “in
detail”, issue no. 01.2012. The journal can be found on the Wärtsilä webpage or it is
directly accessible via the link:
http://www.wartsila.com/file/Wartsila/1278525950755a1267106724867-Wartsila-SP-A-Id12-1-BOB.pdf

2.3 Cylinder cooling water outlet temperature

In order to improve the piston running performance and reduce the risk of cold
corrosion in cylinder liners, the temperature range of the cylinder cooling water outlet is
increased. In fact Wärtsilä recommends keeping the cylinder cooling water outlet
temperature as close as possible to the alarm limit. As a consequence of the increase
of the cylinder cooling water temperature the respective alarm and slowdown setting
need to be adjusted as well.

Table 1, Cooling water temperature settings

Mode New value Previous value

Operating temperature 85 °C to 95 °C 80 °C to 90 °C
Alarm 95 °C 90 °C
97 °C 95 °C
Slowdown 60 seconds delay in 60 seconds delay in
Engine Safety System (ESS) Engine Safety System (ESS)

ATTENTION:
In case that additional information and instruction on how to apply the new values is
needed, please contact the respective Alarm and Monitoring System (AMS) maker.
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2.4 Modified load program

Loading up of a Wärtsilä two stroke main engine is controlled by the load program built
into the Remote Control System (RCS).
For a fix pitch propeller (FPP) installation there is a fix relation between main engine
speed and power. Therefore the load program in the RCS is defined as main engine
speed versus time.

By altering the load program, i.e. extending the acceleration time of the engine, the
piston running behaviour can be improved. This can be achieved by increasing the time
values of the load program in the RCS.

With the extended load program the condensate flow peak from the scavenge air
cooler can be reduced during acceleration of the engine, especially when operating in
tropical areas. With the present condensate flow peak there is a certain risk of water
carry-over through the water separator. Water carry-over can be harmful for the piston
running behaviour depending on the amount of water and ambient conditions.

Wärtsilä specifies 5 break points for the load/speed program in the RCS as per Table 2
and graphically presented in Figure 1.

Table 2, Parameter settings in RCS

Break point Wärtsilä recommendation

Speed Time interval Time interval
Old setting New setting
[% CMCR] [min] [min]
0 0% 0 0
1 25% 0 0
2 45–55% 0.1 0.1
3 60–70% 0.5 0.5
4 92% T4 = 23 T4 = 45
5 104% T5 = 49 T5 = 60
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100
CMCR

 2
80
Speed [% CMCR]

60 

40
T4 T5

20


0

0 20 40 60 80 100
Time [min]
1. Old setting  to  Break points
2. New setting
Figure 1, Load-up curve for RTA82T and RT-flex82T engines

Break points 0 to 3 define the manoeuvring range from engine start to full manoeuvring
speed. This remains unchanged.
Break points 3 to 5 define the load program. It has to be mentioned that Wärtsilä
defines T4 and T5 as intervals between break points 3 and 4 (T4) and break points 4
and 5 (T5), see Figure 1.
It also needs to be pointed out that Wärtsilä defines an over range up to 104% CMCR
speed. Therefore the time interval between break point 4 and the point where 100%
CMCR speed is reached is only 2/3 of T5.

With the new settings specified in Table 2 the loading-up between break point 3 and
break point 5 will be increased by 33 min from 72 min (23 min + 49 min) to 105 min
(45 min + 60 min).
At the same time the loading up between break point 3 and full sea speed (100%
CMCR speed) will be increased by 29 min from 56 min (23 min + 33 min) to 85 min
(45 min + 40 min).

To achieve the extended load program as per Wärtsilä’s recommendation the values
T4 and T5 need to be changed in the RCS.

NOTE:
The code for the parameters T4 and T5 – Wärtsilä designation – depends on the
Remote Control System (RCS) manufacturer. A short instruction how to adjust the
parameters of the Remote Control Systems is given in the next paragraph.
For more detailed information please refer to the documentation of the respective
maker or contact the RCS manufacturer for assistance.
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2.4.1 Parameter changes in Kongsberg Auto Chief AC C-20 system

NOTE:
Whereas Wärtsilä defines T4 and T5 as time intervals Kongsberg uses parameters as
total times, i.e. for T4 from break point 0 to break point 4 and for T5 from break point 0
to break point 5.

Due to Kongsberg’s different load program setup the values that need to be set in the
AC C-20 system are recalculated as follows:

Time to break point 4 = 45 min

Time to break point 5 = 105 min
The short time between break point 0 and 3 is negligible and not taken into account.

The load program values can be adjusted from the Autochief Control Panel ACP in the
engine control room.

Starting from the main view navigate to “MISC MENU” -> “PARAM. CHANGE” -> “RPM
LIMITERS” -> “SPEED PROGRAM”. Use “Next Page” to go to page 2.

Adjust “Time to breakpoint #4 (32.61 F)” to 45 minutes

Adjust “Time to breakpoint #5 (32.61 H)” to 105 minutes

2.4.2 Parameter changes in Lyngsoe Marine / SAM DMS2100 system

The load program settings in Lyngsoe Marine / SAM DMS2100 system can be adjusted
from the panel in the engine control room.

NOTE:
The settings for the load up times are made in seconds.

Adjust time for Lower Sea Range (= T4) to 2700 seconds (45 minutes)
Adjust time for Upper Sea Range (= T5) to 3600 seconds (60 minutes)

2.4.3 Parameter changes in Nabtesco M800-III system

The load program settings in Nabtesco M-800-III system can be adjusted from the
numerical keyboard “TENKEY” in the engine control room.

Adjust parameter “110 LOAD UP PROGRAM LOWER ZONE” to 45 minutes

Adjust parameter “111 LOAD UP PROGRAM UPPER ZONE” to 60 minutes
Adjust parameter “042 KNUCKLE POINT OF LOAD UP PROGRAM” in (RPM) to 92%
of CMCR speed (speed value of break point 4).
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2.5 Feed rate curve, dosage correction factor adjustment

To reduce the risk of cold corrosion, the feed rate curve can be optimised for low load
operation. The following proposal will increase the feed rate break points at low load
operation (below 60% CMCR). This dosage correction factor adjustment can be done
with the flexAdjust file, which can be ordered from Wärtsilä free of charge.

• Change dosage factor at 20% load from 125% to 150%

• Change dosage factor at 10% load from 156% to 220%
• Change load from 50% to 60% for dosage factor 106%

Table 3, flexView adjust screen shots

2.5
Feed rate factor

Recommended pulse feed curve

for RTA82T and RT-flex82T engines
1.5

Original pulse feed curve 75%

1
0% 10% 20% 30% 40% 50% 60% 70% 80%
Load
Figure 2, Feed factor curve
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2.6 Insulation of cooling bores in cylinder liners

Wärtsilä’s experience confirmed the reliability of insulated cylinder liners specially for
preventing cold corrosion at low load operation. In addition to the already existing
bandage for mid-stroke insulation (also called Haramaki), we recommend the
installation of the cylinder liner cooling bore insulation.

2
5

3 1 6

1. Cylinder liner 4. Anti-polishing ring

2. Cylinder liner insulation tubes 5. Cylinder cover
3. Mid-stroke insulation – Haramaki 6. Piston rod with piston
Figure 3, Insulation of cylinder liners

For cylinder liners without insulation and running at low load (below 60% CMCR),
Wärtsilä recommends insulating the cylinder liners.

Table 4, Cylinder liner insulation executions

Engine types Engines in service with New spare

cylinder liner insulation cylinder liner
Insulation tube Haramaki Insulation tube Haramaki
RTA82T Recommended Standard Yes Yes
RT-flex82T Recommended Standard Yes Yes

NOTE:
All new spare cylinder liners will be delivered with pre-installed insulation tubes and
Haramaki.
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2.6.1 Order information

Please contact your nearest Wärtsilä representative for ordering insulation tubes
installation. The insulation is depending on the location of the CMCR point in the rating
field of the engine.

2.7 Lubricating oil grooves

Field test investigations showed that additional and optimised lubricating oil grooves
improve the distribution of cylinder lubricating oil and as a consequence, the piston
running behaviour will be improved.

ATTENTION:
Pulse feed execution: Old and new executions of pulse feed cylinder liners are in
operation. Old executions can be upgraded on request, see Chapter 2.7.2.

Former pulse feed execution New pulse feed execution

2 2

1. Umbrella grooves
2. Zig-zag grooves
3. Lubricating oil collecting grooves
Figure 4, Location and type of grooves in RTA82T and RT-flex82T cylinder liners
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2.7.1 Benefit of grooves

Umbrella grooves
• Enhances the vertical lubricating oil distribution, hence reduces the wear of the
cylinder liner.

Zig-zag grooves
• Enhances the main horizontal lubricating oil distribution.

Lubricating oil collecting grooves (LOCG)

• Reduced lubricating oil losses through inlet ports to piston underside and reduced
particle transfer to neighbour cylinder liners.

1 3

1. Umbrella grooves 3. Zig-zag grooves

2. Zig-zag grooves
Figure 5, Cylinder liners with grooves

2.7.2 Cylinder liner grooves upgrade

New pulse feed cylinder liners will be delivered according to the execution as shown in
Figure 4.

The umbrella grooves can be applied in situ on request. Please contact Wärtsilä.

When pulse feed cylinder liners are sent for re-honing, the latest execution of the
grooves can be applied on owner’s request.
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2.8 References to other related documents

NOTE:
Check always for the latest version of the listed Service Bulletins in Table 5.

Table 5

Publication Title Topic

Maintenance Manual Maintenance Schedule,
RTA82T, RT-flex82T Inspection and Overhaul
Intervals
Group 0, Chapter 0380-1
Technical Bulletin Sulphur-dependent cylinder oil Feed rate adjustment depending
RT-113 feed rate on the fuel sulphur content.
Service Letter Cylinder lubrication at low load The use of high BN lubricating oil
RT-148 operation – use of intermediate (higher than BN 70) is
BN lubricating oils recommended when using a fuel
with a sulphur content higher
than 2.50% and
continuous low load operation
(below 60% CMCR).
Data & Specifications Lubricating oils Chapter 3.2:
RT-138 Oil analysis of the piston
underside drain or
scrape down samples.
Data & Specifications Appendix 1 to RT-138, Follow the recommendations
RT-138_A1 Validated lubricating oils about lubricating oils.
Data & Specifications Diesel engine fuels Follow the recommendations
RT-126 about fuel oils.
Service Letter Piston running behaviour at
RT-93 low load operation
Service Bulletin Continuous Low Load Operation
RTA-79.2 / RT-flex-08.2 (Slow Steaming)
Service Letter Non-return valve of pulse feed Check the version of non-return
RT-117 lubricating system valve of the pulse feed
lubricating system.
Technical Bulletin CLU4 pulse lubricating module:
RT-110 Pressure check and
maintenance
Service Bulletin Running-in of Cylinder Liners
RT-18.4 and Piston Rings
Technical Bulletin Catalyst fines in fuel oils
RT-140
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3 Contacts
3.1 How to contact Wärtsilä
For questions about the content of this Technical Bulletin, 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

3.2 Contact details for emergency issues

3.2.1 Operational support
For questions concerning operational issues, please send your enquiry to:
[email protected]
or phone 24hrs support: +41 52 262 80 10.

3.2.2 Field service

If you need Wärtsilä Field Service, please send your enquiry to:
[email protected]
or phone 24hrs support: +41 79 255 68 80.

3.2.3 Spare parts

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

© 2013 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 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.