Diesel After-Sales Service

Service Letter RLB–90

Technical Information to all the Owners 24.12.93
of Sulzer RLB 90 Type Diesel Engines (Revised: 01.03.95)

Conversion to Loop Cooled

Cylinder Liners to Improve
Piston Running Performance

Contents: Page

– INTRODUCTION 1

– 1. RETROFIT KIT WITH ”LOOP 1

COOLED” CYLINDER LINER
(”FULL PACKAGE”)

– 2. INTERMEDIATE PACKAGE 2

– 3. CONVERSION FROM INTER- 3

MEDIATE TO FULL PACKAGE

New Sulzer Diesel Ltd Diesel After-Sales Service PO Box 414 CH-8401 Winterthur, Switzerland
Phone: (052) 262 80 10 (24hours) Telex: 896 659 NSDL CH Telefax: (052) 213 94 83
 -1-

INTRODUCTION

This Service Letter informs you about the possibilities of how to improve the piston running
performance.
Based on tests carried out over the past two years we have developed a retrofit kit which will
be referred to here as the "RLB 90 package". This package can be introduced as a whole
("Full Package") or also step by step ("Intermediate Package") to your engine if service expe
rience with cylinder liners and in general piston running behaviour are not up to your expecta
tions.
It is also possible to replace single cylinders by "Loop cooled" cylinder liners whenever cylin
der liners need to be renewed i.e. there is no problem to run "Loop Cooled" cylinder liners
and existing cylinder liners together in the same engine.
Once the "Full Package" is introduced and the new "Loop Cooled" cylinder liners are
installed a TBO (Time Between Overhauls) of two years can be expected.

1. RETROFIT KIT WITH "LOOP COOLED" CYLINDER LINER ("FULL PACKAGE")

The complete RLB 90 Package comprises the following items:

PER CYLINDER:
- 1 off new "Loop Cooled" cylinder liner R 21405, GG25K or Tarkalloy (complete with
O-rings R 21411/412, insulating tubes R 21415/16/17, lubricating quills R 21550, joint
ring R 21410 and filling piece R 21406/407) with optimized surface temperature, depend
ing on the rating of engine, with multilevel cylinder lubrication and with one set of new
cylinder lubricating pipes (8 additional lubricating quills with accumulators will be
required if the engine was not previously fitted with multilevel lubricated cylinder liners).
- 1 off water guide jacket for cylinder liner R 21280, together with 8 transition (crossover)
pipes R 21281, 32 hexagon head screws M12 x 30 and 32 O-rings R 21282 for crossover
pipes.
- 1 off water guide jacket for cylinder cover R 21305.
- 1 off assembly set complete for water guide jacket consisting of: 1 off holder R 21266, 4 off
holders R 21268, 1 off centering pin R 21269, 4 off hexagon head bolts M20 x 150, 8 off
hexagon head bolts M20 x 80, 4 off hexagon head bolts M16 x 85, 4 off hexagon socket head
screws M16 x 110, 2 off spring dowel pins VSM 1278512x80, 4 off locking plates R 21270
and 2 off Orings for cylinder cover R 27127
- 1 off fine turned "GTP" 22mm high, gastight vermicular cast iron top piston ring R 34402.
- 4 off fine turned "KN" piston rings 18mm high, for the lower grooves R 34401.
Modification of existing parts:
- In addition to the above it is necessary to modify the piston crown according to the drawing
on enclosure RLB 90 / 3 to accommodate the 22mm high "GTP" gastight ring.
- Rebandaged piston skirt or new piston skirt if worn below admissible limits.
PER ENGINE:
- 1 off position gauge for measuring cylinder liner bores.
- 1 pair of lifting screws (needed for transport and fitting of cylinder liners).
 -2-

Modification of existing parts:

- The tool for fitting the piston rings has to be equipped with two new 22mm jaws.
- To obtain optimum results the water separator and the water drains from the charge air
receiver m u s t be modified according to the enclosures RLB 90 / 1, 1a and 1b.

2. INTERMEDIATE PACKAGE

As already mentioned the retrofit package can be introduced gradually by an "Intermediate

Package". It serves to reduce the risk of possible exhaust blowby situations and consequen
tial damages such as scuffing of piston skirt on cylinder liner surface or even cracking on the
top part of the cylinder liners.
This "Intermediate Package" consists of 22mm GTP vermicular cast iron top piston ring and
the modification of piston crown and the charge air receiver.
This method has the advantage that the whole modification can be exercised over a time span
which is suitable to the vessel's operating schedule and that the existing cylinder liners, if still
in acceptable condition, can be used until they have reached their maximum wear limit.
2.1. Modification to a Gastight Top Piston Ring "GTP" 22mm
As a first step to the "Intermediate Package", we suggest to introduce the "GTP" 22mm top
piston ring. The advantage of fitting the thicker gastight top piston ring lies in the facts, that
the lateral forces acting on the piston can be considerably reduced and blowby will be elimi
nated.
The cylinder liner wear rate may slightly increase, depending on the operating conditions and
on the sulphur content of the fuel used, however, the risk of cracks in the cylinder liners and
the seizing of piston skirts will be to a great extent eliminated.
To accommodate the 22mm gastight top ring it is necessary to modify the top ring groove of
the existing piston crowns (please refer to enclosure RLB 90 / 3).
It is also important that the maximum diameter of a worn cylinder liner does not exceed
904mm and the maximum ovality is not more than 1mm at its biggest point when a new "GTP"
22mm ring is fitted.
When fitted to a cylinder liner with nominal diameter, a new gastight piston ring will display a gap
of ∼ 9.8 mm, corresponding to a butt overlap length of 41 mm (see Fig. 1). This gap can be mea
sured, if visible, through the scavenge ports.

22mm "GTP" Top Piston Ring Gap ~9.8

(New piston ring in new cylinder liner)

Fig. 1
Top
22-0.03
0

Gap ~9.8 mm

When fitted to a cylinder liner with a diameter of 904 mm at TDC, a new gastight piston ring will
have a gap of ∼ 22.4 mm (at TDC).
 -3-

With increasing running hours, the cylinder liner diameter may increase and the radial piston
ring width will decrease due to normal wear, thus expanding the gap (please refer to Fig. 2)
To ensure gastightness of the piston ring a minimum butt overlap length is required (please
refer to Fig. 2).
For RLB 90 engines the minimum butt overlap length should not be less than 16 mm (at any point
of the stroke), corresponding to a maximum gap of ∼ 35 mm.
Maximum allowable gap ~ 35mm
22mm "GTP" Top Piston Ring Minimum butt overlap length = 16mm

(Used piston ring in worn cylinder liner)

Fig. 2
Top Minimum butt overlap length = 16mm

Maximum allowable gap ~ 35mm

In addition it is absolutely essential to remove the wear ridge at the top of the cylinder liner
c a r e f u l l y to avoid damage to the cylinder liner running surface.
(Please refer to specially designed wear ridge milling machine on enclosure RLB 90 / 4).

2.2. Modifications to Charge Air Receiver

When fitting 22mm GTP rings it is e s s e n t i a l to modify the charge air receiver simulta
neously to improve the drainage from the air trunking to avoid carryover of condensate.
Optimum corrosion protection can be achieved if, after the modification to the charge air
receiver according to enclosures RLB 90 / 1, 1a and 1b, the trunking is painted with the special
epoxide coating Ex No. 600 to minimize corrosion (refer to enclosure RLB 90 / 2).
Before the special epoxide resin is applied, it is essential that the surface which is to be
painted is thoroughly cleaned and is free of rust, millscale, dirt, oil, salt and moisture.
Please note: It is absolutely essential that the charge air receiver is also modified when only
the "Intermediate Package" is introduced.

3. CONVERSION FROM INTERMEDIATE TO FULL PACKAGE

When renewal of the original cylinder liners becomes necessary due to reaching the upper
wear limit (diameter 905mm with gastight ring due to butt overlap) we strongly recommend
that the new "Loop Cooled" cylinder liners with multilevel cylinder lubrication together with
the new water guide jackets and the water guide assembly are fitted (please refer to enclosure
RLB 90 / 5).
The application of the "Loop Cooled" cylinder liner with its higher running surface tempera
ture is o n l y t o b e i n c o n j u n c t i o n with the 22mm gastight vermicular cast iron top
piston ring, four (4) fine turned "KN" 18mm high piston rings together with a new or reban
daged piston skirt and the modified charge air receiver.
Experience with this type of liner which has now completed successful tests is very promising
and very low wear rates may be achieved with a TBO of two years.
 -4-

With the "Full Package" (as described in paragraph 1) it will be possible to achieve this TBO
of two years, whereas the retrofit with the "Intermediate Package" can only be considered as a
temporary measure when piston running problems are experienced.
The whole retrofit package as well as single items and the necessary tools for fitting and dis
mantling insulating tubes, removal of wear ridge etc. can be obtained from:

New Sulzer Diesel After Sales Service, Winterthur or through any of their Representatives.
For your information we have enclosed the following new pages for the Code Book:

R 2141 Cylinder Liner and Lubricating Oil Studs (dated 12.93).

R 340 Piston (dated 12.93).

R 3401 Piston (dated 12.93).

ENCLOSURES: as mentioned in the text

CHARGE AIR RECEIVER RL 90 88.7267

ON BOTH SIDES OF THE BOTTOM FIXATION FOR THE

WATER SEPARATORS, STEEL PLATES F AND G HAVE TO A-A
BE WELDEDIN TO PREVENT DRAINED WATER FROM
ENTERING THE SCAVENGE AIR RECEIVER. ON BOTH
SIDES OF THE SEPARATORS ANGLE IRONS I HAVE TO
BE BOLTEDON TO PREVENT WATER BYPASSING THE
SEPARATORS.
ADDITIONALLY STEEL PLATES H HAVE TO BE WELDED
IN. THESE PLATES WILL MAINTAIN THE SAME LEVEL ON
THE INLET AND OUTLET SIDE OF THE SEPARATORS, TO
ENSURE PROPER DRAINAGE OF THE WATER FROM THE
SEPARATORS.
OPENINGS E (R=60MM) IN PLATES X HAVE TO BE CUT
OUT CAREFULLY (BURNTOUT) TO ENSURE OIL DRAIN
AGE FROM RECEIVER.
I D D
ANGLE IRONS J HAVE TO BE WELDEDIN TO CREATE A
WATER TRAP AND HOLES K HAVE TO BE CUT-OUT TO
ENSURE THAT EXCESS WATER IS DRAINED OFF
THROUGH PIPING L BEFORE IT REACHES THE SEPARA C J K
TORS.
IT IS RECOMMENDED THAT AFTER MODIFICATION THE H
TRUNKING IS THOROUGHLY CLEANED AND TREATED
WITH AN EPOXIDE COATING Ex No. 600 (SEE SPECIFI G
CATION ON ENCLOSURE RLB 90 / 2).
F DRAIN FWD + AF T,
E PIPING L , MINIMUM
DIAMETER 30mm

D-D
EXISTING DRAINS M
(forward and aft)
L
TO BE CONNECTED TO
DIRTY OIL COLLECTOR
C
A B-B
B B 88.7263
F
G K J

88.7268

L
I
A
X
VTR 564

VTR 714

88.7262

RLB 90 / 1
CONDENSATE WATER DRAIN FROM CHARGE AIR RECEIVER

PREVIOUS DESIGN

Condensate water separator

Drain cock only to be shut when

washing cooler in port
Sight glass

Drain cock for charge air cooler

cleaning system
To portable cleaning unit,
cleaning tank or bilge
Throttling disc
Drain to dirty oil tank

To bilge or oily-water drain tank

NEW DESIGN

Cocks 1 and 2:
Normal running condition:
Cock 1 = open / cock 2 = closed.
When washing air cooler in port:
Cock 1 = closed / cock 2 = open.

Condensate water separator

Level switch for receiver drainage
(high level alarm)
Automatic drain valve

By-pass (permanently open)

1
Condensate water drain from
charge air receiver
To bilge or preferably oilywater
drain tank
Drain to dirty oil tank
2 To portable cleaning unit, cleaning
tank or bilge
Wash water from charge air cooler

RLB 90 / 1a
 AUTOMATIC DRAIN VALVE

4
1

9
ÇÇ
ÇÇ
ÇÇ
ÇÇ
Ç Ç
ÇÇ
ÇÇ
É É 2
É
É É
É É
É
É
É É
É
ÉÉ
7
6
8
3

Mesh filter to be removed if fitted

1 Housing upper part 6 Float control

2 Joint ring (copper or soft iron) 7 Float control body with rotary valve
3 Housing lower part 8 Float with lever
4 Control valve 9 Fixation screw
5 By-pass (connection)

RLB 90 / 1b
 INSTRUCTIONS FOR SURFACE PROTECTION FOR
AIR DUCT / INSIDE OF RECEIVER

1. APPLICATION RANGE
AIR DUCT / INSIDE OF RECEIVER BETWEEN CHARGE AIR COOLER AND CONDENSATE
SEPARATOR IN ACCORDANCE WITH THE INSTRUCTIONS GIVEN ON BOTTOM OF PAGE.

2. COATING BRAND AND PROPERTIES

BRAND: EPOMARINE EX No. 600
EPOXIDE COATING EX No. 600
EPOXIDE RESIN, LIGHT TAR COATING.
HIGHLY RESISTANT TO SEA WATER, OIL AND CHEMICALS.

COLOUR: GREY

APPLICATION: AIRLESS SPRAYING

FILM THICKNESS: 0,25 mm DRY

CONDITION OF
STEEL SURFACE: FREE OF RUST, MILLSCALE, DIRT, OIL, SALT AND MOISTURE.
STEEL GRIT BLASTING RECOMMENDED.

3. MANUFACTURERS
SchleswigHolsteinische Farbenfabriken Kansai Marine Paints
M. Wickens Sohn GmbH & Co. KG 2415 HigashiOhi 5chome
Am Proviantgraben 1 Marine Head Quarter
D  25348 Glückstadt, Deutschland ShinagawaKu
Tokyo, Japan

PLEASE NOTE: WHEN APPLYING THIS COATING THE MANUFACTURER'S INSTRUCTIONS

MUST BE STRICTLY OBSERVED!

AREA TO BE COATED

Text: From instruction E 4- 107.271.289 / page 1 mod. RLB 90 / 2

 MODIFICATION OF PISTON CROWN TO
22mm TOP RING GROOVE

ATTENTION!
FOR GROOVE A
AFTER CHROMIUM PLATING
THE LOWER SURFACE IS TO
BE GROUND CLEAN AND THE A
LAYER THICKNESS CHECKED.
THEN THE UPPER SURFACE IS
TO BE GROUND TO FINISHED
SIZE.
mm
-1
0
X = 265

ATTENTION ! BEFORE FITTING MODIFIED PISTON CROWNS CARE

HAS TO BE TAKEN THAT THE EXISTING WEAR RIDGE
IN THE CYLINDER LINER HAS BEEN REMOVED.

A
+0,05
0

0,5
0,4

X N6
GROUND

ELECTRO  HARD
+0,05

CHROME PLATED
+0,51
+0,46
0

0,4 . . 0,45
N8
23,31

22

X N5
=

28
0,5

PREMACHINED X N6
SIZE BEFORE
CHROMING
+0,05
0

N7
0,4

LOWER RING LANDING SURFACE TO BE MACHINED CLEAR, SO THAT

0
DISTANCE X = 265 - 1 mm AFTER CHROME PLATING AND GRINDING.

RLB 90 / 3
REMOVAL OF WEAR RIDGE IN CYLINDER LINER

A B

TDC

2-3mm

1mm

Top Piston Ring Cylinder Liner

RLB 90 / 4
 NEW RL 90 "LOOP COOLED" CYLINDER LINER
Cylinder Liner with "Loop" Cooling and New Cooling Water Transfer to Cylinder Cover

Water Guide
Jacket to
Cyl. Cover

Transition Insulating Tube

Pipe

Light Duty Spring Dowel Pin

Tube
Water Guide Jacket Fitting Tool for Insulating Tubes
to Cylinder Liner and Light Duty Spring Dowel Pins
"Loop Cooled"
Cylinder Liner
RLB 90 / 5

Cooling Water Guide

Dismantling Tool
RLB90 / 6
RLB90 / 7
RLB90 / 8
RLB90 / 9