GENERAL

INFORMATION

Wärtsilä low-speed engines RT-119

Services 2-stroke Issue 1, 17.01.2012

Component remanufacturing At your convenience

services Concerned products and components

Major components of Wärtsilä RT-flex
engines, such as:
Information to all Owners and Operators of • Injection control unit
Wärtsilä RT-flex engines • Fuel oil pump
• Servo oil pump
• Pressure control valve
• Intermediate fuel accumulator
The list of components will be continuously
extended.

Current situation
After reviewing the maintenance costs
experienced over the lifetime of an engine,
new maintenance concepts have been
developed to help Operators and Owners
to reduce the operating costs of their
engines.

This General Information bulletin provides

an overview of the maintenance services
available from Wärtsilä when an overhaul
of a major component becomes
necessary. This document should be
consulted when planning maintenance for
those components listed here.

Fault-finding and repair of the components

are dealt with in separate Technical
Bulletins.

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

PO Box 414 Fax: +41 52 262 07 31
CH-8401 Winterthur technicalsupport.chts@wartsila.com
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Contents
Page
 
Introduction 2 
The concept 3 
Available remanufactured components 3 
The standard ordering process 4 
Optional process – Remanufacturing of own components 6 
Logistics 6 
Remanufacturing and Quality of components 7 
Appendix 7 
Contacts 8 
Return sheet Appendix 1

Introduction
Ship owners and operators put continuous efforts into reducing vessels’
operating costs. To support the optimisation of total cost of ownership by
reduction of the main engine’s operating costs the Component Remanufacturing
Services have been developed and introduced as one of Wärtsilä’s maintenance
cost-down solutions.
This service was developed for specific components, which in future can be
returned to Wärtsilä for remanufacturing at the recommended overhaul intervals.
Remanufacturing substantially reduces the costs of maintenance compared to a
replacement by new components. Remanufacturing will always be carried out to
the latest standards and specifications to ensure or even improve the component
functionality and lifetime expectancy.
As a result of this initiative, Wärtsilä customers can enjoy reduced operating
costs of their main engines.

Component Remanufacturing Services are available in two ways:

• Exchange Parts Services
Obtain a remanufactured component ex stock, returning the old component
and receive a refund Î this is the recommended and preferred way.
• Remanufacturing of the customer’s own component(s)
Send used component to Wärtsilä workshop for remanufacturing and receive
the same component back Î optional on request, with lead time.

Wärtsilä Remanufacturing Services use the latest industrial processes specifically

developed for this task, which ensures the best quality and economy for the
customers. Therefore, remanufacturing is the Wärtsilä chosen concept for the
components as listed in Table 1.
This means that new components are not kept in stock for maintenance
purposes. New components remain available for supply of initial or additional
spare parts to keep onboard stock. New components are delivered with lead
time. In case of ordering new components, please clearly indicate “order for
onboard stock”.
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The concept
The remanufactured components are available ex stock and sold at a reduced
cost to the customer. To enable this service, Wärtsilä created a pool of parts
– Exchange Parts – in Wärtsilä’s warehouses in Kampen (the Netherlands) and
Singapore. The pool enables that customer orders can be delivered while the
used parts to be taken into the process are returned to Wärtsilä or are in the
remanufacturing process, see Figure 1. The used components are
remanufactured in dedicated and specialised Wärtsilä workshops and put back in
stock.

For the long-term sustainability of this service and continual replenishment of

stock, it is essential that in all cases used parts are returned to Wärtsilä for
processing on exchange basis. Upon receipt of the used parts, Wärtsilä issues a
refund in the form of a Credit Note. The net costs (remanufactured part price
minus refund) enable a substantial maintenance cost reduction for customers.

Exchange parts services process

1 2 4 3
st nd
1. Material flow 1 step, 2. Material flow 2 step, 3. Material flow within Wärtsilä,
4. Pool owner WGLS – Wärtsilä Global Logistics Services
Fig. 1

Available remanufactured components

The Exchange Parts Service is currently valid for major components of Wärtsilä
two-stroke RT-flex engines. The following remanufactured components are
already available:
The components as listed in Table 1 can be supplied from one of Wärtsilä’s
warehouses in Kampen (the Netherlands) or Singapore.

Available components of RT-flex engines

Components Engine bore sizes (values in cm)

Injection Control Unit (ICU) All bore sizes
Fuel Oil Pump (FOP) 96 and 84 bores
Servo Oil Pump (SOP) from DYNEX 96 and 84 bores
Pressure Control Valve (PCV) All bore sizes
Intermediate Fuel Accumulator (IFA) 96 and 84 bores

Tab. 1
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Components of RT-flex engines in preparation

Components Engine bore sizes (values in cm)

Fuel Oil Pump (FOP) 50, 58, 60, 68 and 82 bores
Servo Oil Pump (SOP) from DYNEX 50, 58, 60 and 68 bores
Cylinder Lubrication Unit CLU4 & CLU4-C All bore sizes

Tab. 2

The standard ordering process

To place an order, make contact with your Wärtsilä representative for the
required remanufactured component. Wärtsilä will then send an offer with the
price and delivery time for the required component. The net cost will be the price
of the remanufactured component minus the refund value for the returned used
component.
The detailed ordering flow process is shown in Figure 2.
It is important that the steps are followed, but special attention is to be given to
the Return sheet (1) that has to be filled out, see example in Appendix 1.

Process flow

Customer will receive 
Order  instructions for return  Upon receipt of 
Send order for 
confirmation,  delivery the used parts, 
remanufactured  (incl. return delivery 
delivery of  Wärtsilä will 
part to your  sheet). Please provide
remanufactured  ALL necessary part  issue a Credit 
normal sales 
part and  information  Note for 
contact: (existing markings on 
invoicing. parts for example).
returned parts.

• When ordering a 
remanufactured part, 
please send information 
about vessel name, 
engine type  
& number, required 
delivery time and place. 
 
1
• When returning used 
parts, please send 
information about where 
you intend to land or 
deliver to, and the 
running hours of the part. 

1. Return sheet, see Appendix 1

Fig. 2
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Wärtsilä will send the remanufactured component from the nearest Wärtsilä
warehouse to the requested delivery address.

Most components are transported in a special box. For the return delivery of the
used parts the same box should be used, see Figure 3. The special boxes are
the property of Wärtsilä.

Once the used component is received in the Wärtsilä warehouse together with
the respective transportation box, a Credit Note will be generated as the refund
for a pre-determined amount.

Note:
For efficient Credit Note processing, ensure quick return of the used component
to a Wärtsilä warehouse. Fill in the return sheet and include the Wärtsilä return
order number provided, see Appendix 1. Without the Wärtsilä Return Order
Number, the components cannot be processed and therefore a Credit Note
cannot be created.

Wooden transportation box

1 2

3
2

1. Component placed in box with shipping documents, 2. Box closed and secured
by catches for easy opening and closing without destroying the box and cover,
3. Box size and appearance depending on component
Fig. 3
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Note:
Used components shall be returned in the specially designed wooden box only.
The wooden boxes are the property of Wärtsilä.

Optional process – Remanufacturing of own components

In some cases Customers may require their own components to be returned after
remanufacturing. Although this is not the standard process, Wärtsilä can also
offer the remanufacturing of customers’ own components on an optional basis.
Here the customer’s own component is sent to one of the dedicated Wärtsilä
remanufacturing workshops, and after remanufacturing, the same component is
received back.

To cover the additional costs for the special handling of the components a small
additional fee is charged. The lead time for these components is longer due to
the remanufacturing process. In this case the customer has to keep his own
“pool” of components to cover this lead time period.

To proceed with an order in this case, contact should be made as usual with your
local Wärtsilä representative.

Remanufacturing process of own components

1
1. Material flow
Fig. 4

Logistics
Wärtsilä maintains an exchange pool of remanufactured components within its’
own logistics centres from which the customer’s orders are served.

The used components should preferably be returned directly to one of the

Wärtsilä logistics centres.

Wärtsilä logistics centres locations:

• Central Distribution Centre, Kampen (the Netherlands)
• Spare Parts Centre, Singapore
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If requested by the Customer and agreed in advance with your local Wärtsilä
contact, pick-up and return of the component(s) from/to the place of landing can
be arranged.
The same also applies for transportation requests for remanufacturing of
customer’s own components.

Note:
Always ensure the packing of used components in the special Wärtsilä wooden
boxes, including the return sheet and labelling the box with the Wärtsilä return
order number.

Remanufacturing and Quality of components

High quality remanufacturing processes and quality control are carried out in
specialised and dedicated Wärtsilä workshops to ensure the high quality of the
original Wärtsilä spare parts.

Remanufacturing
Remanufacturing in the workshop will include the following tasks:
• Registering of used returned components
• Disassembly
• Cleaning
• Replacement of all necessary components
• Re-assembly of complete component
• Functionality testing
• Report and certificate
• Packing

Quality
Remanufacturing of components by Wärtsilä will always be carried out according
to the latest design and specifications.

Remanufacturing of a component comprises the points as listed above including

re-machining, sub-component replacement or reconditioning and applying the
latest technical specification and standards. This results in remanufactured
components being “as new” with the same or even improved functionality and
lifetime.

Before entering the Wärtsilä warehouse, the remanufactured components are

tested in specifically designed test benches. All remanufactured components are
inspected and certified by Wärtsilä Quality Control as a standard part of the
remanufacturing process.

Appendix
1. Return delivery sheet, example only
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Contacts

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.
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

Contact details for emergency issues

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.

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.

Spare parts
If you need Wärtsilä spare parts and/or tools, please send you enquiry to:
ch.spareparts.wgls@wartsila.com
or phone 24hrs support: +41 52 262 24 02

© 2012 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 is to be construed as
provided due to a defect in the engine, but merely as an improvement of the engine 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.
 APPENDIX 1

Return sheet – Example only

Wärtsilä Services

A) Return to warehouse: Singapore

B) Return to warehouse: Kampen, the Netherlands
RT-flex component: Part "X" for remanufacturing

The subject part is to be sent back to the Wärtsilä warehouse as indicated on this sheet. Procedure:
• Decide where to return the component: A) to Singapore or B) to Kampen, the Netherlands
• Fill in this form. Make sure that the Wärtsilä "Return Order Number" is inserted – for crediting reasons.
• Include a copy of the completed form with the consignment.
• Additionally send an electronic copy of the completed form to the respective contact persons mentioned below under A) or B).

A) Contacts for Singapore B) Contacts for Kampen, the Netherlands

Name: Logistic Manager Name: Logistic Manager
Email: WGLS.SPCasia@wartsila.com Email: cdc-kampen.returns@wartsila.com
Phone: +65 62 67 42 17 Phone: +31 38 42 79 231
Fax: +65 62 62 17 89 Fax: +31 38 42 23 564
Name: Cc: Production Planner Name: Cc: Production Planner
Email: production.planning@wartsila.com Email: production.planning@wartsila.com

Do not disassemble the component

Wärtsilä Return Order Number: >> Number will be given by Wärtsilä to customer <<

The complete component must be returned in Wärtsilä's wooden transportation box to the selected shipping address A) or B):

A) Shipping address to Singapore B) Shipping address to Kampen, the Netherlands

Wärtsilä Singapore Pte Ltd Wärtsilä Switzerland Ltd

14 Benoi Crescent Wärtsilä Global Logistics Services
Singapore 629977 Genuakade 8 / Zuiderzeehaven
8263 CG Kampen
Contact: The Netherlands
Attn.: Logistic Manager
Phone: +65 62 67 42 17 Phone: +31 38 42 79 231
Fax: +65 62 62 17 89 Fax: +31 38 42 23 564

Name of installation:
Hull No.:
Engine type:

Order/Claim No.: Exchange programme Engine running hours:

Date of failure: Part running hours:
Part position:
Part serial number (4 digits): (S/N)

Description of damage / Sequence of damage

Text:

Predifined questions: Yes / No

Please be informed that the complete defective component must be returned to one of the above mentioned
address A) or B) – or Wärtsilä has to be informed of the port of discharge, within 30 days. Otherwise,
Wärtsilä reserves the right not to issue a Credit Note for the component.

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