RECONDITIONING SERVICES

WÄRTSIlÄ REcONDITIONINg WORKShOPS

WÄRTSIlÄ
REcONDITIONINg Wärtsilä Canada Inc.
1771 Savage Road
SERVIcES Richmond
BC V6V 1R1
Reconditioning is an ideal way to enable Canada
your installation to continue operating Tel. +1 604 244 8181
profitably while meeting regulations and Fax +1 604 244 1181
performance requirements. With Wärtsilä's
Wärtsilä Nederland Kruiningen BV.
cost-effective reconditioning methods you Stationsweg 6a
will be able to achieve maximum service life 4416 PJ Kruiningen
of components with minimized maintenance The Netherlands
costs and without compromising reliability. Tel. +31113 383461
Fax +31113 383656

Our Reconditioning services cover: Wärtsilä Italia S.P.A

• Components and parts reconditioning Via al Molo Giano
• Complete engine reconditioning IT-16128 Genova
Italy
• Exchange pool services with parts
Tel. +39 010 599 5891
exchange service and sale of Fax +39 010 247 2341
reconditioned parts and engines direct
from our global stocks.

TWO-STROKE EXhauST ValVE SPINDlE aND SEaT

In order to withstand the high combustion
valve spindle is exposed can reach 900°C. Even
the most modern and sophisticated alloys erode
ValVE SPINDlE aND temperatures generated in high performance when temperatures reach these high levels.
SEaTS 2-stroke diesel engines, exhaust valves have The traditional material used for
been made of sophisticated alloys. Surface manufacturing 2-stroke exhaust valves is
All current large bore 2-stroke marine diesel temperatures to which the combustion face of the stainless steel with a stellite layer inserted in
engines now use the 'uniflow' scavenging the seating surface. Later generation uniflow
system, which incorporates an exhaust valve Sulzer and MAN/B&W engines are fitted with
in the cylinder cover. Expensive materials are exhaust valves made from solid nimonic alloys.
required to endure the high temperatures and Since these alloys are quite expensive, the
pressures in the combustion chamber. The cost reconditioning of worn exhaust valves made
of these materials is a significant portion of the from solid nimonic alloys is a very attractive
price of an exhaust valve. The reconditioning cost-saving alternative, provided that the
of worn valves is therefore a highly cost reconditioning process is carried out in a
effective way of prolonging the lifetime of these controlled way.
components. Meeting or even exceeding the Stainless steel exhaust valves manufactured
OEM standards requires a reconditioning process by different OEM licensees around the world
that is clearly defined and carried out under may have variations in the metallurgical
controlled conditions. specification and composition of the
The initial cost savings obtained by material. Failing to identify the exact material
reconditioning can very rapidly be lost by composition and/or applying the improper
premature failures resulting from applying welding procedure will result in disastrous
uncontrolled and sub-standard reconditioning component failures. Wärtsilä welding
procedures. Inadequate welding technology, procedures include careful identification of
machinery and materials may result in the material composition before starting the
disintegration of the valve, causing major reconditioning, ensuring that the final product
damage to the cylinder unit. has a lifetime expectancy equal to a new valve.

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 Wärtsilä LLC
Plot 597-572, P.O. Box 32785
Dubai Investment Park 2
Dubai, United Arab Emirates
Tel. +9714 8857222
Fax: +9714 8857020

Wärtsilä China Ltd.

TYTL 108 RP
Sai Tso Wan Rd., Tsing Yi Island
New Territories, Hong Kong
China
Tel. +852 2528 6605
Fax +852 2750 3669

Wärtsilä Singapore Pte Ltd.

11 Pandan Crescent
Singapore 128467
Singapore
Tel. +65 6775 0333 / 6775 0335 / 585 1701
Fax +65 6861 2045

Wärtsilä procedures include building up and TWO-STROKE from forged steel with cooling bores. Failure
re-profiling the exhaust valve to the original in service can be caused by a range of
manufacturer templates. The combustion
cylINDER cOVER problems including erosion and corrosion in
face and the upper face of the valve disc Wärtsilä total reconditioning procedures are air start and safety valve bores, erosion in the
are remanufactured using advanced robottic designed to bring cylinder covers back to area adjacent to the injectors, leakage from
welding equipment. The re-stelliting of the original dimensions and tolerances to regain sealing rings, cracking from the cooling bores,
seating surface is carried out with Plasma fully functionality. Wärtsilä's exchange pool and fretting of the sealing faces and o-ring
Transfer Arc process, which ensures a high makes it possible to supply several types grooves.
quality weld with minimum dilution of the base of full reconditioned covers direct from our Standard Wärtsilä repair procedures on
material. The valve stem is carefully measured global stocks. B&W cylinder covers include replacing the
and if it is worn, it is reconditioned using the cooling rings.
HVOF spraying process. Wear incurred by bORE cOOlED cylINDER cOVERS Reconditioning of Sulzer cylinder covers
chromium plated stems can be rectified by Bore cooled cylinder covers for B&W, Sulzer includes a number of modifications which are
removing the existing chromium layer and and Mitsubishi engines are manufactured approved by the OEM.
replacing it with an HVOF cermet coating.
Special and controlled Wärtsilä procedures
are also applied when reconditioning exhaust
valve seats for all types of engines. The
existing stellite layer is removed, the sub-
strata is then built up, and this is followed by
re-stelliting, machining and grinding the valve
seat back to original dimensions.

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 TWO-STROKE
PISTON RODS
Worn piston rods cause high lubricating
oil consumption and contamination of the
lubrication oil system of two-stroke engines.
Wärtsilä has engineered a new type of
reconditioning or piston rods. The engineering
process involves making the surface of
the piston rod wear resistant and ensures
extreme load capacity and a long lifetime.
Reconditioning means applying special
welding, surfacing and other techniques
including skilful machining in our workshop
to bring the parts back to original drawing-
board specifications and full functionality.
All reconditioned parts are of a uniform
high standard, offering full OEM quality and
guaranteed performance according to the
latest specifications and modifications.
For two-stroke piston rods, Wärtsilä
specializes in their reconditioning with
TWO-STROKE PISTON •• Topside cracks. Pistons that fail in this
manner can be rebuilt by using Wärtsilä’s
special material steel welding-up and
remachining / grinding to the original size, i.e.
Wärtsilä two-stroke piston reconditioning is processes. without any undersize and the consequent
designed to give ship operators ready access •• Corroded cooling water pockets. These need to fit undersized stuffing box rings. Each
to low cost reconditioned pistons which in all pockets can be rebuilt to original reconditioned piston rod is carefully checked
respects, dimensionally and metallurgically, dimensions. by dyepenetrant- ultrasonic and dimensional
are the equal of new. Long term operation •• Ring groove wear and cracking. The ring tests, reports and register certificates are
can only be guaranteed if a thorough grooves and the outer diameter will be issued, everything in accordance with to the
metallurgical examination is carried out rebuilt completely. The ring grooves will be ISO-9002 certified quality system.
before, during and after reconditioning. hard chromium plated to a thickness as
specified by the OEM.
Total reconditioning procedures •• Crown burning. All damage and cracks
Different piston designs have different must be removed, the crown will be
weakness and failure patterns. The Wärtsilä rebuilt to its original height, and if required Mechanical and physical properties
total reconditioning procedure is designed to special protection layers can be applied. •• Wear resistant surface
address all critical areas of the piston at the •• Severe crown burning and cracking. 10 •• High micro hardness
pre-inspection stage before reconditioning mm deep burning and cracks are not •• Low coefficient of friction
starts. Typical examples are the Sulzer (RND uncommon. All cracks must be identified •• High resistance to abrasive and
and RNDM, RTA), MAN/B&W (GF, GB and MC) and removed and the crown will be rebuilt adhesive wear
and Mitsubishi UEC piston crowns. to its original height and profile. Crown
burning on more modern types can be so Customer benefits
Failure characteristics severe that the crown must be replaced •• Excellent price performance
•• Internal cracks. These cracks must be by a complete new section, using the •• Reduced downtime
identified, removed and re-welded to avoid appropriate welding preparations and •• Improved service lifetime
premature failure. procedures. •• Short lead-time

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FOUR-STROKE
CONNECTING RODS
Wärtsilä leads the way in the development
of cost-effective reconditioning methods for
all generations of diesel engine components,
in close cooperation with engine designers
and operators. Wärtsilä connecting rod
reconditioning has been developed to give
ship operators ready access to low cost
reconditioning of worn connecting rods.
Reconditioning extends the lifecycle of engine
components, and quality is guaranteed by our
controlled and approved welding technologies
and machining processes, and thorough
metallurgical examinations before, during and
after reconditioning.

Method A
If no cracks are found during inspection,
the following repair procedure is applied.
Serrations on the rod and cap side are
skimmed on a CNC milling machine, which
will reduce the diameter in the vertical
direction at the split. The separate parts are
fitted together again and the mating faces are
checked with blue paste, bolts are tightened
in accordance with the engine maker’s
instructions, and the big-end bore is machined
to its original dimensions. The results of final
crack detection and connecting rod geometry
are then recorded. The connecting rod is
protected against corrosion and made ready
Reconditioning of connecting rods according to the engine maker’s instructions, for shipment.
for four-stroke medium-speed and the big-end bore is measured at different
engines locations. Method B
A frequently found wear pattern on If cracks are found in the serration area,
connecting rods is excessive ovality of the The following data will be recorded and the connecting rod will be reconditioned
big-end bore. In the long run, oval shaped reported: completely, as per Wärtsilä procedures. The
big-end bores may cause crankpin bearing •• Geometry of the bores cracked serration is machined off completely,
failures, resulting in crankshaft damage. •• Pitch of the serrations until the cracks have disappeared. The
•• Position of the serrations machined connecting rod is preheated
Inspection procedure •• Top angle of the serrations in the oven. Having reached the required
After cleaning the connecting rod, all •• Position of the locating pin holes temperature, the machined area is rebuilt with
serrations and bolts are inspected visually, •• Straightness of the rod certified Wärtsilä high quality alloys, following
after which crack detection is carried out. If •• Distance between the centre line of the big a controlled and strict welding procedure.
cracks are found inside the threaded holes and small end bores After welding, the rod will be stress relieved
of the connecting rod, the rod is beyond •• Total weight of the rod immediately. In the final step, all serrations
repair and must be rejected. If cracks appear and bores will be machined to the original
in other locations, reconditioning could still Repair procedure dimensions. The connecting rod geometry is
be possible. After crack detection the rod Two class-approved repair procedures are recorded and the connecting rod is protected
and cap are assembled, bolts are tightened available for reconditioning: against corrosion and made ready.

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 05.2010 / Bock´s Office / Litoset
Wärtsilä is a global leader in complete lifecycle power solutions for the
marine and energy markets. By emphasising technological innovation
and total efficiency, Wärtsilä maximises the environmental and economic
performance of the vessels and power plants of its customers. In 2009,
Wärtsilä’s net sales totalled EUR 5.3 billion with more than 18,000
employees. The company has operations in 160 locations in 70 countries
around the world. Wärtsilä is listed on the NASDAQ OMX Helsinki, Finland.

WÄRTSILÄ® is a registered trademark. Copyright © 2010

2009 Wärtsilä Corporation.