Service Bulletin ZAS–3509.06.99

1. Introduction 1

2. The Reason for a Plunger 1with Variable Damping

3. Measurements prior to fitting 2Variable Damping Plungers

4. Retrofit and Re–adjustment of the 2Fuel Pump with Variable Damping Plunger

5. Checklist for Subsequent 3Re-adjustments

6. Engines with ABB DEGO II 4Governor

7. Engines with Woodward 721 5Digital Speed Control Governor

8. Service Bulletins Published for 5ZA 40S Engines

28.6

5.71

.40

– P

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Sw

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land

Technical Information to all Owners / Operatorsof Sulzer ZA 40S Engines

Contents: Page

Wärtsilä NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22Wärtsilä NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17Wärtsilä NSD Suisse SA Switzerland Tlx 896 659 NSDL CH

Variable Damping Plunger

Load indicator pos.

Delivery stroke (mm)

1 / 6 Service Bulletin ZAS-35

1. INTRODUCTION

This Service Bulletin informs you about the operational advantages of the variable damping plungeras well as its fitting instructions, fuel injection pump adjustments and the required re-settings to becarried out on the engine and various control systems.

This Service Bulletin should be kept in a separate file in the control room. The respective pages ortables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manualor Code Book should be copied and filed in the respective Manual or Book.

2. THE REASON FOR A PLUNGER WITH VARIABLE DAMPING

The nominal lifetime of a fuel injection plunger and barrel can in some cases be negatively influencedby increased wear depending on the engine operating conditions and load profile, as well as thecondition and adjustment of the fuel system.

We have received reports of the appearance of cavitation and erosion in one or more of the followingareas:

� cavitation / erosion in the spill bores of the fuel pump cylinder with possible subsequent fatiguecracking of the cylinder and possibly also fuel pump cover

� cavitation damage at the upper end of the high pressure fuel pipe with possible subsequent fatiguecrack

Based on this knowledge and in order to improve the situation, the variable damping plunger wasdeveloped as shown in enclosure ZAS-35/1 and, after long-term field testing, introduced as thecurrently valid standard for new engines with a cylinder output of 660 kW or higher.

If damage as described above occurs to an appreciable extent, even though the adjustment of the fuelsystem (pressure, temperature, circulating quantity, fuel preparation, etc.) is in accordance with therecommendations given in the corresponding Service Bulletin, then it is recommendable in suchcases to retrofit the engines with fuel pump elements having the variable damping plunger. Thevariable damping plunger prevents cavitation and erosion damage and increases the lifetime of thefuel injection components. It is only available for engines with cylinder output of 660 kW or higher inthe CIT-version (Constant Injection Timing).

2.1. Effects of the Variable Damping Plunger on Engine Operation

� Engine parameters such as maximum cylinder pressure, specific fuel consumption, charge airpressure and exhaust gas temperatures will remain practically the same after fitting variabledamping plungers. However, the characteristic of the engine load indicator will be different.

� No adjustment is necessary to fuel or valve cams.

� If the engine speed shows a tendency to oscillate under idling conditions this can be sufficientlyreduced by correcting the governor dynamic settings.

� The control edge of the variable damping plunger has a different gradient to that of the previousstandard plunger. Re-adjustment of the fuel injection pumps is therefore necessary, together withall settings of the engine and speed governor which depend on the load indicator (LI) position.Please refer to the fuel pump adjustment graph and load indicator comparison graph onenclosures ZAS-35/2 and ZAS-35/3 respectively.

2 / 6 Service Bulletin ZAS�35

3. MEASUREMENTS PRIOR TO FITTING VARIABLE DAMPING PLUNGERS

Wherever possible the following engine performance data should be recorded with the currentlyfitted plungers at Service Load:

� load indicator position

� maximum cylinder pressures

� charge air pressure

� turbocharger speed (s)

� exhaust gas temperatures after cylinders / before and after turbine(s)

This performance data will be used as a reference for later comparison with variable dampingplungers fitted.All load indicator dependent settings as mentioned in section 5 should also be known.

4. RETROFIT AND RE-ADJUSTMENT OF THE FUEL PUMPWITH VARIABLE DAMPING PLUNGER

Due to the difference in gradient of the plunger control edge, the effective delivery stroke of thevariable damping plunger should be set to 15.88 mm with a load indicator position of 8.65 comparedto a stroke of 14.73 mm for the previous plunger, see enclosure ZAS-35/2. The new values togetherwith the change to variable damping plungers must be recorded in the engine setting table(s).

Re-adjustment is basically carried out with the same device (included in the set of tools) as for thepreviously used CIT (constant injection timing) plunger.

Adjustment of the pumps must be carried out with accurate pressure gauges and a working airpressure of at least 7 bar.

Note:

Mixing of old and new plunger types is strictly forbidden. Only complete engines are to beretrofitted with the variable damping plungers and never just individual cylinders.

Multi-engine installations: Engines connected to the same gearbox should be retrofitted at the sametime whenever possible. If two engines operate with different plungers, then balanced load sharing isdifficult to achieve as the Load Indicator Position of the two engines will not be identical. Inexceptional cases, e.g. for a short time during the retrofit, the load sharing has to be adapted. A serviceengineer from Wärtsilä NSD could be consulted for this work.

Engines fitted with VIT (variable injection timing): As already mentioned there is no retrofitavailable.

3 / 6 Service Bulletin ZAS-35

5. CHECK–LIST FOR SUBSEQUENT RE-ADJUSTMENTS

Generally speaking, all functions and limits that depend on engine Load Indicator position have to beconsidered for re-adjustment after fitting variable damping plungers.

Based on the following list, you have to check the functions and limits applicable for your particularinstallation.

For the actual re-adjustments you should use the load indicator comparison graph as shown inenclosure ZAS-35/3.

Basis: All fuel pumps re-adjusted as specified in Section 4.

Function and Limits ActuallyInstalled Yes/No

Original Setting Re-setting forVariable

Damping Plunger

1 Mechanical Limits at the engine

2 Starting fuel limiter mechanical

3 Maximum load limit mechanical

4

5 Mechanical Speed Governor

6 Charge air pressure fuel limiter (smokelimiter) 1)

7 Speed setting fuel limiter (torque limiter) 1)

8 Speed droop 2)

9 Load (Pitch) control 1)

10 Load indicating switches

11

12 Electric Speed Governor

13 Start fuel limit

14 Clutch fuel limit

15 Charge air pressure fuel limiter (smokelimiter) 1)

16 Speed dependent fuel limiter (torque limiter) 1)

17 Maximum fuel limit

18 Slave limit at clutching (min. level load up ramp of 2nd engine connected to a com–mon gear box)

19 Minimum unload level (min. level load down ramp unloading one engine only while parallel working to a common gear box)

20 Break point load up / down ramp

21 Speed droop 2)

4 / 6 Service Bulletin ZAS�35

Function ActuallyInstalled Yes/ No

Original Setting Re-Setting forVariable

Damping Plunger

22 Actuator feed back signal 1) 3)

23

24 Electric Actuator

25 Maximum actuator pos. limit switch

26

27 Control System EC 40 or similar in other Control systems Denis 21 (Load Indicator Limit Switches)

28 Overload indication EC 40

29 Overload used external EC 40 (e.g. Pitchreduction)

30 Engine running without fuel (dragging) if failure of Woodward actuator (directacting) in parallel operation

31 Charge air by-pass flap control

32 Charge air preheating at low load

33

34 CP Propeller Load Control

35 Load Indicator feed back signal 1) 4)

36 Load curve 1) 4)

37 Charge air pressure load limit 1)

38

39 Monitoring and Alarm System

40 Overload alarm

41

42 Control System

43 Feed forward functions by Load Indicator pos. e.g. HTCW temperature control

44

45 Any other Load Indicator dependentFunction

46

Foot notes: 1) Curve characteristic2) Will be smaller without resetting3) To be determined from case to case if actuator feed back signal and/or

governor internal fuel values need to be adjusted.4) For unchanged service condition relating to allowable load versus engine speed, the load indicator feed back signal and/or the whole load curve need re-adjustment.

5 / 6 Service Bulletin ZAS-35

Note:

The above list is not conclusive.

The above re-settings are of importance to avoid overloading of the engine as the Load IndicatorPosition with new Variable Damping Plungers will be lower at the upper load range.

Following the above re-adjustments, performance data at service load as under section 3 should betaken again for comparison, especially in regard of turbocharger speed, charge air pressure firingpressures etc. to verify the above re-adjustments to be correct. In case of larger deviations e.g. meanfiring pressure larger than ± 3 bar, respective corrections have to be made.

6. ENGINES WITH ABB DEGO II GOVERNOR

The actual (original) engine Voltage / Load Indicator Characteristic as shown as an example inenclosure ZAS-35/4 has to be established first. This characteristic is expected to be similar forengines in a system (smaller deviations are possible).

The respective ABB test protocol and manuals may assist you in your work.

The established Voltage / Load Indicator Characteristic in combination with the Load IndicatorComparison Curve ZAS-35/3 now form the base for the re-adjustment of the load indicatordependent adjustment values measurable at the governor test points.

Example: New Smoke Limit at 0 charge air pressure (SFL) :

from ZAS-35/4: SFL was 5.25 V�Load indicator Pos. 4.0 (example only)

from ZAS-35/3: Previous Load indicator Pos. 4.0 �new Load Indicator Pos. 4.5

from ZAS-35/4 New Load Indicator Pos. 4.5 � new SFL 5.9 V (example only)

7. ENGINE WITH WOODWARD 721 DIGITAL SPEED CONTROL

The actual (original) Actuator Output Load Indicator Characteristic as shown as an example inenclosure ZAS-35/5, has to be established first for each engine and actuator.The respective Woodward Setting Protocol and manuals may assist you in your work.

The established Actuator Output Load Indicator Characteristic in combination with the LoadIndicator Comparison Curve ZAS-35/3 now form the base for re-adjustment of the load indicatordependent setting of the Woodward Governor DSC 721.

Example: New Charge Air Limiter at 0 bar charge air pressure (charge air at P1 [%]).

from ZAS-35/5: P1 was 38% � Load Indicator Pos. 4.0 (example only)

from ZAS-35/3: Previous Load Indicator Pos. 4.0 � new Load Indicator Pos. 4.5

from ZAS-35/5: New Load Indicator Pos. 4.5 � new 42% (example only)

If questions arise, please contact Wärtsilä NSD and / or the governor manufacturer or control systemsupplier to avoid misunderstandings during adjustment of the engine or governor parameters.

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 containedin 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 aspublished by Wärtsilä Switzerland Ltd, are not permitted.

6 / 6 Service Bulletin ZAS�35

8. SERVICE BULLETINS PUBLISHED FOR ZA 40S ENGINES

We have so far published the following Service Bulletins which are valid for ZA 40S type engines:

ZAS–1.2 dated 02.02.96 Cylinder Liner OverhaulZAS–2.1 dated 29.08.97 Overhaul of Cylinder HeadZAS–3 dated 10.06.93 Oil Scraper RingsZAS–4.4 dated 26.02.99 Piston RingsZAS–5 dated 03.12.93 Instruction for Testing of Fuel Injection NozzlesZAS–6.1 dated 23.02.96 Piston Rotating MechanismZAS–7 dated 05.04.94 Adjustments and Maintenance Requirements on Oil Mist DetectorZAS–8.1 dated 16.05.97 Turnomat for Exhaust Valves and Rotocap for Inlet ValvesZAS–9 dated 01.06.94 Exhaust Pipe Expansion BellowsZAS–10 dated 01.08.94 High Temperature Cooling Water SystemZAS–11.1 dated 31.03.98 Cylinder Liner with a Thread

ZAS–12 dated 01.03.95 New Spindle Design for Pressure Control Valve KS 87085ZAS–13.1 dated 18.12.98 Inlet ValvesZAS–14.1 dated 27.02.98 High Pressure Fuel PipeZAS–15.1 dated 30.01.98 Fuel Injection Nozzle SpecificationZAS–16 dated 10.08.95 Flow Control Valve KS 72126 for Cylinder LubricationZAS–17.3 dated 18.05.99 VTR ..4 Turbochargers After Sales Service Information issued by ABBZAS–18.1 dated 27.02.98 Tightening InstructionsZAS–19 dated 17.11.95 New Piston Ring Fitting ToolZAS–20 dated 17.11.95 New Spring Cage KS 28042 for Rocker GearZAS–21 dated 22.03.96 Differences in the Drive for the Cylinder Lubrication between

Engines with 660 kW/Cyl. and 720 kW/Cyl.ZAS–22 dated 08.11.96 Adjustments of Fuel Oil SystemsZAS–23 dated 19.11.96 Modification to the Oil Mist DetectorZAS–24 dated 28.01.97 Alphabetical Index of Topics of Service BulletinsZAS–25 dated 16.05,97 Tightening Instructions for the Connecting Rod Big End BearingZAS–26 dated 30.05.97 ABB Type VTR..4 Turbochargers

Cleaning of Turbine and Blower SideZAS–27 dated 29.08.97 Lubricating Oil Treatment and RequirementsZAS–28 dated 29.08.97 Assessment of Main and Connecting Rod BearingsZAS–29 dated 29.08.97 Undersized Bearings and Reconditioning of Crankshafts

ZAS–30 dated 31.10.87 ABB Type VTR..4 Turbochargers Cooling Water ArrangementZAS–31 dated 31.10.97 Flushing InstructionsZAS–32 dated 31.03.98 Fuel PumpZAS–33 dated 31.03.98 Shim between Connecting Rod and Big End BearingZAS–34 dated 26.08.98 Hand Rails for Engine-mounted PlatformsZAS–35 dated 09.06.99 Variable Damping Plunger

Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contact your localWärtsilä NSD representative for your copy.

Enclosures: ZAS-35/1 Pump plunger with variable damping arrangementZAS-35/2 Adjustment of previous plunger and new variable damping plungerZAS-35/3 Load indicator comparison curveZAS-35/4 Voltage/Load Indicator Characteristic for ABB-Governor DEGO IIZAS-35/5 Actuator Output / Load Indicator Characteristic for

Woodward - Governor DSC 721

Fuel Pump Plunger with Variable Damping Arrangement

Throttled passage to first step release

Service B

ulletin Enclosure Z

AS

–35/1

Damping Groove

�

�

�

�

�

� Control edge

Variable Damping Plunger (277. 992)

0

0 8.65Load indicator position

The delivery stroke adjustment 15.88 mm at 8.65load indicator position is mandatory

Deliverystroke(mm)

15.88

Previous Plunger (188. 616)

Load indicator position0

0

8.65

14.73

Adjustment of previous Plunger and new Variable Damping Plunger

Service B

ulletin Enclosure Z

AS

-35/2

Deliverystroke(mm)

Re�Adjustment

Engine LI with Variable Damping Plunger277.992 *)

Equivalent LI - Value with Variable Damping Plunger

LI–V

alue

w

ith p

revi

ous

plun

gers

The comparison curve is to be usedfor re-adjusting of all LI-dependentsettings of the engine and systems

*) Check number stamped on the concerned plunger

Engine LI with previous PlungerCIT 188.616*)

Load Indicator Comparison Curve between previous CIT Plunger and Variable Damping Plunger

Serv

ice B

ulle

tin E

nclo

sure

ZA

S�3

5/3

This comparison curve representsmean values.

Service B

ulletin Enclosure Z

AS

-35/4

*) This information serves as an example only. The actual (original) adjustementcurve has to be established for eachinstallation, but can be left as it is.

Voltage / Load Indicator Characteristic

for ABB - Governor DEGO II

Example only of anengine - adjustmentcurve*)

Actuator Position Value (T3)

Engine Load Indicator Position LI

Small offset from zero possible

Normally approx. 10V at 100% Load

100%

Loa

d w

ith p

revi

ous

Plu

nger

*)

100%

Loa

d w

ith V

aria

ble

Dam

ping

Plu

nger

*)

Engine Load Indicator Position LI

Actuator Output / Load Indicator Characteristic

for Woodward- Governor DSC 721

Service B

ulletin Enclosure Z

AS

-35/5

*) This information serves as an example only.The actual (original) adjustment curvehas to be established for each engine and actuator respectively, but can be left as it is.

Example only of an engineadjustment curve *)

100

% L

oad

with

pre

viou

s pl

unge

r *)

Woodward Actuator Output(actually governor actuator control output signal)

100

% L

oad

with

Varia

ble

Dam

ping

Plu

nge

*)