Pipe module final flushing check, W38 & W46 engine

See the flow diagram WDAAA167409 .

Perform the final flushing check after the pipe and cooler module assembly has been completed.

NOTE

The flushing of the pipe module must be supervised.

Procedure

1 Fabricate all needed equipment: flushing tank, hose connections and flushing filters.

Carry out a pickling cleaning on all steel equipment. See drawing WDAAA167687 .

16. Cleaning and flushing of external piping Installation Manual

2 Install the flushing tank slightly higher than the pre-lubrication pump, to avoid harmful cavitation.

If an electrical heater is used for heating the flushing oil, install it in the flushing tank.

3 Open the pipe module lube oil connections number 201, 204 and 205, located on the engine side. If a lube oil separator is used for heating the flushing oil, open number 213 and 214 as well.

Visually inspect the inside of the piping and clean it if it is dirty.

4 Install all hoses, couplings and flushing filters.

See drawing WDAAA180309 .

Carefully tighten the connections and make sure that there are no lo ose parts or any dirt inside the pipes or hoses. Cover the flushing tank with a tarpaulin.

5 Visually inspect the pipe and cooler module.

Check that all flange connections are tight and that they have gaskets.

6 Follow the pipe/cooler module lube oil pipe flow diagram and do the following:

● Check the position of the non-return valve and open the closing valve after the pre-lubrication pump.

● Open the inlet and outlet valves of the lube oil cooler.

● Close the inlet and outlet valves of the automatic filter.

● Open the automatic filter bypass valve.

● Open the lube oil safety filter top covers (two).

● Take out the filters from the safety filter; cover and store them in a dry place. Do the same with the filter tightening nuts.

● Inspect visually the cleanness of the inside of the safety filter; check the condition of the cover’s O-ring gasket and reinstall the covers on the filter.

● Close the drain valves at the bottom of the lube oil safety filter and if the piping has several drain valves, close them all.

● In order to fill the system with flushing oil, turn the change-over valve’s position from the safety filter to both filters.

● Close the drain valve from the hose coupling number 201.

● Open the valve from the hose coupling number 204.

● If a lube oil separator is used for heating the flushing oil, check the hoses, pipes and the position of the valves leading from the separator. Close the valve.

7 Install the flushing mesh to the filters on top of the flushing tank.

Start with mesh 60.

8 Fill the flushing tank with clean oil (fill through a fine filter).

Check that there are no leaks.

9 Start heating the oil.

Stop the heating when the temperature of the oil reaches 60 °C.

NOTE

Check the cable connection of the heater. Continuously check the oil temperature.

When using the LO separator for oil circulation, monitor the flushing oil pressure and temperature. When the flushing oil pressure has increased by 2 bar from the starting pressure, stop the flushing and clean the mesh.

10 Fill the pump and the motor bearings with grease according to the service manual.

 Installation Manual 16. Cleaning and flushing of external piping

Check the direction of rotation for the pre-lube oil pump. Turn the pump pressure adjusting screw a few rounds anticlockwise in order to decrease the pressure. Check the level in flushing oil tank.

11 Start filling the system.

Run the pump for a few seconds only and top up the tank when required until the system is filled up. Open the venting valves at the LO cooler and the safety filter during the filling. Close the valves when oil starts to come out. Turn the safety filter change-over valve to the one-filter position.

12 When the flushing oil tank is full and oil is circulating from the flushing tank to the pipe module and returning back to the tank via the flushing filter, adjust the oil pressure to 1 bar.

Record the starting pressure and use it as reference pressure for deciding when the mesh has to be cleaned.

13 During the flushing, observe the following important things:

● Open or close the valve from connection 204 every 3 or 4 hours.

● Check the temperatures of the casing and bearings.

● Check that pump does not cavitate.

● Check the oil level in the tank and the temperature of the oil. Check that there are no leaks.

● Check the filters every 4 hours.

● Change to mesh 100 when, after 4 hours of flushing, no more dirt is trapped in mesh 60.

(Note: minimum flushing time is 4 hours.)

● When no more particles are trapped in mesh 100 after 4 hours running, stop the oil heating and circulation.

● Let the oil temperature drop to 40 °C and start the flushing again. The job is ready when after 4 hours of flushing no particles can be found in the mesh 100.

● Change the valve position of the safety filter to “change-over valve”.

NOTE

The flushing result has to be inspected and approved by personnel authorized by Wärtsilä.

14 Disassemble the flushing arrangement.

a Disconnect the power supply.

b Empty the flushing tank to clean barrels.

Use the mobile LO transfer pump.

c Connect the mobile pump to the hose coupling 2/201 drain valve and empty the piping system.

Start the pre-lubricating oil pump a few seconds also in order to empty the suction side.

When the system is drained, disconnect the power supply to the pre-lubricating pump.

Open the venting valves of the LO cooler and the safety filter.

d If the LO separator was used for heating, drain the hoses, piping and separator.

Disconnect the hoses and couplings. Do not let oil drip on the floor. Inspect the piping.

Drain the remaining oil from the pipes with the mobile pump. Cover connections 213 and 214 with temporary plastic caps. Check the cleanness of the separator inlet strainer.

e Drain thoroughly and disconnect all flushing devices. Inspect the piping.

15 Install the filter cartridges in the safety filter.

a Open the top covers.

16. Cleaning and flushing of external piping Installation Manual

b Pump out the oil from the chambers.

c Open the drain valves, and inspect and clean the filter chambers.

d Take new filters from the store (inspect cleanness before installation).

e Check the cleanness of covers and the condition of O-rings.

f Install the covers to the filters.

g Close the drain and venting valves.

16 Start the bellow assembly from the middle of the pipe module/engine.

See the installation instructions. Check that all draining and venting valves are closed.

The pipe module is now ready for the start of the commissioning.