surveyor's day gard/norwegian hull club based maintenance.pdf · surveyor's day...
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1< >MAN Diesel & Turbo 2017
Surveyor's day Gard/Norwegian Hull Club
MAN Diesel & Turbo
2017 Surveyor's day Gard/Norwegian Hull Club
Bergen
October 2017
Peter M. Christensen
Superintendent Engineer
2< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM - Condition based maintenance
• Exhaust valves• Fuel equipment• Engine performance• Air supply system• Cylinder condition• Crank train bearings• Annual Service Package• Annual Extended SP• Pre-docking inspections
4< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Exhaust valve – Damper modification
Clearance controlled and orifice controlled damper (OCD)
5< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Exhaust valves – Wide seat bottom piece
The modification involves:
• ”Wide” (+ 35%) seat contact width and inreased contact area with cylinder cover
New ”Wide-seat”Present ”W-seat”
6< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Exhaust valves – Drop down test
Unit 1 2 3 4 5 6 7 8 9 10Test ok ok ok ok x ok x x ok ok
Running hours 3617 3617 12473 3617 3529 2999 2502 7067 2312 3266
Exhaust spindle #8 dropped after 5 minutes
Non return valve / drop down check
Spindle remain closed after 30 minutes
8< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Fuel equipment – separator cleaning onboard
• Bad maintenance:
• Dirty / damaged separator bowl
• Dirty preheater
• Separators operate:
• Low temperature
• High flow
Poorly operated onboard fuel cleaning systems
Remove the cat fines continuously!
• Operate the separators:
• High temperature
• Low flow
• Clean separators and preheaters
9< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Fuel equipment – MC fuel pump
MC engine:Cam driven Fuel Oil Injection Pump:
• Plunger velocity governed by engine RPM
• At start conditions 15% of full load engine RPM
• Short leakage path
Test for success
• Use un-worn fuel pumps!
10< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Fuel equipment – ME Booster
ME engineFuel Oil Pressure Booster:
• Plunger velocity governed by supply pressure• At start conditions 75-78% of full load pressure• Long leakage path
No problem
13< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Engine Performance
Pressure transducer
PMI controller
PowersupplyEnginecontrolroom
IntermediateOr frequencydivider box
Crankshaft pickupmounted at free endof crankshaft
LEDindicator
Two-stroke diesel engine
14< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Engine Performance
<14 >
Pure Pmax level increasePotential 5-10 barAt full as well as part loads
Reduction in Fuel oil consumption / CO2 emission
1 bar increase in average Pmax => 0.20 - 0.25 g/kWh decrease in fuel oil consumption
Reference Pmax
Potential
Potential
Balancing & Pmax level increasePotential additional 2-5 barGain even with engines already being operated within recommended limits
15< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Engine Performance
Compare measured service parameters with shoptest results.
16< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Engine Performance
Pi average +- 0.5 bar
Pcomp & PmaxPressure rise max 35 bar
Pmax & PcompAverage +-3.0 bar
17< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Engine Performance
Standard load diagram1. Propeller curve through optimising/
matching point (O) –layout curve for engine.
2. Heavy propeller curve – fouled hulland heavy seas.
3. Speed limit.
4. Torque/speed limit.
5. Mean effective pressure limit.
6. Light propeller curve – clean hull and calm weather – layout curve for propeller.
7. Power limit for continuous running.
8. Overload limit.
9. Sea trial speed limit.
3331353.2004.03.10 (2610/BGJ)
80 100 10585
50
70 7565 90 9560
60
70
80
90
100
Engine speed, % A
40
2
4 3
O
1
9
7
8
5
110
Engine shaft power, % A
A 100% reference pointM Specified engine MCRO Optimising/matching point
6
21< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Air supply system
Free water (droplets)• Lub oil break down• High wear• Liner scuffing
Evaporated Water• Black liner deposts• Higher corrosion
24< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition
4.8 mm
When is piston overhaul needed?
3 mm
25< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – filing records / observations
Piston overhaul / Liner measurementsAlways measure the “0”
point when possible
Zero measuring position
26< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – open up inspections
Piston open up / Overhaul
27< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – open up inspections
Piston open up / Overhaul
29< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – piston ring types
Piston rings standard can be divided into three groupsSmall Bore (26 to 50 cm Bore)Medium Bore (60 to 70 cm Bore)Large Bore (80 to 98 cm Bore)
30< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – 60- 80 Large bore alternative
31< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – 80-98 Large bore alternative
Korea, Autumn 2012, by Henrik Rolsted, LEO
33< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition
The original CPR (Controlled Pressure Relive) ring package with CL-grooves (controlled leakages) was introduced on all MAN B&W engines around the new millennium. This design change resulted in an tremendous improvement of the cylinder condition in general, with increased TBO. Main advantages is a better distribution of the pressures across each ring and solving the problem with overheating and collapse of the second ring.
34< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – monitor CL grooves
On a 46- seize engine as an example the wear potential is from 2.5 mm down to 1 mm, i.e. 1.5 mm. This require a wear rate not higher then 0,1 mm/1000h to obtain 15,000 hours TBO.
However, the wear of rings with CPR by means of CL- grooves is “unstable”. High wear of the CL-groove lead to a higher wear rate. If the CL-groove is worn below the min. limit, extremely high wear is seen, sometimes leading to scuffing!
2.5
35< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – small bore
The 6S40ME-B type engine after passing 10,000 service hours, and the first piston has been pulled: The top piston ring is worn down to the minimum value!
Inspection at 9,444 hours
36< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – small bore – POP ring
…. therefore, we have invented Controlled Pressure Relive by means of “POP” –groves (Ports on Plane)
37< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Cylinder Condition – video liner inspection tool
Snapshot from a S70ME – Video
39< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – SL2008-495
Systems that facilitate condition based open-up inspections1. BWM – (Bearing Wear Monitoring)2. MBTM – (Main Bearing Temperature Monitoring)3. WIOM – (Water In Oil Monitoring)
systems are being introduced for new engines and can be retrofitted on vessels in service. When retrofitted, MAN Diesel will accept a change in the maintenance program as outlined on the next page….
40< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – SL2008-495
• Shaft line earthing devices must be kept working and be equipped with monitoring connected to the alarm system.
• Bearing inspection scheduleDue to the higher safety against major failure, MAN Diesel considers it feasible tocompletely omit regular open-up inspections of any of the three crank-train bearingsfeaturing an approved BWM system connected to the alarm and slow-downsystem.For engines comprising an approved MBTM system, regular open-up main bearinginspections can be omitted.If the BWM, the MBTM system or other alarm indications for an abnormal bearingcondition are triggered, investigations must follow and, eventually, extraordinary open-up inspections should be carried out according to the findings.
41< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings - omit regular open-up inspections?
Know your A, B, C:A. Shaft line earthing devices must be kept working and be equipped with monitoring
connected to the alarm system.In addition it is possible to alter the bearing inspection schedule when installing:B. An approved BWM system connected to the alarm and slow-down system will
completely omit regular open-up inspections of any of the 3 crank-train bearings.C. An approved MBTM system, omits only regular open-up inspections of main bearings.In case of an alarm or indication:• If the BWM, the MBTM system or other alarm indications for an abnormal bearing
condition are triggered, investigations must follow and, eventually, extraordinary open-up inspections should be carried out according to the findings.
42< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – XH bearings – Normal operation
44< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – XH Bearings - Water in the LO
Overlay corrosion
Flash Layer (Sn)
Over layer(88% Pb 10% Sn 2% Cu)
Bonding layer (Ni og Ag)
AlSn40
Steel
45< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – XH Bearings - Corrosion
If you see this:
All bearings will be affected & must be exchanged ASAP
Water contamination stopped, water removed
Oil analysis history recorded
Possibly advice for mounting a water-in-oil monitoring system
46< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – unnoticed overlay corrosion
Ultimate consequence of unnoticed overlay corrosion
1. Ni layer exposed
2. Scuffing between Ni and pin
3. Scuffing between AlSn40 and pin
4. Steel-to-Steel contact
5. XH-pin & conrod bore damaged
6. Debris through to crankpin bearing
7. Crankpin bearing wiping / scuffing
8. Crankpin / bearing Steel-to-Steel
9. Crankpin severely damaged
10. Possible overheating and oilmist
11. 14 – 30 days repair
47< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – XH Bearings
Corrosion:• Monitor Pb content in the LO.• Monitor the water content in the LO.Accelerated wear:• Savings in fuel due to slow steaming has a cost of shorter XH bearing TBO.• Monitor oil wedges for bearing metal.
49< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – Spark erosion
• Spark erosion on main bearing journal and in the lower shell
•Spark erosion on fwd trust collar
50< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – Edge feeler
MAN Diesel does not recommend unduly opening up of bearings on 2-Stroke Diesel engines for overhaul or inspection, if they are otherwise performing well.
But…..!
It is mandatory to install a BWM systems, a water in oil (WIO) and a shaft earthing device connectedto the alarm system, in order to comply.
51< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – main bearing – Blend Edge
Examble - The Blended Edge ”BE”, schematically and drawing specification.
The width of the ”BE” the distance from C to B at the drawing, are individual for the different engine /bearing size.
52< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – main bearing – Blend Edge
The Blended Edge was introduced as standard in 2011.Blended edge can be used as ”repair” solution but only after consulting MAN Copenhagen.
54< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Crank train bearings – Why not open?
The human factor
55< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Condition based survey – CIMAC paper No. 21
In continuation of the development from visual inspections of all, to inspection based on condition it is an idea to look into the data file of gathered information as a base of maintenance planning; condition based survey
The process for the survey arrangement condition monitoring itself consists of three parts and is explained in the following using the example of crank-train bearings of crosshead diesel engines:
1. Submission of documents describing the condition monitoring systems (BWM system, water-in-oil sensor and shaft line earthing system) to be used for the survey arrangement, and compiling the correspondinginspection procedures like regular crankcase inspections required by the engine licenser. The submitted documents will be reviewed by GL experts at the head office.
56< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Condition based survey
2. Implementation survey on board to verify that the installation of the bearing wear monitoring system, the water-in-oil sensor, the shaft line earthing system and the implementation of the crankcase inspections in the planned maintenance system is in compliance with the engine licenser’s instructions. One month prior to the implementation survey the owner/manager has to submit an implementation report containing BWM data of at least 50 operating hours and all reports for crankcase inspections, web deflection measurements and system lube oil analyses. The implementation report will be reviewed by GL experts at the head office. A respective statement will be available for the ship owner/manager and the GL surveyor responsible for the implementation survey via the GL web portal “fleet online”.
57< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Condition based survey
3. Regular annual surveys harmonized with other annual surveys for maintaining the survey arrangement. One month prior to the annual survey the owner/manager shall submit an annual report containing the BWM data as XML file and all reports for crankcase inspections, web deflection measurements and system lube oil analyses carried out since the last annual survey. If maintenance or repair actions have been done, the corresponding reports have to be added. The annual report will be reviewed by GL experts at the head office. Again their statement will be available for the involved persons via “fleet online” for preparing the annual survey.
59< >MAN Diesel & Turbo 2017
Special Pre-Docking Inspection
Alongside by Superintendent Engineer
Fuel equipment
Cylinder condition
Visual inspection of crankcase
VAK Measurements
Complete Inspection ReportIncl. spare part recommendations
*Crankshaft deflection is supplied by vessel.
MAN | PrimeServCBM – Pre-docking inspections
60< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Pre-docking inspections
Upcoming dry-dock(7-9 months)
PO for pre-inspection PrimeServ Copenhagen
Pre-Inspection
Report & Spare part offer
PO for Spare partsPrimeServ Copenhagen
Delivery
Shipping instructionsPrimeServ Copenhagen
Co-ordination with local Service Centers
Inspection reportRecommended spare parts
Spare part offerPrimeServ Copenhagen
DD ÷ 6 months
DD ÷ 5 months
DD ÷ 2 weeks
DD ÷ 3-4 weeks
61< >MAN Diesel & Turbo 2017
MAN | PrimeServCBM – Pre-docking inspections
Pre-docking Inspection
• Fuel Equipment
• Cylinder Condition
• VAK Measurement
Spare Parts
• What you need to ensure optimal running
• Availability• Security
Supervision (Optional)
• The knowledge of the engine designer on-site.