Surveyor's day Gard/Norwegian Hull Club

2017

Surveyor's day Gard/Norwegian Hull Club

Bergen
October 2017
Peter M. Christensen
Superintendent Engineer
MAN Diesel & Turbo  2017 <
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CBM - 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

MAN Diesel &  20

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CBM - Exhaust valve - corrosion countermeasures

MAN Diesel &  20

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CBM – Exhaust valve – Damper modification

Clearance controlled and orifice controlled damper (OCD)

MAN Diesel &  20

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CBM – Exhaust valves – Wide seat bottom piece

The modification involves:

”Wide” (+ 35%) seat contact width and inreased conta

Present ”W-seat” New ”Wide-seat”

MAN Diesel &  20

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CBM – Exhaust valves – Drop down test

Spindle remain closed after Non return valve / drop

30 minutes down check

Exhaust spindle #8 dropped after 5 minutes

MAN Diesel &  20

 Unit 1 2 3 4 5 6 7 8 9 10
Test ok ok ok ok x ok x x ok ok
Running hours 3617 3617 12473 3617 3529 2999 2502 7067 2312 3266

MAN Diesel &  20

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CBM – Fuel equipment – cleaning of fuel

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CBM – Fuel equipment – separator cleaning onboard

Poorly operated onboard fuel cleaning systems

Remove the cat fines continuously!

Bad maintenance: Operate the separators:

Dirty / damaged separator bowl High temperature
Dirty preheater Low flow
Separators operate: Clean separators and preheaters
Low temperature
High flow

MAN Diesel & Turbo

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CBM – 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!

MAN Diesel & Turbo

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CBM – Fuel equipment – ME Booster

ME engine
Fuel Oil Pressure Booster:

• Plunger velocity governed by supply pressure

• At start conditions 75-78% of full load pressure
• Long leakage path

 No problem

MAN Diesel &  20

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CBM – Fuel equipment – SL2017-638 – cleaning fuel

MAN Diesel &  20

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CBM – Engine Performance

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CBM – Engine Performance

Pressure transducer
PMI controller

Power
Engine supply
control
room

LED
indicator

Intermediate
Or frequency
divider box

Crankshaft pickup
mounted at free end
of crankshaft
Two-stroke diesel engine

MAN Diesel &  20

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CBM – Engine Performance

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

Pure Pmax level increase Balancing & Pmax level increase

Potential 5-10 bar Potential additional 2-5 bar
At full as well as part Gain even with engines already being
loads operated within recommended limits

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CBM – Engine Performance

 Compare measured service

parameters with shoptest
results.

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CBM – Engine Performance

Pi average +- 0.5 bar

Pcomp & Pmax

Pressure rise max 35 bar

Pmax & Pcomp

Average +-3.0 bar

MAN Diesel & Turbo

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CBM – Engine Performance

Standard load diagram

1. Propeller curve through optimising/ Engine shaft power, % A
matching point (O) –layout curve for 110 A 100% reference point
engine. M Specified engine MCR
100 O Optimising/matching point 7
5
2. Heavy propeller curve – fouled hull 90 O
and heavy seas.
80
3. Speed limit.
70
4. Torque/speed limit.

5. Mean effective pressure limit. 60

6. Light propeller curve – clean hull and

6
calm weather – layout curve for 50
8 4 1 3
propeller.
2 9

7. Power limit for continuous running.

40
8. Overload limit.
60 70 75 80 85 90 95 100 105
Engine speed, % A
9. Sea trial speed limit. 65
MAN Diesel & Turbo 3331353.2004.03.10 (2610/BGJ)  2017 < 17 >
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CBM – Engine Performance

MAN Diesel & Turbo 2017 18

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CBM – Air supply system

Air

Temperature
Water

MAN Diesel &  20

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CBM – Air supply system - WMC

~80 % ~15 % ~5 %

MAN Diesel &  20

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CBM – Air supply system

Free water (droplets)

• Lub oil break down
• High wear
• Liner scuffing

Evaporated Water
• Black liner deposts
• Higher corrosion

MAN Diesel &  20

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CBM – Cylinder Condition – Scavenge air port inspection

MAN Diesel &  20

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CBM – Cylinder Condition – scavenge air port inspection

MAN Diesel &  20

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CBM – Cylinder Condition

When is piston overhaul needed?

3 mm

4.8 mm

MAN Diesel & Turbo  2017 <

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CBM – Cylinder Condition – filing records / observations

Piston overhaul / Liner measurements

Always measure the “0”
point when possible

Zero measuring
position

MAN Diesel & Turbo

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CBM – Cylinder Condition – open up inspections

Piston open up / Overhaul

MAN Diesel &  20

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CBM – Cylinder Condition – open up inspections

Piston open up / Overhaul

MAN Diesel &  20

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CBM – Cylinder Condition – Specific liner wear trends

MAN Diesel & Turbo

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CBM – Cylinder Condition – piston ring types

Piston rings standard can be divided into three

groups Small Bore (26 to 50 cm Bore)
Medium Bore (60 to 70 cm Bore)
Large Bore (80 to 98 cm Bore)

MAN Diesel &  20

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CBM – Cylinder Condition – 60- 80 Large bore alternative

MAN Diesel &  20

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CBM – Cylinder Condition – 80-98 Large bore alternative

MAN Diesel & Turbo Korea, Autumn 2012, by Henrik Rolsted, LEO 2017 31
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CBM – Cylinder Condition – coating thickness of Cermet

MAN Diesel & Turbo

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CBM – 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.

MAN Diesel &  20

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CBM – 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.

2.5

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!

MAN Diesel &  20

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CBM – 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

MAN Diesel &  20
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CBM – Cylinder Condition – small bore – POP ring

…. therefore, we have invented

Controlled Pressure Relive by means
of “POP” –groves (Ports on Plane)

MAN Diesel &  20

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CBM – Cylinder Condition – video liner inspection tool

 Snapshot from a S70ME – Video

MAN Diesel &  20

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CBM – Crank train bearings – Supporting SL

MAN Diesel & Turbo

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CBM – Crank train bearings – SL2008-495

Systems that facilitate condition based open-up inspections

1. 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….

MAN Diesel &  20

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CBM – 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 schedule
Due to the higher safety against major failure, MAN Diesel considers it feasible to
completely omit regular open-up inspections of any of the three crank-train bearings
featuring an approved BWM system connected to the alarm and slow-down
system.
For engines comprising an approved MBTM system, regular open-up main bearing
inspections can be omitted.
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.

MAN Diesel &  20

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CBM – 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.

MAN Diesel &  20

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CBM – Crank train bearings – XH bearings – Normal operation

MAN Diesel &  20

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CBM – Crank train bearings – XH Bearings - TC cut out

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CBM – 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
MAN Diesel & Turbo
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CBM – 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

MAN Diesel &  20

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CBM – 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

MAN Diesel &  20

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CBM – 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.

MAN Diesel &  20

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CBM – Crank train bearings – Main bearings

MAN Diesel &  20

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CBM – Crank train bearings – Spark erosion

• Spark erosion on main

bearing journal and in the lower
shell
•Spark erosion on fwd trust
collar
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CBM – 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 connected
to the alarm system, in order to
comply.

MAN Diesel & Turbo

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CBM – 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.

MAN Diesel &  20

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CBM – 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.
MAN Diesel &  20
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CBM – Crank train bearings – Crank pin bearing

MAN Diesel &  20

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CBM – Crank train bearings – Why not open?

The
human
factor

MAN Diesel &  20

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CBM – 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 corresponding
inspection procedures like regular crankcase inspections required by the
engine licenser. The submitted documents will be reviewed by GL
experts at the head office.

MAN Diesel &  20

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CBM – 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”.

MAN Diesel &  20

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CBM – 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.

MAN Diesel &  20

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CBM – Annual Service Package

MAN Diesel & Turbo

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CBM – Pre-docking inspections

Special Pre-Docking Inspection

 Alongside by Superintendent Engineer

 Fuel equipment

 Cylinder condition

 Visual inspection of crankcase

 VAK Measurements

Complete Inspection Report

Incl. spare part recommendations

*Crankshaft deflection is supplied by vessel.

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CBM – Pre-docking inspections

Upcoming dry-dock
(7-9 months)

PO for pre-inspection
PrimeServ Copenhagen
Co-ordination with local
Service Centers
Inspection report
Pre-Inspection
Recommended spare parts
DD ÷ 6 months

Spare part offer

PrimeServ Copenhagen Report & Spare part offer

PO for Spare parts

PrimeServ Copenhagen
DD ÷ 5 months

Shipping instructions
PrimeServ Copenhagen
DD ÷ 3-4 weeks

Delivery
DD ÷ 2 weeks
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CBM – Pre-docking inspections

Pre-docking Inspection Supervision (Optional)

Spare Parts
Fuel Equipment The knowledge of the engine designer on- site.
Cylinder Condition What you need to ensure optimal running
VAK Measurement Availability
Security

MAN Diesel & Turbo 2017 61

Surveyor's day Gard/Norwegian Hull Club

2017

Thank you very much for your attention

MAN Diesel & Turbo  2017