Professional Documents
Culture Documents
第8章8
第8章8
Exhaust Manifold
Turbocharger
Cylinder Liner
Entablature
Stuffing Box
Scavenge Box/
Manifold
Cross Head
Connecting Rod
A-Frame
Bedplate
Cylinder Cover
Visual inspection
Magnetic powder inspection
Dye penetrant inspection
Hydrostatic test
Symptom of crack during running:
Position
narrow metal sections between such parts as valves
and injectors.
Valve seat insert.
Stress concentration
Causes
The cracks may be caused by cold starting of the engine,
by restricted cooling passages, by obstructions in the
combustion space, or by improper tightening of studs.
The most common cause of cylinder head cracking is
overheating.
overheating
Direct cause- Improper maintenance or operation
Repair
Slight crack- remove by grindstone.
Metalock.
It is also possible to repair them by welding, but this
process requires special equipment and highly skilled
personnel
Replace the seat insert.
Repair
Inspection
Visual inspection
Pencil trace
Oil leakage
Cylinder Liner
Plateau honing
B
A
Aft
Midship
Fore
Stern
Bow
Port
Bow
Starboard
Deck
Waterline
Bottom
Template
Cylinder liner
Inside micrometer caliper
Errors Avoidance
Hold one end of the caliper firmly against the liner wall
Then move the free end back and forth, and up and
down, until you establish the true diameter of the liner.
Considerable experience in using an inside micrometer
or cylinder gauge is necessary to ensure accuracy.
True
diameter
Cocked vertically
Not on
maximum
diameter
Wear
Wearrates
ratesvary,
vary,but
butas
asaageneral
general
rule,
rule,for
foraalarge
largebore
boreengine
engineaa
wear
wearrate
rateof
of0.050.05-0.1
0.1mm/
mm/1000
1000
hours
hoursisisacceptable.
acceptable.
The
Theliner
linershould
shouldbe
bereplaced
replacedas
as
the
thewear
wearapproaches
approaches0.80.8-11%
%of
of
liner
liner diameter.
diameter.
The
Theliner
linerisisgauged
gaugedat
atregular
regular
intervals
intervalsto
toascertain
ascertainthe
thewear
wearrate
rate
Factor
0.99988
0.99976
0.99964
0.99952
0.99940
Causes
insufficient lubrication
improper starting procedures
Dirty condition
low cooling water temperature
Deteriorated Combustion
Repair
Repair size method:
bore the liner, eliminate the circularity and cylindricity
error, replace with a new piston according to the repair
size.
Oversized piston and rings installed.
Restore the size:
Eletroplating.
Causes
Scored cylinder liners may be caused by broken piston rings,
rings
a defective piston,
piston improper cooling,
cooling improper lubrication,
lubrication
or the presence of foreign particles or objects.
objects
Make sure that when you replace a cylinder head, you leave
no metal chips, nuts, bolts, screws, or tools in the cylinder.
The importance of keeping the intake air clean
cannot be overemphasized.
Repairs
Most projections can be removed
by handstoning, using a fine stone.
Carborundum stone (grindstone)
moving the grindstone crosswise, at an angle of 20 to 30
degrees to horizontal.
Leave the scratching marks as coarse as possible
It is not necessary to completely remove all signs of
vertical stripes (micro-seizure)
This is also done to break up the hard surface glaze
Cracked liner
Inspection (same as cylinder cover)
Position
Causes
Thermal stress
Stress concentration
Repairs
Metal stitching
Replacement
Running with less cylinders (emergency)
Piston
4 stroke
2 stroke
Piston crown
Subject to the high temperature, high
pressure, liable to be eroded/burnt away
Steel, alloyed with chromium and molybdenum is used
Piston skirt
Acts as a guide within the cylinder liner
Typical piston materials are light alloys, cast
iron, nodular cast iron, and alloyed steels.
Piston ring groove
The grooves are typically either
induction hardened or chromium plated.
plated
Piston wear
Piston skirt
Causes
Measurement
Measure the piston diameter across the skirt with an outside
micrometer, at 90-degree angles to & in line with the piston pin.
3 Positions
Repairs
Steel piston: welding
Piston Groove
Causes
Measurement
Piston ring side clearance
Check 3-4 places around the groove.
Repairs
Probable Causes
Improper injection timing
Injector contamination
Nozzle failure
Lack of fresh air supply
Exhaust restriction
Piston crack
Piston Ring
Main functions of piston ring
Seal off the combustion pressure
Distribute and control the oil
Transfer heat
Stabilize the piston
Failure modes
Wear
Sticking
Broken
Lack of elastic tension
Attention Please
The port inspection should be carried out at the first stop
after a long voyage, e.g. by anchoring if possible.
A misleading result may be obtained if the port inspection is
carried out after arrival at harbour, or after low-load running.
Procedure
Attention Please
Piston Bowl
Piston
Topland
Liquid
Carbon
Piston
Ring lands
Piston Rings
Micro Seizures
Piston Skirt
Piston Rod
Burning
Carbon
Observations
In good Condition
the rings will move freely in the
grooves and also be well oiled,
intact, and not unduly worn.
Micro-seizure
Scratched
Sticking
Breakage/Collapse
Blow-by
Deposits on Pistons
Lubricating Condition
Causes
Poor maintenance
Measurement
Piston ring end gap
It is a gap to permit the extra
thermal expansion of piston ring.
Place the new rings inside the
cylinder liner or in a ring gauge,
measure the end gap with a
feeler gauge .
If the gap of a new ring is less than specified, file the ends of
the ring with a straight-cut mill file to obtain the proper gap. If
the gap is more than specified, install oversized rings.
Inspection
Methods
Soak the piston overnight in an approved cleaning solvent
or in diesel oil.
If soaking does not free the ring, you must drive it out with
a brass drift. The end of the drift should be shaped and
ground to permit its use without damage to the lands.
lands
Constant
pressure
distribution
Apple Shaped
pressure
distribution
Pear Shaped
pressure
distribution
Cleaning
Clean piston with solvent and dry with compressed air if
available.
Diesel oil or kerosene are satisfactory cleaning agents.
The piston can also be cleaned by mechanical methods.
But, dont remove any metal from the piston while
cleaning.
Inspection
Piston ring end gap
Piston ring side clearance
Installation
After installation
Check the ring-to-land clearance
Coat the entire assembly with oil
Position the rings so the gap of each successive
ring is on an alternate side and the gaps are in line
with the piston pin bosses.
Insert it into the cylinder bore with a special tool
Crankshaft Alignment
Crankshaft deflection
Crank web
3-hypothesis
Principal shaft
Crank pin
TDC
C
Camshaft
Starboard
Looking forward
E
Exhaust side
Port
BDC
=LC - LE
=LT - LB
The locations for recording crankshaft deflection
readings according to the positions of crank pin
L
L
L
L
Measurement
Requirements
Record
Specification
When to measure
Factors
B A
The correct mounting position
is marked with punch marks
on the crank throw.
Measure spot
Deflection indicator
The strain gauge consists of a dial indicator, contact point,
balancing attachment, clamping nut, spring plunger, rods
and extension, and bezel.
a plus or minus reading
opening up or closing of the distance
Requirements
DO NOT touch the gauge until you have taken and
recorded all four readings.
Turning clockwise
Closing of the crank throw (compression of the gauge)
is regarded as negative () and opening as positive (+).
Crankshaft deflection readings should be taken while the
ship is afloat (i.e. not while in dry dock).
Under nearly the same temperature and load conditions
Record
Readings should be taken at the TDC, BDC and horizontal
crank positions
TDC
C
Camshaft
Starboard
E
Exhaust side
Port
BDC
Set the dial gauge to zero at the B1 side near BDC. Whilst
turning clockwise, take the readings when the throw passes
the positions
Specifications
Crankshaft Web Deflection should never exceed the
tolerance permitted by the engine or crankshaft
manufacturer.
manufacturer
Specified by CCS
Situations
After repaired
0.125
Acceptable in
service
0.1250.25
0.3
Limit
When to measure ?
During manufacturing
Keep the crankshaft deflections as low as possible
Take the reading several times (if any disturbance in the line shaft
bearing offset occurs)
During repairing
After replacing any main bearing shells
When in service
Its a task should be undertaken by ships engineer at least once a year.
Factors
Deflection curve
Bridge gauge
Crankshaft deflection
Bridge gauge
Crankshafts Failures
Wear
Causes
Measuring
Outside micrometer caliper
Repairing
Repair size method:
Reground to eliminate the circularity and cylindricity error
Install undersized bearing shells.
Restore the size:
Eletroplating (iron).
Crack
Causes
Inspection
Visual inspection
NDT ()
Repairing
Scrape or grind ()
Replace
Welding (in emergency)
Bearings
Bearing metals
Bearings design
Journal Bearings Failures
Repairing Journal Bearings
Installing Journal Bearings
Measuring Bearing Clearances
Bearing metals
white metal
is an alloy with minimum 88% tin (Sn), the rest of the alloy
composition is antimony (Sb), copper (Cu), cadmium (Cd)
used in the main bearings, crankpin bearings, crosshead
bearings, guide shoes and thrust bearings because of its
excellent load carrying and sliding properties.
Tin aluminum
Overlayers
Flashlayer
Bearings design
Thick shell bearings
Steel back with required stiffness
Top clearances are adjusted with shims
Thin shell bearings
wall thickness: 2% - 2.5% of the journal diameter
with a circumferential over length
Tangential run-out
Bore relief
Axial oil grooves and oil wedges
Top and side clearance
Surface Pitting
High localized temperatures that cause the lead to melt
very close oil clearances
use of an oil having a viscosity higher than recommended.
melt
Cracks
a fatigue phenomenon
Crescent
Method 3 - Comparison
Top clearance =
inside diameter of bearing shell
outside diameter of journal
Precision Coupling
Failure modes
Nozzle Cleaning
Remove the carbon deposit
The center hole should be cleaned
with a spiral drill and the pulverizer
holes with a special cleaning needle.
Nozzle Testing
Turbocharger
Outlet Casing
Nozzle Ring
Inlet Casing
Silencer Filter
Corrosion of casing
Dynamic balance
Cleaning of turbocharger
To avoid the heavy deposit on the rotor.
If vibrations occur after cleaning, then the cleaning must
be repeated.
Cleaning the turbine side
Dry cleaning
a specified volume of crushed nut shells or similar
Water cleaning
injecting atomized water at reduced engine load
Cleaning the compressor side (option)
injecting water through a special pipe arrangement
1
2
3
4
Tie bolt
blanking plate, blower side
inner blanking plate
blanking plate, blower side