Inspection Report

Goltens Job No. 2636

Client’s Ref. “Pacific Prospector”

ROOT CAUSE
Intake and exhaust valves on cylinder head unit no. 6 were wrongly assembled. The
intake valve was fitted to exhaust valve seat position and the exhaust valve was fitted to
intake valve seat position of the cylinder head.

HOW IT HAPPENED.
Before dismantling the cylinder head, it is our normal practice to put a punch mark on the
intake and exhaust valves corresponding to the punch mark on the intake and exhaust
valve seat position on the cylinder head . It is our practice in marking that, mark 1 &
2 should be for the exhaust and mark 3 & 4 for the inlet .

During the inspection and pressure testing of the cylinder head ex-unit no.6, it was found
with leak located on the wall of inlet port (see photo no 5 & no. 6 showing the leak). We
received one spare cylinder head complete from the vessel for inspection and meant as
the replacement of cylinder head unit no. 6 due to leaking problem.

The spare cylinder head was differently having marked 3 & 4 as the exhaust and 1 & 2 as
the inlet. Not knowing this on assembly stage, the valves were assembled in opposite
manner.

EFFECT DURING OPERATION.

Inlet valve fitted on the exhaust valve seat, protruding from actual position and causing to
hit the top surface of the piston during operation and resulting to damages to the cylinder
head valve spindles , fuel injector, pistons and cylinder liner anti polishing ring.
For the exhaust valve, it was seating inward on the inlet valve seat. There will be an
abnormalities on the adjustment of the intake and exhaust valve tappets.

DAMAGED PARTS DURING OPERATION DUE TO

FAILURE OF CYLINDER HEAD.

1. Cylinder head
2. Intake and exhaust valves
3. Fuel injector
4. Piston crown
5. Anti polishing ring
6. High pressure pipe.

PO Box 2811, Dubai, United Arab Emirates.

Tel: 971 4 3241642. Fax: 971 4 3241019. Telex: 46898 GOLT EM.
E-mail: dubai@goltens.com. Website: www.goltens.com
 Inspection Report
Goltens Job No. 2636
Client’s Ref. “Pacific Prospector”

CORRECTIVE ACTIONS

1. Complete checking of affected units pistons, cylinder liner and connecting rod.
2. Replacement of damaged cylinder heads.

PREVENTIVE ACTIONS.

1. Delegate a permanent group of mechanics strictly for dismantling

and assembling the engine major component.
2. Closed supervision during assembling of engine parts
3. Grouping of mechanics with foreman ( at least 2 groups ) to be able to divide the
job and responsibilities. This will prevent the overload in work.
4. Adoption and using of new checklist. Delegate mechanic who will l
perform engine component quality check upon dismantling and upon re-
assembling.
5. Permanent group of mechanics for workshop only ( not to be assigned on the
vessel ).
6. Additional one more Supervisor in the workshop.
7. Minimize mechanics who will do marking of at least 2 only, this will prevent
and reduce the possibility of wrong marking of parts.
8.

PO Box 2811, Dubai, United Arab Emirates.

Tel: 971 4 3241642. Fax: 971 4 3241019. Telex: 46898 GOLT EM.
E-mail: dubai@goltens.com. Website: www.goltens.com
 Inspection Report
Goltens Job No. 2636
Client’s Ref. “Pacific Prospector”

Photo No. 1 : Damaged Piston Crown

Photo No. 2 : Damaged Anti-polishing ring

PO Box 2811, Dubai, United Arab Emirates.

Tel: 971 4 3241642. Fax: 971 4 3241019. Telex: 46898 GOLT EM.
E-mail: dubai@goltens.com. Website: www.goltens.com
 Inspection Report
Goltens Job No. 2636
Client’s Ref. “Pacific Prospector”

Photo No. 3 : Damaged Cylinder Head

Photo No. 4 : Damaged Cylinder Head

PO Box 2811, Dubai, United Arab Emirates.

Tel: 971 4 3241642. Fax: 971 4 3241019. Telex: 46898 GOLT EM.
E-mail: dubai@goltens.com. Website: www.goltens.com
 Inspection Report
Goltens Job No. 2636
Client’s Ref. “Pacific Prospector”

Photo No. 5 : Cylinder Head Ex Unit No.6 showing leaking on inlet

port wall.

Photo No. 6 : Cylinder Head Ex Unit No.6 showing leaking on inlet

port wall.

PO Box 2811, Dubai, United Arab Emirates.

Tel: 971 4 3241642. Fax: 971 4 3241019. Telex: 46898 GOLT EM.
E-mail: dubai@goltens.com. Website: www.goltens.com