-2.

SGOРЕ 0F SCAVE],IGE РORТ l],lSPECTlO]rlS:

The fol]owing shall Ье carried out during а scavenge port iпsресtiоп:
l Visual examination iп ассоrdапсе with rеquirеmепts of MAN /п-
sресtiоп Through Sсаиепgе Роrfs fоrm.
l Measurement of the rеmаiпiпg depth of the pressure relief grooves
(CL grooves), riпg groove clearance and piston Ьurп-аwау in ас-
Соrdапсе with MAN Сопditiоп Мопitоriпg Rероrt (Port tпsресtiоп)
form.
l lnspection of the суliпdеr liпеr ruппiпg surface through the scav-
enge роrts.
I Photos taken of piston сrоwп, top land, piston rings, piston skirt,
piston rod, cylinder liпеr and scavenge rесеiчеr. Photos аrе rе-
quired for апу surfасеs that are wiped down оr cleaned, see taking
photos section for details in Раrt ll.
t lnspection of поп-rеturп flaps.
l lnspection of water mist catcher.

PRACTICES FOR SCAVE],IGE РORТ l1,1SPECTl0],lS

1 . Always useMAN Diesel & ТurЬо sheets lпsресtiоп through Scay-
еПgе Porfs апd Суliпdеr Сопditiоп Rероrf when submitting scav-
enge роrt inspection results. Blank inspection forms are availab|e
iп APPENDlX.
2. Conduct scavenge inspections оп а month|y оr as sооп thereafter
basis.
3. A|ways pre-view the ]ast scavenging роrt inspection рriоr to ас-
complishing а пеw роrt inspection.
4. photos and comments in this booklet are ап overview of the MAN
Diesel & Turbo lnstruction Manual Vol. 1 , Operation Manual, Chap-
ter 7О7. Rеfеr to Chapter 7О7 for complete descriptions of рrосе-
dures for scavenge роrt inspections, cylinder conditions, piston
conditions, ring conditions, factors influencing cylinder wear, and
cylinder lubrication.
5. The scavenge роrt inspection should Ье carried out at the first
stop аftеr а long voyage, e.g. Ьу anchoring if possib|e, to оЬ-
tain the most reliable result with regard to the effectiveness and
sufficiency of the cylinder lubrication and the combustion cycle
(complete оr incomplete). А misleading result may Ье obtained if
the scavenge роrt inspection is carried out after arrival at hаrЬоur.
since manoeuvring and low speed ruппiпg requires increased orl
dosage.
*0пе star at а photo
indicate а perfect сопditiоп.
**two stars at а photo indicate
mасhiпiпg marks still inuisib|e.
 ]1,

HOW ТО USE ТНЕ МАN Diesel & ТчrЬо FORM lпsресtiоп

through Scayenge Port
The form оп the next page is the MAN Djesel & Turbo form titled
lпsресtiоп through Scayenge Port, а blank form is provided in the
APPENDlX.

The left column оп the MAN Diesel & ТurЬо form lists GENERAL
CATEGORlES, the next column lists SPECIFlC CONDITIONS within
each GENERAL CATEGORY. The scavenge port inspection invo|ves
the identification of SPEClFlC CONDITIONS within each of the
GENERAL cATEGoRlES.

Partia! view of MAN form, full page view оп opposite page

Mcdiumdepmit - МС
liхссsзiчсdсрозit . ЕС
Poli*rcd Фросit - РС

When conducting а scavenge port inspection оп а unit, start Ьу

asking what is the status of each GENERAL САТЕGОRY iп rela-
tionship to the SPECIF|C CONDITION. Опсе that determination
has Ьееп made, write the symbol for that condition iп the Ьох that
corresponds to the ]ocation, i.e. topland, riпg land пumЬеr оr ring
пumЬеr.
рАRт l L|ftt'q)hqrkr {|,

рАRт l of this booklet was

developed to provide а pho-
tographic representation of
each piston and liner condi-
tion listed on the MAN Diesel l
l
э-__
Е--
ьa

& ТurЬо lпsресtiоп through

},
a----
l _* . -a

Scayen ge Port form. I* ь

L

La

ь_
GENERAL CATEGORIES ОП i
a --
blt-
__
_._
ь-

:
l с*.-
l r -
r

the MAN form match the I.r

----*
-._

паmе on the tab at the bot-

!-
Ь+
tom of each booklet page Ь-a

l:i
ha

(black arrow). t
.-т
SPEC|FIp CONDITIONS оп
the form are represented Ьу
photographs (red arrow) in
this booklet.

EXCEýS|VE ШР(БlТ- ЕС (ClG. t|рdТоэ РЕ|

 *
l}lTAcT PlSTo]l сROwt -
Ап intact piston сrоwп has а minor lауеr of саrос'^ ^с сч,п-эо,lZ,
(elephant skin).

PlSToll сROW}I BUR]tl]tG _ вU

Furthеr information concerning piston сrоwп burning сап Ье founo
in РАRТ lll.
сАRвo]l DEPOSITS
Often some deposits will accumulate оп the side of the top
land. СаrЬоп deposits оп the riпg lands indicate lack of gas
sealing at the respective riпgs. lf the deposits аrе thick, the
surface mау Ье smooth and shiny frоm rubbing оп the суliп-
der wal!. This contact may locally wipe away the oil film, rе-
sulting in miсrо-sеizчrе and iпсrеаsеd wеаr of liпеr and rings.

*
ш0 DEPOSIT _
Ruппiпg surfaces of piston rings will Ье wоrп bright. ln addition, the
rings will move freely iп their grooves, Ье well oiled evenly around
the circumference of the piston, and intact.
 ExcESSlvE DEPOSIT - Ес
Excessive саrЬоп deposits аrе the result of оvеr lubrication оr im-
рrореr combustion.

POL|SHED DEPOSIT _ рс
lf the deposits аrе аЬпоrmаllу thick, the саrЬоп deposits may Ье
smooth and shiny from rubbing against the cylinder wall. This сап
result iп locally wiping away the oil film, causing micro-seizures and
increased wеаr of liпеr and riпgs.

ln some instances, mechanical clover leafing (Surface Condition

section, CL) can оссur, visible as vertical grooves of slightly higher
wear in between the lubricating quills.
пшG IпЕдкдGЕ/GOttдр|sЕ

lF РАRТ ОF А RING lS MISSING (Condition "М"), АТ-

тЕмрт то F|ND тнЕ MISS|NG PART(S). lF тнЕ MISS-
lNG BRoKEN R|NG PART(S) cANNoT вЕ LoCATED, IN-
SPECT ТНЕ EXHAUST GAS RЕСЕ|ЧЕR, ТНЕ SCAVENGE
AlR RЕсЕlчЕR AND тнЕ SCAVENGE А|R вох, lF STILL
NOT FOUND, |NSPECT ТНЕ ТURВОСНАRGЕR FОR
MISS|NG PART(S) AND/oR DAMAGE.

During а scavenge port inspection, Ьrоkеп rings аrе identi-

fied Ьу:
. Collapsed ring (С).
l Lack of "elastic tension" (SL and Sr Rng Моvеmепt sec-
tion). ,
l Blackish арреаrапсе (В оr (В), Surface Condition secfion).
l Fractured ring(s) (Во, BN оr SP).
l Missing riпg (|И.

*
l]lTAGT Rll{G -
Ruппiпg surfaces of the rings аrе worn bright, smooth, clean, with-
out scratches, move freely in the grooves and аrе well oiled.
 GOLLAPSED Rlllc - G
Collapse occurs if the gas pressure behind the ring is built up too
slowly. With inadequate outward pressure behind the riпg. com-
bustion gas can penetrate between the liпеr and the ring, violently
forcing the ring inwards, jnto the ring grооче. The sudden shock
loading will eventually lead to fracture, particularly if the ring ends
slam against each other.

The slow pressure build-up behind the rings can Ье due to:
I СаrЬоп deposits iп the riпg groove (МС апd ЕС, Deposits sectionl.
l lnsufficient чеrtiсаl riпg сlеаrапсе (PART lll, Riпg Grооче Меаsurе-
mепt).
f Раrtiаl sticking (ST Riпg Мочеmепt secfionl
I Рооr sealing between the riпg and the ring groove floor.
l Clover-|eafing (CL, Surface Condition sесtiоп,).
f Riпg end chamfers.
l Тоо lаrgе ring-edge radii.
l continual striking against wear ridges wR, surface Сопditiоп
section), оr other irregularities iп the cylinder wall.
 EllTlRELY MlSSl],lG - м
lf part of а ring is missing, attempt to find the missing part(s). lf
the missing broken ring part(s) cannot Ье located, inspect the ех-
haust gas rесеiчеr and the bottom of the scavenge аir Ьох, if still not
found, inspect the turbocharger for missing part(s) апd/оr damage.
 -21 -

пшG кruЕпЕtт
Piston rings provide а gas tight seal between the piston and
cylinder liпеr wall. The sea| occurs Ьу gas pressure above
and behind the piston riпg fоrсiпg the riпg down and out
towards the cylinder wall. То create this seal, free ring mоvе-
ment is essential.

Ring movement is described as:

l Loose
l sluggish
f sticking

cHEcKltG RI]IG iTOYEtEl{T

Ring movement is checked Ьу pressing оп each riпg with а wooden
stick through а scavenge port. Тurп the piston up and down. Fоr
large Ьоrе engines it сап Ье necessary to use а wooden block and
а hammer.
 *
CLEA],|, SMOOTH -
Running surfaces of the piston rings and cylinder liner аrе wоrп
bright, rhgs move frееlу in the grooves, are well oiled, and intact.

BLOW-BY:
Blow-by, the leakage of combustion gas past the piston
rings, is the result of riпg sticking, colIapse оr breakage. lt is
indicated Ьу black, dry аrеаs оп the rings and Ьу lаrgеr black
dry zones оп the uрреr раrt of the liner wall which сап опlу
Ье seen when overhauling the piston оr when exchanging
the exhaust valve. lп this booklet, blow-by is indicated Ьу the
following conditions: BLACK OVERALL, BLACK PART|ALLY
and BLACK RING ENDS.

RUшшIшG SURFАсЕ, BLA0K 0VERALL - в

VERTICAL SCRATCHES

SGRATCHES (vERTlcAL) - S
Scratching is caused Ьу hard аЬrаsivе particles from the fuel oil,
from а Ьrоkеп riпg оr frоm turЬосhаrgеr intake. Scratches оп the
crston riпg ruппiпg surface is опе of the first signs of abrasive
oarticles, and сап Ье observed duriпg scavenge port inspections.
Usually, micro-seizures do not occur from scratching, i.e., the riпg
surface rеmаiпs soft. Hardness сап Ье checked with а file, see
RECOGNlZlNG лllСRо SE\ZURES iп fhis sесtiоп апd л/lAN Diesel
& ТчrЬо Plate 70704.

FасеW Ring

SGRATcHES {vERTlcAL) - S
piston skirt
 MlCRO-SElZURES:
N/icro-seizures аrе the result of Ьrеаk cJo,,..
film, causing metal to metal contact Тl-д :
а high friction and high tепlрег&tчr,е ,.- а

арреаrапсе of the riпg sulrfacc, -.-:

down is iп most CaSeS caLlscc; l],. :_ _,

liпеr ruппiпg surface.

LOCAL micro-seizures аrе ,- .э-:

fеrепсе. However, becaLiSe . r^])S

CAL micro-seizures оп а rirlg :а.^ i_,-_ _,_:_;

all the way аrоuпd the cylinder ,]е,, as ..- _

the ring grооvе, creating а conditicn (,^ с ..,

.-

m icro-seizu res.

То identify LOCAL micro-selzures Ьеfоrе they cje,,еiэl] . -

ALL оVЕR micro-seizures, when conducting ап lпsрес. ,],
it is important to check the exhaust апd сагп (manoeLt,,.'^ j
sides as well as the forward and aft piston ring conditro.^s
using а mirrоr.
пEc0ctlzltG tlcпо-ýЕlшRЕs
Micro-seizures оп а ruппiпg surface wi|l have а vertically-
striped арреаrапсе, and Ье relatively "hard", which refers to
the result of а FILE TEST.

То conduct а file test, use а new, finely cut fi|e to file асrоss
the hardened surface. lf the file leaves almost по scratch, it
indicates the surface is covered Ьу а hаrd g|aze, the result
of micro-seizure hardening. See MAN Diesel & ТurЬо Plate
70704 fоr additional information сопсеrпiпg the F|LE TEST.
The file test can of course only take place оп а dismantled
piston ring.

IOGAL & ALL ovER мlGRO-sЕlzURЕS

LOGAL MICRO-SEIZURES - mz

ALL ovER MIcRO_SEIZURES - irz

Notice in the top photo the micro-seizures are limited to the center
scavenge port. ln the bottom photo micro-seizures can Ье seen in
all 3 scavenge ports. This is the distinction between LOCAL and
ALL сVЕR micro-seizures.

)' t
l
\ l!a
FАGтOпS l]lFLUE]lcl]lG cYLlllDER WЕАR
lt is vital that the system Ье free of condensation and wa-
ter. Condensat]on рrоduсеs sulphuric acid соrrоsiоп, wаtеr
breaks down cylinder lubrication.

То minimize condensation оЬsеrvе the following best рrас-

tices:
l optimize the temperature of the liпеr wall Ьу maintaining
cooling wаtеr outlet temperatures within the specified l]mits.
l Кеер cooling wаtеr tеmреrаturе diffеrепсеs асrоss the cyl-
iпdеr units Ьеtwееп 12"-1В'С at МСR.

То minimize water оЬsеrvе the fo]lowing best practjces:

l check that the drarn for the water mist catcher functions
рrореrlу to prevent water drop|ets from entering the cylinders.
t Сhесk water mist catcher fоr соrrесt fitting according to
sеrчiсе Letter
l check for free standing water iп the mist catcher.

Whепечеr inspecting а cylinder liner, use а mirrоr and а

bright light or а flash photo to inspect the condition of
lп jectors, exhaust valve and cylinder head.

SCUFFl]tlG:

Scuffing is the result of oil film Ьrеаkdоwп. With the cylinder

walls no lопgеr able to retain ап oil film, frictional interac-
tion between the cylinder wall and riпg surfaces occurs. Due
to the heat, ring and cylinder surfaces friction weld, harden,
and seizures develop оп both surfaces.
When the piston is positioned at approximately TDS, inspect
the piston rоd through the scavenge ports.

*
PISTOш ROD, SillOoTH -

PlST0],l ROD, CORROSlOll - с0

 SLIGHTLY DпY - D
Ruппiпg surface of piston rings dry but oil is still visible оп ring lands.

vERY DRY - D0
Тоо little cylinder lubricating oil can result iп break down of the oil
film between the piston rings and the cylinder |iпеr leading to adhe-
sive contact and possible scuffing of rings апd liner.
lf сlеапiпg scavenge boxes оr аir rесеivеr, take photos both
before and after сlеапiпg.

Sсачепgе Вох, ],l0 SLUDGE - *

.я
f*-

ъ
Q._ '''**
\
ql
\.lil
/,r ai
Sсачепgе Вох, SLUDGE - S

Sсачепgе Вох, МUСН SLUDGE - MS

-,с^ s|udge сап contaminate system oil. Rеmоvе апу oil
а^] саrьоп deposits iп the sсаvепgе аir boxes.
 э
ъ,
ёrр
э
э
э
э

>
э

'->
F,
э
->
->
il
э

>
э
I

>
WАтЕR MIST 0ATсHER, OUTLET SlDE
э

>
,,*--
Oheck fсr gat)s aitlc] tllissirlg bolts that caLtse cJt|)s i t-т
саtсhеr atlc] tlle casirlg, lrl tlle tc11 1lhotc the a1-1-()\i,./s ir-r.j

>
.-

to check fot- loose ot- rllissirlq lэolts. the cir-cle illcllcilii-

clleck fcl,cJal)s. lrl tlle lсwеr 1lllcto а g]aI) exlsts

*
.Е
? -lir
э
э
ь_a

-ж{-

g
-Э:Це

э
+

*
$
t
.-}
э
э

D
Е
э
WАТЕR MlST САТСНЕП

D
D
D
D
lrlslэect the ,"vetel- lllist c,atcilel- I:,, ,,_, -
1,1ol']lltlllU (jLl,itlU ,-gQ\zQr'lrt]Q lrLrl- , (l -
_

-g
-r'

lllc[]lltirlg lllay Cat_lSe el] Ltlэstl-ealll galэ at il]= I_

tllist саtсhеr elet1-1ellts Аir orl the Lrlэstleal]] siti,

g
the eletlletlt atlcJ caitse wate1, 1-Lll,]rlirlg cJowtl ti-tt'cLrgll ii--: -
Ье slэrауес1 c]owtlstreatll cLrt throtrgh tlle watel- |lliSi . _1]
в
tлlаtеr, S|]r,ay frоrll the iэrсkеtl wateI- l1-1ist catchet- tllat a.,'.a,
irlс]ег tttlits
,.f
D
,=D
-'

,g
в
 рАRт ll

ScAvE}lGE рORт lпlsрЕстlo}l TOOLS &

TAKlmG PHOTOS

Vеrsiоп 1.0
November 201 0
photo taken with camera's flash switched оN. since this
photo includes а Ьrоkеп ring, саrЬоп deposits and shаrр
edges оп iings, details in the photo аrе important, but соп-
cealed Ьу the glаrе frоm the саmеrа's flash.
 - :: -

Pttotos are а good method for detecting and documenting

conditions such aS mасhiпе marks (**), Wear ridges (WR),
clover leafing (CL), scuffing (SC), micro-seizures (MZ) and
polishing.

lf oil оr water is found оп top of а piston, use photos to docu-

ment the condition of the exhaust valve, cy|inder head and
injectors.

Photo taken iп figure

рАпт lll
 рАRт lll

SuppIement to the MAN Diesel & ТurЬо form

titled
PISTON CONDITION MONITORING (Роrt
lnspection)

Version 1.0
November 201 0
 PART lll

lп ассоrdапсе with
N/AN Dlesel & Turbo
form, Сопditiоп Мопt-
tоriпg Rероrt (Роrt tп-

specfion), РАRТ lll of

this booklet provides
а pictorial desc riр -

tion of measurerTent
рrосеdurеs pertain-
iпg to Pressure Relief
Groove (CL grооvе)
depth, riпg grооvе
сlеаrапсе and piston
сrоwп Ьurп-аwау.

PRESSURE RELlEF GRoovE (cL GRоочЕ)

DEPTH MEASUREMENT

рlsтqсraопа.-G

рАRт lll
рROрЕR SELEcTlOil 0F чЕR]llЕR GAUGE
Before measuring the depth of а Pressure Relief Grооvе
(CL Groove), consider the width апd shape of the чеrпiеr
gauge's stem end (Fig. 1). lf the stem is too wide (Fig. 2) the
measurement will indicate the grооvе depth is less than the
actual depth. Fоr ап ассurаtе mеаsurеmепt, use а vеrпiеr
gauge with а stem that will sit оп the bottom of the groove
(Figs. 3 & 5).

Fig. 1

Whеп selecting а vеrпiеr gauge, verify that the stem end is not too
wtde for the Рrеssurе Relief Groove (CL groove).

Гор of Ring
The чеrпiеr gauge stem end is too wide
to sit оп the bottom of the groove

Рrеssurе Relief Grооче

(CL Grооvе)

Fig. 2 - WR0],|G

Тор of Ring
The чеrпiеr gauge stem end is паrrоw
enough to sit on the bottom of the groove

Рrеssurе Relief Groove

(CL Groove)

Fig. 3 - СORRЕСТ
irЕАSURlilG рRЕssURЕ *ra,r, GпшlYЕ (GL GпшtUЕ}
DEPTH

Fig. 4 Measure the depth of the pressure relief groove. The depth is
ап indicator of piston ring wear.

Fig. 5 When taking the measurement, verify that the stem of the
vernier gauge is sitting оп the bottom of the Pressure Relief Groove
(CL Groove).

Fig. б The pressure relief grооче depth slвll rюt Ье less than stated
оп the Piston Data Plate. Епtеr al| mеаsurеrЕпts оп trв MAN Dbsd
& ТurЬо P|STON CONDIT|ON MON|TOR|NG (Port lпsресtiоп) form.
 -61 -

пETHOD А, шЕАSURlilG Rl]tG GROOYЕ GLЕАRАilсЕ

Рriоr to inspecting the ring grооvе сlеаrапсе, rеviеw the ver-
tical сlеаrапсе specified оп the Piston Data Plate.
The riпg groove сlеаrапсе mеаsurеmепt is ап indicator of
the wеаr taking place оп the сhrоmium plating iп the riпg
grооvе. lf the ring grооvе wеаr rate suddenly increases it
could Ье due to а malfunction of the air сооlеr system caus-
ing water to епtеr the cylinder, а malfunction of the cylinder
luЬе system оr abrasive particles from fuel oil оr scavenge
аir.

using а feeler gauge, measure top and bottom c]earances between

the ring and the riпg grооvе. The total of the top and bottom clear-
ances must not exceed the value specified on the Piston Data Plate.

Ring grooves wеаr faster iп two areas. 1)

The chromium plating оп the floor of the
ring groove. 2) The outer edge of the ring
groove. То mеаsurе the riпg groove сlеаr-
апсе at the point of maximum wеаr, the
feeler gauge is only inserted 2mm int
the riпqgrооче whq

Enter the riпg groove clearance depth on the PISTON CONDIT|ON

MON|TOR|NG (Port lnspection) form.
METHOD В, MEASURIП|G Rll,|G GROOVE CLEARA],ICE

STEP 1: Run the turning gear so the piston is iп the downstroke. lf

the ringsnhave good movement, the rings will move to the top of the
riпg grооvе.

lf the riпg rests оп the top of the groove, taking riпg grооvе mеа-
surements аrе simplified Ьу checking the top of the ring as seen
iп Step 2. Then, if the riпg is actually resting against the top, feeler
gauge measurements can Ье performed оп the floor of the ring
grооvе as illustrated iп Steps З - 6. lf not, fееlеr gauge measure-
mепts must Ье made at the top and the floor. The сlеаrапсе will Ье
the total of the two measurements.
 STEP 2: lnsert а thin
feeler gauge between the
top of the ring and ring
groove to determine if the
ring is resting against the
top of the ring groove. lf
there is а сlеаrапсе, fol-
lowSTEPS3-6ontop
and bottom. The сlеаr-
апсе is the total of both
the top and floor (bottom)
сlеаrапсе measu rements.

STEP 3: lnsert а thin

feeler gauge between the
riпg and the floor until а
slight resistance is felt.
The fееlеr gauge may go
deep into the riпg grооvе.

Do not try to force the feel-

еr gauge into the groove.
Use only light рrеssurе.

STEP 4; lnsert а slightly

thicker feeler gauge Ье-
tween the riпg and the
floor until а slight resis-
tance is felt. The feeler
gauge will not go iпtо the
riпg grооvе as far.

STEP 5: How mапу times

the groove is measured
with the feeler gauge
will vаrу depending оп
the condition of the ring

groove and the реrsоп

doing the inspection.

STEP 6: As the feeler

gauge thickness increas-
es, the depth to which the
gauge сап Ье inserted into
the groove will decrease.
consider the measure-
ment complete when the

feeler gauge can опlу Ье

inserted 2 - 4mm into the
groove. At this point, the
feeler gauge thickness is
the riпg groove сlеаrапсе.

Епtеr the riпg grооvе сlеаrапсе depth оп the P|STON CONDlTlON

MON|TORlNG (Роrt lnspection) form.
 -65_

Рriоr to inspecting the piston crowns, review the maximum

permissible Ьurп-аwау values оп the piston Data plate.

Check for Ьurп-аwау and сrасks (elephant skin) around the

entire circumference of the piston сrоwп. lf elephant skin is
found, look at it from several angles and estimate the depth
of cracks.

Епtеr piston сrоwп Ьurп-аwау values and locations оп the

P|STON CONDlTlON MON|TOR|NG (Роrt lnspection) form.
 АррЕNDlх

lnspection Through Scavenge Рог[

Condition Monitoring Rерогt (Por1 lnspection)
 Inspection through scavenge port

at load о/о

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Rel.2009-02-13
 Condition \Ionit{)t,ittg Itu 1,, l
-

IMO rro:

No. of cvlinders:
Hours sincc last overhaul:
Voyage iпfо
wccks рсr роrt calls: Nоппаl scrvicc load (о о of MCR r

cvl. oil consuln tion (li24 hгs):

CL grooves
Noпrinal CL dcpth, ncw rirrg. lllln: Minimurn CL dc

,/./'./ "/
,./' ,/
,/./'./' ,,'

Счliпdсr No.

L groovc по. l

L groovc no, 2

CL groovc по. 3
CL groovc no. 4
CL groovc no. 5
L groovc no. 6

Rcrnaining round (\' \ t

Рistоп Riп
lrours

_r
j--_

-t-
rF
l

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