Nature of the maritime maintenance problem, seen from an engine manufactures point of view.

Michael Petersen
Senior Manager Engine Management / PrimeServ

MAN Diesel & Turbo

23.09.2010

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Agenda

MAN Diesel & Turbo

23.09.2010

Maintenance seen as a life cycle cost.

Life cycle cost is the total cost from design to disposal, the objective of LCC is to choose the most cost effective approach, so that the lowest long term cost of ownership is achieved!

MAN Diesel & Turbo

23.09.2010

Maintenance seen as a life cycle cost. Procurement cost

Procurement cost is widely used as the primary (and sometimes only) criterion for equipment, spare parts or system selection (i.e. the cheaper the better). However, the major costs lie in the care and operation of equipment during its life.

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

CBO
Condition Based Overhaul Strategy, Largely extended Overhaul intervals. Never touch a well running unit

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

The Objective is: Tankers and similar vessels

3 - 5 years operation without immobilisation, equal to

18 / 32,000 hours between major overhauls (dock to dock) Container, bulkers and similar vessels

Up to 5 years between major overhauls of bearings,

turbochargers, pistons, cylinders and piston rings.

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

Status

Major Overhauls / Inspections, which require immobilisation:

Bearings Turbochargers Cylinder units Fuel pumps Exhaust valves

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Condition Based Overhaul (CBO)

How to judge when overhaul is necessary?

2-stroke engine's can be inspected by open-up the doors, go in, see, check and record.

In addition Bearing Wear Monitoring (BWM), Main Bearing Temp. Monitoring (MBTM), Water in Oil Monitoring (WIOM) and Liner Wall Temperature (LWT) systems are essential tools

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Condition Based Overhaul (CBO)

Bearings, CBO overhaul / open-up criteria:

Main bearings should only be opened in case of alarm.
Check every 3 month: Clearance and deflexion readings. Bearing edges to be checked by wire-feeler for
missing- or squeezed-out metal

All parts of the crank case to be checked for loose metal.

Con. rod- and x-head bearings:

Random open up inspection at the 5 year's docking, and in case of external indications

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Condition Based Overhaul (CBO)

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Condition Based Overhaul (CBO)

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Condition Based Overhaul (CBO)

Modern MAN BW 2-stroke engines are designed to extended TBO by means of:

Slide fuel valves Nimonic- or Dura spindles W-seat Oros combustion Chamber,
formed entirely in steel as a result of

low positioned mating

surface

Low positioned ring packages Heavy duty ring packages Optimised liner temperature

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Condition Based Overhaul (CBO)

Nimonic spindle & W-seat, S60MC, 25.500 service hrs

Dura Spindle & W-seat, S60MC, 40.042 service hrs

(DuraSpindle seat welded on Nimonic spindle)

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

Modern MAN BW 2-stroke engines are designed to extended TBO by means of:

Slide fuel valves Nimonic- or Dura spindles W-seat Oros combustion Chamber,
formed entirely in steel as a result of

low positioned mating

surface

Low positioned ring packages Heavy duty ring packages Optimised liner temperature

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Condition based piston overhaul

When is piston overhaul needed?

Before piston burning reach 15

mm

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

CBO example: 10K98MC-C, unit 7, 23,597 hours without overhaul. Note, visual good condition, without being perfect. Is it due for overhaul?
Still rounding Still rounding

Still rounding

Still rounding

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Condition Based Overhaul (CBO)

Visual inspection of piston rings (cermet-alu coated top ring) Status

Fig. 3. Totally scuffed unit. Lubrication should be increased to maximum until overhaul is convenient with regard to the schedule of the ship. Due to the friction heat developed, the piston rings get hardened, and the wear rate of the liner increases significantly. However, the hardening protects the rings, which is why the operation may be continued safely until next convenient port stay.

Fig. 4. Unit with micro-seizures on the top ring as a result of metal-to-metal contact. Should be counteracted by temporarily increased lubrication. It is important to lower the lubrication to normal as soon as the active mz-attack is stopped. Note that old, not active, mz-marks remain visible long after the attack has stopped and do not call for increased lubrication.

Fig. 5. Unit with 23,500 hours without piston overhaul. Note that most of the rounding is still intact, indicating that only of the wear potential is used. Further, the measurements above from the same unit shows that only of the ring groove wear potential is used, and the rate of burnings on the piston top is insignificant. Consequently, overhaul of that unit is not needed at this stage.

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

Status Visual inspection of piston rings (all alu-coated)

Fig. 6. Totally scuffed unit. Lubrication should be increased to maximum until overhaul is convenient with regard to the schedule of the ship. Due to the friction heat developed, the piston rings get hardened, and the wear rate of the liner increases significantly. However, the hardening protects the rings, which is why operation may be continued safely until next convenient port stay.

Fig. 7. Unit with micro-seizures on the top and bottom rings as a result of metal-to-metal contact. Should be counteracted by temporarily increased lubrication. It is important to lower the lubrication to normal as soon as the active mz-atack is stopped. Note that old, not active, mz-marks remain visible a long time and do not call for increased lubrication.

Fig. 8. Unit running very well after 20,021 running hours. Note that the last remains of the alu-coat are still visible on the lower edge, indicating remaining rounding left. This means that the ring wear is less than 2 mm out of possible 3 mm. Consequently, many more hours are left from the point of view of wear.

MAN Diesel & Turbo

23.09.2010

Condition Based Overhaul (CBO)

Normal corrosive Adhesive wear
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Polished wear

Scuffing wear

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Condition Based Overhaul (CBO)

Cylinder Condition Report - la...

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Condition Based Overhaul (CBO)

When is piston overhaul needed?

3 mm

4.8 mm

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Cylinder Lubrication, latest experience

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Cylinder Lubrication, latest experience

Testing flat rate at 0.50 g/kWh abs. 8S60MC Car-carrier High topland piston Alu-coated CPR piston rings Slide fuel valve Low cyl. oil dosages 0.50 g/kWh the last 6,805h on 4 cylinders Piston (number 1) never pulled (picture taken at 42,773 ring hours after running 0.55 g/kWh!) Piston number 1 has now just passed 50,000 hours without overhaul.

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Condition Based Overhaul (CBO)

Overhaul Strategy on MAN B&W 2Stroke Engines :

Tankers:
9 To limit overhauls and inspections by means of extended engine monitoring 9 3 / 5 year overhaul intervals, to coincide with Class-Dockings, are presently possible
on engines with the newest design.

Container and Bulk Carriers:

9 To limit overhauls / inspections by means of Condition Based Overhaul (CBO),
whereby the average TBO of the main components can be increased up to 5 years.

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Condition Based Overhaul (CBO)

Overhaul Strategy on MAN B&W 2Stroke engines 9Expect all pistons to be fully reconditioned
by re-welding and re-chroming

9Heavy duty Piston Ring Packages 9Extended engine monitoring 9Intensified engine survey
(scavenge port inspections)

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Condition Based Overhaul (CBO)

Overhaul Strategy on MAN B&W 2Stroke engines Quality requirements for significantly Extended TBO of the Cylinder Units: 9Sophisticated Piston Ring Packages require high manufacturing quality 9Reconditioning of piston crowns requires high quality from an authorised work
shop

9The piston overhaul jobs require high quality, also regarding the reporting 9Intermediate inspections require qualified engineers and reporting

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Advantage of Versus Maintenance contracts. Service Engine Management Concept Engine Management Concept

MAN Diesel PrimeServ Copenhagen

Spare Parts

Diesel Academy

Upgrades Special Projects

Technical Service

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Advantage of Maintenance contracts.

EMC overview

(1) MAN Diesel conducts the complete logistic works

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Advantage of Maintenance contracts. Maintenance Schedule

MAN Diesel & Turbo

23.09.2010

Advantage of Maintenance contracts. Machinery Otimisation

MAN Diesel & Turbo

23.09.2010

Advantage of Maintenance contracts. Engine Performance

Action:
Observe any abnormality by daily checks of engine parameters. Maintain full engine performance report twice every month Evaluate all obtained engine data carefully and compare with earlier data / shop test / sea trial data.

Benefits:
Safe and Reliable Engine. Low Maintenances Cost. Optimum Plant Economy

MAN Diesel & Turbo

23.09.2010

Questions?

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