CASE STUDY 5: FAILURE OF GUDGEON PIN SEAL RING

CASE STUDY 5

FAILURE OF GUDGEON PIN SEAL RING

Cause of events
The complete air compressor body was broken due to crankcase explosion.
Fortunately no one was injured by this incident however damage was beyond
economical repair and new compressor unit had to be installed. This case study is
circulated to prevent similar incidents.

Extent of damage

Broken crankcase of air

compressor on board
ship due to explosion in
crank case

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 CASE STUDY 5: FAILURE OF GUDGEON PIN SEAL RING

Typical Japanese-made Air Compressor

Piston pin (gudgeon pin) is provided with

Aluminum disc and high temp resistance
O-ring on both sides.
When O-ring is damaged, it allows HP
air to leak in to the crankcase.
Leakage of high pressure air between
Under normal running the piston and liner can blow away the
condition the crankcase lubricating oil film, cause metal to metal
pressure is kept slightly contact and develop a hot spot.
below atmospheric
pressure by the breather
cap.
When the piston pin seal
leaks, high pressure air
will come out of the
breather cap.
This must be
investigated

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CASE STUDY 5: FAILURE OF GUDGEON PIN SEAL RING

Typical Crankcase Explosion Damages of Air Compressor

Shaft seal cover and

casing completely
damaged

Broken piston and

displaced pieces of
piston after the
explosion

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CASE STUDY 5: FAILURE OF GUDGEON PIN SEAL RING

Example of Seal Disc or Piston Pin Seal Arrangement and Seal Damage

Piston pin in HP
stage of Tandem
compounding
type

Aluminum
seal disc

Broken
seal ring (O-ring)

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CASE STUDY 5: FAILURE OF GUDGEON PIN SEAL RING

Cause of accident
During operation, the compressor crankcase got pressurized due to following
reasons:
1) Air leaking from 2nd stage or High pressure side, through the piston pin
(gudgeon pin) Aluminum disc and O-ring ring seal arrangement.
2) Leakage of HP air caused lubrication failure, metal to metal contact,
excessive friction and heat generation.
3) Seized or broken piston rings and scratched liners allowed high pressure air
to leak in the crank case.
4) Inadequate crank case breathing due to restricted or clogged breather caps
prevented discharge of leakage air, resulting in pressurizing of crankcase.

The high pressure air into crankcase can lead to interruption of liner piston
lubrication and develop hot spots.

Air compressor at this stage will be vulnerable to develop explosive atmosphere,

if the crankcase breathing or venting system is not adequate or is restricted, the
situation can led to an explosion.

Lessons to be learned
Daily
1) Ensure that breather cap is venting and no pressure build up in crankcase.
2) Cylinder lubricators to be ensured working satisfactory at all running conditions.

Whenever pressurizing of crankcase is noticed, for example leakage or oozing of

oil through crankcase cover, crank shaft oil seal near flywheel and excessive air
discharge from breather cap.
1) Perform pressure tests for seal disc of piston pin and confirm the defective
seals. ( For tandem compounding through 2nd stage side)

Every Overhaul
Check the piston crown top for cracks, pitting, holes if any disorders.
Replace seal disc and seal rings of piston pin for all units with original high
temperature resistant O-rings.

PMS
Include in PMS system for overhaul of seal discs where appropriate.

Spares
Consumable spares like gaskets, O-rings, split pins, should be available before
carrying out maintenance. Do not use back damaged or old consumable
spares.

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