Binder 1

Inspection through Scavenge Ports Plate 70701-40D

1) Dismount the small covers on thescavenge air boxes, and clean theopenings.

2) When the piston has been turnedbelow the level of the scavengeair ports, inspect the cylinder linerwalls and the piston crown.

3) A tiltable mirror fixed to a tele-scopic rod can be used as illus-trated. Use a powerful light source forinspection.

4) In order to inspect a larger area ofthe cylinder liner and piston, it isexpedient to enter the scavengeair receiver and make observa-tions from the ‘ ‘ exhaust side’’.This should be done every timethe sludge is cleaned out from thescavenge air receiver and box.

5) While the piston is passing thescavenge air port, examine thepiston crown, the rings, and theskirt.In order to be able to correctly ob-serve the running surfaces of thepiston rings, clean them with arag.

Check the free movement and thetension of the piston rings, bypressing them with a woodenstick.

6) When the piston has been turnedupwards past the scavenge airports, inspect the piston rod.

7) Note down the results on Plate70702.

Plate 70702-40D Inspection through Scavenge Ports, Record

M/V Engine Type: Running hours Checked by:Total:Cylinder oildosage:

Yard: Builder: Engine

No.: No.:Built year: Date:

Condition and Symbol Engine PartCylinder No.

1 2 3 4 5 6 7 8 9 10 11 12

Carbon . . . . . . . . . . . . . . .Burning . . . . . . . . . . . . . . .Leakage oil . . . . . . . . . . . .Leakage water . . . . . . . . .

CBULOLW

Piston Crown

No deposit . . . . . . . . . . . .Light deposit . . . . . . . . . . .Excessive deposit . . . . . .Polished deposit . . . . . . .

!

LCECPC

Topland

Ringland 1

Ringland 2

Ringland 3

Intact . . . . . . . . . . . . . . . .Broken opposite ring gapBroken near gap . . . . . . .Several pieces . . . . . . . . .Entirely missing . . . . . . . .Collapsed . . . . . . . . . . . . .

!

BOBNSPM

COL

Ring 1

Ring 2

Ring 3

Ring 4

Loose . . . . . . . . . . . . . . . .Sluggish . . . . . . . . . . . . . .Sticking . . . . . . . . . . . . . . .Running surface, ! Black, overall . . . . . . . . ! Black, partly . . . . . . . . .Black ring ends > 100 mm

!

SLST

B(B)BR

Ring 1

Ring 2

Ring 3

Ring 4

Clean, smooth . . . . . . . . .Scratches (vertical) . . . . .Micro-seizures (local) . . .Micro-seizures (all over) .Micro-seizures, still activeOld MZ . . . . . . . . . . . . . . .Machining marks . . . . . . . still visibleWear ridges near bottom .Scuffing . . . . . . . . . . . . . .Clover-leaf wear . . . . . . . .Corrosion . . . . . . . . . . . . .Rings sharp-edged Top/Bot

!

SmzMZ

MAZOZ!!

WRSCCLCOT/B

Ring 1

Ring 2

Ring 3

Ring 4

Piston skirt

Piston rod

Cylinder liner

Cylinder liner

Optimal . . . . . . . . . . . . . . .Too much oil . . . . . . . . . .Slightly dry . . . . . . . . . . . .Very dry . . . . . . . . . . . . . .Black oil . . . . . . . . . . . . . .

!

OD

DOBO

Ring 1

Ring 2

Ring 3

Ring 4

Piston skirt

Piston rod

Cylinder liner

Little sludge . . . . . . . . . . .Much sludge . . . . . . . . . . .

LSMS

Scavenge box

Scav. receiver

Movable . . . . . . . . . . . . . . MFlaps and non-

Running hours since last overhaul

Edge

Carbo nBurning

Liquid

Piston Bowl

PistonTopland

PistonRinglands1, 2 and 3

PistonRings

PistonSkirt

Piston Rod

Cyl. Linerabove Ports

Area nearScavenge AirPorts

Cyl. Linerbelow Ports

Wear

BECEDBECEDBEEEECEEEEDBEEEEEECEEEEEEE

Inspection through Scavenge Ports, Symbols Plate 70703-40D

Symbo l Condition of inspected part

! SatisfactoryC Carbon DepositBU BurningLO Leakage OilLW Leakage Water

! Satisfactory (no deposits)LC Light carbon depositEC Excessive carbon depositPC Thick carbon deposit worn bright

by rubbing against cyl. liner

! IntactBO Broken, opposite ring gapBN Broken, near ring gapSP Broken in several piecesM Entirely missingCOL Collapsed

! LooseSL Sluggish in grooveST StickingB Black running surface, overall(B) Black running surface, partly

! Clean, smoothS Vertical scratches

mzMZMAZOZWRCOCLT/B

(abrasive (particles)Micro Seizures in spots (local)Micro Seizures, all overMicro Seizures still activeOld (nearly recovered) MZWear ridges near bottom CorrosionClover-leaf wearRings sharp-edged Top/Bot

! Oil film normalO Too much oilD Too dryDD Very dryBO Black oil

A dot (!) always means that the inspected condition is satisfactory, e.g. small deposits, noleakage, no breakages, no sticking, clean smooth surface, normal oil film, etc. However, thisshall be recorded in order to show that the condition has been noted.

Plate 70704-40 Inspection through Scavenge Ports

Running Surface of Piston Rings(see also Plate 70705)

NB: In file tests, use a new very finely cut file

"Polished Mirror Surface”Photo 1 (about X3)A normal, good running surface issmooth, clean, and without scratches.The horizontal line is a scratch markresulting from a file test, which indicatesthat the surface is not hardened.

“Vertically Scratched”Photo 2 (about X3)Here the running surface has beenscratched by sharp, hard abrasiveparticles, e.g. grains of sand.The file test shows that the surface isnot hardened.

“Micro-Seizures”Photo 3 (about X3)A micro-seized running surface canappear as shown here.The file test gives almost no horizontalscratch, which indicates that the surfaceis covered by a hard glaze, i.e. has beenhardened due to micro-seizure.

Inspection through Scavenge Ports, Evaluation Plate 70705-40

Surface Condition Profile Running Surface

Normal good“mirror surface''

“!''�Barrel-shaped Clean, smooth, soft

Scratched by hardabrasive particles

�����“S'

Uniform scratches, dull, soft

����Sharp burrs

NewMicro seizures(still active)

“MAZ''

rks, hardened Flat Irregular ma

�����OldMicro seizures(restoration hasbegun)

�����“OZ''

Curved edges, im- Smooth and soft Still hard inplies that restora- along the edges centre areation has begun

Lubricationorifice

Clover-leaf formation:heavy wear at several areasaround the cylinder liner,in the case illustratedconcentrated between thelubrication orifices

“CL''�������������Horizontal Section of Cyl. Liner

Plate 70706-40 Factors influencing Cylinder Wear

Schematic summary of the most widelyrecognized causes of “cylinder wear”

Water droplets *)Water leakages“Cold” liner wallCleaning agentsCyl. oil film deficiencies --, 1

I

Corrosive- wear - HCL 4

,

r

Salt in intake airSea water in fuelSea water in cyl. oilAir cooler leakage

Cyl. oil film deficiencies

Abrasivewear

I'1

I1’7i

Cyl. oil/fuel oil matchingToo low cyl. oil dosageDistributionWater in cyl. oilWater leakage to cylinder

I

Cyl. oil film deficiencies +.J

Material

x

LinerDesign Ring -,Machining SkirtMechanical loadThermal loadLack of ring tensionDeformation of piston rings

(during fitting)MisalignmentToo high cyl. oil dosage

(deposits)Water droplets *)-Cleaning agents

Impurities in fuel oilImpurities in intake airWear particles

*) Drain for condensed water in scavenge air receiver blocked or out of function.See also Chapter 706, ‘Cleaning of Turbochargers and Air Coolers’, IItem 3.

Abrasive Particles

Typical observations when particles penetrate fromthe combustion chamber into the piston ring zone

Plate 70707-40

Exaggerated illustration of “worn and eroded” pistonrings No. 1 to 4, in “worn” grooves. It is typical forparticle wear that it excessively affects the upper ring(both the running face and the horizontal surfaces) aswell as the groove. Some degree of micro-seizuresometimes occurs on the lower rings, decreasing up-wards. This is contrary to the scratching intensity (orroughness) which decreases, from ring to ring, down-wards.When particle-wear prevails, the cylinder liner wearrate usually rises to between 0.30 and 0.50 mm/l000hours.

Running face ring No. 1The “trumpet-shaped” scratchesindicate that the hard particleshave penetrated from above.

Upper side of the uppermost ringsThe horizontal faces, especially theupper side, often become pock-markeddue to hard grains being crushed whenthe rings are pressed upwards by thegas trapped between the rings.However, such an appearance can alsobe the result of mechanical impactdue to ring collapse.

Upper side of the lower rinosThe part sheltered in the groovestill shows intact machining marks.The exposed part, protruding fromthe groove, becomes sand-blastedby the hard particles blown downthrough the ring gap above.

Designations“S” - Scratched running face“PO” - “pock-marked”

“E” - Erosion. Outer edge sand-blasted“MI” - Machining marks intact.

Numbers 1 to 5 give degree of damage(5 being most).

Plate

70708-40A

brasive Particles

Abrasive P

articlesP

late 70709-40

Plate 70710A

-40BR

un

nin

g-in

Cylin

der O

il Do

sage, K

/L-M

C E

ng

ines

Plate 70710B

-40ER

un

nin

g-in

Cylin

der O

il Do

sage, S

-MC

/MC

-C E

ng

ines

E

F A

M1234 5 6 7 8 9 10 11

F

E

D B

A

C

H

2 mm E (0)

F(270)

A(90)

M (180)

45 degrees

Cylinder Condition Report Plate 70711-40D

M/: Engine Type: No. of cyl.: Cylinder No.: Checked by:

Yard: Builder: Engine No.:

No.: Built year: Engine hrs.: Date:

Voyage info:

Weeks pr. Port calls: Normal service load in % of MCR: Lubricator type (rpm/mep):

Cyl. oil consump. (l/24 hrs): at load %: Cyl. oil type:

Cylinder liner

Liner hrs.: Insulation pipe (Y/N): Liner material:

Drawing no.: Insulation in cyl. frame (Y/N): Liner cool type:

Producer/Marking:

Measuring point 1 2 3 4 5 6 7 8 9 10 11

Depth (mm)

Diameter (mm)F-A

E-M

E : ExhaustA : AftM: ManoeuvreF : Fore

Cyl. cover tightened (Y/N): Temp. betw. liner and measuring tool (EC): Shims (mm):

Liner Remarks:

Piston rings Hours since last overhaul:

"F" to be measuredbefore dismantling

Width of ring (mm) Height of ring (mm)

A B C D E A B C D ENom.height(mm) Degrees

Ring 1

Ring 2

Ring 3

Ring 4

Piston ring typeFree Lock Broken Pist.

ring gap type skirt"F" (Y/N) Routine overhaul: Broken rings:

(mm) (r/l/cpr) Guidering

(Y/N)

Reason for examination (Y)

Routine check: Collapsed rings:

Ring 1 Low p Leaking piston:comp:

Ring 2 Blow-by: Change of piston:

Ring 3 Scavenge fire: Pist. skirt scuffing:

Ring 4 Change of liner: Other:

Ring grooves Piston top

H (mm) Piston no.:

F E A M Crown (hrs.):

Ring 1 Max. burning 1. (mm):

Ring 2 Position 1. (degree):

Ring 3 Max. burning 2. (mm):

Ring 4 Position 2. (degree):

PistonRemarks:

PS. If a liner or piston crown is exchanged, two reports must be filled-in!

Note:

Before m

easuring, the measuring point "I"

should be adjusted to 5 mm

below upper

edge of uppermost ring at T

DC

.

III

IIIIVVV

I

VII

VIII

IXXXI

Plate 70712A

-40DC

ylind

er Lin

er Wear P

oin

ts

Note:

Before m

easuring, the measuring point "I"

should be adjusted to 5 mm

below upper

edge of uppermost ring at T

DC

.

IIIIIIIVVV

I

VII

VIII

IXXXI

Plate 70712B

-40E C

ylind

er Lin

er Wear P

oin

ts, Hig

h-T

op

land

Pisto

n

Calculation of C

ondensate Am

ount P

late 70713-40E

Condensate am

ount per 24 hours, related to average ambient tem

peratureand scavenge air pressure

2s

u)

0 0

s2

2Condensate am

ount t124h, 20,000 kWl-

For other MC

-engines -

nominal rated or derated w

ith nominal m

ean effective pressure -the w

ater condensation is approximately proportional to the M

CR

shaft power.

Plate 70714-40R

unning-in Load

bc.I

-c.-Iii?.I

Feed Rates at Specified MCR Plate 70715-40E

Actual engine data at specified MCR:

Engine Type * Speed at (g/bhph) at Specified (kg/24h) at SpecifiedEngine Basic Setting Pe (bhp) at Feed Rate MEP (bar) at

Specified Specified MCR * Specified MCR *MCR * MCR MCR **

__K/L__MC 1.0

__S__MC/MC-C 1.2

* To be read from the shop test /sea trial reports.** To be calculated as described in Item 4.4.

Examples of engine data at specified MCR:

Engine Type Speed at (g/bhph) at Specified (kg/24h) at SpecifiedEngine Basic Setting Pe (bhp) at Feed Rate MEP (bar) at

Specified Specified MCR Specified MCRMCR MCR MCR

6L60MC 123 1.0 15,600 374.4 17

6S80MC 79 1.2 29,700 855.4 18

6K90MC 94 1.0 35,220 845.3 17

Deck

Fill ing pipe

Service tank for c ylinder oil

Cylinderoil tank

AC

25 mm nominal bore

Cylinder 1

LSA365

FSA366

AC

Fig. 1

Fig. 2

Plate 70716-40D Cylinder Lubricating Oil Pipes