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