Service Provided to M/V Forest Panama 2010

Service I.- M/V Forest Panama

Engine No: 3237
Model: Wartsila Vasa 16V32
Use: Main propulsion engine.
Speed: 750 RPM.
Power: 5,520 Kw.
Fuel: heavy fuel oil.


2-Persons involved:
InServ staff.
3-Client’s initial request:
A- Disassembly main engine units A3, A6, B1, B5, B6. Charge air coolers A side, B side, Spare #1, Spare # 2 for cleaning, pressure test, transporting and reassembly.

B- Disassembly air coolers at auxiliary generator set # 1, 2 and 3, for cleaning, pressure test, transportation and reassembly.

C- Replace shaft engine sealing rings and gaskets; Clean Crankcase; Inspect HFO Separator failure; disassembly, Clean with chemical, pressure test ; reassembly Steam Heaters #1 & #2, and Dumping cooler And Repair ME expansion Joint gas leak.

4-Work Description:
This service was started on March.24.2010 as per client request. The Service is in details as follow:

I Main Engine:

1) Taken Crankshaft Deflection (1&2): Upon the vessel's arrival, prior to any changes in ballast condition and while the vessel is still afloat, crankshaft deflection was taken and recorded. Upon completion of all repairs, and with the vessel once again afloat and ballasted as original, a further set of deflection was taken and recorded. All readings taken were submitted to the Owner's Representative and the vessel's Chief Engineer.

2) Overhaul of cylinder heads (A3, A6, B1, B5, B6): Dismantled and assembled, cleaned the underside, inlet and exhaust valves and ports. Inspect cooling spaces and clean. Inspect the valve rotators. Checked rocker arms.
Were installed new exhaust valves to Cylinder head A6; Cylinder head B1 was found without rotocaps in the inlet valves, these were installed, was changed an exhaust valve and short springs by long. Cylinder head B6 were changed two exhaust valve and were installed two used valve and were changed short springs by long, also was changed a inlet valve by used one. Were left two cylinder heads ready to use for spares. Were mounted fuel injection valves prepared by ship Crew in the respective cylinder heads.

3) Were inspected and completed the two (2) cylinder heads that ship had in spares and they were installed on cylinders A3 and B5.

4) Inspect the cylinder liners (A3, A6, B1, B5, B6, Spare # 1, Spare # 2): Dismantled and assembled. Measured the bore using form No. 3210V014. Honed the liners. Renewed the anti-polishing ring. The cylinder A6 was replaced by new short cylinder liner , All cylinder liners measured were taken any of they were over wear… but the old cylinder liner A6 was left for spare and it can be used only in extreme emergency due a lot of corrosion in the cylinder liner collar. See bottom the measurement report.

5) Disconnected cylinder liner and cylinder head A6: these pulled out together, due to the cylinder had high water leakage and hard corrosion in the cylinder liner collar. Our team avoid to transfer this unit to our workshop and done it disconnection on site.

6) Was Rented an external Cylinder liner honing machine: to hone the Cylinder Liners (A3, A6, B1, B5, B6, Spare #1, Spare #2). Cylinder liners honing were done.

7) Inspected the pistons (A3, A6, B1, B5, B6, one in spare): Composite pistons were dismantled for inspection of mating surfaces between piston skirt and piston crown. Inspected and cleaned oil spaces. Pulled, inspected and cleaned. Checked the height of the ring grooves, use form No. 3211V016. Checked the retainer rings of the gudgeon pins. Replaced complete set of piston rings. The piston B6 has over wear in the first piston crown groove it was replaced by reconditioned one that ship had in spare. See bottom the Measurement report. When the piston A3 was taken out appeared the first piston ring broken.

8) Connecting rods (A3, A6, B1, B5, B6): Replaced big end bearings. Inspected mating surface serrations. Measured the big end bore, used form No. 3211V015. Inspected the small end bearings. Were replaced the screws of connecting rod A6. See measurement report below. The connecting rod big end bearings B6 was found with deep peel.

9) Main Engine Crankcase: was cleaned and closed after finish engine works.

10) AIR COOLERS (A Side, B Side, Spare #1, Spare #2): Makers: GEA.
Type: 68/26/22/2-ESV-S99-20K 192; Size : 830 x 640 x 470 mm.
ME Air Coolers cleaned by chemical, painted and pressure tested.
DETAILS:
A1. Dismounted the cooling water inlet and outlet pipes, side covers, reversing chamber.
A2. Removed cooler elements. Putted elements to workshop and returned
A3. Installed the cooler elements. Assembled covers and pipes with new gaskets.
A4. Carried out pressure test.

11) Cylinder heads valves clearance: All cylinder head valves were adjusted and calibrated.

12) GOVERNOR: SIZE/TYPE:
Governor : Maker - Woodward ; Type: PGE 58. JOB AIDS: Transported from/to vessel.
DETAILS:
1. Governor removed from engines and transported to authorized workshop.
2. Governor was examined. Worn parts not found.
3. Governor was reinstalled back to engines. Engine running tested to ensure proper working operation pending.

13) Main Engine shaft bearing: replaced sealing rings and gaskets. The old sealing rings had a big open clearance in terminals, we suspected that is was the first reason for oil leakage and also didn’t have the appropriated gaskets.

II Auxiliary Engines:

1) AIR COOLERS, Aux engines size 240x200x120 mm. Air Coolers cleaned by chemical and tested.
Pressure test from water side. carried out.
A1. Dismounted the cooling water inlet and outlet pipes, side covers, reversing chamber. A2. Removed cooler elements. Putted elements to workshop and returned. A3. Installed the cooler elements. Assembled covers and pipes with new gaskets. A4. Carried out pressure test.

III Auxiliary Equipments:

1) HFO Separator WHPX-405: “Program failure Not discharge alarm “ was inspected and repaired. Were reviewed all operation and program parameters, checked all electrical actuators MV 1, MV10, MV15, MV16. Was found feed water obtrusions in the valve MV 10 and MV 15. The separator was tested and putted in operation; it was left ready for operation. Our recommendation is that ship has to order the respective water flow disc to the solenoid valves block and change the old one prepared and installed by the ship crew.

2) Heat Exchangers and Heaters: Two (2) HFO Steam Heaters and one (1) dumping cooler: were dismantled Chemical cleaned, painted, tested, inspected and mounted back.

3) Main Engine Expansion Joint (Exhaust Gas Bellow): Repaired gas leak.


5) Measurement Reports.
A) Piston Crown Rings Grooves.
B) Connecting Rods Big End Bearings Bore.
C) Cylinder liners bore.
D) Crankshaft deflection.