M/V Alexandra.
Engine running hrs:. 100,933
Engine No: Main engine
Model: MAN B&W 8L48/60
Use: Main propulsion engine.
Speed: 514 RPM.
Power: 6,980 Kw.
Fuel: heavy fuel oil.
2-Persons involved:
InServ staff.
3-Client’s initial request:
A- Disassembly main engine units # 1 And # 5. Do Turbocharger inspection, Dismantle Charge air coolers for cleaning, pressure test and reassembly.
B- Do complete overhaul to Auxiliary engine # 2, Do Turbocharger inspection, Disassembly air cooler for cleaning, pressure test and reassembly.
4-Work Description:
This service was started on July.15.2010 as per client request. The Service is in details as follow:
1) Main Engine Taken Crankshaft Deflection (1&2): Taken Crankshaft Deflection: Upon the vessel's arrival, prior to any changes in ballast condition and while the vessel is still afloat, crankshaft deflections were taken and recorded. Upon completion of all repairs, and with the vessel once again afloat and ballasted as original, two further set of deflections was taken and recorded (After docking and after engine running-in). All readings taken were submitted to the Owner's Representative and the vessel's Chief Engineer.
2) M.E. Overhaul of cylinder heads (# 1, # 5 and one in Spare):
Disconnected of conducts and other elements to removed cylinder head, cleaned and inspected same and afterwards reassembled with new joints.
Cylinder head were removed and refitted on position on completion and tight.
Cylinder heads were transported to/from ship workshop and complete dismantled.
Mechanical and chemical cleaning of cylinder heads and checking of all elements.
Dismounted, refitted and inspected of safety valves, rotocap. Dismounted of inlet and exhaust valves and mounted. Cleaned and grinded of valves and seats.
3) M.E. Pistons & Connecting rod No. 1 and 5.
Pistons with connecting rods were removed and transported to/from ship workshop. Piston and connective rod were dismantled; all elements were cleaned, inspected and calibrated. Included piston chemical cleaning and renewal of piston rings - Owner's supply - and measurement of piston groves.
Renewed of connecting rods bearings lower/upper bearing shells.
Submitted record of clearances.
4) M.E. Piston crowns No. 1 and 5.
Piston crown cooling galleries were cleaned.
Taken measurements.
5) M.E. Cylinder liners No. 1 and 5.
Done Liner mechanical cleaning of liner outer side and cylinder block inner side and carbon removed from cylinder inner side. Liner inspected and measured.
6) M.E. Done Mechanical honing after inspected liner No. 1 and 5. (The honing was done two times in the same cylinders due to water arrived inside the cylinder after 1st honing). A cooling water valve wasn’t close properly.
7) M.E. Fuel Injection Pumps No. 2,3,5 and one in spare.
Injection pumps were removed and transported to/from ship workshop, refitted back on completion.
Injection pumps were dismantled, all parts were cleaned and checked, and damaged parts were renewed with owner's supplied spare parts.
Injection pumps were assembled in pump test stand and regulated.
8) M.E. Charge Air cooler:
Was dismantled and cleaned thoroughly by chemical water and air sides and carry out pressure test . After that was reassembled to Main Engine in good order.
9) Turbo chargers M. E. MAN-B&W, NA 48 TM: Open up bearings covers and inspected bearings and pumps. Removed air inlet casing and checked the rotor. Clean dismantled parts, checked clearances and reclosed with same bearings. Removed gas inlet casing, clean nozzle ring and reinstalled.
10) Auxiliary Engine No. 2, MAN/B&W L20/27 720 KW, Complete overhaul: A1. Allowed to dismantle all Cylinder heads. A2.Cylinder heads were overhauled with replacement worn details. A3. Crank bearings were disassembled and renewed. A4. Pistons were withdrawn and disassembled with new piston rings. A5. Cylinder liners were measured and honed. A6. All parts were cleaned and measured. A7. All worn parts were replaced. A8. Engine was assembled. A9. Running test was performed. Spare parts were supplied by Owner. Submitted calibration report.
11) Auxiliary Engine # 2 taken three Crankshaft Deflections: crankshaft deflections were taken and recorded before maintenance. Upon completion of all repairs two further set of deflections were taken and recorded. All readings taken were submitted to the Owner's Representative.
12) A.E. Turbo chargers MAN-B&W NR 15/R: D/G N°2.
Open up bearings covers and inspected bearings and pumps. Removed air inlet casing and checked rotor. Cleaned dismantled parts, checked clearances and reclosed with same bearings. Submitted calibration report.
13) DG Nº 2 Air cooler.
Was dismantled and transport to/from ashore work shop, cleaned thoroughly by chemical water and air sides and carried out pressure test . After that was reassembled to Main Engine in good order.
14) Fuel Injection valves No. 1,2,3,4,5,6,7 and 8.
Fuel Injection valves were removed and transported to/from ship workshop, refitted back to engine on completion.
Fuel Valves were dismantled, all parts were cleaned and checked and damaged parts were renewed with owner's supply.
15) Fuel Injection valves in Spare No. 1, 2 and 3.
Fuel Valves were dismantled, all parts were cleaned and checked and damaged parts were renewed with owner's supply.
16) Cleaned Main Engine Crankcase: the crankcase was cleaned completely two times.
17) Repaired two centrifugal Separator distributors: were renewed the guide discs and was mechanized the F.O Distributor.
18) Removed old auxiliary engines ventilators, supplied and installed new ones (Dayton Brand).
19) Auxiliary Generator # 1 Governor. Done complete Overhaul Was inspected, adjusted and calibrated and assembled using overhaul kit.
20) Repair auxiliary engines Governor in Spare. Done complete Overhaul, Was inspected, adjusted and calibrated and assembled using overhaul kit.
21) A.E. # 2 Replaced flexible turbocharger air discharge hose.
22) Inspected Auxiliary engines automation and controllers system.
