.me survey .me unit survey .main engine survey
1. Planning
- Check the survey list of machinery
- Get exact date of survey and get immobilization and inform office
- Check previous record of maintenance
- Check and prepare all necessary spares and tools
- Check all lifting gear
- Check hydraulic pump, jacks, high pressure hose condition
- Ensure enough manpower and time available in port
- Read manual for special instruction and data.
- Carry out briefing for everyone involve, precaution, work to be done, and time available
- Carry out risk assessment
2. Tools
Prepare tools.
- Piston and cylinder head
- Hydraulic pump, hoses and hydraulic jacks
- Piston lifting tool and cylinder head lifting tool
- Piston inserting tool
- Stuffing box spacer
- Piston and cylinder head stand
- Piston ring expander
- Piston crown wear measuring template
2. Liner
- Liner lifting tool and liner support beam.
- Liner jack and jack support
- Liner calibration gauge
- Liner inspection ladder
- Stuffing box area covering plate
3. Chain blocks
- Check its safe load carrying capacity
- Check chain link condition
- Check free movement of chain in both direction
- Check safety lock for proper condition on hanging hook.
- Check condition of hook for sign of crack or damage
4. Eye bolts, shackles, wire sling and safety belt
- Check for safe load carrying capacity
- Check overall condition for any damage
- Check thread condition of eye and shackles
3. Safety during crane operation
- Don’t operate when ship is incline
- Don’t press button simultaneously
- Do not bypass limit switch
- Do not operate if someone under or on the way
- When 2 person directing, do not operate
4. After arriving port
- Once finished with engine, get immobilization permission
- Propeller clearance to be obtain form bridge
- Shut starting air system and hang notice not to start main engine
- Drain the air line, keep open
- Open indicating Cock
- Engage turning gear and turn ME with manual cylinder lubrication
- After half an hour stop LO pump
- Give time to cool engine
- Open crankcase door, lock on open position and give ventilation !
- Isolate jcw inlet and outlet valve for particular unit and drain.
- Isolate fuel inlet and return valve for particular unit.
- Exhaust valve spring air to isolate
- After ventilation of crankcase check, atmosphere check for oxygen content, explosive gas and toxic gas
- Enclose space entry permit to complete
- No naked light inside crankcase
- Proper lighting to be ensure inside crankcase
5. Removal of connection
- with removal of following
- Remove exhaust bellow
- JCW outlet pipe before the valve
- Exhaust valve spring air connection
- Hydraulic actuator high pressure pipe
- Fuel injector high pressure pipe and connection
- Starting air valve connections
6. Removal of cylinder head
- Fit hydraulic jack on all cylinder head nuts and connect high pressure hose.
- Open jack vent and start to pump slowly
- Once air bubbles are removed, shut vent and stop pumping
- Ensure all jack vents are shut then pump to recommended pressure and stop pump
- Use tommy bar to loose nut
- Ensure all nuts are loose
- Release pressure, remove jacks and remove nuts
- Fit cylinder head lifting tool
- Lift slowly the cylinder head using ER crane
- Care to be taken when lifting, to make sure it does not come in contact with other cylinder head.
- Place the cylinder head on cylinder head stand
7. Removal of piston
- After proper ventilation of crankcase, remove the lashing of all secure bolts and remove require pipe connection
- Turn the piston to BDC and remove piston nut and lock device
- Fit the stuffing box spacer on piston rod palm
- Remove stuffing box securing bolts and its locking device
- Remove cylinder head metal gasket
- Clean liner surface of deposits at combustion area so as piston does not get stuck during extraction.
- Turn the piston towards TDC, carefully keeping eye on turning gear ampere
- Clean the lifting holes on crown
- Fit piston lifting tool, ensure all bolt secured
- Ensure crane is in mid-position and ship is even keel
- Slowly lift up piston ensure stuffing box spacer does not get in contact with diaphragm.
- Continue to lift, ensure piston is not swinging causing piston palm get in contact with liner
- Once out, lower the piston on its stand and put cover on stuffing box housing. !
- Remove the lifting tool
8. Inspect and cleaning
Cylinder head
- Before cleaning,
- check for carbon deposit.
- Any trace of water leakage.
- After cleaning,
- crack test to be carried out at change of section (around injector bore, exh valve bore area, indicating cock, starting air valve, relief valve)
- Pressure test cylinder head cooling space
- Keep ready for survey
Piston crown
- Check for burning at the top
- Use template to check wear
- Check for crack on top
Piston and piston ring
- before cleaning check for carbon deposit amount and condition
- check ring condition for sticky, broken, cracks
- after taking out, carry out thorough cleaning
- check for free movement
- check ring clearance and groove clearance
Piston skirt and side wall
- Check for any rubbing mark
Cooling passage
- Scaling due to poor water treatment
- Cracking due to high temperature
- Pressure test as per manual
- Take photo for before after for future reference
- Keep ready
Piston rod and stuffing box
- Piston rod diameter to check at different point in manual
- Record and compare previous record
- Carry out crack test at change of section of piston rod
- Check for any scratch mark
- Overhaul stuffing box, clean all parts, and check clearance of rings.
- Take photograph
Cylinder liner
- Check for dryness and oiliness, clover leafing, hard particle mark, polishing
- Check if scavenge port is choke & inspect
- Check for carbon deposit at top of combustion area
- Calibration to be check and recorded and compare with previous record !
- Check the lubrication points for cylinder lub oil flow by pumping manually !
- After cleaning, crack test to carry out around port edge.
9. Inspection of surveyor
- After cleaning and decarbonizing, all parts to be kept ready for survey. !
- Overhaul stuffing box with rings renewal as required box back !
- All joints, gasket and seal rings renewed and kept ready.
- All calibration and measurement record are recorded and kept ready for surveyor
- Overhauled exhaust valve and fuel injector ready for box up after completion of survey
- After survey, all parts box up as per manual and system to be put in running order, take all precautions. Check for leakage and rectify accordingly.
Piston material
.piston material
- Crown is made up of heat resistant forged steel alloy including chromium, nickel and molybdenum for heat and corrosion resistance without compromising on strength
- Skirt is made up of nodular cast iron or forged silicon aluminium alloy which has the advantage of being light, with low inertia, reducing bearing loading.