Condition Based Maintenance

Surveyor's day Gard/Norwegian Hull Club
2017
Surveyor's
MAN Dieselday Gard/Norwegian
& TurboHull Club
Bergen
October 2017
Peter M. Christensen
Superintendent Engineer
MAN Diesel & Turbo  2017 < 1 >
MAN | PrimeServ
CBM - Condition based maintenance
• Exhaust valves
• Fuel equipment
• Engine performance
• Air supply system
• Cylinder condition
• Crank train bearings
• Annual Service Package
• Annual Extended SP
• Pre-docking inspections

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CBM - Exhaust valve - corrosion countermeasures

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CBM – Exhaust valve – Damper modification
Clearance controlled and orifice controlled damper (OCD)

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CBM – Exhaust valves – Wide seat bottom piece
The modification involves:
• ”Wide” (+ 35%) seat contact width and

inreased contact area with cylinder cover
Present ”W-seat” New ”Wide-seat”

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CBM – Exhaust valves – Drop down test
Spindle remain closed after 30 Non return valve / drop down Exhaust spindle #8 dropped
minutes check after 5 minutes
Unit 1 2 3 4 5 6 7 8 9 10
Test ok ok ok ok x ok x x ok ok
Running hours 3617 3617 12473 3617 3529 2999 2502 7067 2312 3266

MAN | PrimeServ
CBM – Fuel equipment – cleaning of fuel

MAN | PrimeServ
CBM – Fuel equipment – separator cleaning onboard
Poorly operated onboard fuel Remove the cat fines continuously!

cleaning systems
• Bad maintenance: • Operate the separators:

• Dirty / damaged separator bowl • High temperature
• Dirty preheater • Low flow
• Separators operate: • Clean separators and preheaters
• Low temperature
• High flow

MAN | PrimeServ
CBM – Fuel equipment – MC fuel pump
MC engine:
Cam driven Fuel Oil
Injection Pump:
• Plunger velocity governed by engine

RPM
• At start conditions 15% of full load
engine RPM
• Short leakage path
 Test for success
• Use un-worn fuel pumps!

MAN | PrimeServ
CBM – Fuel equipment – ME Booster
ME engine
Fuel Oil Pressure Booster:
• Plunger velocity governed by supply pressure

• At start conditions 75-78% of full load pressure
• Long leakage path
 No problem

MAN | PrimeServ
CBM – Fuel equipment – SL2017-638 – cleaning fuel

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CBM – Engine Performance

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Pressure transducer
PMI controller
Power
Engine supply
control
room
LED
indicator
Intermediate
Or frequency
divider box
Crankshaft pickup
mounted at free end
of crankshaft
Two-stroke diesel engine

MAN | PrimeServ
Reduction in Fuel oil consumption / CO2 emission
1 bar increase in average Pmax => 0.20 - 0.25 g/kWh decrease in fuel oil consumption
Reference Pmax
Potential
Potential
Pure Pmax level increase Balancing & Pmax level increase

Potential 5-10 bar Potential additional 2-5 bar
At full as well as part loads Gain even with engines already being
operated within recommended limits
MAN Diesel & Turbo  2017 < <14

14 >>
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 Compare measured service

parameters with shoptest
results.

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Pi average +- 0.5 bar
Pcomp & Pmax

Pressure rise max 35 bar
Pmax & Pcomp

Average +-3.0 bar

MAN | PrimeServ
Standard load diagram

Engine shaft power, % A
1. Propeller curve through optimising/
matching point (O) –layout curve for 110 A 100% reference point
M Specified engine MCR
engine. 100 O Optimising/matching point 7
5
2. Heavy propeller curve – fouled hull 90 O
and heavy seas.
80
3. Speed limit.
70
4. Torque/speed limit.
5. Mean effective pressure limit. 60
6. Light propeller curve – clean hull and 6

8 4 1 3
calm weather – layout curve for 50
propeller. 2 9
7. Power limit for continuous running.

40
8. Overload limit. 60 65 70 75 80 85 90 95 100 105
Engine speed, % A
9. Sea trial speed limit.
MAN Diesel & Turbo 3331353.2004.03.10 (2610/BGJ)  2017 < 17 >
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CBM – Air supply system
Water
Air
Temperature

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CBM – Air supply system - WMC
~80 % ~15 % ~5 %

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CBM – Air supply system
Free water (droplets)

• Lub oil break down
• High wear
• Liner scuffing
Evaporated Water
• Black liner deposts
• Higher corrosion

MAN | PrimeServ
CBM – Cylinder Condition – Scavenge air port inspection

MAN | PrimeServ
CBM – Cylinder Condition – scavenge air port inspection

MAN | PrimeServ
CBM – Cylinder Condition
When is piston overhaul needed?
3 mm
4.8 mm

MAN | PrimeServ
CBM – Cylinder Condition – filing records / observations
Piston overhaul / Liner measurements

Always measure the “0”
point when possible
Zero measuring
position

MAN | PrimeServ
CBM – Cylinder Condition – open up inspections
Piston open up / Overhaul

MAN | PrimeServ
CBM – Cylinder Condition – open up inspections
Piston open up / Overhaul

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CBM – Cylinder Condition – Specific liner wear trends

MAN | PrimeServ
CBM – Cylinder Condition – piston ring types
Piston rings standard can be divided into three groups

Small Bore (26 to 50 cm Bore)
Medium Bore (60 to 70 cm Bore)
Large Bore (80 to 98 cm Bore)

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CBM – Cylinder Condition – 60- 80 Large bore alternative

MAN | PrimeServ
CBM – Cylinder Condition – 80-98 Large bore alternative
MAN Diesel & Turbo Korea, Autumn 2012, by Henrik Rolsted, LEO  2017 < 31 >
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CBM – Cylinder Condition – coating thickness of Cermet

MAN | PrimeServ
CBM – Cylinder Condition
The original CPR (Controlled Pressure

Relive) ring package with CL-grooves
(controlled leakages) was introduced
on all MAN B&W engines around the
new millennium.
This design change resulted in an
tremendous improvement of the
cylinder condition in general, with
increased TBO.
Main advantages is a better
distribution of the pressures across
each ring and solving the problem with
overheating and collapse of the
second ring.

MAN | PrimeServ
CBM – Cylinder Condition – monitor CL grooves
On a 46- seize engine as an example the wear potential is from 2.5

mm down to 1 mm, i.e. 1.5 mm. This require a wear rate not higher
then 0,1 mm/1000h to obtain 15,000 hours TBO.
2.5
However, the wear of rings with CPR by means of CL- grooves is

“unstable”. High wear of the CL-groove lead to a higher wear rate.
If the CL-groove is worn below the min. limit, extremely high wear is
seen, sometimes leading to scuffing!

MAN | PrimeServ
CBM – Cylinder Condition – small bore
The 6S40ME-B type engine after passing 10,000 service

hours, and the first piston has been pulled: The top piston
ring is worn down to the minimum value!
Inspection at 9,444 hours

MAN | PrimeServ
CBM – Cylinder Condition – small bore – POP ring
…. therefore, we have invented

Controlled Pressure Relive by means
of “POP” –groves (Ports on Plane)

MAN | PrimeServ
CBM – Cylinder Condition – video liner inspection tool
 Snapshot from a S70ME – Video

MAN | PrimeServ
CBM – Crank train bearings – Supporting SL

MAN | PrimeServ
CBM – Crank train bearings – SL2008-495
Systems that facilitate condition based open-up inspections

1. BWM – (Bearing Wear Monitoring)
2. MBTM – (Main Bearing Temperature Monitoring)
3. WIOM – (Water In Oil Monitoring)
systems are being introduced for new engines and can be retrofitted on vessels in
service. When retrofitted, MAN Diesel will accept a change in the maintenance
program as outlined on the next page….

MAN | PrimeServ
CBM – Crank train bearings – SL2008-495
• Shaft line earthing devices must be kept working and be equipped with monitoring
connected to the alarm system.
• Bearing inspection schedule
Due to the higher safety against major failure, MAN Diesel considers it feasible to
completely omit regular open-up inspections of any of the three crank-train bearings
featuring an approved BWM system connected to the alarm and slow-down
system.
For engines comprising an approved MBTM system, regular open-up main bearing
inspections can be omitted.
If the BWM, the MBTM system or other alarm indications for an abnormal bearing
condition are triggered, investigations must follow and, eventually, extraordinary
open-up inspections should be carried out according to the findings.

MAN | PrimeServ
CBM – Crank train bearings - omit regular open-up inspections?
Know your A, B, C:
A. Shaft line earthing devices must be kept working and be equipped with monitoring
connected to the alarm system.
In addition it is possible to alter the bearing inspection schedule when installing:
B. An approved BWM system connected to the alarm and slow-down system will
completely omit regular open-up inspections of any of the 3 crank-train bearings.
C. An approved MBTM system, omits only regular open-up inspections of main bearings.
In case of an alarm or indication:
• If the BWM, the MBTM system or other alarm indications for an abnormal bearing
condition are triggered, investigations must follow and, eventually, extraordinary open-
up inspections should be carried out according to the findings.

MAN | PrimeServ
CBM – Crank train bearings – XH bearings – Normal operation

MAN | PrimeServ
CBM – Crank train bearings – XH Bearings - TC cut out

MAN | PrimeServ
CBM – Crank train bearings – XH Bearings - Water in the LO
Overlay corrosion
Flash Layer (Sn)
Over layer
(88% Pb 10% Sn 2% Cu)
Bonding layer (Ni og Ag)
AlSn40
Steel
MAN | PrimeServ
CBM – Crank train bearings – XH Bearings - Corrosion
If you see this:
 All bearings will be

affected & must be
exchanged ASAP
 Water contamination
stopped, water
removed
 Oil analysis history
recorded
 Possibly advice for
mounting a water-in-
oil monitoring system

MAN | PrimeServ
CBM – Crank train bearings – unnoticed overlay corrosion
Ultimate consequence of unnoticed overlay corrosion
1. Ni layer exposed
2. Scuffing between Ni and pin
3. Scuffing between AlSn40 and pin
4. Steel-to-Steel contact
5. XH-pin & conrod bore damaged
6. Debris through to crankpin bearing
7. Crankpin bearing wiping / scuffing
8. Crankpin / bearing Steel-to-Steel
9. Crankpin severely damaged
10. Possible overheating and oilmist
11. 14 – 30 days repair

MAN | PrimeServ
CBM – Crank train bearings – XH Bearings
Corrosion:
• Monitor Pb content in the LO.
• Monitor the water content in the LO.
Accelerated wear:
• Savings in fuel due to slow steaming has a cost of shorter XH bearing TBO.
• Monitor oil wedges for bearing metal.

MAN | PrimeServ
CBM – Crank train bearings – Main bearings

MAN | PrimeServ
CBM – Crank train bearings – Spark erosion
• Spark erosion on main bearing

journal and in the lower shell
•Spark erosion on fwd trust
collar
MAN | PrimeServ
CBM – Crank train bearings – Edge feeler
MAN Diesel does not recommend

unduly opening up of bearings on
2-Stroke Diesel engines for
overhaul or inspection, if they are
otherwise performing well.
But…..!
It is mandatory to install a BWM

systems, a water in oil (WIO) and a
shaft earthing device connected
to the alarm system, in order to
comply.

MAN | PrimeServ
CBM – Crank train bearings – main bearing – Blend Edge
Examble - The Blended Edge ”BE”, schematically and drawing specification.
The width of the ”BE” the distance from

C to B at the drawing, are individual for the
different engine /bearing size.

MAN | PrimeServ
CBM – Crank train bearings – main bearing – Blend Edge
The Blended Edge was introduced as standard in 2011.

Blended edge can be used as ”repair” solution but only after consulting MAN
Copenhagen.
MAN | PrimeServ
CBM – Crank train bearings – Crank pin bearing

MAN | PrimeServ
CBM – Crank train bearings – Why not open?
The
human
factor

MAN | PrimeServ
CBM – Condition based survey – CIMAC paper No. 21
In continuation of the development from visual inspections of all, to inspection

based on condition it is an idea to look into the data file of gathered
information as a base of maintenance planning; condition based survey
The process for the survey arrangement condition monitoring itself consists of
three parts and is explained in the following using the example of crank-train
bearings of crosshead diesel engines:
1. Submission of documents describing the condition monitoring systems

(BWM system, water-in-oil sensor and shaft line earthing system) to be
used for the survey arrangement, and compiling the corresponding
inspection procedures like regular crankcase inspections required by the
engine licenser. The submitted documents will be reviewed by GL experts
at the head office.

MAN | PrimeServ
CBM – Condition based survey
2. Implementation survey on board to verify that the installation of the

bearing wear monitoring system, the water-in-oil sensor, the shaft line
earthing system and the implementation of the crankcase inspections in
the planned maintenance system is in compliance with the engine
licenser’s instructions. One month prior to the implementation survey the
owner/manager has to submit an implementation report containing BWM
data of at least 50 operating hours and all reports for crankcase
inspections, web deflection measurements and system lube oil analyses.
The implementation report will be reviewed by GL experts at the head
office. A respective statement will be available for the ship owner/manager
and the GL surveyor responsible for the implementation survey via the GL
web portal “fleet online”.

MAN | PrimeServ
CBM – Condition based survey
3. Regular annual surveys harmonized with other annual surveys for

maintaining the survey arrangement. One month prior to the annual
survey the owner/manager shall submit an annual report containing the
BWM data as XML file and all reports for crankcase inspections, web
deflection measurements and system lube oil analyses carried out since
the last annual survey. If maintenance or repair actions have been done,
the corresponding reports have to be added. The annual report will be
reviewed by GL experts at the head office. Again their statement will be
available for the involved persons via “fleet online” for preparing the
annual survey.

MAN | PrimeServ
CBM – Annual Service Package

MAN | PrimeServ
CBM – Pre-docking inspections
Special Pre-Docking Inspection
 Alongside by Superintendent Engineer
 Fuel equipment
 Cylinder condition
 Visual inspection of crankcase
 VAK Measurements
Complete Inspection Report

Incl. spare part recommendations
*Crankshaft deflection is supplied by vessel.

MAN | PrimeServ
Upcoming dry-dock
(7-9 months)
PO for pre-inspection
PrimeServ Copenhagen
Co-ordination with local
Service Centers
Inspection report
Pre-Inspection
Recommended spare parts
DD ÷ 6 months
Spare part offer

Report & Spare part offer
PO for Spare parts

DD ÷ 5 months
Shipping instructions
DD ÷ 3-4 weeks
Delivery
DD ÷ 2 weeks
MAN | PrimeServ
Pre-docking Spare Parts Supervision

Inspection (Optional)
• Fuel • What you • The

Equipment need to knowledge of
ensure optimal the engine
• Cylinder
running designer on-
Condition
• Availability site.
• VAK • Security
Measurement

Surveyor's day Gard/Norwegian Hull Club
2017
Thank you very much for your attention

Condition Based Maintenance

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Surveyor's day Gard/Norwegian Hull Club

MAN Diesel & Turbo  2017 < 2 >

MAN Diesel & Turbo  2017 < 3 >

Clearance controlled and orifice controlled damper (OCD)

MAN Diesel & Turbo  2017 < 4 >

The modification involves:

• ”Wide” (+ 35%) seat contact width and

Present ”W-seat” New ”Wide-seat”

MAN Diesel & Turbo  2017 < 5 >

MAN Diesel & Turbo  2017 < 6 >

MAN Diesel & Turbo  2017 < 7 >

Poorly operated onboard fuel Remove the cat fines continuously!

• Bad maintenance: • Operate the separators:

MAN Diesel & Turbo  2017 < 8 >

• Plunger velocity governed by engine

 Test for success

• Use un-worn fuel pumps!

MAN Diesel & Turbo  2017 < 9 >

• Plunger velocity governed by supply pressure

MAN Diesel & Turbo  2017 < 10 >

MAN Diesel & Turbo  2017 < 11 >

MAN Diesel & Turbo  2017 < 12 >

MAN Diesel & Turbo  2017 < 13 >

Reduction in Fuel oil consumption / CO2 emission

Pure Pmax level increase Balancing & Pmax level increase

MAN Diesel & Turbo  2017 < <14

 Compare measured service

MAN Diesel & Turbo  2017 < 15 >

Pi average +- 0.5 bar

Pcomp & Pmax

Pmax & Pcomp

MAN Diesel & Turbo  2017 < 16 >

Standard load diagram

5. Mean effective pressure limit. 60

6. Light propeller curve – clean hull and 6

7. Power limit for continuous running.

MAN Diesel & Turbo  2017 < 18 >

MAN Diesel & Turbo  2017 < 19 >

MAN Diesel & Turbo  2017 < 20 >

Free water (droplets)

MAN Diesel & Turbo  2017 < 21 >

MAN Diesel & Turbo  2017 < 22 >

MAN Diesel & Turbo  2017 < 23 >

When is piston overhaul needed?

MAN Diesel & Turbo  2017 < 24 >

Piston overhaul / Liner measurements

MAN Diesel & Turbo  2017 < 25 >

Piston open up / Overhaul

MAN Diesel & Turbo  2017 < 26 >

Piston open up / Overhaul

MAN Diesel & Turbo  2017 < 27 >

MAN Diesel & Turbo  2017 < 28 >

Piston rings standard can be divided into three groups

MAN Diesel & Turbo  2017 < 29 >

MAN Diesel & Turbo  2017 < 30 >

MAN Diesel & Turbo  2017 < 32 >

The original CPR (Controlled Pressure

MAN Diesel & Turbo  2017 < 33 >

On a 46- seize engine as an example the wear potential is from 2.5

However, the wear of rings with CPR by means of CL- grooves is

MAN Diesel & Turbo  2017 < 34 >

The 6S40ME-B type engine after passing 10,000 service

Inspection at 9,444 hours