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Michael Petersen
Senior Manager Engine Management / PrimeServ
23.09.2010
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Agenda
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Life cycle cost is the total cost from design to disposal, the objective of LCC is to choose the most cost effective approach, so that the lowest long term cost of ownership is achieved!
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Procurement cost is widely used as the primary (and sometimes only) criterion for equipment, spare parts or system selection (i.e. the cheaper the better). However, the major costs lie in the care and operation of equipment during its life.
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CBO
Condition Based Overhaul Strategy, Largely extended Overhaul intervals. Never touch a well running unit
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2-stroke engine's can be inspected by open-up the doors, go in, see, check and record.
In addition Bearing Wear Monitoring (BWM), Main Bearing Temp. Monitoring (MBTM), Water in Oil Monitoring (WIOM) and Liner Wall Temperature (LWT) systems are essential tools
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Slide fuel valves Nimonic- or Dura spindles W-seat Oros combustion Chamber,
formed entirely in steel as a result of
Low positioned ring packages Heavy duty ring packages Optimised liner temperature
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Slide fuel valves Nimonic- or Dura spindles W-seat Oros combustion Chamber,
formed entirely in steel as a result of
Low positioned ring packages Heavy duty ring packages Optimised liner temperature
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Still rounding
Still rounding
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Fig. 3. Totally scuffed unit. Lubrication should be increased to maximum until overhaul is convenient with regard to the schedule of the ship. Due to the friction heat developed, the piston rings get hardened, and the wear rate of the liner increases significantly. However, the hardening protects the rings, which is why the operation may be continued safely until next convenient port stay.
Fig. 4. Unit with micro-seizures on the top ring as a result of metal-to-metal contact. Should be counteracted by temporarily increased lubrication. It is important to lower the lubrication to normal as soon as the active mz-attack is stopped. Note that old, not active, mz-marks remain visible long after the attack has stopped and do not call for increased lubrication.
Fig. 5. Unit with 23,500 hours without piston overhaul. Note that most of the rounding is still intact, indicating that only of the wear potential is used. Further, the measurements above from the same unit shows that only of the ring groove wear potential is used, and the rate of burnings on the piston top is insignificant. Consequently, overhaul of that unit is not needed at this stage.
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Fig. 6. Totally scuffed unit. Lubrication should be increased to maximum until overhaul is convenient with regard to the schedule of the ship. Due to the friction heat developed, the piston rings get hardened, and the wear rate of the liner increases significantly. However, the hardening protects the rings, which is why operation may be continued safely until next convenient port stay.
Fig. 7. Unit with micro-seizures on the top and bottom rings as a result of metal-to-metal contact. Should be counteracted by temporarily increased lubrication. It is important to lower the lubrication to normal as soon as the active mz-atack is stopped. Note that old, not active, mz-marks remain visible a long time and do not call for increased lubrication.
Fig. 8. Unit running very well after 20,021 running hours. Note that the last remains of the alu-coat are still visible on the lower edge, indicating remaining rounding left. This means that the ring wear is less than 2 mm out of possible 3 mm. Consequently, many more hours are left from the point of view of wear.
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Polished wear
Scuffing wear
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3 mm
4.8 mm
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Testing flat rate at 0.50 g/kWh abs. 8S60MC Car-carrier High topland piston Alu-coated CPR piston rings Slide fuel valve Low cyl. oil dosages 0.50 g/kWh the last 6,805h on 4 cylinders Piston (number 1) never pulled (picture taken at 42,773 ring hours after running 0.55 g/kWh!) Piston number 1 has now just passed 50,000 hours without overhaul.
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Overhaul Strategy on MAN B&W 2Stroke engines 9Expect all pistons to be fully reconditioned
by re-welding and re-chroming
9Heavy duty Piston Ring Packages 9Extended engine monitoring 9Intensified engine survey
(scavenge port inspections)
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Overhaul Strategy on MAN B&W 2Stroke engines Quality requirements for significantly Extended TBO of the Cylinder Units: 9Sophisticated Piston Ring Packages require high manufacturing quality 9Reconditioning of piston crowns requires high quality from an authorised work
shop
9The piston overhaul jobs require high quality, also regarding the reporting 9Intermediate inspections require qualified engineers and reporting
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Advantage of Versus Maintenance contracts. Service Engine Management Concept Engine Management Concept
Spare Parts
Diesel Academy
Technical Service
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Benefits:
Safe and Reliable Engine. Low Maintenances Cost. Optimum Plant Economy
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Questions?
Welcome Home
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