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Maintenance on unit 5
Report on maintenance
Mazhar Uddeen Chutoo, Chutoo Torshan and Mahanand Goorapah

2012

FORT GEORGE POWER

STATION

Maintenance on G5 (4000 hrs) Description of unit 5 Engine : Hyundai 9K801CS Power produced : 30 MW Stroke length : 2300 mm Frequency : 103.04 RPM Firing order : 1 9 4 2 8 5 3 7 6

Date of start of maintenance :

MAINTENANCE 4000 HRS ON UNIT 5

1.0 Scavenge ports inspection This inspection provides useful information about the condition of the cylinders, piston and piston rings at low expense. The inspection consist of visually examining the piston, piston rings,and the lower part of the cylinder liner directly through the scavenge ports.

Piston rings

Cylinder liner with ports

Piston head

Figure 1 : Scavenge ports

Procedure for the ports inspection Keep the cooling water and oil circulating so that any possible leakage can be detected. Block the starting air supply to the valve Open the indicator valve. Engage the turning gear Remove the inspection covers on the camshaft side of the cylinder frame and clean the openings. Remove the covers on the scavenge air receiver. Begin the inspection at the cylinder whose piston is nearest to BDC Inspect the piston, piston rings , and the cylinder walls(Use a powerful lamp to give a true impression of the details) Continue the inspection at the next cylinder whose piston is nearest to BDC and so on according to the Firing order.

MAINTENANCE 4000 HRS ON UNIT 5

The following visual task was done: 1) Inspection of the piston skirt for signs of scuffing. 2) Inspection of rings for damage and ring groves for evidence of carbon build up. 3) sticking of piston rings This consists of finding whether the piston rings can move freely in their grooves. This is done to find evidence of Blow By as the latter may cause breakage of oil film which can cause excessive wear. After this inspection it was found that the piston rings for engine 8 and 9 was broken. So the piston has had to be removed for reconditioning and a new one was installed. 2.0 Cylinder liner maintenance for engine 8 and 9 Measurement of liner is carried out to establish the wear rate of the liner and to predict when we need to change the liner The piston and the cylinder cover was dismounted and the piston was removed for the cylinders 8 and 9. Procedure for cylinder wear measurements The cylinder liner diameter was measured with an inside micrometer along the liner length at 10 different positions. The measurement were taken transversely and longitudinally . To ensure that the liner is always measured in the same place, so that accurate comparisons can be made, a flat bar is hung down the side of the liner with holes drilled through where the measurement are to be taken. Measurement was taken at more frequent intervals at the top of the liner where wear rate is highest.

The liner surface was also inspected for wear

MAINTENANCE 4000 HRS ON UNIT 5

Flat bar with holes drilled in it

Inside micrometer

Cylinder liner

Figure 2: Liner wear measurement

MAINTENANCE 4000 HRS ON UNIT 5

The top view of the cylinder liner is shown below, the liner and the positions where reading were taken is shown aside X

Cylinder liner Tabulations of test of liner wear For cylinder 8 X Y 1.72 1.97 1.59 1.72 1.55 1.64 1.44 0.97 0.74 0.87 0.32 0.41 0.25 0.26 0.43 0.23 0.5 0.18 0.79 0.23 Average = 0.93 Average = 0.85

For Cylinder 9 X Y 1.58 1.74 1.61 1.62 1.60 1.44 1.27 0.67 0.52 0.60 0.38 0.41 0.31 0.26 0.29 0.18 0.47 0.16 0.66 0.19 Average = 0.87 Average = 0.73

The cylinder liner wear limit is 5 mm Since the liner wear does not exceeds the maximum limit of wear the liner is still usable.
MAINTENANCE 4000 HRS ON UNIT 5

2.0 Overhaul injection systems All the injectors were removed and replaced by a spare one. Their was a problem of the injection pump. 2.1 Definition of the problem When the technician opened the crankcase door and were examining the inside of crankcase, they noticed that the lubricating oil was unusual in its color and they concluded that the oil had mixed with fuel. That problem was seen with cylinder 2,9,7 and 6.This means that the fuel injection pump had a damaged seal. That seal is necessary to prevent fuel from leaking. 2.2 Observation

Cam Follower Barrel containing plunger

2 seal rings (not shown here) Figure 3: plunger barrel The seal rings were worn out and as a result it has had to be changed.

MAINTENANCE 4000 HRS ON UNIT 5

3.0 Overhauling of piston It is important to check the thinning of the piston crown due to burning, erosion and corrosion as this crown is subjected to the high temperatures in the combustion space. Normally the piston should also be dismantled to check the cooling space, because If this is subject to build up of cabon, then this may lead to thermal stressing of the piston which may cause thermal cracking of the piston crown

3.1 Measurement of wear on piston crown. The measurement was taken using a template and a depth guage

Template

Depth gauge

Figure 4 : template and depth guage

MAINTENANCE 4000 HRS ON UNIT 5

template

Depth guage

Piston head

Figure 5 : measurement of wear The measurement in mm were taken at 5 places as shown below.

For cylinder 8 A = 2.6 B = 3.0 C = 2.7 D = 1.7 E = 2.0 Figure 6: Top view of piston
For cylinder 9

Conclusion: Since the wear limit is about 5 mm, this means that the Piston for both cylinders are still usable

A= 2.7 B = 2.4 C = 3.0 D = 2.9

MAINTENANCE 4000 HRS ON UNIT 5

E = 1.51

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3.2 Measurement of wear on piston rod The piston rod is also subjected to wear as it pass through the stuffing box. As a result its diameter was measured at 3 places(A,B,C) along the piston rod to know the amount of wear.

Piston for cylinder number 8 A = 309.88 B = 309.91 C = 309.91

Piston for cylinder number 9 A = 309.86 B = 309.93 C = 309.92

Fig 6 : measurement of wear along piston rod

MAINTENANCE 4000 HRS ON UNIT 5