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ME452
Crack Formation at Main Engine Fuel Injection Pipe Distribution
Header
Technical committee

Ship type Tanker

Date of build 2000
Navigation route Japan ~ PG
Trouble machinery
Category Main engine
Name Fuel injection pipe distribution header
Type MHI Sulzer 7RTA58T
Maker Mitsubishi Heavy Industries, Ltd. Kobe Shipyard & Machinery Works
Date of trouble December 2001

1. Outline of breakdown

When main engine total operation time exceeded 8000 hours since entering service, a crack naturally
formed in the thread plug access opening of the No. 4 cylinder fuel injection pipe distribution header
and fuel started to leak out.
About 1 month later, a similar crack formed in the same place in the No. 5 cylinder fuel injection pipe
distribution header.

2. Repair

As there was only one spare, the No. 4 cylinder was replaced. As for the No. 5 cylinder, until the spare
could be delivered, gouging followed by welding repairs was carried on-board on the crack in the dis-
tribution header.
Although on-board welding was carried out, as there was pulsating flow of the injection high pressure
fuel inside the damaged part, a crack formed and the leakage could not be completely stopped. The
amount of leakage was about 1 l/day, but this did not impede voyage.

3. Causes

The concerned damaged distribution header was sent to the maker. It was horizontally cut into two
pieces and a magnetic particle test was carried out. It was discovered that the crack originated at the
intersection of the well leading to the injection pipe and the central penetrating hole of the distribution
header.
An edge had formed at the corner as maintenance after treatment of the intersecting area was insuffi-
cient.
Due to excessive stress applied to this edge, the crack is surmised to have formed from high cycle fa-
tigue relating to high pressure injection fuel pulsation.
(Total operating time 8000 x 60 x 85 rpm = 4.08 x 107 )

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4. Future countermeasures

As general fatigue strength of 107 times has already been exceeded, to be on the safe side, non-
destructive inspection should be carried out on other cylinders to check for the presence/absence of
cracks.

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