EXPERIENCE SHARE FOR PISTON RING BREAKAGE-WEAR RIDGE-LINER HONING

Based on our experiences and information collected from different sources, there are several
reasons for piston ring breakage and collapse.

Below we are sharing some of them under subject heading for your kind attention and future
consideration.

1. Over lubrication or lack of lubrication of the cylinder unit.

2. Too high ring groove clearances.

3. Too high Pmax-Pcomp differential pressure.

4. Improper installation.

5. Excessive wear on piston rings and liners.

6. Excessive wear of CPR/CL grooves.

7. Engine Operation and adjustment.

8. Insufficient piston ring and groove clearances.

9. Wear ridge on liner.

10. Uneven liner surface.

In this bulletin, we would like to give more information for last two items.

1. WEAR RIDGE ON CYLINDER LINER:

The mechanical wear caused by top (1st) piston ring forms a ridge on the top of the liner which is
called as wear ridge.

When the cylinder unit is overhauled, piston crown and rings are renewed, they may positioned a
little bit higher compared to the worn elements due to refreshed chromium plating on the bottom of
the ring grooves. Thus, top ring gets in contact with the ridge and is forced to bend which causes
piston ring breakage within a very short time.

Reference with MAN B&W service letter SL00-383, it is very important to remove such wear ridges
in order to maintain/re-establish a good cylinder condition.

Removal of the wear ridge can be done specially designed milling machine or grinding with special
grinding stone.

VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63
Removal of the wear ridge by manual grinding risky to grind working surfaces of the liner which will
cause blow-by from the piston ring, hence need special attention and strictly follow up the
procedures explained on the service letter by skilled hand.

Below illustration shared with same service letter to explain how proper milling can be done:

VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63
 VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63
 VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63
 2. UNEVEN CYLINDER LINER SURFACE:

The liner surface may change by the time which will affect proper functioning of the piston rings
resulting with blow by or breakage of the piston ring.

Most common problem on liners is losing its circularity after some time due to uneven wear called
as ovality.

Another one is changing the profile of the liner surface by wear which usually the top side of liner
looks like a trumpet when viewed from side. Piston ring running on this surface moves in-out as
the piston travels along the liner bore. This movement can cause fatigue and breakage.

And of course, corrosion marks, polishing and scuffing on the liner surfaces should not be ignored.

As per MAN B&W guidance the cylinder liners must be rehoned during every major service
operation to rectify the above problems if any of them is observed.

Below we are trying to highlight some points to bring into question.

HONING OR DEGLAZING?

The target and application of both processes are the same; obtain proper liner surface.

Basically, deglazing is called refreshing the surface for the unworn cylinder liners without
changing the cylinder geometry.

In case there is ovality, score marks, scuffing or ridges on the unit, then it needs to be corrected,
this process called honing which is more time-consuming job than deglazing.

WHAT IS THE TARGETED SURFACE PROFILE AND ROUGHNESS?

Depending on engine type, honing mesh angle between 90°-150°

VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63
For the roughness values, maker’s guidance to be followed strictly. Final surface profile should be
plateau, hence together with Ra value, Rvp and Rvk values also to be measured.

WHAT IS THE BENEFIT OF HONING?

1. Remove ovality, deformations and scratch marks in the cylinder liner wall.
2. Produce a mesh of various depths in the material for the purpose of allowing the
cylinder lube oil to remain in the mesh grooves for better lubrication.
3. Achieve a fine surface for piston ring contact in a second step (plateau honing).
4. Remove the hardness in the liner wall surface.

WHAT IS THE POINTS TO BE CONSIDERED DURING HONING?

1. Using emery paper is not allowed and no effect to obtain proper surface roughness and
profile even though cosmetic view looks perfect.
2. Check measuring result of the liner surface with surface roughness tester and confirm
plateau profile with proper roughness.
3. Different surface profiles can be obtained in same Ra value, hence recommend also
checking Rvp an Rvk values to make sure plateau surface profile obtained.
4. Cleaning of the cylinder unit after honing is extremely important, as the residues from the
honing process are highly abrasive. The particles can be trapped in the grooves created
during honing and in the cylinder lube oil quills. Wiping the surface with a rag is not
sufficient, hence cylinder liner walls have to be thoroughly cleaned by honing brushes or
similar.

FINAL SURFACE PROFILE SHOULD BE PLATEAU

VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63
 SURFACE PROFILE SHOULD BE MEASURED AND CONFIRMED THAT WITHIN SPECIFICATION

SCUFFING AND SCORE MARKS BEFORE AND AFTER HONING

PROPER CLEANING AFTER COMPLETING THE HONING IS VERY IMPORTANT TO CLEAN THE
PARTICLES FROM VALLEYS

In case you have any questions, please contact us through info@vitatr.com

VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63
VITA ENGINEERING SERVICE SCOPE

1. Maintenance-Troubleshoot of Main Engine Pneumatic Manoeuvring System for

MAN B&W, SULZER RTA, AKASAKA

2. Overhaul and Adjustment of Cylinder Lubrication Systems including alpha

lubrication and mechanical type lubricators such as Hans Jensen,Atlas,Yasec,
Shimadzu etc.

3. Liner measurement through scavenge port by Chris Marine Liner Diameter

Measurement

4. Liner internal inspection through scavenge port by Chris Marine Liner Condition
Camera

5. Overhaul of fuel injection pumps

6. In situ or in workshop liner honing up to 1.000 mm bore

7. Replica analyses and evaluations of M/E cylinder liner

8. Troubleshoot of diesel engine 2 Stroke & 4 Stroke.

9. Spare part supply for pneumatic manoeuvring and alpha lubrication system

10. Dry Docking Support

PREMIUM SERVICE ONLY

VITA Engineering
Orta mah. Erk sok. Aslı Nemutlu San. Sit No7/6 Tuzla/İstanbul/Turkey
www.vitatr.com / e-mail: info@vitatr.com / Tel: +90 533 421 01 83 / Tel: +90 216 766 23 63