Overhaul of Generator Engine

Generator Engine Overview

Generator Engine Overview
Generator Engine Overhaul

Piston & Connecting Rod assembly

Generator Engine Overhaul

Valve Spindles & Valve Gear

Generator Engine Overhaul

Cylinder Head assembly

 Generator Engine Overhaul

Cylinder Liner Honing tool Cylinder Liner Lifting Tool

 Generator Engine Overhaul
Guiding Tool

Piston Installation
Piston Removal
Generator Engine Overview
Generator Engine Overview
Generator Engine Overview
Generator Engine Overview
 Generator Engine Overhaul
Generally ships are fitted with three generators for proving electrical
power . These generators are driven by 4 stroke medium speed diesel
engine which uses HFO(<0.5% S) & Marine Gas oil. Except in special
situations such as ECA area these engines run on Heavy Fuel Oil (HFO
<0.5 % S).Proper running & good maintenance of these machines is
utmost important for efficient running of the ship.
 Generator Engine Overhaul
Planning for Overhaul:
Generator Engine Overhaul to be carried out in following scenario:
 As per PMS schedule which is based on the running hours or monthly &
weekly routines.
 For the inspection during CSM. Generally Major overhaul is aligned with
class survey.
 In case of inefficient operation of generator or on observation of some
abnormalities.
Prior commencing overhaul on generator engine, availability of required
spare parts must be ensured. It is prudent to order required spare parts
much in advance before overhaul activity falls due. For ordering spare
parts instruction manual guidelines must be followed.
 Generator Engine Overhaul
Planning for Overhaul:
Overhaul intervals of these machines are based on operation on specified
fuel oil quality at normal service output which means 70-85 % of MCR.

Generator Engine overhaul program is generally based on following

criteria:
 Program based on Running Hours

 Daily, weekly, monthly & three monthly programs

 Generator Engine Overhaul
Planning of Overhaul:
Generally following Overhaul routines are followed on typical medium
speed 4 Stroke Diesel Engine:
 2000 Hours Routines: This routine consists of:

 Inspection of Valve Rotors While Engine is running

 Check & adjustment of Intake & Exhaust valves clearance (Tappet
Clearance)
 Inspection & adjustment of Fuel injectors opening pressure.
 Fuel Oil High Pressure pipe dismantling & Check.

 
 Generator Engine Overhaul
Planning of Overhaul:
 8000 Hours Routines:

 Connecting Rod Bolts Retightening

 Checking of Main bearing alignment
 Counterweight retightening
 Main Bearings Caps retightening
 Holding Down Bolts retightening
 Check Anti vibration mountings
 Generator Engine Overhaul
Planning of Overhaul:
 16000 Hors Routines:

 Complete overhaul of Cylinder Head assembly: This includes

 overhaul of fuel injectors , intake/exhaust valves spindles & seat,
exhaust /intake valves guides, sleeve for fuel injectors, indicator
valves
 Inspection of Cylinder head cooling water space
 Overhaul of Piston, connecting Rod & Cylinder Liner: This consists of,
 Inspection of piston , piston rings replacement,
 Inspection of piston pins, bushes & measurement of their
clearances
 Generator Engine Overhaul
Planning of Overhaul:
 16000 Hors Routines:

 Inspection of Connecting rods & checking of their ovality.

 Inspection of Big End Bearing Shells.
 Cylinder liners cleaning, honing & measurements .
 Inspection & measurement of clearance of camshaft bearing.
Inspection of Camshaft drive gear & lubrication.
 Inspection of operating gear for inlet valves, exhaust valves & fuel
injection pumps
 Inspection for roller guide of Exhaust/ intake vale gears
 Generator Engine Overhaul
Planning of Overhaul:
 16000 Hors Routines:

 Roller guides for Fuel pumps

  Inspection of Engine Driven Lubrication oil Pump & Electrically
driven Pre Lube pump
 Inspection of Engine Driven Cooling water Pump
 Generator Engine Overhaul
Standby Equipment:
From standby perspective following points to be considered before
undertaking any overhaul on the Generator Engine:
 Most of the ship are provided with three Generators. Before isolating

any generator for major overhaul, it must be ensured that other two
generators are ready for use in all respect with all their minor
maintenance routines such as renewal /cleaning of LO & fuel oil filters
etc completed.
 Generator Engine Overhaul
Standby Equipment:
 Major maintenance on the generator, preferably carried out during port

stay(loading port), anchorage or during long voyages when only one

generator is required for taking sea load (power requirement while
sailing).
 Prior commencement of maneuvering or passage through narrow

channels all three generators must be ready for use. In such scenario
Generator maintenance should only be taken in case of emergency.
 Generator Engine Overhaul
Tools:
All special tools & spanners required for the overhaul should be identified
as per instruction manual & they should be kept ready for use at the work
site.
 Generator Engine Overhaul
Spare Part:
Before commencing major overhaul on Generator Engine, vessel should
identify all the spare parts required as per instruction manual with correct
part number. After taking comprehensive inventory, required spares to be
ordered much in advance. While raising requisition for spare part,
Generator Engine (Aux Eng) model number, manufacturer details & serial
number must be mentioned. This will ensure correct supply of spare
parts. For the sake of discussion let us consider major overhaul of
generator engine. Generally following spare parts must be required for
performing this activity:
 Generator Engine Overhaul
Spare Part:
 Fuel injector nozzles

 Cylinder head gasket, Exhaust & scavenge manifold gaskets

 Various sealing rings for cooling water connectors, Cylinder liner sealing

rings & other O rings

 Intake & Exhaust valve spindles & seats

 Intake & exhaust valve guides

 Piston Ring sets

 Piston
 Generator Engine Overhaul
Spare Part:
 Cylinder liner

 Bottom End Bearing sets

 Assorted copper washers

 Overhaul kit for fuel pumps

Above are the generic list, exact requirement will depend on the type of
Generator Engine. For ordering spare parts instruction manual guidelines
must be adhered to.
 Generator Engine Overhaul
Manpower:
 2000 Hours Routines : 16 Man hours i.e 2 persons for 8 hours.

 8000 Hours Routines : 16 Man hours i.e 2 persons for 8 hours.

 16000Hours Routines: 256 Man hours i.e. 3 persons will work for 8

hours a day for 8 days.

Above are general estimate ,actual man power requirement may vary
depending on the type of generator & working environment on the vessel
& vessel schedule.
 Generator Engine Overhaul
Safety Procedures: Prior commencing any overhaul on a
Generator Engine, instruction manual to be referred to & all safety
instructions therein need to be strictly followed. Important safety
precautions to be taken prior undertaking any overhaul on a Generator
Engine are given in next slide:
 Generator Engine Overhaul
Safety Procedures:
 Work Permit: Prior commencing any overhaul on a Generator, various
hazards such as Automatic starting, Personal injury, Slip, trip & fall,
heavy load lifting & Splash with hot oil should be considered. Robust
Risk assessment with senior engineers & other Engine room team
members to be performed & control measures to be placed for their
mitigation. Work Permit as per Company safety management system to
be issued after tool box talk carried out by senior Engineer. Work Permit
must be signed by Authorizing person & competent persons & all other
crew member participating in the job. After issuance of work permit,
same to be posted at the Worksite by Work team after ensuring proper
isolation of the Generator Engine.
 Generator Engine Overhaul
Safety Procedures:
 Isolation –Lock out/Tag Out: Generator Engine must be completely

isolated & locked out /tagged out by following procedures:

 Stop the Generator after changing over to Marine Gas oil and remote
& Local starting switches of the Generator to be put in manual mode.
Lock out/Tag out notice (Men at work, not to start Generator) must
be secured on these panels.
 Generator Engine Overhaul
Safety Procedures:
 Isolation –Lock out/Tag Out: Generator Engine must be completely

isolated & locked out /tagged out by following procedures:

 Shut Air Start Valve for the Generator & drain Air starting system.
 Above mentioned valves & starting switches must be Locked out &
tagged out by responsible person. Notice “DO NOT START MEN ARE
AT WORK” to be posted.
 Lock out Tag Out File to be updated & signed by responsible person.
 Generator Engine Overhaul
Overhaul:
Instruction manual guidelines must be followed for performing any
overhaul on Generator engine. We will discuss here the procedures for
performing 16000 hours routines on the Generator Engine MAN B&W L
23/30H having 6 cylinders. This activity is also called decarbonisation or
Major Overhaul of the generator.

Detailed work description for this activity is given in next slide.

 Generator Engine Overhaul
Overhaul:
 Generator to be isolated, locked out & tagged out, work permit to be

issued after performing Risk assessment with work team. Tool box talk
detailing scope of the job & various safety procedures must be
performed by senior Engineer (2nd engineer or Chief Engineer).
 Special tools & other spanners, grinder, buffing tools,. additional lights

(hand lamps etc) must be mustered near the generator.

 Paper roll/Burlap must be spread around the generator; this is done to

keep working area clean. Enough cotton rags must be kept near
worksite.
 Generator Engine Overhaul
Overhaul:
 Ensure all personnel involved in the job is properly attired (Boiler suit) &

issued with Personal Protective Equipment (PPE) such as goggles, hand

gloves, helmet etc.
 Small plastic buckets to be kept ready for storing/securing small spare

parts such as nuts & bolts etc.

 After sufficient cooling of the generator engine, shut off Jacket water

inlet /outlet valves & drain the cooling water from generator engine
jacket.
 Generator Engine Overhaul
Overhaul:
 Shut off Generator MGO oil system inlet & outlet valves & ensure the

system is depressurized.
 Remove all units Cylinder head covers & front covers for fuel pumps.

Remove High pressure pipes from all units fuel injectors, disconnect
rocker arm lubrication oil pipes, remove exhaust pipe flange securing
screws.
 Generator Engine Overhaul
Overhaul:
 Remove cylinder head securing bolts hydraulically by use of special

hydraulic jacks supplied by the manufacturer. Instruction manual

guidelines in regard to use of hydraulic jack & the hydraulic pressure
must be followed. Generally hydraulic jacks are pressed up to 700-900
bar. Instruction manual data must be referred to before deciding about
the hydraulic pressure.
 Mount special lifting tool on the cylinder head & lift the cylinder head off

the generator frame by use of chain block slowly. Cylinder head to be

placed on the wooden block & to be secured against rolling.
 Generator Engine Overhaul
Overhaul:
 Clean the upper part of the cylinder, remove Flame ring from the liner.

 Turn the Crankshaft to bring the Crank throw into a position of

approximately 50 Deg before TDC.

 Clean the threaded hole in the piston top & mount the lifting Eye

(special tool) on it.

 Mount Cylinder Liner Holding Tube(special tool) on top of cylinder liner.

This tool will keep the liner in place while piston is being lifted.
 Connect chain block hook to the lifting eye already mounted on the

piston. Chain block is mounted on lifting trolley above the generator.

 Generator Engine Overhaul
Overhaul:
 Unscrew Connecting rod screws & remove the connecting rod big end

bearing cap with the help of Guide pin (special tool for extracting the
bearing cap).
 Pull out piston & connecting rod out of the engine frame with the help

of chain block. Piston to be secured on special rack provided for it.

 Same procedures to be adopted for extraction removal of cylinder head

& piston and connecting rod assembly from remaining units of the
generator ( Usually generator engine will have 6 & more cylinders,
depending upon the power requirement of the vessel).
 Generator Engine Overhaul
Overhaul:
 Dismantle all six cylinder heads by removing rocker arm assemblies,

exhaust /intake valve, fuel injector. Cylinder head body & other
dismantled components to be cleaned thoroughly. Clean & inspect
cooling water space for cylinder head. Calibrate Intake/Exhaust valve
spindles & valve seats, valve guides and fuel injector sleeve & compare
them with the instruction manual data, if in limit they should be re used.
Ground Intake & exhaust valve and respective seats by the use of fine
grinding paste. Inspect Rocker arm & springs. Box up the cylinder head
assemblies with new sealing rings & overhauled fuel injectors.
 Generator Engine Overhaul
Overhaul:
 All six units piston & connecting rod to be dismantled cleaned &

inspected. Inspect & calibrate piston crown & groves. Compare the data
with that of instruction manual. Inspect & calibrate Gudgeon pin &
bearing bush for each piston & compare the data with that of instruction
manual. Check the serration on connecting rod & bearing cap and
check the ovality. Box up the piston, connecting rod assembly with
new piston rings. Measure the axial & butt clearance of the piston rings.
 Generator Engine Overhaul
Overhaul:
 Clean/Decarbonise all units cylinder liners & extract them from the place

by use of special extraction tool. All cylinder liners are to be calibrated,

data should be compared with that of instruction manual. Liners having
wear more than the limit specified in the instruction manual must be
replaced. Install all liners with new sealing rings in place after
calibration.
 Open Camshaft cover for all units & inspect fuel, exhaust /intake cams

& Cam shaft bearings.

 Generator Engine Overhaul
Overhaul:
 Roller guide assemblies for exhaust/intake valves & fuel Pump operating

mechanism for all units to be removed from their places, inspected,

overhauled & to be fitted back in place.
 Inspect bottom end bearing shells for all units, replace if needed as per

wear condition of the bearing shells. Also inspect, connecting rod bolts
for all units for any abnormality such as thread damage, crack etc. If
they are in satisfactory condition, same to be re-used. Some
manufacturer recommends to replace these bolts after 32000 hrs of
running. Follow the guidelines of instruction manual for replacing these
bolts.
 Generator Engine Overhaul
Overhaul:
 Install all overhauled piston & connecting rod assemblies on each unit

one by one. While installing piston assembly crank throw of the

respective unit to be turned to approximately 50 deg before TDC, this
will enable easy assembly of bottom end bearing. Tighten connecting
rod bearings hydraulically to the hydraulic pressure as specified in
instruction manual. Generally, it should be at 700 bar. After tightening
connecting rod bolts, connecting rod should be checked if it is floating
or not. This is done by moving the connecting rod sidewise with the
help of screw driver. It should be able to move with the application of
slight force.
 Generator Engine Overhaul
Overhaul:
 After installation of pistons in all units , overhauled cylinder heads to be

installed on all units with new cylinder head gaskets & sealing rings for
cooling water space. Replace exhaust manifold gasket & securing bolts
to be fitted in place. Cylinder heads to be tightened hydraulically to the
pressure specified in instruction manual. Generally, it is tightened at
hydraulic pressure of 700 bar. Instruction manual guidelines must be
followed for dismantling & tightening hydraulic nuts. Tighten all
securing bolts connecting exhaust manifold to the cylinder head
assemblies.
 Generator Engine Overhaul
Overhaul:
 After tightening of cylinder head , rocker arm , push rod ,indicator cock

must be installed on the each cylinder head. Intake & exhaust valve
clearances (tappet clearances) must be adjusted as per instruction
manual data.
 Overhaul all units fuel pumps & install in place. Mount high pressure

pipes with new sealing rings on each unit after proper inspection.
 Engine driven cooling water pump to be overhauled & fitted back in

place. Open cooling water inlet & outlet valves to the engine. Check &
confirm that there is no water leak from any units. Special attention
must be paid for water leak in crankcase.
 Generator Engine Overhaul
Overhaul:
 Drain lubricating oil from crankcase, inspect & overhaul shaft driven

lubrication oil pump. Replenish the Lub Oil sump with fresh oil.
 Start priming Lubricating Oil pump & check for proper oil flow from all

bearings, camshaft lubrication system. Manually rotate the engine by

turning the flywheel with cranking tool. If no abnormality observed
crank case doors to be fitted back in place with new gasket.
 Open MGO inlet outlet valves for the generator & start the MGO pump.

Check the system for any leak & confirm no leakage.

 Generator Engine Overhaul
Overhaul:
 Start jacket heating & ensure jacket temperature of the generator is

about 70-80 deg C . Now generator is ready for starting.

 Remove Lock out tag out from the generator system & update the Lock

out /Tag out file.

 Keep indicator cock open & blow through the engine by turning it on air.

Shut the indicator cocks on all units & start the generator from local
start panel. Check & confirm no abnormal vibration & noise. Check &
ensure correct voltage & frequency on Main Switch board.
 Generator Engine Overhaul
Overhaul:
 Keep the generator idling (no load) for some times. After 10 minutes of
running, stop the generator , open crank case coves on all units &
perform feel over sequence (identification of hot spot) for all units.
Check & ensure all connecting rod bearings are floating. Turn the
engine manually & confirm no abnormality such as wiped white metal
etc & any loose component. If everything is normal , box back the
crankcase cover & start the generator once again after blowing through.
Again confirm no excessive vibrations, abnormal noise & correct voltage
& frequency on Main Switch Board (MSB) panel. Now generator can be
put on part load for about 30 minutes & again feel over sequence for
crankcase & connecting rod bearings to be performed.
 Generator Engine Overhaul
Overhaul:
 If no abnormality observed , then generator to run on part load for a

day or two , this will ensure proper running in of piston rings & liners.
Then after generator can be put on full load.
 Perform comprehensive performance test on the generator at various

load & compare the data with ship trial reports.

 Fill up overhaul reports having all calibration data for all units . Update

PMS work order with detailed descriptions & photographs. Update

inventory with spare part consumed.