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3/e take over checklist
1. PMS:
– Which jobs are really done and which ones are just updated for show?
– Overdue jobs reasons
– Upcoming jobs prep2. SPARES:
– What is the consumption pattern
– When and what was the last order made, and last order received after how many months
– Enough spares for A/E top and unit overhaul? How many units? O-rings, gaskets, suc and exh valve stem seals, suc and exh valves and valve seats, valve guide, protection ring, piston rings.
– FUEL INJECTOR NEW NOZZLES AND SPRINGS ROB? Fuel pump new plunger+barrel set ROB?3. REGULAR CHECKS:
– Any problems with tappet clearance? Locking bolt & nut good condition?
– Crankshaft deflection actual deflection recorded?
– Con rod bolts markings checked?
– Is the fuel injection pump pinion lubricating oil amount for each fuel pump enough? Usually it’s 1 drop per 10-12 seconds.
– IS THE REAL A/E PERFORMANCE RECORDED?? If not, which part of the performance report is real and which is fake? And why?
– How often boiler blow down and gauge blow down?
– Any problems during Saturday routine?
– Is the A/E alarm testing tool working well? Any problem with alarm testing? What are the actual alarm settings?
– Any pressure or temp I need to watch, or just above/below a set value?4. MAINTENENCE:
– How often are the A/E LO, T/C LO and centrifugal L.O filters cleaned and/or renewed?
– What is the actual LO consumption of each A/E per month and per running hours?
– How much difference between C/E ROB and actual ROB?
– How often is boiler burner and swirl plate cleaned?
– If cooling system is S.W., how often are the zinc anodes renewed?
– Is em’cy fire pump attached priming pump working automatically? If not, check the priming pump suction valve on em’cy fire pump suction line.
– is the hyd Jacks, pump, pressure gauge and hoses in good condition?When taking over,
1) Just know the essential valves for your generator. How many valves to top up your sump oil. How much consumption of Lub oil per month. Normally 100 – 300 for 3 generator depend on running hour.
2) How many valves to close when overhauling. Mainly where the FO valves, cooling water valves to close and where to drain, starting air valve.
3) The previous 3e routine, if he had turbo-wash turbocharger gas or turbine side etc. Lub oil & fuel oil filter how frequent changed depending on the oil condition.
3) Check running hours to know around when is the next Top and major overhaul. If average running hour is 300h, how more months to next major. Need to order early.
4) take the first few days to check if you have all the spares required for overhaul, and critical spares.Impt Spares to look out for. Check your Manuel to know exact.
Generator attached pump
1)cooling water pump mechanical seals, oil seal & bearing.
2)lub oil pump spare gear, oil seal.
3)fuel oil attached pump mech seal or oil seal.For Top & major overhaul
For cylinder head;
Valve rotator, often neglected (steel ball, valve spring, spring plates )
Valve guides
Stem seals ( easily damaged when fitting, use proper tools if have or use a old stem seal as a cushion)
Suction & exhaust valves
exhaust & suction valve oring and seating ( rarely need to replace but good to have )
nozzle guide & oring ( rare but experienced leakage from here before )
Orings – for cooling water jacket, for oil return.
Gaskets – for your exhaust/ suction manifold, cylinder head metal gasket,
Piston rings – sufficient for how many times oh?Banjo plugs &spare copper gaskets < for cooling water fittings. From experience,dont need tight too much. if leaking then tight, normally solution is just replace copper gasket.
Fuel pump & injectors – keep spare & ready. Spares new barrel & plunger. when overhauling fuel pump check if barrel & plunger wear ( by covering the holes and feel the vaccum) When replacing injectors ( Test the nozzle before dismantling, so to determine to use back the nozzle or not, Check for leakage, spray and atomisation)
Turbocharger – if you have a new set. Check if got service kits for oh + spare bearings.
It good to make a point to put on your running hour sheet which Unit fuel pump you renewed new barrel and plunger, or new injector nozzle for future reference. Also remember to fill up your Nox Technical file for any job done on your AE.
Routine job for 3e
Tappet clearances
1) 2 rounds of your Flywheel is complete cycle of your 4- stroke generator, so for you to finish your tappet you just need to turn 2 rounds. Each round 3 units to adjust.
2) flywheel got 3 locations and marking; 1/6, 2/5, 3/4. 1st round of turning flywheel ( adjust the unit which both exhaust and suction valve are closed; check by making sure the push rod is free, if not just take out the cam cover and see the cam )
3) firing sequence for example 1-5-3-6-2-4, so go by that order. after adjust unit 1, go to 5, then go to 3. ( just take note sometimes the one turning the flywheel will overshot and give you the wrong flywheel position )
4) go by the feeler gauge. Dont go too tight or too loose, just dont be a perfectionist.. Lock nut dont be too tight either because the thread is easily spoilt. just spanner tight and tight by angle for ~40 degree. Very often the lock nut is damaged, if cant remove, my way is to just replace that particular rocker arm, because its not easy to remove the lock nut.
5) You can use your paint marker to mark on the nut and arm when done adjusting. So you can observe any movement next time you check visually.Crankshaft deflection
not only take reading, but know how to plot to know where is fault.
https://www.youtube.com/watch?v=QD3czPtlBf4
Fuel timing / cam timing
1) Turn the flywheel until the marking on the fuel pump meets the line. ( check manual ) that is the start of the injection,
2) Check the flywheel and note the angle. Fuel injection can be adjusted via adding shims or by adjusting the bolt depending on your generator type.
3) Do so for all units
4) Only adjust if there is fault on the injection timing( too early or late base on your performance chart) else dont touch it.Just sharing from my exp, we’re open for discussion here.
Performance
1) Taken once a month, to check all is well, Pmax and Pcom is normal range, no abnormalities.
2) Normally i would take performance when changing over main running generator. For example this week AE #1 and im changing over to AE#2, i will take both performance at ~85% load. Depend on your company requirement.
3) Next week, when i’m changing from Ae#2 to Ae#3, i will take performance for AE#3. so by month end i will have taken all 3 AE.
4) Normally my practice is change Running AE estimate every 7days~ at sea. its fine to run more but its good to balance the running hours depending on yours.
5) During performance at high load, Check all your Fuel racks are almost equal, and Pcom and pmax are satisfactory.
6) If high deviation or exhaust temperature is high at high load provided at Pmax is okay, and dev more than 30-40degreeC, adjust the fuel racks a little turn and observe.
7)in my opinion, as long your pmax and pcomp is normal and fuel rack is almost equal at low load there tend to have some deviation and that does not matter. ( unit further away from the t/c scav space tend to have higher temp )
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