Main engine survey

• Planning

1. 1. 1. 1. Check the survey list of machinery
         2. Get exact date of survey and get immobilization and inform office
         3. Check and prepare all necessary spares and tools
         4. Ensure enough manpower and time available in port
         5. Check previous record of maintenance.
         6. Check all lifting gear
         7. Check hydraulic pump, jacks, high pressure hose condition
         8. Read manual for special instruction and data. 
         9. Carry out briefing for everyone involve, precaution, work to be done, and time available.
         10. Carry out risk assessment

• Tools

1. 1. 1. 1. For piston and cylinder head

• Hydraulic pump, hoses and hydraulic jacks
• Piston lifting tool and cylinder head lifting tool
• Piston inserting tool
• Stuffing box spacer
• Piston and cylinder head stand
• Piston ring expander
• Piston crown wear measuring template

2. Liner 

• Liner lifting tool and liner support beam.
• Liner jack and jack support 
• Liner calibration gauge
• Liner inspection ladder
• Stuffing box area covering plate

3) Chain blocks 

• Check its safe load carrying capacity
• Check chain link condition
• Check free movement of chain in both direction
• Check safety lock for proper condition on hanging hook.
• Check condition of hook for sign of crack or damage

4) Eye bolts, shackles, wire sling and safety belt

• Check for safe load carrying capacity
• Check overall condition for any damage
• Check thread condition of eye and shackles

Safety during crane operation 

1. 1. 1. Don’t operate when ship is incline
      2. Don’t press button simultaneously
      3. Do not bypass limit switch to enlarge working switch
      4. Do not operate if someone under or on the way
      5. When 2 person directing, do not operate

• After arriving port

1. 1. 1. On finished with engine, get immobilization permission
      2. Propeller clearance to be obtain form bridge
      3. Shut starting air system and hang notice not to start main engine
      4. Drain the air line, keep open
      5. Open indicating Cock
      6. Engage turning gear and turn me with manual cylinder lubrication
      7. After half an hour stop LO pump
      8. Give time to cool engine
      9. Open crankcase door, lock on open position and give ventilation
      10. Isolate jcw inlet and outlet valve for particular unit and drain.
      11. Isolate fuel inlet and return valve for particular unit. 
      12. Exhaust valve spring air to isolate
      13. After ventilation of crankcase check, atmosphere check for oxygen content, explosive gas and toxic gas
      14. Enclose space entry permit to complete
      15. No naked light inside crankcase
      16. Proper lighting to be ensure inside crankcase

• Removal of connection 

1. 1. 1. with removal of following
      2. Remove exhaust bellow 
      3. Jcw outlet pipe before the valve
      4. Exhaust valve spring air connection
      5. Hydraulic actuator high pressure pipe
      6. Fuel injector high pressure pipe and connection
      7. Starting air valve connections

• Removal of cylinder head

1. 1. 1. Fit hydraulic jack on all cylinder head nuts and connect high pressure hose.
      2. Open jack vent and start to pump slowly
      3. Once air bubbles are removed, shut vent and stop pumping
      4. Ensure all jack vents are shut then pump to recommended pressure and stop pump
      5. Use tommy bar to loose nut
      6. Ensure all nuts are loose
      7. Release pressure, remove jacks and remove nuts
      8. Fit cylinder head lifting tool
      9. Lift slowly the cylinder head using ER crane
      10. Care to be taken when lifting, to make sure it does not come in contact with other cylinder head.
      11. Place the cylinder head on cylinder head stand

• Removal of piston

1. 1. 1. After proper ventilation of crankcase, remove the lashing of all secure bolts and remove require pipe connection
      2. Turn the piston to BDC and remove piston nut and lock device
      3. Fit the stuffing box spacer on piston rod palm
      4. Remove stuffing box securing bolts and its locking device 
      5. Remove cylinder head metal gasket
      6. Clean liner surface of deposits at combustion area so as piston does not get stuck during extraction.
      7. Turn the piston towards TDC, carefully keeping eye on turning gear ampere
      8. Clean the lifting holes on crown
      9. Fit piston lifting tool, ensure all bolt secured
      10. Ensure crane is in midpositon and ship is even keel
      11. Slowly lift up piston ensure stuffing box spacer does not get in contact with diaphragm.
      12. Continue to lift, ensure piston is not swinging causing piston palm get in contact with liner
      13. Once out, lower the piston on its stand and put cover on stuffing box housing.
      14. Remove the lifting tool

.Inspect and cleaning

1. 1. 1. Cylinder head 

1. 1. 1. 1. Before cleaning, check for carbon deposit.
         2. Any trace of water leakage
         3. After cleaning, crack test to be carried out at change of section (around injector bore, exh valve bore area, indicating cock, starting air valve, relief valve)
         4. Pressure test cylinder head cooling space
         5. Keep ready for survey

2. Piston and piston ring

1. 1. 1. 1. before cleaning check for carbon deposit amount and condition
         2. check ring condition for sticky, broken, cracks
         3. after taking out, carry out thorough cleaning
         4. check for free movement 
         5. check ring clearance and groove clearance

3.Piston crown 

1. Check for burning at the top 
2. Use template to check
3. Check for crack on top
4. Piston skirt and side wall
5. Check for any rubbing mark

4.Cooling passage

1. 1. 1. 1. Scaling due to poor water treatment
         2. Cracking due to high temperature
         3. Pressure test as per manual 
         4. Take photo for before after for future reference
         5. Pressure test piston as per manual 
         6. Keep ready

5.Piston rod and stuffing box

1. 1. 1. 1. Piston rod diameter to check at different point in manual
         2. Record and compare previous record
         3. Check for any scratch mark
         4. Overhaul stuffing box, clean all parts, and check clearance of rings. 
         5. Take photograph
         6. Carry out crack test at change of section of piston rod

6.Cylinder liner 

1. 1. 1. 1. Check for dryness and oiliness, clover leafing, hard particle park, polishing
         2. Check if scavenge port is choke & inspect
         3. Check for carbon deposit at top of combustion area
         4. Calibration to be check and recorded and compare with previous record
         5. Check the lubrication points for cylinder lub oil flow by pumping manually
         6. After cleaning, crack test to carry out around port edge. 

Inspection of surveyor

1. 1. 1. 1. After cleaning and decarbonizing, all parts to be kept ready for survey.
         2. Overhaul stuffing box with rings renewal as required box back 
         3. All joints, gasket and real rings renewed and kept ready.
         4. All calibration and measurement record are recorded and kept ready for surveyor
         5. Overhauled exhaust valve and fuel injector ready for box up after completion of survey
         6. After survey, all parts box up as per manual and system to be put in running order, take all precautions. Check for leakage and rectify accordingly.