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Damage Cases of Machinery
Part-1
1
February 4th, 2020
Research Institute, ClassNK
Cause of machinery damage
1. Mishandling
2. Fatigue
3. Thermal stress
4. Corrosion
5. Material and structure
6. Poor maintenance
7. Outer factor (ex. Low quality fuel oil)
2
1. Introduction
Contents
4. Shafting
1 Propeller shaft
2 Intermediate shaft bearing
5. Aux. Boiler
1 Internal crack
2 Exhaust gas economizer
6. Others
1 Fire in engine room
2Fire from feeder panel
6-3 BWMS
1. Introduction
2. Main Diesel Engine
1 Crankshaft
2 Crosshead pin
3 Cylinder cover
4 Turbocharger
5 Cooling jacket
6 Damage due to F.O.
3. Aux. Diesel Engine
1 Connecting rod
2 Crankshaft
2. Damage of Main Diesel Engine
4
2-1. Crankshaft
✓ Ship type: Cement Carrier
✓ Ship age :15
✓ Kind of M/E: 4 stroke/4,300PS
✓ Damage parts : Crankshaft, Main bearings,
Crankpin bearings
2. Damage of Main Diesel Engine
No.4 Crankpin bearing No.5 Main bearing No.2 Main bearing
2-1. Crankshaft
All main and crankpin bearings were abnormal worn out and melted
5
2. Damage of Main Diesel Engine
2-1. Crankshaft
Heat crack on crank journal
No.1 crank journal
6
2. Damage of Main Diesel Engine
Waste cloth was found in check valve
2-1. CrankshaftCondition LO Line and LO filter/purifier
Inoperative
・L.O. Purifier
・ Back-flushing ofL.O. Strainer
7
2. Damage of Main Diesel Engine
2-1. Crankshaft
Cause of this trouble?
・LO inlet pressure decreased
・LO degradation
・Inoperable M/E safety device at LO lowest pressure
・Monitor and judgment based on only discharge
pressure of LO pump
8
2. Damage of Main Diesel Engine
2-1. Crankshaft
Point
・Appropriate operation of LO purifier and strainer
・No obstacle in LO line
・Maintenance of M/E safety device
・Comprehensive judgment using various
measurement results and alarms
9
2. Damage of Main Diesel Engine
10
2-2. Damage of crosshead pin and bearings
✓ Ship type: Bulk Carrier
✓ Ship age :15
✓ Kind of M/E: 2 stroke/8,973kW
✓ Damage parts : Crosshead pin and its bearings
Crankpin and its bearings
2. Damage of Main Diesel Engine
2-2. Damage of crosshead pin and bearings
Scratch marks on crosshead pin and its bearing
11
2. Damage of Main Diesel Engine
2-2. Damage of crosshead pin and bearings
Scratch marks on crankpin and its bearing
12
2. Damage of Main Diesel Engine
2-2. Damage of crosshead pin and bearings
M/E LO filter
Damage of LO filter element
13
2. Damage of Main Diesel Engine
2-2. Damage of crosshead pin and bearings
Cause of this trouble?
Broken steel wires of LO filter element were entered
into lubrication parts for M/E
Point
・ Proper maintenance of LO filter element in
accordance with maker instruction
・ Regular analysis of LO
14
2. Damage of Main Diesel Engine
15
2-3. Cylinder Cover
✓ Ship type: Vehicle Carrier
✓ Ship age :5
✓ Kind of M/E: 2 stroke/15,345kW
✓ Damage parts : Cylinder cover
Stud bolts/nuts for cylinder cover
Piping attached to the cylinder cover
✓ Outline of damages:
Cylinder cover was lifted. Fuel oil and cooling water
were splashed.
2. Damage of Main Diesel Engine
2-3. Cylinder Cover
Lifted cylinder cover
Approx.
45mm
Deformed packing between the cover and liner
16
2. Damage of Main Diesel Engine
2-3. Cylinder Cover
Damaged stud bolts and nuts for cover
Nut (lower side)17
Damaged thread of stud bolts
2. Damage of Main Diesel Engine
2-3. Cylinder Cover
Cause of this trouble?
Insufficient tightening of stud bolts/nuts
Point
・Confirmation of tightening torque
・Usage ofthe proper tightening tool for stud bolts/nuts
18
2. Damage of Main Diesel Engine
19
2-4. Turbocharger
✓ Ship type: Water Carrier
✓ Ship age : 23
✓ Kind of M/E: 2 stroke/6,000PS
✓ Damage parts: Turbo charger for M/E
Engine Room
✓ Outline of damages:
T/C was over run and exploded. Engine room fire
was occurred.
2. Damage of Main Diesel Engine
2-4. TurbochargerOver-run- Breakage of turbine blade/blower
- Heat damage of rotor shaft/bearings
- Fracture of casing
20
2. Damage of Main Diesel Engine
2-3. Turbocharger
Broken Engine Control Room Window
21
2. Damage of Main Diesel Engine
2-4. Turbocharger
Atomizing Conditions of FO injection valve
No.5 Injection valve
22
No.6 Injection valve
2. Damage of Main Diesel Engine
2-4.Turbocharger
・Unbalanced atomization of FO valve
・Accumulation of unburned FO in exhaust pipe
Cause of this trouble?
23
M/E cylinder
Incomplete
combustion
Accumulation of unburnt F.O
Explosion
Exhaust pipe
24
2. Damage of Main Diesel Engine
2. Damage of Main Diesel Engine
2-4. Turbocharger
Point
・Appropriate maintenance interval for injection valve
in accordance with the manufacturer’s instruction
・Cleaning accumulated FO in exhaust pipe
25