Tài liệu PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD doc

PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD Edition 02 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD A-1 Preservation Procedure Of Main Engine At Shipyard (In Complete Engine case) 1.0 General 1.1 This manual provides technical advice for anti-corrosion in the period of engine storage at shipyard before the delivery of engine to the ship owner is completed The shipyard absolutely undertakes responsibility on the anticorrosion of engine 1.2 DOOSAN Engine applies anti-corrosion oil for engine parts as follow (reference 1) and long term protection is the standard if there is no request 1.3 The engine and related parts have to be stored in clean and dry indoor space (over 20 degree Celsius, below 50% of relative humidity) from arrival at shipyard to installation However, if the engine and related parts have to be stored outside inevitably, they must be protected against the external weather condition and alien substances by packing with waterproof cloth or partition 1.4 To remove the internal humidity of chamber, a dehumidifier (over 1.000CC/H) and an explosion-proof light creating enough heat (over 300W) shall be installed inside of chamber to remove humidity sufficiently The dehumidifier and explosion-proof light have to be operated continuously and temperature, humidity shall be recorded in the Log Sheet on a daily basis 2.0 Arrival checking 2.1 Upon the engine arrives at the shipyard, it has to be examined the existence of corrosion on the whole parts of the engine under the responsibility and by expense of shipyard The specific arrival checking facts shall be performed by following “3.0 routine check points” 2.2 If there is a serious corrosion on engine parts, please let the engine maker knows sending related report at the following contacts - Doosan Engine Co, Ltd Site Operation Team - Tel : +82-55-260-6802 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD - E-Mail : gunhyo.byen@doosan.com 2.3 If there is no request on corrosion within days, after the arrival of engine at shipyard, the engine and related parts will be considered that they are stored at shipyard in perfect condition without any corrosion 2.4 Even if the corrosion is not indicated on the engine parts, periodical inspection and preventive work must be implemented in accordance with the following number clause 3.0 Inspection matters 3.1 Inspection of corrosion, preservation condition of engine and related parts has to be carried out on a regular basis paid by and under the responsibility of shipbuilder The result shall be managed and recorded in the sheet 3.2 The main inspection parts and inspection period is as follow Please note that the period should be reduced in case of the condition of weather is high temperature and humidity or store the engine outside Main inspection parts Period of inspection Daily De-humidifier Every Week Every Two Week ● Crankshaft ● Con-rod ● Crosshead ● Piston rod ● Cam & Camshaft ● Cylinder liner ● Inside ● Outside ● Engine rotating ● 3.3 Before the inspection, main inspection parts shall be washed by following procedure to facilitate the inspection process - Remove anti-corrosion oil thoroughly with clean cloth after embrocate cleansing oil (petroleum based solvent or high temperature alkali cleansing liquid) To remove the hardened anti-corrosion oil from the surface and avoid damage on engine parts, please use plastic scrapers and remove the PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD film of anti-corrosion oil *Note: Please not use steel scrapers It may create damage on the surface of engine parts 3.4 Do inspection on the surface and verify the condition of corrosion after remove the anti-corrosion oil 3.5 When the corrosion is indicated, please report the fact to the engine maker and manage the problem as following methods provided from the engine maker 3.6 When the inspection of corrosion is completed, the corrosion preventive work shall be carried out under the responsibility of and paid by shipbuilder in accordance with the following number clause 4.0 Turning of engine and corrosion preventive work Carry out the following preparation work for engine turning and then rotate the engine three and one-third times(3 and 1/3) *Note: Please feed lubricated protection oil and L.O to embrocate the whole surface sufficiently preventing insert of alien substance through the wholes 4.1 Crankshaft 4.1.1 Feed TECTYL 930A or equivalent oil through the Main bearing L.O Hole to supply on the Crankshaft Main Journal 4.1.2 Feed TECTYL 930A or equivalent oil through the Oil Inlet Hole on the Crosshead to supply on the Crankpin Journal 4.1.3 Embrocate TECTYL 930A or equivalent oil on the rest of manufactured surface 4.2 Crosshead & Guide Rail 4.2.1 Feed TECTYL 930A or equivalent oil on around the exposed surface of assembled Crosshead Bearing Cap and Piston Rod 4.2.2 Embrocate TECTYL 930A or equivalent oil on the Guide Rail to supply oil on the Guide Shoe PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 4.3 Piston & Con Rod 4.3.1 Embrocate TECTYL 930A or equivalent oil on the surface of Piston and Con Rod through the Inspection door of Frame Box 4.4 Cam & Camshaft 4.4.1 Embrocate TECTYL 930A or equivalent oil on the surface of Cam, Roller and Camshaft through the Inspection door of Roller Guide 4.5 Cylinder liner 4.5.1 Get into the scavenge port and embrocate TECTYL 930A or equivalent oil on the inner wall of Liner and Piston Rod through the Cylinder Liner Air Port 4.6 Chain & Chain Wheel 4.6.1 Embrocate TECTYL 930A or equivalent oil on the surface of Main Chain, Crankshaft Chain and Camshaft Chain through the Inspection door 4.7 The others 4.7.1 Embrocate TECTYL 930A or equivalent oil on the rest of slide ways(습동 부) and manufactured surface in the chamber without margin 4.7.2 Feed TECTYL 930A or equivalent oil through the Oil Inlet Hole of Crosshead and carry out the engine turning process about 15 minutes later A-2 Storage procedure manual for disassembled engine 1.0 General 1.1 This manual provides technical advice for anti-corrosion in the period of engine storage at shipyard before the delivery of engine to the ship owner is completed The shipyard absolutely undertakes responsibility on the anticorrosion of engine 1.2 DOOSAN Engine applies anti-corrosion oil for engine parts as follow (reference 1) and long term protection is the standard if there is no request PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 1.3 The engine and related parts have to be stored in clean and dry indoor space (over 20 degree Celsius, below 50% of relative humidity) from arrival at shipyard to installation However, if the engine and related parts have to be stored outside inevitably, they must be protected against the external weather condition and alien substance by packing with waterproof cloth or partition 1.4 To remove the internal humidity of chamber, a dehumidifier (over 1.000CC/H) and explosion-proof light creating enough heat (over 300W) to sufficiently remove humidity shall be installed inside of chamber The dehumidifier and explosion-proof light have to be operated continuously and temperature, humidity shall be recorded in the Log Sheet on a daily basis 2.0 Arrival checking 2.1 Upon the engine arrives at the shipyard, it has to be examined the existence of corrosion on the whole parts of the engine under the responsibility and by expense of shipyard The specific arrival checking facts shall be performed by following “3.0 routine check points” 2.2 If there is a serious corrosion on engine parts, please let the engine maker knows sending related report at the following contacts - Doosan Engine Co, Ltd Site Operation Team - Tel : +82-55-260-6802 - E-Mail : gunhyo.byen@doosan.com 2.3 If there is no request on corrosion within days, after the arrival of engine at shipyard, the engine and related parts will be considered that they are stored at shipyard in perfect condition without any corrosion in accordance with the clause number 2.2 2.4 Even if the corrosion is not indicated on the engine parts, periodical inspection and preventive work must be implemented in accordance with the following number clause 3.0 Inspection matters 3.1 Inspection of corrosion, preservation condition of engine and related parts has to be performed on a regular basis under responsibility of and paid by PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD shipbuilder The result shall be managed and recorded in the sheet 3.2 The main inspection parts and inspection period is as follow Please note that the period should be reduced in case of the condition of weather is high temperature and humidity or store the engine outside Main inspection parts Period of inspection Daily Every Week Bedplate ● Crankshaft ● Frame box ● Con-rod ● Crosshead ● Piston rod ● Cylinder frame ● Cylinder liner ● Cylinder cover ● Gear & chain wheel ● Camshaft Every Two Week ● 4.0 Inspection of Engine Parts The existence of corrosion on whole engine parts shall be inspected every week and the results have to be recorded and kept in the daily sheet Examine thoroughly the lower and skid touched area of comparatively easily corroded parts Besides, when it comes to the package of engine parts are unpacked for inspection, silica gel begs shall be inside of package when the parts are packed up again 4.1 Crankshaft 4.1.1 Inspection of Journal part 4.1.1.1 Remove all covers applied to the Crank Pin Journals and Main Journals to protect them from corrosion and any kind of damage 4.1.1.2 Remove the hardened protection oil from the surface with plastic scrapers *Note: Please not use steel scrapers It may create damage on the PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD surface of engine parts 4.1.1.3 Remove the protection oil from the surface clearly using cleansing oil and then inspect the condition of the surface 4.1.2 Inspection of Crank throw & Flange parts 4.1.2.1 Remove the hardened protection oil from the surface with plastic scrapers 4.1.2.2 Remove the protection oil from the surface clearly using cleansing oil and then inspect the condition of the surface 4.2 Inspection of Crosshead pin & Connecting Rod parts 4.2.1 Remove the packing boxes and open the vacuum packing paper 4.2.2 Remove the hardened protection oil from the surface with plastic scrapers 4.2.3 Remove the protection oil from the surface clearly using cleansing oil and then inspect the condition of the surface 4.2.4 Note: The existence of corrosion between exposed surface of Crosshead Pin and Cap on the Crosshead Bearing Cap must be inspected thoroughly 4.3 Inspection of Piston Rod 4.3.1 Remove the packing boxes and open the vacuum packing paper 4.3.2 Remove the hardened protection oil from the surface with plastic scrapers 4.3.3 Remove the protection oil from the surface clearly using cleansing oil and then inspect the condition of the surface 4.3.4 Note: The existence of corrosion on the surface of Piston Rod assembled with Stuffing Box must be inspected thoroughly 4.4 Cam & Camshaft 4.4.1 Open the inspection Door and remove the protection oil Then, inspect the existence of corrosion 4.5 Cylinder Liner 4.5.1 Remove the vinyl and plywood covering top of the Cylinder Liner 4.5.2 Remove the protection oil in and outside of the Cylinder Liner, and then inspect the condition of the surface PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 4.5.3 Inspect the existence of corrosion on around the scavenge port of Cylinder Liner in Pump side through the Inspection Door of Cylinder Frame 4.6 When corrosion is detected, please report the fact to the engine maker and handle the circumstance in accordance with the method provided from the engine maker 4.7 When the inspection of corrosion and the treatment is completed, the corrosion preventive work shall be implemented paid by and under the responsibility of shipbuilder according to the following clause number 5.0 5.0 Re-anticorrosion procedure 5.1 Crankshaft 5.1.1 Clean the surface of Crankshaft using petroleum based cleansing oil and then polishes it with soft paper or clothe 5.1.2 Embrocate the Rust VETO 1070HF on the surface of Journals to remove handprints and then polish the surface with soft paper or clothe *Note: Do not touch the surface with bare hands 5.1.3 Embrocate TECTYL 506 or equivalent oil on the manufactured surface After 12 hours of drying, embrocate TECTYL 506 or equivalent oil one more time and dry it again about 24 hours more 5.1.4 The surface of Journal parts shall be protected by wrapping rubber sheet (thickness is mm) 5.1.5 Wrap Rubber Plate, Wooden plate and Steel plate (thickness is about 12~15mm) the lifting points when the crankshaft is installed *Note: Please wrap the plates when the anti-corrosion oil is absolutely dried 5.2 Others 5.2.1 Clean the inspection area using petroleum based cleansing oil and then polishes it with soft paper or clothe 5.2.2 Embrocate TECTYL506 or equivalent oil on the inspection area and dry it about 12 hours Then, embrocate the anti-corrosion oil one more time 5.2.3 Embrocate TECTYL 859A or equivalent oil inside of the Piston Cooling Insert Pipe and then seal it completely PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 5.2.4 Embrocate long term anti-corrosion oil (TECTYL 506or equivalent oil) on the manufactured surface of the rest parts (Guide rail, upper and lower area of huge parts) B Management Procedure (After engine installation) 1.0 General 1.1 The relative humidity of inside engine must be kept up with at below 50% by means of using a dehumidifier, explosion-proof light even after the engine installation is completed 1.2 Every two week, feed recommended high viscosity oil as follow or TECTYL930A or equivalent oil into the parts as indicated at clause number 3.0 at A-1 and then rotate and 1/3 cycles *Note: Embrocate TECTYL930A or equivalent oil again on Piston Rods when the engine turning is completed 1.2.1 Recommended high viscosity oil Statoil : CylWay 1500 Esso : Esso Cylesso Texaco : Meropa 460, 680 Chevron : Ep industrial oil 460 Mobil : Mobilgear 634, 636 Shell : Shell valvata oil 1000 1.3 Visual test has to be carried out on every part once a week 2.0 Feeding Oil 10 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD [Crosshead ] MC MC(ME)-C [Crosshead Pin / Telescopic Pipe] [Main Bearing] [Telescopic Pipe] [Main Bearing] [Telescopic Pipe] 3.0 Installation of Dehumidifier 3.1 Dehumidifier is to be used to prevent the creation of compressed water from the variation of temperature and weather condition while the completed engine is stored or in the middle of transportation 11 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD Moreover, dehumidifier can be used when the engine parts need to be stored in the outdoor tent temporarily 3.2 Recommended installation diagram is as follow ① Dehumidifier ② Camshaft housing(Inlet) 12 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD ③ Camshaft housing (Outlet) ④ Frame box door (Outlet) ⑤ Shield fore (Inlet) 13 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 4.0 Installation of Explosion-Proof Light 4.1When it comes to the installation of dehumidifier is impossible, the temperature and relative humidity of engine and related parts storage shall be increased by means of using explosion-proof light to prevent the frost formation *NOTE: The explosion-proof light has to be operated continuously and protected from loosing heat because the performance of explosion-proof light could possibly be declined due to the variation of external temperature 4.2 The reference installation picture is as follow [Picture of power cable installation] 14 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD [Picture of installation – Inside of the Chamber] [Picture of Explosion-Proof Light] – 300W, Halogen Light [Reference 1] Application of anti-corrosion oil for main parts (Engine maker) *If there is no request from engine maker or ship owner, following anti-corrosion oil shall be used as standard No NAME OF OIL APPLIED OIL ASSEMBLE DISASSEMBLE BED PLAT(lower surface, manufactured part) TECTYL 506 TECTYL 506 BED PLAT(IN,OUT SIDE ,Not coated manufactured TECTYL 506 TECTYL 506 part) MAIN JOURNAL VALVATA1000 TECTYL 506 CRANK PIN JOURNAL VALVATA1000 TECTYL 506 CRANK THROW and other manufactured part TECTYL 506 TECTYL 506 FRAME BOX(manufactured part) TECTYL 506 TECTYL 506 15 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD CHAIN WHEEL & SPROCKET ASS'Y TECTYL 506 TECTYL 506 GUIDE SHOE, GUIDE PLAT TECTYL 506 TECTYL 506 WATR GUIDE JACKET & COOLING JACKET SPACE TECTYL 859A TECTYL 859A 10 TURNING WHEEL manufactured part TECTYL 506 TECTYL 506 11 Whole surface of CON ROD ASS'Y TECTYL 506 TECTYL 506 12 CRANK PIN BRG SHELL VALVATA1000 TECTYL 506 13 Between X-HEAD and CON ROD VALVATA1000 TECTYL 506 14 Inside of the PISTON COOLING OIL HOLE - TECTYL 859A 15 Manufactured part of PISTON ROD TECTYL 506 TECTYL 506 16 CYLINDER LINER TECTYL 506 TECTYL 506 17 CAM SHAFT TECTYL 506 TECTYL 506 18 MAIN CHAIN TECTYL 502C TECTYL 502C 19 THRUST BRG Inside TECTYL 502C TECTYL 506 20 STAY BOLT,NUT, other Joints TECTYL 506 TECTYL 506 21 Manufactured part of SCAVENGE AIR RECEIVER - TECTYL 506 22 Manufactured part of EXH GAS RECEIVER - TECTYL 506 23 Manufactured part of TURBOCHARGER - TECTYL 506 24 CYLINDER COVER upper&lower manufactured part, TECTYL 506 TECTYL 506 surface of combustion chamber 25 EXH.V/V OIL CYLINDER TECTYL 859A TECTYL 859A 26 CYL COVER STUD TECTYL 506 TECTYL 506 27 Inside of the all sorts of PIPES (seal up after anti- - TECTYL 859A - TECTYL 506 corrosion) 28 All sorts of BOLTS/NUTS, DISTANCE PIECES etc 29 MAIN BEARING CAP L.O HOLE Anti-corrosion TECTYL 859A TECTYL 859A 30 Upper and lower BOLT, REAMER BOLT HOLE of TECTYL 506 TECTYL 506 - TECTYL 506 - TECTYL 506 BED PLATE Anti-corrosion 31 Upper and lower BOLT,REAMER BOLT HOLE of FRAME BOX Anti-corrosion 32 Upper and lower BOLT,REAMER BOLT HOLE of CYL.FRAME Anti-corrosion 33 AIR RECEIVER BOLT HOLE Anti-corrosion - TECTYL 506 34 EXH GAS RECEIVER BOLT HOLE Anti-corrosion - TECTYL 506 35 TURBO CHARGER BOLT HOLE Anti-corrosion - TECTYL 506 16 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 36 Other manufactured part Anti-corrosion - TECTYL 506 [Reference 2] Log Sheet Temp & humidity should be measured and recorded about same time once a dry every dry Date Total hour Temp.(°C) Humidity(%) Signature Remark 17 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD E.O.D 18 .. .PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD A-1 Preservation Procedure Of Main Engine At Shipyard (In Complete Engine case) 1.0 General 1.1 This manual... 6S70ME-C> 13 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 4.0 Installation of Explosion-Proof Light 4.1When it comes to the installation of dehumidifier is impossible, the temperature and relative... installation] 14 PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD [Picture of installation – Inside of the Chamber] [Picture of Explosion-Proof Light] – 300W, Halogen Light [Reference 1] Application