MAN Energy Solutions 6645-0320-0007 2 How to take a cylinder unit out of operation On the folowing pages, Case A - F describes five different methods of taking a single cylinder unit out of operation, The extent of the work to be carried out will of Course, Copend on the nature of the trouble. ‘Asummary of the various methods is given in the following table: casoA |CaseB |casec [Cased |casee —|casoF Nature of |Combus- |Compres- | Compres- |Combus- | llrecipro- | Al recipro- the action ten tobe sionand sion and tian tobe eating’ |cating dsabled |comous- |combus- |isabked [paris sus- [parts cut ion tobe |tion tobe |(dueto | pended or disables |oisabled, |fautty out anual | exhaust Inder Libr | vale) callon Somorca- |Blow-by at |Leakng |Falloot |Maltune- |Shouls | Only of sonstor |pston”—oyinder feyinder tion ot onlybe _interestit ‘the action |rngs or — Jeovarer |IUericatin exaust |aone nthe | spare nats exhaust liner ilsystem |vahe, or [event ot [are not vale. exaust ftautsin | avallable Reduction vale [large mow fofoaa on actuator |ing pats, bearings. oylinger Faulty ‘cover or injection ylincer equpment Ine Fue-ol [Disabled [Disabled [Disabled [Disabled | Disabled | Disabled pressure booster (EIVVELED Exhaust [In opera- [Hold open |Hold open [Closed | cosed | Closaa vale ‘Airsuppty [Open Open [Open Open [Open [Open {oar cylin der Exhaust [In opera. [Disables [Disabled [Disabled [Disabled | Cisablos vale FAY ELVA) ‘Stating ar [In opera- |Blanked off|in opera- [In opera- _|Blanked off | Blarked off vale | ton tion tion Piston with [Moving [Moving | Moving [Moving | Suspended | out rod Grosshead [Moving [Moving [Moving [Moving | Suspended | Qut Connecting] Moving [Moving Moving Moving | Out out rod Grankpin |Moving Moving | Moving Moving | Out Out eating ‘Ontetto [Open —fopen Open [Open | Blanked of | larked ott jrosshead A a is Fy & & 3 8 3 A 2 3 A 2 bi = 5 fe Ey 3 a = & = Peer rl CTT CEI KYRULe 3(14)6645-0320-0007 MAN Energy Solutions caseA [Case —|casec Cased [Case | caso ‘Cooing i [Open [open Open [Open | Nat Not ott from ‘applicable | applicable (crosshead ‘Gytnder |r opera-|In opers- [Not opera- ‘Stopped | Stopped Lubricator tion tion ‘ional Table: Summary of methods of taking a single cyindr unit out of operation In cases where the crosshead and crankpin bearings are operative, the Mn Oil inlet to the crosshead must not be blanked off, as the bearings are lubricated through the crosshead, 2,1 Case A: Combustion to be disabled, Piston and exhaust actuator still operating, Compression on, Reasons; Preliminary measure in the event of, for instance: blow-by at piston rings or exhaust valve; bearing feilures which necessitate reduction of bearing load; faults in the fuel injection system, Procedure: 1. Disable the ful ol pressure booster operation by setting the Grief Index Limit t0 "0" on the relevant cylinder. ‘See description 6645-0250 Chief Limiters > Chie index Limit Note; Do not stop cyfinder cooling water flow or piston coolng oil flow, 2, Refer to item 4 (Running wath one (1) cylinder misting) for engine operation restrictions, 5 3 = s & é 5 3 3 5 2 = 3 A = Ei = fo = Ke 3 Ky S = cd A & A ES 22 Case B: Compression and combustion to be disabled. Piston still moving in cylinder. in the event of, for instance liner or cylindor cover. water is leaking into the cy! Engine operation must as soon as possible be superseded by case E or F. “Always contaol the engine bui barred speed range, fr for calculation of allowable output and possible Procedure: Disable the fuel ol pressure booster operation by setting the Chief Index Limit to "0" on the relevant cylinder. S06 descrition 6645-0250 Chiat Limiters > Chief index Lit 2. Disable the exhaust valve operation and secure it in open position. See work card 6665-0201. Close the cooling water inlet and outlet valves for the cylinder. If necessary, drain the coaling water spaces completely CR URULUe ata)MAN Energy Solutions 6645-0320-0007 4, Remove the starting ar pie, and bblank off the main pipe and the control sir pipe for the pertainng cylinder Continue with the measures mentioned in tem 3 (Resuming operation after taking a cylinder unit out of operation). 6. When operating in this manner, the speed should not exceed 85% of MOR See dascription 6645-0250 Chiet Limiters > Chief Max Spead ‘The joints in the crosshead and crankpin bearings have a strength that, for a short time, will accept the loads at full speed without bes ‘compression in the cylinder. However, to avoid unnecessary wear and pitting at the joint faces, itis recommended that, when running a unit continuously with the ‘compression disabled, the engine speed is reduced to 55% of MCR ‘speed, which is normally sufficient to manoeuvre the vessel. During manoeuvres, if found necessary, the engine speed can be raised to 80% of MCR speed for a short period, for example 15 minutes. ‘See description 6845-0250 Chief Limiters > Chiet Max Speed A a is Fy & & 3 8 3 A 2 3 A 2 bi = 5 fe Ey 3 a = & = During these circumstances, in order to ensure that the engine speed is kept within a safe uoper limit, the over-speed level of the engine must be lowered to 83% of MCR speed in the "Safety System’, 23. Caso C: Compression and combustion to be disabled. Manual cylinder lubrication. Reasons: This measure is permitted in the event of afalure of cylinder lubrication on one unit Engine operation must as soon as possible be returned to normal by replacing the lubricator, ‘Always contact the engine builder for calculation of allowable output and possible barred speed range. Procedure: Disable the fuel ol pressure booster operation by setting the Chief Index Limit to '0" on the relevant cylinder. See description 6645-0250 Chiet Limiters > Chief index Limit 2. Disable the exhaust valve operation and secure it in open postion See work card 6665-0101 8, Adjust the lubricators on the neighbouring cylinder(s) to maximum oil delivery. 4. Betore starting the engine, remove or open the inspection cover on the manoouvring side and cistripute 1 liter of eyinder oll va the scavenge air ports, into the circumferential gap between the piston crown and the cylinder Iner Remount the inspection cover and then turn the engine 2 ~ revolutions, Using the turning gear, in order distribute the oi on the iner surface, Peer rl CTT CEI KYRULe 5 (14)6645-0320-0007 MAN Energy Solutions 5, The engine may now be started and operated up to 55 9 speed for the next 6 hours {during manoauvring up to 80% speed for max 15 minutes). 6, After 6 hours, stop the engine and inspect the piston rings via the scavenge ports from the manoeuvring side, Distribute another Iter of ol via the ports, and the operation may be Continued ater turing 2 ~ 3 revolutions. 7. Next stop / inspection should be base on at the previous inspection as folows: ifthe piston rings (and the line) are not dry, Le. stil contains some oil, the next running interval may be increased up lo 12 hours, succeeded by another Inspectio: ~ Incase the piston ting running surfaces are found dry, but without signs of seizure, the next running interval should be 6 hours, succeeded by another inspection. — In case signs of seizures are found on the piston rings, the running inter- vals between inspections and manual lubrications should be decreased to S hours. n the condi 8. After finishing emergency running, . when normal lubrication has been re- established, put the fuel and the exhaust valve operation back to normal 9. Perform a scavenge port inspection, with special focus on the condition of the piston rings. in case of severe seizures, change the rings. During these circumstances, in order to ensure that the engine speed is kept within a safe upper limit, the over-speed level of the engine must be lowered to 183% of MCR speed in the "Safety System". 5 e = s & é 5 3 3 5 2 = 3 A = Ei = S = Ke 3 Ky S = cd A & A ES 24 Case D: Combustion to be disabled, Exhaust valve closed, Piston still moving in cylinder. Reasons: This measure may be used if, for instance, the exaust valve or the actuator is detective. Or f ECS control of the exhaust valve is lost Procedure; 1, Disable the fuel oil pressure booster operation by selting the Chief Index Limit to "0" on the relevant cylinder ‘See description 6645-0250 Chiet Limiters > Chief index Limit 2. Disable the exhaust valve operation so that the valve remains closed by seloct- ing Exhaust Vave Operation "Stopped on the relevant cylinder. ‘See descrintion 6645-0250 Chief Limiters > Exhaust Valve Operation. Stop the oll supply and remove the hydraulic high pressure pipe, See work card 6665-0101. Note; Do not stop cyfinder cooling water flow or piston coolhng oil flow, 3, When the engine is running with one closed exhaust valve, the comoression pressure can be significantly higher than the normal maximum cylinder pres- sur In order to avoid a risk of cylinder cover lit due to the high compression pressure, the ECS has a compression pressure miter which ensures that the avenging air pressure, and thereby the engine load, is not increased above the crtical limit. For more information see description 6645-0250 Chief Liniters > Exhaust Valve Operation and Compression Pres. Lim. 4, Continue with the measures mentioned in tern 3 (Resuming operation after taking a cylinder unit out of operation). CR URULUe 614)MAN Energy Solutions 6645-0320-0007 5. Refer to item 4 (Running with one (1) cylinder mistring) for engine operation restrictions, 2.5 Case E: Piston, piston rod, and crosshead suspended in the engine. Connecting rod out, Reasons: For instance, serious defects in piston, piston rod, connecting rod, cyinder cover, cylinder Iner and crosshead. ‘Always contact the engine builder for calculation of allowable output and possible barred speed range, Procedure; Disable the fuel ol pressure booster operation by setting the Chief Index Limit to "0" on the relevant cylinder, ‘See dscriotion 6645-0250 Chief Limiters > Chief index Limit 2. Disable the oxhaust valve operation so that the valve remains closed by seloct- ing Exhaust Valve Operation “Stopped” on the relevant cylinder. ‘See descriotion 6645-0250 Chie! Limiters > Exhaust Valve Operation. Stop the oll supply and remove the hydraulic high pressure pipe, See work card 6665-0101. Remove the starting air pipe, and blank off the main pipe and the control ir pipe for the pertaining cylinder In this case the blanking-off of the starting air supply is particularly Nias important, as otherwise the supply of starting air will blow down the suspended engine components. 4, Suspend the piston, piston rod and crosshead, and remove the connecting rod aut of the crankcase, in aocordance to the directions given in work care! 1465-0801, 5. Blank off the ol inlet to the crosshead, Set the cylinder lubricator for the pertaining cylinder, to *zer See 6845-0260 Cylinder Lubrication. 7. Continue with the measures mentioned in tem 3 (Resuming operation after taking a eylindor unit our of operation). delivery, 26 Case F: Piston, piston rod, crosshead, connecting rod, and telescopic pipe out. Reasons: This method is only used i ack of spare parts makes it necessary to repair the defective parts during the voyage. Always contact the engine builder for calculation of allowable output and possible barred speed range, Procedure: A a is Fy & & 3 8 3 A 2 3 A 2 bi = 5 fe Ey 3 a = & = Peer rl CTT CEI KYRULe 7 (14)6645-0320-0007 MAN Energy Solutions Disable the fuel ol pressure booster operation by setting the Chief Index Limit "0" on the relevant cylinder. 32e descriotion 6645-0250 Chief Limiters > Chief index Limit 2, Disable the exhaust valve operation so that the valve remains closed by select- ing Exhaust Valve Operation "Stopped" on the relevant oylinder. ‘See description 6645-0250 Chiat Limiters > Exhaust Valve Operation. Stop the oll supply anc remove the hydraulic high pressure pipe, See work card 6665-0101. Remove the starting air pipe, and bank off the main pipe and the control sir pipe for the pertaining cyinder. In this case the blanking-off of the starting air supply is particularly Nias important, as otherwise the supply of starting air will Blow down the ‘suspended engine components. 4. Dismantle piston with piston rod and stuffing box, crosshead, conne and telescopic pipo. Blank off the stufing box opening with the designated cover and seating ring ‘See 2270-0400 Piston Panel Tools ting rod Blank off the oil inlet hole of the telescopic pipe, Set the cylinder lubricator for the pertaining cylinder to “zero" delivery See 6845-0260 Cylinder Lubrication. 7. Continue with the measures mentioned in item 3 (Resuming operation after taking a cylinder unit out of operation). 5 e = s & é 5 3 3 5 2 = 3 A = Ei = S = Ke 3 Ky S = cd A & A ES 3. Resuming operation after taking a cylinder unit out of operation ‘After carrying out any of the procedures described under paints B, C, D, E, and F, itis, belore starting, absolutely necessary to cheok the ol flow through the bear- ings, and the tightness of blaned-off openings, Aller 10 minutes’ running, and again after one nour, the crankcase must be ‘opened for checking of + the bearings + the tomporarly secured parts + the oll low through bearings + the tightness of blanked-off openings Engine operation restrictions In case A and D, see item 4 below. bes In case B, E and F, always contact the engine builder for calculation of allowable output and possible barred speed range. CR URULUe (14)MAN Energy Solutions 6645-0320-0007 4 Running with one (1) cylinder misfiring (Case A or D) NOTICE Misfring is defined as: + No fuelinjection and + Compression is present If only one cylinder is misfring, it may be possible to run the engine with the remaining and working cylinders, given thase twa restrictions: ‘The thermal load of the cylinder units, 2. The torsional vibration in the pr eller shaft system, Ragardhg (1) Thermal oad restriction; ‘The folowing #/min and shaft powers may be obtained with a fxed pitch propeller given by the thermal load of the oylinder units: Total No.of Serimin % Load Cxlinders (ormicr) {otmer) 4 8 57 5 86 68 6 8 or 7 a 71 8 0 3 8 9 75 10 a 7 1" 2 78 2 2 7% 14 8 80 Regarding (2) Torsional vibration restrictions: ‘These restrictions, given as barred speed range, may be found in the class- approved report on the torsional vibration of the actual propeller shaft system, ‘These restrictions are only valid for misfring, Le. item 2, table 1 cases A and D. \With a OP-propeter, the same restrictions apply when running according to the design pitch. During the misfre operation keep the CP-propeler pitch fixed at the gn pit ntacted. lt more than one cylinder is mistring, the engine builder must be c Running limitations In Cases B, E and F In cases B, E and F, the engine builder must always be contacted for calculation of allowable output and possible barred speed range. A a is Fy & & 3 8 3 A 2 3 A 2 bi = 5 fe Ey 3 a = & = Peer rl CTT CEI KYRULe 9(14)