PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD

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PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD

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DOOSAN Engine applies anticorrosion oil for engine parts as follow (reference 1) and long term protection is the standard if there is no request. 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.

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  1. PRESERVATION PROCEDURE  OF MAIN ENGINE AT SHIPYARD Edition 02
  2. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD A­1. 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 anti­corrosion 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   explosion­proof  light   creating   enough   heat   (over   300W)   shall   be  installed   inside   of   chamber   to   remove   humidity  sufficiently.   The   dehumidifier   and   explosion­proof  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  2
  3. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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 : +82­55­260­6802         ­. E­Mail : gunhyo.byen@doosan.com    2.3 If there is no request on corrosion within 7 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 4 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 Every Week Every Two  Week De­humidifier ● Crankshaft ● Con­rod ● Crosshead ● Piston rod ● 3
  4. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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   anti­corrosion   oil   thoroughly   with   clean  cloth   after   embrocate   cleansing   oil   (petroleum   based  solvent or high temperature alkali cleansing liquid).  To   remove   the   hardened   anti­corrosion   oil   from   the  surface  and  avoid damage  on  engine  parts, please  use  plastic scrapers and remove the film of anti­corrosion  oil.      *Note: Please do 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   anti­corrosion  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 4 clause. 4.0 Turning of engine and corrosion preventive work      Carry out the following preparation work for engine  turning and  4
  5. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD then   rotate   the   engine   three   and   one­third   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.     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. 5
  6. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD     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(res) 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. A­2. 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 anti­corrosion 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  6
  7. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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   explosion­proof  light creating enough heat (over 300W) to sufficiently  remove humidity shall be installed inside of chamber.  The dehumidifier and explosion­proof 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 : +82­55­260­6802         ­. E­Mail : gunhyo.byen@doosan.com    2.3 If there is no request on corrosion within 7 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 4 clause. 7
  8. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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  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 Every Two  Week  Bedplate ●  Crankshaft ●  Frame box ●  Con­rod ●  Crosshead ●  Piston rod ●  Cylinder frame ●  Cylinder liner ●  Cylinder cover ●  Gear & chain wheel ●  Camshaft ● 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. 8
  9. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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 do not use steel scrapers. It may  create damage on the 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  9
  10. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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.    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 Re­anticorrosion procedure      5.1 Crankshaft             5.1.1   Clean   the   surface   of   Crankshaft   using  10
  11. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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  5 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 anti­corrosion 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.       5.2.4 Embrocate long term anti­corrosion 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) 11
  12. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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,   explosion­proof   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 A­1 and then rotate 3 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 12
  13. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD [Crosshead ] MC MC(ME)­C [Crosshead  Pin  /  Telescopic  [Telescopic Pipe] Pipe] [Main Bearing] [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  13
  14. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD completed   engine   is   stored   or   in   the   middle   of  transportation.   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) 14
  15. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD ③  Camshaft housing (Outlet)             ④  Frame box door   (Outlet) ⑤ Shield fore (Inlet)  
  16. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 4.0 Installation of Explosion­Proof 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   explosion­proof   light   to   prevent  the frost formation.   *NOTE:   The   explosion­proof   light   has   to   be   operated  continuously and protected from loosing heat because  the   performance   of   explosion­proof   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] 16
  17. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD [Picture   of   installation   –   Inside   of   the   Chamber]           [Picture   of  Explosion­Proof  Light]    – 300W, Halogen Light [Reference. 1] Application of anti­corrosion oil for main  parts (Engine maker)         *If   there   is   no   request   from   engine   maker   or   ship  owner,   following   anti­corrosion   oil   shall   be   used   as  standard. 17
  18. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD No NAME OF OIL APPLIED OIL . ASSEMBLE DISASSEMBLE 1 BED   PLAT(lower   surface,   manufactured  TECTYL 506 TECTYL 506 part) 2 BED   PLAT(IN,OUT   SIDE   ,Not   coated  TECTYL 506 TECTYL 506 manufactured part) 3 MAIN JOURNAL VALVATA1000 TECTYL 506 4 CRANK PIN JOURNAL VALVATA1000 TECTYL 506 5 CRANK   THROW   and   other   manufactured  TECTYL 506 TECTYL 506 part 6 FRAME BOX(manufactured part) TECTYL 506 TECTYL 506 7 CHAIN WHEEL & SPROCKET ASS'Y TECTYL 506 TECTYL 506 8 GUIDE SHOE, GUIDE PLAT TECTYL 506 TECTYL 506 9 WATR   GUIDE   JACKET   &   COOLING   JACKET  TECTYL 859A TECTYL 859A SPACE 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 X­HEAD and CON ROD  VALVATA1000 TECTYL 506 18
  19. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 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  ­ TECTYL 506 RECEIVER  22 Manufactured   part   of   EXH.   GAS  ­ TECTYL 506 RECEIVER  23 Manufactured part of TURBOCHARGER  ­ TECTYL 506 24 CYLINDER   COVER   upper&lower  TECTYL 506 TECTYL 506 manufactured   part,   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  ­ TECTYL 859A (seal up after anti­corrosion) 28 All   sorts   of   BOLTS/NUTS,   DISTANCE  ­ TECTYL 506 PIECES etc.  29 MAIN   BEARING   CAP   L.O   HOLE   Anti­ TECTYL 859A TECTYL 859A corrosion 30 Upper   and   lower   BOLT,   REAMER   BOLT  TECTYL 506 TECTYL 506 HOLE of BED PLATE  Anti­corrosion 31 Upper and lower BOLT,REAMER BOLT HOLE  ­ TECTYL 506 of FRAME BOX Anti­corrosion 32 Upper and lower BOLT,REAMER BOLT HOLE  ­ TECTYL 506 of CYL.FRAME Anti­corrosion 33 AIR RECEIVER BOLT HOLE Anti­corrosion ­ TECTYL 506 34 EXH.   GAS   RECEIVER   BOLT   HOLE   Anti­ ­ TECTYL 506 corrosion 35 TURBO   CHARGER   BOLT   HOLE   Anti­ ­ TECTYL 506 corrosion 36 Other   manufactured   part   Anti­ ­ TECTYL 506 corrosion [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 19
  20. PRESERVATION PROCEDURE OF MAIN ENGINE AT SHIPYARD 20
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