MAN B&W Diesel A/S
Service Letter SL03-423/UM
March 2003
Mean Time Between Overhaul
Piston Overhaul
Action Code: WHEN CONVENIENT
Dear Sirs
On the basis of positive feedback from owners with large bore engines, we changed,
in early 2002, our recommended “Guiding Overhaul Intervals” for piston overhauls
from 8,000 hrs. to 12-16,000 hrs., and new instruction books were changed
accordingly. At the same time, we also changed the interval for small and medium
bore engines from 8,000 hrs. to 12,000-16,000 hrs., see the enclosure “Guiding
Overhaul Intervals and Expected Service Life”.
It is possible to obtain the above MTBO (mean time between overhaul) for engines
fitted with the latest introduced features in the combustion chamber, i.e.:
• PC ring
• Pistons with high topland
• CPR (controlled pressure relief) top piston ring
• Piston rings with Alu-bronze coating
• Piston skirts with bronze rings
For engines with slide fuel valves, a further increase of MTBO can be expected for
pistons and rings.
Against this background, we wish to present a more flexible approach to piston
overhaul, taking also the type of vessel into consideration.
Generally, a well-lubricated piston with a good appearance and with an intact CPR
piston ring should not be overhauled. An intact CPR ring means that the remaining
pressure-relief grooves should be at least 1 mm deep.
HEAD OFFICE (& Postal address) DIESEL SERVICE PRODUCTION FORWARDING MAN B&W Diesel A/S
Teglholmsgade 41 Teglholmsgade 41 Teglholmsgade 35 Teglholmsgade 35 Denmark
DK-2450 Copenhagen SV DK-2450 Copenhagen SV DK-2450 Copenhagen SV DK-2450 Copenhagen SV CVR.No.: 39 66 13 14
Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00
Telex: 16592 manbw dk Telex: 31197 manbw dk Telex: 19023 manfw dk Telex: 19023 manfw dk
Telefax: +45 33 85 10 30 Telefax: +45 33 85 10 49 Telex: 19042 manfw dk Telex: 19042 manfw dk
E-mail: manbw@manbw.dk E-mail: diesel-service@manbw.dk Telefax: +45 33 85 10 17 Telefax: +45 33 85 10 16
http://www.manbw.dk E-mail: manufacturing/copenhagen@manbw.dk
2
For containerships and bulk carriers, the piston overhauls should be based on regular
inspections of the condition through the scavenge air ports, as per the instruction
book, and only pistons which need overhauling according to such inspection should be
pulled.
For tankers where piston overhauls could result in expensive off-hire due to lack of
permission for immobilisation at the tanker terminals, planned overhaul at fixed
intervals, for instance during dockings, is recommended.
For these reasons, we have introduced an overhauling interval instead of a fixed time,
hereby giving the chief engineers the option to pull the pistons when most convenient.
Questions or comments regarding this SL should be directed to our Dept. 2300.
Yours faithfully
MAN B&W Diesel A/S
Ole Grøne Mikael C Jensen
Encl.
MAN B&W Diesel A/S
Guiding Overhaul Intervals
and Expected Service Life
Component Overhauling Expected service Remarks
intervals life in hours,
(in hours) based on
average wear
Cylinder liner 12-16,000 98MC 80,000 Overall cylinder
90MC 80,000 condition to be
80MC 70,000 checked frequently
70MC 70,000 through scavenge
60MC 60,000 ports, preferably
50MC 60,000 once every month
46MC 50,000
42MC 50,000
35MC 50,000
26MC 40,000
Piston rings 12-16,000 12-16,000
Piston crown 12-16,000 Same as for cylinder Pressure test at
liner for the respec- every second piston
tive type overhaul
Rechroming of ring
grooves when need
indicated by meas-
urements, typically at
every second sche-
duled overhaul
Reconditioning of
piston crown by
welding-up is
possible two times
Stuffing box 12-16,000 12-24,000 Renewal of lamellas
Exhaust valve Grinding of seats: 100,000 for Nimonic Originally chrome-
spindle and exhaust valves plated spindle stem
bottom piece 98-70MC may be reconditioned
1) 6,000 2) 16,000 60,000 for austenitic
(cage) by either rechroming
steel spindles
or by HVOF-coating.
60-26MC Reconditioning of
1) 3,000 2) 16,000 seat (hard facing) Originally HVOF-
and possible welding- coated stem or HVOF
1) Initial inspection up of spindle disc reconditioned stem
2) Subsequent inspections underside for auste- will normally not need
nitic steel spindles reconditioning
MAN B&W Diesel A/S 2
Component Overhaul intervals Expected lifetime Remarks
Actuator gear 32,000 hydraulic 64,000
system
Fuel valve 8,000 depending on 8,000 valve nozzle Overhaul, and
fuel quality 16,000 spindle guide replace nozzle every
8,000 hours
Fuel pump 16,000 based on 40,000 renewal or Change sealing rings
plunger and engine observations reconditioning on barrel, plunger
barrel, suction and suction valve
valve and shock
absorber
Cylinder cover 96,000 Check for burned
grooves at fuel valve
nozzle holes. Perform
welding-up if required
Starting valve, 12,000 Total engine lifetime
safety valve and
indicator cock
Cylinder Mechanical lubricator Total engine lifetime Cleaning of oil reser-
lubricator 16,000 voir, filter and pumps.
Checking of timing
and adjustment
Alpha Lubricator Total engine lifetime Accumulators to be
16,000 refilled
Crosshead 6-8,000 (every year) 64,000 crosshead Bearings should only
bearings checking of clearan- bearings be opened up if bea-
Main bearings ces and crankshaft 96,000 main bearings ring material frag-
Crank bearings deflection 96,000 crank bearings ments fall out.
Thrust bearing 96,000 thrust bearing Inspections according
to classification
requirements
Roller guide for 1,500 check Total engine lifetime Check running
fuel pump and condition in situ surfaces and free
exhaust valve rotation of roller
Chains 3-4,000 (every six 96,000
months). Retighte-
ning of chains
MAN B&W Diesel A/S 3
Component Overhaul intervals Expected lifetime Remarks
Chain wheels 3-4,000 visual 96,000 chain wheels First inspections and
and rubber inspection 32,000 guide bars retightening after
guide bars 500, 1,000 and 1,500
hours in total service
Reversing and 3-4,000 checking of Total engine lifetime Pneumatic/hydraulic
regulating gear moving parts governor:
Oil change every
4,000 hours
Tie rods 6-8,000 retightening Total engine lifetime
including (every year)
bracing screws
Holding down 6-8,000 retightening Total engine lifetime
bolts (every year)
Turbocharger Dry cleaning normally According to maker’s See manufacturer’s
once a day. recommendations special recommen-
Manual cleaning and dations
condition check of
nozzle ring, turbine
blades and shroud
ring based on obser-
vations, normally
once a year
Air cooler(s) Cleaning based on 40-50,000 Cleaning before
Air filters engine observations differential pressure
has increased by
50% compared to
sea trial value
Flaps and Check movement at Total engine lifetime
butterfly valves every scavenge port
in scavenge air inspection
receiver
Various fuel and Cleaning based on
lubricating oil engine observations
filters.
Camshaft filters
and TCS filters,
if any
Lubricating oil 16,000 cleaning
bottom tank
2300/PXN/JCB
March 2003
