Onboard Engine Care

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the optimum Solution

Onboard maintenance package for LNG vessels caSe Story:

cuStomer: Knutsen oaS Shipping, norway

detailS: • 2 LNG vessels • 4 Wärtsilä 50DF engines onboard each ship• Total of 45 cylinder liners • Already have VSL and DGL onboard, as these were delivered with the engines.

The two LNG vessels from operates in the North and South Pacific oceans with a busy schedule.

As it is difficult to bring these vessels ashore for maintenance, it is important to Knutsen OAS, that the crew is able to maintain the 4 Wärtsilä 50DF engines with safe and efficient machines in order to avoid engine failure.

With the onboard maintenance package from Chris-Marine, Knutsen OAS has purchased the optimal tools for recitifying liners, spindles and seats in order to secure that both vessels can fulfill their duties with their engines running smoothly. Knutson’s benefits of the purchase is: • The crew can respond fast to break downs • They become independent of workshops• The investment is paid back after just 2 overhauls

purchaSed productS:BSP-2 Electrically driven valve spindle grinding machine with pre-set angles for easy operation.

75H High precision grinding tool for valves on high and medium speed engines.

hon SRestoration of cylinder liners according to engine makers’ specifications.

VRL Combined machining for in-situ machining of valve seats and seat recesses.

WR Safe working rig for overhaul of cylinder covers and valve cages.

Application Area Name 2-stroke 4-stroke

Cleaning Equipment

Spray Washing Machines SWM X X

Ultrasonic Cleaners Ultrasonic 130 Twin / 1000

X X

Fuel Injectors

Fuel injector test unit VPUD SV X X

Fuel injector test rig adaptor PPMI 1000-4 X X

Cylinder Liners

Loosening of bolts hpu X X

Remove piston ring upre X X

Wear edge removal VKS X

Honing or deglazing hon X X

Surface roughness measurement Srm X X

Spindles & Seats

Valve seat machining VSL X

Valve spindle grinding 75H X X

Monitoring Portfolio

Monitor purifier performance FAR X X

Measure coating thickness ctm X

Monitor Liner Condition ldm X

Monitor Liner Condition dec X

Service & Training tSa X X

The Optimum Solution for Onboard Engine CareChris-Marine® & IOP Marine offer ship owners and managers complete overhaul and maintenance solutions for the main- and auxiliary diesel and gas-engines onboard their vessels, thereby giving them the opportunity to secure continuous engine operation by using one global supplier.

We are continuously developing new solutions, products and specialist services worldwide to support ship owners and their crew in keeping their vessels’ engines run smoothly and without costly break-downs.

PATENTED ULTRASONIC EFFICIENCyThe Ultrasonic onboard cleaning tanks offer a customized solution to the onboard cleaning requirements of the marine industry.

reduce maintenance coStSThe patented frequency sweep maximizes the ultrasonic efficiency, and helps to reduce the cleaning time, thus saving both time and money as a result of the fast and efficient cleaning.

The specially designed stainless steel work baskets are included for optimal cleaning and protection of smaller engine parts, such as injector nozzles, lube oil filters and fuel pump parts that can be cleaned without damag-ing the fine elements. The thoroughly cleaned engine parts perform better and lasts longer.

Specifications Ultrasonic 130 twin Ultrasonic 1000Dimensions 84 x 80 x 70 cm 100 x 100 x 100

External control panel yes yes

Cleaning tanks 2 1

No. of work baskets 3 1

Typical Usage Small and fragile parts, e.g.injectors and filters larger parts, engine parts, larger filters

ExTEND LIFETIME OF CLEANED ENGINE PARTS

Tested in cooperation with leading fuel injector specialists.

Superior Engine Parts Cleaning

HEAVy DUTy SPRAy WASHING - SWMFront loading single stage aqua spray washers for aqueous clean-ing of small and medium sized components, when a single stage heated cleaning process is enough to fulfill the cleanliness requirements.

The spray wash machines provide excellent cleaning results thanks to a smart design used together with high spray pressures and liquid flow rates achieved by the built in pump.

The spray system rotates around a fixed load giving a perfect cleaning result together with a very easy loading- and unloading system.

In order to work effectively on engine parts, they need to be thoroughly cleaned to remove scale, oil deposits and rust.

To meet the increasing need for suitable washing solutions, IOP Marine & Chris-Marine have introduced both single stage aqua spray washers for overall cleaning of engine parts as well as advanced ultrasonic cleaners that will reach every orifice.

cleaning equipment

The Injector SafeTest technology developed for correct testing of slide-valve fuel injectors has evolved into a new generation of digital fuel injector testers designed for easier and more efficient onboard maintenance of 2- and 4-stroke engine fuel injectors. The guiding system ensures a much easier way to verify details critical to the actual injector performance and prevents insertion of injectors that previously would have caused excessive fuel consumption, higher emission and engine fouling, thus improving the fuel efficiency.

The system simplifies correct execution of all required test-steps, provides precise and consistent data collection and eliminates the risk of injector damage.

The below example is based on a spindle guide for a MAN 7S60MC:

Ensure Optimal Fuel Injector PerformanceWhen a fuel injector performs less than optimal it can start opening at the wrong time as well as leak fuel before or after injection. This results in unnecessary fuel consumption and engine maintenance.

The patented IOP Marine Safe Test Technology installed in our onboard test units enables any engine crew member to evaluate and calibrate the state of the injectors that will power the vessel for the months to come.

FUEL INjECTOR TEST UNIT - VPUD 1100 SV

PPMI 1000-4

REDUCE EMISSIONS & ENGINE FOULING

reduce maintenance coStS

TEST RIG ADAPTER.

MAN spindle guide: 1200 Euro

Test rig adaptor paid back after: 3 damaged injectors

Complete Test rig paid back after: 9 damaged injectors

Approved & Recommended by

MAN Diesel & Wärtsilä

For 2- and 4-stroke engines.

• Features IOP SafeTest Technology• Ensures optimal fuel injector performance• Helps to avoid unnecessary fuel consumption and particle emissions• Operator guiding system to eliminate the possibility of human errors• Test both M/E and A/E

• Can be fitted to an IOP Marine or 3rd party fuel injector test rig. • Features the patented IOP SafeTest Technology • Helps avoid unnecessary fuel consumption and particle emissions• Ensures optimal fuel injector performance

FUEL INjECTOR TESTING

Reduce Lub Oil ConsumptionCylinder liners in poor condition in terms of ovality, bore polished surface and an unnecessary high cylinder liner oil lubrication feed result in reduced performance and increased lub oil consumption.

Most engine makers recommend honing to be carried out prior to exchange of piston rings. Continuous running will increase the lube oil consumption and in the worst cases cause blow by, broken piston rings or piston seizure.

With cylinder liner maintenance machines permanently available in the machine room onboard the vessel, it is always possible to carry out the maintenance in-situ.

INCREASE THE LIFETIME OF yOUR CyLINDER LINER

BENEFITS OF LINER MAINTENANCEThe Chris-Marine cylinder liner maintenance products provides our customers with a range of benefits regarding economy and safety, as it:

• Minimizes the lub-oil consumption and increases the service life of cylinder liners and piston rings. • Reduces cylinder liner wear and thus generates significant savings in the operation cost. • Minimizes the risk of blow-by • Easy to operate, even for un-skilled crew members

Short paybacK timeReconditioning the liners onboard not only saves the costs of removing the liners and sending them ashore for honing, but significantly reduces lubrication oil consumption resulting in cost savings and quick payback time.

When maintaining your liners, you not only reduce future liner- and piston ring wear and increase their life-time, but also reduce engine fouling and problems related to blow-by eliminating the need to “over-lubricate” and keeps the cylinder liner running costs at minimum.

Case: MAN 12K98ME-C7, running HFO at 3% sulphurTypical lube oil consumption, actual SFOC 1 g/kwh -> 0,86 tonnes/day

MAN recommended lube oil consumption 0,6 g/kwh -> 0,52 tonnes/day

Average lube oil price 1000 $/tonnes

POSSIBLE SAVINGS

Reduced lube oil 0,34 tonnes/day -> 340$/day

ROI Chris Marine honing machine 61.000 $ -> 0,49 year

ROI Chris Marine honing job 50.000 $ -> 0,4 year

*Source: MAN Catalogue: http://viewer.zmags.com/publication/f8a9bf2e#/f8a9bf2e/1

liner maintenance

By using our reliable Hydraulic Power Units (HPU) with hoses and couplings you will loosen the stud bolts fast, efficiently and in a safe way. After assembling all parts, we secure everything with the HPU according to the engine manufacturer’s specifications. Approved and recommended by the major engine builders!

Step-by-Step procedure for cylinder liner maintenance

For safe and fast removal of wear edges, we recommend the portable wear edge milling machine VKS that shortens piston pulling time and saves piston rings and liner.

Perform deglazing or honing in accordance with the manufacturer’s specification using the por-table deglazing machine DGL or the portable honing machine HON S.

When investing in a cylinder liner maintenance machine from Chris-Marine, we will guide you towards the correct honing heads and shafts, the different ceramic stones for coarse and plate honing and the correct gearbox for you to achieve the optimal cross pattern, as well as all other necesessary accessories for your specific engine model.

During the honing operation, we strongly recommend our Surface Roughness Measuring device to measure the liner in order for you to be well aware of the condition during and after the operation.

By using the device frequently, you will know when you have achieved the correct surface profile according to the engine manufacturer’s specification, and avoids removing more material than needed.

A complete cylinder liner overhaul has now been performed, which will extend its lifetime and save lubrication oil, and there has been created a good running-in surface of the piston rings.

LOOSEN THE BOLTS WITH HPU

SUPERIOR OVERHAUL FOR ExTENDED LINER LIFETIME COMPLETED!

ENSURE CORRECT SURFACE PROFILE WITH SRM

hone or deglaze to reStore the liner

REMOVE WEAR EDGES WITH VKS

Since Chris-Marine supplies all relevant equipment and data,

you do not require a skilled engineer to perform proper honing.

REMOVE THE PISTON RING WITH UPRELoosen the piston rings safely by using the Unistress Piston Ring Expander, which creates a uniform bending moment throughout the ring.

liner maintenance

Optimize valve seats and spindles

• Up to 6 times faster than traditional grinding machines• Simple to use• Eliminates the risk of mistakes• Not sensitive regarding vibrations.

VALVE SEAT LATHE - VSL• Simple to use with template for correct angle.• High precision and efficient grinding with specially designed grinding wheels. • Cost effective - is used together with existing lathe onboard

Today’s diesel engines are exposed to significant loads, and it is therefore important that the valves and valve seats’ sealing surfaces are carefully rectified to provide a tight seal.

At Chris-Marine, our continuous cooperation with companies such as MAN and Wärtsilä results in customized solutions that ensure easy operation for the onboard crew.

One cylinder head can be completed within 10-15 minutes.

SAVE MAINTENANCE COSTS

Based on a Wärtsilä 46 main engine and Wärsilä 32 auxiliary engines

= 82 cylinder heads

Approx cost for ashore service: € 1.200 / cylinder head

Workshop cost 22 cyl.heads: € 26.400

C-M machines for spindles/seats € 17.055

Save 1st year: € 9.345

GENERAL BENEFITS:

VALVE SPINDLE GRINDER - 75H

• The machines are paid in full after approx. 1-2 overhauls• The machines are easy to operate as they are pre-set prior to delivery. Service is therefore easily done by the existing crew.

SeatS & SpindleS

MONITOR PURIFIER PERFORMANCE TO IMPROVE THE FUEL SySTEM

monitor liner condition

Considerable savings can be made through regular condition monitoring of the combustion chamber in 4-stroke engines. Broken or worn out piston rings, excessive liner wear or worn valve seats lead to greatly increased lube oil consumption and can escalate to engine failures if not discovered in time. Such problems are easily detected by the DEC-TESTER from Chris-Marine.

DEC-TESTER

ldmThe LDM allows you to avoid unplanned off-hire and reduce overhauling costs through continual monitoring of the cylinder condition in 2-stroke engines. The tool also makes it possible to do a pre-inspection of the cylinder condition before a piston overhaul to minimize downtime and cost.

• Innovative measuring tool for 500 - 980 mm bore 2-stroke cylinder liners • Safe, fast and accurate measuring of cylinder liner wear and clover-leafing• No need to remove cylinder head prior to measurement• Important tool in condition-based monitoring of the cylinder condition

EFFICIENT CONDITION MONITORING

Major engine designers conclude that cat fines contribute to increased wear and engine failures for a large number of vessels operating on HFO. These situations can be avoided though proper operation of the on-board fuel treatment plant with the Chris-Marine Fuel Analyzer.

The Fuel Analyzer makes it possible for customers to lower costs for off-hire and minimizes disturbance of operations and emergency repair. Maintenance costs are lowered through less engine wear and tear.

Chris-Marine can offer complete Fuel Analyzer packages including pre-inspection, equipment supply, installation, commissioning, service and technical support.

• Ideal for condition based monitoring of piston rings in 2-stroke engines.• Measures non-magnetic coatings on magnetic base materials, such as chromium plated or plasma coated cast iron.

The piston ring coating serves as protection against cylinder scuffing. Without coating, the risk for cylinder scuffing or high cylinder wear rate increases. Cylinder scuffing means high repair costs and costly operational disturbance (often paid on the fuel bill). Regular CTM monitoring of coated piston rings is a pre-requisite for safe piston condition monitoring.

ctm

coating thicKneSS meaSurement tool

Ensure correct overhaul time with condition-based monitoring

MONITORING PORTFOLIO

TSA - Professional product training and support

IN-SITU INSTALLATIONSAmong the specific service assistance are:• Cylinder liner maintenance• Grinding of gas and water sealing surfaces• Milling of O-ring grooves• Machining on engine frame• Grinding of fuel pumpt and fuel valves• Machining or grinding of valves, valve seats and landing surfaces• Machining of sealing surface on propeller blades• Testing and calibration of fuel injectors

educationTraining courses can be conducted at the Chris-Marine service centres around the world, or at the customer’s own premises. Authentic engine parts are used so that the most efficient working methods can be established.

SIP-INSTALLATIONS - HANS jENSEN LUBRICATORSThe SIP valve is designed to place the lube oil directly where it is most needed: on the upper cylinder liner wall, where most wear takes place. As it is compatible with all 2-stroke diesel engines, the SIP valve is ideal for both retrofits and new vessels.

The Chris-Marine service team is certified for selling and carrying out installation of Hj Lubricators SIP-valves and for preparation of cylinder liners for SIP-valves. For SIP II systems, this can be done without pulling out the liner on MAN Diesel and Wärtsilä engines.

Installation time varies in most cases between one and five days, depending on engine type.

Training at MAN Primeserv Shanghai.

© MAN PrimeServ Shanghai

The Technical Support and Applications (TSA) crew is always standing by to support you, remotely or at your site (in-situ) wherever you are. TSA can offer: • Training, service and technical support for Chris-Marine and IOP Marine machines• Rental agreements for Chris-Marine and IOP Marine machines, optionally including service engineer(s) • Installation services for own and partner’s equipment From our workshops in Sweden, Denmark, Singapore and China we dispatch personnel and/or machines to your vessel, workshop or power plant no later than 24 hours after your call.

Authorized for service on

Uson equipment!

TRAINING & SERVICE

caSe Story:

cuStomer: TeeKay Tankers, U.S.A. detailS: • Teekay Tankers owns a fleet of: 13 Aframax tankers, 10 Suezmax tankers, 10 Product tankers Products purchased: • 20 pcs fuel injector test rig “ VPUD 1000” • 25 pcs fuel injector test rig adaptor “PPMI 1000-4” • Engines include: MAN 5S70MC, MAN 6S70MC, MAN 7S70MC

TeeKay Tankers performed fleetwise replacement of fuel injector testers on all their vessels equipped with MAN slide fuel valves in order to eliminate risk of operator failure and optimize the onboard testing and calibration of fuel valves.

Almost half of the fleet’s test rigs were replaced with the VPUD 1000 as their previous test rigs did not meet the company’s requirements, while the rest were upgraded with the digital adaptor box.

The main reasons for the purchase of the IOP Marine products were to: • improve fuel injector performance • eliminate the risk of human errors. • ease the process of injector testing

PPMI 1000-4 Upgrades existing test rigs and 3rd party test rigs to the same safe test technology as the VPUD 1000.

VPUD 1000 • Approved and Recommended by MAN Diesel for safe testing of slide valves. • OEM product• Patented technology safe test system• Optional testing of auxiliary engines• Patented guiding system to assist the operator in the step-by-step testing of fuel injectors

purchaSed productS:

Fleetwise replacement of fuel injector test units

SOLUTIONS FOR THE FUTUREFor five decades we have designed, manufactured and sold maintenance machines for diesel engines. Today these machines are world-renowned for being operator friendly and of high quality. Now and since the 1960's, quality, reliability and usability remain to be our key trademarks.

We are constantly growing and are represented with offices worldwide and well-equipped workshops in Singapore, Shanghai, Bahamas and Denmark.A close cooperation with local agents also helps us to serve our customers independent of their location.

WELL EDUCATED AND DEDICATED STAFF 130 well educated men and women worldwide are working to improve our products and services. They are constantly increasing the quality, the hallmarks of Chris-Marine® and IOP Marine.

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SwEdENChris-Marine ABStenyxegatan 3PO Box 9025SE-200 39 MalmöTel: +46 - 40 671 2600Fax: +46 - 40 671 2699info@chris-marine.com

dENMARKIOP Marine A/Sengager 7DK-2605 BrøndbyTel: +45 - 4498 3833Fax: +45- 4498 1125contact@iopmarine.dk

SINGAPOREChris-Marine (S) Pte. Ltd.46 Lokyang Way, jurongSingapore 628646Tel: +65 - 6268 8611Fax: +65 - 6264 3932chrism@chris-marine.com.sg

P.R. OF CHINAChris-Marine Trading (Shanghai) Co,. Ltd. Room 311, No.1 Building, No.288 Wu Hua Road, Shanghai 200086Tel: +86 - 21 6575 9331 Fax: +86 - 21 6575 9552info.cn@chris-marine.com

INdIAChris-Marine Rep Office IndiaPlot No. 1/1, Vikas ApartmentTrimurty Nagar, Ring RoadNagpur-440022, MaharashtraTel: +91 - 712 224 6902info.in@chris-marine.com

JAPAN IOP & Chris-Marine japan OfficeKobe Kokusai Kaikan 22 Fl., 8-1-6 Goko-doriChuo-ku, Kobe, 651-0087Tel: +81 - 78 570 5642 Fax: +81 - 78 570 5601info.jp@chris-marine.com

ECUAdORChris-Marine Rep Office Ecuador Amazonas 14-192 y pasaje 2,San Rafael, Quito Ecuador, South America. Tel.no: +593 979 000 379info.ec@chris-marine.com

THE OPTIMUM SOLUTION FOR ONBOARD ENGINE CARE