MAIN ENGINE DECARB PREPARATION, PROCEDURE & COMMISSIONING

Sumit Narayan

What is Decarbonization ?
Removal of the accumulation of carbon from cylinder heads and valve gear, pistons and rings,
allowing the inspection of the liner. Decarbonization is an important part of the maintenance of main
engine. Carried out after every 10000 running hours as a repair work, process can be down in less
span, if there is a major problem in the engine. One engine overhaul unit takes a time span of around
12 to 14 hours. So this process is conducted only when sufficient time is there and that too when
engine is not running.

Preparation
The chief engineer is the person who decides what has to be done in the ship machinery and tells the
second engineer to implement the process. The second engineer is the sole and master of this whole
process and he or she will be the one who will decide what we have to do in the whole process.
Various types of tools which will be used while carrying out the whole work is assembled at one
position. What person will do what type of job are assigned by the second engineer only and this
avoids any type of confusion during the time of overhauling of the engine.

Now when the ship comes to halt like port or the dry dock. The designated engine staff comes to the
engine room and they are ready to do the process. Bridge is informed before carrying out this process
as it would be dangerous if they are not informed and they gave the power to start the engine.

1. Make sure the all stand by auxiliary engines are ready

2. Keep all the special tools and other tools ready
3. Go through the previous records/manual for clearance and adjustments
4. Put the display card "MEN AT WORK", "DON'T START"
5. Close air bottle valve to auxiliary engine and engine start and stop valve
6. See that the turning bar is not in the flywheel and should be in place
7. Open the indicator cocks
8. If the main bearing is to be removed, check crank shaft deflections
9. Close lube oil, fuel oil, fresh water inlet/outlet valve, drain the cooling water line and remove
connections

The list of the faults which were noted when the engine was running is also taken out and stick at a
place so that everyone is aware what we have to do and what are the tools which are needed in this
process.

Now the engine staff engages the turning gear. The main purpose of the engaging of the turning gear
is that you will not experience the turning of shaft due to turning of propeller which may happen due to
the currents of water.

The whole unit which is to be dismantled is isolated from each system like the fuel, water cooling, lube
cooling etc.

Procedure:

Removal of cylinder head

1. Scavenge manifold, exhaust manifold rocker arm, lube oil drain connection from rocker arm,
rocker arm tank and cover connection to be removed
2. Fuel oil high pressure connection from fuel pump to the injector, fuel valve cooling connections
in and out (either diesel or water) to be removed
3. Remove the rocker arm assembly and the push rod. Remove all the mountings such as
starting valve, indicator cock, relief valve and exhaust valve assembly
 4. Remove the rocker cover and check any marking on cylinder head nuts and studs. If no torque
spanner is available, note down the markings.
5. Open the cylinder head nut with box spanner and extension rod. Never use the torque
spanner. With box spanner available note down the marking .
6. Put the cylinder head lifting tool and before lifting make sure all the connections are removed.
Also ensure that the liner is not removed along with the cylinder head.

Removal of piston and connecting rod

1. After lifting the head, check the liner surface for score marks, blow past etc. Crack remove the
ridges or deposits if any on the top surface to avoid the lifting of liner along with the piston and
breakage of piston rings while lifting piston
2. Open the crank case door and remove the bottom end bearing bolts after removing the lock
arrangement and the remove the bolts
3. Remove the bottom half of the bottom end bearing
4. Bring the piston to TDC. Make sure the bolt holes on the piston top, lifting tool holes must be
cleared from carbon deposits. Threads should also be checked and cleared
5. Put the piston lifting tools and tighten the bolts
6. Lift the piston and remove top shell of bottom end bearing
7. Place the piston on the piston stand and cover the crankcase pin to avoid the foreign material
damaging the crank-pin.

Removal of piston and connecting rod

1. After lifting the head, check the liner surface for score marks, blow past etc. Crack remove the
ridges or deposits if any on the top surface to avoid the lifting of liner along with the piston and
breakage of piston rings while lifting piston
2. Open the crank case door and remove the bottom end bearing bolts after removing the lock
arrangement and the remove the bolts
3. Remove the bottom half of the bottom end bearing
4. Bring the piston to TDC. Make sure the bolt holes on the piston top, lifting tool holes must be
cleared from carbon deposits. Threads should also be checked and cleared
5. Put the piston lifting tools and tighten the bolts
6. Lift the piston and remove top shell of bottom end bearing
7. Place the piston on the piston stand and cover the crankcase pin to avoid the foreign material
damaging the crank-pin.

Things to be checked:
1) The piston crown is checked and cleaned to remove carbon.

2) The piston ring groves are also cleaned to remove carbon.

3) The inlet and outlet valves are also checked for the carbon deposits.

4) The fuel injector nozzle is also checked for carbon deposits.

5) The stuffing box is also cleaned if any carbon deposits are there.

6) Calibration of liner diameter. The diameter of the liner decreases as wear down take places
between engine liner and the piston.

7) Checking the clearances of the piston rings.

8) Fuel injector is checked.

9) Stuffing box sealing rings are checked.

Recommissioning:
1. First put the piston rings one by one and measure the butt clearance for all the rings
 2. Then measure the axial clearance between piston rings & grooves
3. Place the piston guide on top of the liner and bring the particular crank shaft to TDC. Apply
sufficient lube oil and start lowering the piston. Make sure that butt gap should not be in line it
may cause blow past
4. Before engaging check the crankpin for any cracks or scratch
5. Check the bottom end bearing clearance and if needed measure the main bearing clearance
as well
6. Taper clearance is checked
7. Check for any cracks in the water jacket and in the cylinder head
8. Replace all rubber joints and copper gasket to be put on the cylinder cover
9. Put the cylinder head gasket in the top of the cylinder
10. Anti-seizure coating or powder like molycote, copper slip should be used. It is applied to avoid
any seizure mainly on the threads or joints and it will be easier while removal
11. Tighten the cylinder mounting according to torque specified as in manual and make all
connection like lube oil, fuel, jacket cooling water connections etc
12. Fit the rocker arm back

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