维修展示
海洋船舶柴油机运转时的应急抢险维修

维修详情

2)活塞组件拆出,十字头和连杆留在机内

如果是活塞、气缸盖或气缸裂纹或损坏而无法修复使用,但连杆和十字头尚能正常工作,则必须拆掉活塞组件(含填料函),并采取下列措施:

提起喷油泵滚轮停止泵油;

弯流扫气者用专用工具封住气缸套排气口,直流扫气者或四冲程柴油机将气阀锁住

在正常关闭位置;

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用专用工具封住活塞杆填料函孔;

在十字头上安装专用封盖;

Marine marine diesel engine when running emergency repair

First, seal cylinders of diesel engine running

Diesel engine running if one or more of the moment by faulty cylinder cannot be repaired, you can stop it

Measure of cylinder runs with disabilities, that seal cylinder to run.

1, cylinder runs three scenarios and solutions

(1) stop the cylinder oil ignition

If you have a cylinder fails, such as system failure, valves, cylinder leak bitten to death, which simply make the cylinder not firing and moving parts can still be running. In such cases, according to the specific circumstances of diesel engine injection pump wheel may be instituted, causes the fuel pump to stop working or open Injector valve back, to stop the fuel injected into the cylinder. But avoid close the import and export of fuel injection pump valve, resulting in dry grinding of injection pump coupling were bitten to death. Run or also known as reduction of such cylinder cylinder cylinder runs.

If it is a DC two-stroke diesel engine, while stopping injection, exhaust valve should also be locked in open position, in order to reduce the consumption of piston compression work.

(2) remove piston Kit, cross head and Rod stay inside the machine

If the piston, cylinder head or cylinder crack or damage that cannot be repaired, but link and crosshead is still functioning, you must remove piston Kit (including stuffing), and to take the following measures:

① lift the wheel stops for fuel pump pump oil;

② Bend flow scanning close cylinder exhaust gas with special tools, uniflow scavenging or four-stroke diesel engines valve locks

In the normal closed position;

③ seal piston rod stuffing holes with special tools;

④ cross head is installed on dedicated the cover;

⑤ enclosed piston cooling system;

⑥ disassemble the cylinder valve controlled air tube and seal;

⑦ Remove cylinder Starter starting air valve pipe and seal;

⑧ close cylinder cooling water imports and exports of the cylinder valve;

Issues to minimize the cylinder cylinder injection tubing;

⑩ piston Kit remove then reinstall cylinder head.

(3) piston, connecting rod, cross head all split out

If connecting rod, severely damaged cross head or guides, bearing damage, you need to remove all the moving parts. In addition to taking the second of these measures, also need to take the following measures:

① oil hole in the crank pins in the clamp closed;

② close crosshead lubrication system.

, A 2 cylinder closure operation of emergency treatment

Should, as appropriate, reduce the running speed of diesel engine cylinder run time, you can select the appropriate speed to maintain navigation according to the following principles:

① cylinder exhaust temperatures exceeding the calibration value is not allowed;

② exhaust gas turbocharger surge does not occur;

③ the abnormal vibration of a hull or body does not occur;

④ minimize the starting number.

Second, stop supercharger of diesel engine running

Supercharger in diesel engine run damage (such as fracture of bearing burning, Blade, etc) and cannot be repaired, you diesel engines should go

Stopped into the supercharger emergency runs. Turbocharger technology for treatment of failure (such as locking hinges, or hanging out the hinge), while diesel recovery operation as soon as possible.

1 stop, four-stroke diesel engine turbocharger running

Stops turbocharger running the equivalent of four-stroke diesel engine non-turbo-charged diesel engine. Rely on the piston's suction effect at this time, you can still complete the breath stroke, diesel engines can still be functioning. But because of its cylinder charging significantly reduced, running power and speed will drop significantly.

If you need long-term operation, you should increase the compression ratio compression pressure to lower exhaust temperature; adjust valve timing, reduced valve overlap angle down so as not to waste gas flushing; suitable reducing valve clearances in order to avoid stem impact.

2 run stopped, two-stroke diesel engine supercharger

When the two-stroke diesel engine supercharger runtime itself gas exchange process could not be completed and cannot be run. Measures taken vary depending on model. Such as Sulzer RTA, and emergency measures were taken by the MAN-B&WL-MC model:

① starting electric auxiliary blower;

② turbocharger shaft fixed at both ends using the special tools, such as emergency operation takes a long time, you should pull the rotor and

Cover seal turbocharger shell at both ends;

③ removed from the exhaust by-pass pipe closed under blind Board, allows exhaust gas bypass to the chimney.

Three, diesel engine cylinder

1, pull cylinders phenomenon, causes and signs before scuffing

See the 6th page.

2, when the cylinder of emergency treatment

① early when a cylinder is found to be first of all increase the amount of oil cylinder lubricating oil. If overheating has not changed, you can take single cylinder

Stop oil, reduce speed, strengthen piston cooling measures, until the heat eliminated.

② When the cylinder is detected, must be rapidly reducing speed, and then stop. Continue to increase the piston cooling, while turning.

But do not strengthen the cylinder cooled, otherwise it will exacerbate cylinder, making accidents more deterioration.

③ When Pistons bitten to death do not allow such as turning, piston cooling after a period of time, and then turning to activities.

④ When more serious when Pistons bitten to death, kerosene can be pumped into the cylinder, piston cooling after move the handwheel or disk

Car. If the Pistons still not action, lifting bolt can be mounted on a crane on top of piston a piston. When lifting edge into kerosene, beat Pistons top edges with a soft metal rod, slowly lifting piston to prevent lifting bolt pull off or lifting screw hole broach bad.

⑤ lifting cylinder inspection, piston and cylinder liner should be traces on the surface of the cylinder with oil stone Grind. Damaged piston rings

Shall be renewed, if the Pistons and cylinder was badly damaged and should be replaced.

⑥ When Pistons refitted, you must carefully check the oiling hole on the cylinder oil is normal. If the Pistons and cylinder sleeves are for

New, refitted after break-in, break-in began from the low load when loading and continuous operation.

Cannot be repaired ⑦ cylinder accident or when not allowed to fix, take the cylinders approach continues to run.

Four, diesel engine knocking

1, knocking phenomenon

Diesel engines have a rule at run time is not normal or abnormal sound of knocking, a phenomenon known as knocking.

2, knocking causes

(1) causes combustion knocking

① premature fuel injection timing, average increase in pressure growth and maximum explosion pressure;

② the injector nozzle needle valve is stuck in the open position of oil spills;

③ Injector spring break and oil spills;

④ Injector spring loose, Kai valve pressure drops, spray oil in advance;

⑤ overstretched the cylinder, fuel injection quantity is too large;

⑥ the poor combustion of the fuel, ignition delay.

(2) causes of mechanical knocking

Pneumatic cylinder upper mechanical knocking causes are:

① first came across the upper part of the cylinder liner wear of piston rings;

② the centerline of piston connecting rod and the crankshaft centre line is not vertical, the piston to a tilt movements;

③ slap caused by eccentric wear of crank pin bearings.

Central mechanical knocking cylinder causes are:

① four-stroke diesel engine piston pin clearance is too large;

② the four-stroke diesel engine piston and cylinder gap is too large;

③ severe wear of the cylinder liner.

Cylinder lower mechanical knocking causes are:

① crosshead bearing clearance is too large;

② cross head slider and guide clearance is too large;

③ connecting rod bearing or bearing clearance is too large;

④ the main moving parts of the bolt.

3, knocking of emergency treatment

① to pressure test the injectors and adjust them if necessary to get a new;

② Check fuel pump fuel delivery and, if necessary, to adjust their effective travel;

③ check and adjust the fuel injection timing.

Five, diesel engines scavenging box fire

1, scavenging box fire causes

Scavenging box fire must have two conditions: first, scavenge boxes within the accumulation of large amounts of fuel; the second is a high temperature

Ignition source exists.

2, scavenging box ignition and preventive measures

Sweep gas box fire, its phenomenon performance for row smoke temperature increased, and sweep temperatures degrees improve, and chimney risk black smoke, and sweep gas box overheating, and open sweep gas box placed release cock check Shi has smoke or sparks spray out; diesel engine speed automatically declined; and the cylinder connected of booster Manager occurs asthma vibration; sweep gas box fire Shi due to pressure temperature sharp rise occurs sweep gas box explosion makes safety valve takeoff.

Preventive measures include:

① Open the relief valve scavenging box on a regular basis, residual oil drain;

② periodically check the clean sweep gas space and avoid accumulating too much oil scavenge space;

③ in part load, reduce the amount of oil cylinder injection;

④ control the sweep of normal temperature;

⑤ to avoid long periods of low-speed running, will result in bad Burns;

⑥ avoid overload operation, overload increased wear and tear and gas leaks;

⑦ When a big storm reduced engine speed to avoid loading mutations range is too large;

⑧ the correct adjustment of atomization of the fuel injector status;

Issues fuel injector fuel injection timing correctly;

⑩ periodically checks the status of piston rings, piston rings to wear, break up and stick replaced in a timely manner.

3, scavenging box ignition of emergency treatment

① first of all reduce the speed of the diesel engine, ignition cylinder and cut off the fuel supply;

② If the fire was serious, you can slow down or stop immediately, extinguishing measures taken;

③ steam fire or carbon dioxide fire extinguishing;

④ Jet sweeps the air box shell with warm water, if necessary, reduce the temperature;

⑤ ignition cylinder due to increase of volume of lube oil, ensure adequate lubrication within cylinders;

⑥ should stop checking the fire has gone out.

Six, diesel engine crankcase explosion

1, crankcase explosion causes

① become deflagration within the crankcase oil mist concentration mixing ratio are basic requirements for explosion;

② high-temperature heat source exists are decisive factors in the explosion.

2, crankcase explosion prevention

① to avoid heat sources in the diesel engine;

② installed oil mist concentration detector in diesel engine;

③ take crankcase, ventilation;

④ on the exhaust side of the crankcase cover fitted with explosion-proof door.

3, emergency treatment

① If there is signs of explosion hazard, should immediately stop running or spin down, spin down after generator should load conversion games

Line. If the generator stopped, comes with lubricating oil pump and cooling water pump will stop, but easy to just stop crankcase explosion occurred.

② When they discover a crankcase explosion dangerous during the cabin crew are not allowed in the side of diesel engines fitted with explosion-proof door stop

To avoid casualties.

③ When the explosion occurred in the crankcase and explosion-proof valve after sitting, to take immediate measures, but not immediately opening song

Axle box door or manhole fire.

④ If due to certain parts of the crankcase heating, parking, parking 15min at least, and then clear the door checking to avoid fresh air

After tank exploded.

⑤ fire extinguishing installation within the crankcase on the crank shaft tube into which carbon dioxide of carbon dioxide.

Seven, diesel engine chimneys sparkling

1, chimney sparkling causes

① oil mist formed by combustion sparks;

② oil residue formed by combustion of sparks;

③ soot formed by sediment burning sparks.

2 prevention measures, chimney, sparkling

① keep in-cylinder combustion in diesel engine in good condition;

② strengthened cylinder combustion process monitoring, timely detection of irregularities;

③ strengthening the management of exhaust boiler, maintains good combustion results;

④ to select proper carbon removal by chemicals such as agent;

⑤ to guarantee the safety of oil tankers, chimney equipped with sprinkler devices, preventing chimney sparkling.

3, emergency treatment

① If there is spark in this category, should immediately reduce the load of diesel engines or slowly stop;

② If this class two or three sparks in environmental conditions should be allowed to continue "blowing risk", in the exhaust system

Oily sediments blow out as much as possible, burn.

③ do not use fire-fighting equipment easily, particularly carbon dioxide fire extinguishing equipment in order to prevent high-temperature metal explosion due to temperature sharply reduced.

Eight, diesel engine connecting-rod bolt fracture

1, check of the connecting rod bolts

① check for defects using a magnifying glass or the naked eye, especially check the bolt head, rib and rib root.

② tooth gauge and ruler check the pitch and bending of rib.

③ nut loaded, see if its too loose to check the wear of ribbing, especially to check the nut and bolt head and

Bearing contact surface is uniform contact lamination is good.

④ bolts with wire rope hanging together, Bishop beat, with new bolts compared their sound to identify the defect-free and

Degree of fatigue.

⑤ bolts on the bearing, loose in the following two and a half hole for Fay, bearing cap displacement due to centrifugal force, will enable

Bolts subjected to shearing force role. If upper and lower bearing joints exposed hundreds of alloys, when a bolt is installed it to find, or Burr hole edge, easy to make bolt bitten to death.

⑥ check connecting rod bolt and bolt hole clearance, not too tight.

⑦ check whether the PIN is loose or worn.

⑧ tightening nut when you insert a split pin, split pin is contact with the upper surface of the nut should be checked.

Issues measure the total length of the connecting rod bolt to check its elongation.

⑩ medium following the life of a four-stroke engine connecting rod bolts about 15 000~20 000 hours. Over this time,

Even though the appearance is also should be renewed.

Considerations 2, tighten the connecting rod bolt

① You must keep the gasket and bearing joint surface clean, ensuring their full access.

② General almost no tightening bolts fastening State of insufficient, excessive ground bolts to fatigue, is not secure.

③ on either side of the connecting rod bolt must alternate

封闭活塞冷却系统;

拆下气缸起动阀控制空气管并封住;

拆下气缸起动阀起动空气管并封住;

关闭该缸气缸冷却水的进出口阀;

该缸气缸油注油管减至最小;

活塞组件拆除后重新安装气缸盖。

3)活塞、连杆、十字头全部拆出

如果连杆、十字头或导板严重损坏、轴承损坏,则需拆除全部运动部件。此时除采取上述第二种措施外,还需采取下列措施:

用夹具封闭曲柄销上的油孔;

封闭十字头润滑系统。

2、封缸运行的应急处理

封缸运行时应酌情降低柴油机的运行转速,可按以下原则选择适宜的转速维持航行:

各缸排气温度不允许超过标定值;

废气涡轮增压器不发生喘振;

船体或机体不发生异常振动;

尽量减少起动次数。

二、柴油机停增压器运转

柴油机运行中如增压器损坏(如轴承烧毁、叶片断裂等)而无法修复,则柴油机应转

入停增压器紧急运行。此时应对故障增压器进行技术处理(如锁住转轴或吊出转轴),同时尽快使柴油机恢复运转。

1、四冲程柴油机的停增压器运行

四冲程柴油机停增压器运行时相当于非增压柴油机。此时依靠活塞的吸排作用,仍可完成换气冲程,因而柴油机尚可运转。但因其气缸充气量大幅度降低,运转功率和转速会明显下降。

如需长期运转,则应增大压缩比提高压缩压力以降低排气温度;适当调整气阀正时,减少气阀重迭角以免废气倒冲;适当减小气阀间隙以免阀杆撞击。

2、二冲程柴油机的停增压器运行

当二冲程柴油机停增压器运行时,本身无法完成换气过程,因而无法运转。采取的措施因机型而异。如Sulzer RTAMAN-B&WL-MC机型所采取的应急措施是:

起动电动辅助鼓风机;

使用专用工具将增压器转轴两端固定,如应急运转时间很长,则应拉出转子并用专

用盖板封住增压器壳体两端;

从排气旁通管上拆下封闭盲板,使排气旁通到烟囱。

三、柴油机拉缸

1、拉缸现象、原因及拉缸前的征兆

见第6页。

2、拉缸时的应急处理

早期发现拉缸时应首先加大气缸滑油的注油量。如过热现象没有改变,可采取单缸

停油、降低转速、加强活塞冷却等措施,直到过热消除为止。

当发现拉缸时,必须迅速降低转速,然后停车。继续增加活塞冷却,同时进行盘车。

但此时切勿加强气缸冷却,否则会使拉缸加剧,使事故更恶化。

如因活塞咬死而不能盘车时,可待活塞冷却一段时间后,再盘车使之活动。

当活塞咬死的情况比较严重时,可向气缸内注入煤油,待活塞冷却后撬动飞轮或盘

车。如活塞仍不能动作时,可将起吊螺栓装在活塞顶上用吊车吊出活塞。起吊时应边注入煤油,边用软金属棒敲打活塞顶,慢慢吊出活塞,防止起吊螺栓拉断或起吊螺孔拉坏。

吊缸检查时,应将活塞与缸套表面上的拉缸痕迹用油石打磨平整。损坏的活塞环必

须换新,若活塞和缸套损坏严重,应予换新。

活塞装复时,必须仔细检查气缸上的各注油孔注油是否正常。若活塞和气缸套均换

新,则在装复后应进行磨合,磨合时应从低负荷开始逐渐加负荷并连续运转。

如拉缸事故不能修复或不允许修复时,可采取封缸的办法继续运行。

四、柴油机敲缸

1、敲缸现象

柴油机在运行时产生有规律的不正常异音或敲击声,这种现象称为敲缸。

2、敲缸的原因

1)燃烧敲缸的原因

燃油喷射时间过早,使平均压力增长率和最高爆发压力增高;

喷油器的喷嘴针阀在开启位置卡住发生漏油;

喷油器弹簧断裂而漏油;

喷油器弹簧松动,启阀压力下降,喷油提前;

该缸超负荷运转,喷油量过大;

所用燃油的燃烧性能差,发火滞后。

2)机械敲缸的原因

气缸上部机械敲缸的原因有:

第一道活塞环碰到气缸套上部的磨台;

活塞连杆中心线与曲轴中心线不垂直,使活塞有倾斜运动;

曲柄销轴承的偏磨引起活塞敲击声。

气缸中部机械敲缸的原因有:

四冲程柴油机活塞销间隙过大;

四冲程柴油机活塞与气缸套间隙过大;

气缸套严重磨损。

气缸下部机械敲缸的原因有:

十字头轴承间隙过大;

十字头滑块与导板间隙过大;

连杆轴承或主轴承间隙过大;

主要运动部件的螺栓松动。

3、敲缸时的应急处理

对喷油器进行试压和调整,必要时予以换新;

检查喷油泵的供油量,必要时调整其有效行程;

检查和调整喷油定时。

五、柴油机扫气箱着火

1、扫气箱着火的原因

扫气箱着火必须同时具备两个条件:一是扫气箱内积聚有大量的可燃物;二是有高温

火源的存在。

2、扫气箱着火的现象和预防措施

扫气箱着火,其现象表现为排烟温度增加、扫气温度提高、烟囱冒黑烟、扫气箱过热、打开扫气箱放泄考克检查时有烟或火花喷出;柴油机转速自动下降;与该缸相连的增压器发生喘振;扫气箱着火时因压力温度急剧升高发生扫气箱爆炸使安全阀起跳。

预防措施有:

定期打开扫气箱的排放阀,放泄残油;

定期检查清洁扫气空间,避免扫气空间内积聚油污过多;

在部分负荷时,减少气缸油的注入量;

控制好正常的扫气温度;

避免长时间的低速运行,将造成不良燃烧;

避免超负荷运行,超负荷加剧磨损和燃气泄漏;

在大风浪时降低柴油机的转速,避免负荷突变的范围过大;

正确调整喷油器的雾化状态;

正确调整喷油器的喷油定时;

定期检查活塞环的状态,对磨损、断裂和粘住的活塞环及时更换。

3、扫气箱着火的应急处理

首先降低柴油机的转速,并切断着火气缸的燃油供应;

如火势严重,可立即减速或停车,采取灭火措施;

采用蒸汽灭火或二氧化碳灭火;

必要时用温水喷洒扫气箱外壳,降低温度;

适当加大着火气缸的滑油注油量,保证缸内充分润滑;

火熄灭后应停车检查。

六、柴油机曲轴箱爆炸

1、曲轴箱爆炸的原因

曲轴箱内油雾浓度达到可爆燃的混合比是爆炸的基本条件;

高温热源的存在是爆炸的决定性因素。

2、曲轴箱爆炸的预防

尽量避免使柴油机出现热源;

在柴油机上装设油雾浓度检测器;

采取曲轴箱, 通风措施;

在曲轴箱的排气侧盖上装有防爆门。

3、应急处理

如发现有爆炸危险的征兆,应立即停车或降速运行,发电机应在转换负荷后降速运

行。如果发电机停车,自带的滑油泵和冷却水泵也会停泵,反而容易在刚停车时发生曲轴箱爆炸。

在发现曲轴箱有爆炸危险期间,机舱人员不允许在柴油机的装有防爆门的一侧停

留,以免造成人员伤亡。

当曲轴箱发生爆炸并将防爆门冲开以后,要立即采取灭火措施,但不可马上打开曲

轴箱道门或检查孔救火。

如因曲轴箱内某些机件发热而停车,至少停车15min后再开道门检查,以免新鲜空

气进入后引起爆炸。

曲轴箱内部的灭火采用装设在曲轴上的二氧化碳管系把二氧化碳冲入其中。

七、柴油机烟囱冒火

1、烟囱冒火的原因

油雾燃烧所形成的火花;

残油燃烧所形成的火花;

烟灰沉积物燃烧所形成的火花。

2、烟囱冒火的预防措施

使柴油机气缸内的燃烧保持良好状态;

加强对各缸燃烧过程的监控,及时发现不正常情况;

加强废气锅炉的管理,保持良好的燃烧效果;

选用合适的除碳剂等化学品;

为保证油轮的安全,烟囱内装有喷水灭火装置,防止烟囱冒火。

3、应急处理

若出现这一类火花,应立即降低柴油机负荷或慢慢停车;

若出现这二、三类火花,在环境允许的条件下应让其继续“喷冒”,使排气系统内

的油性沉积物尽量吹掉、烧尽。

③不要轻易使用灭火设备,特别是二氧化碳灭火设备,以防止高温金属因温度急剧降低而产生爆炸。

八、柴油机连杆螺栓断裂

1、对连杆螺栓的检查

使用放大镜或肉眼检查有无缺陷,特别要注意检查螺栓的头部、罗纹与罗纹根部。

用牙规和直尺检查罗纹的螺距和弯曲情况。

装上螺帽,看其是否过松来检查罗纹的磨损情况,尤其是要检查螺帽和螺栓头部与

轴承的接触面是否均匀接触,贴合是否好。

将螺栓用丝绳吊起来,用手锤敲打,与新的螺栓比较它们的声音来判别有无缺陷和

疲劳程度。

螺栓若在轴承上、下两半紧配处的孔中松动,则轴承盖由于离心力而位移,就会使

螺栓受到剪切力的作用。若上下轴承合缝处露出百合金,则在安装螺栓时会将其挤出来,或者由于孔边缘有毛刺,易使螺栓咬死。

检查连杆螺栓与螺栓孔的配合间隙,不可过紧。

检查定位销是否松动或磨损。

上紧螺帽插入开口销时,应检查开口销是否与螺帽上表面接触。

测量连杆螺栓的总长以检查其伸长量。

中型以下的四冲程发动机连杆螺栓的寿命约为15 00020 000小时。超过此时间,

即使外表上无异状也应换新。

2、上紧连杆螺栓的注意事项

必须保持垫片和轴承上下结合面的清洁,确保其完全接触。

一般螺栓的紧固状态几乎没有上紧不足的,过度地上紧螺栓将使其疲劳,并不安全。

两侧的连杆螺栓必须交替上紧而不要造成单边紧固。应顺次增大力量同时又交替地

上紧。上紧的适当,则螺栓的伸长量是一定的。