Goltens received a call from the operator of a nine year old crude oil tanker about damage to one of its three HiMSEN 6H 25/33 diesel generator sets. The engine had recently undergone routine overhaul but during operation, the engine went to overspeed and triggered a shutdown.
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Goltens was engaged by the owner of an offshore supply vessel to upgrade two medium speed engines operating with obsolete Woodward 723Plus controllers.
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Goltens acquired a “serviced” UG15D governor from a governor repair shop claiming to be Woodward authorized. Physically the governor looked like a UG15D however after further inspection was found to be only partially serviced and rebuilt with incorrect parts and worn parts.
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The crew of a nine year old container ship, equipped with a Wartsila 6RT-FLEX82C main engine, observed exhaust gas blow by on cylinder #5 during normal operation and could not increase the load above 35%. The cylinder liner had 22,452 running hours and the crew suspected the cylinder liner was excessively worn and needed to be replaced.
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Goltens received a call from a Nuclear Power Station in upstate New York to perform an inspection on one of their EMD 645-20 Emergency Diesel Backup Generators (EDBG) for Unit 2, one of the two nuclear reactors that generate a combined capacity of 1,907MW power.
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PROJECT EXECUTION: Goltens prepared the detailed installation and chocking plan for class submittal and deployed a team to the site. Upon arrival, the port engine had already been lowered into position and Goltens proceeded to weld the jacking plates in …
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BRIEF The vessel equipped with two variable speed Wartsila 9L20 propulsion engines each driving a propeller and fire pump. Each engine is equipped with a mechanical 3161 governor with pneumatic speed setting, shutdown solenoid and start fuel limiter solenoid. The …
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PLANNING & PREPARATION After surveying the vessel for rigging logistics, Goltens prepared all required lifting brackets and rigging gear at its work shop and reviewed the repair schedule and timeline with the customer. Goltens then mobilized the tools and a …
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Diamond Offshore contracted Goltens Houston to provide complete service maintenance and supervision for two 20,000 hour and three 10,000 hour overhauls on their engines. To minimize operational impact, Goltens technicians worked around the clock in two, twelve hour shifts in …
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LIFTING OPERATIONS Goltens’ diesel team arrived onsite with the most of the engine already disassembled by the powerhouse team. The team removed some remaining components from the engine, removed the foundation bolts from the engine and fit the 4 prefabricated …
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SCOPE OF REPAIR Goltens dispatched a team of Mechanical, Electrical & Instrument and Turbine Control experts to Bangladesh to carry out the scope of work assisted by local mechanics, riggers and fitters. Scope included: Preparation of special tools and replacement …
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Once the gearbox was moved to a safe work area and the gears were secured, Goltens machined the damaged areas on the gear to ready the surface for repair. Technicians then applied selective electroplating to the damaged gear teeth using …
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BRIEF Two generators are dedicated to their respective Port and Starboard busbars, the third having two breakers to allow Port or Starboard feed. A coupler connecting the two busbars is normally closed and can be opened manually. The existing system …
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BRIEF The analogue 2301A LSSC is commonly used on supply vessels such as this, and in many other applications especially where isochronous load sharing between generators is desired. The 2301A was originally designed more than 30 years ago and is …
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3D SCANNING LEVERAGED TO SPEED PROCESS Given the limited availability & questionable accuracy of the engineering data of the existing plant, customer was genuinely concerned about the cost and time needed for performing the upgrade design. To overcome this challenge …
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THE INSPECTION Goltens got the call on Sunday and engineers were on site the next day to evaluate the condition of the shaft and identify a repair method for the damage on the EDBG. Goltens undertook an inspection of main …
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THE RESULT The entire repair was completed inside of 5 days onsite inclusive of waiting and staging. Both sets of slip rings were machined to a surface finish of 1.0Ra in accordance with the manufacturer’s specifications and the turbine generator …
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PROJECT FACTS Description: MAN B&W HUYNDAI 7L23/30H Location: Portugal – US (under voyage)
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TURBINE ROTOR SHAFT REPAIR SCOPE Complete inspection of the rotor shaft including hardness checks, MPI, measurement etc Machining of journal radius/fillets Machining of the shaft journal to undersize 1.00mm Honing and polishing of rotor shaft journal Fabrication of bluing dummy …
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REPAIR RESULTS: Once the engine was rebuilt, Goltens laser aligned the engine and the generator and flushed the lube oil system to clear any debris. The prescribed running in procedures and operational testing were accomplished on voyage after the dry-dock. …
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IN-PLACE MACHINING AND ANNEALING After the tender was awarded, Goltens in-place machinists first machined the crankpin to -4.5mm to remove all surface cracks leaving a hard spot 250mm x 120mm. Goltens then performed the annealing process and reduced the crankshaft …
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THE INSPECTION AND THE PROPOSAL During the inspection, Goltens learned that the engine had suffered the same casualty on the same cylinders 30 years earlier. The block had significant damage to the crankcase near the doors, liner landings and the …
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INSPECTION AND REPAIR PLANNING Goltens diesel experts were asked to inspect the damage and determined that the crankshaft could be salvaged within the rated diameter with in-situ machining and annealing. Crankpin journal number 7 (450mm diameter) and main journals number …
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CRANKSHAFT REPLACEMENT AND REBUILD: Disassembly of engine and rigging of crankshaft from engine room and re-assembled of engine components. Full inspection of crankshaft including MPI test on all journals to ensure no crack Straightening of crankshaft and machining crankpins to …
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Goltens was called to answer these questions, when this nightmare turned reality aboard a 34-year-old rail vehicles carrier. Goltens specialists surveyed the engine and discovered, in addition to the large hole in the engine block, damage to the lower liner-landing …
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