The auxiliary engine (AE) plays a vital role in providing electricity and supporting critical systems on tankers like MT Maritim Indonesia. During operation, the AE operates continuously, requiring regular maintenance, including general overhauls, to ensure optimal performance, maintain efficiency, and minimize downtime.
On the MT Maritim Indonesia vessel, a general overhaul was performed because the engine had reached its factory operating hours and showed several signs of declining performance. This case study describes the work process, findings, and final results of the overhaul.
Component Disassembly
- Remove the cylinder head per cylinder.
- Remove the piston, connecting rod, and piston ring set.
- Remove the cylinder liner for abrasion measurement.
- Remove the rocker arm, camshaft inspection cover, and valve mechanism.
- Remove the fuel injection pump and injectors for internal inspection.
- Remove the lube oil pump and seawater pump.
Technical Measurement & Inspection
- Measuring liner wear: ovality and taper.
- Measuring piston ring groove clearance.
- Checking the main bearing and crankpin bearing for scoring.
- Calibrating the fuel pump and injectors on the test bench.
- Checking valve leaks and seat condition.
- Compression testing after temporary assembly.
Cleaning & Reconditioning
- Cleaning carbon deposits on the piston crown and combustion chamber.
- Chemical cleaning of the coolers (L.O. cooler and SW cooler).
- Lapping the exhaust and intake valves.
- Flushing the lubrication system to remove sludge.
- Cleaning the fuel supply line of deposits.
Replacement Parts
All worn components are replaced with standard manufacturer spare parts:
- Piston ring sets.
- Exhaust valve & intake valve.
- Gaskets & seal kits.
- Main bearing & conrod bearing.
- Injector nozzles.
- Lube oil filter & fuel filter.
Assembly & Commissioning
- Engine testing at various loads: no-load, 25%, 50%, 75%, and 100%.
- Reassembly of all components with torque according to the manual.
- Monitoring oil pressure, coolant temperature, and exhaust gas readings for each cylinder.
- Checking for leaks and vibrations.
- Evaluating fuel efficiency after overhaul.
The general overhaul of the auxiliary engine at MT Maritim Indonesia has proven successful in restoring optimal engine performance. Through detailed inspections, precise measurements, and precise parts replacement, the auxiliary engine now operates more efficiently and reliably.
This case study highlights the critical importance of preventive maintenance, such as general overhauls, to maintaining the continuity and safety of tanker operations.
