轮机维护与修理 英文版PDF电子书下载

Chapter 1 Failure and Maintenance 1

1.1 Failure 1

1.1.1 Introduction of Failure 1

1.1.2 Failure Classification 2

1.1.3 Frequency of Failure 4

1.1.4 Human Error in Shipping 6

1.2 Maintenance 7

1.2.1 Corrective Maintenance 8

1.2.2 Scheduled Maintenance 9

1.2.3 Predictive Maintenance 10

1.2.4 Reliability 11

1.2.5 Maintainability 13

1.2.6 Reliability-Centered Maintenance(RCM) 14

1.3 Ship's Maintenance and Survey Systems 16

1.3.1 Ship Control 16

1.3.2 Port State Control 16

1.3.3 Classification Society 18

1.3.4 Planned Maintenance Survey System(PMS) 22

1.3.5 CWBT 23

1.3.6 Near-Miss Activity 25

Chapter 2 Tribology 28

2.1 Tribology 28

2.1.1 Definition of Tribology 28

2.1.2 Tribological System 28

2.2 Friction 29

2.2.1 Structure of Surfaces 30

2.2.2 Surface Texture 31

2.2.3 Origins of Friction 33

2.3 Wear 35

2.3.1 Basic Concepts 35

2.3.2 Basic Wear Process 37

2.3.3 Running-in 38

2.3.4 Wear Mechanisms 39

2.4 Lubrication 44

2.4.1 Stribeck Curve 44

2.4.2 Fluid Film Lubrication 45

2.4.3 Elastohydrodynamic Lubrication 46

2.4.4 Boundary Lubrication 47

2.4.5 Mixed Film Lubrication 49

2.5 Lubricant 49

2.5.1 Functions of Lubricants 50

2.5.2 Important Properties of Lubricants 50

2.5.3 Additives 52

2.5.4 Classifications of Lubricating Oil 55

2.5.5 Solid Lubricants 57

2.6 Cylinder Lubrication 58

2.6.1 Friction of Piston Skirt and Piston Rings Against the Cylinder Liner 58

2.6.2 Cylinder Lubrication 62

2.6.3 Running-in of Liners and Rings 63

2.7 Sleeve Bearing Lubrication 64

2.7.1 Plain Bearing's Lubrication 64

2.7.2 Wear and Failure Modes in Plain Bearings 64

Chapter 3 Corrosion 66

3.1 Introduction 66

3.1.1 Definition 66

3.1.2 Classification of Corrosion 66

3.1.3 Corrosion Rate 67

3.2 Hot Corrosion 68

3.3 Electrochemical Corrosion 68

3.3.1 Electrochemical Corrosion Theory 68

3.3.2 Various Types of Corrosion 70

3.4 Control of Corrosion 72

3.4.1 Conditioning the Metal 72

3.4.2 Conditioning the Corrosive Environment 72

3.4.3 Electrochemical Control 73

3.5 Cavitation 74

3.5.1 Cavitation of Cylinder Liners 74

3.5.2 Cavitation of Propeller 76

3.5.3 Cavitation in a Journal Bearing and Fuel Oil Injection System 77

Chapter 4 Fatigue Failure 78

4.1 Introduction 78

4.2 Characteristics of Fatigue Fracture Surfaces 78

4.3 Nature of the Fatigue Process 79

4.4 Recognition of Fatigue Failure 81

4.5 Cyclic Stresses 82

4.5.1 Fatigue Loading 82

4.5.2 The S-N Curve 83

4.5.3 Stress Concentration Factor 84

4.5.4 Notch Sensitivity Factor 85

4.6 Factors Affecting Fatigue Life 85

4.7 Preventing Fatigue Failure 86

4.8 Thermal Fatigue 87

4.9 Crankshaft Fatigue Failures 88

Chapter 5 Defect Detection and Fault Diagnostics 90

5.1 Defect Detection 90

5.1.1 Common Testing Methods 90

5.1.2 Nondestructive Testing 92

5.2 Machine Condition Monitoring and Faults Diagnosis 106

5.2.1 Introduction 106

5.2.2 Temperature Measurement Techniques 107

5.2.3 Oil Analysis 108

5.2.4 Performance Trending 121

5.2.5 Vibration Analysis 124

Chapter 6 Repairing Technologies 127

6.1 Electroplating 127

6.1.1 Introduction of Electroplating 127

6.1.2 Procedure of Electroplating 129

6.1.3 Typical Electroplating 131

6.1.4 Brush Plating 135

6.2 Thermal Spray Coating 136

6.2.1 Definition of Thermal Spray 136

6.2.2 Process of Thermal Spray 137

6.2.3 Classification of Thermal Spray Coating 139

6.2.4 Applications of Thermal Spray Coating 139

6.3 Welding 141

6.3.1 Introduction 141

6.3.2 Surfacing 142

6.3.3 Welding Technologies 146

6.3.4 Welding of Cast Iron 148

6.3.5 Soldering and Brazing 151

6.4 Metal Stitching 152

6.4.1 Introduction 152

6.4.2 Metal Stitching Process 152

6.4.3 Locks and Pins 154

6.4.4 Advantages of the Repair by Metal Stitching 155

6.5 Adhesion 156

6.5.1Organic Adhesives 156

6.5.2 Inorganic Adhesives 159

6.6 Shot Peening 160

Chapter 7 Ship Repair 161

7.1 Types of Ship Repair 161

7.2 Drydocking 162

7.2.1 Types of Dock 162

7.2.2 Machinery Overhauls and Repairs During Drydocking 164

7.3 Dismantling Techniques 165

7.3.1 Fundamental Rules of Dismantling 165

7.3.2 Hydraulic Tools 166

7.3.3 Removing Seized Nuts and Bolts 168

7.4 Mechanical and Chemical Cleaning 170

7.4.1 Mechanical Cleaning 170

7.4.2 Chemical Cleaning 170

7.4.3 System Flushing 172

7.5 Mooring Test and Sea Trial 175

7.5.1 Mooring Test 175

7.5.2 Sea Trial 177

Chapter 8 Overhauling and Maintenance of Marine Diesel Engine 179

8.1 Cylinder Head 179

8.1.1 Inspecting and Repairing of Cylinder Head Cracking 179

8.1.2 Inspecting and Repairing of Exhaust Valve 181

8.2 Cylinder Liner 183

8.2.1 Introducrion 183

8.2.2 Excessive Worn of Liners 184

8.2.3 Scored Cylinder Liners 188

8.2.4 Cracked Liners 189

8.2.5 Scuffing of Liners 190

8.3 Piston 190

8.3.1 Piston Wear 190

8.3.2 Piston Crown Burning 193

8.3.3 Piston Crown Crack 193

8.3.4 Reconditioning of Pistons 194

8.4 Piston Ring 195

8.4.1 Piston Ring Materials and Coatings 195

8.4.2 Wear of Piston Rings 196

8.4.3 Sticking 198

8.4.4 Breakage/Collapse 199

8.4.5 Blow-by 201

8.4.6 Low Piston Ring Tension 201

8.4.7 Scavenge Port Inspection 203

8.4.8 Replacement of Piston Rings 205

8.5 Crankshaft 207

8.5.1 Crankshaft Alignment 208

8.5.2 Crankshaft Failures 215

8.6 Bearing 219

8.6.1 Classifications of Bearing 219

8.6.2 Materials and Structure of Bearing 220

8.6.3 Journal Bearing Failures,Causes and Repairing Technologies 223

8.6.4 Repairing Journal Bearings 226

8.6.5 Installation and Checking 227

8.7 Precision Couplings 230

8.7.1 Plunger and Barrel Assembly 230

8.7.2 Delivery Valve and Seat 231

8.7.3 Fuel Injector 232

8.7.4 Repair Strategies and Storage for Precision Couplings 237

8.8 Turbocharger 238

8.8.1 Turbocharger Construction 238

8.8.2 Corrosion of the Casing 239

8.8.3 Overhauling of the Bearing 240

8.8.4 Overhauling of the Blades 242

8.8.5 Overhauling of the Sealing 243

8.8.6 Dismantling and Alignment 244

8.8.7 Dynamic Balancing of the Rotator 247

8.8.8 Temporary Measures When Turbocharger Is Damaged 253

Chapter 9 Ship's Shafting 255

9.1 Introduction of Ship's Shafting 255

9.1.1 Shafting Components 255

9.1.2 Arrangement of Shafting 256

9.1.3 Establishing Shaft Centerline 256

9.2 Stern Tube Arrangement 257

9.2.1 Stern Tube 257

9.2.2 Water-Lubricated Stern Tube Bearing 258

9.2.3 Oil-Lubricated Stern Tube Bearing 262

9.2.4 Sealing Arrangements 264

9.3 Shafts and Bearings 268

9.3.1 Intermediate Shaft 268

9.3.2 Intermediate Bearings 269

9.3.3 Thrust Bearings 269

9.4 Propeller 271

9.4.1 Propeller Geometry and Terminologies 271

9.4.2 Materials for Marine Propeller 273

9.4.3 Propeller Types 274

9.4.4 Propeller Mounting 276

9.4.5 Failures of Propeller 278

9.4.6 Methods of Repair 280

9.4.7 Testing and Measurement 283

9.5 Shaft Alignment 285

9.5.1 Types of Misalignment 285

9.5.2 Shaft Alignment Procedure 286

9.5.3 Sag and Gap 287

9.5.4 Sighting Through 290

9.5.5 Slope Boring/Bearing Inclination 292

9.5.6 Engine Bedplate Pre-sagging 295

9.5.7 Jack-up Method 295

9.5.8 Strain Gauge Method 298

9.5.9 Alignment Optimization 300

9.5.10 Reverse Shafting Alignment Calculation of the Bearing Offsets 302