Q2 (16 Marks) Engine Construction & Components 🔥 Repeated 3x in exams
MEKM • Written Exam

(a) Describe, with the aid of sketches, the procedure for cutting out and "hanging-up" an engine cylinder of a two-stroke crosshead engine in the event of complete failure of the crosshead pin such that the crosshead pin cannot be operated and no replacement is immediately available. (12)

(b) State, with reasons, the factors which may inhibit starting and limit the operating speed of the engine with 1 cylinder cut out. (4)

Appeared In: Aug 2026Mar 2024Dec 2022

Verified Model Answer (Text Solution)

Structured for DG Shipping MEO Class II examination scoring criteria.

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Part (a)

If the top end bearing is damaged, the engine must be modified to allow the vessel to limp to port. The primary action is removing the affected cylinder's connecting rod and suspending the piston, thus effectively isolating the seized unit. The following procedure is to be followed:

  • The lower half of the bottom end bearing is secured using a chain block to prevent it from falling into the crankcase during disassembly.
  • The hydraulic nut securing the lower half of the bottom end bearing is opened, and the bearing is carefully removed from the crankcase.
  • The connecting rod is then secured using a chain block.
  • The crosshead is locked in position on the crosshead guide using a dedicated locking tool.
  • The crosshead bearing cap nut is opened.
  • With the engine carefully turned using the turning gear, the connecting rod is slowly lowered and removed from the crankcase. This controlled movement is very important to prevent damage.

Post-Connecting Rod Removal:

Once the connecting rod is removed and piston suspended, the following steps are taken to isolate the affected cylinder and allow continued operation (following the maker's recommendation):

  • The fuel pump for the affected cylinder is disabled by bypassing its cam roller, preventing fuel injection into the disabled cylinder. In the case of an Electronic engine, set the fuel index to Zero (0) from the MOP computer.
  • The exhaust valve is deactivated by lifting its roller off the camshaft using a specialised lifting tool. With the Electronic engine, Disable the exhaust valve operation in the MOP computer. This prevents exhaust gases from escaping into the system from the disabled cylinder, although the cylinder will likely be vented in some other way.
  • The starting air pipe to the cylinder is disconnected and blanked off at the main control air valve, preventing accidental air ingress.
  • The lubricating oil supply to the crosshead of the affected cylinder is blanked off to prevent pressure drop of oil.
  • The cylinder lubricator for the affected unit is set to "zero" delivery to prevent further lubrication of a seized and immobile piston.
Part (b)

Engine Operation under Reduced Load:

  • The damaged cylinder is isolated by suspending the piston and crosshead, removing the connecting rod, and cutting off the unit's combustion. This results in power imbalance and uneven loading on the crankshaft.
  • The absence of power generation in the affected cylinder creates an imbalance in the crankshaft. Operating the engine at a reduced speed minimizes crankshaft deflection and prevents further damage to engine components.
  • With one cylinder out of operation, the engine cannot develop its rated power.
  • It is recommended to reduce the engine speed to 55% MCR (Maximum Continuous Rating), as this is sufficient to manoeuvre the vessel safely while reducing the risk of further damage. The engine load must remain within the manufacturer’s specified limits to avoid overloading the remaining cylinders.
  • Continuous monitoring of parameters such as temperature, pressure, and vibration is essential to detect any abnormal behaviour during operation. Regular checks help ensure the engine’s condition is stable.
  • The engine must be operated strictly within the conditions specified by the manufacturer for Emergency operating conditions.
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