Leaflet H.cegiELSKI-SERVICE NEW Reconditioning Dec 2010

8/12/2019 Leaflet H.cegiELSKI-SERVICE NEW Reconditioning Dec 2010

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H. Cegielski SERVICE Sp. z o.o.

n e w s o l u t i o n s - i n v e n t i o n - s e r v i c e se w s o l u t i o n s i n v e n t i o n s e r v i c e s


a p p r o v e d q u a l i t y

r e c o n d i t i o

n i n g

r e c o n d i t i o

n i n g

m o d e r n t e c h n o l o g y

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5 -years

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Piston rods Arc spraying coating (executed without Classi cation Societies certi cate) Crosshead pins

Camshafts other spares from industrial, non-engine, equipment, especially

of big dimensions

Since 2005 H.Cegielski-SERVICE Sp. z o.o. deals with reconditioning, ofmarine and industrial main and relatively quickly used up spares, as anenrichment and supplement of our service offer.

We are entitled to implement such a complicated branch of industry by50-years experience in marine and stationary engine production. It gives us thepossibility of bene t from modern technical background gathered throughyears of engine production as well as possibilities of the execution of sparesaccording to requirements being in force in the past and at present.Such experiences enables us to design and execute process of reconditioningto make used spares after reconditioning be of at least the same quality as newspares.It is known fact that reconditioning, in principle, concerns the repair of surfacesmostly worn as being exposed to the highest loads applied on the engineparts, allows us to design of reconditioning process and materials in such a waythat the new resistance and consequently life time of parts reconditioned byH.Cegielski-SERVICE may be even higher than the new parts.

For cooperation we use the production potential of experienced HCP enginefactory.

Due to above mentioned reasons we have also the possibilities of close cooperation with Class Societies which havea very good conditions for supervision and inspection during reconditioning process.Processes of main elements which technologies shall be authorized by Class Societies are being successively submit-ted for getting the approval of WPQR (Welding Procedure Quali cation Records).

Most important engine parts, which we recondition, require applying of highly specialized Technologies (we do recon-ditioning with supervision of Classi cation Societies, most frequently LR) and which are always delivered with thecerti cate of Classi cation Societies, are as follows:

Cylinder covers Piston crowns Piston rods - Hardfacing

We do also reconditioning of other important engine parts which do not require certi cates of Classi cation Societies(delivery with certi cate of H.Cegielski-SERVICE Sp. z o.o.):

Exhaust valves Exhaust valve seats Air cylinders Guide shoes

We apply following technologies, based on equipment of reputable companies as FST, ESAB, Lorch, Castolin:

Welding, overlay welding and hardfacing with MIG/MAG method Welding and overlay welding with both manual and cold wire TIG welding PTA (Plasma Transfer Arc) cladding using a robot and manipulator, with metal powders AWS (Arc Wire Spray) with different materials FWS (Flame Wire Spray) for different materials from Babbit to Molybdenum SAW overlay welding under ux welding

For welding processes we use carefully selected best materials from proven companies, with all quality certi cates andacceptances gained from Classi cation Societies.Elements after reconditioning are carefully veri ed according to requirements of original technical documentation andrules of engineering art. For properly executed process of reconditioning we do ultrasonic examination (UT) as well asmagnetic-powder (MT) and penetration examinations (PT). In special cases we do initial laboratory tests of real materialof which original part sent for reconditioning is made of.Parts after recondition are supplied with measurement sheets and quality certi cates. H.Cegielski-SERVICE is carryingon Quality Management System according to standards ISO 9001. We are still improving the technical scope eachenquiry is acutely analyzed and agreed with the client.

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2 stro e S E R V I EH. Cegielski SERVICE Sp. z o.o.2 STROKECylinder Cover Reconditioning

H.Cegielski-SERVICE Sp. z o.o. offers more than one scope of reconditioning, which is being applied in respect to realdamages on elements for reconditioning. The advantage to shipowner is such process gives full technical efficiencyof reconditioned element, with the lowest possible cost.

The condition of Cylinder covers delivered for reconditioning to H.Cegielski-SERVICE is always extensively technicallyveri ed due to estimate the required scope of repair, before starting the process of reconditioning. Basing on veri ca-tion, we work the recondition technology out for particular element.

Full scope of reconditioning anticipates the complete removal of surface of combustion chamber down to bottom ofcooling holes, landing surfaces and outer sealing surfaces in o-rings area. Next overlay welding on mentionedsurfaces using various kind of materials, applicable according to temperatures, and thermal loads of working place of

reconditioned surface. The valve seats under exhaust valves, injection, starting and safely valves may be submitted to reconditioning process. The combustion chamber surface is covered with overlay welding with chrome-molybdenum steel, which has appro-priate resistance parameters in high temperatures.

Repair process is always carried on with supervision of Classi cation Society, according to ISO 9001 procedures. The quality of repaired Cylinder cover is subjected to UT, MT, PT examinations and pressure test.

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Cylinder cover after reconditioningand machining.

Combustion chamber prepared toInconel cladding.

Cylinder cover. Combustion chamberafter machining -down to cooling holes.

Combustion chamber day-check beforemachining.

Combustion chamber after overlaywelding.

Damaged combustion chamber.

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We offer various scope of reconditioning, depending on real condition of damages on parts.

Full scope of reconditioning of Piston crown involves the removal the whole capacity of material as: grooves under piston rings bymachining, overlay welding of removed capacity with special Cr-Mo steel, and rebuilding of original shape through machining,groove chromium plating and their grinding.In case the level of damages is smaller, the reconditioning may be limited only to reconditioning of all grooves under piston ringsor only limited to rst upper groove. Such an offer enables to choose the most cost effective reconditioning alternative.

Reconditioning is supervised by the Inspector of Classi cation Society according to ISO 9001 procedures. Where necessary the UT,MT, PT examinations and pressure test are carried on.

SAW overlay welding side surfaceunder Piston rings grooves.

Piston crown prepared for overlaywelding.

Overlay welded surface.SAW overlay welding, bottom part.

Piston crowns after reconditioning.

2stroke2 STROKEPiston Crown Reconditioning

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Arc wire spray on the shaft.

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C EH. Cegielski SERVICE Sp. z o.o.

Piston rods which are being ordered with the certi cate and

approval of Classi cation Society are being reconditioned

with hardfacing. The layer which is put on the surface has the

hardness parameters which conforms harness parameters

after induction hardening applied with new Piston rods

production. There is worth to emphasis that the structure of

layer after hardfacing which are with alloy components

covered, gives the wear resistance of whole hardfaced capac-ity layer if even bigger than new Piston rods which has only

induction hardening.

Applied technology makes the process of hardfacing

adequate to all types of Piston rods, regardless the type of

basic material which the Piston rod is made of.

Reconditioning is supervised by the Inspector of Classi ca-

tion Society. Piston rod after reconditioning is submitted to

MT examination.

Slightly cheaper method of reconditioning of Piston rods is

covering with thermal spraying. This layer has properties in

scope of surface hardness and wear resistance, it has at least of

equal status to layer after induction hardening, applied for new

produced Piston rods.

The Classi cation Society according to own rules does not

certi cate the recondition with thermal spraying method for

engine spares working under dynamic load. That is the reason

why Piston rods reconditioned with thermal spraying methodare being delivered without Classi cation Societies certi cate.

Piston rod after reconditioning is submitted to MT examina-

tion.

stroke2 STROKEPiston Rod Reconditioning

Before reconditioning. Testing of Piston rod.

Piston rod - ready.

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H A R D F A C I N G

M E T H O D

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C EH. Cegielski SERVICE Sp. z o.o.

Examples of other reconditioned parts, both engineand no engine, industrial parts.H.Cegielski-SERVICE Sp. z o.o. carries also the reconditioning of no-engine parts and elements. Each case is deeply analyzed.

Depending on applicable technology and type of basic material H.Cegielski-SERVICE prepares an adequate technology. Each case

is subjected to separate individual offer, when required with additional communication with the client.

H.Cegielski-SERVICE Sp. z o.o. implemented also the recondition technology of crosshead pins with hardfacing method. Applied

hardfacing method makes it possible to execute the layer with better hardness and wear parameters than new Crosshead pin. Such

layer is mating even better with crosshead bearing. Recondition, under supervision of Inspector from Classi cation Society is

applicable for all kinds of material which Crosshead bearings are made of. After hardfacing the surface of Crosshead pin is submitted

to grinding and super nish which leads to gain parameters about at least roughness level as at new produced Crosshead pins.

Crosshead pins after reconditioning are submitted to MT examination.

stro e2 STROKECrosshead Pin Reconditioning

Reconditioned Crosshead pin.

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Exhaust valve before repair example 1. Exhaust valve after reconditioning.

Exhaust valve before repair - example 2. Exhaust valve after reconditioning.

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Reconditioned exhaust valve.

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Air cylinder molybdenum coating.

Exhaust valve seat after reconditioning.Exhaust valve seat before repair.

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Rudder shaft cone coupling in theprocess of reconditioning.

High pressure pump crankshaftmolybdenum coating.

High pressure pump crankshaft aftermolybdenum coating.


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n e w s o l u t i o n s - i n v e n t i o n - s e r v i c e se w s o l u t i o n s i n v e n t i o n s e r v i c e s

H. Cegielski SERVICE Sp. z o.o.ul. 28 Czerwca 1956r. nr 223/229

61-485 Pozna / Polandtel: +48 61 831 12 61, 15-93

fax: +48 61 831 15 91mail: [email protected]

i h l

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Leaflet H.cegiELSKI-SERVICE NEW Reconditioning Dec 2010

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