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We currently have two Napier turbochargers in for

We currently have two Napier turbochargers in for overhaul from a locomotive engine. ⠀
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One is an HP200 INT and the other is an HP211. ⠀
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You can see from the image that the left and right bank compressor wheels are different. ⠀
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These would create different boost pressures which, as they are on the same engine is not ideal. During the overhaul, we will rectify this so they will both provide the same boost pressure, ensuring the smooth running of the engine.⠀
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#Locomotive #napier #turbocharger

We recently completed the overhaul of a Baudouin P

We recently completed the overhaul of a Baudouin P15 pump engine, and when it came to the 24hr FAT (Factory acceptance test) we noted something worrying, leading us to perform an RCA.⠀
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There were no issues to start, with the engine test being carried out as usual:⠀
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* Engine installed onto testbed and all connections were made⠀
* The engine was then primed by turning the engine over⠀
* All rocker covers were removed, and it was checked that oil was at the rocker gear. - - This was noted and the rocker covers were replaced⠀
* The engine was then run with no load for 2 hours so the engine could be checked for operation and leaks⠀
* After 2 hours the engine was running as it should and the panels were showing expected readings.⠀
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The load was increased to 100% before being brought back down to 80% after confirmation all ok at 100%.⠀
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* All engine temperatures were recorded as normal⠀
* Oil was recorded at the top of the engine in the rocker gear⠀
* No abnormal noises or vibrations were noted⠀
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After several hours running at 1800rpm @ 335hp, with good temperatures, the oil pressure was reported @ 98psi before settling at 90psi*. ⠀
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*The manual states it should be between 50 and 60 psi.⠀
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The load was taken off and the engine was run down to idle speed and shut down. Once cooled the fluids were drained, ready for investigation work to commence.⠀
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We then carried out an RCA, covering all possible causes including:⠀
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* The engine oil circulating pump⠀
* The cooler⠀
* The filters⠀
* Big end and main bearings (as a precautionary measure only to check for any damage from the oil pressure increase)⠀
* Pressure relief valve – set to operate at 5.5bar of pressure. (This valve did not trip as the pressure was recorded at 98psi, this would point to the pressure issue being located before this point in the circuit.)⠀
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With all possible components checked and ruled out, we asked the operator to send through engine running logs from previous onsite 12-hour performance test runs, so we could compare the running data, and see if the oil lubricating pump was standard 50 – 60 psi operating pressure.⠀
See comment...

Our senior machinist Gary has been using his skill

Our senior machinist Gary has been using his skills and our in-house machining capabilities to manufacture these obsolete crankcase door replacements for a marine operator.⠀
#machining #engineering #marine

We were recently on a vessel carrying out some ser

We were recently on a vessel carrying out some servicing and repair operations on a Caterpillar 3208 engine, and one of the tasks was to clean the engine mounted gearbox oil cooler.⠀
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Whilst we were doing that, we found that on the entry port the sacrificial anode was no longer in place, having travelled into the cooler and restricting the water flow.⠀
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This transmission oil cooler is located at the rear of the engine above the gearbox and is mounted in such a way that the oil in and out ports are both at the same height - halfway up the cooler.⠀
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As a result, any oil remaining inside the cooler when the engine has stopped drains back to the gearbox down to the level of the ports on the side. ⠀
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When the engineers removed the cooler from the engine, approximately 120 ml was drained from it, but as the gearbox contained nearly 8 litres of oil, any oil remaining in the cooler would have little effect on the oil level in the gearbox. ⠀
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Once the work was completed, we checked the oil level read as LOW, and the engine was run. (The operator’s manual for the gearbox states that when cold, the level should be on the low mark on the dipstick.)⠀
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After the initial run of the engine, the gearbox was topped up.⠀
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During that run, we heard a noise at regular intervals for 15-20 seconds and then the gearbox would run quietly - as you might imagine the client was quite concerned that there was now a new issue with the gearbox!⠀
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Our engineers recorded the engine running; whilst making the noise the output shaft was stationery and when the gearbox was quiet, the shaft was turning. This would indicate an issue with moving in/out of gear.⠀
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Click here to hear the cause of concern: https://buff.ly/350lYuc⠀
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The recording was sent to the local agents for the gearbox for their opinion and we received confirmation that the noises heard from the marine gear are consistent with noises experienced in the past with this application.⠀
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They also advised that when at, or near, low idle and in neutral, the vibratory torque from the engine may exceed the light transmitted torque load on the gear teeth in the transmission.⠀
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See comment for the rest of the post...

We are currently building 4 x ABB VTC254 turbochar

We are currently building 4 x ABB VTC254 turbochargers in our Colchester workshop, they certainly look happy to be here, check out the one on the bottom left!⠀
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#ABB #turbocharger #turbo #engineering

The fuel pump has now been fitted on this Baudouin

The fuel pump has now been fitted on this Baudouin P15, as have the new custom fuel pipes that were manufactured in-house. Next step - spill timing.⠀
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#baudouin #spilltiming #overhaul

As you might know, we’ve got multiple ex-Wartsil

As you might know, we’ve got multiple ex-Wartsila Senior Service Engineers on the Bartech team.⠀
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And as a result, we’ve got some fascinating case studies showing how issues experienced on-site can be resolved or prevented on various engine types.⠀
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During planned maintenance on one of the first Wartsila dual-fuel 9L 50DF engines, our engineer came across a very unusual issue that – at the time – had never been recorded before.⠀
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The discovery was made after the field service engineering team had removed all the pistons from the engine and started to remove the shim from each big end bearing upper cap.⠀
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On removal of the shim, signs of cavitation were found on the bearing block lube oil cooling galleries, visible in the picture attached.⠀
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What made this case unique was that this was localised cavitation, with nothing visible on the shim (attached), so a full RCA was carried out.⠀
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The root cause analysis established the diameter of the central hole on the bearing caps was too small and this was creating a harmonic pulsation of the lube oil pressure from the driven pump.⠀
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All big end bearing caps were manually machined to remove the cavitation and a new type of bearing cap shim with a larger diameter was installed.⠀
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A further inspection was carried out after 8000 running hours and no signs of cavitation were noted.⠀
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If you have an engine – Wartsila or other – that will benefit from this level of technical knowledge, get in touch we’d be happy to assist. Call +44 (0)1206 673101.⠀
#Wartsila #Marine #Engineering

We’ve overhauled this Baudouin P15 coolant pump

Andy our governor specialist is busy working on UG

Andy our governor specialist is busy working on UGA and PG-EG overhauls in the governor bay this week.⠀
#woodward #governor #overhaul

We have recently completed the overhaul of a 1970’s Napier MS90 turbocharger, and I wanted to share how it’s possible to save money and keep your older equipment running safely and reliably for longer.⠀
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During the inspection and strip-down of the turbo, we found evidence of a failed labyrinth seal and bushes.⠀
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These seals and bushes required replacing, but are unfortunately now obsolete. ⠀
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This could have led to the need for a replacement turbocharger, something you don’t want to hear when your kit is only in for an overhaul!⠀
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Fortunately for the operator, using the old ones used for patterns alongside 15 years of making engine parts, our senior machinist Gary made replacements in-house to OEM spec, which allowed the overhaul to be completed, in time and on budget.⠀
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We have specialist knowledge of out of production engines, meaning we are able to offer solutions others can’t.⠀
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Before you settle for replacing your engine or assembly, let us know and we’ll be happy to help.⠀
#engines #turbos #heritage

Inspection, clean and rebuild of 12 Bergen 12KVG c

Inspection, clean and rebuild of 12 Bergen 12KVG cylinder heads and rocker gear in the workshop.⠀
#bergen #oilandgas #offshore

Our engineers were offsite this weekend carrying o

Our engineers were offsite this weekend carrying out routine maintenance, ensuring the reliability of this MTU 16V4000G63.⠀
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#mtu #weekendwork #powergeneration

Woodward PG-EG hydraulic-powered electric actuator

Woodward PG-EG hydraulic-powered electric actuator in the governor bay on test before overhaul.⠀
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#woodward #actuator #governorspecialists

You probably saw our post earlier this week showin

You probably saw our post earlier this week showing a John Deere emergency fire pump engine in our workshop that needed urgent attention.⠀
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The water hose had failed (which is a common fault on these engines), so the operator called in their service company for a replacement.⠀
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The hose and thermostat were replaced as expected, but no other investigation was carried out on the engine before it was run again.⠀
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After less than 30 seconds, the unit had to be shut down due to a severe knocking noise. And when the attending engineer took a look at the engine discolouration, he could see a full overhaul was required. ⠀
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Unfortunately, they couldn’t fit this in for at least a month, so – due to the urgency of the work – we were called in.⠀
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Our engineers were quickly on-site, found water in the oil and suspected a hydraulic piston. The engine wouldn’t bar over and they were amazed that the conrod hadn’t ejected itself out of the side of the crankcase!⠀
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The engine is now at our workshop and is undergoing a full and thorough overhaul to ensure it can be relied upon again and is back on-site ASAP.⠀
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As you can see from the pictures above, the operator had avoided a catastrophic failure – two of the conrods had reached such a high temperature they had melted and one of the pistons had seized completely.⠀
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You can also see the damage caused to the pushrod which was moments from disaster.⠀
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Gary, our senior machinist is measuring the case and e bores to ensure they have not warped and can be re-used. If not, we will machine them as long as they will remain within OEM tolerances.⠀
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Along with the complete overhaul, we’ll be retrofitting a water level indicator to the existing gauge panel for clearer visibility and reliable monitoring to alert if this type of issue occurs again.⠀
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What started as a simple issue, went from hose replacement to full overhaul, and narrowly avoided the need for a replacement engine.⠀
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I just wanted to highlight how easy it is for something like this to happen, and ask you to check your monitoring systems: would you benefit from additional indicators for your critical diesel engine?

As part of the overhaul of a Dorman 6PTCR engine,

As part of the overhaul of a Dorman 6PTCR engine, this Bosch fuel pump has been disassembled and inspected. ⠀
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We found erosion to the back of the pump caused by the plunger and barrel being inserted the wrong way previously!⠀
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A new body has been sourced for the rebuild.⠀
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#bosch #fuelpump #overhaul

We are carrying out an emergency overhaul in the w

We are carrying out an emergency overhaul in the workshop at the moment on this John Deere emergency fire pump engine for a power station. More info coming next week…⠀
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#johndeere #emergency #power #engineering

Thanks to @RedBoxTools for supplying us with this

Thanks to @RedBoxTools for supplying us with this great new kit for our offsite support engineers – just booking in the last couple of sockets!⠀
#redboxtools #engineering #support

We are currently overhauling a Napier MS90 turboch

We are currently overhauling a Napier MS90 turbocharger from a marine operator’s Mirrlees Blackstone engine.⠀
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The engine has just over 12.5k hours on the clock and is in good condition, however, the turbo was on the radar as needing some attention.⠀
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Once our engineers had removed it and sent it to the workshop, the overhaul started with the usual inspection, dismantle and clean.⠀
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As part of the overhaul, we knew the labyrinth seals and bushes would require replacing. ⠀
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These replacements are becoming harder to source due to the rarity of the turbocharger, so to ensure we are in a position to offer you continued support for them, Gary, our machinist designed and manufactured our own version to matching specification.⠀
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We don’t have the history of this turbocharger, but what is apparent is the result of the engine spending a significant amount of time idling – excessive carbon build-up.⠀
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Luckily, this operator is aware of this and the issues prolonged idling can cause, so they are proactive in preventing unplanned downtime and costly repairs.⠀
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Do you have an engine that often runs idling for extended periods? ⠀
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If you do and would like us to check it over for you, let me know, we’d be happy to help.⠀
#marine #turbocharger #maintenance

2 Napier and 1 ABB turbocharger fully overhauled f

2 Napier and 1 ABB turbocharger fully overhauled for a locomotive operator and ready to go.⠀
#napier #abb #turbocharger #locomotive

One of our values is continuous improvement, and l

One of our values is continuous improvement, and last week our engineers were increasing their governor knowledge with dedicated in house training…⠀
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#training #engineers #governors

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An amazing video we wanted to share from Marine Insight.

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Here to keep your critical engines running in 2 easy steps during COVID-19 outbreak

Call 01206 645070 anytime to speak to an engineer to help you resolve issues yourself. This is a free service, intended to minimise downtime and stop the need for a visit
If things cannot be resolved on the video call, our service engineering team are ready to attend your site. They are home based with stocked vehicles ready to deploy.

All our usual support is still available on the general number and email address

How we can support you at this difficult time