What you need from an engine overhaul

Regardless of whether you need an engine overhaul because of hours, time, or it is unplanned you need to know it is done right.

The first consideration is the content of the overhaul. Is it just a top-end, major overhaul, half-life or to rectify damage after a failure?

Next, is where the work is to be carried out? Ideally, this would be in a fully equipped workshop like ours, but sometimes this is not logistically possible or practical.

For site overhauls, swing engines or swing assemblies can be a great way to reduce timescales and costs.

When we are carrying out overhauls, we follow our 9 stage process. Each one is outlined below:

1. Dismantle

The following SOP is followed during the engine dismantle stage:

  • Ensure the engine is drained of all fluids
  • Check drained oil for metallic residues
  • Mark and remove the engine wiring harness
  • Remove Engine subassemblies (Turbocharger, Governor, Starter motor etc) and set aside
  • Remove Exhaust and Intake manifolds
  • Remove coolant rails
  • Remove fuel pipes
  • Bar the engine over so the piston of the required cylinder is at TDC
  • Remove cylinder head covers
  • Remove rocker gear and injectors
  • Remove pushrods
  • Remove cylinder heads
  • Remove engine from mountings and place on supporting frame or a turnover frame
  • Remove flywheel
  • Mark up alignment of free-end and driven-end gears
  • Remove front end and driven end gearwheels
  • Remove Exhaust and Intake manifolds
  • Remove coolant rails
  • Remove fuel pipes
  • Bar the engine over so the piston of the required cylinder is at TDC
  • Remove cylinder head covers
  • Remove rocker gear and injectors
  • Remove pushrods
  • Remove cylinder heads
  • Remove pistons and connecting rods
  • Remove cylinder liners
  • If possible, rotate the engine to give easy access to the crankshaft
  • Remove bottom of crankcase
  • Remove main bearing caps, crankshaft and camshaft

2. Clean

All items are thoroughly cleaned in our workshop using mechanical and chemical methods as appropriate.

We also have ultrasonic tanks, wash tanks and a Guyson bead blaster available.

3. Inspect

Each part of the assembly is then inspected  and measured to ascertain if it is good condition, in need of replacement, machining or other work to bring it back to OEM specification.

4. Report & Approval

All workscopes we complete include a fully comprehensive report after stage one detailing our findings and recommended plan of action, along with cost and time implications.

Once we have your approval, we will progress the overhaul.

You will also receive updates as we progress through each stage.

This ensures you know exactly what stage we are working on, and have the peace of mind that all steps have been documented for your reference.

5. Replace

Where a replacement is the only option for any of your components, we can source directly from the OEM or component manufacturers.

As an established business we have direct links to OEMs and original component manufacturers and can offer fast turnaround times at great prices.

We are also dealers for MTU, Baudouin and Bosch, so can guarantee preferred rates and lead-times.

6. Refurbish

With our in-house manufacturing and machining capabilities, we are able to offer alternative solutions rather than just replace.

All these repairs are covered by a 12-month warranty and comply with OEM specifications or industry standards.

This can provide a more cost-effective and quicker option than replacements.

7. Build

The following SOP is followed during the engine rebuild stage:

  1. Fit crankshaft. Install new main bearing shells, and torque to OEM spec. Ensure bearing caps match up with crankcase.
  2. Measure end float and check free rotation of the crankshaft
  3. Rotate engine to insert cylinder liners
  4. Check liners for ovality to ensure fitted correctly
  5. Pressure test crankcase
  6. Insert pistons and connecting rods
  7. Mark connecting rod ends when torqued up
  8. Check the bumping clearance of each cylinder
  9. Install camshaft and check end float
  10. Fit front end and driven end gearwheels
  11. Fit cylinder heads with new gaskets
  12. Bolt down cylinder heads, increasing torque setting in stages up to OEM spec. (i.e. torque all bolts to 1/3 OEM value, then 2/3, then 100%)
  13. Fit rocker gear and injectors
  14. Fit cylinder head covers
  15. Fit bottom of crankcase/sump to engine
  16. Fit inlet and exhaust manifolds
  17. Fit coolant and oil lines
  18. Fit fuel lines
  19. Fit flywheel
  20. Fit engine subassemblies (Turbocharger, Governor, Starter motor etc)
  21. Final Assembly
  22. Fill engine with fluids and check for leaks
  23. Rotate crankshaft two full rotations
  24. Fit engine guards

8. Test

On completion of the overhaul, the engine will be tested against an agreed test plan and can be witnessed by you, a representative or live streamed.

Once accepted, the engine can be packaged and shipped back to the site or stored in our warehouse, ready when needed.

Our engineers can then attend to re-install and commission, checking alignments and test running on site.

9. Final Report

On completion of the overhaul, a full report including all stages will be provided, along with our 12-month warranty as standard.

For an example of an overhaul report, click here.

If your engine is in need of an overhaul that you can count on, fill in your details below – we’d be happy to Help.

Contact Bartech

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“Thank you.

The site report and the overhaul at site have been conducted to a high standard.

Well done.”

Wood Group Asset Management Solutions

“Bartech’s work ethic permeates through the organization, from Rob Lee the Bartech Project & Commercial Manager through to the technicians overhauling, testing, installing and commissioning the engines.

The communication is exactly what we expect from a supplier of products and services delivered to us here at Hartlepool PowerStation from weekly updates to overhaul documentation showing exactly where they are in the sequence of work.

It is excellent to see and sets a standard most do not achieve.”

Daniel Lanna ~ EDF Hartlepool

“One of the most impressive aspects Taqa found with Bartech was there response time.

A recovery plan to get P-7230 returned to service was quickly established and implemented. Bartech were extremely flexible and fully onboard with all of Taqa’s requirements.

Bartech meet and exceeded our expectations during this intervention.

We are hopeful that this level of service can be maintained & look forward to working with Bartech in the future.”

Pete Walker ~ Taqa Bratani

“Well done, it is great to see the final “three for three, FYFP 1, De-Sup Station and CW valve” risk mitigations now delivered safely before year end.

Can I reinforce and recognise the drive, team work and clear communications during the last month especially.

This rounds off a very positive risk mitigation year for Team Hartlepool and the wider support provided via CTO and the Supply Chain with 22 oo 23 Key Deliverables completed and handed back to the operations teams.”

Bill Liu ~ EDF

“Please pass on my thanks to your team for the fantastic effort in getting this rearranged visit complete.

We had constraints on labour and lead time of equipment however all went seamlessly.

Please also pass this on to Matt and William and thank them for their workmanship whilst offshore, very much appreciated by all here at Fairfield.”

Martin Baxter ~ Fairfield Energy

“Thanks for the help, and the fact that you were able to keep your promises regarding delivery time etc.

We’ll keep in touch.”

URS

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