COMPANY DIRECTIVE To: All fleets

Card No CPOM-031 Version 03 2020-08-10

Page 1 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
Superintendents, Chief Engineers, 2nd Engineers shall apply this Company Directive.

Purpose of the document

This Company Directive provides instructions and guidelines on how to carry out inspection of 2-stroke engines cylinder units,
record inspection results and subsequently to take immediate actions and plan cylinder units overhauls based on findings.

Scope of the document

This Company Directives applies to all owned vessels equipped with two-stroke engines (MAN and WinGD/Wärtsilä).

Definitions and abbreviations

CBO : Condition-Based Overhaul
C/E : Chief Engineer
SI : Superintendent

Introduction
On top of the monitoring of engine parameters, the evaluation of the actual cylinder condition by means of regular and
frequent scavenge port inspections and by recording of wear measurements are of utmost importance to:
• Timely detect any abnormal wear and ensure trouble-free operation by taking immediate actions based on findings,
• Continuously optimize the cylinder lubrication,
• Plan enough in advance the cylinder unit overhauls.
Company has implemented a CBO strategy, to obtain the highest number possible of safe running hours and to carry overhaul
only when necessary. Findings and measurements reported by crews are crucial for C/E and SI making the right decisions.
Poor cylinder condition monitoring will result in engine components reduced lifetime and last-minute unplanned overhaul,
affecting vessel schedule and budget.
Responsibilities
CE is responsible for the implementation of this CD on board, including cylinder units overhaul planning based on inspection
findings and analysis of measurements.
▪ All abnormal findings shall be systematically documented and commented.
▪ C/E considers the remedial actions to be applied, without any delay, working closely with SI if they may affect vessel
schedule or budget.

SI shall:
• Ensure that this CD is strictly implemented for vessels under his responsibility.
• review systematically the reports, monitor the trends over months and look at any deviation that could affect vessel
schedule or budget.

Safety
Before performing a scavenge port inspection and cylinder unit overhaul, C/E shall make sure proper permit to work and risk
assessment are in place and have been reviewed with the attending team.
Enclosed space permit and procedure shall be strictly followed (IMS cards “Work in enclosed space “ and “Permit to work in
enclosed space”
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 2 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
Visual inspection of Cylinder Units (routine)

PERIODICITY Monthly

Caution: On top of the periodical inspections, cylinder unit(s) shall be inspected more often in case of abnormal conditions
(high liner temperature fluctuation., scavenge drain oil in alert, scuffing, broken or collapsed rings, problem fuel…)

PURPOSE
• Detect any abnormalities at an early stage and take appropriate corrective actions.
• Confirm results obtained by others means (scavenge drain oil analysis, liner temperature sensors...).
• Document the Cylinder condition on a frequent basis and identify the changes over time.
• Optimize lubrication to actual cylinder condition.
High liner temperatures fluctuation and Scuffing
In case of high liner temperatures fluctuation or when scuffing is suspected, immediate actions shall be applied
without waiting for the visual inspection – see CD 133-“ FLEET and Engine maker’s instructions”.

PROCESS
• Visual inspection of cylinder units shall include the following:
o Cleanliness of Scavenge Air Receiver and Pistons Undersides (sludge…)
o Water Mist Catchers (crack, water, corrosion), Air Flap Valves and Auxiliary Blowers
o Piston Rods (corrosion, scratches, discoloration, oil leakages…) and Locking Wires of piston skirts bolts
o Piston Skirts (scratches, hard contacts…)
o Ring Pack before (lubrication and combustion) and after wiping (carbon deposits)
o Ring Movement by moving the piston up and down and by pressing each ring with a wooden stick
o For each ring: Running Surfaces (scuffing, seizure, hard contact..), Bottom / Top Edges, Ring Ends, Grooves…
o Top Lands (carbon or calcium carbonate deposits, vertical scratch, polished deposits…)
o Piston Crown surface (calcium carbonate or others deposits, water of fuel leakages, burn-away…)
o Cylinder liner walls (scuffing, wear ridges, burred air port edges, bore polishing, corrosion, black lacquers,
rust…) and lubrication grooves
o Fuel Valves and Exhaust Valves (indirect)
• Photos shall be taken and recorded as per the template form see Annex I
• Morover, each abnormality shall be recorded by taking photographs (wide and close-up shots) in order to be
reviewed by C/E, SI or external companies.
• Reference documents provided by MAN or WinGD shall be used to judge the condition of various cylinder
components. The wording provided in those booklets should be used accordingly.
• The findings and photos of this inspection shall be compared with the previous reports to identify any significant
changes.
Critical or Abnormal Cylinder Condition
Any critical or abnormal condition identified shall be documented, analyzed and commented. Chief Engineer
immediately considers the remedial actions that should be taken.

REFERENCE DOCUMENTS
• MAN Booklet “Procedure for inspection of Piston & Liners” – [see Annex V]
• MAN Service Letter 2019-671/JAP - “Cylinder lubrication update for 0 to 0.50% sulphur fuels” - Appendix I & II, page
6-7
• WinGD Booklet “Guide for judging condition of relevant piston-running components” [see Annex VI]

RECORDS
• Annex I (Coating) or Annex II (CL grooves) “CYL UNIT INSPECTION” shall be used
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 3 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
Measurements (routine)
1. PISTON RINGS - COATING THICKNESS MEASUREMENTS

CL-grooves depth shall not be measured on MAN engine types having Cermet coating applied on top ring (listed below)

ENGINES MAN S90ME-C, K98ME-C, K98MC-C, K90MC-C, G60ME-C

WinGD : All RTA, RT Flex, W-X engines

PERIODICITY Monthly

PURPOSE
Monitor the piston rings radial wear and plan overhauls.

PROCESS
• Coating thickness of Top piston ring (1st) shall be measured only. [highest wear rate] Fig. 1
• Coating Thickness Gauge* shall be used for this purpose.
• Gauge shall be calibrated prior to taking readings. Zero test plate shall be used. - see User manual
• Instructions given in User manual shall be strictly applied when taking readings to improve accuracy (+/- 20 microns).
• Unit of measure shall be microns. [typical range is 0 to 800 microns]
• Coating thickness shall be measured at 3 locations around the ring circumference. [as coating not equally applied and
worn out]- see Fig. 1
• Coating thickness should always be taken at about one third of ring height. [to ensure consistent measurement on barrel
shaped rings]- see Fig. 2
• Middle value shall be recorded only. [precision +/- 10 microns]

 1/3
Fig. 2
GUIDELINE VALUES (ref: MAN SL2019-685/KAMO and Wärtsilä RT-135)
New Rings
For a given engine type, various coating thickness can be found depending on piston ring configuration. Moreover, running-in
and hard coatings are not equally applied by makers around the ring circumference. Hard coating thickness is usually between
300 and 600 microns (depending on bore and engine designer).
Wear Rates (indicative only)
• Normal :  10-15 microns / 1000 h [normal or extended lifetime]
• Alert :  20-25 microns / 1000 h [risk of reduced lifetime]
• Danger : > 30 microns / 1000h [abnormal wear – root cause to identified/action to be taken]
Minimum values
ALERT : < 100 microns Alert limit is expected to be reached over the next few months
-DANGER- : < 20 microns Overhaul shall be scheduled at first opportunity (not later than 1000 hours)

RECORDS
Annex I : “CYL UNIT INSPECTION – HARD COATING”

* Ordering information (TOUCH / PURCHASE / GENERAL EQUIPMENT / ELCOMETER)

ELCO-0000001 : COATING THICKNESS GAUGE- ELCOMETER 456 B (Device)
ELCO-0000002 : COATING THICKNESS GAUGE- ELCOMETER 456 MODEL F1 (Separate Probe)
ELCO-0000003 : FERROUS ZERO TEST PLATE (Zero calibration)
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 4 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
2. PISTON RINGS – CL-GROOVES DEPTH MEASUREMENTS (MAN Engines only)
• CL-grooves depth shall not be any longer measured whether coating thickness of top ring is measured (see para 1).
• CL-grooves shall be measured on all others MAN engines. Instructions given in Appendix I shall be followed.

ENGINES : K90MC (old) , K80MC-C, L70ME-C, S70MC-C, L60MC, S60ME-C, S60MC/MC-C, S50MC/MC-C
____________________________________________

3. PISTON CROWN - GROOVE MEASUREMENTS

PERIODICITY Monthly

PURPOSE
Monitor the wear and the cleanliness of ring grooves and plan overhauls of piston crowns.

PROCESS
• Groove clearance of Top piston ring (1st) shall be measured only. [highest wear rate]
• Feeler gauge shall be used for measuring the bottom and top clearances.
• Piston shall be moved down with turning gear to move the rings to the top of the grooves.
• Top clearance shall be mesured first with thin gauge– [ring is not systematically fully pushed and tight to the upper face]
• Then, Bottom clearance shall be measured. See Fig 3 (MAN) and Fig 4 (WinGD).
• The sum of bottom and top values shall be recorded as the total clearance (e.g. X1 + X2).
The measuring point (1) shall be at inner side of groove for Wärtsilä / WinGD - see RT 149 for further information
• The full methodology is given in the “Procedure For Inspection Of Pistons & Liners” (MAN) and RT-149 (WinGD).

pt 1

Fig. 3
Fig. 4

Fig 3 : MAN Guidelines Fig 4 : WinGD Guidelines

GUIDELINES VALUES FOR TOP RINGS (ref: Engine Maintenance Manuals, RT-149, OEM files)
Clearance New Max. Clearance New Max.
K98MC-C/ME-C 0.50 - 0.60 1.10 RT-flex 96C-B 0.44 - 0.52 pt 1: 0.75
S90ME-C 0.45 - 0.50 1.00 X 92DF / X 92 / X 72 0.50 - 0.58 pt 1: 0.80
K90MC/MC-C / K80MC-C 0.45 - 0.50 1.00 RT-flex 82C 0.50 - 0.58 pt 1: 0.80
L70ME-C / S70MC-C 0.40 - 0.45 0.95 RTA 72U-B 0.40 - 0.48 pt 1: 0.65
S60ME-C / G60ME-C 0.40 - 0.45 0.95 RTA 62U 0.37 – 0.45 pt 1: 0.60
L60MC / S60MC/MC-C 0.40 - 0.45 0.95 RT-flex 58T-E 0.35 – 0.43 pt 1: 0.60
S50MC/MC-C 0.35 - 0.40 0.90 RT-flex 50DF 0.33 – 0.41 pt 1: 0.60

Wear Rates (indicative only)

• Normal : < 0.01 mm / 1000 h [normal or extended lifetime]
• Alert : > 0.01 mm / 1000 h [risk of reduced lifetime]
• Danger : > 0.02 mm / 1000h [abnormal wear – root cause to identified/action to be taken]
Minimum values
ALERT : (Max. value) - 0.10 mm : Alert limit is expected to be reached over the next few months
-DANGER- : Max. value : Overhaul shall be scheduled at first opportunity (not later than 1000 hours)
RECORDS
Annex I (Coating) or Annex II (CL grooves) “CYL UNIT INSPECTION” shall be used
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 5 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
Plan the Cylinder Unit Overhauls

PERIODICITY Monthly review by C/E – Biannual review by SI

PURPOSE
• Quickly react to early warnings to avoid major breakdown or downtime (e.g. scuffing) and schedule the overhaul
without impacting vessel schedule [Condition Based Maintenance].
• Schedule in advance the future maintenance based on analysis of visual inspection, measurements, and others
parameters to optimize the time between overhaul and anticipate spare parts requirements (budget) [Predictive
Maintenance]

PROCESS
• Following information should reviewed to plan Cylinder Unit Overhauls:
o Component running hours
o Visual inspections over the past 6 months
o Coating thickness or CL-groove measurements, Groove clearances [last measurements + trends ]
o Piston crown history: last overhaul measurements, n° of reconditionning, burn-away…
o Cylinder liner history : last calibration measurements, ovalization and rehonning
o Engine parameters, M/E Performances, Stuffing Box Leakages, Scavenge Drain Oil analysis results,
o Any other relevant information
• DANGER Cylinder overhaul shall be scheduled at the first opportunity (and not later than 1000 running hours) if one
of the Alert limits, listed below, are reached or critical condition are shown by visual examiantion shows
o Top-ring coating thickness : < 20 microns [or Top-ring CL-groove depth at Minimum
value for concerned vessels]
o Top-ring groove clearance : Maximum value
o Critical ring condition : Scuffing, Ring broken, Ring collapsed…
o Critical liner condition : Local scuffing, Wear steps (port area), Burrs (edges of scavenge air
ports)…
o Leakages : Water or Oil leakages from liner, valve or piston underside
o Iron contents : > 400 ppm systematically despite feed rates  1.20 g/kWh
o Stuffing Box Leakages : > 24L / day / cyl for the third month in sucession.
• ALERT If Caution limits, listed below, are reached or abnormal conditions are shown by visual examination then a
closer monitoring shall be put in place as one Alert limit might be reached over the next few months.
SI shall consider the next steps and define priorities with Chief Engineer to minimize the risks on vessel operations
and/or identify upcoming maintenance needs (investigations, monitoring, ordering spares, increasing feed rate…)
- Top-ring coating thickness : < 100 microns
- Top-ring groove clearance : (Maximum value) – 0.10 mm
- Abnormal ring condition : Hard contact, Local micro seizures, Excessive peeling of Hard coating, Sharp edges, Heavy
deposits [that cannot be recovered by increasing feed rate or reducing load]
- Abnormal liner condition : Scoring marks, Bore polishing, Extensive cold corrosion [that develops further despite increasing
feed rate or reducing load]
- Stuffing Box Leakages : 24 L / day / cyl repeatedly
RECORDS : NIL
Popup notifications and a summary report related to cylinder condition are expected to be developped in TOUCH by year end.

Perform the Cylinder Unit Overhaul

PURPOSE
• Make sure that the cylinder unit, once inspected and overhauled, will perform well for another trouble free period
of 20-30000 running hours.
• Evaluate whether the piston crown shall be re-used after cleaning, reconditionned by welding or scraped.
• Evaluate whether the cylinder liner shall be replaced , be rehonned or be kept in use.
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 6 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
PROCESS
• Procedure for overhaul of Piston with Rod and Stuffing Box, Cylinder Liner, Cylinder Cover, Exhaust Valves given in
Engine Maintenance Manuals shall be stricly followed;
• As cylinder cover is dismantled, liner wear shall be systematically measured – See next section
• If the liner or the piston crowns is exchanged with spares, two cylinder unit overhaul report reports shall be filled in,
with measurements for old and new parts (for rings, only new ones).
Removal of Wear ridges on Cylinder Liners (TDC, BDC, Ports)
Recent cases of Scuffing and Broken rings are suspected of being related to wear ridges on cylinder liner that have
no been properly removed in connection with piston overhauls. See MAN Service Letter SL00-383/SBJ.

RECORDS
See Annex III (MAN) or Annex IV (Wartsila -WinGD) “CYLINDER UNIT OVERHAUL REPORT”

Measurement of Cylinder Liner

PERIODICITY Cylinder Unit Overhaul and Special survey

PURPOSE
• Evaluate whether the cylinder liner shall be replaced, be rehonned or be kept in use.
• Estimate the Cylinder liner expected lifetime.

PROCESS
• Liner calibration, without Cylinder cover, shall be performed at each Cylinder Unit Overhaul.
• Procedure for Cylinder Liner calibration after removing cylinder cover, given in Engine Operations & Maintenance
Manuals shall be stricly followed [-Chap 707 and 903 - or -Chap 22- for MAN ; page 0330-1 and 2124-2 for WinGD-Wärtsilä].
Measuring points for Liner calibration
Measuring points are often not precisely defined in Engine Manuals. Position shall be determined with the
template tool provided by maker (guide rail gauge). In case of doubt, engine designer shall be contacted.
• All measurements, including measurement done by service companies with sensor based devices (e.g. VAK, LDM),
shall be properly recorded.
• Liner wear should be calculated at each position / in both directions [F-A & E-M] by substracting the diameter
measured on non sliding parts - i.e. above TDC or below BDC - to the maximum diameter usually found at the rings
position at TDC. e.g. : Max wear : 982.40 [E-M ; Pos 3]] - 980.20 [E-M ; Pos 0 or 11] = 2.20 mm (0.22% of DNOM)
• Absolute Max. liner wear, the highest value of all F-A and E-M liner wears, shall be used to calculate the wear rate
and expected liner lifetime.
• Ovality should be calculated at each position by substracting the E.M. from the F.A. measurement at all positions.
Maximum ovality, as the maximum absolute value, shall be recorded.

GUIDELINE VALUES (ref: Engine Operations & Maintenance manuals)

Maximum Allowable Wear : absolute values
ALERT : 0.3-0.4 % x Diameter Consider whether liner rehoning (in workshop, as in situ not
recommended by engine maker) is an economical option.
-DANGER- : 0.7-0.8 % x Diameter Liner shall be repalced at first opportunity (not later than 1000 hours)

Maximum Ovality
ALERT : 0.1 % x Diameter Consider liner rehoning in workshop if it is still an economical option.
Wear Rates (indicative)
• Normal : +/- 0.05 mm / 1000 h [normal or extended lifetime]
• Alert : > 0.10 mm / 1000 h [risk of reduced lifetime]
• Danger : > 0.20 mm / 1000h [abnormal wear – root cause to identified/action to be quicly taken]
RECORDS
See Annex III (MAN) or Annex IV (Wartsila-WinGD) “CYLINDER UNIT OVERHAUL REPORT”
A Tech-form allowing the record of the liner measurements over the years is expected to be developped in TOUCH by year end.
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 7 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
List of appendices
Appendix I : CL-GROOVES DEPTH MEASUREMENTS PROCESS FOR MAN ENGINES (if applicable).
Appendix II : CYLINDER LINER DIAMETER – GUIDELINE VALUES

Appendix III : CYL UNIT INSPECTION PICTURES – HARD COATING (standard form except for engine typed listed in Appendix I)
Appendix IV : CYL UNIT INSPECTION PICTURES – CL GROOVES (only engine type listed in Appendix I)
Appendix V : MAN - CYLINDER UNIT OVERHAUL REPORT
Appendix VI : WINGD - CYLINDER UNIT OVERHAUL REPORT
Appendix VII : MAN booklet “Procedure for inspection of Piston & Liners” – Version 1.1 – March 2012
Appendix VIII : WinGD booklet “Guide for judging condition of piston-running components” – V5 – April 2021

References
Prev-023 Work in enclosed space
Prev-023A Permit to work in enclosed space
Engine Maintenance Manual(s)
MAN Service letters: SL2019-685/KAMO, SL2019-681/SRJ, SL2017-650/SRJ, SL2019-671/JAP, SL2019SL2014-587/JAP, SL2007-
483/HRR
WinGD/Wärtsilä bulletins: RT-161, RT-135, RT-123, RTA-65, RTA-39
CD 133 FLEET “Lube Oil Management”

Modifications of the document

Description of the Modification Date N° Version
Update of Appendix VII 2021-07-06 3
Rewriting + WinGD + Coating thickness 2020-09-24 2
First version 2017-09-27 1

Validation and approval

Version of the document 3

Anouchka GOLITIN
Author
Senior Engineer (2-stroke)
2021-07-06
Shaj THAYIL
Validation
Fleet Director
2021-07-06

Xavier LECLERCQ
Approval
Vice President CMA Ships
2021-07-06
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 8 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition
Appendices
APPENDIX I : CL-GROOVES DEPTH MEASUREMENTS FOR MAN ENGINES (if applicable)

ENGINES K90MC (old), K80MC-C, L70ME-C, S70MC-C, L60MC, S60ME-C, S60MC/MC-C, S50MC/MC-C

PERIODICITY Monthly

PURPOSE
• Monitor the Top-rings radial wear [ CL-grooves depth is not considered as useful to plan overhauls].

PROCESS
• Ad-hoc vernier gauge stern shall be used for measuring CL-grooves depths – see Fig 5.
• There are normally 6 CL-grooves per Top-ring. The depth of one or two CL-grooves only can be measured at Exhaust
side.
• When none of the CL-grooves is accessible at Exhaust side, CL-grooves depth shall be measured at Manoeuvre side
for the considered Cylinder Unit(s).
• The methodology to properly measure the CL-groove depth is described in the “Procedure For Inspection Of Pistons
& Liners” Booklet (MAN).
• Minimum depth should not be considered as a reliable indicator to predict piston rings lifetime.
• CL-grooves successive measurements can be used to estimate a trend : normal / abnormal wear.

 ✓

Fig. 5
GUIDELINES VALUES (ref MAN Service Letter SL2014-587/JAP)
Bore size CL-groove depth (new) Minimum depth
98 (no Cermet coating) 5.5 mm 2.2 mm
90 (no Cermet coating) 5.0 mm 2.0 mm
80 4.0 mm 1.8 mm
70 3.5 mm 1.6 mm
60 3.5 mm 1.3 mm
50 3.0 mm 1.1 mm
Wear Rates (indicative)
• Normal :  0.05-0.10 mm / 1000 h [normal wear]
• Danger : > 0.20 mm / 1000h [abnormal wear – root cause to identified/action to be taken]
Minimum values
-DANGER- : Min. depth Overhaul shall be scheduled at first opportunity (not later than 1000 hours)

RECORDS
• Annex II : “CYL UNIT INSPECTION PICTURES – CL GROOVES”
 COMPANY DIRECTIVE To: All fleets
Card No CPOM-031 Version 03 2020-08-10
Page 9 of 9
102-3-2021 FLEET Version 3 2021-07-06
2-Stroke Engines Cylinder Condition

APPENDIX II : CYLINDER LINER DIAMETER – GUIDELINE VALUES

MAN
Maximum diameter Diameter requiring special Maximum ovality
Bore in mm attention in mm
in mm (Max wear : 0.7-0.8 % x Diameter) in mm (0.1 % x Diameter)
(Wear : 0.3-0.4 % x Diameter)
Status DANGER- ALERT ALERT
980 987.0 >983.5 1.0
900 906.5 >903.5 0.9
800 806.0 >803.0 0.8
700 705.5 >703.0 0.7
600 604.8 >602.5 0.6
500 504.0 >502.0 0.5

WINGD - Wärtsilä
Maximum diameter Diameter requiring special Maximum ovality
Bore in mm attention in mm
in mm (as per Maintenance Manual) in mm (0.1 % x Diameter)
(Wear : 0.3-0.4 % x Diameter)
Status DANGER- ALERT ALERT
960 966.7 >963.5 1.0
920 926.0 >923.5 0.9
820 825.9 >823.0 0.8
720 725.0 >723.0 0.7
620 624.4 >622.5 0.6
580 584.0 >582.5 0.6
500 503.5 >502.0 0.5

________________________
Example of Wear calculation (K98ME-C)

Maximum diameter (mm) : 982.40 [E-M ; Pos 3]

Reference diameter (mm) : 980.20 [E-M ; Pos 0 or Pos 11]
Max. wear (mm) : 2.20 [=0.24% x Bore] => OK
Wear rate (mm/1000h) : 0.035 [< 0.05 mm/1000h] =>OK
Maximum Ovality (mm) : 1.20 [Pos 3 : 982.40-981.20] [=0.12% x Bore] => ALERT → Consider Rehoning
Liner hours 62579

Completed