Project Results
MAN B&W 5S60MC-C | Piraeus, Greece
INTEGRATED OVERHAUL & RECONDITIONING
Onboard work and in-house reconditioning under one coordinated scope.
ADVANCED REPAIR TECHNOLOGIES
AI robotic welding, laser cladding, CNC machining, and grinding.
COORDINATED PROJECT DELIVERY
Workshop repairs synchronised with onboard reassembly and the vessel’s dry-docking schedule.
VERIFIED REPAIR QUALITY | IN-HOUSE LAB
Dimensional measurements, NDT and pressure tests performed in accordance with OEM specifications.
MAN B&W 5S60MC-C Overhaul | Onboard Dismantling & Reassembly
KIMI’s onboard engineers dismantled the engine assemblies, assessed component condition and identified repair requirements through inspection and recorded measurements.
Scope of work:
Cylinder Covers & Exhaust Valve Assemblies
- Removal and dismantling of cylinder covers and exhaust valves.
- Inspection of combustion chamber surfaces, cooling-water passages and sealing faces.
- Cleaning, dimensional measurements and Dye Penetrant Testing (PT), with hydraulic pressure testing performed where required.
- Inspection of exhaust valve spindles, seats and sealing surfaces.
- Reassembly and Reinstallation.
Piston Assemblies& Stuffing Boxes Overhauling
- Removal and dismantling of piston, piston skirt and piston rod cleaning.
- Piston rings clearance measurements.
- Inspection of piston rods and associated components for wear and surface defects.
- Replacement of piston rings, sealing elements and O-rings as required.
- Stuffing box dismantling, inspection and reassembly.
- Reassembly and reinstallation of reconditioned piston assemblies, with a 20,000-operating-hour warranty on the reconditioned components.
Cylinder Liner & Cooling Jacket Inspection
- Visual inspection of cylinder liner running surfaces for scoring, scuffing, polishing and abnormal wear.
- Dimensional measurements of liner diameter, ovality and taper.
- Inspection of cooling jacket for corrosion, cracks and leakages.
- Non-Destructive Testing (NDT) of critical areas.
- Issuance of Dimensional measurements report and NDT certificates.
- Reinstallation.
Fuel Injection Equipment Inspection
- Dismantling and inspection of fuel valves and associated injection equipment.
- Ultrasonic cleaning.
- Inspection of spindle guides, non-return valves and fuel valve bodies for wear, leakage and defects.
- Replacement of worn or damaged components with new spare parts.
- Pressure testing and verification of fuel valve opening pressure and spray performance against OEM specifications.
- Reassembly and reinstallation of serviced fuel injection equipment.
MAN B&W 5S60MC-C In-House Reconditioning | Restoring Critical Components
Components requiring specialist repair were transferred to KIMI’s workshops. Restoration addressed the findings recorded during dismantling and inspection, connecting onboard assessment directly with in-house welding, laser cladding and CNC machining.
Main Engine Cylinder Covers
- Sand blasting.
- Dimensional inspection, NDT by Level II- Certified Personnel and hydraulic pressure testing.
- Restoration of corroded cooling grooves and exhaust valve cage sealing surfaces.
- Repair of Cracks in Fuel valve bores and air starting valve bores.
- Precision CNC machining of repaired areas to restore OEM geometry & tolerances.
- Stress relieving.
- Final quality assurance and component marking.
Piston Crown Reconditioning of Grooves & Top surface | 20.000Op Hrs Warranty
- Complete removal of grooves and burnt areas on top surface.
- Precision prior to, post CNC machining and grinding.
- AI robotic welding.
- Stress Relieving.
- 0.50mm Chrome plating on each groove side as per Maker’s guidelines.
- Final quality inspection, component marking and traceability.
MAN B&W Exhaust Valve Spindles & Seats
Piston Rods & Stuffing Boxes
Piston rods underwent dimensional and surface inspections, hardness testing to assess wear, scoring, corrosion, cracking, hardness or diameter deviations. Where required, damaged running surfaces were restored using laser cladding, followed by precision grinding and polishing to specified dimensional tolerances and surface roughness.
Stuffing boxes were completely dismantled, cleaned and inspected for wear and damage. Sealing rings, scraper rings and drain passages were checked, with defective components renewed as necessary to restore sealing efficiency, oil control and effective separation between the crankcase and scavenge space.
MAN B&W 5S60MC-C | Onboard Reassembly, Commissioning & Sea Trials
Following in-house component reconditioning, KIMI’s engineering team completed the onboard reassembly of the MAN B&W 5S60MC-C main engine during the vessel’s scheduled dry-docking in Piraeus. Reconditioned piston assemblies, cylinder covers, exhaust valves and associated components were reinstalled, with critical clearances, alignment and sealing arrangements verified against OEM specifications and tolerances.
Following pre-start inspections of the lubrication, cooling, fuel injection and starting-air systems, the engine underwent initial start-up, operational checks and progressive load testing. Key operating parameters were monitored to verify proper engine operation.
Upon successful completion of sea trials and performance verification under operating conditions, the main engine was commissioned and handed over fully operational, completing the coordinated overhaul within the vessel’s scheduled dry-docking window.
Coordinated Two-Stroke Main Engine Overhaul in Piraeus
This MAN B&W 5S60MC-C main engine overhaul in Piraeus demonstrates KIMI’s integrated approach to dry-docking support, combining onboard execution, in-house component reconditioning and coordinated workshop delivery under one engineering partner.
Inspection, NDT, dimensional verification, testing and full reporting were carried out within KIMI’s facilities, supported by its in-house ISO/IEC 17025-accredited laboratory, ensuring traceable quality control and verification against applicable OEM specifications.
By aligning repair findings with advanced restoration capabilities and onboard reassembly priorities, KIMI provides vessel operators with a coordinated solution for MAN B&W 5S60MC-C overhauling, OEM-spec component reconditioning and dry-docking support in Piraeus, Greece.
Plan Your Next Main Engine Overhaul with KIMI.
