Project Snapshot
During a scheduled overhaul of a MAN B&W 5S60MC-C low-speed 2-stroke engine, five cylinder covers were removed for complete reconditioning.
Inspection identified thermal fatigue, combustion-chamber erosion, wear in the exhaust-valve pockets and injector seating areas, and corrosion within the cooling-water passages.
KIMI reconditioned all five covers in-house after detailed inspection, using certified welding, precision CNC machining, and final quality control. Each component was restored to OEM dimensions and prepared for reliable operation during the next service cycle.
Complex Reconditioning & Engineering Challenges
Although all five cylinder covers belonged to the same engine, each component exhibited different defects and levels of wear, requiring an individually tailored repair scheme. Maintaining consistent geometry, sealing performance, and dimensional accuracy across all five covers was essential to ensure proper engine operation after reassembly.
The Main Challenges Included
Thermal-fatigue cracks in high-temperature combustion areas.
Erosion of the combustion chamber caused by prolonged engine operation.
Worn exhaust-valve pockets requiring controlled rebuilding.
Damaged fuel-injector seating surfaces affecting sealing performance.
Corrosion and deposits within the cooling-water passages.
Restoration of critical sealing surfaces and dimensional tolerances to OEM specifications.
Complete Cylinder Cover Reconditioning Process
INITIAL INSPECTION & NDT
Each cylinder cover underwent visual, dimensional, and NDT inspection of critical surfaces for cracks, erosion, corrosion, distortion, and material loss.
CLEANING & DAMAGE REMOVAL
All surfaces were cleaned of deposits and scale, while damaged material was removed to reach stable metal for controlled restoration.
CERTIFIED WELDING REPAIRS
Damaged areas were rebuilt using class-approved welding and compatible filling material, with heat treatment applied where required for metallurgical stability.
PRECISION CNC MACHINING
Damaged areas were restored using approved welding class procedures and suitable filler materials. Heat treatment was performed where required to control residual stresses and ensure metallurgical properties.
VALVE SEAT GRINDING & SURFACE FINISHING
Valve and injector seating areas were precision-ground, with geometry, flatness, concentricity, and sealing verified for reliable combustion sealing.
FINAL INSPECTION & QUALITY ASSURANCE
Each cover underwent final dimensional inspection, NDT, and pressure testing before release for installation upon meeting OEM criteria.
Project Achievements
✔ Five cylinder covers successfully restored to OEM specifications.
✔ Significant cost reduction compared with purchasing new OEM components.
✔ Critical combustion and cooling geometries fully recovered.
✔ Uniform dimensional accuracy achieved across all five cylinder covers.
✔ Reduced vessel downtime by completing the repairs within the scheduled overhaul period.
✔ Extended component service life through comprehensive reconditioning.
✔ Reliable sealing and cooling-water integrity confirmed through final testing.
Why Rely on KIMI
Every cylinder cover reconditioned by KIMI undergoes a fully controlled engineering process combining advanced repair technologies, certified inspection, and precision machining. From the initial condition assessment to final quality inspection and approval, every stage is performed in-house to ensure full traceability, repeatable quality, and reliable long-term performance.
Complete In-House Capability
All inspection, repair, machining, testing, and quality assurance are completed in-house.
OEM-Level Precision
Critical geometries and sealing areas are restored to OEM dimensions and tolerances.
Certified Quality Control
ISO 17025 support and PCN Level II personnel inspections ensure consistent quality.
Cost-Effective Lifecycle Extension
Reconditioning extends cylinder-cover life while reducing cost, lead time, and the vessel’s downtime.