轮机维护与修理

Chapter 1 Failure and Maintenance

1．1 Failure

1．1．1 Introduction of Failure

1．1．2 Fai Jure Classification

1．1．3 Frequency of Failure

1．1．4 Human Error in Shipping

1．2 Maintenance

1．2．1 Corrective Maintenance

1．2．2 Scheduled Maintenance

1．2．3 Predictive Maintenance

1．2．4 Reliability

1．2．5 Maintainability

1．2．6 Reliability-Centered Maintenance（RCM）

1．3 Ship's Maintenance and Survey Systems

1．3．1 Ship Control

1．3．2 Port State Control

1．3．3 C1assification Society

1．3．4 Planned Maintenance Survey System（PMS）

1．3．5 CWBT

1．3．6 Near-Miss Activity

Chapter 2 Tribology

2．1 Tribology

2．1．1 Definition of Tribology

2．1．2 Tribological System

2．2 Friction

2．2．1 Structure of Surfaces

2．2．2 Surface Texture

2．2．3 Origins of Friction

2．3 Wear

2．3．1 Basic Concepts

2．3．2 Basic Wear Process

2．3．3 Running—in

2．3．4 Wear Mechanisms

2．4 Lubrication

2．4．1 Stribeck Curve

2．4．2 Fluid Film Lubrication

2．4．3 Elastohydrodynamic Lubrication

2．4．4 Boundary Lubrication

2．4．5 Mixed Film Lubrication

2．5 Lubricant

2．5．1 Functions of Lubricants

2．5．2 Important Properties of Lubricants

2．5．3 Additives

2．5．4 Classifications of Lubricating Oil

2．5．5 Solid Lubricants

2．6 Cylinder Lubrication

2．6．1 Friction of Piston Skirt and Piston Rings Against the Cylinder Liner

2．6．2 Cylinder Lubrication

2．6．3 Running—in of Liners and Rings

2．7 Sleeve Bearing Lubrication

2．7．1 Plain Bearing's Lubrication

2．7．2 Wear and Failure Modes in Plain Bearings

Chapter 3 Corrosion

3．1 IntroductiOn

3．1．1 Definition

3．1．2 Classification of Corrosion

3．1．3 Corrosion Rate

3．2 Hot Corrosion

3．3 Electrochemical Corrosion

3．3．1 Electrochemical Corrosion Theory

3．3．2 Various Types of Corrosion

3．4 Control of Corrosion

3．4．1 Conditioning the Metal

3．4．2 Conditioning the Corrosive Environment

3．4．3 Electrochemical Control

3．5 Cavitation

3．5．1 Cavitation of Cylinder Liners

3．5．2 Cavitation of Propeller

3．5．3 Cavitation in a Journal Bearing and Fuel Oil Injection System

Chapter 4 Fatigue Failure

4．1 Introduction

4．2 Characteristics of Fatigue Fracture Surfaces

4．3 Nature of the Fatigue Process

4．4 Recognition of Fatigue Failure

4．5 Cyclic Stresses

4．5．1 Fatigue Loading

4．5．2 The S-N Cllrve

4．5．3 Stress ConcentratiOn Factor

4．5．4 Notch Sensitivity Factor

4．6 Factors Affecting Fatigue Life

4．7 Preventing Fatigue Failure

4．8 Thermal Fatigue

4．9 Crankshaft Fatigue Failures

Chapter 5 Defect Detection and Fault Diagnostics

5．1 Defect Detection

5．1．1 Common Testing Methods

5．1．2 Nondestructive Testing

5．2 Machine Condition Monitoring and Faults Diagnosis

5．2．1 Introduction

5．2．2 Temperature Measurement Techniques

5．2．3 Oil Analysis -

5．2．4 Performance Trending

5．2．5 Vibration Analysis

Chapter 6 Repairing Technologies

6．1 Electr6pIating

6．1．1 Introduction of Electroplating

6．1．2 Procedure of Electroplating

6．1．3 Typical Electroplating

6．1．4 Brush Plating

6．2 Thermal Spray Coating

6．2．1 Definition of Thermal Spray

6．2．2 Process of Thermal Spray

6．2．3 Classification of Thermal Spray Coating

6．2．4 Applications of Thermal Spray Coating

6．3 Welding

6．3．1 Introduction

6．3．2 Surfacing

6．3．3 Welding Technologies

6．3．4 Welding of Cast Iron

6．3．5 Soldering and Brazing

6．4 Metal Stitching

6．4．1 Introduction

6．4．2 Metal Stitching Process

6．4．3 Locks and Pias

6．4．4 Advantages of the Repair by Metal Stitching

6．5 Adhesion-

6．5．1 Organic Adhesives

6．5．2 Inorganic Adhesives

6．6 Shot Peening

Chapter 7 Ship Repair

7．1 Types of Ship Repair

7．2 Drydocking

7．2．1 Types of Dock

7．2．2 Machinery Overhauls and Repairs During Drydocking

7．3 Dismantling Techniques

7．3．1 Fundamental Rules of Dismantling

7．3．2 Hydraulic Tools

7．3．3 Removing Seized Nuts and Bolts

7．4 Mechanical and Chemical Cleaning

7．4．1 Mechanical Cleaning

7．4．2 Chemical Cleaning

7．4．3 System F[ushiag

7．5 Mooring Test and Sea Trial

7．5．1 Mooring Test

7．5．2 Sea Trial

Chapter 8 Overhauling and Maintenance of Marine Diesel Engine

8．1 Cylinder Head

8．1．1 Inspecting and Repairing of Cylinder Head Cracking

8．1．2 Inspecting and Repairing of Exhaust Valve

8．2 Cylinder Liner

8．2．1 Introduction

8．2．2 Excessive Worn of Liners

8．2．3 Scored Cylinder Liners

8．2．4 Cracked Liners

8．2．5 Scuffing of Liners

8．3 Piston

8．3．1 Piston Wear

8．3．2 Piston Crown Burning

8．3．3 Piston Crown Crack

8．3．4 Reconditioning of Pistons

8．4 Piston Ring

8．4．1 Piston Ring Materials and Coatings

8．4．2 Wear of Piston Rings

8．4．3 Sticking

8．4．4 Breakage／Collapse

8．4．5 Blow-by

8．4．6 Low Piston Ring Tension

8．4．7 Scavenge Port Inspection

8．4．8 Replacement of Piston Rings

8．5 Crankshaft

8．5．1 Crankshaft Alignment

8．5．2 Crankshaft Failures

8．6 Bearing

8．6．1 Classifications of Bearing

8．6．2 Materials and Structure of Bearing

8．6．3 Journal Bearing Failures，Causes and Repairing Technologies

8．6．4 Repairing Journal Bearings

8．6．5 Installation and Checking

8．7 Precision Couplings

8．7．1 Plunger and Barrel Assembly

8．7．2 Delivery Valve and Seat

8．7．3 Fuel Injector

8．7．4 Repair Strategies and Storage for Precision Couplings

8．8 Turbocharger

8．8．1 Turbocharger Construction

8．8．2 Corrosion of the Casing

8．8．3 Overhauling of the Bearing

8．8．4 Overhauling of the Blades

8．8．5 Overhauling of the Sealing

8．8．6 Dismantling and Alignment

8．8．7 Dynamic Balancing of the Rotator

8．8．8 Temporary Measures When Turbocharger Is Damaged

Chapter 9 Ship's Shafting

9．1 Introduction of Ship's Shafting

9．1．1 Shafting Components

9．1．2 Arrangement of ShaftingChapter 1 Failure and Maintenance

1．1 Failure

1．1．1 Introduction of Failure

1．1．2 Fai Jure Classification

1．1．3 Frequency of Failure

1．1．4 Human Error in Shipping

1．2 Maintenance

1．2．1 Corrective Maintenance

1．2．2 Scheduled Maintenance

1．2．3 Predictive Maintenance

1．2．4 Reliability

1．2．5 Maintainability

1．2．6 Reliability-Centered Maintenance（RCM）

1．3 Ship's Maintenance and Survey Systems

1．3．1 Ship Control

1．3．2 Port State Control

1．3．3 C1assification Society

1．3．4 Planned Maintenance Survey System（PMS）

1．3．5 CWBT

1．3．6 Near-Miss Activity

Chapter 2 Tribology

2．1 Tribology

2．1．1 Definition of Tribology

2．1．2 Tribological System

2．2 Friction

2．2．1 Structure of Surfaces

2．2．2 Surface Texture

2．2．3 Origins of Friction

2．3 Wear

2．3．1 Basic Concepts

2．3．2 Basic Wear Process

2．3．3 Running-in

2．3．4 Wear Mechanisms

2．4 Lubrication

2．4．1 Stribeck Curve

2．4．2 Fluid Film Lubrication

2．4．3 Elastohydrodynamic Lubrication

2．4．4 Boundary Lubrication

2．4．5 Mixed Film Lubrication

2．5 Lubricant

2．5．1 Functions of Lubricants

2．5．2 Important Properties of Lubricants

2．5．3 Additives

2．5．4 Classifications of Lubricating Oil

2．5．5 Solid Lubricants

2．6 Cylinder Lubrication

2．6．1 Friction of Piston Skirt and Piston Rings Against the Cylinder Liner

2．6．2 Cylinder Lubrication

2．6．3 Running-in of Liners and Rings

2．7 Sleeve Bearing Lubrication

2．7．1 Plain Bearing's Lubrication

2．7．2 Wear and Failure Modes in Plain Bearings

Chapter 3 Corrosion

3．1 IntroductiOn

3．1．1 Definition

3．1．2 Classification of Corrosion

3．1．3 Corrosion Rate

3．2 Hot Corrosion

3．3 Electrochemical Corrosion

3．3．1 Electrochemical Corrosion Theory

3．3．2 Various Types of Corrosion

3．4 Control of Corrosion

3．4．1 Conditioning the Metal

3．4．2 Conditioning the Corrosive Environment

3．4．3 Electrochemical Control

3．5 Cavitation

3．5．1 Cavitation of Cylinder Liners

3．5．2 Cavitation of Propeller

3．5．3 Cavitation in a Journal Bearing and Fuel Oil Injection System

Chapter 4 Fatigue Failure

4．1 Introduction

4．2 Characteristics of Fatigue Fracture Surfaces

4．3 Nature of the Fatigue Process

4．4 Recognition of Fatigue Failure

4．5 Cyclic Stresses

4．5．1 Fatigue Loading

4．5．2 The S-N Cllrve

4．5．3 Stress ConcentratiOn Factor

4．5．4 Notch Sensitivity Factor

4．6 Factors Affecting Fatigue Life

4．7 Preventing Fatigue Failure

4．8 Thermal Fatigue

4．9 Crankshaft Fatigue Failures

Chapter 5 Defect Detection and Fault Diagnostics

5．1 Defect Detection

5．1．1 Common Testing Methods

5．1．2 Nondestructive Testing

5．2 Machine Condition Monitoring and Faults Diagnosis

5．2．1 Introduction

5．2．2 Temperature Measurement Techniques

5．2．3 Oil Analysis

5．2．4 Performance Trending

5．2．5 Vibration Analysis

Chapter 6 Repairing Technologies

6．1 Electr6pIating

6．1．1 Introduction of Electroplating

6．1．2 Procedure of Electroplating

6．1．3 Typical Electroplating

6．1．4 Brush Plating

6．2 Thermal Spray Coating

6．2．1 Definition of Thermal Spray

6．2．2 Process of Thermal Spray

6．2．3 Classification of Thermal Spray Coating

6．2．4 Applications of Thermal Spray Coating

6．3 Welding

6．3．1 Introduction

6．3．2 Surfacing

6．3．3 Welding Technologies

6．3．4 Welding of Cast Iron

6．3．5 Soldering and Brazing

6．4 Metal Stitching

6．4．1 Introduction

6．4．2 Metal Stitching Process

6．4．3 Locks and Pias

6．4．4 Advantages of the Repair by Metal Stitching

6．5 Adhesion-

6．5．1 Organic Adhesives

6．5．2 Inorganic Adhesives

6．6 Shot Peening

Chapter 7 Ship Repair

7．1 Types of Ship Repair

7．2 Drydocking

7．2．1 Types of Dock

7．2．2 Machinery Overhauls and Repairs During Drydocking

7．3 Dismantling Techniques

7．3．1 Fundamental Rules of Dismantling

7．3．2 Hydraulic Tools

7．3．3 Removing Seized Nuts and Bolts

7．4 Mechanical and Chemical Cleaning

7．4．1 Mechanical Cleaning

7．4．2 Chemical Cleaning

7．4．3 System F[ushiag

7．5 Mooring Test and Sea Trial

7．5．1 Mooring Test

7．5．2 Sea Trial

Chapter 8 Overhauling and Maintenance of Marine Diesel Engine

8．1 Cylinder Head

8．1．1 Inspecting and Repairing of Cylinder Head Cracking

8．1．2 Inspecting and Repairing of Exhaust Valve

8．2 Cylinder Liner

8．2．1 Introduction

8．2．2 Excessive Worn of Liners

8．2．3 Scored Cylinder Liners

8．2．4 Cracked Liners

8．2．5 Scuffing of Liners

8．3 Piston

8．3．1 Piston Wear

8．3．2 Piston Crown Burning

8．3．3 Piston Crown Crack

8．3．4 Reconditioning of Pistons

8．4 Piston Ring

8．4．1 Piston Ring Materials and Coatings

8．4．2 Wear of Piston Rings

8．4．3 Sticking

8．4．4 Breakage／Collapse

8．4．5 Blow-by

8．4．6 Low Piston Ring Tension

8．4．7 Scavenge Port Inspection

8．4．8 Replacement of Piston Rings

8．5 Crankshaft

8．5．1 Crankshaft Alignment

8．5．2 Crankshaft Failures

8．6 Bearing

8．6．1 Classifications of Bearing

8．6．2 Materials and Structure of Bearing

8．6．3 Journal Bearing Failures，Causes and Repairing Technologies

8．6．4 Repairing Journal Bearings

8．6．5 Installation and Checking

8．7 Precision Couplings

8．7．1 Plunger and Barrel Assembly

8．7．2 Delivery Valve and Seat

8．7．3 Fuel Injector

8．7．4 Repair Strategies and Storage for Precision Couplings

8．8 Turbocharger

8．8．1 Turbocharger Construction

8．8．2 Corrosion of the Casing

8．8．3 Overhauling of the Bearing

8．8．4 Overhauling of the Blades

8．8．5 Overhauling of the Sealing

8．8．6 Dismantling and Alignment

8．8．7 Dynamic Balancing of the Rotator

8．8．8 Temporary Measures When Turbocharger Is Damaged

Chapter 9 Ship's Shafting

9．1 Introduction of Ship's Shafting

9．1．1 Shafting Components

9．1．2 Arrangement of Shafting

9．1．3 Establishing Shaft Centerline

9．2 Stern Tube Arrangement

9．2．1 Stern Tube

9．2．2 Water-Lubricated Stern Tube Bearing

9．2．3 Oil-Lubricated Stern Tube Bearing

9．2．4 Sealing Arrangements

9．3 Shafts and Bearings

9．3．1 Intermediate Shaft

9．3．2 Intermediate Bearings

9．3．3 Thrust Bearings

9．4 Propeller

9．4．1 Propeller Geometry and Terminologies

9．4．2 Materials for Marine Propeller

9．4．3 Propeller Types

9．4．4 Propeller Mounting

9．4．5 Failures of Propeller

9．4．6 Methods of Repair

9．4．7 Testing and Measurement

9．5 Shaft Alignment

9．5．1 Types of Misalignment

9．5．2 Shaft Alignment Procedure

9．5．3 Sag and Gap

9．5．4 Sighting Through

9．5．5 Slope Boring／Bearing Inclination

9．5．6 Engine Bedplate Pre-sagging

9．5．7 Jack-up Method

9．5．8 Strain Gauge Method

9．5．9 Alignment Optimization

9．5．10 Reverse Shafting Alignment Calculation of the Bearing Offsets

9．1．3 Establishing Shaft Centerline

9．2 Stern Tube Arrangement

9．2．1 Stern Tube

9．2．2 Water-Lubricated Stern Tube Bearing

9．2．3 Oil-Lubricated Stern Tube Bearing

9．2．4 Sealing Arrangements

9．3 Shafts and Bearings

9．3．1 Intermediate Shaft

9．3．2 Intermediate Bearings

9．3．3 Thrust Bearings

9．4 Propeller

9．4．1 Propeller Geometry and Terminologies

9．4．2 Materials for Marine Propeller

9．4．3 Propeller Types

9．4．4 Propeller Mounting

9．4．5 Failures of Propeller

9．4．6 Methods of Repair

9．4．7 Testing and Measurement

9．5 Shaft Alignment

9．5．1 Types of Misalignment

9．5．2 Shaft Alignment Procedure

9．5．3 Sag and Gap

9．5．4 Sighting Through

9．5．5 Slope Boring／Bearing Inclination

9．5．6 Engine Bedplate Pre-sagging

9．5．7 Jack-up Method

9．5．8 Strain Gauge Method

9．5．9 Alignment Optimization

9．5．10 Reverse Shafting Alignment Calculation of the Bearing Offsets

《轮机维护与修理（英文版）》主要内容包括：The book is divided into 9 chapters， which include the basic theories of maintenance and failure analysis （including failure and maintenance， tribology， corrosion， fatigue failure， defect detection and fault diagnostics）， repairing process and technologies （including mechanical repair methods， electroplating， thermal spray， welding， metal stitching， adhesive， grinding， repairing process， cleaning， dry docking， and testing）， overhauling and maintenance of marine machinery （including cylinder cover， cylinder liner， piston， piston ring， crankshaft， bearing， precision coupling， turbocharger， shafting， and propeller）， installation and alignment （including diesel engine installation， shafting alignment）.