Page 22: of Maritime Reporter Magazine (January 2013)

Goltens is not new to taking on some of the most de-manding repairs in the ma-rine industry, with a histo- ry built on performing under some of the most stressful conditions. Expand-ing the company?s horizons, Goltens Singapore won a turnkey contract to complete a challenging project on a barge-mounted power plant, as part of Goltens? global initiative to increase its activities in the power generation market. The 120-MW barge-mounted power plant in Haripur, Bangladesh, owned and operated by power gen-eration providers NEPC and Covanta Energy, has been in operation since 1999. One of its eight Wärtsilä 18V 46GD engines required significant re-pair work, including the supply of a fully reconditioned engine block. The full scope of work was carried out in three locations, culminating in the re-building of the engine and commissioning on-site in Haripur, near Dhaka, Bangladesh in February 2012. This was a challenging project that required complicated logistical arrangements and operations between the Philippines, Singapore and Ban-gladesh.Goltens? started the work by dis- mantling and extracting the 80-ton engine block from an existing power plant in a rural location in the Philip-pines. At this stage, visual inspection and non-destructive testing were per- formed to confirm suitability of the block for the project. Once ready for land transportation, the engine block was transported 50 km to the port by multi-wheeler trailer. The engine block was then loaded onto a heavy lift vessel for onward transportation to Singapore.Upon arrival at the Port of Singa-pore, the engine block was unloaded and moved overnight to the Goltens workshop, accompanied by a police escort for increased safety. Goltens Singapore carried out the modifica-tion and conversion of the used die-sel engine block into a gas-diesel engine block using specialized In Situ Machining equipment. Follow-ing reconditioning in Singapore, the engine block was shipped to the Port of Mongla in Bangladesh by a heavy lift vessel, then loaded onto a barge for onward river towage to the final location.Goltens? dismantled the existing en- gine, jacked up the damaged engine block from its original position and shifted the crankshaft aside. A full inspection of the existing crankshaft was carried out on-site, resulting in honing of the crankpins and main journals, as well as milling counter- weight contact landings. A delicate skidding operation was then per- formed whereby the existing engine block was removed and replaced by the reconditioned block. Goltens? die- sel team then rebuilt the engine cul-minating in successful commissioning and handover in February 2012. ?We are very satisfied with the out- come of the project and our working relationship with the customer,? said Tom Boyle, VP Vice President of Gol- tens South East Asia. ?The engine is running smoothly to the satisfaction of both ourselves and the customer. The In-Situ Machining work on the block and crankshaft, as well as the rebuild-ing and commissioning of the engine, were routine tasks for our experienced Diesel and In-Situ Machining teams, but the logistics were complicated due to various geographic challenges.?Project Fast Facts Project scope: Supply of a fully reconditioned engine block for a barge-mount- ed power plait in Haripur, Ban- gladeshOwned and operated by: NEPC, Covanta Energy Total electric output: 120 MWEngine Type: Wärtsilä 18V 46GD Locations: Philippines, Singapore, BangladeshTECHNICAL FEATURE PROPULSIONMoving MountainsRelocation and Reconditioning of 80-Ton Wärtsilä Engine Block Goltens mobilizes In-Situ Machining and Diesel Engines teams to complete challenging project on a barge-mounted power plant.22 MARITIME REPORTER & ENGINEERING NEWS ? JANUARY 2013 MR #1 (18-25).indd 22MR #1 (18-25).indd 221/2/2013 11:00:21 AM1/2/2013 11:00:21 AM