Maintenance & Operation of Deisel Engines Asif Ali RajputContents History of Deisel Engine Working Principles Main Parts and functionHistory Rudolf Diesel, a German national designed first IC engine in 1897 and named it Deisel engine. He was born in 1858 in Paris, and educated at Munich Polytechnic. After graduation he was employed as a refrigerator engineer but his true love lay in engine design. Diesel designed many heat engines, including a solar-powered air engine. In 1893, he published a paper describing an engine with combustion within a cylinder, the internal combustion engine.Patent 1893: Rudolf Deisel obtains patent on his engine design 1897: On August 10 Diesel builds nls rking an Aedatf Diesel Fageninns ¢ Retin1899: Diesel licenses his engine to builders 1906: A diesel engPrinciples of Diesel Operation In diesel engine, air is introduced into the combustion chamber. The air is then compressed by piston in the cylinder with a compression ratio typically between 15 and 22 resulting a 40 bar / 600 psi pressure. This high compression heats the air up to 550 °C / 1000 °F. At this moment, fuel is injected through fuel injector directly into the compressed air in combustion chamber. The fuel injector ensures that fuel is broken down into small droplets, and that the fuel is distributed as evenly as possible. The heat of the compressed air vaporizes fuel from the surface of the droplets. The vapour is then ignited by the heat of compressed air in the combustion chamber. Fuel droplets continue to vaporize from their surfaces and burn, getting anal & smaller, until all the fuel in the droplets has been burnt.Deisel Engine Parts & Function Each engine part has its own particular function to perform and in conjunction with other parts, equally important, comprises the assembly called the jnternal-combustion engine or, in short, combustion engine. An understanding of the operation or functions of the individual parts is necessary for a better understanding of the whole engine. A person who intends to work in the field of diesel-engines, must have know how to recognize the engine parts by sight and mustMarine Diesel EngineFigure 1 The section of cylinder head is taken through the injector, or spray nozzle, andFigure 2 The section through the center line of the engine and in the cylinder head shows the intake and exhaust valves.Engine Parts & Their Function For understanding of the component parts used in the diesel engine, let us see the function of individual engine parts shown in the x-sectional drawings fig 1 & 2:Engine Parts & Their Function Air filter: Adevice for filtering the air, to prevent particles of dust from entering the engine. Air injection: The system of injecting fuel into the combustion chamber of a diesel engine by means of a blast of highly compressed air. Air starter: A system to turn the engine by admitting compressed air into the cylinders in order to initiate firing Atomizer: Breaks up fuel into extremely fine particles for burning inside the cylinder. Bedplate: The lower part of the engine resting on the foundation.Engine Parts & Their Function iston rings placed in the upper part of a piston to seal against loss of compression pressure and Compression Rings: against gas blowing. ‘Combustion chamber. The space above the piston in which the fuel-air mixture starts to burn ‘Common rail: A pipe or header from which branch lines lead to each of the fuel valves in the different cylinder heads of a diesel engine and in which fuet is carried at high pressure, ready for delivery to each separate cylinder when the fuel valve is opened by 2 ‘Connecting rod: The engine part which connects the piston to the crankshaft. It changes reciprocating motion of the piston into rotary motion of the crankshaft or vice versa. ‘Connecting rod bearin:. The bearing located in the large end of the connecting rod by which itis attached to the crankshaft. ‘Crankcase: The middle part of the engine structure surrounding the working parts.Engine Parts & Their Function Cylinder: The cylindrical part of the engine in which the piston moves. Cylinder head. The part which covers and seals the end of the cylinder and usually contains the valves. Exhaust manifold. The pipe that collects the burnt gases as they are expelled from the cylinders. Flywheel. The wheel on the end of the crankshaft that gives the crankshaft momentum to carry the pistons through the compression stroke. Fuel injector. The device which sprays the fuel into the cylinder. Fuel pump. The pump that delivers the fuel to the injectorEngine Parts & Their Function Piston Ring: A split ring placed in a groove of the piston to form a leak proof joint between the piston and the cylinder wall. Super charger: Supplying of combustion air to an engine at higher than atmospheric pressure, usually 2 to 4 psig, in some engines up to 30 psig Tachometer. An instrument indicating instantaneous rotary speed of a shaft in rpm. Water jacket: The outer casing forming space around an engine cylinder to permit circulation of cooling “water.Operating Parameters There are many parameters to monitor, but following are the most important in continuing safe operations: Engine Temperature Lube Oil Pressure Speed or FrequencyChecks Duration Operations Check Every 8 Hours Operation of pre-lube pump. Operation of starting air compressors or battery charger. Batteries are charged. Control po is available to the control system and all controls are in the proper position to allowTrouble Shooting TROUBLE CAUSE REMEDY Engine Cranks Slowly |"resn"smrccion clagesateres Fix cable connection erste Make free to move Towtemporengine ot Maintain Engine Temperature HofisdlBiealtdes Checkfuel injection nozzles Nofuelin injector pump. Check injector pump Pluggedairtitter Clean air fitter Pluggeatuet titer Clean fuel filter Engine Cranks Pluggedtueltankritter Sars Normally, Won't Start Faulty fuel pump. Fuel return system blocked Clear fuel return system No veltage to fuel solenoid nese prNerh serene aieainmateanian Remove contaminants or refi Incorrect inj. pumptiming Foc inj pump timing Low compression Faulty injection pump Rectify inl pump Fuel solenoid closedin RUN position | Open solenoidEngine starts won't idle TacorrecisTow tale SeHING Pluggedairfilter Faultyfastidie solenoid Airin fuel system, fuel retum system blocked, Incorrect Inj. pump timing, No uelto injector pump, Incorrectcontaminatedtuel, Faultyinjection pump Low compression ‘Adjust idie setting Cleanair fitter Adjust solenoid opening Purge air from fuel system Clear fuel return system Fix injection pump timing Maintain fuel level Remove contaminants or refi fresh fuel Fix the injection pump. Maintain Piston clearances Engine starts idle but roughly TncOrTeeT STOW Ia SeRING, Pluggedairfilter, Fuel leakt injection tine Fuel return system blocked Airin fuet system Incorrect/contaminatedtuel Faulty injector! nozzle Low compression. Correct idle setting Cleanair fitter Fix leakage Clearfuel return system Purgeair from fuel system Remove contaminants or refi fresh fuel Fix injector nozzle Maintain Piston clearancesEngine misfires above idle Pluggedtueltitter Incorrectinj. pump timing, Incorrect/ contaminated uel CleanFuel Filter Maintain inj. Pump timing Remove contaminants or refill fresh fuel Engine lacks power Restricted alr intake, Faulty EGR (Exhaust Gas Recycle) Restricted exhaust system, Blocked fuel cap vent (Breather), Restricted fuel supply trom tank to Injection pump, Contaminated 1uel, Faulty injector nozzle, Low compression or throttle linkage adjustment, improper Clearairintake Not applicable in our case Cleartail / exhaust pipe Cleanthe breather Remove contaminants or refill fresh fuel Adjust fuel valve linkage Fix ipj nozzle Maintain clearanceTrouble Shooting Cylinder knocking noise Injector nozzle stuck open, Low injector nozzle pressure, Piston strikes Maintain injection Nozzles Maintain TOC / BDC Engine won't shut off Injector pump solenoid does not shut ofr fuel valve Attendthe Solenoid Valve Engine smokes white Dirty injectors lean out the air / uel mixture, which cause loss of power & rough idle White smoke usually occurs when there is not enough Neat to burn the fuel. Unburned fuel particles go out through the tailpipe and produce a ‘ypical rich fuel sme Bad glow plugs of a faulty glow plugs control module also cause ‘white smoke on engine start up. white smoke is still visible after th engine fas warmed up. the engine ‘Maintain injectors Maintain engine oit ‘Temperature ls not unusualto see white smoke in the exhaust during coldweatheruntithe engine warms up, Maintain glow plugsContinued: Engine smokes white ‘may have one or more bad injectors, felarded injection timing or a worn injection pump. Low Compression can also be a source of white smoke. Maintain retarded injectors, ction timing or a worn, Injection pump ‘Maintain Piston Ring Clearance: Engine smokes black Leaky Injectors enrich air 7 Tuet modure and cause black smoke. Blacksmokeis usually indicates that there's too. much fuel insufficient air Inigstion pump timing is off. The most common cause of black smoke Is an ail inlet restriction; may be dirty air filter, a collapsed intake hose or even an exhaust restriction, Maintain injectors and Injection pump timing. ‘Adjust ip) pump timing Cleaniniet air filter, intake and exhaust linesPreventive Maintenance Diesel Engines are most efficient and durable than any other engines. So, it’s maintenance requirement is preventive in nature. Diesel Engine PM consists of the following operations: * General inspection * Lubrication service * Cooling system service * Fuel system service‘vice Time ‘Daily | Weekiy] Monty | Quarery | Yearhy 1M Schedule for Diesel Engin: Maintenance Requirement Activities Generalinspecton: Look for abnormal noise, vibration and leaks v ‘Check Coolant Level Check Lube Oi Level CheckFuel Level Check Charge Air Piping Clean Air Fiter Z CheckBattery Charger Drain Fuel Fiter Drain Water from fuel tank Checkcoolant concentration Z Check drive belt tension 7 Drain exhaust condensate Checkstarting batteries Zz Change oll and filter = 7 ‘Change coolant filter > Clean crankcase breather ¥ ChangeairFiter element = Z Checkradiator hoses Clean Radiators * v Inspect belt drives and adjust tension 7 * Maintenance requirement are recommended in view of Sul enviroment. Note:. Yearly maintenance intervals are subject to engine condition and performance) dyConclusion Preventive Maintenance for diesel engine generators plays a critical role in maximizing reliability, minimizing repairs and reducing | term costs by followingThank You