REVIEWER MATERIAL FOR MIDTERM: PPD

3 different methods in starting marine diesel engine generator:

 Air Starting System or pneumatic system

 Hydraulic Starting system
 Electric starting system
GENERATOR: is known as the heart of the ship.

 The air stored in receivers which are charged by compressors. A pressure of

about 28 bars is usual.
 The opening of the remote operating valve and the air starting valve is controlled
by a pilot air system.
 The pilot air is drawn from the large bore pipe and passes to a pilot air control
valve which is operated by the engine starting air lever.
 Another supply of pilot air for the appropriate direction- ahead or astern- is
passed to the air distributor.
 Timing is controlled by cams or gear drive from the engine camshaft.
 Interlock is shown in the remote operating valve line which stops the valve
opening when the engine turning gear is engaged.
 Remote operating valve prevents the return of air which has been further
compressed by the engine into the system.
 In order to prevent such an occurrence, cylinder starting valve should be
properly maintained and pipelines regularly drained.
 Power Management System (pms).
 Hydraulic starters are alternative starting systems, most commonly used in
the marine, oil and gas, mining and construction industries.
 Electric Starting System starting motor for diesel and gasoline engines
operates on the same principle as a direct current electric motor.
 Motor is designed to carry extremely heavy loads but draws a high current (300
to 665 amperes), tends to overheat quickly. Run for 30 sec / cool 2-3 minutes.
 The starting motor is located near the flywheel and drive gear on the flywheel.
 Mechanical governors: the output or controlling force is created by centrifugal
force acting on a set of rotating weights.
 Hydraulic Governors: the rotating weight assemblies connect to a control valve
rather than directly to the fuel control racks.
 Electric-Hydraulic Governors: normally utilized in nuclear service have a
governor actuator w/ 2 sections a mechanical hydraulic backup governor and an
electric governor.
 Filter is a fine mesh screen which is used to remove impurities from oil, water,
and air on the ship. Fitted on discharge side.
 Strainer is a type of filter used mostly on low pressure or suction side and is
used to remove large contamination particles from the system.

 Larger cargo vessels: maximum speed of 100–130 rpm.

 Heavy fuel has to be heated to 110–130⁰C.
 Smaller vessels: medium speed engines 720–750 rpm.
 Reduction gear reducing the revolutions about 100–120 rpm.
 Specialized vessels use offshore support vessels and some cruise vessels use
diesel electric propulsion systems with thrusters, commonly known as pods.
 Thrusters can turn 360 degree.
 CPP propeller: To increase or reduce the vessel’s speed the pitch is altered
increased pitch will give increased speed. Movable pitch type.
 Fixed pitch propeller: To increase or reduce the vessel’s speed, the rpm of the
propeller is increased or reduced. A propeller with fixed pitch.
 Most commonly used propellers on cargo vessels have four or five propeller
blades.
  The propeller: diameter of more than 9 meters / weight of 130 tons. Commonly
used materials are stainless steel / bronze alloy.
 Low-speed two-stroke diesel: 70 to 120 rpm.
 Medium-speed four-stroke engine: 250 to 1200 rpm.
 High-speed diesel engine: Trunk piston type engine 1400 rpm or above.
 Medium-speed diesel engine: Trunk piston type engine 400 rpm to 1200 rpm.
 Low-speed diesel engine: Crosshead type engine less than 400 rpm.

Main Component of Diesel Engine:

1. Engine block: made of nodular cast iron. They are guided sideways by the
engine block at the top as well as at the bottom.
2. Crankshaft: The crankshaft is forged in one piece. Counterweights are fitted on
every web.
3. Connecting rod: The connecting rod of alloy steel is forged and machined with
round sections.
4. Main bearings and big end bearings: tri-metal type with steel back, lead
bronze lining and a soft and thick running layer.
5. Cylinder liner: Has a high and rigid collar to minimize deformations and the liner
material is a special grey cast iron alloy.
6. Piston and piston rings: The piston is of composite design with nodular cast
iron skirt and steel crown.
7. Cylinder head: The cylinder head is designed for easy maintenance with only
four hydraulically tightened studs.
  The gear tooth profile is produced using a horizontal machining process known
as “Hobbing”.
 Engine indicator: is the device used to take the indicator diagram, which can be
considered as a 'stethoscope' for diesel engines.
 Indicator diagrams give efficiency of combustion in the cylinder.
 Pcom: Compression Pressure
 Pmax: Maximum Pressure
 The area of indicator diagram is calculated by Planimeter.

4 types of indicator diagrams that can be taken from the engine cylinder to know the
condition and performance of the engine:

1. Power card / Power indicator diagram: taken with the indicator drum rotating
in phase with the piston movement.
2. Compression diagram: taken in similar manner to the power card but the fuel
shut off in the cylinder.
3. Draw card / Out of phase diagram: taken in a similar manner to power card
with fuel pump engaged.
4. Light spring diagram: taken similar to the power card and in phase with the
engine and with a light compression spring fitted to the indicator.

 Mean Indicated Pressure (MIP)

Irregularities in Indicator Diagram:

1. Early Ignition
2. Late Ignition
3. After Burning
4. Leaky Fuel Injector
5. Partly Choked Fuel Valve
6. Low Compression
7. Exhaust Valve Opening
8. Choked Exhaust

 Crosshead is a mechanism used as part of the slider-crank linkages of long

reciprocating engines.
 Crosshead piston is a two-piece unit with a crown that can withstand the high
heat and pressure.
 Crown and skirt are held together by the piston pin.
 Lubricating oil is fed upward by pressure to cool the piston pins and piston
crown.
 Jacking gear (also known as a turning gear) is a device placed on
the main shaft of an engine or the rotor of a turbine.
 Turning gear is a reversible electric motor connected with the toothed flywheel
to turn a large diesel.
 The turning speed of the flywheel is about 0.6 RPM.
 The engaging and disengaging of the turning gear is accomplished by the lever
with yellow ball knob.
 The turning device is provided with a start blocking valve which prevents
starting if the turning gear is engaged.
 Engine is a machine that converts the heat energy of fuel into mechanical
energy.
 Stroke is the distance traveled by the piston from top to bottom dead center and
vice versa. 180 revolution of the crank angle.
 Intake Stroke: This process begins with the piston moving from TDC to BDC.
 Compression Stroke: Once the piston reaches from BDC to TDC compressing
the air within the cylinder.
 Combustion Stroke: This is where the power is created
 Exhaust Stroke: The combustion produces energy and causes the gas to
expand.
 Four Stroke Engine: For one power stroke, it takes 2 revolutions of the
crankshaft.
 Two Stroke Engine: For one power stroke, it takes one revolution crankshaft.
 What is crankcase explosion: It is an explosion that occurs in the crankcase
because of the mixture of oil mist and air in the ratio that is within the range of
flammability.
1. Minimize the formation of explosive mixture breather pipe or exhaust fan
fitted on crankcase.
2. Prevent the formation of hot spot in the crankcase.
3. The piston with rings and cylinders should be in safe working limits.
4. Good fitting and efficient locking of working parts.
 Malfunctioning and diesel engine failures are the most common cause for
emergency.
 The normal engine jacket outlet temperature is usually maintained at about 68 to
70 degree Centigrade.
 Piston cooling outlet temperature about 55 degree Centigrade.
 The lubrication oil temperature is maintained to about 40 degree Centigrade.
The main diesel engine cooling systems consists of the following:

1. Jacket Cooling Water System: The water circulates inside the engine
compartment surrounding the cylinder liner and also the cylinder head.
2. Piston Cooling Water System: Water after passing through the piston
compartments is allowed to flow out to a collection tank outside the engine
3. Lubrication Oil Cooling System: Oil after lubricating the moving parts of the
bearings will finally drop down to the sump tank of the engine.
4. Fuel Valve Cooling Water System: This component of the engine is subjected
to intense heat of the combustion and needs to be cooled. 92 degree
centigrade.

Generally four major types of protection systems are used to secure the propulsion
engine:

1. Alarm: Early warning of the problem.

2. Slow down: The engine is slowed down to counteract the disrupted parameter.
3. Shut down: Safety devices cut off the fuel supply and the engine stops.
4. Starting Interlock: This will not allow the engine to start from the stand-off
condition.

ALARM:

 Fuel oil high temp

 Fuel oil Low pressure
 High exhaust alarm
 Expansion tank low level alarm
 Jacket cooling water high temp alarm
 Jacket cooling water low pressure alarm

Different Starting Interlocks are:

 Turning gear engage interlock: this system prevents the engine from starting.
 Running Directions Interlock: It avoids the supply of the fuel if the engine’s.
 Auxiliary blower off interlock: In case of constant pressure turbo charging.
 Starting Air Distributor in end position: This prevents starting from taking
place.
 Air Spring Pressure Interlock: controlling the present generation of engines
using exhaust valves shut down.