TROUBLESHOOTING SCENARIOS TEMPLATE

F0RM NO
CRO004. Rev. 1

SCENARIO NAME
Main Engine Slowdown – Exhaust Valve No. 5 burned out

SYSTEM NAME
Main Engine

SYSTEM ER Equipment
EQUIPMENTS/INDICATORS - Main Engine
/GAUAGES/PANELS/COMPONENTS - ECR Contol Panel
Alarm and Montioring Equipment
- Signal Columns in ER (inlcuding horn alarm)
- ECR Alarm Computer Panel (Alarm System)
- ECR Gauge Panel
- Main Engine Safety System Panel

SYSTEM DESCRIPTION
Main Engine onboard simulated ship is a crosshead engine of two-stroke
type (Fig.1.). The engine is equipped with scavenging ports and exhaust
valve. Exhaust valve opens at the end of combustion/expansion process
and creates uniflow scavenging system within engine cylinder. Exhaust
valve is operated hydraulically either by mechanical or electrical
activation. In this particular simulator it is assumed that exhaust valve is
operated mechanically (Fig. 2.). Exhaust valve is submitted to high
mechanical and thermal overstresses and therefore is subject to
potential failures. One of the potential failures is exhaust valve burning
(Fig. 3.). that might happen due to various reasons, mainly due to poor
combustion process, fuel quality and/or material quality.

ABBREVATIONS ER: Engine Room

SYSTEM OPERATING AND ALARM
PARAMETERS
ECR: Engine Control Room
ME: Main Engine
EV: Exhaust valve
JCW: Jacket Cooling Water
LO: Lubricating Oil
SWBD: Switchboard
Exhaust gas temperature after each cylinder: 350 – 380 ˚C (Alarm 400 ˚C)

ALARM TYPE When High exhaust gad temeprature is reached an alarm will be on ECR
computer panel followed by alarm/light in signal column. If problem is not
solved on time the ME slowdown function will be activated. Following
alarms and changes will be triggered:
- You will hear heavy sound in ER (beyond sound of running M/E)
- Signal light column for machinery alarm is illuminated
- Message on ECR computer panel will appear: “CYLINDER No. 5
EXHAUST GAS TEMPERATURE HIGH – 400˚C” and “HIGH EXHAUST
GAS TEMEPRATURE DEVIATIONS”
- Local Temperature gauge at Cylinder No. 5 show 400˚C
 If problem is not solved within 30 sec following alarms and changes will
be triggered:
- You will hear heavy sound in ER and machinery alarm light is
illuminated (if privously not acknowladged and silenced)
- Message on ECR computer panel will appear: CYLINDER No. 5
EXHAUST GAS TEMPERATURE HIGH HIGH – 450˚C” and “MAIN
ENGINE SLOWDOWN”
- Alarm lamp No. 12 – Cylinder Exhaust Gas Outlet High
Temperature on SSU unit on ECR Panel is illuminated/blinking
- Local Temperature gauge at Cylinder No. 5 will show 450 ˚C
PLANT CONDITION BEFORE TO Vessel is undreway at full main engine speed and one auxiliry engine
START SCENARIO (generator) is in operation. Present engine speed is 85 rev/min. One
auxiliry engine (generator) is in operation. Exhaust gas temeprature at
cylinder outlet is 360˚C.
Following indication is shown before scenario:
- No any sound alarm in ER – SILENCE (only machinery noise and ME
increasing sound as increase speed)
- Signal light column for machinery alarm is NOT illuminated
- NO Messages on ECR computer panel
- Temperature gauge at each Cylinder Temeprature Guage is 360˚C.

SCENARIO Scenario chronology:

1. Heavy Alarm sound and Signal light column for machinery
alarm is illuminated (Fig.8.)
2. Message on ECR computer panel will appear: “CYLINDER No.
5 EXHAUST GAS TEMPERATURE HIGH – 400˚C” and “HIGH
EXHAUST GAS TEMEPRATURE DEVIATIONS” in red letters (Fig.
4. and Fig. 5.)
3. Local Temperature gauge at Cylinder No. 5 show 400˚C (Fig.9.)
4. ME Revolution gauge in ECR will show 85 in green area
(Fig.10.)
5. Student will have to press ACKNOWLEDGE BUTTON in ECR
computer panel (Fig.6)
6. The alarm horn will SILENT and light on signal column will go
OFF (Fig.8.)
7. The letters on message on ECR computer panel “CYLINDER No.
5 EXHAUST GAS TEMPERATURE HIGH – 400˚C” and “HIGH
EXHAUST GAS TEMEPRATURE DEVIATIONS” will change color
to yellow (Fig.5.)
From this point the time frame of approx. 30 sec should be given to the
student to stop the ME by means of operating lever in ECR:
8. Student will physically have to operate telegraph lever in ECR
to stop the main engine as soon as possible. (Fig. 11.)
9. ME Revolution gauge will start decline and sound of ME will
start to decline (dropping down from 85 towards 0 in green
area) (Fig. 10.)
In case student does not perfrom step 8. following actions will take place:
10. Heavy Alarm sound and Signal light column for machinery
alarm is illuminated (Fig.8.)
11. Message on ECR computer panel will appear: “CYLINDER No.
5 EXHAUST GAS TEMPERATURE HIGH HIGH – 450˚C” and
“MAIN ENGINE SLOWDOWN” (Fig.4. and Fig.5.) in red color
 12. Alarm lamp No.12 – Cylinder Exhaust Gas Outlet High – Jacket
Cool. Fresh Water Outlet High Temp on SSU unit on ECR Panel
is illuminated/blinking (Fig. 7.)
13. Local Temperature gauge at Cylinder No. 5 show 450˚C (Fig.
9.)
14. ME Revolution gauge will start slowly to decline and sound of
ME will start to decline (dropping down from 85 towards 0 in
green area) (Fig. 10.)
15. Student will have to press ACKNOWLEDGE BUTTON in ECR
computer panel (Fig.6)
16. The alarm horn will SILENT and light on signal column will go
OFF (Fig.8.)
17. The letters on message on ECR computer panel “CYLINDER No.
5 EXHAUST GAS TEMPERATURE HIGH HIGH – 450˚C” and
“CYLINDER No. 5 EXHAUST GAS TEMPERATURE HIGH – 450˚C”
and “MAIN ENGINE SLOWDOWN” will change color to yellow
(Fig.5.)
18. The ME will be stopped
FINISHED SCENARIO OR/AND repair work can be carried out as:
19. Close inlet and outlet JCW valves on damaged cylinder – No. 5
(Fig. 12.- valves D)
20. Drain water from exhuast valve casing (Fig. 12. – valve)
21. Switch off ME LO Pump in ECR at main SWBD by pressing RED
STOP button (Fig.13)
22. Close Air spring valve (Fig. 12 – valve G)
23. Remove exhaust valve hydraulic actuator pipe (Fig. 14 - A)
24. Remove bolts on exhaust manifold flange (Fig. 14 - B)
25. Loose and remove nuts at exhaust valve casing (4 nuts - Fig.
14 - C)
26. Remove exhaust valve casing (Fig. 15).
27. Install spare exhaust valve casing (Fig. 15)
28. Install ans tight nuts at exhaust valve casing (4 nuts - Fig. 14 -
C)
29. Re-install and tight bolts on exhaust manifold flange (Fig. 14 -
B)
30. Re-install exhaust valve hydraulic actuator pipe (Fig. 14 - A)
31. Open Air spring valve (Fig. 12 – valve G)
32. Start ME LO Pump in ECR at main SWBD by pressing GREEN
START button
33. CLOSE Drain water valve (Fig. 12. – valve)
34. Open inlet and outlet JCW valves on damaged cylinder – No. 5
(Fig. 12.- valves D)

35. Start ME by operate telegraph lever in ECR to the main engine

and increase rpm to 85 (Fig. 11.)
36. The engine will slowly increase rpm to 85 rpm in time frame of
10 min
37. Temperature gauge at each Cylinder Temeprature Guage is
360˚C (Fig. 9.)

FINISHED SCENARIO
PICTURES, DRAWINGS, Please attach pictures, schematics, drawings not only for describing
SCHEMATICS, ETC. purposes but also software animation.
(eg.);

Fig. 1.: Cross-section of ME

Fig. 2.: Cross-section of hydraulically operated exhaust valve

Fig. 3.: Exhaust valve burning

Fig. 4.: ECR Computer panel

Fig. 5.: ECR Computer panel (screenshoot)

Fig. 6.: ECR Computer panel (Acknowladge button)

Fig. 7.: ME SSU - Safety System Unit Panel installed at ECR panel unit

Fig. 8.: Alarm horn and signal column (Machinery alarm marked with arrow)
Fig. 9.: Local Temperature gauge at each cylinder exhaust gas outlet

Fig.10.: ME Revolution gauge in ECR

Fig. 11.: Telegraph lever in ECR

Fig. 12.: Exhaust valve dismantling procedure

Fıg. 13.: MSWBD Main Switchboard LO pump starter

Fig. 14: Exhaust valve components

Fig. 15. Removal/Installation of exhaust valve casing