MAINLINE ENGINE

OVERVIEW

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Important Terms Related to the Engine

 Arrangement of Cylinders
- Horizontal,
- Vertical,
- V type

 Naturally Aspirated Engines

Drawing intake air directly from atmosphere

 Turbo Charged / Super Charged engines

Recycling of waste exhaust heat by pressurized
supply of intake air and more efficiency of the
engine
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 Main Components of Mainline Engines
•Bed Plate & Main Bearings
•Crankshaft & Flywheel
•Connecting Rod & Piston
•Entablature (Cylinder Block) & Cylinder Liners
•Cylinder Heads
•Camshaft & Cam Followers
•Governor
•Turbocharger
•Radiators
•Various priming and lubricating pumps
• TorsionalVibration Damper
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 Important Systems of the Mainline Engines

• Starting Air System

• Fuel Oil System
• Lubricating Oil System
• Charge Air System
• Cooling Water System
• Injector Temperature Control System (ITCL)

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 Cylinder Liner

Honing operation for cylinder liners to generate crisscross pattern on

liner surface for retention of lubricating oil.
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 Piston

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 Cylinder Head

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 Various clearances
Subassembly Clearance in mm

Crankshaft bearing 0.38

End float 0.635

Deflection Capstan Gauge .090

Journal or pin ovality 0.102

Connecting rod end bearing 0.38

Big end bearing end float

Small end bearing clearance 0.200

Cylinder liner distortion .076

Cylinder
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liner wear 1.524 9

IndianOil
 Various clearances
Sub assembly Clearance in mm
Piston clearance Top Groove 0.300

Piston clearance 2nd grove 0.300

Piston clearance 3rd groove 0.300

Piston clearance Scrapper 0.15

Gudgeon pin 0.15

Piston ring Top ceramic pr. Ring gap in 1.5
unworn part
Piston ring 2nd / 3rd pr. Ring gap in 3.15
unworn part
Piston ring chrome Scraper pr. Ring 2.28
gap in unworn part
Camshaft bearing 0.51

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 BASIC INPUTS IN ENGINE

ENGINE

FUEL LUBE OIL CHARGE AIR WATER

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 MONITORING OF OUR ENGINE

FUEL
IMPORTANT PARAMETERS- FUEL TEMPERATURE

 Measured through a Temperature Valve mounted

on inlet pipe near fuel header

 Fuel Temperature High- 70 Deg C- Ist Stage Alarm

 Fuel Temperature Low- 50 Deg C- Ist Stage Alarm
 Fuel Temp Low-Low- 40 Deg C- 2nd Stage Alarm

Make fuel less viscous, moderates flash point, avoids Cold

Corrosion of nozzle, Improves Fuel efficiency , Reduces fuel
dilution…………………
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 MONITORING OF OUR ENGINE

FUEL
IMPORTANT PARAMETERS- FUEL PRESSURE

 Fuel Pressure Low- 2.5 Kg/Sqcm Ist Stage Alarm

Inadequate fuel combustion, Whitish Smoke

Reasons: Choked Fuel Filter, Improper working of engine
driven fuel pump
 Fuel Level: Through level switch in DST
Low Level Alarm: Ist Stage
High Level Alarm: Ist Stage
 Water content: Draining of DST everyday

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MONITORING OF OUR ENGINE
CHARGE AIR
IMPORTANT PARAMETERS- CHARGE AIR PRESSURE

 NO ALARM
Indicates the functioning of

 Turbocharger
 Oil Bath Filter
 Engine Fuel System Performance
 Leakages in Charge Air Pressure Line

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MONITORING OF OUR ENGINE
CHARGE AIR
IMPORTANT PARAMETERS- CHARGE AIR TEMPERATURE

 CHARGE AIR TEMPERATURE HIGH- 66 Deg C Ist Stage Alarm

Indicates the functioning of

 Turbocharger- Compressor end

 Oil Bath Filter
 Engine Jacket Water & Secondary Water Cooling System
 Efficiency of Charge Air Inter Cooler
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MONITORING OF OUR ENGINE
LUBE OIL
IMPORTANT PARAMETERS- LUBE OIL TEMPERATURE

 Lube Oil Temperature HIGH- 80 Deg C 2nd Stage Alarm

Indicates the functioning of

 Engine Secondary Water Cooling System
 Efficiency of Lube Oil Cooler
 Efficiency of thermostatic valves
 Life of lube Oil
 Quality of lube Oil
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MONITORING OF OUR ENGINE
LUBE OIL
IMPORTANT PARAMETERS- LUBE OIL PRESSURE

 Lube Oil Pressure LO- 2.10 Kg/Sqcm 1st Stage Alarm

 Lube Oil Pressure LO-LO- 1.50 Kg/Sqcm. 2nd Stage Alarm

Indicates the functioning of

 Lube Oil Circulation System
 Efficiency of Engine Driven Lube Oil Pump
 Efficiency of Lube Oil Filters
 Life of lube Oil
 Quality of lube Oil

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 MONITORING OF OUR ENGINE

WATER
IMPORTANT PARAMETERS- JACKET WATER TEMPERATURE

 JW Temp. High- 86.0 Deg C 1st Stage Alarm

 JW Temp. High- High 93.0 Deg C 2nd Stage Alarm
Indicates the functioning of
 Jacket Water Circulation System
 Engine Overall Performance
 Jacket water cooling system
 Thermostatic Valves
 Jacket Water Pump
 Water Quality

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 MONITORING OF OUR ENGINE

WATER
IMPORTANT PARAMETERS- JACKET WATER PRESSURE

 JW Pressure- Low 0.84 Kg/Sqcm. 2nd Stage Alarm

Indicates the functioning of

 Jacket Water Circulation System
 Engine Overall Performance
 Jacket water cooling system
 Level Valve in Make Up water tank
 Jacket Water Pump
 Water Quality

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Air filter
CHARGE AIR/ TURBO-SUPERCHARGING
SYSTEM

Exhaust
chimney
Turbine
Exhaust manifold

After
cooler
Impeller Fixed nozzle ring

Inlet Exhaust

Exhaust manifold
Air
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Piston 20

manifold
 Level Gauge
WATER COOLING SYSTEM

Vent Line Make-

up water
tank

Water Outlet Header

Riser Pipe

Lube Oil cooler

Header
Turbo
Radiator
Cylinders

1 2 3 4 5 6

ENGINE
BLOCK

Water Pump
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 ENGINE CONTROLS & SAFETY
EQUIPMENTS

•Governor : Speed Control

•Over Speed Trip : Trip in case of Overspeed (set at 15% above
normal operating speed)
•Crank Case Relief Valve : Releases excess pressure without
allowing air to get in.
•Oil Mist Detector (OMD) : Detects Oil Mist formation

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 ENGINE CONTROLS & SAFETY EQUIPMENTS

•First Stage Alarms : Indicative Alarms, Engine continues to

run
•Lube Oil Temperature High
•Fuel Oil Pressure Low
•Exhaust Temperature High
•Exhaust temp. Deviation
•Charge Air Temperature High
•Jacket Water Level Low
•Jacket Water Temperature High
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•Gear Box Sump Level Low 23
 ENGINE CONTROLS & SAFETY EQUIPMENTS

•First Stage Alarms : Indicative Alarms, Engine continues to

run
•Engine Sump Level Lo/High
•Lube oil Differential pressure High
•Gear Box bearing Temp. High
•Pump Bearing Temp. High
•Suction Header Pressure Lo
•Discharge header pressure High

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 ENGINE CONTROLS & SAFETY EQUIPMENTS

•Second Stage Alarms : The Engine trips

•Lube Oil Pressure Lo- Lo
•Jacket Water Temperature High High
•Over Speed
•Oil Mist Detected
•Main Bearing Temperature High
•Exhaust Temp. High
•Gear Box Oil Pressure Low
•Lube oil temp Hi-Hi
•Instrumentation Pressure Low
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 ENGINE CONTROLS & SAFETY EQUIPMENTS

•Second Stage Alarms : The Engine trips

•Gear Box Oil Temp. Hi-Hi
•Lube oil temp Hi-Hi
•Instrumentation Pressure Low
•Jacker water pressure Lo-Lo
•Suction header press. Lo-Lo
•Discharge header pressure Hi-Hi
•Pump Casing Temp Hi
•Pump Vibration Hi
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 NORMAL TEMPERATURE AND PRESSURE
SETTINGS IN NEW ‘G;SERIES ALLEN ENGINES

LUBERICATING OIL SYSTEM

Oil pressure at inlet to engine 2.5 Kg/sq.cm.

Max.allowable pr.drp across oil filter 0.7 -do-
Engine oil pr. valve-1st stage alarm 2.1 -do-
Engine oil pr. valve-2nd stage alarm (S/D) 1.5 -do-
Crank case pressure relief valve 0.186 -do-

STARTING AIR SYSTEM

Air receiver fusible plug melting temp. 138 deg.cen.

Air receiver relief valve 0.7 Kg/sq.cm.
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(above normal working pressure) 27
 PREVENTIVE MAINTENANCE PRACTICE

• 250 hrs : Cleaning of glacier filter

• 750 hrs : Over speed Trip Check
• 1500 hrs. : Fuel injectors (clean nozzle and reset)
• 3000 hrs. : Overhauling of fuel injector
• 9000 hrs : Cylinder heads reconditioning, heat exchanger
cleaning, inspection of piston rings, small and big end
bearings, inspection of cam shaft and its drive, stripping
turbocharger and its cleaning
• 18000 hrs : Complete overhaul including withdrawal of liners,
cleaning of cylinder block, inspection of main bearings,
measurement of crankshaft pins. Journals.
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 MAINLINE ENGINE
TROUBLESHOOTING

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TROUBLE SHOOTING (ENGINE DOES NOT START)

Fuel pump cut out lever not in Put fuel lever in run in run
run condition. condition.

Over speed trip not re-set. Re-set over speed trip.

Fuel tank empty/not primed. Open fuel supply valve from

DST to fuel forwarding pump.

Starting air pressure low Recharge air receiver to

correct pressure

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 ENGINE DOES NOT START
Poor compression due to:
 Valve not seating
 Valve sticking in guide
 Starting air valve in
cylinder head not seating
properly
 liners worn out
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 Check tappet clearance.
 Check lubrication , check
valve and valve guide
 Clean / service the valve
 Identify and replace the liner
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TROUBLE SHOOTING (ENGINE STOPS SUDDENLY)

Fuel filter choked Change to other element and

renew the dirty element.

Fuel tank empty Refill fuel tank

Occurrence of second stage Analyze and rectify the fault

fault

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 TROUBLE SHOOTING (ENGINE HUNTS)

Fuel control linkages not free Clean and lubricate

Fuel injection pump delivery Overhaul fuel pump

valve stucking

Dirt in the fuel system Renew filter,clean pumps &

injectors, examine and clean
fuel tank
Air in the fuel system Prime the fuel system

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 TROUBLE SHOOTING (ENGINE HUNTS)

Water in fuel system Drain water and check

centrifuge

Uneven loading of cylinders Check the cylinder

temperatures and rectify

Incorrect governor adjustment Overhaul governor

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 TROUBLE SHOOTING (SMOKY EXHAUST)

Engine overload Check and reduce load

Faulty injection equipment Check fuel pump

Holes in the injector nozzle Check and clean injector

body choked on one Or more
cylinders
Fuel supply to cylinders is Adjust fuel pump racks
disturbed
Nozzle dribbling Overhaul nozzle

Incorrect fuel pump timing Check and rectify timing

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MONITORING OF OUR ENGINE
WATER
IMPORTANT PARAMETERS- JACKET WATER QUALITY

NITRITE LEVEL Above 1500 –2000 ppm

HARDNESS Less than 50 ppm

CHLORIDE Less than 50 ppm

PH 7.5 to 9.5

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 ACTIVITIES FOR 12000 HOURS
MAINTENANCE
1. PRE TEST RUN & RECORDING OF ALL
PARAMETERS. 7.5 to 9.5
2. 250 HOURS SCHEDULE COMPLETED.
3. 1500 HOURS SCHEDULE COMPLETED
4. 3000/4000 HOURS SCHEDULE COMPLETED
5. 6000/8000 HOURS SCHEDULE COMPLETED

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 ACTIVITIES FOR 12000 HOURS
MAINTENANCE
7.DESCALING OF COMPLETE ENGINE DONE &
WATER JACKETS CLEANED
7.5 to 9.5
8.LINER WITHDRAWN, DESCALED INSPECTED,
COPPER JOINTS & LINER ‘O’ RINGS RENEWED
9.RUNNING CLEARANCES OF CAMSHAFT
CHECKED
10.CRANK PIN DIAMETER MEASURED AND
CHECKED FOR QUALITY

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 ACTIVITIES FOR 12000 HOURS
MAINTENANCE
11.PUSH ROD & FUEL PUMP ROLLER GUIDE,
SPRINGS & PUSH7.5
ROD ENDS INSPECTED FOR
to 9.5
WEAR AND DEFECTS
12.LUBRICATING OIL PUMP AND DRIVE
STRIPPED, GEAR, SPINDLES AND BEARINGS
INSPECTED
13.WATER PUMP DRIVE STRIPPED AND
INSPECTED
14.CHECK ENGINE BED PLATE JOINT FOR
TIGHTNESS
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ACTIVITIES FOR 12000 HOURS MAINTENANCE
15.RELATIVE MOTION OF THE FLYWHEEL & DRIVING
PINION SHAFT OF GEAR BOX CHECKED FOR
ASCERTAINING CONDITION OF COUPLING (BETWEEN
7.5 to 9.5
ENGINE – GEAR BOX)
16.ITCL PUMP OVERHAULED
17.HEAT EXCHANGERS IN FUEL MODULE OPENED
CLEANED & PRESSURE TESTED.
18.GEAR BOX MAINTENANCE.
19.EQUIPMENT ALIGNEMENT.
20.TEST RUN TO ASCERTAIN IMPROVEMENT IN
PERFORMANCE.

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Thank you

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