SET F

QUESTION 1

Q1 (A)

sketch
Q1 (B) working of the hydraulic actuator on such valve

• Opening and clossing valve

• controlled by a cam mounted on camshaft
1

• cam operates a hidraulic pump

• not by push rod
2
• Oil from camshaft oil supply (2.5 bars) is pressurised
• pressurised up to 200 bar
• acts on a servo piston mounted at the top of exhaust valve spindle
3 • valve open (push)

• valve open
• it compresses air supplied to the air spring (via non return valve) (7 bar)
4 • Provide cushioning effect

• Cam follower move down

• the slope of the cam to the base circle
• the compressed air act on spring piston
5 • valve closed

• Valve closed
• Damping pin enter the top of the server piston
• restricting the flow of oil
6 • preventing the valve from hammering
Question 2

Q2 (A)

Event that may lead to a CRANKCASE EXPLOSION

• * Explosion accour because a source of (air/oxygen,fuel,ignition)

• * Oxygen present in crankcase

• * Lubricating oil splashing around in the crankcase in too large droplets to start burning at speed
needed

• * The oil/air concentration to weak

• * If mechanical fault develops rubbing of moving parts --> (a hot spot accour)

• * This happen in ( crankcase, chaincase, camcase)

• * When temperature o the spot reaches 200 degre celcius --> (lubricating oil splashing on to this spot
vaporises.

• * The vapour circulates to a cooler part of the crankcase

• * And condenses into WHITE OIL MIST

• * The oil droplet in this mis are very small

• * The most comman cause of lacalized hotspot is :

1. friction

2. a cracked piston crown blow

3.external fire have caused crankcase explosion in the past

 • When the concentration of oil mist reaches 50mg/l

• It isat lower explosive limit

• If oil ignited by the hot spot and shown necessary for temperature 850 degree celcius then the
explosion occour

• When explosion accour

• A flame front travel down the crankcase with pressure wave in front of it.

• The turbulence caused by moving engine component causing churning and vq=apourse increase the
speed of flame → (increase in pressure)

• Turbulence caused by venting of the pressurethrough the relief valve → (also influence the explosion)
 Q2 (B) Precaution to be taken to minimize the possibility of explosion and tramision of
dangerous flame into machinery.

Provided bearing temperatures

Use good quality oil
indication and alarm
recommended by engine maker

Installed oil mist detector

Provided arrangement for efficient
purification of lubricating oil

BY DESIGN AND
EQUIPMENT
Provided cranckcase ventilation
Bearing material should be chosen

- minimum friction

-generation of heat

Adequate lubricating oild should be

delivered to the loaded area to assist
Oil pump, filter, cooler and pipeline system hydrodynamic oil film
should be desing

(sufficient at correct pressure and temperature)

 Test regularly and ensure the oil mist
Investigated any sign of overheat detector, monitoring and alarm system
after stopping the engine working properly

Planned maintenance and

inspection of crankcase Hot feel any bearings when
renewed or work on

Continue run the lubricating oil

atleast 30min after stopping Sent oil regularly for
BY OPERATING
PERSONNEL analysis and remedial
based on report

Maintain adequate level of

oil in the sump tank

Maintained L.O
Run L.O purifier at all time temperature and pressure
QUESTION 3

Q3(A) SKETCH calibrating cylinder liner

Q3(B) how to ensured accuracy of calibrations

The micrometer
Should have valid
should be at the same
calibration
temperature as the
cerificate liner

To ensure
accuracy of
calibratios

A gauging point The temperature of

template must be the liner should be
employed to make recorded to allow
sure the reading are for expansion
taken at same place
 QUESTION 4

Q4 (A) HOW different moving parts are subjected to various stresses

Crankshaft →crankweb and crank pins

The main moving

part of the diesel
engine

Piston with rings and skirt, piston

rod, crosshead and guide shoes Connecting rod with
which are vertically reciprocating bearing which both rotate
member and reciprocate

The above component create centrifugal and vertical inertia force and stresses on the part.

The gas pressure in the cylinder → varies pressure change during the cycle

By thermal loading of part when they are not uniformly heated.

Q4(B) MECHANISM of the forces causing these stresses

MECHANISM
of the forces CRANKSHAFT

causing
turning momment due to gas force causing shear
these stresses
stresses
bending moment between main bearing due to gas
force

PISTON AND PISTON RODS

Gas pressure force cause bending and shear on top of

the piston crown.

thermal loading causes stresses upper crown.

the pistone rod comprasive stresses form gas force

CONNECTING ROD

connecting rod stresses are of complex

nature

consist compressive and bending

stresses due to gas pressure & inertia
QUESTION 5 (A) HOW the effectiveness of stuffing box (kotak pemadat) deteriotes (merosot) in
service

▪ The diaphragm gland metallic are in 3 or 4 segments in each set arranged in

layers
▪ The packing segments press against the piston rod & prevent passage of
scavenge air & sludge (enapan) into cranckcase

▪ When the gland segment are new → there is a clearance of 3 – 4mm between
adjacent segment
▪ The gland are made of soft low friction material ( wears as they rub against the
piston rod)

▪ As a result of wear, the segment come closer together

▪ When this happen, → further wear will come in a clearance developing between
the piston rod and the gland segment
▪ Will allow the passage of scanvenge air, sludge and oil

▪ Makers advise replacement of the gland segments when the specified clearances between the
segments reach half of the values
Q5(B) HOW stuffing box gland are overhauled

(AKU PENING …CANNOT BRAIN…)

Occour inside the crankcase

without using the pinston

How stuffing
box gland
overhauled???
QUESTION 6 (A) SKETCH scavenge air supply system.
 Q6(B) WHY scavenge air is normally cooled before its supplied to the cylinder ??

when air is
compressed its getting
hot (polythrophic
compression)

this hot air was put

So, more fuel can be
burnt per cycle
directly into the
engine

excessive thermal loading of the the thermal

engine is avoided and a greater loading on the
mas of air is introduced in engine would
cylinder increase

By cooling the air cylinder

liner surface temperature leading excessively
are kept within limits high exhaust
temperatures

As, air increases in

temperature its And burning of the
relative density
decreases, so volume
cylinder oil from
of air contains smaller the liner surfaces
mass of oxygen
QUESTION 7 (A) SKETCH high lift valve with nozzle effect and blow down adjustment
Q7 (B) identify any SAFETY FEATURE provided that may render the valve inoperative

The lugs will prevent

the guide from fully blocking the steam passage

in case of an accidental loosening

QUESTION 8

WHY the speed continuously fluctuates (turun naik) even under steady load condition? Justifikasikan
jawapan berdasarkan di bawah.

(A) Quality of fuel

➢ A bad fuel will result in ;

1. improper combustion,
2. high exhaust temperature,
3. smoke in the funnel
4. loss of power

➢ The rpm may fall

➢ The fuel contained a large fraction of asphaltenes and unstable due to improper bending
➢ Asphatltenes are hydrocarbon containing a very high proportion of carbon and have poor
burning characteristic
➢ If separation takes place in the service tank, there may be slugs of normal fuel.
➢ Asphaltene compound injected into the cylinder.

(B) The quality of serving of the governer in the last port

➢ The flunctuation of speed

➢ Any retifications should be carried out at the time of servicing of the govener
➢ If the quality of servicing of the govener has been poor, some defect gave rise to the problem

(C) SUPPLY OF CHARGE AIR

➢ insufficient scavenge pressure or improper temperature, will have an adverse effect.

➢ The steady-state operation of the engine
➢ But the engine speed will not fluctuate

(D) Overhaul of fuel injectors at the last de carbonisation

➢ if cleaning all component was not carried out during overhaul..

➢ its possible that one or more injector needle would occasionally stick and resulting speed
flunctuation
QUESTION 9 (A) what is understood by Variable Injection Timing (VIT) and why it necessary ???

To ensure good
fuel efficiency
To provide fuel when engine
sufficient , specific operates at higher
CA point must be rpm
in advance

Some fuel will

burn only after
the cuttoff point ,
resulting in fuel To adjust the
and power less actual duration
of fuel injection
What is VIT
machine ?

Why need VIT ??

CA point → points
of injection and Ensure that the
fuel cutoff will fuel burns fully
reduced when with specific CA
engine operate degree.
higher speed

Provided by CA The injected

between the quantity of fuel
points of needs a definite
injection and time duration to
fuel cutoff at complete burn
certain speed

CA = Crank Angle (unit degree)

Q9 (B) Explain The principle of fuel metering in a jerk type of pump with simple sketches

metering refers to the quantity control of the fuel in jection into the
engine cylinder.
Quantity of fuel injection is controlled by maintaining the relative
vertical position of the pluger helix face in helix jerk pump.
Vertical distance between the helix face and spill port determines the
effective fuel discharges stroke of the pump.
If this distance is greater more fuel will be injected and vice versa.
The position between helix face and spill port is maintained by rotating
the pump barrel through the rack and pinion.
QUESTION 10 (A)
Describe the condition required to take an accurate indicator card reading.

✓ Engine running at full

✓ Indicator cams correctly timed
load.
to engine
✓ Engine should be running
✓ Can be checked by taking a
at between 85% and
compression card with the fuel
100%,
off the cylinder
✓ So, optimum fuel
✓ Compression and expansion
injection condition are
curve should be overlap
being achieved

Condition that need to

take for accurate
indicator card reading

✓ Engine running at steady load

✓ No change of course or speed
reduction
✓ The sea should be calm
 Q10 (B) IDENTIFY the problems that may develop from poor cylinder load balance

Excessive cranckshaft vibrations

Excessive bearing loading on due to unbalanced cylinder
overloaded cylinders leading to loading
bearing failure

problems that
may develop
from poor
cylinder load
balance

Turbocharger surging leading to vibration High exhaust tempertaures from

damage to turbocharger overloaded cylinders, leading to burning
of valve
Q10(C) EXPLAIN using an equation how the power is calculated

IHP = PMLAN 2-stroke

IHP = PMLAN/2 4-stroke

P M = Mean indicated pressure (kN/m²)

L = length of stroke (m)
A = area of piston (m²)
N = no of working strokes per second

✓ Power in Kilowatts
✓ For a 4-stroke engine,N is divided by 2 as there is
one power stroke every two revolution