Aux. Engine: insufficient output (*Engine can't run with full Load, *Rpm doesn’t rise)

Phenomenon1: Cannot Insert The Rack.

Reasons & Countermeasures:
1. Defective Fuel Control System, Due To:
a. Defective Governor.
Countermeasure: Maintenance/Repair.
b. Control Link Is Caught Or Shaky.
Countermeasure: Maintenance/Repair.

Phenomenon2: Excessive Reading on Rack Scale.
Observation: High Exhaust Temperature.
Reasons & Countermeasures:
1. Overload (Torque-Rich).
Countermeasure: Reduce Load.
High Resistance On Moving Parts (e.g. seizing)
(* Cylinder Liners, Piston,
* Crankshaft)
Countermeasure: Maintenance/Repair.

Observation: Low Exhaust Temperature.
Reasons & Countermeasures:
1. Insufficient Fuel Oil Supply Pressure, due to:
a. Defective Fuel Oil Relief Valve
Countermeasure: Maintenance/Repair.
b. Defective Fuel Oil Feed Pump.
Countermeasure: Maintenance/Repair.

2. Clogged Fuel Oil Filter.
Countermeasure: Clean.

3. Water in Fuel Oil.
Countermeasure: Separate And Eliminate Water.

4. Air in Fuel Oil.
Countermeasure: Remove Air.

Phenomenon3: Leakage, Breakage in Fuel Injection System.
Countermeasure: Maintenance/Repair.

Phenomenon4: Uneven Combustion In Between
Countermeasure: refer ‘Uneven Combustion In Between’

Aux. Engine: Abnormal Vibration

Phenomenon1: Engine Sounds

Reasons & Countermeasures:

1. Loose Mounting Bolts.
Countermeasure: Tighten Bolts.

2. Loose Bolts on Holding Moving Parts.
Countermeasure: Tighten Bolts.

3. Excessively Worn Cylinder Liners (Seizing).
Countermeasure: Maintenance/Replacement.

4. Excessive Intake & Exhaust Valve End Clearance.
Countermeasure: Adjustment.

5. Increase in Gear Backlash.
Countermeasure: Adjustment/Repair.

6. Abnormal Lubricating Oil Pump.
Countermeasure: Maintenance/Replacement.

Aux. Engine: Abnormal Noise

Phenomenon1: Knocking
Reasons & Countermeasures:
1. Abnormal combustion, due to:
a. Overcooling Of Engine.
Countermeasure: Warm Up The Engine.
b. Defective Fuel Oil Injection Pump.
Countermeasure: Maintenance/Repair.
c. Faulty Spraying By Fuel Oil Injection Nozzle.
Countermeasure: Maintenance/Replacement.
d. Improper Fuel Oil Properties.
Countermeasure: Use High-Grade Oil.

Phenomenon2: Turbocharger surging.
Reasons & Countermeasures:
1. Improper load conditions.
(Due to: *sticking of Rack,
*sticking of plunger,
*faulty delivery/isobaric valve)
Countermeasure: change the load properly.

2. Defective Turbocharger:
a. Fouled Blower Side.
Countermeasure: Clean.
b. Fouled Turbine Side.
Countermeasure: Clean.
c. Deformed Or Damaged Parts (Diffuser, Turbine Nozzle, Turbine Rotor)
Countermeasure: Replace.

3. Fouled/Clogged Air Cooler Fin.
Countermeasure: Clean.

4. Clogged (Resistance: High) Exhaust Outlet (Exhaust Pipe).
Countermeasure: Clean.

5. Defective Fuel Oil Injection Pump.
Countermeasure: Maintenance/Replacement.

6. Faulty spraying by fuel oil injection nozzle.
Countermeasure: Maintenance/Replacement.

Aux. Engine: Low Cooling Water Temperature(Jacket Line)

Indication: Jacket Water Temperature may not rise.

Reasons & Countermeasures:
1. Excessive flow rate of warming-up water to standby engine. (Particularly under low load). Countermeasure: adjust the flow rate of warming-up water to standby engine.

2. Defective cooling water Temperature control valve.
Countermeasure: maintenance or replace.

3. Low Cooling water Temperature on low temperature side.
Countermeasure: adjustment.

Aux. Engine: High Cooling Water Temperature(Jacket Line)

Indication: high at cylinder collective outlet. Or, high at some cylinders.

Reasons & Countermeasures:
1. Stain in Fresh Water Cooler.
Countermeasure: clean.

2. Air in Cooling Water system.
Countermeasure: Remove air.

3. High cooling water Temperature in Cooler system.
Countermeasure: adjustment.

4. Insufficient cooling water quantity, due to:
a. Defective cooling water pump (damaged/worn impeller).
Countermeasure: maintenance/ replacement.

b. Clogged filter/c.w. piping.
Countermeasure: clean.

C. Improperly regulated water quantity.
Countermeasure: adjustment.

5. Defective cooling water Temperature control valve.
Countermeasure: maintenance/ repair.

6. Overload.
Countermeasure: adjust load.

7. Over heating of cylinder, due to:
a. Clogged cooling water channel.
Countermeasure: clean.

b. Seizing of piston and cylinder liners.
Countermeasure: repair.

8. High exhaust temperature.
(See defect & troubleshooting for High Exhaust Temperature)

Aux. Engine: Low Cooling Water Pressure(Jacket Line)

Phenomenon1: large temperature difference between inlet & outlet.

Reasons & Countermeasures:
1. Insufficient cooling water quantity, due to:
a. Defective cooling water pump(damaged/worn impeller).
Countermeasure: maintenance/repair.
b. Contaminated air cooler.
Countermeasure: clean.
c. Clogged piping.
Countermeasure: clean.
d. Improperly regulated water quantity.
Countermeasure: adjustment.
e. Defective cooling water thermostat valve.
Countermeasure: maintenance/repair.
f. Defective cooling water stop valve (seizing).
Countermeasure: maintenance/repair.

2. Air in Cooling Water system.
Countermeasure: Remove air.

Phenomenon2: small temperature difference between inlet and outlet.

Reasons & Countermeasures:
1. Excessively large cooling water quantity, due to:
a. Improperly regulated water quantity.
Countermeasure: adjustment.
b. Defective cooling water thermostat valve.
Countermeasure: maintenance/repair.

Phenomenon3: Low Cooling water Pressure on Low Temperature side.

Reasons & Countermeasures:
1. Contaminated cooler on Low Temperature line.
Countermeasure: clean/ maintenance.

Phenomenon4: Insufficient amount of water in head tank.
Countermeasure: inspection/supply.

Aux. Engine: High Lubricating Oil Temperature

Reasons & Countermeasures:
1. Fouled Lube oil cooler.
Countermeasure: clean.

2. Defective Lube oil thermostat valve (due to: Damaged pellet or Sticking of Valve)
Countermeasure: maintenance/repair.

3. Insufficient cooling water quantity, due to:
a. Defective cooling water pump. (Damaged/worn impeller)
Countermeasure: maintenance/repair.
b. Clogged filter/cooling water piping.
Countermeasure: clean.
c. Improperly regulated water quantity.
Countermeasure: adjustment.

4. Overload.
Countermeasure: adjust load.

5. Low airtight cylinders (due to: *wear & sticking of piston rings.
*wear of cylinder liners)
Countermeasure: maintenance/repair.

6. Seizing of Bearings.
Countermeasure: maintenance/ repair.

Aux. Engine: Low Lubricating Oil Pressure Or Drop in Pressure during operation.

Reasons & Countermeasures:
1. Low lube oil level in the tank (below lower limit)
Countermeasure: Replenish.

2. Improper oil viscosity.
Countermeasure: Replace.

3. Clogged lube oil filter (pump suction side).
Countermeasure: clean it.

4. Air sucked from inlet side (due to: *damaged piping or *non air-tight joint).
Countermeasure: maintenance/ replacement.

5. Leak from or damage to oil piping (discharge side).
Countermeasure: maintenance/ replacement.

6. Defective Lubricating Oil Pump
(*sticking of safety valve/broken spring
*wear of pump gear
*wear of Bearings)
Countermeasure: maintenance/ replacement.

7. Defective relief valve.
Countermeasure: maintenance/ replacement.

8. Damaged cooling water piping in Lubricating oil cooler.
Countermeasure: maintenance.

9. Wear of Bearings.
Countermeasure: maintenance/replacement.

#'Drop in Pressure during operation' may even happen due to 'High Lubricating oil temperature'..
(Refer 'High L.O. Temp' Defects & Troubleshooting)

Aux. Engine: Unable to stop engine Or Overspeed (activation of protective device)

Reasons & Countermeasures:
1. Defective Fuel control system, due to:
a. Defective Governor
Countermeasure: maintenance/ repair
b. Control Link is Caught or shaky.
Countermeasure: maintenance/ repair.

2. Sticking of Fuel Oil Injection pump rack.
Countermeasure: maintenance/ replacement

3. Abnormal control power supply system
(*abnormal automatic control panel,
*Abnormal/broken electrical contacts for control,
*defective solenoid valve for control,
*abnormal rotation preventive device)
Countermeasure: maintenance/ repair.

4. Defective Fuel Oil Shutdown system, due to:
a. Defective Fuel shutdown device.
Countermeasure: maintenance/ repair.
b. Defective speed detector.
Countermeasure: maintenance/ repair.
c. Insufficient control air pressure
(*clogged piping/filter,
*drop in Pressure)
Countermeasure: clean/ repair.

Aux. Engine stops suddenly

Phenomenon1: Protective Device activated.

Reasons & Countermeasures:
1. Overload (torque-rich)
Countermeasures: refer 'Overload'-defects n countermeasures.
2. Low Lubricating Oil Pressure
Countermeasures: refer 'Low Lube Oil Pressure'-defects n countermeasures. 3. Abnormal cooling water Temperature.
Countermeasures: refer 'cooling water Temperature abnormal'-defects n countermeasures. 4. Defective control power system.
Countermeasure: repair.
5. Defective Fuel Oil Shutdown device.
Countermeasure: repair.

Phenomenon2: Turning is not Smooth or impossible.
Reasons & Countermeasures:
1. Seizing of or damage to moving parts (*piston
*Crankshaft
*Timinggear
*Camshaft)
Countermeasure: repair.
2. Defective drive equipment
(*Generator
*others)
Countermeasure: repair.

Phenomenon3: Normal Turning is possible.
Reasons & Countermeasures:
1. Defective Fuel Oil supply system, due to:
a. No oil in oil tank.
Countermeasure: supply.
b. Clogged fuel oil filter.
Countermeasure: clean.
c. Defective Fuel Oil relief valve.
Countermeasure: repair.
d. Defective supply pump.
Countermeasure: repair.
e. Air in oil.
Countermeasure: Remove air.
f. Improper viscosity of Fuel Oil (HFO)
Countermeasure: adjust to proper temperature by heating.

2. Defective Fuel control system:
a. Defective Governor
Countermeasure: maintenance/ repair.
b. Control Link is Caught or shaky.
Countermeasure:maintenance/ repair.

3. Defective Fuel Oil Injection pump
(*Sticking of rack,
*Sticking of Plunger,
*faulty delivery/Isobaric value)
Countermeasure: adjustment/ replacement.

4. Defective Fuel Oil Injection valve:
a. Faulty nozzle.
Countermeasure: repair/ replacement.
b. Improper opening pressure value.
Countermeasure: adjustment

5. Leakage from Fuel Oil High Pressure block.
Countermeasure: adjustment/ replacement.

Main Engine Crankcase Inspection

Safety Precautions before Crankcase Inspection:
*Ask Bridge for propeller clearance.
*Have proper Immobilization Certificate by the port authorities.
*Carry out Tool Box Meeting and discuss out important aspects of the operation.
*Enclosed space check list needs to be filled and followed.
*Shutoff of main air staring valve and air bottle main valve.
*Open indicator cocks and engage turning gear.
*Ensure engine has been turned for at least half an hour before stopping lube oil pump and cross head lubrication pump.
*Stop lube oil pumps and cross head oil pump and place the circuit breakers in OFF-position.
*Place “Don’t start - Men at work”-placards.
*Open crankcase door and ventilate properly for at-least an hour.
*Use PPE (Personal Protective Equipment), e.g. helmet, boots, water proof boiler suit, gloves etc.
*Use lamp with safeties such as rubber coating and metal mesh on bulb, torches and tools.
*Make sure that you carry counted number of tools inside and count them back when boxing up the crank case.
*A responsible person must be available outside at all times during the inspection.

Inspection Procedure to follow:
*Firstly check oil condition for any smell, discoloration or degradation.
*Turn the engine to BDC and start checking from under stuffing box area for any sign of black oil, an indication of stuffing box leaking.
*Check the piston rod surface for scoring marks and roughness.
*Check piston palm bolts and locking device for slackness and fretting by hammering using a brass hammer.
*Check the guide and guide shoe bearing's condition and the area around frame where guide is attached for any visible cracks.
*Check that the guide shoe end cover bolts are in place and not slack.
*Check X-head bearing general condition.
*Evaluate top and bottom end of connecting rod bolt, nut and locking device for slackness, signs of fretting, etc.
*Check for sliding of bottom end bearing (axial movement) or floating of connecting rod.
*Check for slip of webs and journal by checking the reference mark.
*Check cross girder, area around main bearing & bearing-keep for sign of cracks and check around main bearing.
*All bearings must be checked for silvery color (indicates bearing wiping).
*Check the surroundings of the oil pan area of all units for any sludge deposits, bearing metal pieces, etc.
*Check crank case relief door- wire mesh (should be wet), spring tension, sealing ring condition, etc.
*Check the teeth of transmission gear for sign of wear at the chain case.Check chain drive for tightness.
*Inspect OMD sampling pipe to be clear of obstructions.
.
.
Carryout CRANK SHAFT DEFLECTION.
.
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*Start lube oil pump and x-head lubricating pump and check for the oil flow and distribution.
*Check crankcase door sealing condition and close the crankcase door.
*Inform chief engineer (for satisfactory checking of crank case) and duty officer!
*Fill out the inspection survey form and get it signed by C/E.
*Fill out the Crankshaft deflection form and keep in the record book!
*Mention with time that Crankcase Inspection was carried out in the E/R Log Book!

Raja Bhoj & the Farmer woman..

Once Raja Bhoj and Magh Pandit were out for the walk, but while returning they lost their way. Confused both as they couldn't find their way back to Ujjain, decided to ask someone as the dusk started to deepen.
"Lets ask way for Ujjain from that woman who is working on the Wheat field nearby" suggests Magh Pandit.
Both approached the woman at her Wheat field.

Raja Bhoj: greetings lady, where does this road go to? Please tell.

Woman answers, "the road stays here only, but goers are those who travel on it. And who are you both?"

Raja Bhoj: lady, we are ambulators.
Woman: ambulators are two. One, the Sun and two, the moon. And who are you?

Raja Bhoj: we are guests.
Woman: guests but are two. Wealth & youthhood. But who are you?

Raja Bhoj: I'm the King.
Woman: Kings are two. Indra & Yama. But who are you?

Raja Bhoj: I'm Gracious.
Woman: gracious are two, the Earth & women. But who are you?

Raja Bhoj: we are strollers.
Woman: strollers are two. Life And the Leaf of a tree. But who are you?

Raja Bhoj: we give up. We surrender.
Woman: surrenderers are two. Debtor and the Bride's father.
Woman: (smiling) I can tell that you are his Majesty Raja Bhoj and you sir are Pandit Magh. Please take this route, it leads to Ujjain. You would reach Ujjain before nightfall.

Remark: In olden days, the Kings\Rulers used to superintend & examine that whether or not their schemes have taken into effect. To ensure that the schemes & projects are helping the beneficiaries, they often used to disguise themselves as commoners and take an audit among the people. This is whence the interesting conversation happened.

Comment: people then, were good at communication skills, creative, innovative and had great oratorship!
Its irony that the present-generation is leaning & likely predisposed to be 'pancake people' (& me too) :p