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.
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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!