Gas Engines

(Working & Maintenance)

Presented By: Mohsin Imtiaz

 Contents
• Introduction to Engines
• Spark & Compression Ignition Engines
• Construction
• Engine Systems
– Speed Governing System

– Fuel System

– Ignition System

– Air Intake System

– Turbocharger System

– Auxiliary & Jacket Water System

– Lubrication System

• Maintenance Plans
 Introduction to Engine

“ Engines convert chemical energy of the fuel into

thermal by combustion and then convert thermal
energy into mechanical by expanding high pressure
gases inside the cylinder ”
 Introduction to Engine

Water
Jacket

Piston
Cylinder
Connecting
Rod

Oil Sump
Crankshaft
 Introduction to Engine
Feature 12V275GL+ L7042GL

No. of Cylinders 12 12
Bore x Stroke (mm) 275 x 300 238.125 x 215.9

Compression Ratio 9.0:1 10.5:1

Dry Weight (Ton) 23.5 9.5

Power Rating (BHP) 3625 1480

De-rated Power at Site
3254 1443
Conditions
Rated Speed 1000 1200

Hydro-Mechanical or Hydro-
Speed Governing System ESM Controlled
Electrical Governing

Fuel System Lean Burn, ESM Controlled Lean Burn, Manual Control
 Spark Ignition Engines

Carburetor prepares fuel air mixture

Ignition by spark plug

High pressure gases expand over piston top

Energy transmitted to crankshaft

 Compression Ignition Engine

Compressed air is introduced in the cylinder

Fuel is injected by nozzles

Fuel auto-ignites and gases expand over piston top

Energy transmitted to crankshaft

 Four Stroke SI
Engine Intake
Valve
Exhaust Valve

Spark Plug Cylinder

Head

Intake Stroke
Water
Piston Jacket
Compression
Stroke

Cylinder
Power Stroke

Exhaust Stroke
Connecting Rod
 Construction (Left Side)
Thermostat Water Manifold Venturi Extractor

Exhaust
Manifold

Emergency
Stop Switch
Lube Oil
Cooler Manual
Barring
Device
Microspin

Breather Flywheel

Pre Lube Lube Oil

Pump Filter

Aux. Water Pump Crankcase Regulator Carburetor Lube Oil Pan Access Doors
 Construction (Right Side)
Emergency
Air Filter Stop Switch
Housing
Prechamber
Manifold
Intercooler Prechamber
Regulator
Exhaust
Manifold Governor

Intake Lube Oil

Manifold Cooler
Thermostat

Starting Lube Oil

Motor Pump

Lube Oil Manual Carburetor Regulator Ignition Module Magneto Drive

Strainer Shutdown Lever
 Speed Governing System

Speed governing system comprises of following components:

Electro-Pneumatic Actuator

UG-8L Governor (for EK-1501 A/B/C Engine)

EG-3P Actuator (for EK-1501 D Engine)

ESM Actuated Throttle (for EK-1521 A/B/C Engine)

Mechanical Linkages

Carburetor Butterfly Valve

 Speed Governing System

Output shaft Speed setting

lever shaft lever

Actuator
I/P
Governor convertor
UG-8L
Instrument
Butterfly Valve Gas Supply

Engine Speed Reference Signal

From PLC

Speed Governing System of EK-1501 A/B/C

 Speed Governing System

Output shaft
lever
4-20mA Signal from
Electronic Governor

Actuator
EG-3P
Butterfly Valve

Speed Governing System of EK-1501 D

 Speed Governing System
Air inlet
Pressure drop
communicated to back of
diaphragm through holes
causing air/gas valve to rise

Diaphragm
Gas metering
Air Valve valve
Gas
Inlet

Butterfly
Governor opening
butterfly in
response to load
increase/RPM
decrease
 Fuel System
Start gas

PRVs To Flare Header

Scrubber Pressure Regulator

Suction PSV
From Main

Filter
Fuel Gas
Header (~475
45-60 Psig
Psig)
150 Psig

Main Fuel Gas To

Pressure Regulator Prechamber
R.B.
Carburetor R.B. Relay Gas
Valve

Carburetor L.B.
Main Fuel Gas Pressure
Regulator L.B.
 Fuel System

Cylinder Head

Prechamber Gas
Pressure Regulator
Admission V/V

Prechamber Manifold R.B.

Prechamber Manifold L.B.

 Ignition System
Spark Plug

Ignition Coils

Spark Plug Lead

Wire Conduit R.B.

24V Supply Ignition Module Input from Hall

Effect Pickup

Wire Conduit L.B.

Spark Plug
Extension

Spark Plug
Carrier
 Ignition System

Ignition Coil

Manifold
Prechamber
Spark Plug Carrier

Cylinder Head

Spark Plug

Prechamber
Admission Valve
 Air Intake System

Exhaust gas in
Exhaust gas out

A.W. in

A.W. out
Intake Turbocharger
From Atm Air
Filter

Intercooler
Intake Manifold

Air/Fuel mixture

Fuel Gas
 Turbocharger System
Turbine
Waste Gate

Air
Compressor
 Auxiliary Water System

Auxiliary A.W.
From Compressor
Coolant Section J.W.
L.O. cooler
Surge Tank
2 Compartment

A.W. Pump

To Compressor
L.O. cooler

Engine L.O. cooler Turbo Intercooler

 Jacket Water System

Surge Tank
2 Compartment A.W.
J.W.

From Water
Manifold

To Engine
J.W. header
J.W. Pump

Jacket Coolant
Section
 Jacket Water System

Water Outlet Elbow

Water Manifold

Cylinder Head
Exhaust Manifold
Segment

Crank Case

Cylinder Sleeve

From J.W. header From J.W. header

Lubrication System

Rocker Arm
Oil Header Turbocharger

Cam shaft

L.O. Header

Crank shaft
 Lubrication System

Drilled Passages in Crank Drilled Passage in Connecting

Shaft Rod
Lubrication System

Internal Passages to
cam shaft bearings
Lubrication System

Rocker arm Oil Header

 Maintenance Plans
Maintenance Type Major Activities
- Oil Replacement
- Oil Filters Replacement
2500 Hrs - Spark Plug Cleaning
- Carburetor Inspection
- Tappet Adjustment
- 2500 Hrs Maintenance Scope
4000 Hrs - Cylinder Compression Test
- Borescopic Inspection of Cylinders and Heads
- 4000 Hrs Maintenance Scope
- Crankshaft Web Deflection Checks
8000 Hrs
- Engine to Compressor Alignment
- Inspection of Turbochargers
- 8000 Hrs Maintenance Scope
Top End Overhauling
- Reclamation of All Cylinder Heads
- Top End Overhauling Scope
- Replacement of All Piston, Liners and Bearings
Major Overhauling
- Inspection of Camshaft and Crankshaft
- Inspection / Cleaning of Crankcase