INTRODUCTION TO

GAS & DIESEL

ENGINE
• What is engine?
Engine is a mechanical equipment which convert thermal energy in the
fuel into mechanical energy through Thermo-Dynamic Process.

FUEL THERMO-DYNAMIC (COMBUSTION) MECHANICAL

ENERGY

Diesel Fuel (Cetane) :

C16 H34

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Engine Classification
HEAT ENGINE

EXTERNAL COMBUSTION INTERNAL COMBUSTION

• STEAM ENGINE RECIPROCATING ROTARY

• STEAM TURBINE

SPARK IGNITED COMPRESSION IGNITED

* GASOLINE ENGINE * DIESEL ENGINE * GAS TURBINE

* GAS ENGINE * WANKEL

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ENGINE
COMPARISON BETWEEN DIESEL ENGINE & GASOLINE ENGINE

COMPARISON DIESEL ENGINE GASOLINE ENGINE

Type of IGNITION Heat of Compression Spark from Ignition system
Type of Induction Only fresh air at intake Mixture of fuel and air
Fuel Charge Method Injected to Combustion ~ Carburetor
Chamber ~ Injected to Intake Manifold
Fuel (Heating Value) Diesel (162,000 BTU/gal) Petroleum (146,000 BTU/gal)
Combustion Gradual, constant Spontan, constant volume
pressure
Thermal Efficiency Higher (30-55 %) Lower (20-35%)
Compression Ratio Higher (1 : 13 – 22) Lower (1 : 8 – 11)
Engine Speed Lower (300-2,500 rpm) Higher (1,000-15,000 rpm)
Torque Relatively higher Relatively lower
Construction Heavier & stronger Lighter

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• Advantages of the diesel engine
• Better efficiency: due to the higher compression ratio, the combustion is
more complete giving a lower specific consumption (on average of 200
g/kW/h compared to 330 g/kW/h for a petrol engine).
• Higher engine torque which remains approximately constant at low speeds.
• Cheaper fuel.
• Lower fire risks
• Exhaust gases less toxic

• Disadvantages of the diesel engine

• Mechanical components must be over dimensioned.
• High operating noise
• High temperature in the combustion chambers which requires more efficient
cooling
• Cold starting not as good as with a controlled ignition engine

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TYPICAL CONSTRUCTION

6
MAIN COMPONENTS

7
MAIN COMPONENTS

8
MAIN COMPONENTS

 CYLINDER BLOCK
As a back-bone of Engine
components. There are two types :
~ Dry type, using cylinder sleeve.
~ Wet type, using cylinder liners.
Cylinder Block has water jacket
cavities for coolant and lube oil rifle
passages.

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MAIN COMPONENTS
 PISTON & RINGS
There are two types of Piston :
~ One Piece, aluminum piston
~ Two Pieces, ductile-iron piston
Each Piston is usually equipped with :
 Two Compression Rings
 One Oil Rings & Expander

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MAIN COMPONENTS

 CONNECTING RODS
Functions to transfer Pistons motion
Small to the crankshaft.
End
It has two replaceable bushings.

Big End

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 MAIN COMPONENTS

 CRANKSHAFT
Crankshaft converts translation motion from the piston
movements into rotational motion to drive flywheel and other
engine accessories.

Main Bearing Journals

Lube Oil Passages

Rod Bearing Journals
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MAIN COMPONENTS

 CYLINDER HEAD(S)
~ As a top roof of Combustion Chamber.
It has special gasket to prevent leak of
compressed gas.
~ Place for Intake & Exhaust valves
mechanism. It also has passages for Intake &
Exhaust Ports.
~ Mounting for Intake Manifold (Aftercooler)
& Exhaust Manifold.
~ Place for Fuel Injector/Nozzle.

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 DIESEL ENGINE

COMBUSTION CHAMBER
There are two types of Diesel Combustion Chamber :
 Direct Injection (DI) Combustion Chamber
 Indirect Injection / Pre-Combustion Chamber

Direct Injection
 Fuel is directly injected into
the combustion chamber.
 Piston crown has a capsized
heart shape, to create
turbulence effect of fuel.
 Utilize Multi-hole Injection
Nozzle having high injection
pressure for fine atomization
between fuel and air.
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DIESEL ENGINE
COMBUSTION CHAMBER

Indirect Injection / Pre-Combustion Chamber

 Fuel is injected into a pre-

combustion chamber. Some fuel
is burnt there, then enter the
cylinder through a narrow troath
passage.
 Usually use single-hole Pintle
Injection Nozzle having lower
injection pressure.
 Reduce the vibration of the
engine, lower exhaust emission,
not sensitive with fuel grade, but
having lower efficiency than
Direct Injection in counterpart.
 Utilize a Glow Plug to pre-heat
the chamber for easy starting.
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• Two combustion techniques are used:

• Injector energy: used in large slow-running engines

• Swirl: this is the most commonly used process on all modern engines

Injector energy
Swirl chamber

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• Indirect injection - Engine with pre combustion chamber

• The pintle injector is placed on the cylinder head and in a non-cooled

cavity called the "pre chamber".

• The fuel injected into this pre chamber starts to burn since it contains air
that has been previously compressed

• This staged combustion reduces operating noise since the injection

pressures are moderate

Pintle injector

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• Indirect injection - Engine with swirl chamber:

• This system is a variation of the previous one, the swirl chamber

represents almost the totality of the combustion chamber volume.

• This prechamber communicates with the cylinder via a large-section

cone-shaped orifice

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• Indirect injection - Engine with air chamber:

• The reserve of air communicates with the cylinder through a large

orifice but the injector is placed outside this chamber

• These systems were abandoned several years ago

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MAIN COMPONENTS

 VALVE
Common engine has two kinds of
Valves in the cylinder head, to control the
flow of intake air and exhaust gases.
o Intake Valve, has bigger diameter.
o Exhaust Valve, smaller diameter but strong.

Both valves are driven by a Valve Train

mechanism.

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 MAIN COMPONENTS

• CAMSHAFT
• Camshaft functions to control the opening and
closing of the Intake and Exhaust Valves at the
correct timing as Engine Firing Order (FO).
• Camshaft has several number of “LOBES”,
to lift the valves.
• Camshaft is driven by Crankshaft.
• At “Four Stroke” Diesel Engine, camshaft speed
is a half of crankshaft speed. (Two crankshaft
revolutions equals to one camchaft revolution).
• Camshaft to crankshaft is connected
by three manners:
~ Using Drive Gears (OHV).
~ Using Chain (OHC/DOHC).
~ Using Drive Belt (OHC/DOHC).

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 MAIN COMPONENTS

 VALVE TRAIN MECHANISM

Functions to open and close Intake and Exhaust Valves as
sequence Engine Firing Order.
Based on the position and number of the camshaft, there are
three configurations of Valve Train Mechanism :
 OVERHEAD VALVE (OHV)
 OVERHEAD CAMSHAFT (OHC)
 DUAL OVERHEAD CAMSHAFT (DOHC) 22
DIESEL ENGINE
MAIN COMPONENTS

• Overhead Valve (OHV)

• Camshaft is located at Cylinder Block,
which is driven directly by Crankshaft by
gears.
• Camshaft lifts the “Valve Lifter/Tapped” and
“Push Rod” to actuate “Rocker Arm”
which pivoted at a shaft.
• Usually used at old design engines and no
longer used at modern engines, d/t more
number of components and slower response
time than OHC.

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DIESEL ENGINE
MAIN COMPONENTS

• Overhead Camshaft (OHC)

• Camshaft is located at Cylinder
Head, which is driven by Crankshaft
by a “Timing Chain” or “Timing
Belt”.
• Camshaft lobes directly push the
“Valve Stem” or via a “Crosshead”.
• Usually used at modern engines,
d/t less number of components and
higher response time than OHV.

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DIESEL ENGINE
MAIN COMPONENTS
• Dual Overhead Camshaft
(DOHC)
• Same as OHC, instead has two
camshafts at cylinder head.
• Usually has four valves per cylinder,
two intake valves and two exhaust
valves.
• One Camshaft drives Intake valves,
while another drives exhaust valves.
• Usually used at very modern engines,
which has high performance.

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DIESEL ENGINE
MIAN COMPONENTS

 FRONT GEARS
Crankshaft Gear at the front turns
several gears;
~ Camshaft Gear.
~ Fuel Pump Gear.
~ Water Pump Gear.
~ Oil Pump Gear.
~ Accessories Gear.

There are two types of gears :

~ Spur Gear, has straight teeth.
~ Helical Gear, has helical teeth for
reducing noise.
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 DIESEL ENGINE
MAIN COMPONENTS

 FLYWHEEL
o Flywheel is attached to the rear of the Crankshaft.
o Flywheel saving inertia moment to ensure continuous rotation.
o Engine driven equipments, such as Generator, Compressor or Pump Input
Shaft is coupled at Flywheel by means of a Coupling.
o Flywheel has hundreds teeth at its outside diameter for:
 Engine Magnetic Pick-up(MPU) for speed detection.
 Starting the engine by means of a Starter Motor.
 Barring the engine for maintenance purpose such as Valve Lash Adjustment.
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 DIESEL ENGINE
ENGINE CONSTRUCTION

VIBRATION DAMPER
 Vibration Damper is attached to the
front of the Crankshaft.
 As its name, it used for absorbing the vibration by means of
special liquid inside.
 Sometimes equipped with a pulley to drive “Cooling Fan” and
“Alternator”.

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DIESEL ENGINE
MODERN ENGINE CONSTRUCTION

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2. Diesel Engine Cycle (4-stroke)
CHARACTERISTICS
.

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2. Diesel Engine Cycle (4-stroke)
TERMINOLOGY
• Bore: internal Ø of the cylinder.
• Stroke (C): distance between the TDC (or UDC) and the BDC (or LDC).
• Dead centre points: extreme position of the piston at the top or bottom of its stroke.
• TDC (or UDC): top dead centre (or upper dead centre), the piston is at the highest point on its stroke.
• BDC (or LDC): bottom dead centre (or lower dead centre), the piston is at the lowest point on its
stroke.
• Combustion chamber (CC): space between the TDC and the cylinder head.
• Dead volume: it is the volume of the CC when the piston is at the TDC.
• Cubic capacity per cylinder: volume between the total volume (V) and the volume of the combustion
chamber.
• Power: work done by a machine divided by the time taken to carry it out (W / t). For an engine, we
calculate the power output in rpm.
• The unit of power is the Watt or the Kilowatt. It can also be expressed in horsepower (hp) 1 hp = 736
W
• Torque: set of two forces F with the same intensity which can be parallel or opposed.
• Engine torque is the work done by the combustion which applies a pressure P on the surface area S
of the top of the piston.
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•DIESEL ENGINE

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 DIESEL ENGINE

BASIC PRINCIPLE
Diesel Engine is also called “ Compression Ignition Engine”, despite of
using spark from ignition system like Gasoline Engine, Diesel Engine uses high
temperature of high pressure compressed air to ignite the fuel which is
injected to hot air.
The mixture of fuel-air is ignited itself when it has reached auto-ignition
temperature of the fuel (about 500⁰C).
High temperature can be achieved due to high compression ratio, can be
around 1 : 13 as high 1 : 20, which creates a typical 500-600 psi (34-41 bar) of
pressure with temperature around 900-1100 ⁰F (482-593 ⁰C) at compression
stroke.
Once the air-fuel mixture starts to burn, the peak pressure can run
between 1800-2300 psi (124-160 bar) with the temperature peaking to 3500-
4000 ⁰F (1927-2204 ⁰C).
That’s the reason Diesel Engine has high Thermal Efficiency.

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DIESEL ENGINE

Mixture of FUEL
Fresh air Certain degrees
and hot AIR
is compressed, before TDC,
is burnt itself
Pressure & FUEL in precise
d/t high
Temperature raise amount is injected
temperature

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 DIESEL ENGINE

Combustion Process in Diesel Engine…

2 C16H34 + 49 O2 32 CO2 + 34 H2O

Fuel + Air + Heat COMBUS

TION
Carbon Dioxide + Water + ENERGY

(back)

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 DIESEL ENGINE

4 Elements of Combustion…

FUEL
Precise Amount
Correct Timing
Well-atomized

PHYRAMIDE
of FIRE

AIR adequat HEAT

Compression
Oxygen Temperature 36
 DIESEL ENGINE
FOUR-STROKE DIESEL ENGINE
Four stroke diesel engines requires two revolutions (720 degrees) of the crankshaft, twice piston moving upward and twice piston

moving downward to create one complete cycle of combustion, consists of :

1) INTAKE STROKE

2) COMPRESSION STROKE

3) POWER STROKE

4) EXHAUST STROKE

Each stroke takes place in 180 degrees of crankshaft revolution.

Four-Stroke Diesel Engine is equipped with some valves at Cylinder Head.

Intake valve(s) controls the flow of intake air entering the cylinder. Exhaust valve(s) controls the flow of exhaust gases leaving the

cylinder.

Both valves are actuated by camshaft, which turns a half revolution of one revolution of crankshaft.

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Diesel Engine Cycle (4-stroke)
The operating cycle of a four-stroke engine is as follows:

1st stroke: induction

2nd stroke: compression
3rd stroke: injection/power
4th stroke: exhaust

38
DIESEL ENGINE
FOUR-STROKE CYCLE

INTAKE STROKE
Intake Valve opens and piston
moving downward, creating lower
pressure inside the cylinder.
Fresh air from intake manifold is
sucked into cylinder. Intake stroke ends
when intake valve closes several
degrees after BDC (Bottom Dead
Center). (see Valve Diagram)
Why ?
Intake valve opens longer to increase
the volume of fresh air entering the
cylinder (increasing Volumetric
Efficiency of Cylinder).

39
Intake valve opens several degrees
before TCD and closes several degrees
after BDC (Bottom Dead Center).
(see Valve Diagram)

Why ?
* Intake valve opens longer to increase
the volume of fresh air entering the
cylinder (increasing Volumetric
Efficiency of Cylinder).
* Creating valve over-lapping to cool
down the engine components and
lower emission.

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 DIESEL ENGINE
FOUR-STROKE CYCLE

COMPRESSION STROKE
Compression stroke begins when the intake
valve closes and the piston moving upward,
compressing the fresh air above the piston.
The pressure of the air inside the cylinder
increases, as well as the temperature.
The Compression Pressure & Temperature
depend on :
1) Original design of pressure ratio
2) How tight the intake valve & exhaust valve
3) Clearance between the piston rings &
cylinder liner

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 DIESEL ENGINE
FOUR-STROKE CYCLE

POWER STROKE
Certain degrees before the top,
fuel injector sprays fuel into hot
compressed air.
The fuel-air mixture will be burnt
itself when it has reached auto-
ignition temperature.
The combustion creates high
pressure of hot gases, pushing the
piston downward. Then the piston
motion turns the crankshaft, giving
mechanical energy at the flywheel.
The power stroke ends when the
exhaust valve opens several degrees
before BDC.
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DIESEL ENGINE

COMBUSTION DYNAMICS

A : Start of Injection
B : Self Ignition begins
 A-B : Delay Period (0.001-0.003 second)
 B-C : Uncontrolled Burning / Flame Propagation Period
 C-D : Constant Pressure Combustion
 D-E : After-Burning Period

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 DIESEL ENGINE
FOUR-STROKE CYCLE

EXHAUST STROKE
The exhaust stroke begins when
the exhaust valve opens several
degrees before BDC.
The piston moving upward,
expels the exhaust gases out of the
cylinder through exhaust valve.
Then the exhaust gases drives the
turbocharger wheels (optional).
Several degrees before TDC, the
intake valve opens, allowing fresh
air to purge exhaust gases. The
exhaust stroke ends when the
exhaust valve closes several degrees
after TDC.

44
 DIESEL ENGINE
FOUR-STROKE CYCLE

POLAR VALVE TIMING

Valves Overlapping
At the end of exhaust stroke,
both intake & exhaust
valves are open together at the
same time what is called valve
overlapping.
What is the purpose?
Valve overlapping is to ensure
complete scavenging of
all the exhaust gases from the
cylinder by purging it with fresh
air from intake.

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 DIESEL ENGINE
FOUR-STROKE CYCLE

POLAR VALVE TIMING

The timing of opening & closing of Intake &

Exhaust Valves are very critical to achieve

maximum engine performance & lifetime.

The degrees are determined by :

1) The design of Camshaft Lobes (height

& duration)

2) Valve Lash Adjustment

3) Valve Mechanism Type (OHV, OHC,

DOHC or Spring, Hydraulic, Pneumatic)

46
DIESEL ENGINE
PRESSURE-VOLUME DIAGRAM

TYPICAL
FOUR-STROKE
DIESEL ENGINES

1-2 : Intake Stroke (Isobaric)

23 : Compression Stroke (Isentropic)
3-3a : Rapid Combustion (Isochoric)
3a-3b : Gradual Combustion (Isobaric)
3b-4 : Power Stroke (Isentropic)
4-6 : Exhaust Stroke (Isobaric)
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Diesel Engine Combustion
Combustion Analysis
• From the start of injection, there are four successive phases:
• Ignition delay
• Flame propagation
• Main combustion
• Post-combustion or diffused combustion

A: Start of injection
A-B: Ignition delay
B-C: Rapid combustion (uncontrolled
phase)
C-D: Main combustion (controlled
phase)
D: End of injection
D-E > Post combustion or diffusion
phase
- - - - - : Curve without injection

48
Diesel Engine Combustion
• The ignition delay (point A-B) is the (very short) preparatory phase for
combustion, which separates the start of injection from the start of the
ignition of the fuel.
• This delay, which depends on the type of fuel used (cetane index) and on
certain physical and chemical phenomena, can be divided into:

• Physical delay: the time during which the fine droplets of diesel fuel
heat up in contact with the air until they vaporise

• Chemical delay: during the time preceding the ignition the fuel
combines with the oxygen in the air

49
 DIESEL ENGINE

IGNITION DELAY
Fuel takes certain time to vaporize, mixed with hot air and ignited.
α = 0.375 x Furthest distance between Nozzle Tip to Piston Crown
Burning Velocity of the Fuel

Normally, delay period is about 0.001-0.003 second.

The longer the delay period may cause Engine Detonation which
lowering the Engine Performance and shorten the Engine Lifetime.

Factors that affect to Ignition Delay :

~ Distance of Nozzle Tip to the Piston Crown
~ Cetane Number of the fuel used
~ Cylinder Pressure & Temperature at injection begins
~ Temperature & Pressure of Intake Air
~ Injection Timing

50
Diesel Engine Combustion
• Flame propagation

• The fuel mixture has formed (point B-C)

• The ignition process has begun at a large number of points at an

extremely high velocity

51
Diesel Engine Combustion
• Main combustion
• The injection continues (point C-D), the fuel progressively continues to
burn and the combustion speed falls whereas the pressure and
temperature continue to increase

• During this phase the fuel molecules are broken down (cracking) thus
producing:
• Gaseous and light products which burn.
• Heavier products (tarry) which are much more difficult to burn

52
Diesel Engine Combustion
• Post combustion or diffused combustion
• The end of injection (point D-E) takes place at point "D" when the injector
closes, but the remaining fuel mixture continues to burn.
• The conditions are more and more unfavourable:
• Rarefaction of the oxygen
• Increasing volume of the combustion chamber
• Remaining hydrocarbons difficult to burn
• The post combustion phase must be as short as possible

53
 DIESEL ENGINE
DENOTATION

If the ignition delay takes too long, while the fuel is progressively
injected into the cylinder, so the fuel will be accumulated for short time.
Once the fuel is burn for the first time, all accumulated fuel will be burn at
the same time, creating rapid explosion inside the cylinder. Raising the
pressure & temperature very rapidly, “hammering” all inside engine
components; especially Piston Crown, creating “knocking” noise.
Detonation reduces Engine Performance & Life-time.
(back)
54
 DIESEL ENGINE
DIESEL FUEL TYPES
 High Speed Diesel Fuel (HSDF)
It’s used for high-speed diesel engines operating from 800 to 3,000 rpm.
The specific gravity ranges in 0.82 to 0.87.
 Marine Fuel Oil (MFO)
MFO is used for marine diesel engines operating from 300 to 800 rpm.
The specific gravity ranges in 0.88 to 0.90.
 Industrial Diesel Fuel (IDF)
IDF is used for low-speed diesel engines operating under 300 rpm.
The specific gravity is about 0.99.

 CETANE NUMBER
Diesel Fuel with cetane number 48 means, it is made up from 48 %
cetane (C16H34) and 52 % alpha-methyl-naphthalene (C11H10).
The higher the Cetane number, the shorter ignition delay period, the better
the combustion. Fuel having low cetane number may cause “Detonation”.

55
•gas ENGINE

56
 GAS ENGINE

BASIC PRINCIPLE
Gas Engine as well as Gasoline Engine are also called “ Spark
Ignition Engine”, to ignite the mixture of air and fuel which has
been completely mixed in certain ratio when entering the
cylinder then compressed.
Then the mixture of hot gases instantaneously ignited by the
spark, resulting in rapid combustion which happens on constant
volume.
This is quite different with Diesel Engine which the combustion
process is gradual and takes place more longer at constant
pressure.
This is one reason why the thermal efficiency of gas/gasoline
engine is slightly lower than Diesel Engine.
Fuel system mixes the gas fuel and air at stoichiometry ratio to
gain perfect combustion to obtain higher horsepower and lower
exhaust emission.
One additional system of Gas Engine is “Ignition System” which
provide spark to ignite the mixture of air and fuel on correct
timing depends on engine speed.
57
 GAS ENGINE
FOUR-STROKE CYCLE

INTAKE STROKE
Intake Valve opens and piston
moving downward, creating lower
pressure inside the cylinder.
The mixture of gas fuel and air
which has been mixed by fuel system is
sucked into cylinder. Intake stroke ends
when intake valve closes several
degrees after BDC (Bottom Dead
Center). (see Valve Diagram)
Why ?
Intake valve opens longer to increase
Volumetric Efficiency of Cylinder.

58
 GAS ENGINE
FOUR-STROKE CYCLE

COMPRESSION STROKE
Compression stroke begins when the intake
valve closes and the piston moving upward,
compressing the mixture of air and gas fuel
above the piston.
The pressure of the air and gas fuel mixture
inside the cylinder increases, as well as the
temperature.
The Compression Pressure & Temperature
depend on :
1) Original design of pressure ratio
2) How tight the intake valve & exhaust valve
3) Clearance between the piston rings &
cylinder liner
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GAS ENGINE
FOUR-STROKE CYCLE

POWER STROKE
Certain degrees before the TDC,
the spark plug ignite the hot
compressed air-gas fuel mixture. Then
they instantaneous ignited and
explode.
The combustion creates high
pressure of hot gases, pushing the
piston downward. Then the piston
motion turns the crankshaft, giving
mechanical energy at the flywheel.
The power stroke ends when the
exhaust valve opens several degrees
before BDC.

60
 GAS ENGINE
FOUR-STROKE CYCLE

EXHAUST STROKE
The exhaust stroke begins when
the exhaust valve opens several
degrees before BDC.
The piston moving upward,
expels the exhaust gases out of the
cylinder through exhaust valve.
Then the exhaust gases drives the
turbocharger wheels (optional).
Several degrees before TDC, the
intake valve opens, allowing fresh
air to purge exhaust gases. The
exhaust stroke ends when the
exhaust valve closes several degrees
after TDC.

61
P-V Diagram of Gas Engine

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GAS ENGINE DETONATION

DENOTATION

Denotation on Gas/Gasoline engine happens when the mixture and fuel burned by itself before the spark plug
ignites it. This can cause damage to engine components, especially piston crown which hit by combustion pressure
while it moves upward.
One cause of denotation is low octane number, which burnt by itself d/t low self ignition temperature. Other causes
are wrong ignition timing or engine over-heating.
Detonation reduces Engine Performance & Life-time.

63
ENGINE OPERATION
GUIDELINE

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 OPERATING PROCEDURE

 PRE-START CHECK
Before starting the engine, operator MUST CHECK :

65
 OPERATING PROCEDURES
 START PROCEDURE
 If possible, put the engine at no load condition.
Throttle at minimum.
 Start the engine just for several seconds.
Do not more than 15 seconds for cranking.
If the engine doesn’t run, wait for a moment
before recranking the engine.
 After the engine running, please immediately
monitor the LUBE OIL PRESSURE.
Nominal Pressure : 60 – 70 psi
Minimum Pressure : 35 psi
 Monitor the engine performance.
 Listen for any noise.
 Visual check for any leakings, loosen
components, exhaust smoke, or any abnormal
conditions.
66
 Contact Maintenance Team for any abnormality.
 DIESEL ENGINE
OPERATING PROCEDURES
 WARMING-UP PROCEDURE
 Running the engine at idle speed (if possible)
or no load for about 3 – 5 minutes.

 It is to ensure lubrication oil has been

circulating adequately and engine achieves
operating temperature.

 DO NOT running the engine at no load

MORE THAN 10 minutes.
It may lower the engine temperature below
normal, causing incomplete combustion and
carbon deposit that may stick the Valve and
premature wear to the Cylinder Liners.
67
 OPERATING PROCEDURES
 LOADING PROCEDURE
 Increase the engine speed from Idle Speed to
Rated Speed gradually.
 Apply the load step by step.

 DO NOT OVERLOADED the engine.

Never operate the engine below its Torque
Peak Speed.

 Always listen to the engine for any noise or

engine surging.

68
 OPERATING PROCEDURES
 SHUT-DOWN PROCEDURE
 Remove the engine load gradually.
 Reduce the engine speed to idle speed.

 Running the engine at idle speed for 3 – 5

minutes for cooling down.
 NEVER HOT SHUT-DOWN, except in case
of emergency.
Hot Shut-down will shorten the engine
lifetime, especially the Turbocharger.
 Shutdown the engine by turning the key or
pushing the stop button to off position.
 Reset any switches (Lube Oil Pressure
Sensor, Over-speed or Air-Shutoff Valve).
69
MAINTENANCE PROCEDURE

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 MAINTENANCE
To achieve a satisfactory Engine Operation, maximum Engine
Performance, longer Engine Life-time and low cost operation,
Diesel Engine has to be maintained properly as Manufacturer
Recommendation as in Operation & Manual Book.
Types of Maintenance :
 Preventive Maintenance
Time-base maintenance to prevent Engine Break-down.
 Curative Maintenance
Repair action to fix any trouble happened on Engine.
 Predictive Maintenance
Maintenance Plan as Engine Trend Condition.

71
DIESEL ENGINE
MAINTENANCE

72
 DIESEL ENGINE
DAILY MAINTENANCE
Check Lube Oil level Check Coolant level Drain water from
 Add if necessary  Add if necessary Fuel Filter

 Check Batteries &  Visual Engine Check  Check Engine

connections  Listen for noise Instrumentations

73
 DIESEL ENGINE
250-hour or 6-month PM
 Open Cold Work Permit & Electrical
Consignation.
 Put the key at OFF position. Remove
batteries connection or switch-off
Breaker.
 REPLACE LUBE OIL
 Drain Engine Lube Oil, put it in a
container, then waste it to open drain.
 Apply seal-tape to the plug.
 Install the plug and tighten securely to
prevent loosen during operation.
CAUTION : Do not over-tighten that may
broken the thread.
 Refill lube oil with new SAE 15W-40
Diesel Lube Oil until high level. 74
 DIESEL ENGINE
250-hour or 6-month PM
 REPLACE LUBE OIL FILTER(S)
 Remove Lube Oil Filter(s) using a belt-wrench.
Pull the wrench toward us.
 Clean the Filter Head with a lean-free tissue or
cloth.
 Fill the filter with a new oil through outside
holes, not from inside hole.
 Apply oil to the Filter Seal.
 Install the Filter with hand until the seal just
touching.
 Turn the Filter ½ to ¾ rotation.
 REPLACE FUEL FILTER(S)
 Do the same procedure as above.
 Fill the filter with Diesel Fuel before installing.
75
 DIESEL ENGINE
250-hour or 6-month PM

 COOLING SYSTEM MAINTENANCE

 Remove Radiator Cap carefully.
DANGER : DO NOT OPEN Radiator Cap
while the engine still hot.
Depressurize the pressure by
pushing the cap for a moment before
turning.
 Check concentration of Engine Coolant using a
Coolant Test Kit.
Low concentration may cause corrosion, high
concentration may cause gelling.
 Top up the coolant level with DCA (Diesel
Coolant Addictive) and fresh water with
correct ratio.

76
 DIESEL ENGINE
250-hour or 6-month PM

 COOLING SYSTEM MAINTENANCE

 Check the condition of Radiator Cap.
Check the Spring and Seal condition.
 Check and clean the Radiator fins.
 Check for any leaking.
 Check the hoses condition for any stratches,
damage, kicking or over-sized.
Replace if necessary.
 Check the condition of Cooling Fan Blades
for any crack or loosen rifets.
Ask Inspection Team if necessary.

77
 DIESEL ENGINE
250-hour or 6-month PM

 COOLING SYSTEM MAINTENANCE

 Grease the Cooling Fan Hub and Belt
Tensioner (if any). Refer to Manual for the
type and amount of grease.
 Check the condition of Cooling Fan Belt for
any crack, wear or damage.
Replace as necessary.
 Check the tension of Cooling Fan Belt.
Use a Belt Tension Meter Tool if available.

 ALTERNATOR BELT
 Also check the condition and the tension of
Alternator Drive Belt.
78
 DIESEL ENGINE
250-hour or 6-month PM

 ENGINE MOUNTINGS
 Check the condition of Engine Mountings.
 Tighten the Engine Mounting Bolts.

 GENERAL INSPECTION
 Visual check the Engine for any loosen
components, damage, or abnormalities.

 Grease Engine Front Mounting or Flexible

Joint Coupling (if any).

79
 DIESEL ENGINE
250-hour or 6-month PM

 BATTERY MAINTENANCE
 Check the Density of Battery Electrolite.
Nominal : 1.27
 Check the Voltage and Current Test.
 Tighten the Batteries connections.
 Visual check the battery for any crack,
deformation or leaking.
 ELECTRICAL MAINTENANCE
 Check all electrical connections.
 Check & simulate Protection/Shutdown
System.
 INSTRUMENTATION MAINTENANCE
 Check the condition and setting of all Sensors.
80
 Check the Engine Control Panel.
DIESEL ENGINE

TOP OVERHAUL : 12,000-hours or 3-years

 Adjust VALVE CLEARANCE
 Repair/recalibrate FUEL PUMP
 Repair/recalibrate FUEL INJECTOR(S)
 Repair WATER PUMP
 Repair TURBO-CHARGER(S)
 Repair FAN DRIVE
 Repair CYLINDER HEAD(S)
 Replace THERMOSTAT(S)
 Check AFTERCOOLER

GENERAL OVERHAUL : 24,000-hours or 6-years

81
TECHNICAL TERMS
EXPLANATION

12/09/2022 82
 TECHNICAL TERMS
POWER : How much WORK (force x distance) done in a period of time.

1 Horse Power = 330 lbs x 100 ft / min

= 33,000 ft.lbs / min.
= 746 watt

Indicated Horse Power (IHP)

Indicated Horsepower is
calculated horsepower of engine.
P = Brake Mean Effective Pressure (psi)
IHP = PxLxAxN L = Length of Piston Stroke (feet)
33,000 A = Area of Piston Crown (inch2)
N = Number of Power Stroke per minute
(2-cycle : Number of Cylinder x RPM)
83
(4-cycle : Number of Cylinder x RPM)
 TECHNICAL TERMS

o BHP : Actual Horse Power available o Torque

at Engine Flywheel. A turning force developed
at the Engine Crankshaft.
o Mechanical Efficiency = BHP
IHP
The higher the Mechanical Efficiency,
the lower the Brake Specific Fuel
Consumption (BSFC).

o BSFC = pounds of fuel per hour

BHP
= ft3 of gas x Heating Value x 60
time of test (min) x BHP

(back)
84
PERFORMANCE CURVE

o TORQUE PEAK
Maximum torque that Engine
can develop.
(back)

o BHP
Net horsepower available at the
Engine Flywheel.

o RATED SPEED
Speed at which Engine produces
maximum horsepower.
Should Engine is operated at
this range of speed.

85
THERMAL EFFICIENCY

From 100% Thermal Energy

available in Fuel, only about 25-55
% is successfully converted into
useful Mechanical Energy at the
Engine Flywheel.

The remaining Energy is looses into:

 Cooling : 23 – 27 %
 Exhaust : 23 – 27 %
 Friction & Accessories : 7–9%
 Heat Radiation : 3-5%

(back to Characteristic) (back to Cooling System)

86
 THERMAL EFFICIENCY

Thermal Efficiency = 2545 * .

BSFC x Fuel Heating Value

2545 = A perfect Engine (no looses) requires 2545 BTU/HP-Hr

BSFC = Brake Specific Fuel Consumption ( Pound/HP-Hr)
Fuel Heating Value Table :
FUEL Heating Value
For calculation purpose,
Diesel Fuel 162,000 BTU/gal
usually use Diesel Fuel
Gasoline 146,000 BTU/gal
having 36 degrees API
Propane 21, 570 BTU/lb
LHV : 18,410 BTU/lb
Natural Gas 1,000 BTU/ft3
HHV : 19,620 BTU/lb
Coal 8,500-15,000 BTU/lb

Electricity 3412 BTU/kWh 87

THERMAL EFFICIENCY
 Example Calculation
From the chart, the Engine
produces 475 HP @ 1,800 rpm
with BSFC = 0.316 lb/HP-Hr.

Use Fuel with LHV=18,410 BTU/lb

BTE = 2545 . x 100 %
0.316 x 18,410
= 43, 74 %

The chart is calculation at ISO

Condition (sea level with 25⁰C
ambient temperature).
Actual Condition may produce
lower Engine Performance.
88
 ELECTRIC POWER

Engine HP = KVA Generator Output (KW)

= KVA x cos Phi
= V x A x √3 x 0.8

 KVA  KW
KVA is the input Power of KW is the real Output Power
Generator, equivalent to Engine of Generator.
Horse Power. KW = KVA x α (cos Phi)
1 HP = 746 watt Cos Phi is the efficiency
1 watt = 1 volt x 1 coefficient of Generator
ampere commonly about 80% (0.8).

KVA = Volt x Ampere x √3 KW = Volt x Ampere x √3 x 0.8

89
 ELECTRIC POWER CALCULATION
A Diesel Engine has 500 HP drives a
three-phase Generator with α = 0.8.
If the voltage is 400 volt, count :
a) KVA
b) KW
c) Maximum Current
 KVA  Current
1 HP = 746 watt
KW = volt x current x √3 x 0.8
500 HP = 500 x 746 watt
Current = KW .
= 373,000 watt
= 373 KVA volt x √3 x 0.8
= 298,400 .

 KW .

KW = 373 KVA x 0.8 400 x 1.732 x 0.8

= 298.4 KW = 538 Amperes
90
TERIMA KASIH
END OF SLIDE