SIME DARBY PLANTATION SDN. BHD.

MANAGEMENT TRAINEE PROGRAMME – CADET ENGINEERS (BATCH 3-09/10)

DIESEL GENERATORS
AT SIME DARBY PLANTATION ACADEMY, CAREY ISLAND
21th & 22nd DEC-09

PRESENTED BY
ABDUL RAZAK BIN HAJI YUSAK,
MILL MANAGER,
SEPANG OIL MILL,
SEPANG, SELANGOR
1
 DIESEL GENERATORS
OVERVIEW.

WHAT IS A DIESEL ENGINE ?

The best way to describe a diesel engine is to look at the

following characteristics of the engine:
A. RECIPROCATING ENGINE
B. INTERNAL COMBUSTION ENGINE
C. COMPRESSION IGNITION ENGINE
D. TWO OR FOUR STROKE ENGINE

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 2
 A. RECIPROCATING ENGINE.

Reciprocating engines are engines with

piston moving forward and backwards to
produce power, as opposed to rotary
engines. Diesel, petrol and steam engines
are examples of reciprocating engines
where turbines are rotary engines.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 3
 B. INTERNAL COMBUSTION ENGINE

Internal combustion engines are

engines where the fuel is burnt inside
the engine rather than outside the
engine. In the case of diesel engines,
the fuel is burnt inside the engine
cylinder.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 4
 C. COMPRESSION IGNITION ENGINE
There are two main types of internal combustion engines
– the spark ignition engines
– compression ignition engine.

Petrol engines are spark ignition engines. In petrol engines, control

amount of mixture of petrol & air is drawn into the engine cylinder,
compressed and ignited by means of sparks through the spark plug.

Diesel engines are compression ignition engines. Maximum amount

of air is drawn into the engine, compressed to a temperature
sufficient to ignite diesel. Diesel is then injected into the compressed
air inside the cylinder and is ignited by the compressed air.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 5
 D. TWO OR FOUR STROKE ENGINE
Diesel engines can be four stroke or two stroke
engines, just like petrol engines. In the four
stroke engines, it takes four stroke to complete
one cycle namely;
– Intake stroke
– Compression stroke
– Power stroke
– Exhaust stroke

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 6
 D. TWO OR FOUR STROKE ENGINE

The difference between the diesel and

petrol engines is at the intake. Air/fuel
mixture is drawn into the petrol
engine whereas only air is drawn into
the diesel engine.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 7
 D. TWO OR FOUR STROKE ENGINE
INTAKE VALVE INTAKE INTAKE INTAKE VALVE
OPEN & EXHAUST & EXHAUST CLOSE
EXHAUST VALVE VALVES VALVES EXHAUST VALVE
CLOSE CLOSE CLOSE OPEN

a) INTAKE b) COMPRESSIONc) POWER d) EXHAUST

STROKE STROKE STROKE STROKE
(Only air is drawn in) (Fuel is injected)
Training Material. For Internal Circulation Only
8
18 DEC-09 SEPANG OIL MILL
 D. TWO OR FOUR STROKE ENGINE

It can be seen that it only takes

two strokes to complete a cycle
in a two stroke engine. The 2. COMPRESSION
1. SCAVENGING
intake and compression
constitute the up stroke and
power& exhaust constitute the
down stroke.

3. POWER 4. EXHAUST

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 9
 D. TWO OR FOUR STROKE ENGINE

It is noted that it takes two revolutions of

the engine crankshaft to complete one
cycle of a four stroke engine and only one
revolution of the crankshaft to complete
one cycle of a two stroke engine. marine
operations.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 10
 D. TWO OR FOUR STROKE ENGINE

This means that for a given horsepower, the two stroke

engine should be half the size of a four stroke engine
because every revolution of a two stroke engine
contains a power stroke whereas in a four stroke
engine, there is a power stroke only in every two
revolutions of the crankshaft. Due to the higher output
of the two stroke engines, they are widely used in
marine operations.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 11
 COMPONENTS OF A SIMPLE
DIESEL ENGINE
The simple diesel engine has a cylinder, a piston, a connecting rod
and a crankshaft. The end of the cylinder is sealed with a cylinder
head. The piston which is sealed to the cylinder wall by piston rings
is connected to the crankshaft by a connecting rod and a piston
pin.

This arrangement allows the piston to return to the top of the

cylinder, making continuous rotary motion of the crankshaft
possible. Due to the powerful impulses on the piston as the
fuel is burned in the cylinder, a heavy flywheel blends together
the power impulses into one continuous motion of the crankshaft.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 12
 CONSTRUCTION OF A
DIESEL ENGINE

Basic Components of A
Four Stroke Diesel Engine.
CONNECTING ROD

CRANKSHAFT

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 13
 COMPONENTS OF A SIMPLE
DIESEL ENGINE

For each cylinder, the cylinder head has an inlet valve

port that allows maximum amount of air into the
cylinder. An exhaust valve port allows the burnt gases to
flow out. The head is sealed to the cylinder block with a
head gasket. The opening of the valves is controlled by
the camshaft.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 14
 MAIN COMPONENTS OF A
DIESEL ENGINE
4-stroke and 2-stroke diesel engines both use the principles of
internal combustion, so many of their components have similar
designs.

Diesel engine components are exposed to higher operating

temperatures, pressures and forces than petrol engines of
similar size. Their compression ratios are higher, and they are
often designed to out-last gasoline engines. Their engine parts
are usually heavier or more rugged than those of similar output
gasoline engines.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 15
 MAIN COMPONENTS OF A
DIESEL ENGINE
Diesel blocks are usually made of cast iron, and heavier than in a
petrol engine. The skirt of the block usually extends below the
centre-line of the crankshaft. This adds strength and rigidity.

Machined into it are the cylinders which are usually in the form
of detachable sleeves or liners.

It is sealed at one end by a deep-section piece of metal or alloy

called a cylinder head, which houses the valves and injectors.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 16
 MAIN COMPONENTS OF A
DIESEL ENGINE

Most cylinder heads in diesel engines are cast iron. Depending

on the engine design, single or multiple heads can be used.

Multiple heads avoid large castings that, apart from being heavy,
are liable to distortion.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 17
 MAIN COMPONENTS OF A
DIESEL ENGINE

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 18
 DIESEL ENGINE
DIESEL INDUCTION SYSTEMS.
The two main components of the
4-stroke intake system are the air
cleaner and the intake manifold.
But in a diesel engine, fuel is
delivered separately and the
intake system carries air only.
Also, since the diesel engine
doesn’t have a carburetor, it has
no throttle. Some diesels use a pneumatic governor with a
butterfly valve at the entrance to the inlet manifold. Diesel
engines often have more than one air cleaner.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 19
 DIESEL ENGINE
DIESEL INDUCTION SYSTEMS.
Diesel induction systems (contd.)

Let’s look at the intake system for a 2-stroke diesel engine.

There is only a very short time at the end of its power stroke
to scavenge the exhaust gases and refill the cylinder with
air. To achieve this in the time available, 2-stroke diesels
use an engine-driven air pump, usually called a blower. It
pressurizes the air so that when the inlet ports open, air
from the blower enters the cylinder and helps scavenge the
exhaust gases. Some 2-stroke diesel engines use a
turbocharger which feeds air under pressure to the blower.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 20
 DIESEL ENGINE
DIESEL INDUCTION SYSTEMS.
Diesel induction systems (contd.)
The intake system of the diesel engine can be used to
increase engine output. This can be done by increasing
volumetric efficiency, that is, by increasing the amount of
air-fuel mixture burned in the cylinders.

In diesel injection systems, this partly occurs automatically

because of the increased efficiency of fuel injection. Output
can also be improved by using large, free-flowing intake
manifolds, and by increasing the number, or the size, of inlet
valves per cylinder to admit more charge into the
combustion chamber.

Another method is to use forced induction or supercharging.

Training Material. For Internal Circulation Only 21
18 DEC-09 SEPANG OIL MILL
 DIESEL ENGINE
EXHAUST SYSTEM.
During engine operation, each time the exhaust valve opens,
pulses of hot exhaust gases are forced
into the exhaust manifold. These hot,
rapidly expanding gases produce a lot
of noise, some of it at very high
frequency.

The exhaust system does several jobs.

It has to reduce the noise of the exhausting gases to acceptable
levels. It has to discharge the gases safely, far enough away to
prevent them re-entering the vehicle.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 22
 DIESEL ENGINE
EXHAUST SYSTEM.
(contd.)

Some of these gases are highly poisonous. In an enclosed space,

carbon monoxide can cause death in minutes. It is odorless and
colorless, which makes it difficult to detect, and removing it is
especially important.

In modern vehicles, it also keeps harmful emissions to a

minimum. The exhaust system is designed to enhance engine
operation. A well-designed system can improve drivability and
performance.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 23
 DIESEL ENGINE
EXHAUST SYSTEM.
(contd.)

In this simplified model, burned gases exit the cylinder through

the exhaust port and pass into the exhaust manifold.
The first pipe is usually called the engine pipe. It is connected to
the outlet of the manifold which carries the exhaust gases to the
muffler, which reduces exhaust noise.

Exhaust gases are then discharged through a tail pipe, usually at

the rear, or sometimes, to the side or above the vehicle.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 24
 DIESEL ENGINE
AIR CLEANERS.
An air cleaner filters air that passes through it to stop harmful
particles reaching the engine. The air
cleaner on a carbureted engine can
be on top of the carburetor, or beside
the engine, connected to the
carburetor by a hose or duct.

Position is usually decided by how

much space there is, or bonnet
profile. On some electronically fuel injected engines, the air
cleaner is on top of the throttle body, similar to a carburetor.
Other air cleaners are connected by ducts.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 25
 DIESEL ENGINE
AIR CLEANERS.
(contd.)

Diesel engines often have more than one air cleaner. This
may be due to their severe working conditions. They’re
usually mounted away from the engine to obtain cleaner,
cooler air.

A lot of air passes through the intake system into the engine.
In a petrol engine, it’s about 15 times the amount of fuel by
weight. By volume that’s 10,000 times more air than fuel.

The air-fuel mixture enters the engine so the air needs to be

clean. Any abrasives that enter the engine can cause wear
and damage. Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL
26
 DIESEL ENGINE
AIR CLEANERS.
(contd.)

It also has a silencing effect, muffling noise produced

by the air entering the engine. It can act as a flame
trap. So if a petrol engine backfires, the air cleaner
can contain the flame within the intake manifold or
carburetor.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 27
 DIESEL ENGINE
INTAKE MANIFOLDS.
The intake manifold is usually a metal part with several
tubular branches, though it can also be made of a special
plastic. In carbureted engines, the intake manifold carries
the air-fuel mixture into the engine. The cross-sectional area
of each tube needs to be kept small to maintain the high air
speeds that improve vaporization. At the same time, it
cannot be too small, since that restricts the airflow to the
engine at higher speeds.

Electronic fuel injected engines with throttle body injection

also have intake manifolds that carry air-fuel mixture.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 28
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd.)

With multi-point injection, the

intake manifolds carry air only,
so heating of the intake
manifold is not needed, and the
cross-sectional area of the
tubes can be larger. More air
can flow and the engine can
produce more power. Fuel is
injected into the intake ports of
the cylinder head.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 29
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd.)

This cylinder head has intake and

exhaust manifolds for a 4-cylinder
carbureted engine. It is a cross flow
head. That means the intake
manifold is on one side and the
exhaust manifold is on the other.

On many cars, the intake manifold has a mounting for the

carburetor and a flange that bolts onto the cylinder head. It
has a branch for each cylinder to carry air-fuel mixture into
the combustion chamber.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 30
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd.)

This intake manifold has a

water jacket under the
carburetor mounting. Hot
coolant from the cooling
system flows through the
water-jacket and heats the
manifold. Heating is required
in a carbureted engine to
provide better vaporization
of the air-fuel mixture.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 31
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd.)

This fuel-injected engine manifold

has a plenum chamber that provides
a reservoir of air and helps prevent
interference with the flow of air
between individual branches. It also
acts as a silencer. On this primary
manifold, the intake pipes are
fixed in length.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 32
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd.)

Other kinds of manifolds have extra valves to change the

effective pipe length. They’re computer-controlled by the engine
management system to open at a specified engine speed and
extend the torque output.

A diesel engine intake manifold carries air only, not fuel. And
since no fuel is vaporized in the manifold, it isn’t heated.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 33
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd.)

The diesel engine doesn’t have a carburetor, therefore has no

need for the throttle.

Some diesels use a pneumatic or air-operated governor with a

butterfly valve at the entrance to the inlet manifold. This
butterfly valve is only used to operate the governor. It is not a
throttle butterfly valve as seen on gasoline engines.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 34
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd)

MATERIALS.

Traditionally, intake manifolds were normally made of light alloy

metal castings, however in approximately 70% of modern
vehicles the intake manifold are now made from special heat
resistant polymers and plastics. Manifolds using this type of
construction lighten manifold part weight by up to 50% and
contribute to higher fuel efficiency.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 35
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd)

These intake manifolds are normally molded from a glass fiber

reinforced grade of crystalline polymer that consists of a blend a
of syndiotactic polystyrene and polyamide.

The polyamide nylon based materials provide a good solution for

these components because of their mechanical properties and
their ease of processing during their manufacture.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 36
 DIESEL ENGINE
INTAKE MANIFOLDS.
(contd)

This type of material is ideally suited for replacing metal in

under-the-hood applications because of its strength, stiffness,
and chemical resistance under high temperature operating
conditions.

In addition, intake manifolds made out of polyamide nylon have

succeeded in improving the environmental performance of cars
because of the materials ability to be recycled.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 37
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION .

The intake manifold has several tubular branches and carries air
and or air/fuel mixture from the air cleaner to the inlet valves in
the cylinder head.

In carbureted engines, the intake manifold carries the air-fuel

mixture into the engine.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 38
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION (contd.)

The cross-sectional area of each tube needs to be kept small to

maintain the high air speeds that improve vaporization. At the
same time, it cannot be too small, since that restricts the airflow
to the engine at higher speeds.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 39
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION (contd.)

Electronic fuel injected engines with throttle body injection also

have intake manifolds that carry air-fuel mixture. With multi-
point injection, the intake manifolds carry air only and the cross-
sectional area of the tubes can be larger. More air can flow and
the engine can produce more power. Fuel is injected into the
intake ports of the cylinder head.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 40
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION (contd.)

Cylinder heads that have separate intake and exhaust manifolds

are know as "cross-flow heads". That means the intake manifold
is on one side and the exhaust manifold is on the other.

On many cars, the intake manifold has a mounting for the

carburetor and a flange that bolts onto the cylinder head. It has
a branch for each cylinder to carry air-fuel mixture into the
combustion chamber.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 41
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION (contd.)

Many intake manifolds have a water-jacket under the carburetor

mounting. Hot coolant from the cooling system flows through
the water-jacket and heats the manifold.

Heating is required in a carbureted engine to provide better

vaporization of the air-fuel mixture.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 42
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION (contd.)

Fuel-injected engine manifolds normally have a plenum chamber

that provides a reservoir of air and helps prevent interference
with the flow of air between individual branches. It also acts as a
silencer.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 43
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION (contd.)

Normally on primary manifolds, the intake pipes are fixed in

length. Other kinds of manifolds have extra valves to change the
effective pipe length. They may be computer-controlled by the
engine management system to open at a specified engine speed
and extend the torque output.

A diesel engine intake manifold carries air only, not fuel. And
since no fuel is vaporized in the manifold, it isn’t heated.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 44
 DIESEL ENGINE
INTAKE MANIFOLDS.
APPLICATION (contd.)

Some diesels use a pneumatic or air-operated governor with a

butterfly valve at the entrance to the inlet manifold. This
butterfly valve is only used to operate the governor. It is not a
throttle butterfly valve as seen on gasoline engines.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 45
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.
The primary components of the automotive exhaust
system are:
• Exhaust Manifold
• Engine Pipe
• Catalytic Converter
• Exhaust Brackets
• Muffler & Components

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 46
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.
EXHAUST MANIFOLD.

The exhaust manifold is bolted to

the engine's cylinder head.
It can be of a one-piece or two-
piece construction. In performance
type vehicles, the exhaust manifold
is often replaced with extractors.

A normal exhaust manifold is usually made from cast iron.

Due to the extreme temperatures generated at the exhaust
manifold, heat shields can be installed to protect other vehicle
components from heat damage.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 47
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.
ENGINE PIPE.

The engine pipe is attached to the

exhaust manifold. It takes the
gases away through the catalytic
converter, then through the
muffler system to the outside
environment.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 48
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.

CATALYTIC CONVERTER.

The catalytic converter is

attached to the engine pipe,
between the engine and the
muffler.

It converts the harmful by-products of combustion to

relatively harmless gases.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 49
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.
EXHAUST BRACKETS.

The exhaust components are

supported along the length of the
vehicle by brackets suspended from
the underbody.

These are usually rubber-mounted

supports that help isolate the
vibrations of the exhaust from the main body of the vehicle.

Rubber is preferred because of its natural dampening effect.

Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 50
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.
MUFFLERS & COMPONENTS.

Muffler.

The muffler is located between the

engine and the exhaust outlet. It is
designed to reduce the noise levels
of the exhaust by breaking up the
sound frequencies of the gases.

Mufflers can be of various designs but their function is common

to all.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 51
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.
MUFFLER & COMPONENTS.

Resonator.

Many manufacturers use a

resonator in the exhaust system.
It is located between the muffler
and the exhaust outlet.

Its function is to reduce any resonance levels that the muffler

could not adequately suppress.
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 52
 DIESEL ENGINE
EXHAUST SYSTEM COMPONENTS.
MUFFLER & COMPONENTS.

Tail pipe.

The tail pipe takes the exhaust

gases away from the vehicle. Its
exit point must not allow any of
the exhaust gases to enter the
vehicle.

Training Material. For Internal Circulation Only

18 DEC-09 SEPANG OIL MILL 53
 DIESEL ENGINE

THANK YOU
Training Material. For Internal Circulation Only
18 DEC-09 SEPANG OIL MILL 54