Diesel Doctor Training Reciprocating Engine Analysis Lear earning - - PowerPoint PPT Presentation

MI MILITARY S SEA EALIFT COMM COMMAND

Diesel Doctor Training

Reciprocating Engine Analysis

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Lear earning O g Objec ectiv ives es

Upon Finishing this Training, the student will be able to

• List Benefits of Performing Reciprocating Analysis
• List the Doctor DK-2 peripherals and how to connect them

correctly

• Explain How to Find Engine DTAG information
• Explain the Operating Parameters necessary for a Valid

Doctor Reading

• Explain the required Safety Precautions

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Learning Objectives

Upon Finishing this Training, the student will be able to

• Specify the correct starting cylinder and cylinder order for

data collection

• Explain Doctor DK-2 Pressure Reading memory management
• Explain Crank Pickup functionality
• Demonstrate how to take Pressure Readings correctly
• Demonstrate how to verify a good reading before moving on

to the next cylinder

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Lear earning O g Objec ectiv ives es

Upon Finishing this Training, the student will be able to

• Explain accessing the SAMM Reciprocating Analysis Module
• Explain editing an Engine Setup
• Explain correctly transferring the Doctor DK-2 Data to SAMM

correctly

• Explain verifying the data downloaded is valid data for the

Engine selected

• Analyze the data effectively

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Marine Engines are complex machines Engines are not built from clear materials We can take a pressure sample of the combustion chamber to find out what’s happening inside.

2 – Stroke Engine

Why is Engine Analysis important?

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Why is Engine Analysis important?

Reciprocating Analysis tools show the pressure curve inside the cylinder

• Demonstrating status of engine before and after

servicing

• Troubleshoot anything affecting cylinder pressure
• Injectors
• Valves
• Timing issues
• Etc..
• Reduce catastrophic failures by seeing problems early
• Balancing the cylinder load
• Have better fuel savings
• Less Vibration
• Reduce wear on components

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Historical Context

• Analyzing pressure in steam reciprocating engines
• Check valve timing
• Condensation in Cylinders
• Pressure inflow and outflow
• Calculate Cylinder Power

Example Steam Indicator card

Barton and Stickney, Naval Reciprocating Engines and Auxiliary Machinery, 1914, pgs 214, 215, 225

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Historical Context

• Higher Temperatures

/Pressures

• Polar Planimeter for

Measuring Manual Power Calculations

• Analyzing Combustion

Indicator Card

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Modern Electronic Indicator Card

With modern technology comes modern solutions

• Repeatability
• Less prone to mechanical errors
• Digital database storage
• Precise calculations
• Compare trending over time
• Historical Data easily searched and

accessed Military Sealift Command has chosen the Diesel Doctor System, units maintained, calibrated and data analyzed by Emprise Corporation.

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Analysis Ashore

• Analysis Ashore requires valid data
• Capture errors before you download the data into SAMM
• Shore Analyst
• Provides data analysis within 72 hours
• Entered into Notepad for each data sample
• Significant issues will generate Work Requests
• Shore Analyst can only provide a recommendation!
• Vessel Engineers are the ultimate authorities for the
• peration and maintenance of their assets
• Continuously improve the process with communication

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RA Shore Analyst

Emprise Analyst: Mark Spencer mspencer@emprisecorporation.com (860)464-8555 His goal:

• Review data within 24 hours
• Can be reached by email for specific analysis
• Engine Balancing/tuning
• Overhaul QA

MSC TPOC: Mike Palmer N711 michael.j.palmer1@navy.mil (757)636-9267

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Sensors

KISTLER Pressure Sensor TDC Sensor

Piezoelectric sensor

• Generates voltages for changes in pressure

Picture Showing Dual Pickup Installation

Gap 3mm Gap 3mm

Bolt head to be clear of flywheel surface by a minimum of 8mm (for 18mm pickup)

4-strokes have 1 sensor 2-strokes have 2 sensors

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Large Vee Engine, 4 Stroke Medium Speed

Diesel Doctor DK-2 Installation

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Diesel Doctor DK-2

Dk-2 Crank Pickup Cable

• Press. Sensor

Extension Cable Pressure Sensor Dk-2 Analyzer Crank Pickup Junction Boxes Crank Sensor w/ Cable

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Diesel Doctor DK-2 Interface

Cylinder Pressure Input LCD Displa y Battery Charger Input and Power Circuit Indicators. RS-232 Communication Output ON/OFF Switch Inductive Crank Pickup Input User Keypad

100 - 240 VAC Input -

• - 9 VDC Output

Battery Charger RS 232 Computer Communication Cable (Null Cable, not just any RS 232 Cable)

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Engine DTAG Information

• What is DTAG and Where do I find it?
• DTAG = Diesel Test and Analysis Guide

4: Select “Vibration and Diesel Test Analysis Guides 5: Select Most Recent “VTAG/DTAG” Entry 5: Double Click on the VTAG or DTAG to open 1: Open Machinery History 2: Expand Hull 3: Expand Certificates and Documentation

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Engine DTAG Information

Engine Characteristics Operating Conditions For Taking Readings Pressure Readings Cylinder Order Cylinder and Power Info Doctor Dk-2 Recommended Memory Management Starting Cylinder

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Engine Examples

• Example: Hershel-Williams

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Engine Examples

• Example: Kanawha Main Propulsion

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Safety

WHEN TAKING COMPRESSION READINGS FROM A RUNNING ENGINE, WEAR YOUR PPE!

Significant Hazards:

Face Shield/Goggles Hearing Protection Safety Shoes Protective Clothing Gloves Rotating Machinery Hot Surfaces Airborne Particles Slips, Trips, Falls

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Doctor Dk-2 Setup

Dk-2 Collector can be a standalone unit. Lots of Setup Options. All Software analysis happens in Diesel Doctor Software in SAMM All that matters on Dk-2 is 2 or 4 stroke and sensitivity Everything else is on the Computer Engine Setup!

* * Important * * Average values for MSC engines should be set at 40 for medium speed engines and 20 for slow speed engines.

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Taking Pressure Readings

• Verify Two ways
• 1: Crank Setup mode
• Displays RPM, useful for engine testing
• 2: Emprise TDC Sensor
• Verify at slow speeds /

slow rolling engine

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DK-2 Memory Management

Engine 1 Memory Engine 2 Memory

Cylinder 1A 1 Cylinder 1A 21 Cylinder 2A 2 Cylinder 2A 22 Cylinder 3A 3 Cylinder 3A 23 Cylinder 4A 4 Cylinder 4A 24 Cylinder 5A 5 Cylinder 5A 25 Cylinder 6A 6 Cylinder 6A 26 Cylinder 7A 7 Cylinder 7A 27 Cylinder 8A 8 Cylinder 8A 28 Cylinder 1B 9 Cylinder 1B 29 Cylinder 2B 10 Cylinder 2B 30 Cylinder 3B 11 Cylinder 3B 31 Cylinder 4B 12 Cylinder 4B 32 Cylinder 5B 13 Cylinder 5B 33 Cylinder 6B 14 Cylinder 6B 34 Cylinder 7B 15 Cylinder 7B 35 Cylinder 8B 16 Cylinder 8B 36

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Error Capturing

Due to the nature of test conditions for a running diesel engine there is often a limited time frame to take all pressure readings in. If errors are seen upon downloading the data into SAMM, its often too late as the “window” to capture data is has passed. Its best to Capture and Correct errors before you download:

• Verify Consistent RPM Signal before you start
• Normal Engine fluctuations
• Crank Signal connection is good
• Verify individual cylinder readings are good before moving to next cylinder
• DK-2 moves to next memory point automatically
• Select Previous memory point before re-taking reading

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Verifying Good Data at Engine

Wait for This Screen to Finish

Verify Good Reading for that Cylinder

Pmax is good Correct Memory For Cylinder Pressure Curve is valid

If this is what you see, correct the issue, press “Main”, select previous memory and press “Go” Again.

Bad Cylinder Reading

DK-2 DEFAULTS TO NEXT MEMORY NUMBER FOR PRESSING “GO”

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Diesel Doctor Software

Reciprocating Analysis Software Included in CMS “Condition Monitoring Software” Multiple ways to Access “RA” software:

SAMM Utilities “RA” Link from Workbook From Within CMS Module

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Diesel Doctor Software

Engine Select Measurement Selection Download Data Graph View Table View Bar Graph View

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Diesel Doctor Software

Engine Setup Screen Right Click on Selected Engine click “Edit Engine”

User Data Table Fields Cylinder Firing Order

This is where you can include important additional readings that have to be

• btained seperately

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Downloading Data

IMPORTANT – Make Sure Correct Engine is Selected Click “Download Data” Icon

If Connection Error, adjust COM port under “Download” Menu Select Cylinder 1 and 1st Memory on Dk-2

Click Auto Connect

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Finishing Transfer

Click Transfer

Fuel Pump Index (Rack Readings) Scavenge Air Pressure

After Transfer, and entering Rack Readings, Click Close

Fuel Pump Rack Readings

Click Save

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Adding User Values

Right click on Measurement Click “Edit Sample” Click User Values Enter Exhaust Temp and Fuel Pump Index For Each Cylinder Select Cylinder

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Diesel Doctor Software

Double Click on the downloaded data

By Default Crank Angle Based Pressure Plot Appears

Crank Angle Based Pressure Diagram

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Is My Data Valid?

Good Data Cylinders Taken out of order Banks Taken out of Order of a Vee Engine One Bank Good, One Bank out of order

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Different Data Views

Data Table Bar Graph P-V Diagram Pressure Derivative Plot

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Analyzing Table Data

Another Way to Add User Values, Double Click on “???”

How you can compare variations of values like peak pressures, exhaust temps, power, etc.. Peak pressures +/- 5% for good balance

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Analyzing the Bar Graph

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Analyzing Pressure Curve

Late Injection

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Late Injection

Analyzing Pressure Curve

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Late Injection w/ Derivative Plot

Analyzing Pressure Curve

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Clogged Injector

Analyzing Pressure Curve

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No Combustion

Analyzing Pressure Curve

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Early Injection

Analyzing Pressure Curve

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Early Injection

Analyzing Pressure Curve

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Early Injection w/ Derivative Plot

Analyzing Pressure Curve

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Low Compression

Analyzing Pressure Curve

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Indicator Valve Leak

Analyzing Pressure Curve

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Injector Spray Problems

GOOD

Even Cone

FAIR

Weak

BAD

Split Spray

BAD

Jetting on One Side

BAD

Feathering at Top of Spray

BAD

Dribble

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Clogged Injectors

Analyzing Pressure Curve

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Replaced Injectors, Still Engine Imbalance

Analyzing Pressure Curve

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Bank Imbalance

Analyzing Pressure Curve

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Indicator Valve Restriction

Analyzing Pressure Curve

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Indicator Valve Restriction

Indicator Valve partially open (significantly reduced and graph shifted to the right) Problem corrected, data retaken

Analyzing Pressure Curve

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Data Collection Errors

Flat Line

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Spikes in Trace

Data Collection Errors

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Pressure Sensor Connector

Data Collection Errors

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Intermittent TDC

Data Collection Errors

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• This is a tool! Use it to keep engines running in top shape
• Use it as part of Engine Overhaul Q/A Process
• We see the data as it arrives. If there is a problem, C/E will get an

email.

• Any Questions?

Final Thoughts