Diesel engine

parts
ENTABLATURE

- name given to the cylinder block which incorporates the scavenge air
space and the cooling water spaces
FRAME
The engine load carrying part that includes:
cylinder block
crankcase
bedplate or base
FRAME
The engine load carrying part that includes:
cylinder block
crankcase
bedplate or base
sump or oil pan
end plates
FRAME
The engine load carrying part that includes:
cylinder block
crankcase
bedplate or base
sump or oil pan
end plates

CYLINDER BLOCK
A cast iron casing which encloses / houses cylinder liners &
supports heads.The heads are tightly secured by studs and nuts to
the cylinder block
CRANKCASE
The crankcase is a housing for the crankshaft and provides
space for its rotation.
CRANKCASE
The crankcase is a housing for the crankshaft and
provides space for its rotation.
3.1 MATERIAL
cast steel
cast steel & welded steel plates
CRANKCASE
The crankcase is a housing for the crankshaft and
provides space for its rotation.
3.1 MATERIAL
cast steel
cast steel & welded steel plates

3.2 LOCATION
A column or frame, mounted on the bedplate, forms the engine
crankcase.
3.4 CRANKCASE EXPLOSION
3.4.1 Causes
Oil droplets are formed by oil splashing from the
bearings mix with air.This mixture does not readily
burn or explode unless there are overheated parts
within the crankcase & presence of fuel oil.
3.4.2 Prevention
Proper maintenance, correct lubrication,
cleanliness.

3.4.3 Safety arrangements

Crankcase explosion relief valves;
Inert gas flooding system;
Crankcase mist detector
3.4.4 Consequences
Minor explosion, flames, pressure shock wave
( ruptures crankcase doors )
Major explosion widespread damage

3.4.5 Actions
Stop engine until it cools down.
4. BEDPLATE OR BASE
4.1 DEFINITION
Main strength part providing rigid support for the main bearings
and crankshaft.
4. BEDPLATE OR BASE
4.1 DEFINITION
Main strength part providing rigid support for the main
bearings and crankshaft.

4.2 STRUCTURE
longitudinal box structures with stiffening members and webs
transverse members or girders
4. BEDPLATE OR BASE
4.3 STRESSES
Heavy stresses in operation
While supporting the main bearings and bolts

4.4 FUNCTION
to support the frame and all working parts
to collect crankcase lubricating oil and return it to the sump /
draining tank
5. TIE BOLTS

- long tie bolts are fitted through the bedplate, frames and
entablature to hold these three components in compression and
to transmit the firing forces back to the bedplate

- tightened hydraulically

- positioned as close to the center of crankshaft as possible to

prevent excessive bending moments
1. CRANKSHAFT,MAIN BEARINGS & SHAFT ALIGNMENT
1.1 DEFINITION OF A CRANKSHAFT
The crankshaft converts reciprocating motion in the cylinder into rotary motion of
the propeller shaft.
1. CRANKSHAFT, MAIN BEARINGS & SHAFT ALIGNMENT
1.2 PARTS
The crankshaft is made up of throws and journals. A throw consists of a pin ( secured
or attached to big / bottom end bearings ) and two webs or cranks. Journals rest or
lie in the main bearings.
1. CRANKSHAFT,MAIN BEARINGS & SHAFT ALIGNMENT
1.3 STRESSES
Bending ( when the piston is at TDC );
Shear stress ( in operation );
Torsion ( due to speed change, i.e. acceleration & deceleration )
1.4 MANUFACTURING

Solid forged built in a single piece ( small-slow speed engines )

Semi-built design ( large engines ). Crankpins & webs are forged or cast in one
piece and shrunk on to the journals.
1.5 MATERIALS
Carbon steel
Alloy of nickel, chromium & molybdenum
Specially alloyed grey cast steel

1.6 ARRANGEMENT OF CRANKS

Multi-throw shaft to provide for the engine firing order
2. MAIN BEARINGS / CRANKSHAFT BEARINGS
2.1 LOCATION
In the transverse saddles of the bedplate.
2. MAIN BEARINGS / CRANKSHAFT BEARINGS
2.1 LOCATION
In the transverse saddles of the bedplate.

2.2 PURPOSE
To provide support for the crankshaft

2.3 MATERIAL ( multilayer bearings )

Steel support shell ( basic element );
Bearing metal ( white metal, copper-lead or aluminium-tin alloy, leaded
bronze );
Nickel barrier ( separating the two layers );
Galvanized layer ( good running-in and dry running properties )
Anti-corrosion layer ( lead or indium )
2.4 PARTS
Upper & lower shells (fitted in bedplate seating / saddle )
Thrust bolts
Covers
Shims ( for adjusting vertical bearing play )

2.5 LUBRICATION
Pressure lubricated ( low pressure )

2.6 CLEARANCE
2.6.1 Measurement
lead wire
wear gauge / bridge gauge
feeler gauge
kjaer feeler
2.7 BEARING DAMAGES
2.7.1 Indications
increased temperature
slight oil pressure drop ( sometimes followed by noise )

2.7.2 Kinds
Squeezing of the overlay / white metal ( problems with oil film
formation );
Fatigue cracking ( due to poor quality, shaft misaligment or local
overload );
Dislodgement of overlay or white metal ( due to cracking );
Scoring ( striation due to presence of hard particles );
Wiping ( misshaped overlay or white metal due to high temperature
)
3. CRANKSHAFT ALIGNMENT
Crankshafts are aligned to determine load reactions on each bearing. This is done by laser
techniques and computer calculations.
3.1 CHECKS
3.1.1 Frequency
Once a year
After replacing the main bearing
If the ship has grounded

3.1.2 Techniques
The deflections are measured through one revolution of the crankshaft
by inserting a dial gauge / dial indicator gauge between the webs.
Measurements are taken at TDC, BDC and two horizontal web
positions.
3.1.3 Misalignment
Wear of main bearings;
Distortion of engine bedplate transverse members;
Damage to supporting ships structure.

3.1.4 Consequences
Hogging is closing of the crank throw at TDC.
Sagging is opening of the crank throw at TDC.

3.1.5 Reports
Main / auxiliary engine crankshaft deflection record;
Crankshaft and engine bearing data sheet.
1. DEFINITION
A running component connecting the crankshaft to the piston ( in trunk piston engines )
or to the crosshead ( in crosshead engines ).
It has both linear ( reciprocating, up-and-down ) & rotational ( rotary ) motion.
2. FUNCTION
Primary function: to transmit the push (pressure, thrust) of the piston to the crankshaft,
either directly or indirectly.
Secondary function: (in most designs) to convey cooling oil to the pistons which demands
for a quite a large diameter passage.
4. ELEMENTS
4.1 Crankpin end Bottom end bearing, lower end bearing, big end
bearing, crankpin bearing, or large end bearing.
Attachment point for the crankpin, carrying a bearing.
It consists of two half removable shells ( marine type ) held together by bolts
and nuts. The shells have a lining of bearing metal, white metal or Babbitt ( copper-
lead or tin-aluminium + thin flashing of lead or indium to provide for an
anticorrosion layer).
Bearing housing contains cooling oil grooves.
Between the foot and the box ( bearing housing ) there are shims (distance
pieces, compression shims, compression plates ) for adjustment of cylinder
compression.
 4.2 Rod shank
It is also called the body and may take up different forms. It has d drilling
throughout its length.
4.3 Gudgeon pin end Upper end bearing, top end bearing, or small
end bearing, wristpin bearing.
Upper end bearing is a bushing having an interference fit ( nip ) in the eye
bored in the rod.
The eye is a single piece bearing (bush, bushing) pressed into sleeve.
The bushing is of bronze or of cast steel & centrifugally cast bearing metal.
5. STRESSES
5.1 Axial forces resulting from gas pressure and inertia of piston assembly
modified by the side thrust arrising in consequence of the connecting rod crank angle.
The maximum axial load is compressive ( at TDC ).
Tensile stresses occur after firing, due to piston inertia.
Bending stresses also occur after firing.
5.2 Transverse forces known as whip, are caused by inertia effects of the rod
mass.
Fortunatly axial & transverse forces do not occur at the same time.

6. LUBRICATION
It is carried out through the shank bore (drilling) in running throughout the shank length. It
conducts oil from the big end to the small end for lubrication and to the inside of piston for
its cooling.
1. LINER DEFINITION
A removable component, cylindrical in shape, inserted into the engine block. It can be
replaced when worn out.
1.1 FUNCTION
It provides the surface for the piston to slide and carry out its compression task.
1.2 TYPES
Wet liners ( the water is in direct contact with outer surface of the liner );
Dry liners ( the water is in indirect contact with outer surface of the liner, i.e. cylinder
casting contains wet jackets ).
1.3 MANUFACTIRING
Grey cast steel + vanadium & titanium
Chromium plate liners ( to reduce wear rate ),
Close grained cast iron or
Fine lamellar cast iron ( in recent designs ).
 1.3 MANUFACTIRING
What are the reasons for manufacturing the liner separately from the cylinder block?

1. A liner can be manufactured using a superior material to the cylinder block

(grey cast steel + alloys to help resist corrosion and improve wear resistance at
high temperatures)
2. Replacing a worn liner.
3. At working temperature, the liner is hot. It will expand more and is free to
expand diametrically and lengthwise. If they were cast as one piece, then
unacceptable thermal stresses would be set up, causing fracture of the material.
4. Less risk of defects. The more complex the casting, the more difficult to
produce a homogenous casting with low residual stresses.
1.7 DESIGN
Uninterrupted or continuous liner ( in 4-stroke engines );
Ported liner ( 2-stroke engines )
1.8 SCAVENGING
Traditional two stroke loop scavange engines have ports midway along their
length;
Modern two stroke engines are provided with uniflow scavenging system.
2. COOLING*
2.1 PURPOSE
Reduction of the surface temperature allows for adequate lubrication, ensures
gas seal & diminishes liner & piston ring wear.
Limiting thermal expansion thereby maintaining the piston clearance.
3. LUBRICATION*
3.1 PURPOSE
To reduce piston ring friction & wear;
Oil film acts as gas seal to ( prevent blow by ) & corrosion inibitor;
3.2 TYPE
In large crosshead-type engines sepatate cylinder lubrication system
fitted.
In trunk piston engines by oil splashing from the crankcase.
4. GAUGING*
It is made internally during cylinder overhaul after 6000 8000 hours.
4.1 GAUGE ( micrometer & extension bar / template bar / gauging strip).
4.2 READINGS ( at 6 8 vertical positions total wear from original &
wear since last recording )
4.3 WEAR RATES*
High at the beginning, later almost constant ;
acceptable wear 0.1 mm per 1000 hours;
maximum wear before renewal app. 0.6-0.8 % of the original diametar )
6. RENEWAL & PREPARATION FOR RUNNING-IN
6.1 RENEWAL
At the top of the piston travel & at port bars
ports to be cleaned,
sharp edges to be removed,
lubricators to be tested,
possible craks to be inspected
6.2 PREPARATION FOR RUNNING-IN*
New liners are produced with slightly rough surface to retain oil & facilitate
running in.
New liners require honing ( breaking the liner glaze ).
Hard wearing surfaces are obtained by liner bore nitrading.
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1. DEFINITION
A cylindrical metal component which reciprocates in the cylinder under gas pressure. It
is connected to the piston rod or to the connecting rod.

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2. PISTON TERMINOLOGY
Piston crown is a cylindrical part which tapers to a thinner section.
Piston skirt is a cylindrical part of the piston below the pressure rings, keeping the
piston in alignment with the cylinder. It can contain a scraper ring.

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3. CLASSIFICATION & DESIGN
Marine diesel engine pistons may be classified as:
Trunk pistons ( small diesel engines ) are cast in one-piece.
Pistons with crosshead ( longer than the previous and used in medium-speed and
high-cylinder power engines ) are termed two-piece pistons with detachable crown /
composite pistons ( light metal base and steel crown ).
Pistons of double acting engines.

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5. LOADS & MATERIAL PROPERTIES
5.1 LOADS
Heavy mechanical and thermal loads due to operating conditions.

5.2 MATERIAL PROPERTIES

High strength, high resistance to corrosion and wear.

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6. COOLING
The piston is oil cooled. Different oil cooling arrangements may exist:

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 splash cooled

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 spray cooled

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 chamber cooled

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 coil cooled

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 cocktail shaker

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7. PISTON RING TERMINOLOGY
Piston ring is a spring tensioned ring set in grooves in the circumference of a
piston that push out against the walls of the cylinder forming a gas tight seal.
Scraper ring is a form of a piston ring fitted to the crankcase end of the piston
designed to remove excess lubricating oil from the cylinder walls and return it to
the crankcase.
Piston groove is a channel cut in the piston skirt to accommodate a ring.

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2. FUNCTION
To close toghtly / seal off the top of cylinders.
To form the combustion chamber, together with the piston crown or in some cases
with the liner itself.
To carry the injector and the valves.
3. VALVES
All internal combustion engines ( 2 or 4-stroke ) have:

an air starting valve which admits compressed air into the cylinder for starting
purposes;
a safety or relief valve is a spring loaded valve set to a safe limit which releases
excessive pressure;
an indicator cock which is used as a point of the indicator mechanism attachment.
1. DEFINITION
A device used to regulate or control the flow of fluids (liquid, air or gas), in pipings,
systems and in machinery.
2. VALVE OPERATING GEAR
Cam
Roller
Tappet
Push rod
Rocker arm / lever
Valve spring
Valve
3. PARTS
Valve cage - valve housing.
Valve stem / valve spindle the rod by means of which the disk or plug is moved to open
or close a valve.
Valve head / valve lid disk part of poppet valve that gives a tight closure on the valve
seat.
Valve seat the circular metal ring on which the valve head / valve disk / valve plug of a
poppet valve rests when closed.
Valve guide a channel which supports the stem of a poppet valve for maintanance and
alignment.
Valve rotator a device rotating the valve stem.