Trouble Shooting Guide

BS MARINE

SAFE WATCH KEEPING PRACTICE

MAIN ENGINE TROUBLE SHOOTING BKK

C4

BS MARINE

S.NO PROBLEM SPARKS FROM THE 1. FUNNEL

SAFE WATCH KEEPING PRACTICE

CAUSES It can be caused by too much after burning or poor combustion. In case the exhaust temperature is too high, there could be a soot fire.

2.

TOO MUCH SPARKING FROM THE FUNNEL

If the exhaust gas temperatures are too high in addition to heavy sparking at the funnel , there is a possibility of a fire at the economizer or a scavenge fire.

3.

CYLINDER RELIEF VALVE LIFTING UP

This can be due to excess fuel supplied during starting or maneuverings  accumulated or un burnt fuel igniting with excess air  a sudden increase in load in rough weather  pre-ignition  leaking or sticking air start valves  water or oil accumulation on the piston crown  Excessive peak pressures.

BKK

REMEDIAL ACTION Check fuel oil temperature and scavenge temperatures. Drain the fuel oil tanks. A Dirty economizer should be soot blown and water washed when the engine is stopped. Stop the engine, but do not run at low loads since un burnt fuel is more at low loads. Start the standby economizer water circulating pump to increase cooling. Provide boundary cooling. Stop the engine and shut the air inlets at the turbocharger and auxiliary blowers. Identify cause and take corrective action. Please note B&W design aspect of the relief valve.Cylinder heads nuts may have to be re-tightened prior to starting after excess pressure relief.

C4

REMARKS

BS MARINE

SAFE WATCH KEEPING PRACTICE

4.

CYLINDER RELIEF VALVE LIFTING DURING BLOW THROUGH

Choked indicator cock. An incorrect relief valve setting. Water accumulation in the combustion chamber. Excess water in the starting air.

Identify cause and take corrective action.

5.

SMOKY EXHAUST

Less air supply to the engine due to fouled gas or air side of the turbocharger. Overloaded running conditions. Check load indicator, exhaust temperatures and peak pressures. Excessive cylinder lubrication. Injection nozzles not atomizing the completely, e.g. due to carbon trumpet formation and eroded or blocked spray holes. Incorrect fuel temperatures or viscosity, or a shift in the individual fuel cams. Compression pressure too low due to leaking piston rings or exhaust valve. Too low turbocharger rpm. Scavenge fire.

Identify cause and take corrective action.

This can occur because of fouling in turbocharger, air cooler, and intake air filter, scavenge valves in the air receiver, scavenge ports or exhaust passages Incorrect fuel timings, bad quality fuel or inadequate fuel

Identify cause and take corrective action.

6.

BKK

ALL CYLINDERS EXHAUST TEMPERATURE INCREASE

C4

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

treatment also result in increased temperatures

7.

ONE UNIT EXHAUST TEMPERATURE RISE

Thermometer defective (local or remote). Less air supply due to the individual unit scavenge valves in the air receiver or scavenge ports fouled, or a scavenge fire. Fuel injector nozzle in a poor condition or the tip broken. Incorrect fuel timings or a fuel cam shift. Leaking exhaust valve.

Identify cause and take corrective action.

ME Auto Slow Down as deviation alarm is triggered to safeguard effects of an imbalanced engine.

8.

ENGINE SPEED DROPS

Fuel pressure after the booster pump is too low. Fuel pumps defective or a fuel piping fault. Incorrect fuel injection. Fouling of air or exhaust passages. Fuel air lock, gassing, water in the fuel, or poor fuel combustion. Scavenge fire. Governor problem.

Identify cause and take corrective action.

Auto slow down will be triggered in case of Scavenge Fire, Oil Mist Detector alarm & EGB high temperature.

9.

ONE UNIT EXHAUST TEMPERATURE DROPS

A faulty thermometer. Less fuel supplied due to faulty fuel injection pump, pipes, injector or timings, a shift in cam position, broken piston rings. Exhaust valve does not open due to the malfunctioning of the actuating system.

Identify cause and take corrective action.

ME Auto Slow Down as deviation alarm is triggered to safeguard effects of an imbalanced engine.

BKK

BS MARINE

SAFE WATCH KEEPING PRACTICE

10.

ENGINE RUNNING IRREGULARLY, MISFIRING OR CUTTING OUT

Fuel problems like faulty fuel booster pump or fuel pump, wrong fuel pressure or temperature, air lock or water in fuel, or a defective fuel valve. Governor malfunction. Turbocharger surging. Running gear components over heated, causing severe alternating friction.

Identify cause and take corrective action.

11.

JACKET WATER PRESSURE FLUCTUATION

Air pockets in the jacket cooling water, or insufficient venting. Exhaust gas leaking into jacket cooling water due to a crack in the liner, cylinder head or valve cage. A drop in the static pressure at the pump inlet, due to throttling in the return pipe.

Identify cause and take corrective action.

12.

JACKET WATER TEMPERATURE INCREASE

13.

BKK

ENGINE FAILS TO START ON AIR

Valves may be shut or in sufficient venting. Overloaded engine or piston running hot. Crack in liner, cylinder head or exhaust valve cage. Temperature controller malfunction. Jacket cooler setting is wrong. Low air bottle pressure or air line valves may be shut. Air bottle isolating valve or automatic valve or distributor malfunction. Control air valves faulty or less

Identify cause and take corrective action.

Identify cause and take corrective action.

C4

ME Auto Slow Down as deviation alarm is triggered to safeguard effects of an imbalanced engine.

BS MARINE

SAFE WATCH KEEPING PRACTICE control air pressure. Start air automatic valve jammed. Turning gear engaged or limit switch faulty. Reversing has not taken place completely. Control valve for fuel or start is not in its end position. Bursting diaphragm on start air line damaged. Fuel lever on manoeuvring stand not on remote mode. Not sufficient spring air pressure to shut the exhaust valve, thereby causing loss of compression. Auxiliary blower not running or not on auto mode. No oil pressure due to the exhaust valve being open or insufficient spring air pressure. Start air distributor has not activated its end stop valves. Start air distributor piston is sticking. Start air distributor is wrongly adjusted. Start air distributor control valve is sticking. Cylinder air start valves are defectives or sticky.

14.

BKK

ENGINE TURNS ON AIR, BUT NOT ON FUEL

In B & W engines, the puncture valves are not properly vented. Fuel regulating linkage jammed or held back by the stop cylinder. Fuel lever on local maneuvering stand is not on remote mode. Governor is defective and does not release the fuel linkage, or there is no boost air to the governor. Rotary valve of the rotation direction safeguard is sticking. Shut down of fuel pumps. Fuel filter is blocked or fuel

Identify cause and take corrective action.

C4

BS MARINE

SAFE WATCH KEEPING PRACTICE pump index is too low. Pre-set control air signal to the governor is too low.

15.

ENGINE DOES NOT FIRE

Less fuel being injected or the speed setting knob is set too low. Governor does not release the regulating linkage. VIT & FQS functions are too late. Start air pressure is insufficient to tum engine fast enough.  Fuel is unsuitable or its viscosity high. Compression pressure is too low due to faulty piston ring sealing or exhaust valve closing. Fuel pump defect. Injector nozzle needle sticking or holes blocked. Suction or spill valves leaking or struck. Pump push rods jammed or fuel cams displaced or incorrect timings. Fuel pump relief valve leaking.

16.

BROKEN PISTON RING

Excessive thermal load, insufficient cooling, or a distorted piston crown. Excessive piston ring clearance or distorted grooves. Sticking of piston rings or incompatible materials. Excessive lubrication or loss of lubrication. Collapse of piston rings. Effects: Loss of compression. Blow past of combustion gases. Scavenge fire.

BKK

Identify cause and take corrective action.

C4

BS MARINE

SAFE WATCH KEEPING PRACTICE Scuffing of the cylinder liner.

17.

BEARING TEMPERATURE INCREASE

Low lube oil pressure supply to bearing or low oil level in supply tank. Air lock in the lube oil or lubricating grooves obstructed. Oil piping defective or lube oil valves shut. Lube oil contains water or metal impurities.  Excessive bearing clearances, excessive wear or important tightening.

18.

LUBE OIL SUMP LEVEL RISING

Identify cause and Pitching, rolling or changes in take corrective cargo loading. action. Water leakage from piston cooling or jacket water system. Lube oil purifier wrongly Transfer pump valves wrongly lined up. Lube oil inlet line valve from the storage tank may be open.

19.

AUTOMATIC STOPPING OF THE ENGINE

Activation of safety shut down or over speed cut-out device. Control air pressure in the shutdown servomotor too low, causing pressure to pull the fuel linkage back to zero. Governor defective. Fuel supply stopped due to clogged filter or empty tank or air lock.

Identify cause and take corrective action.

20.

REDUCED

This is due to worn piston rings.

Identify cause and

BKK

C4

BS MARINE

SAFE WATCH KEEPING PRACTICE

COMPRESSION PRESSURE

 Worn liner.  Worn piston crown.  Worn exhaust valve. Incorrect exhaust valve timings

take corrective action.

AUXILIARY ENGINE TROUBLE SHOOTING BKK

C4

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

TROUBLE SHOOTING

TROUBLE SHOOTINGS FOR MAIN AIR COMPRESSOR

S.NO 01

PROBLEMS Main air compressor breaker faulty

CAUSES Breaker is tripping. It is not holding at ON position.

02

Main air compressor outlet temperature high

High air outlet temperature alarm. Compressor will trip on high temperature.

03

Main air compressor low lube oil pressure

04

Main air compressor first stage suction valve leaky

Low lube oil pressure alarm. Compressor will trip on low low pressure. Running amperage Overhaul the valve. will come down. Air Check the first stage bottle filling rate piston rings condition. will reduce. First stage air pressure will reduce and fluctuate at less value.

BKK

REMEDIAL ACTIONS Fill up the air bottle with another air compressor. Isolate the faulty breaker & change with new one. Check the J.C.W. line & valves setting. Check the seawater flow through the cooler. Check the attached fresh water pump. Check the lube oil sump level. Check the sensor. Check the attached pump.

REMARKS

BS MARINE

SAFE WATCH KEEPING PRACTICE

05

Main air compressor first stage discharge valve leaky

Running amperage will be normal. Air filling rate will reduce. First stage air pressure will fluctuate across normal value.

S.NO 06

PROBLEM Main air compressor over current trip

CAUSES Compressor amperage is going high & tripping.

07

Main air compressor first stage disc valve choke or not opening/wrongly fitted

08

Main air compressor second stage suction valve leaky

09

Main air compressor second stage discharge valve leaky

Running amperage will fluctuate. First stage air pressure will increase & relief valve will lift. First stage air pressure will fluctuate at relief valve setting (5 kg). Second stage air pressure will show zero reading. Air filling rate will be zero. Running amperage will remain same but will fluctuate. Air filling rate will reduce. First stage air pressure will increase. Second stage air pressure will be normal & will fluctuate at normal value. Running amperage will remain same but will fluctuate. Air filling rate will reduce. Second

BKK

C4

Overhaul the valve. Check the first stage piston rings condition.

REMEDIAL ACTION Check the compressor easy rotation. Check the over current trip relay function. Overhaul first stage discharge valve.

Overhaul the valve. Check the second stage piston rings condition.

Overhaul the valve. Check the second stage piston rings condition.

REMARKS

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

stage air pressure will be normal & will fluctuate at normal value.

S.NO 10

BKK

PROBLEM Main air compressor second stage disc valve choke or not opening/wrongly fitted

CAUSES Running amperage will increase. Second stage air pressure will increase & relief valve will lift. Second stage air pressure will fluctuate at relief valve setting (31 kg). First stage air pressure will fluctuate at normal value. Air filling rate will be zero.

REMEDIAL ACTION Overhaul second stage discharge valve.

REMARKS

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

TROUBLE SHOOTINGS FOR FRESH WATER GENERATOR & HYDROPHORE SYSTEMS S.NO 01

PROBLEMS Fresh water generator Ejector sea water pump over current trip

CAUSES Pump is drawing high current & over current relay is tripping the breaker.

02

Fresh water generator Ejector sea water pump suction filter choked

03

Fresh water generator Ejector sea water pump worn out

04

Fresh water generator vacuum is less

Suction pressure will be less then normal. In extreme condition suction pressure will be zero. Suction pressure will show suction head. Pump will not build any pressure. Fresh water generator will not develop any vacuum. Difference between the inlet & outlet jacket cooling water temperature. Air ingress in the system. Faulty Ejector pump.

BKK

REMEDIAL ACTIONS Isolate the pump & rotate the shaft by hand. Check for possible reason of tight rotation. Check the electrical circuit for any possible fault. Isolate the pump & clean the filter.

Isolate the pump & overhaul it.

Identify cause & rectify same.

REMARKS

BS MARINE

SAFE WATCH KEEPING PRACTICE

05

Fresh water hydrophore pump breaker faulty

06

Fresh water hydrophore pump worn out

Fouled air ejector Breaker is tripping. It is not holding at ON position. Suction pressure will show suction head. Pump will not build any pressure.

Operate the system with standby pump. Isolate the faulty breaker & change with new one. Start another pump. Isolate the pump & overhaul it.

TROUBLE SHOOTINGS FOR PURIFIERS

S.NO 01

PROBLEM Fuel oil purifier feed pump breaker faulty

CAUSES Breaker is tripping. It is not holding at ON position.

02

Fuel oil purifier feed pump over current trip

Pump is drawing high current & over current relay is tripping the breaker.

03

Fuel oil purifier feed pump suction filter choke

04

Fuel oil purifier feed pump worn out

05

Fuel oil purifier breaker faulty

Suction pressure will come down & in fully choke condition it can show vacuum also. Pump will not build any pressure. Pump is not building any pressure. Flow to purifier will reduce. Breaker is tripping. It is not holding at ON position.

BKK

REMEDIAL ACTION REMARKS Operate the system with the standby pump. Isolate the faulty breaker & change with new one. Isolate the pump & rotate the shaft by hand. Check for possible reason of tight rotation. Check the electrical circuit for any possible fault. Clean the filter. Check the suction line.

Overhaul the pump.

Do the purification through another purifier. Isolate the

C4

BS MARINE

06

S.NO 07

Fuel oil purifier heater surface is dirty

Heater efficiency will drop. User has to increase temp setting to get desired temp. Low temp alarm. Purifier feed will stop.

PROBLEM Fuel oil purifier Desludge auto controller failure

CAUSES Purifier will not desludge on auto mode. Solenoid valves are malfunctioning. Fluctuation in rpm. So in amperage Backpressure will be high. Purifier cannot be desludged. It can cause Oil ingress in the water side. While starting purifier will not be able to gain its maximum speed. Amperage will not go up. On giving feed oil will overflow. While running amperage will come down. If operating water is ON it will overflow to sludge tank. Purifier is drawing high current & over current relay is

08

Fuel oil purifier bowl is dirty

09

Fuel oil purifier friction pads worn out

10

Fuel oil purifier over current trip

BKK

SAFE WATCH KEEPING PRACTICE

C4

faulty breaker & change with new one. Check the steam line and pressure. Check the steam controller. Clean the heater.

REMEDIAL ACTION Desludge purifier on manual mode. Overhaul solenoid valves. Stop the purifier. Open & clean the purifier.

Stop the purifier & inspect the friction pad.

Isolate the purifier & rotate the shaft by hand. Check for possible

REMARKS

BS MARINE

SAFE WATCH KEEPING PRACTICE tripping the breaker.

reason of tight rotation. Check the electrical circuit for any possible fault.

TROUBLE SHOOTINGS FOR AUXILIARY BOILER

S.NO 01

PROBLEM Auxiliary boiler feed water pump breaker faulty

CAUSES Breaker is tripping. It is not holding at ON position.

02

Auxiliary boiler feed water pump over current trip

Pump is drawing high current & over current relay is tripping the breaker.

03

Auxiliary boiler feed water pump break down

Low feed water pressure alarm. Pump is not building pressure.

04

Auxiliary boiler High salinity in feed water

High salinity alarm.

BKK

REMEDIAL ACTION REMARKS Operate the system with the standby pump. Isolate the faulty breaker & change with new one. Isolate the pump & rotate the shaft by hand. Check for possible reason of tight rotation. Check line valves. Check the electrical circuit for any possible fault. Change over to another pump if it is not started on auto and confirm line valves are correctly set. Overhaul the defective pump after isolation. Blow down the water. Check for sea water ingress in system and rectify same before putting the boiler back in operation.

C4

BS MARINE

SAFE WATCH KEEPING PRACTICE

05

Auxiliary boiler feed water turbine pump breakdown

06

Auxiliary boiler feed water auto controller is not working

S.NO 07

PROBLEM Auxiliary boiler water level remote gauge is not working

08

Auxiliary boiler igniter transformer is not working

09

Auxiliary boiler smoke side dirty

10

Auxiliary boiler Auto combustion control failure

BKK

Low feed water pressure alarm. Pump is not building pressure. Boiler water level not maintained as per consumption requirements. Level will come down and may result in shut down.

CAUSES Water level gauge in ECR will show error leading to wrong information. Boiler will not fire & will trip on flame failure.

C4

Check the valve status & cascade tank level. Overhaul the pump if necessary. Change over to manual line. Overhaul the control.

REMEDIAL ACTION Check water level from local gauge glass. Rectify remote gauge glass error. Replace the transformer and put the boiler back in use ONLY after rectifying fault. Boiler steam Soot blow the auxiliary production rate will boiler regularly. reduce. Manual cleaning of Fuel oil smoke side as per consumption will vessels trading pattern. increase. Smoke density increase causing port authorities to stop all operations related to the boiler. Auxiliary boiler is Change burner control not firing on auto. to manual mode & fire the boiler on manual. Keep in mind all alarms & cut outs may not be be in functional in this mode.

REMARKS

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

TROUBLE SHOOTING OF PUMPS Sl. NO 1.

PROBLEMS Failure to build up pressure

2.

Vibration

3.

Overload & Trip

BKK

CAUSES Loss of suction / air ingress Discharge valve stuck in closed position Motor inoperational Internal damage due to wear & tear  It is because of bearing damage Misalignment to coupling Damage to the rotating components  There have also been causes of heavily clogged impellers causing excessive vibration Foundation bolts weak Overload of the motor will occur due to excessive resistance to motion. Imbalance.

SYMPTOMS

REMEDIAL ACTIONS Identify cause & rectify same

Identify cause & rectify same

Identify cause & rectify same

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

 Bent shaft. Insufficient working clearance.  Damaged bearing Clogged impellers.

4.

Drop in capacity

It is usually due to worn parts (excessive clearance of wear rings)  Fault in prime mover (not developing correct rpm). impellers being assembled up in the wrong way, leading to sudden drop in performance (check the direction before dismantling and confirm before re-assembly)

5.

Overheating

 At low capacities, the power supplied to the pump is no longer converted in to mechanical output, which is seen as a drop in efficiency. The excess energy is seen as an increase in the temperature, which could lead to reduction in working clearances, overheating and damage to bearings and seals

Drop in discharge pressure. Rise in temperature of casing. Air lock in system. **** COP will trip on high casing temp.

Identify cause & rectify same.

6.

Loss of suction of pump having positive suction head

Blockage on the suction side. Tank is empty.

suction pressure gauge shows negative pressure for blockage on suction side suction pressure gauge

Identify cause & rectify same

BKK

Identify cause & rectify same

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

shows zero pressure for empty tank

7.

Loss of pump suction pressure having negative suction head.

8.

Pump having less discharge pressure with discharge valve fully open.

9.

Centrifugal pump priming unit malfunction. (e.g. Emergency Fire Pump )

10.

BKK

Gear pumps discharge pressure low.

Blockage on the suction side. Water level drops below the suction pipe. (e.g. Emergency Fire Pump) air ingress in the pipeline through leaky flange , hole, leaky valve or leaky gland packing (common fault in bilge ballast pump’g systems )

the suction pressure shows vacuum more than normal for blockage in suction side  Suction pressure gauge shoes zero for water level drop below suction line. It shows zero for air leakage. Water is re-circulating The discharge within the pump pressure gauge through worn out wear shows less rings, pumps valve. pressure than the normal. Priming pump not No air getting sealing water. discharge from water ring primer. Pump suction pressure gauge shows zero pressure. More clearance Discharge between the casing & the pressure gauge gear wheels due to shows low erosion. pressure than Suction filters clogged. normal.

Identify cause & rectify same

Identify cause & rectify same

Identify cause & rectify same. Ensure sealing water tank is full at all times.

Identify cause & rectify same

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

12.

Reciprocating pump having fluctuating discharge pressure.

Air vessel fitted to the pump discharge line is not working properly. Pressure gauge faulty

discharge pressure gauge pointer is Fluctuating.

Identify cause & rectify same

13.

Reciprocating pump having suction but no discharge. Positive displacement pumps having full suction but very low discharge.

Discharge valve in valve chest sluggish in operation.

Discharge pressure gauge shows zero reading. Discharge pressure gauge shows very low discharge pressure than the normal.

Identify cause & rectify same

14.

BKK

Relief valve in open condition due to improper setting of the spring tension. Due to broken spring of the relief valve .

Identify cause & rectify same

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

TROUBLE SHOOTING FOR STEERING SYSTEM

S.NO 01

PROBLEM Oil consumption High

02

Steering/Rudder movement is sluggish or slow

03

Steering/Rudder movement is not responding Bridge orders Steering motor phase failure

04

05

BKK

Steering motor overload.

CAUSES Low level alarm is triggered due to oil leakage. May result in system being isolated if low low alarm is trigerred. System pump pressure low due suction filter choked. Telemetric system failure. No power supply.

The steering motor is designed to take up to 200% overload & it will give alarm above 100% normal working load.

REMEDIAL ACTION Rectify the leakage at the earliest. Isolate system if leakage is very high and use standby system.

REMARKS

Replace the filters (normally very fine filter cartridge).

Identify cause & rectify same

Change over to emergency steering system. Switch over to standby mode.

Identify cause & rectify same Identify cause & rectify same Identify cause & rectify same

Rudder movement is restricted due to external factors like grounding or collision. Damaged OR Misaligned rams.

Identify cause & rectify same

BS MARINE

BKK

SAFE WATCH KEEPING PRACTICE

C4

BS MARINE

SAFE WATCH KEEPING PRACTICE

C4

ELECTRICAL TROUBLE SHOOTING

TROUBLE SHOOTING FOR ELECTRICAL MACHINERY

S.NO

BKK

PROBLEM

CAUSES

REMEDIAL ACTION

REMARKS

BS MARINE 01

SAFE WATCH KEEPING PRACTICE

Alternator shows no voltage

Exciter field resistance is too high or there is a loss of residual magnetism. Short-circuit in excitation circuit probably between leads to field or alternator slip rings.

02

03

Alternator excites but not to its rated voltage

No Load Voltage Fluctuating

Locate the short-circuit & repair the same.

Insulation of windings is not proper.

Check insulation with Megger instrument.

Fault in AVR card. One or more stator coils are short circuited.

Change the AVR card. Locate & have defective coils replaced.

Some stator coils are connected in the wrong sequence probably after local repair. Adjust the voltage on AVR set point potentiometer.

Check stator winding for symmetry & re-connect any wrongly connected coils.

Check function thyristor.

Change the thyristor, change the AVR if required. Reduce load if possible. Blow out ventilation passages with compressed air. Locate the short circuit fault & rectify it. If necessary have new coils fitted. Locate the break & repair it.

04

Overheating

Overload or ventilation passages blocked.

05

Overheating accompanied by reduction of torque

Short circuit between one or more stator coils.

06

Motor will not start on no load, or runs at low speed

Break at the joint, probably the star point of rotor winding of starter.

BKK

Cut out all excitor field regulator resistance, & check excitation circuit connections. Lift brushes & re-excite.

Change AVR if required.

C4

BS MARINE

07

SAFE WATCH KEEPING PRACTICE

Overheating accompanied by torque deficiency

Bad contact at some joint of stator windings. Connections of star-delta switch wrong. Too high rotor resistance probably due to faulty contact between rotor bars & shortcircuiting rings. Short circuit in rotor winding converting rotor effect into low resistance squirrel cage rotor.

BKK

Investigate & make good the contact. Check with diagram of connections & correct the error.

Re-solder any visibly bad connections.

Locate short circuit & repair, having faulty coils replaced where necessary.

C4