Trouble Shooting Guide

(1)

MAIN

ENGINE

TROUBLE

SHOOTING

(2)

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS

1. SPARKS FROM THE FUNNEL

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.

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.

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.

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.

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.

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.

(3)

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.

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. 6. ALL CYLINDERS EXHAUST TEMPERATURE INCREASE

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

(4)

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.

(5)

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

12. JACKET WATER TEMPERATURE INCREASE

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.

13. ENGINE FAILS TO START ON AIR

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

(6)

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. 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

(7)

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.

(8)

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

Pitching, rolling or changes in cargo loading.

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 shut-down 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.

(9)

COMPRESSION PRESSURE

 Worn liner.

 Worn piston crown.  Worn exhaust valve.

Incorrect exhaust valve timings

take corrective action.

AUXILIARY

ENGINE

TROUBLE

SHOOTING

(10)

TROUBLE SHOOTING

TROUBLE SHOOTINGS FOR MAIN AIR COMPRESSOR

S.NO PROBLEMS CAUSES REMEDIAL ACTIONS REMARKS

01 Main air compressor breaker faulty

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

Fill up the air bottle with another air compressor. Isolate the faulty breaker & change with new one. 02 Main air compressor

outlet temperature high

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

Check the J.C.W. line & valves setting. Check the seawater flow through the cooler. Check the attached fresh water pump.

03 Main air compressor low lube oil pressure

Low lube oil pressure alarm. Compressor will trip on low low pressure.

Check the lube oil sump level. Check the sensor. Check the attached pump.

04 Main air compressor first stage suction valve leaky

Running amperage will come down. Air bottle filling rate will reduce. First stage air pressure will reduce and fluctuate at less value.

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

(11)

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.

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

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS

06 Main air compressor over current trip

Compressor amperage is going high & tripping.

Check the compressor easy rotation. Check the over current trip relay function.

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

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.

Overhaul first stage discharge valve.

08 Main air compressor second stage suction valve leaky

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.

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

09 Main air compressor second stage discharge valve leaky

Running amperage will remain same but will fluctuate. Air filling rate will reduce. Second

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

(12)

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

10 Main air compressor second stage disc valve choke or not

opening/wrongly fitted

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.

Overhaul second stage discharge valve.

(13)

TROUBLE SHOOTINGS FOR FRESH WATER GENERATOR &

HYDROPHORE SYSTEMS

S.NO PROBLEMS CAUSES REMEDIAL ACTIONS REMARKS

01 Fresh water generator Ejector sea water pump over current trip

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

Isolate the pump & rotate the shaft by hand. Check for possible reason of tight rotation.

Check the electrical circuit for any possible fault.

02 Fresh water generator Ejector sea water pump suction filter choked

Suction pressure will be less then normal. In extreme condition suction pressure will be zero.

Isolate the pump & clean the filter.

03 Fresh water generator Ejector sea water pump worn out

Suction pressure will show suction head. Pump will not build any pressure. Fresh water generator will not develop any vacuum.

Isolate the pump & overhaul it.

04 Fresh water generator vacuum is less

Difference between the inlet & outlet jacket cooling water temperature. Air ingress in the system.

Faulty Ejector pump.

Identify cause & rectify same.

(14)

Fouled air ejector 05 Fresh water hydrophore

pump breaker faulty

Operate the system with standby pump. Isolate the faulty breaker & change with new one. 06 Fresh water hydrophore

pump worn out

Suction pressure will show suction head. Pump will not build any pressure.

Start another pump. Isolate the pump & overhaul it.

TROUBLE SHOOTINGS FOR PURIFIERS

01 Fuel oil purifier feed pump breaker faulty

Operate the system with the standby pump. Isolate the faulty breaker & change with new one.

02 Fuel oil purifier feed pump over current trip

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

03 Fuel oil purifier feed pump suction filter choke

Suction pressure will come down & in fully choke condition it can show vacuum also. Pump will not build any pressure.

Clean the filter. Check the suction line.

04 Fuel oil purifier feed pump worn out

Pump is not building any pressure.

Flow to purifier will reduce.

Overhaul the pump.

05 Fuel oil purifier breaker faulty Breaker is tripping. It is not holding at ON position. Do the purification through another purifier. Isolate the

(15)

faulty breaker & change with new one.

06 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.

Check the steam line and pressure. Check the steam controller. Clean the heater.

07 Fuel oil purifier Desludge auto controller failure

Purifier will not desludge on auto mode. Solenoid valves are malfunctioning. Desludge purifier on manual mode. Overhaul solenoid valves.

08 Fuel oil purifier bowl is dirty Fluctuation in rpm. So in amperage Backpressure will be high. Purifier cannot be desludged. It can cause Oil ingress in the water side.

Stop the purifier. Open & clean the purifier.

09 Fuel oil purifier friction pads worn out

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.

Stop the purifier & inspect the friction pad.

10 Fuel oil purifier over current trip

Purifier is drawing high current & over current relay is

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

(16)

tripping the breaker.

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

TROUBLE SHOOTINGS FOR AUXILIARY BOILER

01 Auxiliary boiler feed water pump breaker faulty

Operate the system with the standby pump. Isolate the faulty breaker & change with new one.

02 Auxiliary boiler feed water pump over current trip

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.

03 Auxiliary boiler feed water pump break down

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

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. 04 Auxiliary boiler High

salinity in feed water

High salinity alarm. Blow down the water. Check for sea water ingress in system and rectify same before putting the boiler back in operation.

(17)

05 Auxiliary boiler feed water turbine pump breakdown

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

Check the valve status & cascade tank level. Overhaul the pump if necessary.

06 Auxiliary boiler feed water auto controller is not working

Boiler water level not maintained as per consumption requirements. Level will come down and may result in shut down.

Change over to manual line.

Overhaul the control.

07 Auxiliary boiler water level remote gauge is not working

Water level gauge in ECR will show error leading to wrong information.

Check water level from local gauge glass. Rectify remote gauge glass error.

08 Auxiliary boiler igniter transformer is not working

Boiler will not fire & will trip on flame failure.

Replace the transformer and put the boiler back in use ONLY after rectifying fault. 09 Auxiliary boiler smoke side

dirty

Boiler steam production rate will reduce. Fuel oil consumption will increase. Smoke density increase causing port authorities to stop all operations related to the boiler.

Soot blow the auxiliary boiler regularly. Manual cleaning of smoke side as per vessels trading pattern.

10 Auxiliary boiler Auto combustion control failure

Auxiliary boiler is not firing on auto.

Change burner control to manual mode & fire the boiler on manual. Keep in mind all alarms & cut outs may not be be in functional in this mode.

(18)

TROUBLE SHOOTING OF PUMPS

Sl.

NO

PROBLEMS

CAUSES

SYMPTOMS

REMEDIAL

ACTIONS

1. Failure to build up

pressure

Loss of suction / air

ingress

Discharge valve stuck

in closed position

Motor inoperational

Internal damage due

to wear & tear

Identify cause

& rectify same

2. Vibration

 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

Identify cause

& rectify same

3. Overload & Trip

Overload of the motor

will occur due to

excessive resistance to

motion.

Imbalance.

Identify cause

& rectify same

(19)

 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)

Identify cause

& rectify same

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

(20)

shows zero

pressure for

empty tank

7. Loss of pump

suction pressure

having negative

suction head.

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.

Identify cause

& rectify same

8. Pump having less

discharge pressure

with discharge

valve fully open.

Water is re-circulating

within the pump

through worn out wear

rings, pumps valve.

The discharge

pressure gauge

shows less

pressure than the

normal.

Identify cause

& rectify same

9. Centrifugal pump

priming unit

malfunction.

(e.g. Emergency

Fire Pump )

Priming pump not

getting sealing water.

No air

discharge from

water ring

primer.

Pump suction

pressure gauge

shows zero

pressure.

Identify cause

& rectify same.

Ensure sealing

water tank is

full at all times.

10. Gear pumps

discharge pressure

low.

More clearance

between the casing & the

gear wheels due to

erosion.

Suction filters clogged.

Discharge

pressure gauge

shows low

pressure than

normal.

Identify cause

& rectify same

(21)

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.

Discharge valve in

valve chest sluggish in

operation.

Discharge

pressure gauge

shows zero

reading.

Identify cause

& rectify same

14. Positive

displacement

pumps having full

suction but very

low discharge.

Relief valve in open

condition due to

improper setting of the

spring tension.

Due to broken spring

of the relief valve .

Discharge

pressure gauge

shows very low

discharge

pressure than the

normal.

Identify cause

& rectify same

(22)

TROUBLE SHOOTING FOR STEERING SYSTEM

01 Oil consumption High Low level alarm is triggered due to oil leakage.

May result in system being isolated if low low alarm is trigerred.

Rectify the leakage at the earliest.

Isolate system if leakage is very high and use standby system.

Identify

cause &

rectify same

02 Steering/Rudder movement is sluggish or slow System pump pressure low due suction filter choked.

Replace the filters (normally very fine filter cartridge).

Identify

cause &

rectify same

03 Steering/Rudder movement is not

responding Bridge orders

Telemetric system failure. Change over to emergency steering system.

Identify

cause &

rectify same

04 Steering motor phase failure

No power supply. Switch over to standby mode.

Identify

cause &

rectify same

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

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

Identify

cause &

rectify same

(23)

(24)

ELECTRICAL

TROUBLE

SHOOTING

TROUBLE SHOOTING FOR ELECTRICAL MACHINERY

(25)

01 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. Insulation of windings is not proper.

Fault in AVR card.

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

Locate the short-circuit & repair the same.

Check insulation with Megger instrument.

Change the AVR card. 02 Alternator excites but not

to its rated voltage

One or more stator coils are short circuited.

Some stator coils are connected in the wrong

sequence probably after local repair.

Locate & have defective coils replaced.

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

03 No Load Voltage Fluctuating

Adjust the voltage on AVR set point potentiometer. Check function thyristor.

Change AVR if required.

Change the thyristor, change the AVR if required.

04 Overheating Overload or

ventilation passages blocked.

Reduce load if possible. Blow out ventilation passages with compressed air. 05 Overheating accompanied by reduction of torque Short circuit between one or more stator coils.

Locate the short circuit fault & rectify it. If necessary have new coils fitted.

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.

Locate the break & repair it.

(26)

Bad contact at some joint of stator windings.

Investigate & make good the contact. 07 Overheating accompanied

by torque deficiency

Connections of star-delta switch wrong.

Too high rotor resistance probably due to faulty contact between rotor bars & short-circuiting rings. Short circuit in rotor winding converting rotor effect into low resistance squirrel cage rotor.

Check with diagram of connections & correct the error.

Re-solder any visibly bad connections.

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