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1

MAIN
ENGINE
TROUBLE
SHOOTING
2

S.N PROBLEM CAUSES REMEDIAL REMARKS


O ACTION
1. SPARKS FROM ➔It can be caused by too much ➔Check fuel oil
THE FUNNEL after burning or poor combustion. temperature and
scavenge
temperatures. Drain
➔In case the exhaust temperature
the fuel oil tanks. A
is too high, there could be a soot Dirty economizer
fire. should be soot blown
and water washed
when the engine is
stopped.

2. TOO MUCH ➔If the exhaust gas temperatures ➔Stop the engine,
SPARKING are too high in addition to heavy but do not run at low
FROM THE sparking at the funnel , there is a loads since un burnt
fuel is more at low
FUNNEL possibility of a fire at the
loads. Start the
economizer or a scavenge fire. 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 ➔This can be due to excess fuel Identify cause and
RELIEF VALVE supplied during starting or take corrective
LIFTING UP maneuverings action.
Please note B&W
➔ accumulated or un burnt fuel
design aspect of the
igniting with excess air relief valve.Cylinder
➔ a sudden increase in load in heads nuts may have
rough weather to be re-tightened
➔ pre-ignition prior to starting after
➔ leaking or sticking air start excess pressure relief.
valves
➔ water or oil accumulation on
the piston crown
➔ Excessive peak pressures.
3

4. CYLINDER ➔Choked indicator cock. Identify cause and


RELIEF VALVE ➔An incorrect relief valve setting. take corrective
LIFTING ➔Water accumulation in the action.
DURING BLOW combustion chamber.
THROUGH ➔Excess water in the starting air.

5. SMOKY ➔Less air supply to the engine due Identify cause and
EXHAUST to fouled gas or air side of the take corrective
turbocharger. action.
➔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.

6. ALL CYLINDERS ➔This can occur because of Identify cause and


EXHAUST fouling in turbocharger, air cooler, take corrective
TEMPERATURE and intake air filter, scavenge action.
INCREASE valves in the air receiver, scavenge
ports or exhaust passages
➔Incorrect fuel timings, bad
quality fuel or inadequate fuel
treatment also result in increased
temperatures
4

7. ONE UNIT ➔Thermometer defective (local or Identify cause and ME Auto


EXHAUST remote). take corrective Slow Down
TEMPERATURE ➔Less air supply due to the action. as deviation
RISE individual unit scavenge valves in alarm is
the air receiver or scavenge ports triggered to
fouled, or a scavenge fire. safeguard
➔Fuel injector nozzle in a poor effects of an
condition or the tip broken. imbalanced
➔Incorrect fuel timings or a fuel engine.
cam shift.
➔Leaking exhaust valve.

8. ENGINE SPEED ➔Fuel pressure after the booster Identify cause and Auto slow
DROPS pump is too low. take corrective down will be
➔Fuel pumps defective or a fuel action. triggered in
piping fault. case of
➔Incorrect fuel injection. Scavenge
➔Fouling of air or exhaust Fire, Oil
passages. Mist
➔Fuel air lock, gassing, water in Detector
the fuel, or poor fuel combustion. alarm &
➔​Scavenge fire. EGB high
➔Governor problem. temperature.

9. ONE UNIT ➔A faulty thermometer. Identify cause and ME Auto


EXHAUST ➔Less fuel supplied due to faulty take corrective Slow Down
TEMPERATURE fuel injection pump, pipes, injector action. as deviation
DROPS or timings, a shift in cam position, alarm is
broken piston rings. triggered to
➔Exhaust valve does not open due safeguard
to the malfunctioning of the effects of an
actuating system. imbalanced
engine.
5

10. ENGINE ➔Fuel problems like faulty fuel Identify cause and ME Auto
RUNNING booster pump or fuel pump, wrong take corrective Slow Down
IRREGULARLY, fuel pressure or temperature, air action. as deviation
MISFIRING OR lock or water in fuel, or a defective alarm is
CUTTING OUT fuel valve. triggered to
➔Governor malfunction. safeguard
➔Turbocharger surging. effects of an
➔Running gear components over imbalanced
heated, causing severe alternating engine.
friction.

11. JACKET WATER ➔Air pockets in the jacket cooling Identify cause and
PRESSURE water, or insufficient venting. take corrective
FLUCTUATION ➔Exhaust gas leaking into jacket action.
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 Identify cause and


TEMPERATURE ➔Valves may be shut or in take corrective
INCREASE sufficient venting. action.
➔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 ➔Low air bottle pressure or air Identify cause and
TO START ON line valves may be shut. take corrective
AIR ➔Air bottle isolating valve or action.
automatic valve or distributor
malfunction.
➔Control air valves faulty or less
control air pressure.
➔Start air automatic valve
jammed.
➔Turning gear engaged or limit
switch faulty.
6

➔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 ➔In B & W engines, the puncture Identify cause and
ON AIR, BUT valves are not properly vented. take corrective
NOT ON FUEL ➔Fuel regulating linkage jammed action.
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
pump index is too low.
➔Pre-set control air signal to the
governor is too low.
7

15. ENGINE DOES ➔Less fuel being injected or the


NOT FIRE 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 ➔Excessive thermal load, Identify cause and


RING insufficient cooling, or a distorted take corrective
piston crown. action.
➔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.
➔Scuffing of the cylinder liner.
8

17. BEARING ➔Low lube oil pressure supply to


TEMPERATURE bearing or low oil level in supply
INCREASE 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 ➔Pitching, rolling or changes in Identify cause and
LEVEL RISING cargo loading. take corrective
➔Water leakage from piston action.
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 ➔Activation of safety shut down Identify cause and


STOPPING OF or over speed cut-out device. take corrective
THE ENGINE ➔Control air pressure in the action.
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.

20. REDUCED ➔This is due to worn piston rings. Identify cause and
COMPRESSION ➔ Worn liner. take corrective
PRESSURE ➔ Worn piston crown. action.
➔ Worn exhaust valve.
➔Incorrect exhaust valve timings
9

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 is tripping. Fill up the air bottle with
breaker faulty It is not holding at another air compressor.
ON position. Isolate the faulty breaker
& change with new one.
02 Main air compressor outlet High air outlet Check the J.C.W. line &
temperature high temperature alarm. valves setting. Check the
Compressor will seawater flow through the
trip on high cooler. Check the
temperature. attached fresh water
pump.
03 Main air compressor low Low lube oil Check the lube oil sump
lube oil pressure pressure alarm. level. Check the sensor.
Compressor will Check the attached pump.
trip on low low
pressure.
04 Main air compressor first Running amperage Overhaul the valve.
stage suction valve leaky will come down. Check the first stage
Air bottle filling piston rings condition.
rate will reduce.
First stage air
pressure will reduce
and fluctuate at less
value.
05 Main air compressor first Running amperage Overhaul the valve.
stage discharge valve will be normal. Air Check the first stage
leaky filling rate will piston rings condition.
reduce. First stage
11

air pressure will


fluctuate across
normal value.

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


06 Main air compressor over Compressor Check the compressor
current trip amperage is going easy rotation. Check the
high & tripping. over current trip relay
function.
07 Main air compressor first Running amperage Overhaul first stage
stage disc valve choke or will fluctuate. First discharge valve.
not opening/wrongly fitted 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.
08 Main air compressor second Running amperage Overhaul the valve.
stage suction valve leaky will remain same Check the second stage
but will fluctuate. piston rings condition.
Air filling rate will
reduce. First stage
air pressure will
increase. Second
stage air pressure
will be normal &
will fluctuate at
normal value.
09 Main air compressor second Running amperage Overhaul the valve.
stage discharge valve leaky will remain same Check the second stage
but will fluctuate. piston rings condition.
Air filling rate will
reduce. Second
stage air pressure
will be normal &
will fluctuate at
normal value.
12

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


10 Main air compressor second Running amperage Overhaul second stage
stage disc valve choke or will increase. discharge valve.
not opening/wrongly fitted 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.
13

TROUBLE SHOOTINGS FOR FRESH WATER


GENERATOR & HYDROPHORE SYSTEMS
S.NO PROBLEMS CAUSES REMEDIAL ACTIONS REMARKS
01 Fresh water generator Pump is drawing Isolate the pump & rotate
Ejector sea water pump high current & over the shaft by hand. Check
over current trip current relay is for possible reason of
tripping the tight rotation.
breaker. Check the electrical
circuit for any possible
fault.
02 Fresh water generator Suction pressure Isolate the pump & clean
Ejector sea water pump will be less then the filter.
suction filter choked normal. In extreme
condition suction
pressure will be
zero.
03 Fresh water generator Suction pressure Isolate the pump &
Ejector sea water pump will show suction overhaul it.
worn out head. Pump will
not build any
pressure. Fresh
water generator
will not develop
any vacuum.
04 Fresh water generator Difference between Identify cause & rectify
vacuum is less the inlet & outlet same.
jacket cooling
water temperature.
Air ingress in the
system.
Faulty Ejector
pump.
Fouled air ejector
05 Fresh water hydrophore Breaker is tripping. Operate the system with
pump breaker faulty It is not holding at standby pump. Isolate the
ON position. faulty breaker & change
with new one.
14

06 Fresh water hydrophore Suction pressure Start another pump.


pump worn out will show suction Isolate the pump &
head. Pump will overhaul it.
not build any
pressure.

TROUBLE SHOOTINGS FOR PURIFIERS

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


01 Fuel oil purifier feed pump Breaker is tripping. Operate the system with
breaker faulty It is not holding at the standby pump.
ON position. Isolate the faulty breaker
& change with new one.
02 Fuel oil purifier feed pump Pump is drawing Isolate the pump &
over current trip high current & over rotate the shaft by hand.
current relay is Check for possible
tripping the reason of tight rotation.
breaker. Check the electrical
circuit for any possible
fault.
03 Fuel oil purifier feed pump Suction pressure Clean the filter. Check
suction filter choke will come down & the suction line.
in fully choke
condition it can
show vacuum also.
Pump will not build
any pressure.
04 Fuel oil purifier feed pump Pump is not Overhaul the pump.
worn out building any
pressure.
Flow to purifier
will reduce.
05 Fuel oil purifier breaker Breaker is tripping. Do the purification
faulty It is not holding at through another purifier.
ON position. Isolate the faulty breaker
& change with new one.
15

06 Fuel oil purifier heater Heater efficiency Check the steam line and
surface is dirty will drop. User has pressure.
to increase temp Check the steam
setting to get controller.
desired temp. Low Clean the heater.
temp alarm.
Purifier feed will
stop.

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


07 Fuel oil purifier Desludge Purifier will not Desludge purifier on
auto controller failure desludge on auto manual mode.
mode. Solenoid Overhaul solenoid
valves are valves.
malfunctioning.
08 Fuel oil purifier bowl is Fluctuation in rpm. Stop the purifier. Open
dirty So in amperage & clean the purifier.
Backpressure will
be high.
Purifier cannot be
desludged.
It can cause Oil
ingress in the water
side.
09 Fuel oil purifier friction While starting Stop the purifier &
pads worn out purifier will not be inspect the friction pad.
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.
10 Fuel oil purifier over Purifier is drawing Isolate the purifier &
current trip high current & over rotate the shaft by hand.
current relay is Check for possible
tripping the reason of tight rotation.
breaker. Check the electrical
16

circuit for any possible


fault.

TROUBLE SHOOTINGS FOR AUXILIARY BOILER

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


01 Auxiliary boiler feed water Breaker is tripping. Operate the system with
pump breaker faulty It is not holding at the standby pump.
ON position. Isolate the faulty breaker
& change with new one.
02 Auxiliary boiler feed water Pump is drawing Isolate the pump &
pump over current trip high current & over rotate the shaft by hand.
current relay is Check for possible
tripping the reason of tight rotation.
breaker. Check line valves.
Check the electrical
circuit for any possible
fault.
03 Auxiliary boiler feed water Low feed water Change over to another
pump break down pressure alarm. pump if it is not started
Pump is not on auto and confirm line
building pressure. valves are correctly set.
Overhaul the defective
pump after isolation.
04 Auxiliary boiler High High salinity alarm. Blow down the water.
salinity in feed water Check for sea water
ingress in system and
rectify same before
putting the boiler back in
operation.

05 Auxiliary boiler feed water Low feed water Check the valve status &
turbine pump breakdown pressure alarm. cascade tank level.
Pump is not Overhaul the pump if
building pressure. necessary.
17

06 Auxiliary boiler feed water Boiler water level Change over to manual
auto controller is not not maintained as line.
working per consumption Overhaul the control.
requirements. Level
will come down
and may result in
shut down.

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


07 Auxiliary boiler water level Water level gauge Check water level from
remote gauge is not in ECR will show local gauge glass.
working error leading to Rectify remote gauge
wrong information. glass error.
08 Auxiliary boiler igniter Boiler will not fire Replace the transformer
transformer is not working & will trip on flame and put the boiler back
failure. in use ONLY after
rectifying fault.
09 Auxiliary boiler smoke side Boiler steam Soot blow the auxiliary
dirty 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.
10 Auxiliary boiler Auto Auxiliary boiler is Change burner control to
combustion control failure not firing on auto. 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. PROBLEMS CAUSES SYMPTOMS REMEDIAL


NO ACTIONS
1. Failure to build up ➔Loss of suction / air Identify cause &
pressure ingress rectify same
➔Discharge valve stuck
in closed position
➔Motor inoperational
➔Internal damage due to
wear & tear
2. Vibration ➔ It is because of bearing Identify cause &
damage rectify same
➔Misalignment to
coupling
➔Damage to the rotating
components
➔ There have also been
causes of heavily clogged
impellers causing
excessive vibration
➔Foundation bolts weak
3. Overload & Trip Overload of the motor will Identify cause &
occur due to excessive rectify same
resistance to motion.
➔Imbalance.
➔ Bent shaft.
➔Insufficient working
clearance.
➔ Damaged bearing
➔Clogged impellers.
19

4. Drop in capacity ➔It is usually due to worn Identify cause &


parts (excessive clearance rectify same
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 Drop in discharge Identify cause &


power supplied to the pressure. rectify same.
pump is no longer Rise in
converted in to temperature of
mechanical output, which casing.
is seen as a drop in Air lock in system.
efficiency. The excess ****
energy is seen as an COP will trip on
increase in the high casing temp.
temperature, which could
lead to reduction in
working clearances,
overheating and damage
to bearings and seals

6. Loss of suction of ➔Blockage on the suction ➔suction pressure Identify cause &
pump having side. gauge shows rectify same
positive suction head ➔Tank is empty. negative pressure
for blockage on
suction side
➔suction pressure
gauge shows zero
pressure for empty
tank
20

7. Loss of pump ➔Blockage on the suction ➔the suction Identify cause &
suction pressure side. pressure shows rectify same
having negative ➔Water level drops vacuum more than
suction head. below the suction pipe. normal for
(e.g. Emergency Fire blockage in
Pump) suction side
➔air ingress in the ➔ Suction
pipeline through leaky pressure gauge
flange , hole, leaky valve shoes zero for
or leaky gland packing water level drop
(common fault in bilge below suction line.
ballast pump’g systems ) ➔It shows zero for
air leakage.
8. Pump having less Water is re-circulating ➔The discharge Identify cause &
discharge pressure within the pump through pressure gauge rectify same
with discharge valve worn out wear rings, shows less
fully open. pumps valve. pressure than the
normal.
9. Centrifugal pump ➔Priming pump not ➔No air discharge Identify cause &
priming unit getting sealing water. from water ring rectify same.
malfunction. primer. Ensure sealing
(e.g. Emergency Fire ➔Pump suction water tank is
Pump ) pressure gauge full at all times.
shows zero
pressure.
10. Gear pumps ➔More clearance ➔Discharge Identify cause &
discharge pressure between the casing & the pressure gauge rectify same
low. gear wheels due to shows low
erosion. pressure than
➔Suction filters clogged. normal.
21

12. Reciprocating pump ➔Air vessel fitted to the ➔discharge Identify cause &
having fluctuating pump discharge line is not pressure gauge rectify same
discharge pressure. working properly. pointer is
➔Pressure gauge faulty Fluctuating.

13. Reciprocating pump ➔Discharge valve in ➔Discharge Identify cause &


having suction but valve chest sluggish in pressure gauge rectify same
no discharge. operation. shows zero
reading.
14. Positive ➔Relief valve in open ➔Discharge Identify cause &
displacement pumps condition due to improper pressure gauge rectify same
having full suction setting of the spring shows very low
but very low tension. discharge pressure
discharge. ➔Due to broken spring of than the normal.
the relief valve .
22

TROUBLE SHOOTING FOR STEERING SYSTEM

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


01 Oil consumption High Low level alarm is Rectify the leakage at Identify
triggered due to oil the earliest. cause &
leakage. Isolate system if leakage rectify same
May result in is very high and use
system being standby system.
isolated if low low
alarm is trigerred.
02 Steering/Rudder movement System pump Replace the filters Identify
is sluggish or slow pressure low due (normally very fine filter cause &
suction filter cartridge). rectify same
choked.
03 Steering/Rudder movement Telemetric system Change over to Identify
is not responding Bridge failure. emergency steering cause &
orders system. rectify same
04 Steering motor phase No power supply. Switch over to standby Identify
failure mode. cause &
rectify same
05 Steering motor overload. The steering motor Rudder movement is Identify
is designed to take restricted due to external cause &
up to 200% factors like grounding or rectify same
overload & it will collision. Damaged OR
give alarm above Misaligned rams.
100% normal
working load.
23

ELECTRICA
L TROUBLE
SHOOTING
24

TROUBLE SHOOTING FOR ELECTRICAL MACHINERY

S.NO PROBLEM CAUSES REMEDIAL ACTION REMARKS


01 Alternator shows no voltage Exciter field Cut out all excitor field
resistance is too regulator resistance, &
high or there is a check excitation circuit
loss of residual connections. Lift brushes
magnetism. & re-excite.

Short-circuit in
excitation circuit Locate the short-circuit
probably between & repair the same.
leads to field or
alternator slip rings.

Insulation of
windings is not Check insulation with
proper. Megger instrument.

Fault in AVR card.


Change the AVR card.
02 Alternator excites but not to One or more stator Locate & have defective
its rated voltage coils are short coils replaced.
circuited.
25

Some stator coils Check stator winding for


are connected in the symmetry & re-connect
wrong sequence any wrongly connected
probably after local coils.
repair.
03 No Load Voltage Adjust the voltage Change AVR if
Fluctuating on AVR set point required.
potentiometer.

Check function
thyristor. Change the thyristor,
change the AVR if
required.
04 Overheating Overload or Reduce load if possible.
ventilation passages Blow out ventilation
blocked. passages with
compressed air.
05 Overheating accompanied Short circuit Locate the short circuit
by reduction of torque between one or fault & rectify it. If
more stator coils. necessary have new coils
fitted.
06 Motor will not start on no Break at the joint, Locate the break &
load, or runs at low speed probably the star repair it.
point of rotor
winding of starter.

Bad contact at Investigate & make good


some joint of stator the contact.
windings.
07 Overheating accompanied Connections of Check with diagram of
by torque deficiency star-delta switch connections & correct
wrong. the error.

Too high rotor


resistance probably Re-solder any visibly
due to faulty bad connections.
contact between
rotor bars &
short-circuiting
rings.

Short circuit in Locate short circuit &


rotor winding repair, having faulty
converting rotor coils replaced where
effect into low necessary.
26

resistance squirrel
cage rotor.

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