ENGINE SYSTEMS

Md. Shakil Ahmed

CONFIDENCE POWER HOLDINGS LIMITED. 17th Floor, Awal Center, 34-Kamal Ataturk Avenue,
Banani Commercial Area, Dhaka-1213.
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Engine Systems
There are four specific systems for each engine. These are:

1. Fuel Oil System

2. Lube Oil System
3. Water System
4. Air System
5. Steam System

1. Fuel Oil System:

DO Ring HFO Ring

Main Main

In case of DO Flashing,
Flowmeter DO returns to HFO ring
main through DO
Cooler.

Although return fuel is

Mixing the mixture of HFO &
Tank DO.

Separator
(Booster Pump DO Cooler
& Heater)

Engine (Fuel Engine (Fuel

Filter Return Path)
Gallery)

Block Diagram prepared during physical assessment at plant (Booster Unit)

❖ Leakage Line Collection:

Leakage fuel
collected from Leakage Through waste line of Buffer
Engine HP Pump Fuel Module Separation pump (FTP) Tank
& Injector

Block Diagram prepared during physical assessment at plant (Leakage Line Collection)

ENGINE SYSTEMS | Prepared by MD. SHAKIL AHMED

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❖ Waste Fluid System:

Waste Fluid System collects wasted fuel oil, Lube oil, water etc. and drained it.

2. Lube Oil System:

LO Storage
Tank
LO
Maintenance
Tank

Engine Bearing Engine LO Separator

& other parts LO Sump (with Heater)

Engine Driven LO Pump/

Pre-Lube Pump
There is also a Mist Blower
System to ventilate the
excess Oil Mist.
Cooler

LO Filter
(Duplex-Auto)

Block Diagram prepared during physical assessment at plant (LO System)

Lube Oil system or function can be divided into three consequent parts.

➢ Top up
➢ Filtration
➢ Separation

• Top up requirement depends on the level of LO in Engine LO Sump which can be observed from SCADA
or by checking manual deep strip.
• LO Filtration process continues by Engine driven LO pump during the engine running times. In case of
long idle time, LO filtration process can be run manually by Pre-Lube Pump/ Priming Pump to turn
from cold ramp to hot ramp.
• Separator not only separate the dust particles from LO, but also it can control the viscosity as well as
temperature of the circulating LO.

ENGINE SYSTEMS | Prepared by MD. SHAKIL AHMED

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❖ Oil Mist Detector (OMD):

OMD placed at the b-bank of each engines. Mist is created at the crankcase of engine. The presence
of an oil mist in the crankcase is the result of oil vaporization caused by a hot spot. Oil mist may form
when high pressure fuel oil, lubricating oil, hydraulic oil, or other oil is sprayed through a narrow crack,
or when leaked oil connects with a high temperature surface, vaporizes, and comes in contact with
low air temperature. Oil Mist may contain micro particles due to friction, chip, water content or vapor
etc.

❖ Jack up Pump supplies LO to the alternator shaft points which are DE (Driven End) & NDE (Non-Driven
End).

3. Water System:

There are two types of water-cooling systems. These are:

• LT Cooling Water
• HT Cooling Water

LT Cooling Water applications:

➢ Lube Oil cooling

➢ Nozzle cooling
➢ Charge Air cooling

Block Diagram prepared during physical assessment at plant (LT Cooling Water Flow)

ENGINE SYSTEMS | Prepared by MD. SHAKIL AHMED

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❖ Nozzle Cooling System:

Nozzle Cooling is an isolated system. A closed looped coolant (normally water) is used to flow and get
the heat from engine nozzle. Then this closed looped coolant exchange heat to the LT cooling water
through a heat exchanger.

Engine
Nozzle

Closed Coolant
LT Cooling
Cooler Water
(Heat
Exchanger)

HT Cooling Water applications:

➢ Charge Air cooling

➢ Jacket cooling water/ Engine cooling water

Block Diagram prepared during physical assessment at plant (HT Cooling Water Flow)

❖ Pre-Heating:
Pre-heating pump always runs to remain prepared the engine to start when engine is not running. The
applications of pre-heating are mentioned below:

➢ To escape the engine from thermal shock.

➢ To turn the engine from cold ramp to hot ramp.
➢ To reduce Sulphur corrosion.

ENGINE SYSTEMS | Prepared by MD. SHAKIL AHMED

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4. Air System:

There are different air systems namely:

• Start Air
• Engine Control Air
• Instrument Air
• Start-up Blower
• Charged Air

❖ Start Air:

➢ There are two start air line which gives the crank shaft a slow initial turning.

➢ 1st line contains 30 bar pressure and split into two 8 bar lines. Both lines go to engine cylinders.
One of which is starting air distributor and gives the firing order or make the path to the other one
to hit the piston and so gives the initial turning up to 7-10 rpm.

➢ 2nd line also contains 30 bar pressure and gives the crank shaft turning up to 60 rpm after the 7-
10 rpm reached.

Slow Initial Turning (1st Stage) Slow Initial Turning (2nd Stage)
7-10 rpm Up to 60 rpm

• Engine Control Air:

Help engine to be stopped after getting stop signal. Basically, it detaches the fuel flow to the cylinder

• Instrument Air:
Instrument air is used to operate Numerical Valves which are controlled by pressurized air.

❖ Start-up Blower:

➢ After completing the slow initial turning process by Start Air, Air Blower System sucks air and
blows it to the intake manifold located both sides of the engine line to cylinders. This air is
blown through the Turbocharger Compressor but without running of compressing
mechanism.

➢ This gives the very first air which takes part in the combustion process. Excess air is bypassed
to the engine exhaust manifold.

➢ During starting of engine, blower supplies air which is to be combusted up to 44-45% load.

ENGINE SYSTEMS | Prepared by MD. SHAKIL AHMED

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❖ Charged Air:

➢ After 44-45% load Start-up Blower being stopped and engine gets charged air processed by
Turbo Charger.

Inlet Air
Filter

LPTC HPTC Engine Intake

Cylinder
Compressor Compressor Manifold

LPTC HPTC Engine Exhaust

Turbine Turbine Manifold

Waste Gate Bypass

3-Way To Stack
Damper

EGB

Block Diagram prepared during physical assessment at plant (Engine Air & Exhaust Flow)

➢ There is a cooler in HPTC compressor. Which maintains the temperature of charged air at a
level so that maximum densely air can be utilized for combustion.

➢ Waste Gate opens at/after the increase of 97% load to bypass the exhaust flue/gas. The
bypassed flue skips the HPTC and enters into the LPTC.

❖ TC Wash:

• Wet Wash is performed by water

• Dry Wash is performed by Charcoal (Carbon Powder)

Both washes are performed during engine running stage. The type of TC is Two Stage Turbo-Charger.

ENGINE SYSTEMS | Prepared by MD. SHAKIL AHMED

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• TC Wash Particulars:

Cleaning
Performed Cleaning
Cleaner Interval
Point Type
(Hours)
HPTC Wet Water 250
LPTC Wet Water 150
LPTC Dry Charcoal 24

5. Steam System:

Steam requires for two purposes.

➢ Heating
➢ Co-Generation

Heat tracing is a system used to maintain or raise the temperature of pipe lines or vessels. At the plant the
HFO pipe lines contain the Steam Heat Tracing where required.

Besides steam is used to feed the steam turbine to perform the co-generation process.

Steam is produced by the following two ways:

i. DO Fired Auxiliary Boiler

ii. Exhaust Gas Boiler (EGB)

It may also be mentioned that EGB supports both heating and co-generation. Whereas Aux. Boiler supports
only heating applications. EGB can’t be run unless the exhaust gas flows at a minimum required rate.

The details of EGB have been discussed on the next EGB section.

ENGINE SYSTEMS | Prepared by MD. SHAKIL AHMED