Basic Engine and Compressor Analysis

Embed Size (px)

Citation preview

  • 8/9/2019 Basic Engine and Compressor Analysis

    1/133

    1

    2003 DYNALCO CONTROLSGMRC 2003 GAS MACHINERY CONFERENCE

    BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 1

    Basic Reciprocating Engine &Compressor AnalysisTechniques

    Azonix-DynalcoKathy Boutin, B.Sc.Ben Boutin, P.Eng.

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 2

    Focus of this course

    In this course, we illustrate engine andcompressor behavior using data taken fromrunning machinery

    The data were recorded by analysts runningtheir own predictive maintenance programs

    We show faults that are seen in recipequipment and present techniques to detect

    them

  • 8/9/2019 Basic Engine and Compressor Analysis

    2/133

    2

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 3

    Short Course Outline

    Analysis Programs Characterizing engines and compressors

    Data types Testpoint Locations

    Sequence of events 2-stroke engines 4-stroke engines Compressors

    Analyzing engine faults Analyzing compressor faults Analyzing auxiliary equipment faults

    2003 DYNALCO CONTROLSGMRC 2003 GAS MACHINERY CONFERENCE

    BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 4

    Analysis Programs

    Objectives

    Types of analysis Analysis process

  • 8/9/2019 Basic Engine and Compressor Analysis

    3/133

    3

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 5

    Analysis ProgramsObjectives of analysis programs

    Eliminate expensive, unnecessary maintenance Decrease maintenance costs Increase machine availability Decrease down time Improve performance Reduce emissions

    You cant improve what you dont measure

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 6

    Analysis Programs

    Types of machinery analysis

    Maintenance Analysis Identifies incipient failure so that you can turn unscheduledmaintenance into scheduled maintenance

    Helps avoid in-service failures Goal is to reduce maintenance cost

    Performance Analysis Characterizes the engine/compressor operating potential Efficiency

    Fuel consumption Horsepower Throughput

  • 8/9/2019 Basic Engine and Compressor Analysis

    4/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    5/133

    5

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 9

    Characterizing Engines and CompressorsSpecial data types

    Process data Tell about the process Examples: suction temperature and pressure

    Phase-marked data Data is referenced to the flywheel Example: pressure versus time data

    Non-phased data Sampling is a function of time only Example: acceleration data from aturbocharger bearing

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 10

    Characterizing Engines and Compressors

    Measuring flywheel position

    Once-per-degree Shaft encoder 360 pulses perrevolution

    Better accuracy Once-per-turn

    Magnetic, active oroptical pickups are

    common 1 pulse per revolution Usually permanentlymounted

  • 8/9/2019 Basic Engine and Compressor Analysis

    6/133

    6

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 11

    Characterizing Engines and CompressorsExample of phase-marked pressure (PT)

    500

    600

    700

    800

    900

    1000

    1100

    1200

    1300

    1400

    1500

    1600

    1700

    0 45 90 135 180 225 270 315 360

    C402 - C cylinder 2 09/09/1998 12:02:53 PM HE Period 5, CE Period 5

    P r e s s u r e ( p s i g )

    Crank Angle (deg)

    Head andcrank endpressuretraces on acompressorcylinder

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 12

    Characterizing Engines and Compressors

    Free-running, non-phased data

    Data is recorded independent of crankshaft position Returns

    Overall vibration level Spectrum showing frequency components

    Common applications: Structural vibration Supports, foundations Turbochargers Oil and water pumps Pressure pulsation

  • 8/9/2019 Basic Engine and Compressor Analysis

    7/133

    7

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 13

    Characterizing Engines and CompressorsExample of free-running, non-phased, spectrum data

    Spectrum fromengine framenear anchorbolts. Mils peak-peak, oil pumpend, horizontaldirection.

    Engine speed323 RPM

    Testpoint : OPEH VIBNo. Of Lines : 400No. Of Averages : 5Calc Overall : N/ATrap Overall : 1.325

    Peak At Frequency1.020 at 322.50.507 at 1305.00.122 at 652.50.110 at 487.50.098 at 1627.50.079 at 2932.50.073 at 1357.50.061 at 1140.00.061 at 1020.00.061 at 975.0

    0.0

    0.1

    0.2

    0.3

    0.4

    0.5

    0.6

    0.7

    0.8

    0.9

    1.0

    0 500 1000 1500 2000 2500 3000

    UNIT #4-E Testpoint OPEH 7/17/2002 10:51:55 AM

    m i l ( p s e u d o - p

    k - p k )

    cpm

    1 timesrun speed

    2 timesrun speed

    4 timesrun speed

    Engine Data

    Cylinder exhaust temperatures Infrared temperature wand

    pyrometer

    Cylinder pressure Pressure transducer Time domain data phased to

    crankshaft position Peak pressure statistics

    Cylinder, valve, wrist pinand bearing vibration Ultrasonic microphone Standard accelerometer Time domain data phased to

    crankshaft position

    Frame vibration (displacement) Tri-axial accelerometer (H, V, A)

    taken at opposite corners ofengine frame

    Frequency domain data

    Ignition secondary Inductive connection to unshielded

    spark plug cable Multi-period sampling statistics Ignition secondary patterns

    Ignition primary (not shown)

    Connection to primary box Ignition primary firing patterns

    Turbocharger/blower Standard accelerometer

    mounted on bearings and nearturbine and compressor wheels

    Frequency domain vibration

    TDC Reference Shaft encoder Magnetic pickup Phased data RPM

    2003 DYNALCO CONT ROLS

  • 8/9/2019 Basic Engine and Compressor Analysis

    8/133

    8

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 15

    Characterizing Engines and CompressorsTypical 2-stroke engine PT/VT

    223 Intake137242 Exhaust118

    273Fuel 213

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    500

    550

    600

    0 45 90 135 180 225 270 315 360

    --------------

    --------------

    -

    -

    -

    -

    -

    -

    -

    -

    -

    - Scale 2.4

    P5 VT4

    20905-E Cylinder P5 3/27/2002 8:57:46 AM Period 0

    P r e s s u r e ( p s i g )

    Angle (deg)

    PT

    VT

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 16

    Characterizing Engines and Compressors

    Typical 4-stroke engine PT/VT620Intake 281

    391 Exhaust140583Fuel 315

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    1100

    0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

    --------------

    --------------

    -

    -

    -

    -

    -

    -

    -

    -

    -

    - Scale 5.0

    2L VT4

    5302-E Cylinder 2L 12/3/2001 9:15:58 AM Period 1

    P r e s s u r e ( p s i g )

    Angle (deg)

    PT

    VT

  • 8/9/2019 Basic Engine and Compressor Analysis

    9/133

    9

    TDC Reference Shaft encoder Magnetic pickup Phased data RPM

    Suction/discharge temperatures Infrared temperature wand thermocouples, RTDs

    Head/crank end pressure Pressure transducer Time domain data phased to

    crankshaft position

    Multi-period sampling statistics

    Suction/discharge valve vibrationCompressor ring leak vibrationLiner scoring Ultrasonic microphone Standard accelerometer Time domain data phased to

    crankshaft position

    Frame vibration (displacement) Tri-axial accelerometer (H, V, A)

    taken at opposite corners ofengine frame

    Frequency domain data

    Rod Motion Proximity probes Time-domain data phased to

    crankshaft position Rod displacement trends

    Suction/discharge nozzle pressure Pressure transducer Time domain data phased to crankshaft

    position (valve/passage loss calculations) Frequency domain (pulsation spectrum) Multi-period sampling statistics

    Valve cap temperatures Infrared temperature wand thermocouples, RTDs

    Crosshead Vibration Standard accelerometer Time domain data phased to

    crankshaft position

    Relate to rod load

    Compressor Data

    2003 DYNALCO CONT ROLS

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 18

    Characterizing Engines and Compressors

    Typical HE compressor pattern

    250

    300

    350

    400

    450

    500

    550

    600

    0 45 90 135 180 225 270 315 360

    --------------

    --------------

    --------------

    --------------

    --------------

    ---------------------------------------

    - Scale 3.084 DGF

    - Scale 3.084 DGF

    - Scale 3.0146 DGF

    - Scale 3.0145 DGF

    4HS2 VT1

    4HS1 VT1

    4HD2 VT1

    4HD1 VT1

    K200 - C cylinder 4 9/23/1998 9:52:15 AM HE Period 5, CE Period 7

    P r e s s u r e ( p s i g )

    Crank Angle (deg)

    HE PT

    HE VT

    CE PT

  • 8/9/2019 Basic Engine and Compressor Analysis

    10/133

    10

    2003 DYNALCO CONTROLSGMRC 2003 GAS MACHINERY CONFERENCE

    BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 19

    Sequence of events

    2-stroke, spark-ignited engine 4-stroke, spark-ignited engine Double-acting, reciprocating compressor

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 20

    Understanding Machine Faults

    To recognize faults in compressors andengines, we must understand how theybehave in normal operation

    Do the mechanical events you expect to seeactually happen?

    Do the events appear to be normal? when do they occur? what is the relative magnitude?

    do they look the same as they did last time? do they look the same as the next machine?

    What is the performance of the machine?

  • 8/9/2019 Basic Engine and Compressor Analysis

    11/133

    11

    2003 DYNALCO CONTROLSGMRC 2003 GAS MACHINERY CONFERENCE

    BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 21

    Sequence of eventsfor a 2 stroke engine

    Pressure versus crank angle (PT) Pressure-Volume (PV) Vibration versus crank angle (VT)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 22

    Sequence of events for a 2-stroke engine

    PT: start of cycle

    180 270 360900

    Crank Angle (Deg)

    P r e s s u r e

    Ignition has occurred

    Flame front travel has begun

    Mixture is superheated air and fuel

  • 8/9/2019 Basic Engine and Compressor Analysis

    12/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    13/133

    13

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 25

    Sequence of events for a 2-stroke enginePT: exhaust blowdown

    Piston uncovers exhaust port

    Pressure drops more rapidly (blowdown)

    Temperature is now about 800F

    P r e s s u r e

    00

    90 180 270 360

    Crank Angle (deg)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 26

    Sequence of events for a 2-stroke engine

    PT: air intake

    Intake port is uncovered

    Cylinder pressure intake pressure

    Fresh air under pressure sweeps and cools

    180 270 360900

    Crank Angle (Deg)

    P r e s s u r e

  • 8/9/2019 Basic Engine and Compressor Analysis

    14/133

    14

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 27

    Sequence of events for a 2-stroke enginePT: scavenging

    Scavenging continues until intake closes

    Cylinder cooling continues

    P r e s s u r e

    00

    90 180 270 360

    Crank Angle (deg)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 28

    Sequence of events for a 2-stroke engine

    PT: fuel intake

    Scavenging continues until intake closes

    This is the lowest pressure in the cylinder

    Fuel is injected just prior to exhaust closure

    Open exhaust port drags fuel down

    Port closes before any fuel escapes

    P r e s s u r e

    0

    0

    90 180 270 360

    Crank Angle (deg)

  • 8/9/2019 Basic Engine and Compressor Analysis

    15/133

    15

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 29

    Sequence of events for a 2-stroke enginePT: compression

    Fuel injection ceases, ports are closed

    Pressure begins to rise

    Air-fuel charge is turbulent

    Turbulence mixes the air-fuel charge

    Temperature rises

    P r e s s u r e

    00

    90 180 270 360

    Crank Angle (deg)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 30

    Sequence of events for a 2-stroke engine

    PT: ignition

    Ignition occurs 5-10 degrees BTDC

    Advance gives time to initiate combustionand for flame front travel

    Air-fuel charge is superheated

    P r e s s u r e

    0

    0

    90 180 270 360

    Crank Angle (deg)

  • 8/9/2019 Basic Engine and Compressor Analysis

    16/133

    16

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 31

    Sequence of events for a 2-stroke enginePT: end of cycle

    Flame front begins propagatingthrough chamber

    P r e s s u r e

    00

    90 180 270 360

    Crank Angle (deg)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 32

    Sequence of events for a 2-stroke engine

    PV: start of cycle (TDC)

    Ignition has occurred

    Flame front travel has begun

    Mixture is superheated air and fuel

    P r e s s u r e

    0

    0

    25 50 75 100

    Swept Volume (%)

  • 8/9/2019 Basic Engine and Compressor Analysis

    17/133

    17

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 33

    Sequence of events for a 2-stroke enginePV: combustion

    Flame travels through chamber

    Heat is released, pressure rises

    Temperature at flame front isabout 3500F

    Peak occurs 10-15 deg ATDC

    Speed of propagation is critical

    Too fast, detonation

    Too slow, soft fire

    P r e s s u r e

    00

    25 50 75 100

    Swept Volume (%)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 34

    Sequence of events for a 2-stroke engine

    PV: power

    Combustion is complete

    Pressure drives piston down

    As volume increases, pressure decreases

    P r e s s u r e

    0

    0

    25 50 75 100

    Swept Volume (%)

  • 8/9/2019 Basic Engine and Compressor Analysis

    18/133

    18

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 35

    Sequence of events for a 2-stroke enginePV: exhaust blowdown

    Piston uncovers exhaust port

    Pressure drops more rapidly (blowdown)

    Temperature is now about 800F

    P r e s s u r e

    00

    25 50 75 100

    Swept Volume (%)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 36

    Sequence of events for a 2-stroke engine

    PV: air intake

    Intake port is uncovered

    Cylinder pressure intake pressure

    Fresh air under pressure sweeps and cools

    P r e s s u r e

    0

    0

    25 50 75 100

    Swept Volume (%)

  • 8/9/2019 Basic Engine and Compressor Analysis

    19/133

    19

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 37

    Sequence of events for a 2-stroke enginePV: scavenging

    Scavenging continues until intake closes

    Cylinder cooling continues

    P r e s s u r e

    00

    25 50 75 100

    Swept Volume (%)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 38

    Sequence of events for a 2-stroke engine

    PV: fuel intake

    Scavenging continues until intake closes

    This is the lowest pressure in the cylinder

    Fuel is injected just prior to exhaust closure

    Open exhaust port drags fuel down

    P r e s s u r e

    0

    0

    25 50 75 100

    Swept Volume (%)

  • 8/9/2019 Basic Engine and Compressor Analysis

    20/133

    20

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 39

    Sequence of events for a 2-stroke enginePV: compression

    Fuel injection ceases, ports are closed

    Pressure begins to rise

    Air-fuel charge is turbulent

    Turbulence mixes the air-fuel charge

    Temperature rises

    P r e s s u r e

    00

    25 50 75 100

    Swept Volume (%)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 40

    Sequence of events for a 2-stroke engine

    PV: ignition

    Ignition occurs 5-10 degrees BTDC

    Advance gives time to initiate combustionand for flame front travel

    Air-fuel charge is superheated

    P r e s s u r e

    0

    0

    25 50 75 100

    Swept Volume (%)

  • 8/9/2019 Basic Engine and Compressor Analysis

    21/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    22/133

    22

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 43

    Sequence of events for a 2-stroke engineCylinder vibration: combustion

    223 Intake137242 Exhaust118

    273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    Rings become fully loaded by gaspressure

    May see some vibration resultingfrom combustion

    P r e s s u r e

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 44

    Sequence of events for a 2-stroke engine

    Cylinder vibration: power223 Intake137

    242 Exhaust118273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    Ring noise

    P r e s s u r e

  • 8/9/2019 Basic Engine and Compressor Analysis

    23/133

    23

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 45

    Sequence of events for a 2-stroke engine VTCylinder vibration: exhaust blowdown

    223 Intake137242 Exhaust118

    273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    ExhaustBlowdown

    P r e s s u r e

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 46

    Sequence of events for a 2-stroke engine VT

    Cylinder vibration: air intake and scavenging223 Intake137

    242 Exhaust118273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    P r e s s u r e

  • 8/9/2019 Basic Engine and Compressor Analysis

    24/133

    24

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 47

    Sequence of events for a 2-stroke engine VTCylinder vibration: fuel intake

    223 Intake137242 Exhaust118

    273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    P r e s s u r e

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 48

    Sequence of events for a 2-stroke engine VT

    Cylinder vibration: compression223 Intake137

    242 Exhaust118273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    Fuel ValveClosure

    P r e s s u r e

  • 8/9/2019 Basic Engine and Compressor Analysis

    25/133

    25

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 49

    Sequence of events for a 2-stroke engine VTCylinder vibration: ignition

    223 Intake137242 Exhaust118

    273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    P r e s s u r e

    Ignition 5-10degrees BTDC

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 50

    Sequence of events for a 2-stroke engine VT

    Cylinder vibration: end of cycle223 Intake137

    242 Exhaust118273Fuel 213

    0 45 90 135 180 2 25 270 315 360Angle (deg)

    P r e s s u r e

  • 8/9/2019 Basic Engine and Compressor Analysis

    26/133

    26

    2003 DYNALCO CONTROLSGMRC 2003 GAS MACHINERY CONFERENCE

    BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 51

    Sequence of eventsfor a 4 stroke engine

    Pressure and vibration (PT/VT)

    Pressure-Volume (PV)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 52

    Sequence of events for a 4-stroke engine

    PT/VT: top dead center

    Ignition has occurred

    Flame front propagation has begun

    Mixture is superheated air and fuel

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    Fuel 502565Intake 300

    137 417 Exhaust

    611

    12

    1 2 3 4Combustion Exhaust Intake Compression

  • 8/9/2019 Basic Engine and Compressor Analysis

    27/133

    27

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 53

    Sequence of events for a 4-stroke enginePT/VT: peak firing pressure

    Pressure

    Flame front propagation through cylinder

    Pressure and temperature rise

    Too fast, detonation

    Too slow, soft fire

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    12

    1 2 3 4Combustion Exhaust Intake Compression

    Fuel 502565Intake 300

    137 417 Exhaust

    611

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 54

    Sequence of events for a 4-stroke engine

    PT/VT: power stroke

    Pressure

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    12

    1 2 3 4Combustion Exhaust Intake Compression

    Fuel 502565Intake 300

    137 417 Exhaust

    611

  • 8/9/2019 Basic Engine and Compressor Analysis

    28/133

    28

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 55

    Sequence of events for a 4-stroke enginePT/VT: exhaust blowdown

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    12

    1 2 3 4Combustion Exhaust Intake Compression

    Fuel 502565Intake 300

    137 417 Exhaust

    611

    Blowdown Exhaust gases leave through exhaust

    valve port to exhaust header andthen to the turbocharger

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 56

    Sequence of events for a 4-stroke engine

    PT/VT: air intake

    Exhaust valveclosure

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    34

    1 2 3 4Combustion Exhaust Intake Compression

    Fuel 502565Intake 300

    137 417 Exhaust

    611

  • 8/9/2019 Basic Engine and Compressor Analysis

    29/133

    29

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 57

    Sequence of events for a 4-stroke enginePT/VT: fuel intake

    Intake valveclosure

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    34

    1 2 3 4Combustion Exhaust Intake Compression

    Fuel 502565Intake 300

    137 417 Exhaust

    611

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 58

    Sequence of events for a 4-stroke engine

    PT/VT: compression and ignition

    Fuel valveclosure

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    34

    1 2 3 4Combustion Exhaust Intake Compression

    Fuel 502565Intake 300

    137 417 Exhaust

    611

  • 8/9/2019 Basic Engine and Compressor Analysis

    30/133

    30

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 59

    Sequence of events for a 4-stroke enginePT/VT: end of cycle

    Pressure

    Crank Angle (deg)

    P r e s s u r e

    0

    0

    180 360 540 720

    12

    1 2 3 4Combustion Exhaust Intake Compression

    Fuel 502565Intake 300

    137 417 Exhaust

    611

    Whatsthis?

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 60

    Sequence of events for a 4-stroke engine

    VT: crosstalk (KVS 412)Engine Cylinders: Phased Vibration VT4:

    90 180 270 360 450 540 630 720

    K200 - E 9/10/1995 6:51:46 AM

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0

    P1

    P2

    P3

    P4

    P5

    P6

    This engine has solid lifters 312

    672

    192

    432

    72

    552

  • 8/9/2019 Basic Engine and Compressor Analysis

    31/133

    31

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 61

    Sequence of events for a 4-stroke enginePV: top dead center

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    12

    0 25 50 75 1000

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 62

    Sequence of events for a 4-stroke engine

    PV: air intake

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    Fresh air enters cylinder

    012

  • 8/9/2019 Basic Engine and Compressor Analysis

    32/133

    32

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 63

    Sequence of events for a 4-stroke enginePV: fuel intake & compression

    0 25 50 75 100

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    12

    Fuel intake starts BBDC

    Turbulence stirs mixture

    0

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 64

    Sequence of events for a 4-stroke engine

    PV: ignition

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    0

    Mixture is compressed andsuperheated

    Ignition occurs 10-20 deg BTDC

    12

  • 8/9/2019 Basic Engine and Compressor Analysis

    33/133

    33

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 65

    Sequence of events for a 4-stroke enginePV: top dead center

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    0

    Ignition has occurred

    Flame front travel has begun

    34

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 66

    Sequence of events for a 4-stroke engine

    PV: peak firing pressure

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    0

    Flame travels through chamber

    Heat is released, pressure rises

    Peak occurs 15-20 deg ATDC

    If pressure increase is

    Too fast, detonation

    Too slow, soft fire

    34

  • 8/9/2019 Basic Engine and Compressor Analysis

    34/133

    34

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 67

    Sequence of events for a 4-stroke enginePV: power stroke

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    0

    Combustion is complete

    Pressure drives piston down

    As volume increases, pressure decreases

    34

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 68

    Sequence of events for a 4-stroke engine

    PV: bottom dead center

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    0

    Exhaust valve opens just before BDC

    34

  • 8/9/2019 Basic Engine and Compressor Analysis

    35/133

    35

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 69

    Sequence of events for a 4-stroke enginePV: exhaust

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    Pressure drops rapidly(blowdown)

    0

    4 3

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 70

    Sequence of events for a 4-stroke engine

    PV: end of cycle

    3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION

    0 25 50 75 100

    340 25 50 75 100

    34 0

  • 8/9/2019 Basic Engine and Compressor Analysis

    36/133

    36

    2003 DYNALCO CONTROLSGMRC 2003 GAS MACHINERY CONFERENCE

    BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 71

    Sequence of eventsfor a double actingreciprocating compressor

    Head End (HE) compression cycle (PV) Crank End (CE) compression cycle (PV) HE valve events HE and CE pressure-time (PT) HE and CE vibration-time (VT)

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 72 2003 DYNALCO CONTROLS

    Sequence of events in a reciprocating compressor

    HE compression cycle

    Pressure

    ClearanceVolume

    C l e a r a n c e V o l u m e

    Ps

    Pd

    P r e s s u r e

    Volume

    Swept Volume

    Compression

    2

    1

    HECompression1-2

    HEDischarge2-3

    Discharge3

    Suction

    HESuction4-1

    4

    Expansion

    HEExpansion3-4

  • 8/9/2019 Basic Engine and Compressor Analysis

    37/133

    37

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 73 2003 DYNALCO CONTROLS

    Sequence of events in a reciprocating compressorCE compression cycle

    C l e a r a n c e V o l u m e

    Ps

    Pd

    P r e s s u r e

    Volume

    CECompression1-2

    1

    Compression

    Discharge2

    CEDischarge2-3

    3

    Expansion

    CEExpansion3-4

    Suction 4

    CESuction4-1

    Swept Volume

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 74 2003 DYNALCO CONTROLS

    Sequence of events in a reciprocating compressor

    PV: HE compression event

    C l e a r a n c e V o l u m e

    Ps

    Pd

    P r e s s u r e

    Volume

    2

    1

    Compression

    AD

    AP

    Discharge Line Pressure (Pd)

    Dischargeclosed

    AS

    AP

    Suction Line Pressure (Ps)

    Cylinder Pressure (Pcyl)is above Ps and increasing to Pd.Discharge valve opens when Pcylis greater than Pd (2).

    Suctionclosed

  • 8/9/2019 Basic Engine and Compressor Analysis

    38/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    39/133

    39

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 77 2003 DYNALCO CONTROLS

    Sequence of events in a reciprocating compressorPV: HE suction event

    C l e a r a n c e V o l u m e

    Ps

    Pd

    P r e s s u r e

    Volume

    2

    1

    Compression

    3 Discharge

    4

    Expansion

    SuctionAD

    AP

    Discharge Line Pressure (Pd)

    Cylinder Pressure (Pcyl)is below Ps and increasing to Ps.Suction valve closes when Pcyl isequal to Ps (1) at BDC.

    AS

    Suction Line Pressure (Ps)

    Piston Stroke Volume

    Dischargeclosed

    Suctionopen

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 78 2003 DYNALCO CONTROLS

    Sequence of events in a reciprocating compressor

    Example: HE and CE PV

    250

    300

    350

    400

    450

    500

    550

    600

    0 25 50 75 100

    K200 - C cylinder 4 9/23/1998 9:52:15 AM HE Period 5, CE Period 7

    Percent swept volume

    P r e s s u r e ( p s i g )

  • 8/9/2019 Basic Engine and Compressor Analysis

    40/133

    40

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 79 2003 DYNALCO CONTROLS

    A

    1

    Discharge (D-A)

    Suction (4-1)

    Sequence of events in a reciprocating compressorPT: HE and CE

    HE PT

    CE PT

    DischargePressure

    SuctionPressure

    A

    1

    2

    B

    Expansion (A-B)

    Compression (1-2)

    Head End:

    Crank End:

    Crank Angle (Deg)3600 180

    3

    C

    Suction (B-C)

    Discharge (2-3)

    4

    D

    Compression (C-D)

    Expansion (3-4)

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 80 2003 DYNALCO CONTROLS

    Sequence of events in a reciprocating compressor

    HE valve vibration

    0 180 360

    HE Suction

    HE Discharge

    Gas blowing noise is loudest at valveopening and gradually diminishes asgas velocity through the valve decreases.

    2

    Suction gas fills the cylinder.2

    3

    Suction valve is lowered gentlyonto the seat at BDC closingevent is not always visible.

    3

    1

    Suction valve opens(depends on clearance volume)

    1

    5

    5 High pressure gas isdischarged into dischargeline.

    6

    6 Discharge valve is gentlylowered onto the seat atTDC not always visible.

    4 Discharge valve opens(typically the loudest)

    4

  • 8/9/2019 Basic Engine and Compressor Analysis

    41/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    42/133

    42

    GMRC 2003 GAS MACHINERY CONFERENCEBASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 83 2003 DYNALCO CONTROLS

    Sequence of events in a reciprocating compressorTypical HE PT/VT signature

    250

    300

    350

    400

    450

    500

    550

    600

    0 45 90 135 180 225 270 315 360

    --------------

    --------------

    --------------

    --------------

    --------------

    ---------------------------------------

    - Scale 3.084 DGF

    - Scale 3.084 DGF

    - Scale 3.0146 DGF

    - Scale 3.0145 DGF

    4HS2 VT1

    4HS1 VT1

    4HD2 VT1

    4HD1 VT1

    K200 - C cylinder 4 9/23/1998 9:52:15 AM HE Period 5, CE Period 7

    P r e s s u r e ( p s i g )

    Crank Angle (deg)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 84

    Quick Recap

    So far, weve talked about the normalbehavior of:

    2-stroke, spark-ignited recip engine 4-stroke, spark-ignited recip engine double-acting, reciprocating compressor

    Now we know what they are supposed to looklike, we can look at faults

  • 8/9/2019 Basic Engine and Compressor Analysis

    43/133

    43

    2003 DYNALCO CONTROLSGMRC 2003 GAS MACHINERY CONFERENCE

    BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 85

    Analyzing Engine Faults

    Combustion

    Mechanical

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 86

    Engine faults we can monitor

    Port/bridge wear Excessive Emissions

    Leaking valves Unbalance

    Ignition problems Efficiency

    Leaking rings Detonation Valve train (cam, guides, lifters, linkage) Misfire Worn, scored liner and piston Pre-ignition

    Frame, foundation vibration Fuel consumption

    Oil Pump, water pump problems Fuel cost

    Turbocharger faultsEconomic Performance

    Main bearings, crank pins Torque

    Wrist pin Indicated horsepower

    Carbon in portsOperating Performance

    Mechanical ConditionCombustion Quality

  • 8/9/2019 Basic Engine and Compressor Analysis

    44/133

    44

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 87

    Combustion

    Many of the problems we face with enginesare due to variable combustion

    Engines do not fire the same way each cycle

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 88

    Combustion

    Chemical equation of combustion

    Engines convert chemical energy to heat Take a simple gas such as Methane (CH 4) Combine it with oxygen and start the reaction

    Produces carbon dioxide plus water vapor

    and releases heat of about 1000 BTU/ft3

    ofmethane consumed

    OHCOOCH 2224 22 ++

  • 8/9/2019 Basic Engine and Compressor Analysis

    45/133

    45

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 89

    CombustionIf only it was that simple

    Air is primarily O2 (23%) and N 2 (77%) Both are involved in the chemical reaction The combustion process is neither completenor instantaneous

    Many intermediate steps and reactions occur This leads to other exhaust products such asNOx, HC, CO and particulates (smoke)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 90

    Combustion

    Why is combustion so variable?

    incomplete mixing in the cylinder difficulty burning lean air/fuel mixtures inconsistent air/fuel charge in each cycle poor fuel quality ignition faults incorrect valve timing

    varying ambient conditions

  • 8/9/2019 Basic Engine and Compressor Analysis

    46/133

    46

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 91

    CombustionResults of poor combustion

    Firing in each becomes inconsistent, highfires followed by low fires

    Stress the engine thermally and mechanically Reduce the life of engine components Waste fuel Increase emissions This costs a great deal of money

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 92

    Combustion

    Typical faults

    Unbalance Dead cylinders Early firing Soft firing Detonation Pre-ignition

  • 8/9/2019 Basic Engine and Compressor Analysis

    47/133

    47

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 93

    Engine balance

    The manufacturer designed the engine tohandle specific cylinder pressures andtemperatures

    Cylinders with high peak pressures developmuch greater mechanical and thermal stress

    Engine balancing distributes this mechanicaland thermal stress across the engine to

    maximize component life

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 94

    Engine Balance

    Cylinder pressures (balanced HBA)

    P r e s s u r e ( p s i g )

    P1P2

    P3P4 P5

    P6P7

    P8

    0

    100

    200

    300

    400

    500

    600

    700

    800

    0 45 90 135 180 225 270 315 360

    +2%

    -2%

    +10%

    -10%

    Unit2 4/15/2002 9:21:55 AMAll cylinders - In Bank Order

    Crank Angle (deg)

  • 8/9/2019 Basic Engine and Compressor Analysis

    48/133

    48

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 95

    Engine BalancePressure rise rate (balanced HBA)

    -15

    -10

    -5

    0

    5

    10

    15

    20

    25

    30

    35

    P r e s s u r e R i s e R a t e ( d p / d )

    P1

    P2

    P3

    P4 P5

    P6

    P7

    0 45 90 135 180 225 270 315 360

    Unit2 4/15/2002 9:21:55 AMAll cylinders - In Bank Order

    Crank Angle (deg)

    P8

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 96

    Engine Balance

    Cylinder pressures (unbalanced HLA)C2B-E 6/6/2001 7:22:02 AM

    P r e s s u r e ( p s i g )

    1

    2

    34 5

    6

    7

    8

    0

    100

    200

    300

    400

    500

    600

    700

    0 45 90 135 180 225 270 315 360

    +2%-2%

    +10%

    -10%

    All cylinders - In Bank Order

    Crank Angle (deg)

  • 8/9/2019 Basic Engine and Compressor Analysis

    49/133

    49

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 97

    Engine BalancePressure rise rate (unbalanced HLA)

    P r e s s u r e R i s e R a t e ( d p / d )

    1

    3

    4 5

    6

    7

    8

    -10

    -5

    0

    5

    10

    15

    20

    0 45 90 135 180 225 270 315 360

    C2B-E 6/6/2001 7:22:02 AMAll cylinders - In Bank Order

    Crank Angle (deg)

    2 Highly variable

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 98

    Detonation

    Detonation is rapid and uncontrolled combustion.Detonation can lead to rapid failure due to high thermal and

    mechanical stress.Causes of detonation:

    Mixture too rich Clogged/dirty air intake (air inlet filters, aftercoolers orblowers)

    Incomplete scavenging inconsistent fuel composition

    Overloaded engine Ignition timing too advanced Highly loaded cylinders in an unbalanced engine are moresusceptible to detonation.

  • 8/9/2019 Basic Engine and Compressor Analysis

    50/133

    50

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 99

    P1

    P2 P4

    DetonationEngine PT parade (Ajax DPC-720-LE-H-2)

    P3 DetonatingCylinder

    +2%-2%

    +10%

    -10%

    K203 - E 11/21/1996 2:13:03 PMAll cylinders - In Bank Order

    0 45 90 135 180 225 270 315 360Crank Angle (deg)

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    500

    550

    600

    P r e s s u r e ( p s i g )

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 100

    Detonation

    Multiple PT cycles for a power cylinder (P3)

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    500

    550

    500 1000 1500 2000 2500 3000 3500

    K203 - E - P3 PT3 11/21/1996 2:13:03 PM

    Samples

    Misfire Misfire

    Detonation DetonationDetonation

  • 8/9/2019 Basic Engine and Compressor Analysis

    51/133

    51

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 101

    Soft Firing

    Soft Firing occurs when the pressure in the cylinderrises too late (also called late firing).

    The PFP is usually low and late.Causes of soft fires:

    incomplete scavenging air/fuel ratio too lean causing slow flame front air/fuel ratio too rich for proper combustion late ignition timing

    poor fuel composition

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 102

    Soft Firing

    Engine pressure signature comparisons

    P r e s s u r e ( p s i g )

    P1R

    P2R

    P3RP4R P5R P1L

    P2L

    P3LP4L

    P5L

    0

    100

    200

    300

    400

    500

    600

    700

    800

    0 45 90 135 180 225 270 315 360

    1A - E 5/22/1997 10:34:26 AMAll cylinders - In Bank Order

    Crank Angle (deg)

  • 8/9/2019 Basic Engine and Compressor Analysis

    52/133

    52

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 103

    Normal

    Soft FiringPT: comparison to normal (HBA)

    0

    Soft (Late)Fire

    223 Intake137

    242 Exhaust118

    273Fuel 213

    20905-E Cylinder P8 7/14/1999 6:46:53 AM Period 3

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    500

    550

    45 90 135 180 225 270 315 360Crank Angle (deg)

    P r e s s u r e ( p s i g )

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 104

    Soft Firing

    PV: comparison to normal (HBA)

    % swept volume

    20905-E cylinder P8 7/14/1999 6:46:53 AM Period 3

    0

    50100

    150

    200

    250

    300

    350

    400

    450

    500

    550

    0 25 50 75 100

    P r e s s u r e ( p s i g )

    Normal

    Soft (Late)Fire

  • 8/9/2019 Basic Engine and Compressor Analysis

    53/133

    53

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 105

    Soft FiringAnother example comparing engine PTs (CB QUAD)

    P2L

    P3LP4L

    P5L P6L

    P1R P2R P3RP4R

    P5R P6R

    0100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    0 45 90 135 180 225 270 315 360

    +2%-2%

    +10%

    -10%

    C402 - E 9/9/1998 12:02:53 PMAll cylinders - In Bank Order - CRC is corrected

    Crank Angle (deg)

    P r e s s u r e ( p s i g )

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 106

    Early Firing

    Early firing occurs when the pressure in the cylinderrises too early.

    The PFP is usually high and close to TDC.Causes of early firing:

    air/fuel ratio too rich early ignition timing warm air temperature

  • 8/9/2019 Basic Engine and Compressor Analysis

    54/133

    54

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 107

    Early Firingengine pressure comparison

    P1R

    P2R

    P3RP4R P5R P1L

    P2L

    P3L P4L

    P5L

    0

    100

    200

    300

    400

    500

    600

    700

    800

    0 45 90 135 180 225 270 315 360

    1A - E 5/22/1997 10:34:26 AMAll cylinders - In Bank Order

    P r e s s u r e ( p s i g )

    Crank Angle (deg)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 108

    Dead Cylinders

    Dead cylinders have no discernablecombustion.

    Causes of dead cylinders: ignition problem improper air/fuel charge

  • 8/9/2019 Basic Engine and Compressor Analysis

    55/133

    55

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 109

    Dead CylindersCylinder comparisons of peak pressures (QUAD)

    P2L

    P3LP4L

    P5L P6L

    P1R P2R P3RP4R

    P5R P6R

    0100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    0 45 90 135 180 225 270 315 360

    +2%-2%

    +10%

    -10%

    C402 - E 9/9/1998 12:02:53 PMAll cylinders - In Bank Order - CRC is corrected

    Crank Angle (deg)

    P r e s s u r e ( p s i g )

    P1L

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 110

    P2L soft fire

    Dead Cylinders

    Cylinder comparisons of pressure shape & timing

    -180

    0

    100200

    300

    400

    500

    600

    700

    800

    900

    1000

    -135 -90 -45 0 45 90 135 180

    C402 - E 9/9/1998 12:02:53 PMAll cylinders - To Center of Plot - CRC is corrected

    Crank Angle (deg)

    P r e s s u r e ( p s i g )

    P1LDead Cylinder

  • 8/9/2019 Basic Engine and Compressor Analysis

    56/133

    56

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 111

    Other cylinders

    P2L Soft Fire

    Dead CylindersCylinder comparisons of pressure rise rate

    -20

    -180

    -15

    -10

    -5

    0

    5

    10

    15

    20

    25

    30

    35

    -135 -90 -45 0 45 90 135 180

    C402 - E 9/9/1998 12:02:53 PMAll cylinders - To Center of Plot - CRC is corrected

    Crank Angle (deg)

    P r e s s u r e R i s e R a t e ( d P / d )

    Normal

    P1L Dead Cylinder

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 112

    Normal PT

    Dead Cylinders

    Pressure and pressure rise rate relationship

    Crank Angle (deg)

    900

    1000

    C402 - E Cylinder P1L 9/9/1998 12:02:53 PM Period 4CRC is corrected

    -103 EXHAUST PORT 100-123 INTAKE PORT 119

    -65 FUEL VALVE-125

    0

    100

    200

    300

    400

    500

    600

    700

    800

    -180 -135 -90 -45 0 45 90 135 180

    P r e s s u r e ( p s i g )

    P

    PT

  • 8/9/2019 Basic Engine and Compressor Analysis

    57/133

    57

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 113

    Dead CylindersPV comparison to normal

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    0 25 50 75 100

    C402 - E cylinder P1L 9/9/1998 12:02:53 PM Period 4CRC is corrected

    % swept volume

    Normal

    Dead Cylinder

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 114

    Pre-ignition

    Pre-ignition is the premature combustion of the air/fuelmixture before the normal ignition event (auto-combustion).

    PFP may occur before TDC causing excessive force onthe piston, wrist pin, connecting rod and bearings.

    The mechanical and thermal stress resulting from pre-ignition can cause cracked heads, torched or seizedpistons.

    Causes of pre-ignition hot spots in the cylinder caused by ash or carbonbuild up hot spots created by detonation

    early ignition timing is not normally considered pre-ignition.

  • 8/9/2019 Basic Engine and Compressor Analysis

    58/133

    58

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 115

    Pre-ignitionPT comparison to normal

    -130 Intake 130-110 Exhaust 110

    -77 Fuel-145

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    -180 -135 -90 -45 0 45 90 135 180

    5E Cylinder P4 8/15/2002 4:39:48 PM Period 5

    P r e s s u r e ( p s i g )

    Angle (deg)

    Normal

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 116

    Pre-ignition

    PV showing 2 crank revolutions

    Negative work

    Positive workPositive work

  • 8/9/2019 Basic Engine and Compressor Analysis

    59/133

    59

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 117

    CombustionAnalysis summary

    Uneven average peak firing pressuresHigh deviation in PFP for cylinderUneven exhaust temperaturesUsually accompanied by higher NOx and HC

    Unbalanced

    Often audible

    High PFP with early PFP angle Very high pressure rise rate compared to other cylinders Often develops a shock wave that is seen in the PT Combustion may make more noise than normal

    Detonation

    All cylinder average PFPs fall within 10-15% of the engineaverage PFPLow cycle-to-cycle deviation in cylinder PFPPFP angle consistent and at expected locationSimilar exhaust temperatures among power cylinders

    Normal

    CharacteristicsObservation

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 118

    Combustion

    Analysis summary (cont.)

    PFP angle earlier than normal Average PFP higher than normal Higher pressure rise rate when compared to other cylinders (orhistory) Lower exhaust temperature

    Early Firing

    Type of misfire Average PFP lower than normal PFP angle later than normal Low pressure rise rate when compared to other cylinders (orhistory) May be followed by detonation Increased exhaust temperature

    Soft Firing

    CharacteristicsObservation

  • 8/9/2019 Basic Engine and Compressor Analysis

    60/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    61/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    62/133

    62

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 123

    Valve Train

    Valve Seat

    Exhaust Port

    Valve Stem

    Valve Springs

    Valve LifterRocker Arm

    Cam Follower

    Cam Lobe

    Push Rod

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 124

    Valve Train

    Common problems

    Mechanical Loose/worn rocker arm Improper lifter clearance Broken springs Incorrect spring tension Worn valve guide Worn or mis-timed cam

    Excessive cam gear lash

    Leakage Burnt valves Deposits on valve seat Damaged seat Bent valve stem

  • 8/9/2019 Basic Engine and Compressor Analysis

    63/133

    63

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 125

    Valve TrainIncorrect clearance

    May cause the valve toopen and close at thewrong time

    Valve opening eventcan be noisy theclearance is taken upon the leading edge ofthe cam lobe

    Can cause noisy valveclosure if the valve isdropped onto the seat

    Crank Angle

    L i f t

    V i b r a t i o n

    ExcessiveLash

    Valve openslate & sharp

    Valve closesearly & drops

    on seat

    NormalLift

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 126

    Valve Train

    Hydraulic lifters

    Hydraulic lifters maintain correct valve timingand minimize valve train wear over a widerange of operating conditions

    Oil pressure within the lifter maintains correctclearances in the valve train

    If the lifter collapses The valve may open late and close early The vibration pattern shows impacts atopening and closure

  • 8/9/2019 Basic Engine and Compressor Analysis

    64/133

    64

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 127

    Valve TrainExcessive EV clearance (KVGR with solid lifters)

    P 1

    P 2

    P 3

    P

    4

    P 5

    P 6

    K1F - E 12/13/1994 11:19:43 AMEngine Cylinders: Phased Vibration VT4:

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    0 90 180 270 360 450 540 630 720

    P1

    P2

    P3

    P4

    P5

    P6

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    90 180 270 360 450 540 630 720

    P7

    P8

    P9

    P10

    P11

    P12

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 128

    Valve Train

    Vibration comparison for a leaking EV (KVGR)P1

    P2

    P3

    P4

    P5

    P6

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    0 90 180 270 360 450 540 630 720

    P7

    P8

    P9

    P10

    P11

    P12

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    0 90 180 270 360 450 540 630 720

  • 8/9/2019 Basic Engine and Compressor Analysis

    65/133

    65

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 129

    NormalNormal

    Valve TrainPT and PV: leaking exhaust valves (KVGR)

    580Intake 294390 Exhaust150

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    500

    0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720Angle (deg)

    P r e s s u r e ( p s i g )

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    500

    0 25 50 75 100% swept volume

    2 low PFP

    22

    3 3

    3 low expansion

    1

    1

    1 low compression

    High exhaust temp

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 130

    Valve Train

    Worn rocker arms (KVGR)K1D - E 2/3/1997 10:52:37 AM

    Engine Cylinders: Phased Vibration VT4:

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    0 90 180 270 360 450 540 630 72090 180 270 360 450 540 630 720

    P1

    P3

    P4

    P5

    P6

    P7

    P8

    P9

    P10

    P11

    P12

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    -2.5

    0.0

    2.5

    0

    P2

  • 8/9/2019 Basic Engine and Compressor Analysis

    66/133

    66

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 131

    Valve TrainWorn cam gear (KVS)

    NO-4 - E 2/28/1995 1:38:59 PMEngine Cylinders: Phased Vibration VT4:

    P10

    P7

    P8

    P9

    P11

    P12

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0

    2

    -2

    P1

    P2

    P3

    P4

    P5

    P6

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0

    2

    -2

    0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 132

    Valve Train

    Worn cam gear (KVS)410 EXHAUST VALVE161

    575INTAKE VALVE 325621FUEL VALVE 536

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

    NO-4 - E Cylinder P12 2/28/1995 1:38:59 PM

    Angle (deg)

    410 EXHAUST VALVE161575INTAKE VALVE 325

    621FUEL VALVE 536

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

    -

    -

    -

    -

    -

    -

    -

    -

    -

    - Scale 2.0

    P6 VT4

    NO-4 - E Cylinder P6 2/28/1995 1:38:59 PM

    Angle (deg)

    P r e s s u r e ( p s i g )

    P r e s s u r e ( p s i g )

  • 8/9/2019 Basic Engine and Compressor Analysis

    67/133

    67

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 133

    Valve TrainLeaking fuel valve (HLA)

    C2A-E 10/10/2001 6:28:53 AMEngine Cylinders: Phased Ultrasonic ULT:

    360135 180 225 27045 90 315

    -5

    0

    5

    -5

    0

    5

    -5

    0

    5

    -5

    0

    5

    0

    1F

    2F

    3F

    4F

    -5

    360

    -5

    0

    5

    -5

    0

    5

    -5

    0

    5

    0

    5

    0 45 90 135 180 225 270 315

    5F

    6F

    7F

    8F

    Hard closures

    Leakage

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 134

    Valve Train

    Leaking fuel valve (HLA)

    45 90 135 180 225 270 315 360

    --------------

    --------------

    --------------

    --------------

    -----------------------------

    - Scale 2.0

    - Scale 4.0

    - Scale 4.0

    8 VT4

    8 ULT

    8FV ULT

    230 Intake130250 Exhaust110

    283Fuel 213

    C2A-E Cylinder 8 10/10/2001 6:28:53 AM Period 9

    Angle (deg)

    0

    100

    200

    300

    400

    500

    600

    700

    0

    P r e s s u r e ( p s i g )

    Leak asP rises

  • 8/9/2019 Basic Engine and Compressor Analysis

    68/133

    68

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 135

    Valve TrainAnalysis summary

    Multiple impact following normal valve closure Excessive noise on opening or closure

    Worn rockerbushing

    Valve opens late and closes early Impact noises on valve closure

    Sometimes see impact on opening Early closing exhaust valves may raise the PV toe

    Excessivelifterclearance

    Valve opening events are quiet or absent Valve events are similar across the entire engine Closing events are at expected crank angle, singleimpact of short duration

    No leakage occurs after valve closure

    NormalCharacteristicsFault

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 136

    Valve Train

    Analysis summary (cont.)

    Roughness seen in vibration pattern as valve opensand closes

    Valve may hang up in the guide and not close at thecorrect time

    May see gas leakage if valve does not seat properly

    Worn valveguide

    Impacts in the vibration as gear teeth pass each other May cause excessive wear on the cam lobe leading torough vibration pattern

    When troubleshooting, be prepared to move thevibration transducer around

    Cam gearfaults

    Impact noises on opening and closure Valve may close late

    Brokenvalve spring

    CharacteristicsFault

  • 8/9/2019 Basic Engine and Compressor Analysis

    69/133

    69

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 137

    Valve TrainAnalysis summary (cont.)

    Multiple impacts on valve closure as valve finds theseat

    Look for differences in valve closure across the engine Can be caused by beat-out seat, worn/broken/incorrectspring, worn guide, loose rocker arm, bent valve stem

    May see blowby pattern when pressure is high in thecylinder

    Impropervalveseating

    Blowby pattern appears when pressure rises in thecylinder

    Leakingvalves

    CharacteristicsFault

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 138

    Pistons, Rods, Rings and Liners

    SOURCE: navsci.berkeley.edu/ ns10/piston.htm

  • 8/9/2019 Basic Engine and Compressor Analysis

    70/133

    70

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 139

    Piston slap

    Piston slap occurs when the piston skirtimpacts the liner

    Tends to occur after peak pressure when thepressure is high and there are side forces onthe piston

    Becomes more pronounced when theclearance in the upper cylinder increases due

    to ring wear

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 140

    Piston Slap

    Low frequency vibration showing piston slap (HLA)

    -5

    0

    5

    -5

    0

    5

    -5

    0

    5

    -5

    0

    5

    0 45 90 135 180 2 25 2 70 3 15 3 60

    C2A-E 6/5/2001 8:23:09 AMEngine Cylinders: Phased Acceleration VTL:

    -5

    0

    5

    -5

    0

    5

    -5

    0

    5

    -5

    0

    5

    0 45 90 135 180 2 25 2 70 315 360

    1

    2

    3

    4

    5

    6

    7

    8

  • 8/9/2019 Basic Engine and Compressor Analysis

    71/133

    71

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 141

    Piston SlapLow frequency vibration showing piston slap (HLA)

    C2A-E Cylinder 3 6/5/2001 8:23:09 AM Period 6

    230 Intake130250 Exhaust110

    283Fuel 213

    0

    100

    200

    300

    400

    500

    600

    700

    0 45 90 135 180 225 270 315 360

    --------------

    --------------

    --------------

    --------------

    --------------

    ---------------------------------------

    - Scale 2.0

    - Scale 6.0

    - Scale 4.0

    - Scale 20.0

    3 VT4

    3 VTL

    3 ULT

    3FV ULT

    Angle (deg)

    P r e s s u r e ( p s i g )

    Not always visiblein ultrasonic

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 142

    Piston Rods

    Excessive wrist pin and connecting rodbearing clearances produce impacts at loadreversal in the piston pin bushing

    in 4-stroke engines, vibration spikes occurnear TDC

    in 2-stroke engines, vibration spikes occurnear BDC

    There is usually cycle-to-cycle variability inthe location of the vibration

  • 8/9/2019 Basic Engine and Compressor Analysis

    72/133

    72

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 143

    Piston RodsWrist pin load for a 2-stroke engine

    Wrist pin load in a 2 stroke engine

    -50000

    0

    50000

    100000

    150000

    200000

    250000

    0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

    Degrees

    F o r c e ( l b s )

    Vibration occursaround BDC

    where load is minimal

    Inertia

    Gas force

    Total force

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 144

    Piston Rods

    Wrist pin load for a 4-stroke engineWrist pin load in a 4 stroke engine

    -50000

    0

    50000

    100000

    150000

    200000

    250000

    0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

    Degrees

    F o r c e ( l b s )

    Vibration occursaround TDC

    where load reverses

    Inertia

    Gas force

    Total force

  • 8/9/2019 Basic Engine and Compressor Analysis

    73/133

    73

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 145

    Piston RodsExcessive wrist pin clearance (KVS)

    417 EXHAUST VALVE137565INTAKE VALVE 300

    611FUEL VALVE 502

    0

    100

    200

    300

    400

    500

    600

    700

    0 45 90 135 1 80 225 270 3 15 360 405 450 495 540 585 630 675 7 20

    --------------

    --------------

    -

    -

    -

    -

    -

    -

    -

    -

    -

    - Scale 2.0

    P6 VT4

    K200 - E Cylinder P6 1/16/1996 9:39:11 AM Period 6

    Angle (deg)

    P r e s s u r e ( p s i g )

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 146

    Piston Rings

    Worn or improperly loaded rings

    The presence of gas passing noise whencylinder pressures are high indicates blowby

    Be careful though, it could be leakage aroundrings or valves

    A damaged liner will prevent rings fromsealing properly

    Even moderate blowby may be sufficient tocause a significant rise in the enginecrankcase pressure

    Ring fouling prevents pressure from gettingbehind the rings to load them properly

  • 8/9/2019 Basic Engine and Compressor Analysis

    74/133

    74

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 147

    LinersScuffing and scoring

    Liner scuffing or scoring is often seen as symmetricvibration spikes around TDC

    For a 2-stroke engine, piston rings pass the same pointtwice in one cycle

    For a 4-stroke engine, piston rings pass the same point4 times in one cycle

    Ring loading affects the degree that each event is seen Wear is usually faster in the upper liner due to highPFP

    Crankcase pressure may increase due to blowbyresulting from the liner wear

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 148

    Liners

    Liner groove (KVS, P2, 10 rotations)NO-6 - E 12/21/1995 8:14:16 AM

    Engine Cylinders: Phased Vibration VT4:

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0 90 180 270 360 450 540 630 720

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0 90 180 270 360 450 540 630 720

    P2 (MMM)

    P2 (1)

    P2 (Med 2)

    P2 (3)

    P2 (4)

    P2 (5)

    P2 (6)

    P2 (7)

    P2 (8)

    P2 (9)

    P2 (10)

  • 8/9/2019 Basic Engine and Compressor Analysis

    75/133

    75

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 149

    LinersLiner groove (KVS)

    FUEL VALVE 504

    403 EXHAUST VALVE560

    0 720

    NO-6 - E Cylinder P2 12/21/1995 8:14:16 AM Period 2

    Symmetric angle cursorsreveal liner groove

    151INTAKE VALVE 345

    610

    20 340 380 7000

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    45 90 135 180 225 270 315 360 405 450 495 540 585 630 675

    --------------

    --------------

    -

    -

    -

    -

    -

    -

    -

    -

    -

    - Scale 2.0

    P2 VT4

    Angle (deg)

    P r e s s u r e ( p s i g )

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 150

    Liners

    Liner groove (KVS)NO-6 - E 12/21/1995 8:14:16 AM

    Engine Cylinders: Phased Vibration VT4:

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0 90 180 270 360 450 540 630 720

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0 90 180 270 360 450 540 630 720

    P2 (MMM)

    P2 (1)

    P2 (Med 2)

    P2 (3)

    P2 (4)

    P2 (5)

    P2 (6)

    P2 (7)

    P2 (8)

    P2 (9)

    P2 (10)

    Crosstalk from P3 exhaust blowdown

    Crosstalk from P1exhaust blowdown

  • 8/9/2019 Basic Engine and Compressor Analysis

    76/133

    76

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 151

    LinersCrosstalk from exhaust event on P3 (KVS)

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0 90 180 270 360 450 540 630 720

    NO-6 - E 12/21/1995 8:14:16 AMEngine Cylinders: Phased Vibration VT4:

    422

    662

    182

    542

    302

    62

    17

    257

    497

    137

    617

    377

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0 90 180 270 360 450 540 630 720

    P1

    P2

    P3

    P4

    P5

    P6

    P7

    P8

    P9

    P10

    P11

    P12

    Unphased cursor indicatescrosstalk from other cylinders

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 152

    Liners

    Liner wear (KVS)

    90 180 270 360 450 540 630 720-2

    0 90 180 270 360 450 540 630 720

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0

    P1

    P2

    P3

    P4

    P5

    P6

    NO-6 - E 3/19/1996 1:28:36 PMEngine Cylinders: Phased Vibration VT4:

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    -2

    0

    2

    0

    2

    P7

    P8

    P9

    P10

    P11

    P12

    Chatter as loadedrings pass over wear

    NO-6 - E 3/19/1996 1:28:36 PMEngine Cylinders: Phased Vibration VT4:

  • 8/9/2019 Basic Engine and Compressor Analysis

    77/133

    77

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 153

    LinersLiner wear (KVS)

    403 EXHAUST VALVE151560INTAKE VALVE 345

    610FUEL VALVE 504

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 6 75 7 20

    --------------

    --------------

    -

    -

    -

    -

    -

    -

    -

    -

    -

    - Scale 2.0

    P7 VT4

    NO-6 - E Cylinder P7 3/19/1996 1:28:36 PM Period 2

    Angle (deg)

    P r e s s u r e ( p s i g )

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 154

    Liners

    Liner wear confirmed by symmetric cursor (KVS)NO-3 - E Cylinder P5 5/1/1995 8:06:19 AM Period 2410 EXHAUST VALVE

    575621FUEL VALVE 536

    405 450 495 540 585 630 675 720

    --------------

    --------------

    -

    -

    -

    -

    -

    -

    -

    -

    -

    - Scale 2.0

    P5 VT4

    Angle (deg)

    161INTAKE VALVE 325

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    0 45 90 135 180 225 270 315 360

    P r e s s u r e ( p s i g )

    128 232 488 592

    Symmetric cursor indicatesthe liner is worn.

  • 8/9/2019 Basic Engine and Compressor Analysis

    78/133

    78

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 155

    LinersLiner wear (KVS)

    P7

    P8

    P9

    P10

    P11

    P12

    NO-3 - E 5/1/1995 8:06:19 AMEngine Cylinders: Phased Vibration VT4:

    P1

    P2

    P3

    P4

    P5

    P6

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    0

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    -1

    0

    1

    90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 156

    Liners

    Port bridge wear (HLA)

    -10

    0

    10

    -10

    0

    10

    -10

    0

    10

    -10

    0

    10

    0 45 90 135 180 225 270 315 360

    -10

    0

    10

    -10

    0

    10

    -10

    0

    10

    -10

    0

    10

    0 45 90 135 180 225 270 315 360

    C2A-E 10/10/2001 6:28:53 AMEngine Cylinders: Phased Ultrasonic ULT:

    1

    2

    3

    4

    5

    6

    7

    8

  • 8/9/2019 Basic Engine and Compressor Analysis

    79/133

    79

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 157

    230 Intake130250 Exhaust110

    283Fuel 213

    0

    100

    200

    300

    400

    500

    600

    700

    0 45 90 135 180 225 270 315 360

    --------------

    --------------

    --------------

    --------------

    -----

    ------------------------

    - Scale 2.0

    - Scale 10.0

    - Scale 10.0

    4 VT4

    4 ULT

    4FV ULT

    C2A-E Cylinder 4 10/10/2001 6:28:53 AM Period 6

    Angle (deg)

    P r e s s u r e ( p s i g )

    LinersPort bridge (HLA)

    Excessivering noise

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 158

    Ignition Systems

    Provide the energy to begin the chainreaction in the air/fuel mixture and consistsof

    Power supply Timing circuit Distribution mechanism Transformer

    Spark plug

  • 8/9/2019 Basic Engine and Compressor Analysis

    80/133

    80

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 159

    Ignition SystemsIgnition Primaries

    P1LP2L P3LP4L P5L P6LP1R P2R P3RP4R P5R P6R

    0.0

    0.5

    1.0

    1.5

    2.0

    2.5

    3.0

    3.5

    4.0

    4.5

    5.0

    5.5

    0 45 90 135 180 225 270 315 360

    C402 - E Cylinder P1L 07/03/1997 8:07:43 AM

    V o l t a g e ( V )

    Crank Angle (deg)

    TDC

    Voltages shouldbe similar

    ZenerGates

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 160

    Ignition Systems

    Ignition secondaries

    0 1 2 3 4 5

    S e c o n d a r y V o l t a g e

    Time (ms)

    CapacitorDischarges

    Indication ofionization voltage

    Coil ring down

    Arc Duration

    Plug Stops Firing

  • 8/9/2019 Basic Engine and Compressor Analysis

    81/133

    81

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 161

    Ignition SystemsTypical ignition secondary patterns

    C402 - E 09/09/1998 12:02:53 PM

    Ignition timing angle = 5.7

    Ignition timing angle = 5.9

    Ignition timing angle = 6.3

    0

    0

    0

    0 1 2 3 4 5

    P4LL(Med 1)

    P4LR(Med 1)

    P5LL(Med 1)

    Ignition timing angle = 5.9

    Ignition timing angle = 5.9

    Ignition timing angle = 6.1

    0

    0

    0

    0 1 2 3 4 5

    P5LR(Med 1)

    P6LL(Med 1)

    P6LR(Med 1)

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 162

    Ignition Faults

    Timing

    Advanced timing can cause early combustion early and increased PFP detonation lower exhaust temps

    Retarded timing can cause delayed combustion

    late and low PFP misfires/soft fires higher exhaust temperatures

  • 8/9/2019 Basic Engine and Compressor Analysis

    82/133

  • 8/9/2019 Basic Engine and Compressor Analysis

    83/133

    83

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 165

    Ignition FaultsCoils

    Check for correct polarity Look at coil ring down to assess coil windingcondition

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 166

    Ignition Faults

    Two bad coils plug did not fire

    Ignition timing angle = 5.5

    Ignition timing angle = 6.4

    Ignition timing angle = 5.4

    Ignition timing angle = 5.1

    Ignition timing angle = 5.7

    Ignition timing angle = 5.9

    -250

    0

    -250

    0

    -250

    0

    -250

    0

    -250

    0

    -250

    0

    0 1 2 3 4 5

    C402 - E 9/9/1998 12:02:53 PM Secondary Ignition (Y Axis: mV -- X Axis: ms)

    P1LL

    P1LR

    P2LL

    P2LR

    P3LL

    P3LR

    Ignition timing angle = 5.7

    Ignition timing angle = 5.9

    Ignition timing angle = 5.6

    Ignition timing angle = 5.5

    Ignition timing angle = 5.9

    Ignition timing angle = 5.4

    -250

    0

    -250

    0

    -250

    0

    -250

    0

    -250

    0

    -250

    0

    0 1 2 3 4 5

    P1RL

    P1RR

    P2RL

    P2RR

    P3RL

    P3RR

  • 8/9/2019 Basic Engine and Compressor Analysis

    84/133

    84

    2003 DYNALCO CONT ROLSGMRC 2003 GAS MACHINERY CONFERENCE

    SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 167

    Ignition FaultsReversed coil

    -100

    0

    100

    200

    -100

    0

    100

    200

    -1