Page 53 - CARILEC CE Industry Journal_Oct_2019

How Comprehensive

Diesel Engine Analysis Improves

Performance and Reliability

- Edward P. Kelleher, Windrock, Inc.

This paper presents a proven technology and approach to reducing unexpected engine failures and optimizing
performance for all types of diesel engines. Utilizing comprehensive engine analysis and monitoring techniques, a
detailed view of the condition of internal parts such as valves and valve train components, injectors, fuel pumps,
liners, rings, and bearings can be made in a non-intrusive manner to identify any degradation or change before a
component fails. A detailed explanation of the technology as well as case studies from a variety of different engine
models will be presented in this paper.

INTRODUCTION The engine indicator and Indicator Card go as far back as
the late 1700’s as shown in Figures 1 and 2.
This paper presents a proven technology that has been
utilized in many industries for decades to reduce engine
failures and optimize performance on high, medium, and
slow speed diesel engines. Engine owners and operators
have historically performed engine OEM maintenance
activities, oil analysis, and typically obtain indicator card
measurements or peak firing pressures on a periodic basis.
Even with these procedures and processes in use, diesel
engines still have unexpected failures on a regular basis
between these scheduled or planned maintenance activities.
Although the cost of fuel today is more than 50% of what
it was just a few years ago, fuel is still the biggest cost of
operating an engine in the power generation arena. Fig. 1 - Engine Indicator
Additionally, when an engine fails un-expectantly, there
are lost production costs, parts and labor costs and in
some cases, regulatory fines.

Comprehensive Engine Analysis employs the use of
traditional engine performance measurements (similar to
traditional indicator cards), it also utilizes crank-angle
based, degree-bydegree, electronically collected vibration
and ultrasonic data. Full utilization of the digitized
cylinder pressure data combined with phased vibration
and ultrasonic signatures allows for a complete Fig. 2 - Indicator Card
non-intrusive assessment of the internal cylinder
components and identification of degraded components. The use of electronic or digital engine analyzers began in
the late 1980s and started to incorporate analysis
Most power plants today will use some form of software. Peak Pressure gauges are still widely used,
combustion analyzer, whether it is the older indicator however, they provide very limited information and, in
card type, a MEP device, a simple electronic peak some ways, is a step backwards from the indicator
pressure device or crank angle based combustion measurement technique
analyzers to assess engine balance. The author would ask
whether this information is utilized in full and more
importantly is it acted on.
CE INDUSTRY Journal 51