NYK-TDG Maritime Academy

Knowledge Avenue, Carmeltown, Canlubang

4037, Calamba City, Laguna Philippines

MAIN ENGINE’S OVERHEATED PISTON FAILURE: DETECTION,

CAUSES AND COUNTERMEASURES

(Thesis topic)

Requirement for the Course

BS Marine Engineering

E/CDT. GASPAR, CHRISTOPHER F.

BATCH 2011

March 2010

CHAPTER I
 INTRODUCTION

Background

One of the main requirements of the job profile of a marine

engineers at any rank is to act quickly and thoughtfully to handle any kind

of situation on board the ship. It is important for a marine engineer to

know what to do when he hears main diesel engine is knocking. And

finding the reason for engine problems is essential in order to prevent

future breakdowns. Among the reasons for engine problems is piston

failure. It is important for all engineers onboard to understand all of the

issues surrounding piston failure should maintain the main engine and

encounter an engine problem that involves a failure of the piston.

In the field of maritime industry it is important to understand for an

engineer or any person onboard the vessels to insure the safe and

efficient operation of the ship insure the operation of machineries. The

main engine is the center of power to propel the ship; the piston is a very

important component of the any engines like pumps, reciprocating

engines, and compressors. But steam engine are not using piston instead

they are using steam. This is very will known in the LNG (Liquefied natural

gas) and LPG (liquefied petroleum gas) ships. Piston is made-up of a high

quality of material that compresses fuel and air to produce power to the

moving body of any object. Its purpose is to transfer force from expanding

gas during combustion in the combustion chamber and cylinder to the

crankshaft via a piston rod and/or connecting rod. Hence; in a pump the

purpose of the piston is to compressing air or fluid in the cylinder. And

there are three kinds of combustion in the engine these are two stroke

engines, four stroke engines, and internal combustion engines. Adding to

that the steam engines, there are very useful in the operation but differ in

the use and a kind of ship.

It is the greatest and most vital failure of the piston to cause trouble

in the engine since it has much purpose on the operation and propelling of

the ship. The life of a piston is directly related to its environment. As a

result, virtually all situations resulting in damage to a piston can be traced

related to the construction and quality of the piston itself.

Statement of the problem

This study will identify the most vital problem of the Main engine.

This is called Overheated piston failure: and how to detect the problem, its

causes and countermeasures.

This study will seek the answer of the following questions.

• What is the purpose of the piston in the main engine?

• How does Piston constructed and the properties of the material use?

• What are the External Symptoms of the overheated piston to be

observed outside the main engine?

• What is used to detect the overheated piston?

a) By the use of instruments and

b) By the use of the 5 senses

• What are the possible causes of overheating?

• How does an overheated piston affect the operation of the main

engine?

• What is the initial step to follow when overheating is arise?

• How can overheated piston be prevented?

• What is the procedure on how to replace an overheated piston?

Theoretical/conceptualize framework

According to Ricky Nadu, An Indian managing editor and author of

his article the electrical and marine engineering knowledge, as Marine

engineer he shared his ideas all about his experience encounter onboard

the ship, he encounter troubles mostly in the piston, a failure which

happen in the main engine during operation. According to him a piston

can identify problems in a very simple way of observing the engine during

operation. He said that piston performs its work silently within the cylinder

liner invisible from outside, but there might be problems inside which

could make it overheated causing a knocking sound. Despite the best of

maintenance and care, faults and piston failure can occur in main diesel

engines. If the failure starts the engineers know

 From James kumar, according to his blog the pistons are performing

a great job in the operation of the ship. Hence the pistons are the mean

source of power to propel the ship and continuous the operation of the

ship unlike the other machineries which has a partner, in the operation

the one is used in the daily operation of the ship and the order one is on

standby mode. If the one used is failed to operate, the other one is

automatically change and handle the operation, so that the one will be

trouble shout. While in the main engine which each cylinder has

equivalent piston or per cylinder has a corresponding piston. In short there

is no partner or standby mode during the operation of the piston. So in the

case of failure it is impossible to change instantly with another piston

during the failure occurs. It Takes a several hours to change the

overheated piston or to trouble shout the main engine problem.

These frameworks recommend a compilation of all causes, result

and countermeasures, as a set of tables to show the organization of the

idea on how the overheated piston are identify.

Frame work model:

PICTURE

“Damage
EXTERNAL
COUNTERM
piston
SYNTO DETECTION CAUSES
EASURE
due to
MS
overhe

ating”

Picture no. Recommen

“ “ Causes
1 dation

Picture no. Recommen

“ “ Causes
2 dation

Picture no. “ Recommen

“ Causes
3 dation

Picture no. Recommen

“ “ Causes
4 dation
 This framework shows the compilation of all problems resulting to

overheating of the piston up to its countermeasure. This will the help the

researcher and the reader to understand all possible problems, how to

detect, identify that causes of the problem and their equivalent

countermeasure.

Significance of the study

This research serve as guidelines to help the reader to research

more about the main diesel engine troubles, it serve as a tool to NYK-TDG

Maritime Academy (NTMA) engineering cadets to further more their

studies about the engine problem in line with their course and as a future

marine engineer officer onboard NYK-LINE VESSELS.

This study will be beneficial to the NTMA engineering cadets, Since

this topic will discuss the benefits of learning on how the overheated

piston will able to see the external symptoms, how to detected and

identify the causes of the overheated piston failure, how to determine the

overheated piston and its affect in the performance of the main engine,

initial steps to follow after identifying and the its equivalent

countermeasures in an educational establishment, And it will serve as

evidence to the fact that advanced learning in main diesel engine trouble

shooting is really contribute to the NTMA engineering cadets in terms of

the learning processes and study habits that these future marine

engineers are developing within this academy. This study will be

beneficial also to the future research as to develop and find more ways to

contribute to the learning process here in NTMA.

Scope and Limitations

This research includes all kind of ship engines that cover during the

year 2005 up to the present which has main engine except LNG and LPG

which uses turbine engines as sources of propelling power. The history

and related incident which occurs during the year of 2005 up to present

which may use as reference on this study.

This research includes 5 respondents for the same questions. They

are one chief engineer, two first assistant engineers and two second

assistant engineer. And this research focuses only the study of the

overheated piston, the external symptoms, how to detects, how it affects

the performance of the main diesel engine, what are the possible causes,

and countermeasure. This also includes the result of the overheating as

well as the procedure on how to replace the overheated piston.

DIFINITIONS OF TERMS

1) Overheated piston- is a common cause of main diesel engine

failures; overheating is a failure on the piston in which the

temperature is exceeded in his maximum allowable temperature.

2) Engine Knocking -- (simply “knock”) Occurs when combustion of

the air/fuel mixture in the cylinder starts off correctly in response to

ignition by the spark plug, but one or more pockets of air/fuel

mixture explode outside the envelope of the normal combustion

front.

3) Scuffing or scoring- is another condition that can damage pistons.

Scuffing is often the result of overheating, but loss of lubrication,

detonation or preignition can also be contributing factors. When an

engine runs hot, the pistons swell.

4) Detonation -- is an erratic form of combustion that can cause head

gasket failure as well as other engine damage. Detonation occurs

when excessive heat and pressure in the combustion chamber

cause the air/fuel mixture to auto ignite.

5) Pre-ignition --This occurs when a point within the combustion

chamber becomes so hot that it becomes a source of ignition and

causes the fuel to ignite before the fuel injector inject fuel to start a

fire.

6) Normal combustion -- combustion engine burns the fuel/air

mixture in the cylinder in an orderly and controlled.

7) Abnormal combustion -- unburned fuel/air mixture beyond the

boundary of the flame front is subjected to a combination of heat

and pressure for a certain duration (beyond the delay period of the

fuel used), detonation may occur.

 CHAPTER II

REVIEW OF RELATED LITERATURE AND STUDIES

Among the possible reasons for engine problems is the overheated

piston failure. It is important for marine engineers to understand all of the

issues surrounding main diesel engine and all machineries should they or

one of their diesel engines encounters an engine problem that involves a

failure piston.

RELATED LITERATURE AND STUDY

“DETERMINE THE CAUSE OF PISTON FAILURE”

According to Bill Mirth, Manager of FP Diesel brand of Federal-

Mogul Corporation. If a piston is found to be at fault, it is critical to find

out what caused the piston to fail. According to his article; finding of the

reasons for main diesel engine problems are essential in order to prevent

future breakdowns. If a piston is found to be at fault, it is critical to find

out what caused the piston to fail. It is important to understand that very

few pistons actually fail. But they are damaged by a faulty operating

environment. These conditions commonly include lack of lubrication,

abnormal combustion, the presence of debris within the engine, clearance

issues that lead to physical contact between the piston and another part

and operational issues such as overriding or overloading the engine or

improper shutdown.

The life of a piston is directly related to its environment. And as a

result, all situations resulting in damage to a piston can be traced to an

issue related to the construction and quality of the piston itself. In other

words, the worst thing a Marine Engineer can do is simply assume that the

piston was at fault and ignore the actual cause of the damage. In that

case, engineers just throwing parts at the problem, which invariably leads

to additional issues. Another problem is the fueling system cause of piston

to fail. If the engine injection system is delivering wrong amount of fuel, at

the wrong time or for the wrong duration and with a poor spray pattern,

this can result in excessive heat, erosion or a washing of cylinder walls

with fuel. In order to prevent heat build-up problem that can lead to piston

damage or overheat, it is important the correct level of lubrication

reaches the piston at the skirt and piston pin.

Another possible cause is the Water contamination causes erosion

and fuel and lubricant dilution. Contamination can be water, fuel,

particulates from the air intake or foreign objects. Particulates can wear

the ring lands, resulting in increased oil consumption. Foreign matter can

be anything including particles of a nuts, bolts, valve train or turbocharger

parts which are remove during the movement of parts in contact with
another parts and much of the time foreign matter in the combustion

chamber is the result of another component to fail. Scuffing and scoring

are the results of contaminants entering the air intake or lubrication

system leading to a piston to overheat. If a an Marine Engineers suspects

an abnormalities of the engine they should begin inspecting the following:

engine coolant temperature; engine oil temperature, level and grade; oil

pump; cylinder liner surface finish; piston ring pack design; cylinder

pressures and temperatures; piston and ring clearance in the cylinder;

incorrect combustion; injector overspray and fuel sulfur content are signs

of abnormalities of the engine if this components tends to fail, or can

include fluctuations in oil pressure, higher than normal operating

temperatures, unusual noises and any change in fuel and oil consumption.

Then follow by failure of piston or overheating of piston due to improper

look out of components which related to the overheating of piston. And

will be a result of engine breakdown.

Pistons should be inspected for any symptoms, check for

abnormalities within the in the bowl due to heat stress; cracks on the

surface area of the wrist pin bore and wear in the piston ring grooves.

Another failure is a Detonation related issue will be fairly obvious because

of the damage to the head of the piston. The results of lubricant

starvation will be evident on the walls of the cylinder or liner as well as on

the piston skirt. Piston crown may be an indication of a clearance issue,

meaning the piston may have made contact with a valve. A fracture
around the piston pin bore might indicate that the pin was installed

improperly, which then caused it to overheat.

Pistons are subjected to extreme heat during combustion of fuel in

the combustion chamber, if exceeded to its allowable temperature limit

then following phenomena are failure or will subjected to overheating; it is

understandable for an engineer of any ship to manage the occurring

failure. He/she knows how to handle the situation which is very

complicated in the field of maritime industry. Jay Wagner, heavy-duty

brand manager with Clevite Engine Parts, cites that the fueling problem is

another cause of piston failure. If the main diesel engine injection system

is delivering the wrong amount of fuel, at the wrong time or for the wrong

duration and with a poor spray pattern, this can result in excessive heat,

erosion or a washing of the cylinder walls with fuel. This is very dangerous

to the engine since the engine is the heart of the ship.

Reference:

file:///C:/Users/user/Documents/research/web%20reference%28research

%29/piston_failure.htm

file:///C:/Users/user/Documents/research/web%20reference%28research
%29/piston_failure_1_06.aspx.htm
 CHAPTER III

METHODOLOGY

This research was conducted in order to determine the

overheated piston failure in the solving the problem all about the main

diesel engine which is the piston. The advantages and disadvantages as

well as the reliability of this instrument were also part of the objectives. In

order to answer these research goals, the researcher opted to obtain the

view of a Marine Engineer in line with this topic.

THE RESEARCH DESIGN

The descriptive and historical method of research was used for this

study. To define the descriptive and the historical type of research stated

that the descriptive and historical method of research is to gather

information about the past and present existing condition. The emphasis

is on describing rather than on judging or interpreting. The aim of

descriptive and historical method is to verify the present situation in order

to understand it. The descriptive approach is quick and practical in terms

of the financial aspect. Moreover, this method allows a flexible approach,

thus, when important new issues and questions arise during the duration

of the study, further investigation may be conducted.

Descriptive and historical research on the other hand is a type of

research that is mainly concerned with describing the nature or condition

and the degree in detail of the past and a present situation. Thus this

method is used to describe the nature of a problem, as it exists at the

time of the study and to explore the cause/s and countermeasure of a

particular phenomenon. The aim of descriptive research is to obtain an

accurate profile of the problem of the engine, events or situations. With

this research type, it is essential that the researcher already has a clear

view or picture of the phenomena being investigated before the data

collection procedure is carried out. The researcher used this kind of

research to obtain first hand data from the respondents so as to formulate

rational and sound conclusions and recommendations for the study. In this

study, the descriptive and historical research method was employed so as

to identify the role and significance of using interview questionnaire in

recruiting and selecting Marine Engineers during the time of research. The

researcher opted to use this research method considering the objective to

obtain first hand data from the respondents. The descriptive and historical

method is advantageous for the researcher due to its flexibility; this

method can use either qualitative or quantitative data or both, giving the

researcher greater options in selecting the instrument for data-gathering.

THE RESPONDENTS

In order to determine whether an interview questionnaire does play

an important role in conducting human resource processes, a total of 5

respondents were asked to participate 3 respondents from NYK-Line

companies within NTMA and 2 from other companies were personally

selected to make up the sample. The participants answered an interview

questionnaire. Data gathered from this research instrument were then

computed for interpretation. To achieve pertinent information, certain

inclusion criteria were imposed. The participants qualified for sample

selection must be Marine Engineers from their respective companies

department. This qualification ensured that the participants understand

the nature of problem and its countermeasure they experience, making

the interview items easy for them to accomplish.

Purposive sampling was done for the selection of respondents. This

sampling method is conducted where each member of a Marine Engineers

has purposely selected for the research because of lack of officers on the

date of interview. The respondents are chosen purposely to a part of the

research participant, this is said to be the most efficient sampling

procedure. In order to conduct this sampling strategy, the researcher

defined availability and listed down all available Marine Engineers.

The Instrument

Statistical Treatment

The Procedure

In order to gather the needed information, the researcher will

undergo the following steps presented below:

Period/ Person(s)-in-
Activity KRI
Schedule Charge
Content and
Preparation of
03 Feb. outline of the
interview Researcher
2010 questionnair
questionnaires
es
Typing of
Writing the interview 04 Feb. interview
Researcher
questionnaires 2010 questionnair
e

Printing of the Hard copy of

05 Feb.
interview Adviser/s the interview
2010
questionnaire questionnair
e
Adviser’s
Validation of the
08 Feb. comments
interview Adviser/s
2010 and
questionnaires
suggestions.
Validated
Revision of interview 09 Feb. interview
Researcher
questionnaires 2010 questionnair
es.
Identify 3
marine
Determining the
10 Feb. engineers
respondents of the Researcher
2010 officer of
study
NYK-line in
NTMA
Identify 2
Determining the marine
11 Feb.
respondents of the Researcher engineers
2010
study officer of
outside
Preparing and 12 Feb. Researcher Approved
submitting the letter 2010 letter of
 of request request.
Administering and Will depend on Accomplishe
conducting the Feb. 2010 available of the d the data
survey respondents gathering
Analyzing and
22-26 Feb. Analyzed
interpreting the Researcher
2010 data
gathered data
Finished
Writing of 01-05 Mar.
Researcher Chapter 4
Chapter 4 and 5 2010
and 5
Revised
Submission and 08-10 Mar.
Adviser/s Chapter 4
consultation 2010
and 5
Will depend
Defended
on the
Defense of the study Panelists the research
schedule of
study
defense
Completion and
revision of the over- Produced
19 Mar.
all study based on Researcher softcopy and
2010
the suggestion of the hardcopy.
examiners.