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Course Description

Selection, Applications, Operation, Inspection, Diagnostic Testing, Troubleshooting, Maintenance, Refurbishment, Performance Monitoring, Power Augmentation, and Economics

Introduction

Turbocharged marine diesel engines have the highest efficiency and reliability for powering ships. They also have low capital, operation, and maintenance cost. Diesel engines have been used to power ships of various sizes. The environmental emissions of these engines are minimal. This seminar will provide in-depth coverage of the selection, operation, inspection, diagnostic testing, troubleshooting, maintenance, refurbishment, performance monitoring, power augmentation, and economics of all types of turbocharged marine diesel engines. The main focus of this seminar will be on the inspection, testing, troubleshooting, maintenance, and refurbishment of these engines. All the components, instrumentation, and control systems of turbocharged diesel engines will be covered in detail. The design, selection considerations, operation, maintenance, the economics of turbocharged marine diesel engines as well as, emission limits, reliability, monitoring and governing systems will also be covered in detail.  This seminar will also provide updated information in respect to all the significant improvements that have been made to turbocharged marine diesel engines during the last two decades.

Who Should Attend

  • Engineers of all disciplines
  • Managers
  • Technicians
  • Maintenance personnel
  • Other technical individuals

Seminar Outcome

Turbocharged Marine Diesel Engines Components and Systems: Learn about all components and subsystems of the various types of turbocharged marine diesel engines

Turbocharged Marine Diesel Engine Failure Modes, Inspection, Diagnostic Testing, Troubleshooting, Maintenance, and Refurbishment: Learn about all the failure modes of turbocharged marine diesel engines, inspection techniques, diagnostic testing, troubleshooting, maintenance and refurbishment activities required for these engines to minimize their operating cost and maximize their efficiency, reliability, and longevity.

Turbocharged Marine Diesel Engine Environmental Emissions: Learn about the monitoring and control of turbocharged marine diesel engine environmental emissions

Turbocharged Marine Diesel Engine Instrumentation and Control Systems: Learn about the latest instrumentation and control systems of turbocharged marine diesel engines

Turbocharged Marine Diesel Engine Reliability and Testing: Increase your knowledge of turbocharged marine diesel engines predictive and preventive maintenance, reliability and testing.

Turbocharged Marine Diesel Engine Selection and Applications: Gain a detailed understanding of the selection considerations and applications of turbocharged marine diesel engines

Learning Outcomes

  • Gain a thorough understanding of all components and subsystems of the various types of turbocharged marine diesel engines
  • Examine the advantages, applications, performance, and economics of turbocharged marine diesel engines
  • Learn about various equipment including pistons, cylinders, two- and four-stroke diesel engines, fuel systems, governing systems, and electronic management systems of turbocharged marine diesel engines
  • Discover the inspection, diagnostic testing, troubleshooting, and maintenance activities required for turbocharged marine diesel engines to minimize their operating cost and maximize their efficiency, reliability, and longevity
  • Learn about the monitoring and control of turbocharged marine diesel engine environmental emissions
  • Discover the latest instrumentation and control systems of turbocharged marine diesel engine power generating plants
  • Increase your knowledge of predictive and preventive maintenance, reliability and testing required for turbocharged marine diesel engines
  • Gain a thorough understanding of the selection considerations and applications of turbocharged marine diesel engines

Training Methodology

The instructor relies on a highly interactive training method to enhance the learning process. This method ensures that all the delegates gain a complete understanding of all the topics covered. The training environment is highly stimulating, challenging, and effective because the participants will learn from case studies which will allow them to apply the material taught to their own organization.

Special Feature

Each participant will receive a copy of the following materials written by the instructor:

Turbocharged Marine Diesel Engines Manual (250 pages – covering operation, maintenance, testing, troubleshooting, and refurbishment of turbocharged marine diesel engines)

Course Outline

Day One

Turbocharged Marine Diesel Engine Design, Features, Efficiency, Components, Advantages, Fuel System, Electronic  Management System, Safety, Applications, and Cost

  • Diesel engine efficiency, features, operation, and fuel injection systems
  • Diesel engine pistons, cylinders, strokes, diagrams, valves, air flow and fuel
  • Indirect injection and direct injection of diesel engines
  • Cold weather effects on diesel engines: starting and gelling
  • Two-stroke diesel engine design and types
  • Two-stroke diesel engine intake, crankcase compression, transfer and exhaust
  • Advantages and disadvantages of two-stroke diesel engines
  • Four-stroke diesel engine design, components, and types
  • Diesel engine supercharging and turbocharging
  • Modern high- and medium-speed engines
  • Modern low-speed engines, gas generator
  • Advantages and disadvantages of diesel engines versus spark-ignition engines: fuel economy, torque, power, forced induction, emissions, noise, reliability, quality, and variety of fuels
  • Diesel engine fuel and fluid characteristics
  • Diesel engine safety: fuel flammability, and maintenance hazards
  • Diesel engine applications: power generation, passenger cars, railroad rolling stock, other transport applications, military fuel standardization, marine applications
  • Diesel engine speeds: high-speed engines, medium-speed engines, and low-speed engines
  • Diesel engine fuel systems: air blast, jerk pump system, inline pumps, distributor pumps, Bosch VE, Injector pump service (bleeding and timing), delivery valves (service), injectors (injector service, spray pattern, nozzle opening pressure, sealing, chatter), timers, diaphragm controls, centrifugal governors (service), pneumatic governor (MZ, service), unit injection, low-pressure system (lift pumps, lift-pump service), fuel filters and water separators
  • Electronic Management Systems: background, modern diesel engines, solenoid-actuated injectors, piezo-actuated injectors (service), unit injection, analog versus digital, Bosch CAN bus, on-board computer (central processing unit, memory, peripherals, sensors, actuators), tools, troubleshooting (methods for troubleshooting every component in EMS-equipped diesel engine), Caterpillar
  •  EMS, components of Caterpillar EMS, electronic unit injector, low-pressure circuit, high-pressure circuit, hydraulic/electronic unit injector (injector service, HEUI hydraulics, fuel pressure, boost pressure, throttle-position sensor, trouble codes, list of Caterpillar HEUI trouble codes, Power Stroke (slow or no-start, power stroke sensor nomenclature and functions, erratic idle, low oil pressure, air in lube oil, injector-drive module, air in fuel circuit, camshaft position sensor), Diesel (electronic unit injectors, Diesel electronic control nomenclature, no start, VGT/EGR, major DDEC flash and PID codes)   

Day Two

Turbochargers in Diesel Engines, Pulse System of Turbocharging, Turbocharged Marine Diesel Engine Failure Modes, Inspection, Troubleshooting, Maintenance, and Refurbishment, Diesel Engine Generators, Governor, Automatic Voltage Regulator, and Excitation Systems

  • Superchargers and turbochargers in diesel engines: applications, construction,  wastegate, aftercoolers, routine maintenance, lubrication system, air inlet system, crankcase ventilation system
  • Constant Pressure System Turbocharging, turbocharger arrangement in constant pressure system, advantages and disadvantages for constant pressure system
  • Pulse system of turbocharging, turbocharger arrangement in pulse system, advantages and disadvantages of pulse system
  • Under piston pressure supercharging, advantages
  • Turbocharger surging, causes of turbocharger surging
  • Exhaust tuning
  • Advantages of intercooling the charged air
  • Types of turbocharger lube oil system
  • Types of turbocharger bearings: ball type bearing (rolling), sleeve type bearings
  • Function of the labyrinth seal
  • Indication of choked air filter turbocharger
  • Function of nozzle ring in turbocharger
  • Function of shroud ring in turbocharger
  • Purpose of inducer in turbochargers
  • Function of diffuser in turbochargers
  • K value in turbochargers, purpose of K value in turbochargers
  • Engine operation following turbocharger failure
  • Cut off damaged turbochargers for engine operation
  • Engines with one turbocharger (engines without exhaust by-pass)
  • Engines with two or more turbochargers
  • Turbocharger faults diagnostics: symptoms, probable causes, and corrective actions
  • Turbocharger exhaust system, inspection, overhaul
  • Variable geometry turbine
  • Common failure modes of diesel engines
  • Turbocharged marine diesel engine instrumentation and alarms
  • Turbocharged marine diesel engine inspection
  • Turbocharged marine diesel engine diagnostics
  • Turbocharged marine diesel engine maintenance activities
  • Turbocharged marine diesel engine operational activities
  • Turbocharged marine diesel engine troubleshooting: malfunctions (engine does not start, cranks slowly, trips after operating for one or two minutes, misfires, fail to develop normal power)
  • Turbocharged marine diesel engine tests: fuel quality, fuel system, bleeding, low- pressure circuit tests, high-pressure circuit tests
  • Turbocharged marine diesel air inlet system: air filter, positive crankcase  ventilation (PCV), exhaust gas recirculation, turbocharger, glow plugs, exhaust  backpressure
  • Turbocharged marine diesel engine mechanical: fuel leaks, oil leaks, coolant  leaks, excessive oil consumption, loss of compression, and oil analysis
  • Maintenance of turbocharged marine diesel engines
  • Maintenance of turbocharged marine diesel engine lubrication and cooling systems
  • Turbocharged marine diesel engine current and future developments
  • Turbocharged marine diesel engine capital cost, operation, and maintenance cost, and economics
  • Marine diesel generators, components, governor, automatic voltage regulator, and excitation systems
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