Marine Engine Overview:
A marine engine is the primary source of propulsion onboard a ship. It converts
chemical energy from fuel into mechanical energy to rotate the propeller. The most
common type used in merchant vessels is the marine diesel engine.
Main Classifications:
1. Main Engine – Propulsion
2. Auxiliary Engines – Power generation
Main engines are typically large, two-stroke, slow-speed diesel engines directly
coupled to the propeller. Auxiliary engines are four-stroke medium-speed engines
used for electrical power generation.
Main Engine:
The main engine is the heart of a ship’s propulsion system. Most modern commercial
vessels use a slow-speed, two-stroke diesel engine that operates directly on heavy
fuel oil (HFO) or marine diesel oil (MDO).
Key Features:
- Two-stroke cycle
- Low-speed (~60–100 RPM)
- Direct drive to propeller shaft
- High thermal efficiency (~50%)
- Uses turbocharging and scavenging systems
Common Makers: MAN B&W, Wärtsilä, Mitsubishi
Diesel Engine:
A diesel engine operates using compression ignition, where air is compressed to a
high pressure and temperature before fuel is injected, causing combustion.
Marine diesel engines are either:
- Two-stroke: Used for propulsion (main engine)
- Four-stroke: Used for power generation (auxiliary engine)
Advantages:
- High efficiency
- Reliability
- Long service life
Critical Systems:
- Fuel system
- Lubrication system
- Cooling system
- Air starting system
Air Starting System – Marine Diesel Engine:
The air starting system is used to initiate the rotation of the main engine's
crankshaft to start the engine. It uses compressed air directed into the engine
cylinders in a controlled sequence to turn the engine over.
**Key Components:**
- Starting air receiver (bottle)
- Starting air compressor
- Starting air valves (on each cylinder)
- Air distributor
- Control valves and solenoids
**Working Principle:**
1. Compressed air (~30 bar) from the air bottle is stored.
2. When the engine is to be started, a control signal opens the air starting
valves.
3. The air is admitted to each cylinder just after TDC in the correct firing order
via the air distributor.
4. The engine rotates until fuel injection takes over.
**Pressures:**
- Starting Air Bottle Pressure: **~30 bar**
- Minimum Pressure to Attempt Start: **20–25 bar**
- Control Air (for solenoids): **6–8 bar**
- Compressor Cut-In: **~27 bar**
- Compressor Cut-Out: **~30 bar**
**Safety Features:**
- Interlock prevents starting when engine is engaged in gear.
- Relief valve on air bottle
- Flame arrestors to prevent backfire
**Maintenance Tip:**
- Regularly drain condensate from air bottles and pipes to avoid water carry-over.
- Test starting sequence during maneuvering drills.
Air Starting System – Working Principle:
The air starting system is designed to rotate the crankshaft of a marine diesel
engine using high-pressure compressed air, enabling it to reach a speed sufficient
for fuel combustion to take over.
Step-by-Step Working:
1. **Air Storage:**
- Compressed air is stored in starting air bottles at approximately 30 bar
pressure.
- This air is supplied by air compressors.
2. **Control Signal Initiation:**
- When the engine start command is given, control air (6–8 bar) activates the
pilot valve and air distributor.
3. **Air Distributor Operation:**
- The air distributor controls the timing of air admission into each cylinder
based on the engine’s firing order.
- It ensures air enters a cylinder just after top dead center (TDC), pushing the
piston down.
4. **Starting Air Valve Opening:**
- For each cylinder, the starting air valve opens as directed by the
distributor.
- High-pressure air enters the cylinder and pushes the piston down, rotating the
crankshaft.
5. **Sequential Cylinder Firing:**
- The distributor continues the cycle, sending air to successive cylinders.
- This creates continuous rotation of the engine.
6. **Fuel Injection Takes Over:**
- As engine speed increases, fuel is injected and combustion starts.
- Once firing is self-sustained, the air valves close and the engine runs
normally.
7. **System Reset:**
- The system resets and waits for the next start sequence.
**Note:** This process is usually automatic and completed within seconds. Starting
interlocks prevent unsafe starting conditions (e.g., turning the engine in the
wrong direction or with turning gear engaged).
Air Starting System – Safety Features Explained:
The air starting system involves high-pressure compressed air (~30 bar), which can
be hazardous if not controlled properly. Therefore, multiple safety features are
built in to prevent accidents and ensure safe operation.
1. **Turning Gear Interlock:**
- Prevents the engine from starting when the turning gear is engaged.
- Ensures the engine isn’t rotated manually and pneumatically at the same time.
2. **Directional Interlock (Astern/Ahead):**
- Prevents starting in the wrong direction.
- The engine will only receive starting air in the correct rotational sequence
(ahead or astern) as selected.
3. **Starting Air Valve Design:**
- Each cylinder has a spring-loaded, pneumatically operated air starting valve.
- The valve opens only when activated by the air distributor.
- Closes automatically after air is admitted.
4. **Non-Return Valve at Air Bottles:**
- Prevents backflow from the air receiver to the compressor or other lines in
case of failure.
- Ensures compressed air is stored safely.
5. **Relief Valve on Air Bottle:**
- Protects the air bottle from overpressure.
- Automatically releases air if the pressure exceeds the safe limit (~32–35
bar).
6. **Flame Arrestors:**
- Installed in air lines to prevent backfiring or explosion from reaching the
air bottle.
- Protects against ignition of residual oil mist in air pipes.
7. **Automatic Drain Valves:**
- Removes accumulated water and oil from the air lines.
- Prevents hydraulic shock and contamination in starting air valves.
8. **Pressure Gauges and Alarms:**
- Pressure gauges on the air bottle and control air lines monitor safe levels.
- Alarms are activated if pressure drops below starting requirement (usually <20
bar).
9. **Control Air Pressure Regulation:**
- Control air used to operate solenoids and pilot valves is reduced to a safer
6–8 bar.
- Prevents damage to small control components.
10. **Manual Emergency Shut-off:**
- Valves are provided to isolate the air system manually in case of malfunction
or fire.
These safety measures are crucial to avoid dangerous overpressure, backfire, or
unintended engine movement during starting operations.
Air Starting System – Maintenance Procedures:
Regular maintenance of the air starting system ensures reliable engine starts and
prevents failures due to contamination, leakage, or wear. The following checks are
carried out during routine engine room maintenance:
1. **Air Bottle (Receiver):**
- **Drain Water/Oil Daily:** Use manual or automatic drains to remove
condensate.
- **Check Relief Valve Operation:** Test periodically for correct lifting
pressure (~32–35 bar).
- **Inspect for Corrosion or Dents:** Especially at the bottom where water
accumulates.
- **Pressure Gauge Calibration:** Ensure pressure readings are accurate.
2. **Starting Air Compressor:**
- **Check Oil Level and Quality:** Replace as per maker’s schedule.
- **Clean/Replace Air Filters:** Prevent dust/oil contamination.
- **Inspect Intercoolers:** Clean air cooler fins to maintain cooling
efficiency.
- **Overhaul Valves and Piston Rings:** As per running hours or poor
performance.
3. **Starting Air Valves (on Cylinders):**
- **Function Test:** During maneuvering tests, ensure each valve opens and
closes at the right crank angle.
- **Check for Air Leakage:** Listen for hissing or apply soap solution to
joints.
- **Disassemble and Clean:** Carbon deposits or oil residues can cause sticking.
- **Spring Tension Check:** Replace weak or broken springs.
4. **Air Distributor:**
- **Timing Check:** Ensure correct firing sequence and phase angle.
- **Lubrication:** Apply correct lubricant if required by design.
- **Check for Wear on Cam or Shaft:** Excess clearance can affect timing.
5. **Control Air System:**
- **Inspect Control Solenoids and Pilots:** Ensure fast response during
actuation.
- **Maintain Filter/Regulator Units:** To keep clean 6–8 bar supply for reliable
operation.
6. **Pipework and Connections:**
- **Tightness Check:** No air leakage at flanges or joints.
- **Check for Vibration Cracks or Loose Supports.**
- **Insulation Check:** If installed, ensure insulation is dry and undamaged.
7. **Safety Device Inspection:**
- **Relief Valves, Flame Arrestors, and Non-return Valves:** Test and clean as
per PMS (Planned Maintenance System).
- **Check Interlocks:** Confirm turning gear and directional interlocks are
functioning.
8. **Functional Test Run:**
- **Weekly or Before Departure:** Turn engine on air only without fuel to
confirm all cylinders receive air in proper order.
**Documentation:**
- Record maintenance done, parts changed, and test results in the engine logbook.
- Follow maker-specific intervals (e.g., 1,000–2,000 hours overhaul for air start
valves).
**Common Issues Noted During Maintenance:**
- Air leakage due to gasket failure
- Sticky air valves due to oil carry-over
- Water/oil contamination causing air hammer
- Control air malfunction due to dirty solenoid valves
Good maintenance ensures engine readiness during critical operations like
maneuvering and emergencies.