MARPOW

Engine- Any device which can convert heat energy of fuel into mechanical
energy is known as engine or heat engine.
However, there do exist some alternative fuel types such as biofuels and
natural gas. In thermodynamic terms, engines are generally referred to as
heat engines, which produce macroscopic motion from heat. The heat in this
case comes from the combustion of fuel in the engine, which moves piston
engine may be classified into two types.
1. External Combustion Engine (E.C Engine) the combustion of fuel
takes place outside the engines
2. Internal Combustion Engine (I.C Engine) the combustion of fuels
takes place insides the engine. Two-stroke and four-stroke petrol &
diesel engine are examples of an internal combustion engine.

5 Types Of Engines
1. Thermal engine- These may be combustive (that burn stuff). they
operate either through a propellant's direct combustion or through the
transformation of a fluid to produce work.
2. Heat Engine- A heat engine is a system that converts heat or thermal
energy to mechanical energy, which can be used to do mechanical
work.
3. Reaction engines- colloquially known as jet engines, generate thrust
by expelling reactionary mass. The basic principle behind a reactionary
engine is Newton’s Third Law — basically, if you blow something with
enough force through the back end of the engine, it will push the front
end forward.
4. Electrical engines- Plugging into a charge point and
taking electricity from the grid. They store the electricity in
rechargeable batteries that power an electric motor, which turns the
wheels.

3 types of classical electrical engines:

1. Magnetic - the most used of the three. It relies on the
interaction between a magnetic field and electrical flow to
generate work. It functions on the same principle a dynamo
uses to generate electricity, but in reverse. In fact, you can
 generate a bit of electrical power if you hand crank an
electrical-magnetic motor.

2. Piezoelectric - are types of engines that harness some

materials’ property of generating ultrasonic vibrations when
subjected to a flow of electricity in order to create work.
3. Electrostatic - use like-charges to repulse each other and
generate rotation in the rotor. Since the first uses expensive
materials and the second requires comparatively high
voltages to run, they’re not as common as magnetic drives.
5. Physical engines- These engines rely on stored mechanical energy to
function. Clockwork engines, pneumatic, and hydraulic engines are all
physical drives. Pneumatic and hydraulic types of engines must carry hefty
tubes of compressed fluids around, which generally don’t last very long.

According to the Design of Engine:

1. Reciprocating Engine (piston engine) the pressure force generates

by combustion exerted on the piston (A device which is free to move in
reciprocation inside the cylinder) and it transmits the pressure force to
the crankshaft by use of the connecting rod. So, the crankshaft starts
to rotate and rotate the wheel of the vehicle.
2. Rotary Engine (Wankel Engine)
In the rotary engine, there is a rotor that is free to rotate. The pressure
force generated by the burning of fuel is exerted on this rotor, so the
rotor rotates and starts to rotate the wheel of the vehicle.

According to Fuel use:

1. Diesel Engine (Compression Ignition Engine)- diesel is used

as a fuel. It is also known as the C.I. engine because there is no
extra equipment to burn the fuel. The burning of the fuel starts
due to the temperature rise in the compression of air.
 2. Petrol Engine (Spark Ignition Engine)- petrol is used as a
fuel. It is also known as S.I. engine because in this the fuel is
burned by the spark generated inside the cylinder by some extra
equipment (spark plug).
According to the Stroke:

1. Two stroke engine:In two stroke engine, the crankshaft rotates one
revolution in one time of fuel burn.

2. Four stroke engine:In four stroke engine, the crankshaft rotate two
revolutions in one time of fuel burn.

3. Six stroke engine:In six stroke engine, the crankshaft rotate three
revolutions in one time of fuel burn.

According to the Number of Cylinders:

1. Single Cylinder Engine: The engine has only one cylinder and a piston
connected to the crankshaft. This engine is used in light vehicles (generally
in two-wheelers) such as in motorcycles, scooters etc,
2. Multi-Cylinder Engine:- In this type of engine, more than one cylinder
and piston connected to the crankshaft is used. The Multi cylinder engines
are used where we require more power. It is mainly used in heavy vehicles
like cars, buses, trucks etc.

According to the Arrangement of Cylinder:

1.In-line Engine - The Cylinders are positioned in a straight line one behind
the other along the length of the crankshaft.
2.V-type Engine - An engine with two-cylinder inclined at an angle to each
other and with one crankshaft that forms a V shape known as V-type engine.
3.Opposed Cylinder Engine - An engine with two cylinders banks opposite
to each other on a single crankshaft (V-type engine with 180-degree angle
between banks).
4. W-type Engine - An engine same as a V-type engine except with three
banks of cylinders on the same crankshaft known as W-type engine.
5.Opposite Piston Engine - In this type of engine, there are two pistons in
each cylinder with the combustion chamber in the center between the
pistons. In this engine, a single combustion process causes two power
strokes, at the same time.
6. Radial Engine - It is an engine with pistons positioned in a circular plane
around the central crankshaft. The connecting rods of pistons are connected
to a master rod which, in turn, connected to the crankshaft.
BASIC PARTS OF THE ENGINE
1.Intake Valve - Opens at the proper time to let in air and fuel.
2.Valve Cover - Protects the valves and the valve springs. Keeps dirt out
and lubricating oil in.
3.Intake Port- Doorway that lets the gases in and out of the engine.
4.Cylinder Head - A platform containing most of the parts of the
combustion chamber. Forms the top of the combustion chamber. Contains
the valves, the passageways for the fuel mixture to move in and out of the
engine.
5.Coolant- Circulating water and antifreeze to keep the temperature
regulated.
6.Engine Block - Cast in one piece. The basis for most of the parts of the
engine.
7.Oil Pan - Where the oil is collected and recirculated.
8.Oil Sump - The collected oil primarily for lubricating the crankshaft and
rod bearing.
9.Camshaft - A round shaft with lobes, that rotates to open and close the
fuel and exhaust valves. Using an eccentric, the cam lobes push the valves
open. The valve springs close them.
10.Exhaust Valve - Open at the proper time to release the exhaust.
11.Spark Plug - A device inserted into the combustion chamber for firing an
electrical spark to ignite air-fuel mixture.
12.Injector (For Diesel) - Fuel injection is a system for admitting fuel into
an internal combustion engine(Diesel Engine)
13.Piston- the part of the engine that moves up and down in the cylinder
converting the gasoline into motion
14.Piston Rings - The rings seal the compression gases above the piston
keep the oil below the piston rings.
15.Piston Pins - Also known as the wrist pin, it connects the piston to the
small end of the connecting rod. It transfers the force and allows the rod to
swing back and forth.
16.Connecting Rod- Links - The Piston to The Crankshaft.
17.Rod Bearing- Used to reduce friction to the rod and crankshaft
18.Crankshaft - converts the up and down motion of the piston into a
turning, or rotating motion. Along the piston pin and connecting rod it
converts the up and down motion (reciprocating) of the engine to spinning
(rotary) motion.
Two Stroke & Four stroke Engine
Stroke- Reciprocating motion, used in reciprocating engines and other
mechanisms, is back- and-forth motion. Each cycle of reciprocation consists
of two opposite motions: there is a motion in one direction, and then a
motion back in the opposite direction.

During an engine’s combustion cycle, the piston moves up and down within
the cylinder. The terms “top dead center” (TDC) and “bottom dead
center” (BDC) refer to the piston’s position within the cylinder.

TDC is its position nearest to the valves

BDC is its position furthest from them.

A combustion revolution or combustion cycle is the complete process of

gas and air being sucked into the piston, igniting it, and expelling the
exhaust:

 Intake: The piston moves down the cylinder allowing a mixture of furl
and air into the combustion chamber
 Compression: The piston moves back up the cylinder; the intake
valve is closed to compress the gasses within
  Combustion: A spark from the spark plug ignites the gas
 Exhaust: The piston goes back up the cylinder and the exhaust valve
is opened

Two Stroke/two-cycle, engine is a type of internal combustion engine

which completes a power cycle with two strokes (up and down movements)
of the piston during only crankshaft revolution. A two-stroke engine performs
all the same steps, but in just two piston strokes. The simplest two-stroke
engines do this by using the crankcase and the underside of the moving
piston as a fresh charge pump. Such engines carry the official name
"crankcase-scavenged two-strokes."

 Intake: Fuel and air mix is drawn into the crank case by vacuum and
then into the cylinder.
 Compression: Fuel air mix is then compresses inside the cylinder.
 Power: Fuel air mix is ignited forcing the piston down exposing the
exhaust port.
 Exhaust The exhaust gases are forced out by the incoming fuel air
mix.

Four Stroke: In a 4-stroke engine, the piston completes 2-strokes during

each revolution: one compression stroke and one exhaust stroke, each being
followed by a return stroke. The spark plugs fire only once every other
revolution, and power is produced

every 4-strokes of the piston. These https://www.britannica.co/technology/four-stroke-

cycle
engines also do not require pre-mixing of
fuel and oil, as they have a separate compartment for the

 Intake stroke: Piston moving down Intake valve open Exhaust valve
closed
  Compression stroke: Piston moving up Intake valve closed Exhaust
valve closed
 Power stroke: Piston moving down Intake valve closed Exhaust valve
closed
 Exhaust stroke: Piston moving up Intake valve closed Exhaust valve
open

Difference between 2 Stroke vs 4 Stroke Engine

2Stroke 4Stroke
 Cycle - 1 rev & 2 strokes  Cycle-2rev & 4strokes
 1 power stroke per Rev.  1 Power stroke per 2 Rev
 Ports  valves
 Simple, light weight, low cost  Complicated, heavy
 More power for same size  costly
engine  Less power
 Piston shape –crown  Flat piston
 Less efficiency  More efficiency
 E.g., mopeds, scooters  Cars, bikes,trucks,buses
DIESEL GENERATOR is the combination of a diesel engine with an electric
generator to generate electrical energy. This is a specific case of engine-
generator. A diesel compression-ignition engine is usually designed to run on
diesel fuel, but some types are adapted for other liquid fuels or natural gas.
GENERATOR SET – sometimes called ‘a genset’ is a unit of equipment built
up of an engine, an electric generator (alternator) to generate electrical
energy from a fuel.

How does a Diesel Generator create Electricity?

A diesel generator converts mechanical energy (movement) into electrical
power and channels it through power cables. It can be helpful to imagine
electricity flowing through wires in much the same way water flows through
pipes. A generator can be thought of as a kind of ‘electrical pump’ which
causes the electricity to flow through the wires. It doesn’t create or destroy
the electrons that flow through the wires any more than a water pump
creates new water. It just causes it to move in a useful fashion.

3 Types of Generators

1 Portable Generator A portable generator is powered by gas or diesel fuel

and can provide temporary electrical power.

Here are some characteristics to note about these types of

generators:

 Uses a combustion engine to conduct electricity.

 Can plug into electrical appliances or tools via its sockets.
 Can be wired into a facility’s subpanels.
 Can be used in remote sites.
 Has enough power to run a television, freezer and refrigerator.
 The engine should run at 3600 rpm to render the standard 60hz of
current.
 Use a governor to control the engine’s speed.
 Can power tools and lights.
2.Inverter Generator An inverter generator uses an engine connected to
an alternator to produce AC power. It also uses a rectifier unlike other
generators to convert the AC power into DC power.

Here are some characteristics to note about these types of

generators:
 Relies on high-tech magnets.
 Uses advanced electronic circuitry.
 Undergoes three phases to produce electricity.
 Outputs AC current, convert it to DC current and finally invert
it to AC.
 Maintains a constant flowing of current to an appliance.
 Is more energy-efficient, as the engine speed adjusts itself
according to how much power is needed.
 Its AC can be set to any voltage and frequency when used
with proper equipment.
 Tends to be little and lightweight.
 Can fit into a car, RV or boat.

3.Inverter Generator An inverter generator uses an engine connected to

an alternator to produce AC power. It also uses a rectifier unlike other
generators to convert the AC power into DC power.

Here are some characteristics to note about these types of

generators:
 Relies on high-tech magnets.
 Uses advanced electronic circuitry.
 Undergoes three phases to produce electricity.
 Outputs AC current, convert it to DC current and finally invert it
to AC.
 Maintains a constant flowing of current to an appliance.
 Is more energy-efficient, as the engine speed adjusts itself
according to how much power is needed.
 Its AC can be set to any voltage and frequency when used with
proper equipment.
 Tends to be little and lightweight. Can fit into a car, RV or boat

Best Generator for Different Outages

 Generator Type Best Use

Portable Generator Refrigerators, spray gun systems, nail guns

Inverter Generator Car batteries, laptops

Standby Generator Emergency settings, hospital machinery

Generator maintenance requires:

 Annual fuel cleaning and filtering, as diesel fuel degrades quickly. After a few
weeks of operation, diesel fuel degrades via contamination of water and
microbes, resulting in clogged fuel lines and filters. Fuel cleaning involves using
biocides annually in all generators except for the standby generator, in which it
will attract moisture.

 The cooling system to be maintained, which requires checking the coolant level
at existing intervals. This must be done during shutdown periods.

 Checking for battery power; this is especially true for standby generators, as
battery issues are their primary cause of failure. Make sure the batteries are
robust and charged enough to last long so as to not incur any start-up hitches for
the generator.

 Regular testing to inform of the battery’s current status. Testing involves

checking the electrolyte levels and specific gravity of the batteries. The batteries
themselves also must be clean.

Main Components of a Generator

 Engine
 Alternator
 Fuel System
 Voltage Regulator
  Cooling and Exhaust Systems
 Lubrication System
 Battery Charger
 Control Panel
 Main Assembly / Frame https://www.adeltd.co.uk/blog/how-does-an-electric-generator-work.php

Engine- The engine is the source of the input mechanical energy to the generator. The
size of the engine is directly proportional to the maximum power output the generator
can supply. There are several factors that you need to keep in mind while assessing the
engine of your generator. The manufacturer of the engine should be consulted to obtain
full engine operation specifications and maintenance schedules.

Alternator- The alternator, also known as the ‘gen

head’, is the part of the generator that produces the
electrical output from the mechanical input supplied
by the engine. It contains an assembly of stationary
and moving parts encased in a housing. The
components work together to cause relative
https://www.linquip.com/blog/alternator-vs-
movement between the magnetic and electric fields, generator/

which in turn generates electricity.

 Stator – This is the stationary

component. It contains a set of
electrical conductors wound in
coils over an iron core.
 Rotor / Armature – This is the
moving component that produces
a rotating magnetic. https://www.electrician-1.com/2020/07/difference-
between-stator-rotor.html
Fuel System- The fuel tank usually has sufficient
capacity to keep the generator operational for 6 to
8 hours on an average. In the case of small
generator units, the fuel tank is a part of the
generator’s skid base or is mounted on top of the
generator frame. For commercial applications, it https://www.generatorsource.com/
How_Generators_Work.aspx
may be necessary to erect and install an external
fuel tank.

Common features of the fuel system include the following:

Pipe connection from fuel tank to engine – The supply line directs fuel from the tank
to the engine and the return line directs fuel from the engine to the tank.
Ventilation pipe for fuel tank – The fuel tank has a ventilation pipe to prevent the
build-up of pressure or vacuum during refilling and drainage of the tank. When you refill
the fuel tank, ensure metal-to-metal contact between the filler nozzle and the fuel tank
to avoid sparks
Overflow connection from fuel tank to the drain pipe – This is required so that any
overflow during refilling of the tank does not cause spillage of the liquid on the generator
set.
Fuel pump – This transfers fuel from the main storage tank to the day tank. The fuel
pump is typically electrically operated.
Fuel Water Separator / Fuel Filter – This separates water and foreign matter from the
liquid fuel to protect other components of the generator from corrosion and
contamination.
Fuel Injector – This atomizes the liquid fuel and sprays the required amount of fuel into
the combustion chamber of the engine.

Voltage Regulator- this component regulates the output voltage of the generator. The
mechanism is described below against each component that plays a part in the cyclical
process of voltage regulation.
 1. Voltage Regulator: Conversion of AC Voltage to DC Current – The voltage
regulator takes up a small portion of the generator’s output of AC voltage and
converts it into DC current. The voltage regulator then feeds this DC current to a
set of secondary windings in the stator, known as exciter windings.
2. Exciter Windings: Conversion of DC Current to AC Current – The exciter
windings now function similar to the primary stator windings and generate a
small AC current. The exciter windings are connected to units known as rotating
rectifiers.

3. Rotating Rectifiers: Conversion of AC Current to DC Current – These rectify

the AC current generated by the exciter windings and convert it to DC current.
This DC current is fed to the rotor / armature to create an electromagnetic field in
addition to the rotating magnetic field of the rotor / armature.
4. Rotor / Armature: Conversion of DC Current to AC Voltage – The rotor /
armature now induces a larger AC voltage across the windings of the stator,
which the generator now produces as a larger output AC voltage.

Cooling & Exhaust System

a. Cooling System - Continuous usage of the generator causes its various

components to get heated up. It is essential to have a cooling and
ventilation system to withdraw heat produced in the process.
b. Exhaust System - Exhaust fumes emitted by a generator are just like
exhaust from any other diesel or gasoline engine and contain highly toxic
chemicals that need to be properly managed. Hence, it is essential to
install an adequate exhaust system to dispose of the exhaust gases. This
point cannot be emphasized enough as carbon monoxide poisoning
remains one of the most common causes for death in post hurricane
affected areas because people tend to not even think about it until it’s too
late.
Lubricating System- Since the generator comprises moving parts in its engine, it
requires lubrication to ensure durability and smooth operations for a long period of time.
The generator’s engine is lubricated by oil stored in a pump. You should check the level
of lubricating oil every 8 hours of generator operation. You should also check for any
leakages of lubricant and change the lubricating oil every 500 hours of generator
operation.

Battery Charger- The start function of a generator is battery-operated. The battery

charger keeps the generator battery charged by supplying it with a precise ‘float’
voltage. If the float voltage is very low, the battery will remain undercharged. If the float
voltage is very high, it will shorten the life of the battery. Battery chargers are usually
made of stainless steel to prevent corrosion. They are also fully automatic and do not
require any adjustments to be made or any settings to be changed. The DC output
voltage of the battery charger is set at 2.33 Volts per cell, which is the precise float
voltage for lead acid batteries. The battery charger has an isolated DC voltage output
that does interfere with the normal functioning of the generator.

Control Panel- This is the user interface of the generator and contains provisions for
electrical outlets and controls. The following article provides further details regarding the
generator control panel.

Different manufacturers have varied features to offer in the control panels of their units.
Some of these are mentioned below.

a. Electric start and shut-down – Auto start control panels automatically start
your generator during a power outage, monitor the generator while in
operation, and automatically shut down the unit when no longer required.
b. Engine gauges – Different gauges indicate important parameters such as oil
pressure, temperature of coolant, battery voltage, engine rotation speed, and
 duration of operation. Constant measurement and monitoring of these
parameters enables built-in shut down of the generator when any of these
cross their respective threshold levels.
c. Generator gauges – The control panel also has meters for the measurement
of output current and voltage, and operating frequency.
d. Other controls – Phase selector switch, frequency switch, and engine control
switch (manual mode, auto mode) among others.

Main Assembly/Frame- All generators, portable or stationary, have customized

housings that provide a structural base support. The frame also allows for the generated
to be earthed for safety.

EMERGENCY GENERATOR on ship provides power in case the main generator of the
ship fails and creates a “dead or blackout condition”. According to general
requirement, at least two modes of starting an emergency generator should be
available. The two modes should be – battery start and hydraulic or pneumatic start.

Testing of Emergency Generator- The testing of ship’s emergency generator is done

every week (as part of weekly checks) by running it unloaded to check if it starts on
battery mode. The hydraulic start is done every month to ensure that it is working
fine. Also, every month automatic start of generator is also done to check its
automatic operation and to see whether it comes on load.

Procedure for Battery Start

1. Go to the emergency generator room and find the panel for emergency
generator.
2. Put the switch on the test mode from automatic mode. The generator will start
automatically but will not come on load.
3. Check voltage and frequency in the meter.
 4. Keep the generator running for 10-15 min and check the exhaust temp and other
parameters.
5. Check the sump level.
6. For stopping the generator, put the switch in manual and then stop the generator.

Procedure for Hydraulic Start

1. Out the switch in manual mode as stated above and check the pressure gauge
for sufficient oil pressure.
2. Open the valve from accumulator to generator.
3. Push the spring loaded valve and the generator should start.
4. Check voltage and frequency.
5. Keep the generator running for 10-15 min and check the exhaust temp and other
parameters.
6. Check the sump level
7. For stopping, use the manual stop button from the panel.
8. After stopping the generator, pressurize the hydraulic accumulator to desired
pressure.
9. Close the valve from accumulator to generator.

Procedure for Automatic Start

1. For automatic start, we know that there is a breaker which connects Emergency
Switch Board (ESB) and Main Switch Board (MSB); and there is also an interlock
provided due to which the emergency generator and Main power of the ship
cannot be supplied together.

2. Therefore, we simulate by opening the breaker from the tie line, which can be
done from the MSB or the ESB panel.

3. After opening the breaker, the emergency generator starts automatically with the
help of batteries and will supply essential power to machinery and pumps
connected to ESB.
 4. For stopping the generator, the breaker is closed again and due to the interlock
the generator becomes off load.

5. Now again put the switch to manual mode to stop the generator.

6. Press stop and the generator will stop.

8 Important Points to Note For Maintenance Of Emergency Generators On Ship

1. Change of Engine Sump Oil: It is important to check the oil level in the
sump regularly. Since the emergency generator is kept on auto mode, which
ensures the generator starts and comes on load automatically, it is necessary
that before starting the engine for operation, oil level is checked on regularly
basis. The condition of the oil will be known during this period and if the oil is
having carbon or soot particles, change of complete oil system needs to be
done. The running hours for changing of engine oil depends on the
manufacturer, the engine make and the oil grade in use. Normally it is done
between 250-500 hrs.
The oil changing period must be cut by half when the fuel used in generator is
more than 0.5% to 1% sulfur.

2. Clean Air Cleaner: The combustion air for the engine is passed through an
air filter, which can be of following types:

 oil bath air cleaner

 dry type air cleaner (cartridge or dust collector)
 It is important to clean the air filter at correct intervals of time as delay will
lead to clogging and less air going in the engine. This will reduce the
efficiency of the engine and increase the thermal parameters. When using
dry cartridge, ensure to replace them at intervals stated by the maker.
Normal replacement schedule is one year or after 5-7 cleanings.

3. Check Water Separator: Some emergency generators are provided with

water separator to prevent mixing of water with fuel. Check the level of water
and make sure it is below the marked level and regularly drained off. This is
to be done to avoid rust and corrosion of fuel line devices and to avoid
incomplete combustion.

4. Check Electrolyte in the Battery: A battery is used in one of the starting

methods of the emergency generator. The electrolyte level in the battery must
be checked at regular intervals either by inserting a level stick or by checking
the water level in the level tester cap (if provided). Use distilled water to make
up for the low level.

5. Check Alarms and Shutdowns: All the safety devices and alarms fitted in
the emergency generator must be checked and tested regularly. Generator
with V-belts have additional alarm which will be sounded in the event of belt
failure and operated by idler pulley.

6. Check V belt Tension: When V belt is fitted, inspect the same for cracks
and damages. Renew the belt if damage/ cracking appearance is more. To
check the belt tension, press the belt by thumb in midway of the pulleys and
check the inward deflection in mm. It should not be more than 10-15 mm
depending upon the make of the generator.
7. Clean Oil Filter Cartridge: The emergency generator is provided with
various oil filters such as by pass filter, centrifuge filter, lube oil filter, fuel feed
pump filter etc. These filters need to be cleaned or renewal of filter cartridge
is to be carried out as per the maker’s instruction or oil condition.

8. Check Valve Clearance: The tappet clearance of the inlet and exhaust valve
should be checked at running hours stated in the maintenance section of the
generator’s manual. Also ensure the engine is cold before taking the tappet
clearance.