Q6 (16 Marks) Fuel Injection & Systems 🔥 Repeated 2x in exams
MEKM • Written Exam

During recent months a number of fuel injector needle valves have seized in their bodies during engine operation.

(a) Explain the effects on engine operation.

(b) State the possible causes.

(c) As Second Engineer, state with reasons, the instructions to be issued in order to minimize this problem:

Appeared In: Jun 2023Jul 2019

Verified Model Answer (Text Solution)

Structured for DG Shipping MEO Class II examination scoring criteria.

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Part (a)

Effects on engine operation of seized fuel injector needle valves (6 marks)

If a fuel injector needle valve seizes in its body during engine operation, the effects depend on whether it seizes open or closed:

  1. If the needle seizes open (stuck open): fuel flows continuously into the cylinder, causing over-fueling, very high combustion pressure, high exhaust temperature, and possible damage to the piston, liner, and cylinder head. The cylinder produces excessive power and the engine runs roughly, with a high exhaust temperature on that cylinder. It can also cause a relief valve to lift and, in severe cases, a scavenge fire or piston seizure.
  2. If the needle seizes closed (stuck closed): no fuel is injected into that cylinder, so the cylinder produces no power (misfiring). The exhaust temperature of that cylinder falls, the engine runs unevenly, and the other cylinders must carry the load, causing them to overheat. The engine loses power and runs roughly.

In both cases, the engine runs unevenly, with abnormal exhaust temperatures, vibration, and reduced efficiency, and there is a risk of serious damage if not corrected.

Part (b)

Possible causes of the seizure (5 marks)

  1. Poor fuel quality: fuel with high carbon residue, asphaltenes, or contaminants (catalytic fines, water) can cause carbon and deposits to build up on the needle, sticking it.
  2. Overheating of the injector: if the injector is not cooled properly (cooling water fault) or the fuel is too hot, the needle can overheat and seize.
  3. Incorrect fuel viscosity: fuel that is too viscous (not heated enough) or too thin can cause poor atomization and carbon build-up, sticking the needle.
  4. Wear or damage: wear of the needle and body, or damage from foreign material, can cause the needle to stick.
  5. Corrosion: water or corrosive products in the fuel can corrode the needle and body, causing sticking.
  6. Carbon build-up from prolonged low-load operation or poor combustion.
Part (c)

Instructions to be issued as Second Engineer to minimize this problem (5 marks)

As Second Engineer, I would issue the following instructions:

  1. Maintain the correct fuel temperature/viscosity at the injector (heat the fuel to the correct viscosity) to ensure good atomization and prevent carbon build-up.
  2. Ensure the injector cooling system is operating correctly (adequate cooling water flow and temperature) to prevent overheating.
  3. Use good-quality fuel and ensure proper purification (centrifugal separators) to remove water, sludge, and catalytic fines.
  4. Operate the engine at the correct load and avoid prolonged low-load operation (which causes carbon build-up); periodically run at higher load to burn off deposits.
  5. Carry out regular maintenance of the injectors (inspection, cleaning, and testing) at the recommended intervals.
  6. Monitor the exhaust temperatures and the injector condition; investigate any abnormal temperature or rough running immediately.
  7. Use the correct fuel for the engine and avoid mixing incompatible fuels.

These measures minimize the risk of injector needle seizure.

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