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Millwrong > Engines - Installation and Start-up > Flashcards

Engines - Installation and Start-up Flashcards

1
Q

What five factors should be considered when mounting industrial engines?

A
  • Size
  • Weight
  • Characteristics
  • Driven loads
  • Operating cycle of the machine

Each factor influences how the engine should be installed to ensure optimal performance.

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2
Q

What three problems can arise from inadequate engine foundation and mounting?

A
  • Machine misalignment
  • Machine and building vibration
  • Machine torsional stress

These issues can lead to operational inefficiencies and damage to machinery.

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3
Q

True or False: There is a single universal mounting system for all industrial engines.

A

False

Each engine must be mounted according to its specific application and requirements.

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4
Q

What is the role of vibration isolators in engine installations?

A

To isolate the engine from vibrations produced by other machinery

This helps to reduce noise and improve operational stability.

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5
Q

What are the two fundamental concerns in the foundation of any industrial engine?

A
  1. Prevent distortion of the engine block or base
  2. Ensure alignment of the crankshaft with the driven machine
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6
Q

What can happen to the crankshaft if the hold-down bolts are tightened to a deformed foundation?

A

The crankshaft can be forced into a bent position

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7
Q

Why must the driven machine be aligned to the engine crankshaft?

A

The load must be aligned to the engine crankshaft to ensure proper operation

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8
Q

What is the consequence of a base that is not strong enough or that moves?

A

It causes misalignment between the machines

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9
Q

What effect does misalignment due to a poor foundation have on the engine structure?

A

It results in stresses on the engine structure, potentially leading to component damage

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10
Q

What should the mass of the foundation be in relation to the complete engine?

A

At least 2½ times the mass of the complete engine

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11
Q

Fill in the blank: A foundation must rest on an adequate _______.

A

Base

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12
Q

True or False: A strong foundation can help prevent catastrophic failure of coupled machines.

A

True

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13
Q

What can result from stresses on the engine structure due to misalignment?

A

Component damage of the coupled machines

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14
Q

What is the importance of the foundation in relation to installation problems?

A

A well-constructed foundation reduces the likelihood of installation problems

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15
Q

What separates the engine foundation from the building in a properly engineered installation?

A

Isolators, usually wood or rubber separators about ¾ inches thick

These isolators are placed between the building foundation and the engine mounting block (inertia block).

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16
Q

Why is it better to isolate each engine foundation from others in a building?

A

It reduces the possibility of vibration transfer from one engine to another

This isolation helps in minimizing potential problems related to vibrations.

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17
Q

What is a major concern regarding the engine foundation throughout its life?

A

The integrity of the engine foundation

Protecting the foundation is crucial as regrouting or refurbishing it is time-consuming and costly.

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18
Q

What can cause premature deterioration of the engine foundation?

A

Impregnation with oil or water

This is a major cause of foundation failure.

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19
Q

What is the best preventive measure for protecting the engine foundation?

A

Use a high quality concrete sealer on the entire engine foundation

This helps in preventing deterioration due to oil or water.

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20
Q

What must be ensured regarding the expansion of the engine foundation?

A

It must be allowed to expand freely and evenly along with the machine

This ensures that the foundation does not become stressed or damaged.

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21
Q

Fill in the blank: The engine must be mounted so that the oil reservoir does not contact the _______.

A

foundation

This is important to prevent potential issues related to oil contamination.

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22
Q

What should you inspect on the entire engine during installation?

A

Damage, loose connections, broken or sharply bent lines, loose nuts or bolts

Ensuring all engine components are intact is crucial for safe operation.

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23
Q

What types of openings on the engine should be checked for foreign objects?

A

Intake, exhaust, water, fuel lines

Openings without coverings can allow debris to enter the engine, potentially causing damage.

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24
Q

What does it mean if the engine has abnormal resistance to rotation?

A

It may indicate rust or corrosion causing seizure

Seizure may require engine disassembly to resolve.

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25
Q

True or False: The engine should be checked for free cranking.

A

True

Free cranking is essential to ensure the engine operates smoothly.

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26
Q

Fill in the blank: All openings on the engine that do not have a covering should be checked for the presence of _______.

A

foreign objects

This is vital to prevent damage to the engine.

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27
Q

What is the purpose of the concrete mass in the foundation of an engine?

A

Acts as an inertia block to absorb vibration and minimize flexing

It also changes the natural frequency of the installed unit.

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28
Q

What should be included in the foundation to facilitate service?

A

Openings for proper service piping and engine components

These openings are essential for maintenance and operation.

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29
Q

What is a key requirement for a good foundation in engine installation?

A

Sufficient clearance for proper alignment of machine components and thermal expansion

This ensures that the engine operates effectively under varying temperatures.

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30
Q

What type of rigidity should a base have in engine installations?

A

Adequate torsional rigidity

This prevents misalignment of the engine due to twisting from load.

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31
Q

List the basic types of engine mounting.

A
  • Skid-mount
  • Block-mount (inertia mounted)
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32
Q

What is the most common engine mounting method?

A

Skid-mount

This method is particularly effective for smaller engines.

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33
Q

How can skids in permanent installations be made more rigid?

A

By pouring concrete or grout into the cavity of the skid

However, this framework may still distort during loading and off-loading.

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34
Q

What must be ensured during the installation of skid-mounted engines?

A

The unit must be properly levelled and aligned

This is crucial to prevent operational issues.

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35
Q

What is a block-mounted engine?

A

An engine mounted on a large concrete foundation with the driven unit on the same foundation.

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36
Q

What are two advantages of block-mounted engines?

A
  • Staying in alignment
  • Dampening vibrations from the machinery.
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37
Q

What two factors influence the size, mass, and shape of the concrete foundation for block-mounted engines?

A
  • Soil conditions
  • Mass of the engine.
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38
Q

How does the size of the foundation affect its ability to absorb vibrations?

A

The larger foundation, the better it absorbs vibratory impulses.

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39
Q

What happens when the vibratory impulses from the engine match the natural frequency of the foundation?

A

The vibration becomes excessive and can cause serious damage to the machinery.

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40
Q

Why is the foundation of the engine usually isolated from the building foundation?

A

To prevent vibrations from other machines from being transferred to the engines.

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41
Q

What is recommended for the construction of foundation blocks to ensure strength?

A

Foundation blocks should be cast in a continuous pour with steel reinforcement inside.

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42
Q

What is the purpose of combining block mount and skid mount installations?

A

To provide the rigidity of the block mount and the flexibility of the skid.

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43
Q

Why is skid mount preferred for packaging by manufacturers?

A

It is easier for the manufacturer to package.

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44
Q

In what types of packages is skid mounting commonly used?

A
  • Engine packages
  • Compressor packages
  • Generator sets
  • Pumping packages.
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45
Q

True or false:

A block mount engine installation is the same as an inertia mount.

A

True

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46
Q

On a block mount installation, what must the engine be fastened to?

A

The foundation with anchor bolts

Ensures stability and prevents movement.

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47
Q

What should be selected to avoid problems later during installation?

A

The installation method with anchor bolts

Proper selection is crucial for long-term performance.

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48
Q

Which type of bolts should be avoided due to low holding power?

A

J bolts

They also have direct contact with concrete, leading to deterioration.

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49
Q

What type of foundation bolts allows some flexibility for installation?

A

Piped anchor bolts;

A.K.A Vertical style foundation bolts with a pipe around them

They are filled with grout for added rigidity.

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50
Q

What is a benefit of boxed foundation bolts?

A

The bolt can be changed through access to the bottom of the bolt

Facilitates maintenance and replacement.

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51
Q

True or False: J bolts are recommended for their high holding power.

A

False

J bolts have low holding power and can deteriorate prematurely.

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52
Q

Identify the following fasteners and rate them from best to worst for as a hold-down bolt:

A

Left = J-bolt ⟶ worst
Middle = piped anchor bolt ⟶ good
Right = boxed anchor bolt ⟶ best

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53
Q

What are sole plates?

A

Load-bearing steel plates grouted into the foundation around the mounting areas of the engine

Sole plates can also be welded onto the skin of the engine.

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54
Q

What is the purpose of sole plates?

A

To provide a flat surface for shims and support the engine during adjustments

They are critical for engine alignment and stability.

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55
Q

What is a shim?

A

A device used to make fine adjustments between the sole plate and the engine base

Shims help correct crankshaft deflections and adjust engine height.

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56
Q

List three purposes of using shims.

A
  • Straighten the engine base to correct crankshaft deflections
  • Remove soft legs on the engine mounting positions
  • Lift or lower the whole engine for shaft alignment
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57
Q

What materials are commonly used to make shims?

A
  • Stainless steel
  • Brass
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58
Q

True or False: The number of shims used should be maximized.

A

False

59
Q

What should be considered when selecting materials for shims?

A

Materials that do not rust

60
Q

What is the role of jacking screws in relation to sole plates?

A

They bear on the sole plates to lift the engine when shimming

61
Q

True or false:

Chock can be made of steel or vibration dampening elastomers.

A

True;

Chock is a grouted shim

62
Q

What are three common methods for moving large engines into place?

A
  1. large cranes ⟶ lift the whole unit
  2. rolling the engine into positon with pipe rollers
  3. lifting the engine with hydraulic jacks
63
Q

What are four reasons epoxy grouts very popular when comapred to cement based grouts?

A

*easy to use
* very strong
* resistant to most fluids
* seal the foundation

64
Q

When using a deflection gauge on crankshaft webs, what does a deflection reading indicate?

A

That the crankshaft is bent, and in which direction

If the gauge reads a positive reading, it is bent towards the gauge, and if the gauge reads a negative reading it is bent away from the gauge

65
Q

What does a deflection gauge indicate about the crankshaft alignment if there is no deflection measured?

A

That the crankshaft and bearing bores are exactly aligned

66
Q

What is the procedure for taking crankshaft deflections?

A

Deflections can be taken with the engine rods in place or with the pistons and rods removed

67
Q

Which method is easier for taking deflection readings?

A

Taking deflection readings without the rods in place

68
Q

Why might it be more work to take deflection readings without the rods?

A

It takes much more work to get to that point, typically done during an overhaul

69
Q

How does removing the rods affect the crankshaft deflections?

A

It changes the weight of the engine and can affect the true deflections

70
Q

What limitation exists when taking deflections with the rods in place?

A

The engine cannot rotate a full 360°

71
Q

In how many positions are crankshaft deflections taken with the rods in place?

A

Ideally five positions

72
Q

What positions should deflections be taken at when the rods are not on the crank?

A

At the 12:00, 9:00, 6:00, and 3:00 positions

73
Q

Fill in the blank: Crankshaft deflections can be taken at the _______ positions when the crankshaft is removed.

A

12:00, 9:00, 6:00, and 3:00

74
Q

True or False: Deflection readings can be accurately taken at any position without the rods.

A

False

75
Q

What are the detrimental effects of excessive deflection on engine life?

A

Can lead to overheating and failure of bearings, breaking of crankshaft, and alignment issues

Excessive deflection affects the integrity and performance of engine components.

76
Q

What happens to bearing clearances due to excessive deflection?

A

They can be reduced to the point where the bearings overheat and fail

This can significantly shorten the lifespan of the bearings.

77
Q

What can excessive and continual flexing of the crankshaft cause?

A

It can break the crankshaft

This is critical as the crankshaft is a major component in engine functionality.

78
Q

What is a common problem associated with excessive deflections or alignment issues?

A

Short coupling life

Proper alignment is essential for the longevity of couplings in engine systems.

79
Q

True or False: Accurate alignment between the engine and load can be achieved despite excessive deflection.

A

False

Excessive deflection prevents accurate alignment, leading to operational issues.

80
Q

True or false:

Excessive engine crankshaft deflection may not affect performance until the point where failure is reached.

A

True

81
Q

True or false:

Installation of an engine in a building should include a well-planned arrangement of the instrumentation, fuel, cooling, intake and exhaust and ventilation systems.

A

True

82
Q

Piping should be pickled after it is welded together. What is this?

A

Running an acid bath through the pipe and then completely cleaning it before it is attached to the sytem

It is a recommended practise when plumbing in external oil filters and oil coolers due to the possibility of welding slag, pipe thread debris or nay other contaminant that may go through the engine.

83
Q

How should stationary engine exhaust piping be supported?

A

With independent supports

84
Q

What should be added to a stationary engines exhaust piping to isolate vibration and allow for thermal expansion?

A

Flexible steel pipe

This allows helps to keep weight off of the engine.

85
Q

What issue can arise if engine exhausts are combined into one?

A

Exhaust gas from a running engine can enter an engine that is shutdown.

This can cause condensation or soot buil-up in the stopped engine, resulting in damage.

86
Q

True or false: Multiple engines can share the same exhaust system.

A

False

Every engine must have it’s own exhaust system.

87
Q

True or false: The inlet of an engine room ventilation system should come from a lower source, and the outlet should be at the highest point of the engine room.

A

True

This allows for a good exchange of air within the room.

88
Q

If there is a choice of air cleaners on an engines intake air system, paper air cleaners are preferred. Why is this?

A

Efficiency

Paper air cleaners are 99% efficient.

89
Q

What is the purpose of a prelube oil pump in a lubrication system?

A

To ensure that all oil galleries are full of oil before engine rotation occurs and to fill oil filters and lines after an oil change.

A prelube oil pump can be driven by either an electric or a pneumatic motor.

90
Q

What is a duplex oil filter system?

A

A system that allows filter changes while the engine is running at full load.

This system helps maintain oil cleanliness without stopping the engine.

91
Q

What is the function of oil heaters in a lubrication system?

A

To assist with cold starting applications and for standby engine systems that need to drive a load immediately after starting.

Oil heaters prevent oil from becoming too viscous in cold temperatures.

92
Q

What types of filters can be used as remote supplementary bypass filters?

A
  • Centrifugal filters
  • Absorptive filters made of cotton or cellulose fibres

Centrifugal filters remove solids, while absorptive filters absorb acids, moisture, and contaminants.

93
Q

True or False: A prelube oil pump operates after engine rotation begins.

A

False.

The prelube oil pump operates before any engine rotation occurs.

94
Q

Fill in the blank: Duplex oil filter systems allow filter changes while the engine is running at _______.

A

Full load

95
Q

What is the role of remote supplementary bypass filters in larger engines?

A

To remove solids and absorb contaminants from the oil.

These filters enhance the overall oil quality and extend engine life.

96
Q

What are some conditions that can be considered an initial start-up of an engine?

A
  1. Engine started for the first time after leaving the factory
  2. Engine out of operation for an extended period
  3. Engine moved to a new location
  4. Engine had major reconditioning or major part repaired/replaced

These conditions indicate that the engine is in a state where it requires careful handling before operation.

97
Q

What process is done to the engine before it leaves the factory?

A

The engine is rust proofed on both the inside and outside, including the lubrication system.

This rust proofing ensures that the engine oil remains uncontaminated.

98
Q

What method can be used when the engine is put into storage?

A

A mist of oil is sprayed into the engine, and all intake inlet and exhaust openings are covered along with other protective measures.

This helps to protect the engine from rust and damage during storage.

99
Q

When preparing to start an engine that has been sitting for a long time, what should be performed?

A

Crank the engine over by hand.

These checks ensure the engine is safe and ready for operation after a long period of inactivity.

100
Q

True or false: Ideally, engines should be started with the load disconnected.

A

True

101
Q

What are the initial checks to perform before starting big engines?

A

Check for obstructions in the inlet and exhaust system

These systems may have been taped closed and should be cleared of any coverings.

102
Q

What should be done if an engine does not have a prelube oil pump?

A

Remove the turbocharger oil inlet line and pour clean engine oil into the turbocharger bearing cavity

This ensures that the bearings are not starved for oil when the engine is first started.

103
Q

What is the correct procedure for filling the engine oil sump?

A

Fill to the correct level with the proper engine oil

You may need to change the oil and filters if the engine has been down for an extended period.

104
Q

What should be lubricated during the start-up checks?

A

Governor, throttle linkage, and any other exposed linkage

This helps ensure smooth operation during engine start-up.

105
Q

What is necessary for the engine’s cooling system before starting?

A

Fill with a clean coolant mixture and vent the thermostat housing

This prevents air from being trapped in the engine block or cylinder heads.

106
Q

What should be done to the valve stems before starting the engine?

A

Remove valve covers and lubricate the valve stems

Run the pre-lube pump to check if oil reaches the valve train.

107
Q

What should be checked after removing the side doors of the engine?

A

Observe if oil is travelling to the main and connecting rod bearings

This indicates proper lubrication before starting the engine.

108
Q

What should be done with the decompression valves or spark plugs before starting the engine?

A

Open the decompression valves or remove the spark plugs

Bar the engine over several times by hand to ensure it turns freely.

109
Q

After ensuring the engine turns freely, what is the next step?

A

Use the starting system to turn the engine over again and reinstall the spark plugs

This prepares the engine for starting.

110
Q

What is the purpose of priming the fuel lines in a diesel engine?

A

To remove any air from the fuel lines

This is typically done using a plunger pump, button pump, or lever pump.

111
Q

What should be monitored when starting up a diesel engine?

A

The governor holding the fuel valve fully open

This ensures that the engine receives the necessary fuel for proper operation.

112
Q

On initial engine start-up, what steps should be taken after running the engine for a few minutes?

A

Monitor gauges, check for leaks, noises, and vibration, then shut it down

Followed by checking for hot spots on main bearings or connecting rods.

113
Q

How can hot spots be checked if the engine lacks doors?

A

Using a thermometer along the side of the engine

This should be done in the relative location of the bearings.

114
Q

What should be done if all checks yield satisfactory results?

A

Reinstall engine covers and start up the engine again

This includes warming up and loading the engine.

115
Q

What types of systems are typically included in engine installations?

A

Instrumentation, shut-off systems, and alarm systems

Each system varies in sophistication based on the engine and process.

116
Q

What should be confirmed regarding instrumentation before starting the engine?

A

That all instruments are present, connected, and functional

This may require verification by the appropriate technician.

117
Q

What are some examples of shut-off systems in diesel engines?

A
  • Low oil pressure
  • Low coolant levels
  • High-temperature shutdown
  • Over speed shutdown
  • High vibration shutdown

These systems should be checked for proper operation and settings.

118
Q

What types of alarm systems may be installed in hazardous engine installations?

A
  • Flash detectors
  • Fire detectors
  • Smoke detectors
  • Hazardous gas detectors

Technicians should check these systems, especially those with automatic firefighting equipment.

119
Q

True or False: It is important to avoid accidentally activating automatic firefighting equipment in engine installations.

A

True

This is crucial to prevent unnecessary disruptions or damage.

120
Q

Fill in the blank: The governor holds the fuel valve ______ during engine startup.

A

Fully open

121
Q

What is the most important engine gauge to observe during an engine start-up?

A

The oil pressure gauge

122
Q

What should be done before starting an engine that has been recently running?

A

Bar the engine over to make sure it turns freely

This checks for any potential issues like water leaks into the cylinder that could cause hydrostatic lock.

123
Q

What can cause hydrostatic lock in an engine cylinder?

A

Accumulation of water or other fluids

Hydrostatic lock can bend the connecting rod, break the piston, lift the head off, or crack the cylinder liner.

124
Q

What is the purpose of turning the pre-lube pump on before starting the engine?

A

To ensure bearings receive proper lubrication

This helps protect the engine components during the initial start.

125
Q

How long should the engine be cranked with the ignition off before starting?

A

About 15 seconds

This step purges any gases that may be in the cylinders.

126
Q

What position should the ignition be in when starting to crank the engine?

A

On position

This is necessary to allow the engine to start after cranking.

127
Q

How far should the fuel valve be opened initially when cranking a natural gas engine?

A

About ½ open

This helps provide enough fuel for the engine to fire.

128
Q

What should be monitored during the initial warm-up period of the engine?

A

Oil pressure, water pressure, and all other engine conditions

Monitoring these conditions ensures the engine is operating correctly.

129
Q

What is the correct method to shut down a natural gas engine?

A

Turn off the fuel valve

Never shut off the engine by other means to avoid leaving the gas valve open.

130
Q

True or False: It’s safe to shut off a natural gas engine by any means other than turning off the fuel valve.

A

False

Shutting off the engine improperly can lead to dangerous situations, including fuel gas filling the cylinders and crankcase.

131
Q

Fill in the blank: If water leaks into the cylinder, it may cause _______.

A

hydrostatic (hydraulic) lock

This condition can lead to severe engine damage.

132
Q

What should be done as a natural gas engine begins to gain speed after starting?

A

Shut off the cranking motor and gradually open the fuel valve to full open position

This allows the engine to operate efficiently after starting.

133
Q

What is the recommended operation for the engine after starting?

A

Run it at low speed with no load for a few minutes

This helps to warm up the engine properly before applying load.

134
Q

When starting a natural gas engine, with the ingnition in the off position, crank the engine over for about ________ seconds to purge any gases that jay be in the cylinders.

A

15 seconds

135
Q

When starting a natrual gas engine, with the ignition in the on position, start cranking the engine and then crack the fuel valve so that it is about ________ open.

A

1/8 open

Continue to crank the engine and open the fuel valve a further 1/4 turn open, at which point the engine should now have enough fuel to start.

136
Q

True or false:

If the crankshaft cannot be rotated completely to perform a web deflection check, measure the deflection at the three points, where access is unrestricted, then measure, on both sides of the connecting rod, as close to the final position as possible.

A

True

137
Q

What are two problems that could be caused by a faulty exhaust rain cap being stuck open.

A
  1. Hydrostatic lock
  2. Rust in the exhaust system
138
Q

What is an engine misfire?

A

When combustion does not take place in the cylinder

139
Q

True or false:

An oxygen sensor is commonly used to measure the oxygen content of the exhaust produced by a natural gas engine when setting up the AFR on the carburator for the first time.

A

True

140
Q

What colour is the exhaust of a diesel engine that has not warmed up when first started?

A

White

141
Q

What type of engine control system is best to use when the engine is located in a hazardous environment?

A

Pneumatic

142
Q

True or false:

Skid-mounted equipment must be levelled and aligned where it is to be attached to the foundation.

A

True

143
Q

True or false:

A shim is placed between the engine base and sole plate.

A

True

144
Q

True or false:

Engine buildings require proper ventilation if the intake and air cleaner are inside the building.

A

True

Millwrong (27 decks)

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