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A New Method of Identifying the Limit Condition of Injection Pump Wear in Self-Ignition Engines

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A New Method of Identifying the Limit Condition of Injection Pump Wear in Self-Ignition Engines energies Article A New Method of Identifying the Limit Condition of Injection Pump Wear in Self-Ignition Engines Artur Bejger * and Jan Bohdan Drzewieniecki * Department of Condition Monitoring & Maintenance of Machinery, Maritime University of Szczecin, 71-650 Szczecin, Poland * Correspondence: [email protected] (A.B.); [email protected] (J.B.D.); Tel.: +48-602368470 (A.B.) Received: 19 February 2020; Accepted: 20 March 2020; Published: 1 April 2020 Abstract: The quality or reliability of diagnostics is understood as obtaining the most likely diagnosis, and finding possible causes leading to incorrect operation of the system. In real engine running conditions it is often very difficult. Dependable methods providing the most reliable diagnoses have not been developed yet. It becomes more and more important to identify the limit state in condition monitoring—the state that should not be exceeded because continued operation of such a machine is not advisable for technical, economic, or operational safety reasons. The authors have implemented a method using acoustic emission signal analysis for the identification of the injection pump limit state in a working engine. The use of the cross gain function allows one to reliably diagnose limit conditions related to the wear of the precision pair in injection pumps of running engines, working as energy transmission systems on ships and in land-based power stations. The paper draws the results for two different marine diesel engines: two-stroke (by MAN B&W type 7S80MC-C) and four-stroke (by Wartsila type SW 380). The experiment results obtained indicate that the use of the cross gain function allows us to determine the limit condition for a various type of injection pump. Keywords: acoustic emission; diesel engines; cross gain function; condition monitoring; fuel injection pumps 1. Introduction The International Maritime Organization (IMO) policies changes related to the global control of emissions included in the International Convention for the Prevention of Pollution from ships: MARPOL-Annex VI, followed by IMO 2020 Sulphur Limit compliance with the 1 January, 2020 deadline, not only forced ship owners/ managers to comply with the provisions of the Convention, but above all, had an impact on far-reaching consequences on shipping company operating costs, global freight rates, low sulfur fuels or scrubber demands, accelerated ship scrappage, and more. It necessitated the use of fuel oils with low sulfur content called low-sulfur fuels, and in many cases, has ruled out the use of residual fuel to distillate fuels. Next, it is observed that the steadily deteriorating quality of fuel oils combined with increased content of catalytic additives (cat-fines) used in the refining processes of crude oil, caused the problem of the deterioration of working conditions in fuel system precision pairs. According to the literature [1] and the author’s own experience, it has become significant, with respect to, therefore, accelerated wear occurring in the fuel injectors and injection pumps, and then following, operational problems. In addition, as it follows from an analysis of operational reports and author research [2,3] that damage to injection systems, apart from poor quality fuel, is also caused by increasingly worsening quality of materials used for atomizers and spare parts of injection pumps (service life is almost half shorter compared to one or two decades ago). The damage to the injection system for medium size ships (length 200 to 250 m) accounts for approximately 50–70% [3]. Energies 2020, 13, 1601; doi:10.3390/en13071601 www.mdpi.com/journal/energies EnergiesEnergies 2020, 2020x, x FOR, x, x PEERFOR PEER REVIEW REVIEW 2 of 102 of 10 Energies 2020, 13, 1601 2 of 11 two twodecades decades ago). ago). The Thedamage damage to the to injectionthe injection syst emsyst forem medium for medium size sizeships ships (length (length 200 to200 250 to m)250 m) accounts for approximately 50–70% [3]. accountsThe inability for approximately to on-line diagnose 50–70% and [3]. monitor the condition of injection systems often leads to The inability to on-line diagnose and monitor the condition of injection systems often leads to secondaryThe damages, inability suchto on-line as a burnt, diagnose torn and off atomizer monitor nosethe condition or coking of of injection atomizer systems holes, as often shown leads in to secondary damages, such as a burnt, torn off atomizer nose or coking of atomizer holes, as shown in Figuresecondary1a, and damages, damages tosuch the as fuel a burnt, injector’s torn blownoff atomizer by seats nose and, or coking as a consequence, of atomizer damageholes, as toshown the in Figure 1a, and damages to the fuel injector’s blown by seats and, as a consequence, damage to the cylinderFigure head, 1a, and as shown damages in Figure to the1 b,c.fuel Theseinjector’s defects blown result by inseats improper and, as fuel a consequence, spray, or carbon damage deposit to the cylinder head, as shown in Figure 1b,c. These defects result in improper fuel spray, or carbon deposit on pistoncylinder ring head, grooves. as shown Consequently, in Figure 1b,c. sealing These rings defects get cracked,result in improper the crankshaft fuel spray, load is or uneven, carbon anddeposit on piston ring grooves. Consequently, sealing rings get cracked, the crankshaft load is uneven, and thison leads piston to more ring seriousgrooves. damage Consequent or failuresly, sealing of the rings entire get engine. cracked, the crankshaft load is uneven, and this leadsthis leads to more to more serious serious damage damage or failures or failures of the of entire the entire engine. engine. (a) (a) (b) (b) (c) (c) FigureFigureFigure 1. 1. TroubleTrouble 1. Trouble with with withfuel fuel injectors fuel injectors injectors related related related to: to: coking cokingto: coking of of atomizer atomizer of atomizer holes holes holes in in the the in four-stroke the four-stroke four-stroke by by Wartsila Wartsilaby Wartsila typetype typeSW SW 380 380SW trunk trunk380 trunk piston piston piston engine engine engine ( a), blow (a), blow by damagedamage by damage ofof injectorinjector of injector ((bb),), andand (b), its itsand seat seat its in inseat cylinder cylinder in cylinder head head ( chead ()c in) (c) inthe the two-strokein two-stroke the two-stroke by by Mitsubishi Mitsubishi by Mitsubishi MHI MHI type MHItype 7UEC type7UEC 85LII7UEC 85LII crosshead 85LII crosshead crosshead engine. engine. engine. The general principle of the operation of the fuel injection pump (FIP) with a rotary plunger The Thegeneral general principle principle of the of operationthe operation of the of futheel fuinjectionel injection pump pump (FIP) (FIP) with with a rotary a rotary plunger plunger consists in delivering fuel by reciprocating motion of the plunger in the barrel. Fuel dose regulation is consistsconsists in delivering in delivering fuel fuelby reciprocating by reciprocating motion motion of the of plunger the plunger in the in barre the barrel. Fuell. Fueldose dose regulation regulation enabled by the helix edge on the plunger. Such pumps are subject to tribological abrasive wear caused is enabledis enabled by the by helixthe helix edge edge on the on plunger.the plunger. Such Such pumps pumps are subjectare subject to tribological to tribological abrasive abrasive wear wear by poor quality fuels with high cat-fines content, resulting in increased plunger-barrel clearance, as causedcaused by poorby poor quality quality fuels fuels with with high high cat-fines cat-fines content, content, resulting resulting in increased in increased plunger-barrel plunger-barrel well as erosion and high pressure cavitation, as shown in Figure2. clearance,clearance, as well as wellas erosion as erosion and highand high pressure pressure cavitation, cavitation, as shown as shown in Figure in Figure 2. 2. (a) (a) (b) (b) FigureFigureFigure 2. 2. TroubleTrouble 2. Trouble with with withthe the fuel fuelthe injectorfuel injector injector pump pump pump (FIP) (FIP) (FIP)related related related to: to: a awornto: worn a worn do downwn do plunger plungerwn plunger due due to due to cavitation cavitation to cavitation erosionerosionerosion in in the the in four-stroke four-strokethe four-stroke by by Wartsila Wartsila by Wartsila type type typeSW SW 380 380SW trunk trunk380 trunk piston piston piston engine engine engine (a (a),), damaged damaged(a), damaged suction suction suction valve valve valve in in in FIP’sFIP’sFIP’s top top cover covertop cover caused caused caused by by abrasive abrasive by abrasive wear wear wear in in the the in by bythe MAN MAN by MAN B&W B&W B&W type type type7S80MC-C 7S80MC-C 7S80MC-C crosshead crosshead crosshead engine engine engine ( (bb).). (b). TheThe Theaim aim aimof of this this of articlethis article article is is to to ispresent present to present the the author author’sthe author’s developed developed’s developed method method method for for condition conditionfor condition assessing assessing assessing and and and identifyingidentifyingidentifying the the limit the limit limit condition condition condition of of the the of tribological the tribological tribological system, system, system, applicable applicable applicable to to the the to two-stroke the two-stroke two-stroke crosshead crosshead crosshead and and and thethe four-strokethe four-stroke four-stroke trunk trunk pistonpiston piston dieseldiesel diesel engines, engines, engines, and and their andtheir fuel th fueleir injection fuelinjection injection pump’s pump’s pump’s precision precision precision pair, pair, to findpair, to find early to find earlystageearly stage worn stage worn out worn symptoms out symptomsout symptoms to avoid to avoid breakto avoid break downs. break downs. downs. Energies 2020, 13, 1601 3 of 11 Energies 2020, x, x FOR PEER REVIEW 3 of 11 2.2. Materials and Methods TheThe mainmain partpart ofof thethe fuelfuel injectioninjection pumppump (FIP)(FIP) isis itsits hydraulichydraulic precisionprecision pair,pair, whichwhich consistsconsists ofof twotwo elements:elements: the cylinder, calledcalled barrelbarrel (B),(B), andand piston,piston, calledcalled plungerplunger (P).
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