FUEL PUMP

Puncture valve is operated in the event of actuation of the shutdown system, during the air start sequence or when
excessive leakage is detected from the double skinned fuel pipes.
Puncture valve actuation returns the fuel oil to fuel pump housing and no injection takes place.

Fuel may be metered by controlling the fuel-pump suction valve or by helix and port control. What
important difference in effect does each system have on injection timing with change of load?

Fuel pumps using the suction valve to control fuel quantity complete injection at the same crank position,
irrespective of load. As the load increases the suction valve must close earlier and injection commence earlier.

Fuel pumps metering fuel quantity by helix and port control commence injection at the same crank position,
irrespective of load. As the load increases completion of injection must occur later.

How to check the fuel injection pump timing ?

Lock off the starring mechanism

Start L.O pump
Open all indicator cock
By hair line method
Turn the engine so that the unit to be check is toward the TDC of compression stroke (plunger upstroke) so that hair
line on plunger & pump body are coincided.
When hair lines are coincided, stopped turning and check the mark on the fly wheel whether timing is correct or
not.

In hair line not given Take out fuel in/out pipe on pump (by removing binjo bolt)
By using hand torch & mirror on each side
Turn the engine so that the unit to be check is toward the TDC of compression (at plunger upstroke)
so that the light on mirror is disappearing ( ie torch light has gone on mirror )
AT this time, stopped engine turning & check the mark on flywheel.

By Goose net method

Turn the engine so that No.1 piston is at the top dead centre position at the beginning of the firing stroke
Turn the engine backwards to a point which is a little earlier than the fuel injection point.
Shut fuel oil supply and remove delivery valve assembly with delivery pipe to fuel valve of No. 1 unit and put on a
bent pipe in place of the delivery pipe on the pump discharge.
Fuel supply valve to the engine is to be opened and put the fuel lever to running position. Fuel oil will flow out
from the bent pipe.
Turn the engine towards the TDC in its running direction slowly until fuel cease to flow and check the marks on the
flywheel whether the timing position is correct or not;

Adjustment

By adding or reduction shims on the pump base, or

By turning the plunger up and down adjustment screw on the pump roller guide, or
By shifting the coupling flange between the pump and the drive side of the engine in case of combined unit system,
(for small engine)
Large engine

The timing can be altered by shifting the camshaft to the position relative to the crankshaft
(after removing the idler gear between the crankshaft and the camshaft.) For large engine
#For adjustable cam type engines timing can be altered by individual cams of the fuel pumps.

If no TDC mark on flywheel, How will you check pump timing?

IN M/E

1) Make a marking between cross head and guide Shoe while they are before TDC and also mark at the flywheel.
2) Turn the crank shaft in the same direction until the crosshead and guide shoe are at the
previous mark (coincide)
3) Make the second marking on the fly wheel. We got two marks on the flywheel mid point between the two points
is TDC.
4) I will divide 360C around the flywheel.

IN G/E

1) Remove the fuel valve

2) Insert the rod onto the piston (mark on rod and flywheel)
3) Turn crank until the rod previous mark
4) Make the second marking on the fly wheel
5) Mid point between the two points is TDC
How to cut fuel in MAN engine?

Running Marine Engines with Cylinders out of Operation

The engine is designed and balanced to run with all cylinders as well as all turbochargers working. If a breakdown
occurs which disables one or more cylinders, or turbochargers, repair should preferably be carried out immediately.

One unit may need to be disabled when any of these conditions exist:

 Damage to a main component of the combustion chamber

 Damage to a crosshead or bottom end bearing on that cylinder

Precautions Before Cutting off Cylinder Unit

If immediate repair is not possible, the engine can be operated with one or more cylinders or turbochargers out of
operation, but with reduced speed owing to the following:

 Pressure pulsations may occur in the scavenge and exhaust receivers, which can give a reduced air supply to
any one of the cylinders, and as a result cause the respective exhaust temperatures to increase. The fuel
pump index for these cylinders must therefore be reduced to keep the exhaust temperatures (after valves)
within prescribed limits.
 Since the turbochargers will be working outside their normal range, surging may occur. This can generally
be remedied by “blowing off” from the scavenge air receiver.
 If more than one cylinder must be cut out of operation, and the engine has two or more turbochargers, it may
be advantageous to cut out one of the turbochargers.
 When cylinders are out of operation, governor hunting may occur. When this happens, the fuel pump index
must be limited by operating the electric governor on “index control”.
 With one or more cylinders out of operation, torsional vibrations, as well as other mechanical vibrations,
may occur at certain engine speeds. Should unusual noise or extreme vibrations occur at the chosen speed,
the speed must be further reduced.
 If the engine is to be run for a prolonged period with cylinders out of operation, the engine builder should
always be contacted in order to obtain advice concerning possible recommended barred speed ranges.

Procedure for Cutting off Cylinder Unit

The following sequence would be carried out for ships which use the MAN B&W slow speed engine:

1. Stop engine, isolate systems and allow to cool

2. Ensure a procedure is written that minimises the risk to personnel during the operation.
3. Discuss the task and written procedure with the engine room personnel to ensure they are familiar with the
risks, and the methods to be used to minimise these risks.
4. Ensure the fuel pump is de-activated by lifting roller and locking.
5. Lift exhaust valve actuators so exhaust valve remains closed during running. (Note: the air spring supply to
be left open)
6. Dismantle air start supply line, and blank with suitable steel plates, the main and control air pipes
7. Blank off main lube oil inlet to crosshead within the crankcase with a blanking plate.
8. the cylinder lubricator for that cylinder should be there if piston is not removed.

Difficulties During Manoeuvring

When one engine cylinder is isolated, then one problem that may occur is a “dead spot” during manoeuvring. This
is due to the air start valve being isolated for that unit, and is more likely when a smaller number of cylinders are
present. The Master must be informed that this could occur, and the remedy would be to kick the engine in the
opposite direction, and then restart in the required direction.
How to change timing of fuel pump?

Changing timing hydraulically in case of crankshaft slippage 2 to 5 degrees by taking the unit to TDC lift the roller
by checking mark on flywheel hydraulic connection given to Individual cam to float using hydraulic pressure and
turned to adjust the timing. Shims added to late injection to fuel pump.

Anti dribbling arrangement

As the valve closes at the end of pumping, the piston section of the pin, or unloading collar, enters the valve seat
bore to extract a small amount of fuel from the high-pressure line before the valve is completely closed.
This extraction causes a negative pressure wave which travels along the fuel line to the nozzle and ensures that the
nozzle valve closes rapidly to give a sharp cut-off to the end of the injection, to prevent dribble and secondary
injections.

1. Draw MAN B&W fuel pump and its working ?

2. Types of fuel pump in each, Then under what circumstances you will cut out the fuel pump
3. How to cut out one unit of main engine
4. What is the function of suction valve, Why u require ?
5. Purpose of suction valve on main engine fuel pumps and why not in generator pumps ?
6. How to activate puncture valve for individual unit
7. Everything about MAN B&W fuel pumps from conventional to latest
8. Deflector is also called plug screw or erosion plug or both ?
9. How to measure the plunger lift and adjust..What is the name of the tool to measure lift ?
10. SULZER fuel pump timing procedure Cross cut and oblique type
11. How RT flex fuel pump works ?