Name: Nagendra Etikala Date:07/09/2019

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1. What is the max high step load can gas and diesel generator accept?

Max is 10 % of Fuel capacity load of engine.

2. What is the difference between Miller engine and normal engine?

--------- The Miller cycle is an over-expanded cycle implemented with either early (EIVC) or
late (LIVC) intake valve closing ------------------------------------------------------------------------------in
normal engine ---works on otto cycle.------------------------------------------------------------------------------
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3. What we suppose to do if we have high step load on gas engine?

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4. What is the max air inlet temperature allowed and what is the effect of high inlet temperature on
engine performance?
---70 degrees and engine efficiency will reduce , Load deration will happen if high intake air
temperature.--------------------------------------------------------------------------------------------------------------
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5. If engine is running with low jacket water temperature, what is the effect of this temperature on
the engine component?
----------------------------------if jacket water temperature is low, fuel consumption increases.------------
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6. What is the function of the thermostat and what is the effect of running generator without
thermostat?
------------Controlling of temperature to be maintained at set valve. If without thermo start --,
then jacketwater temperature should not increase fastly & fuel consumption will increase till
engine warmup.----------------------------------------------------------------------------------------------------------
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7. What is the normal operating temperature of gas and diesel engine?

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 ----------------90 degree celcius-----------------------------------------------------------------------------------------
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8. What is the methane number and what is the effect of gas with low methane or high methane
number on the engine?
----- methane number describes how likely it is to combust uncontrollably --.High methane
number will good for gas engine.------------------------------------------------------------------------------------
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9. Which compound in gas will determines the methane number?
-------- proportions of methane, ethane, propane and butane ------------------------------------------
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10. What is the effect of sulfur on engine component and how to reduce its effect?
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-------------------Sulfur in fuel reacts with lube oil , reduces TBN value, makes -serious damage to
engine releases gas like H2S which harm to environments.--------------------------------------------------
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11. Specify reason can lead to intercool restriction.
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12. What is the function of zero pressure regulator and what is the pressure of gas at its outlet?
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13. What is CNG, LNG and NG and what method used to produce CNG and LNG?
-------compressed natural gas, liquid natural gas and natural gas
---------- compressing natural gas to less than 1 percent of the volume it occupies at
standard atmospheric pressure. ---------------------------------------------------------------------------------
--------------- LNG is natural gas that has been cooled to a liquid state, at about -260°
Fahrenheit, for shipping and storage. The volume of natural gas in its liquid state is about
600 times smaller than its volume in its gaseous state. ----------------------------------------------------
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14. If we are using CNG what equipment needed between the gas cylinder and generator?
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-------------------------------regulator------------------------------------------------------------------------------------
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15. If we are using LNG what equipment needed between the gas cylinder and generator?
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16. Can we use LPG on gas engine?
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----------------------------------no------------------------------------------------------------------------------------------
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17. What is the reason of detonation?
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-------------------------------------due to un controlled combustion detonation occurs----------------------
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18. How the knocking system control the ignition box to reduce detonation level?
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--------by changing ignition timing------------------------------------------------------------------------------------
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19. How the speed of the gas engine is controlled?
--------by governor--------------------------------------------------------------------------------------------------------
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20. What is the max crankcase pressure of a gas engine?
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------------------------22 mm of water coloumn----------------------------------------------------------------------
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21. What is the reason of high crankcase pressure?
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------------------------mixing of water in lube oil . excessive blow by-------------------------------------------
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22. What is the function of gas oil mist?
---- gas Oil mist refers to oil droplets suspended in gas in size range 1~10 µm -------------------
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23. At what kw % of engine rating the turbocharger operate?
-------30 % kw of engine rating ---------------------------------------------------------------------------------------
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24. What is the major problem of turbocharger and what can cause it?
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Damaged blade caused by contamination from dirt or other particles entering the
turbine or compressor housing.---------------------------------------------------------------------------------
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25. What is the difference between lean and rich mixture?
-------lean means lesser fuel ( air fuel ratio ) , richer mean high fuel ---( air fuel ratio )----------------
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26. How the gas engine controls the air/fuel ratio?
--------------------- Waste gate actuator, fuel actuator and choke actuator in caterpillar engine ------
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27. What is lambda and what it’s value for gas engine?
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----- t is a measure of the efficiency of the gasoline engine by measuring the percentage
of oxygen in the exhaust .----& lamba value og gas engine is 1-------------.-----------------------------
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28. How the gas engine control lambda ratio
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-------- Lambda O2 sensor is an electronic device that measures the proportion of oxygen (O2)
in the gas being analyzed. It controls the AFR in internal combustion engine which is lean,
rich or stoichiometric.--------------------------------------------------------------------------------------------------
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29. What is the normal rate of NOX for gas engine and how to control it?
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-------- Selective Catalytic Reduction (SCR) technology for Nitrogen Oxide (NOx) reduction. --
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30. What can cause the cylinder temperature to go high and how to control it?
--------due excessive air fuel ratio , due injector failure --------------------------------------------------------
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31. What is the max back pressure of exhaust and how it affects the engine performance?
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---------- 2.75 psi and ------ As back pressure increases, the pressure drop across the
turbine will decrease, the turbocharger shaft speed will be reduced and the intake
boost pressure and intake air mass flow will decrease. ... Higher engine speeds are able
to tolerate higher exhaust back pressure before performance starts to be affected.----------

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32. What is the max temperature of the air/gas mixture and what is the effect of high mixture
temperature on engine performance?
------------------70 degrees & higher mixture temperature, Fuel consumption will rise-----------------
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33. If the gas/air mixture temperature go high, what could be the reason?
--------------------- clogged state of mixer cooler.-------------------------------------------------------------------
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34. How you determined spark plug faulty?
---------------------------------if spark plug misfires, --- & defficult to start the engine,----------------------
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35. What is the supply voltage from ignition coil to spark plug?
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-------------------------40000 volts---------------------------------------------------------------------------------------
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36. What is the method of troubleshooting all the following: spark plug, sark plug cord, ignition coil,
ignition box and hall effect magnetic pickup?
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37. How to determine engine damper faulty?
--------excessive vibration is due damper --------------------------------------------------------------------------
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38. What is the period for greasing main alternator bearing?
--------------------------every 2000 hrs----------------------------------------------------------------------------------
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39. What is the min insulation reading of the main alternator winding and what we will do in case
found too low?
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-------one megohm for each 1,000 volts of operating voltage , alternator rewinding to be
done-------------------------------------------------------------------------------------------------------------------------
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40. What is the max voltage difference allowed at the alternator terminal in %?
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----------------------------2 %-----------------------------------------------------------------------------------------------
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41. Hunting engine, what could be the reason?
------Fuel injector or fuel pump problem,--------------------------------------------------------------------------
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42. Main alternator not producing voltage, state step of troubleshooting
------------Check we residual magnatisam of alternator---------------------------------------------------------
------------Check AVR
Check rotating rectifiers condition-----------------------------------------------------------------------------------
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43. During inlet and exhaust valve clearance adjustment, what measurement we must take before
and after adjustment and for what reason?
--------Both inlet and exhaust valves are to be present at TDC -----------------------------------------------
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44. Engine timing, how you confirm the gas engine is running with correct timing?
------------If there no detonation and knocking, it means engine is running at correct timing------------
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45. The following tool is used for what and when: stroboscope, endoscope.
------------1.used for measuring -speed and ignition timing-----& Endo scope is check inside part of
cylinder with out removal of cylinder head from engine-------------------------------------------------------
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46. During detonation the ignition box will advance or retard the timing?
---------------------advance the timing---------------------------------------------------------------------------------
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47. Why pre-lubrication is important in big engine?
-------Beyond significantly reducing engine wear, the engine prelube system is the only
such system that ensures oil pressure is built before the engine can crank. ... In all of
these situations, the engine Prelube system will significantly reduce engine wear and
help to lower your operating costs per hour. ----------------------------------------------------------------
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48. what modification need to be done of the engine for fast starting?
----------pre heating & prelubrication--------------------------------------------------------------------------------
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49. if Oil found mixed with water inside the radiator, what could be the reason?
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--------------------Damage of cylinder head gasket between engine block and cylinder.------------------
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50. if water found mixed with oil inside the sump, what could be the reason?
--------Exhaust seat ring o ring leakage or Fuel injector sleeve in cylinder head cracked--------------
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51. if small bubble of air coming out from the radiator cap, what could be the reason?
---Exhaust gases are passing through radiator water.-----------------------------------------------------------
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52. engine overheating, state some reason?
--Radiator fans tripped condition, Jacket water circulation pump problem, Radiator is chocked---
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53. low oil pressure, state reason?
-----Due lube oil filter choked, Lube oil pump problem. Low Lube oil level, Damaged Bearings ----
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54. engine hunting and run erratically, state reason?
--Turbo charger Nozzle ring checked, Governor problem, Fuel supply problems-----------------------
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55. engine can’t carry full load, state reason?
--High intake air temperatures, fuel /gas quality, High jacket water temperature.---------------------
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56. Red turbocharger, state reason?

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 --executive exhaust gas temperature which is due to very lean burning.---------------------------------
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57. Exhaust black smoke state reason?
--Due excessive fuel consumption, which is due to fuel injector problem, air filter chocking ,
Damaged piston rings---------------------------------------------------------------------------------------------------
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58. Exhaust white or blue smoke, state reason?
---------HT water is entered in exhaust system-( jacket water is mixed with exhaust gases )---------
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59. how the hydraulic injector HEUI works? Hydraulic actuated
A typical injection event of an HEUI injector occurs as follows:
The electro-magnet solenoid at the top of the injector is activated by the injector drive module (IDM)
after an injection event is commanded by the powertrain control module (PCM).
Once the solenoid is activated, the spring loaded poppet valve on the oil side of the system opens -
high pressure oil fills the cavity and applies force to the intensifier plunger.
The intensifier plunger applies force on fuel contained in the fuel cavity in the nozzle of the injector.
Once fuel pressure is great enough to overcome the force of the spring on the nozzle valve, the
nozzle valve lifts from its seat and fuel is atomized through the injector nozzle and is injected into the
combustion chamber.
Once the solenoid is deactivated, oil pressure drops, the poppet valve returns to the closed position,
the nozzle valve returns to the closed position, and the cavity in the injector nozzle refills with diesel
fuel.
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60. how the MEUI Injectors works? Mechanical actuated
-------- The Mechanically actuated Electronically controlled Unit Injectors (MEUI), also known
as Electronic Unit Injectors (EUI), also use the engine camshaft and push rods to generate
fuel injection pressure, but use an Electronic Control Module (ECM) to control the amount of
fuel injected into the cylinders. -------------------------------------------------------------------------------------
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61. oil leak from the exhaust, state reason?
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---Due to damaged valve guides or damaged piston rings and piston--------------------------------------
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62. what is the difference between droop mode and isochronous mode speed and what is the max
droop in mechanical pump?

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-------------------------- In the isochronous speed control mode the speed will return to the original
speed setpoint after a load has been applied or rejected. ... In the droop speed control mode the
speed will decrease by a fixed percentage when the generator is loaded from no-load to full
load.-------------------------------------------------------------------------------------------------------------------------
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63. during valve adjustment why we record their clearance and valve sinkage?
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64. Why we do oil analysis and how it helps in troubleshooting
-- can determine the amount of contamination, the wear rates and overall condition of
your engine. The real benefit of an oil analysis is that it acts as an early warning
system, alerting you to potential problems before they become an equipment failure-------
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65. engine hard to start, reason
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-----------Fuel injection problem or Spark plug problem---------------------------------------------------------
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66. what is overhauling symptom?
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----- Excessive Smoke, Burning Oil Quickly, Using Too Much Fuel. Oil Sludge, Lesser values
of cylinder head tightness readings----------------------------------------------------------------------------------
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67. Fail to start reason
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----- Fuel injection problem or Spark plug problem -------------------------------------------------------------
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68. Engine misfire, state the reason?
---due to faulty spark plugs, faulty injectors, ---------------------------------------------------------------------
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69. high fuel consumption, state reason?
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-----------faulty fuel injectors ,------------------------------------------------------------------------------------------
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70. engine excess vibration, state reason?

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 -----miss alignment of engine and alternator , Problems / faulty injector pump------------------------
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71. high oil pressure, state reason?
--------------- blockage of oil passage, ---lube oil pump regulating value faulty ----------------------------
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72. high crank case pressure, state reason?
----------------water mixed in engine lube oil , ---- exhaust leakage from piston and piston rings-----
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73. Cylinder low compression, state reason and how you test it?
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---------worn piston and piston rings------------------------------------------------------------------------------------
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74. State steps to configure a blank ECM using EST tool
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75. Flash file for ECM programming, how you identify it’s the correct file for the engine?
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76. How you test the injector of an electronic engine using EST tool
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77. How you convert an engine using ECM from 50Hz to 60Hz
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78. State the difference between the following three application: continuous, prime, standby

------- prime generator is one that serves as the primary source of power for the
operation. It is designed to work long term & variable amount of power.
Continuous – Instead, it is designed to provide a steady power load over the entire
time frame it is used. --------------------------------------------------------------------------------------------------
---Stand By _ standby generator is a backup generator, one used for emergency use
only. It generally has the ability to run for a short amount of time as the main power
supply ------------------------------------------------------------------------------------------------------------------------

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79. State the Effect of high ambient temperature, high altitude and high humidity on engine rating.
------- The higher the altitude, the lower the air density—
High Ambient temperature affect the air density , Space heaters should be used to raise the
temperature to 5°C above the ambient temperature to prevent condensation in high humidity
areas.--------------------------------------------------------------------------------------------------------------------------
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80. What is the difference between mechanical and electrical governing?
--------------------In electric governor , engine speed is controlled by electric controller. In
mechanical governor uses gears and flyweights inside the crankcase to detect changes in the load
and adjusts the throttle accordingly This closes the throttle, limiting the air-fuel released into the
engine--------------------------------------------------------------------------------------------------------------------------
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81. Why would you oversize the alternator?
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-----------------Better stator life, fuel saving ,---alternator will run with less strain.--------------------------
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82. Why alternator heater used?
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------- prevent corrosive damage of electrical and mechanical components in high humidity
environments ------------------------------------------------------------------------------------------------------------
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