Assessment of accidental | Engine Damage
In this post on Assessment accidental Engine Damage, we will discuss the real-life incident of an accident. This accident has taken at one of the refineries. Readers will learn about the repercussions of an Engine handled carelessly without taking the safety measures during shifting.
Engine Fallen from Trailer
This incident took place in a factory while shifting the machine. The refinery staffs were to shift the DG set from their stockyard to the power plant site. Loading of the DG on the trailer without proper securing arrangement was the cause of this accident.
Observation of the following instructions during the shifting could have prevented this accident.
1. Preparation of Ground: – Prepare the ground in the loading area for the movement of the Crane. Compact the jack base area. Provide sufficient wooden /steel plates for the even load distribution.
2. Proper securing the machine on the trailer to prevent the DG from falling.
3. Take the trailer carrying the DG set near the Point of unloading the DG house and position suitably.
4. Place the wedges under the wheel of the truck for arresting any movement during unloading.
5. Place the Crane suitably by the side of the trailer.
All the above instructions are mandatory and to comply.
The road was not even, full of ditches all over the road. At some places, the road had broken areas. During the shifting operation, the trailer got tilted on one side. This tilting of the trailer caused the DG to slide down and fall on the road.
Fortunately, no causality took place since no human being was around.
During the fall, the DG had suffered heavy losses amounting to damage of components.
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Damages in the Engine (Assessment accidental Engine Damage)
Visual inspection of the Diesel generator revealed the following apparent damages.
- Exhaust Pipe Assembly;- The internal parts of the pipe ( Exhaust pipe piece and compensator) were broken. Need replacement.
- Pre- Lubricating Oil Pump;- There were visible crack mark on the pump housing. Other damages to the internal parts were also anticipated.
- Pre- heater;- Pre-heater was found broken, internal electrical parts were also suffered damage. Complete pre-heater needs the replacement.
- Cylinder head Stud & Hydro Nut;– There is a speculation of impact on the integrity of stud hydraulic nuts. Therefore there were strong recommendations of replacement of all the nuts and studs.
- Engine Elastic Mountings;- Due to the impact of engine fall from trailer, there are chances of elastic mountings damage. All the components need inspection for any damage to the individual parts (Rubber and metallic). Damaged part of the elastic mounting need replacement.
- Lubricating oil cooler;- The hydraulic test of the cooler must be undertaken. Change the components or replace the cooler if found beyond the economical repairs.
- Fuel oil inlet filter;- from the pictures of the accident fuel inlet parts , few parts of the fuel oil filter are visible with damage and cracks. The complete fuel filter assembly needs replacement.
- Cylinder Head;- carry out the hydro and NDT (MGT) test of the cylinder heads and replace the damaged cylinder head.
- Air Cooler;- Subject the air cooler to hydro test
- Turbocharger;- carry out the overhauling of Turbocharger. Overhauling of the turbocharger is to be accomplished by the manufacturer of Turbocharger. Change th parts as per the advice of Turbocharger expert.
- Crankshaft;– Carry out the run out NDT (MPT) and dimensional check of the crankshaft. This check is to be carried out in OEM’s factory. Crankshaft is to be sent to the factory.
- Base Frame;- Dimensional check of the base frame need to be carried out. This test is to be carried out in Base frame manufacturer’s factory. Base frame need to be sent to the base frame manufacturer.
Further Inspections, and replacements suggested by the Equipment Manufacturer.
Carry out the visual and Hydro test of the following components wherever required( Assessment accidental Engine Damage )
- Flywheel cover
- Governor drive assembly
- Turbocharger support
- Flywheel
- Front end block
- Oil throw ring
- Sealing ring
- Camshaft
- Cam thrust case
- Main bearings
- Main bearing/ Thrust bering cap
- Main bearing stud bolt, side bolts
- Con-rod housing and con-rod bearing
- Cam shaft bearings
- Thrust washer
- Crank-gear
- Idle gear
- Cam gear
- Pump drive gear
- Fuel injection pumps
- Drive for Fuel Injection Pump
- All the test on Pistons
- Connecting Rod
- Cylinder liner
- Push rod
- Flame ring
- Air inlet box
- Torsional Vibration damper
- Flywheel cover
- Cam/ Crankcase cover and relief valve
- Fuel oil high pressure block
- Fuel oil, Lube oil, Cooling water pipe lines
- Turning gear
- FIP cover
- Centrifugal oil filter
- Swing arm roller
- Starting motor
- Gallery
- Flywheel stud bolt
- Lube oil filter
- Lube oil, Ht water and LT water pumps.
- Speed sensor
- Lube oil sup tank level switch
- Fuel oil linkage level switch
Following sensors and instruments need to be replaced after the required checks and tests mention against their name. Even if there is no crack appears, but an abnormality may occur due the small internal crack. Therefore all electrical and instrumentation parts need to be replaced. Cabling will be required due to the breakage or replacement of the parts. Damaged tray reproduction, re-fitting and re-support will be required.
- Exhaust gas each cylinder outlet temperature sensor- remove each individual cylinder and subject to calibration.
- Exhaust gas turbocharger inlet temperature sensor;- Subject the sensor to calibration.
- Exhaust gas turbocharger outlet temperature sensor;- carry out the calibration
- Main bearing temperature sensor
- Fuel oil, Lubricating oil, cooling water and Air pressure sensor
Replace the following instruments (Assessment accidental Engine Damage)
- Arrangement of starting box / terminal box
- Governor
Blog Conclusion
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