Only Diesel Bombers Brings You - The Diesel Necronomicon - Book Of The Dead Diesel

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BOOK 1 Theory

The theory of compression ignition engines

1.1 Introduction
1.1.1 Historical
1.1.2 Classifications
1.2 Two-stroke and four-stroke engines
1.2.1 Two-stroke engines
1.2.2 Four-stroke engines
1.2.3 Evaluation of power output of two-stroke and four-stroke engines
1.2.4 Other operating parameters
1.3 Air standard cycles: constant pressure—constant volume—dual combustion
1.3.1 Theoretical expressions for air standard cycles
1.3.2 Further comments on air standard cycles
1.4 Basic thermodynamics of real gases
1.4.1 Gas properties
1.4.2 Combustion
1.4.3 Dissociation and reaction kinetics
1.5 Real diesel engine cyclic processes
1.5.1 Closed period
1.5.2 Open period
1.6 Detailed cycle analysis methods
1.6.1 Closed period
1.6.2 Open period (gas exchange process)
1.6.3 Completion of calculation sequence

The theory of turbocharging

2.1 Introduction
2.2 Turbocharging
2.2.1 Turbochargers for automotive diesel engines
2.2.2 Small industrial and marine engine turbochargers
2.2.3 Large industrial and marine engine turbochargers
2.3 Turbocharger performance
2.3.1 Compressor and turbine efficiency
2.3.2 Non-dimensional representation of compressor and turbine characteristics
2.3.3 Compressor performance
2.3.4 Turbine performance
2.4 Turbocharging systems—principles
2.4.1 The energy in the exhaust system
2.4.2 Principles of constant pressure turbocharging
2.4.3 Principles of pulse turbocharging
2.4.4 Principles of pulse converter and other turbocharging systems
2.5 Charge air cooling
2.5.1 Charge cooling principles
2.5.2 Charge air cooling and engine performance
2.6 Turbocharger matching
2.6.1 Introduction
2.6.2 Air flow characteristics of engine and turbocharger
2.6.3 Matching for constant speed operation
2.6.4 Matching the marine engine
2.6.5 Matching for diesel-electric traction
2.6.6 Matching for other industrial duties
2.6.7 Matching the four-stroke vehicle engine
2.6.8 Matching the two-stroke vehicle engine
2.7 Changes in ambient conditions
2.7.1 Introduction
2.7.2 Operation under changing ambient conditions
2.7.3 Rematching to suit local ambient conditions

Compound and other engine systems

3.1 Introduction
3.2 Gas generator and compound schemes compared with the turbocharged engine
3.3 Analysis of turbocharged and compound engine systems based on full cycle simulation
3.3.1 Analysis based on compression and expansion machines with fixed polytropic efficiencies of 85% and 80%, respectively
3.3.2 Analysis based on fully modelled system, including compressor, turbine and cooler characteristics
3.4 Other compounded or related engine schemes
3.4.1 The differential compound engine (DCE)
3.4.2 The differentially supercharged diesel engine (DDE)
3.5 Other turbocharged or pressure charging systems
3.5.1 Two-st=age turbocharging
3.5.2 Variable geometry turbocharging
3.5.3 The pressure wave supercharger

Diesel combustion and fuels

4.1 Diesel combustion
4.1.1 Basic combustion theory
4.1.2 Ignition delay
4.1.3 Mixing controlled combustion
4.1.4 Combustion system design
4.1.5 Analysis of cylinder pressure data
4.2 Diesel fuels
4.2.1 Hydrocarbon types
4.2.2 Petroleum-derived fuels
4.2.3 Diesel fuel properties
4.2.4 Diesel fuel quality issues
4.2.5 Diesel fuel specifications
4.2.6 Alternative fuels

Thermal loading

5.1 Introduction
5.2 Gross heat losses
5.3 Prediction of local heat flows
5.4 Heat transfer at coolant side
5.4.1 Stationary surfaces—liner
5.4.2 Moving components
5.4.3 Establishing temperature
5.5 Thermal stress
5.5.1 Thermal stress failures
5.5.2 Materials
5.5.3 Strongbacked constructions
5.5.4 Calculation of thermal
5.6 Limiting conditions in operation
5.6.1 To meet lubrication
5.6.2 For thermal strength
5.6.3 Fuel injector
5.7 Designing to meet thermal requirements
5.7.1 Cylinder head
5.7.2 Cylinder liner
5.7.3 Piston design
5.7.4 Injector cooling
5.8 Measurement of local temperature heat fluxes
5.8.1 Fixed thermocouples
5.8.2 Traversing thermocouples
5.8.3 Hardness recovery
5.8.4 Fusible plugs
5.9 Exhaust valves and seats

 

Book 2 Engine design practice

Thermodynamic mathematical modelling

6.1 Introduction
6.2 Fundamentals and the energy equation
6.3 Gas properties
6.4 Pipe flows, valves, throttles and flow restrictions
6.5 Turbomachinery and charge air coolers
6.6 The cylinder
6.7 Injection and combustion
6.8 Heal transfer and friction
6.9 Model results and engine performance
6.10 Transient modelling
6.11 Other engine components
6.11.1 Turbomachinery
6.11.2 Control valves
6.11.3 Indirect injection and other fuellingmethods
6.11.4 Two-stroke engines
6.12 Energy equation, gas properties and combustion extensions
6.13 Gas dynamics

Computational fluid dynamics

7.1 Introduction
7.2 Model description
7.2.1 Gas-phase modelling
7.2.2 Liquid-phase modelling
7 2.3 Ignition, combustion and emissions
7.3 Applications
7.3.1 Modelling the gas-exchange process
7.3.2 Combustion and emissions model validation
7.3.3 Effect of multiple injections
7.3.4 Use of CFD in engine design
7.4 Summary and conclusions

Modern control in diesel engine management

8.1 What is the purpose of control
8.1.1 Fundamental components
8.1.2 The structure of a control
8.1.3 The shape of the future—control
8.2 The context of engine control
8.3 What a control system does
8.3.1 Sensors for control
8.3.2 Actuators for control
8.4 Current engine control technology
8.5 Algorithms for control
8.5.1 Predictors and filters
8.5.2 The Future
8.5.3 Modern control—an example
8.6 Designer’s guide
8.6.1 Developing control systems
8.6.2 General comments about development
8.6.3 Specifying functions

 

BOOK 3 Engine sub-systems

Inlet and exhaust systems

9.1 Introduction
9.2 Gas flow
9.3 Four-stroke engines
9.3.1 Valve timings
9.3.2 Valve areas
9.3.3 Determination of flow coefficients
9.3.4 Engine breathing demands
9.3.5 Actual non-swirling port shapes
9.3.6 Swirl producing ports
9.4 Turbocharging
9.5 Two-stroke engine scavenging
9.5.1 Cross scavenging
9.5.2 Loop scavenging
9.5.3 Uniflow scavenging
9.5.4 Port areas and timings
9.6 Silencers

Design layout options

10.1 Introduction
10.2 The balancing of engines
10.2.1 Consideration of the forces involved
10.2.2 Balance of a single-cylinder engine
10.2.3 Two-cylinder engines
10.2.4 Four-cylinder in-line engines
10.2.5 Three-cylinder engines
10.2.6 Six-cylinder engines
10.2.7 Vee engines
10.2.8 Two-stroke engines
10.2.9 Control of torque reaction
10.3 Torsional vibration
10.3.1 Simple systems
10.3.2 The solution of multi-cylinder crankshaft systems
10.3.3 Vibration dampers
10.3.4 Torsiographs and torsional vibration tests
10.4 General design practice and use of materials
10.4.1 Introduction
10.4.2 The design process
10.4.3 General properties of materials
10.4.4 Behaviour of materials under repeated loads—fatigue
10.4.5 Typical materials used in production

Fuel injection systems

11.1 Introduction 263
11.2 Diesel fuel injection systems—Lucas Diesel Systems
11.2.1 Compression ignition combustion processes
11.2.2 Formation of nitric oxide by lean combustion
11.2.3 Unburned hydrocarbons
11.2.4 Origins of noise in diesel combustion processes
11.2.5 Particulate emissions
11.2.6 Traditional jerk pump
11.2.7 Unit injectors
11.2.8 DP rotary distributor pumps
11.2.9 Electronically controlled rotary pumps (EPIC)
11.2.10 Advanced rotary distributor pumps
11.2.11 Control of rate of injection with conventional FIE
11.2.12 Lubrication of fuel injection components
11.2.13 Common rail systems
11.2.14 Integrated fuel injection systems
11.2.15 Summary
11.2.16 Acknowledgement
11.3 Diesel fuel injection systems—Robert Bosch Corp.
11.3.1 Fuel-injection systems
11.3.2 Fuel-injection techniques
11.3.3 Pump-and-barrel assemblies (pumping elements)
11.3.4 Standard PE in-line injection pumps
11.3.5 PE in-line injection pumps for alternative fuels
11.3.6 In-line control sleeve fuel-injection pumps
11.3.7 Electronic Diesel Control (EDC)
11.3.8 Bosch—Single-plunger fuel-injection pumps
11.3.9 Innovative fuel-injection systems
11.3.10 Peripheral equipment for diesel fuel-injection systems
11.3.11 Bosch—Distributor injection pumps VE
11.4 Diesel fuel injection systems—Caterpillar Inc.
11.4.1 Caterpillar’s hydraulically-actuated electronic unit injector (HEUI) fuel system
11.4.2 Next generation: HEUI-B

Lubrication and lubricating oils

12.1 Introduction
12.2 Lubricating oils
12.2.1 Mineral oils
12.2.2 Synthetic oils
12.3 Viscosity—its significance in lubrication
12.3.1 Viscosity and coefficient of friction
12.3.2 Viscosity measurement and units
12.3.3 Change in viscosity with temperature and pressure
12.3.4 Viscosity classification
12.3.5 Low-temperature viscosity and ease of starting
12.3.6 Viscosity at running temperatures;friction losses and oil consumption
12.4 Additives
12.5 Oil deterioration
12.6 Operational problems
12.6.1 Piston deposits
12.6.2 Engine wear
12.6.3 Bearing corrosion
12.6.4 Sludge
12.7 API classification
12.8 Engine tests and associated specifications
12.8.1 Engine test rating
12.9 Laboratory inspection tests
12.10 Spot tests

Bearings and bearing metals

13.1 Introduction
13.2 Bearing designs
13.2.1 Wall thickness
13.2.2 Interference fit
13.2.3 Locating tangs
13.2.4 Free spread
13.2.5 Loading on crankpin and main bearings
13.2.6 Prediction of oil film thickness
13.2.7 Grooving configuration
13.2.8 Clearance
13.3 Bearing damage
13.3.1 Abrasion
13.3.2 Fatigue
13.3.3 Corrosion
13.3.4 Wiping
13.3.5 Cavitation
13.3.6 Fretting
13.3.7 Design faults
13.3.8 Incorrect assembly
13.3.9 Environmental factors
13.3.10 Geometric factors
13.4 Slow-speed engine crosshead bearings
13.5 Bearing metals
13.5.1 Fatigue strength
13.5.2 Scuff resistance
13.5.3 Wear resistance
13.5.4 Cavitation erosion resistance
13.5.5 Overlays
13.5.6 White metals
13.5.7 Copper-lead and lead-bronze alloys
13.5.8 Aluminium-tin alloys
13.5.9 Aluminium-silicon alloys

Pistons, rings and liners

14.1 Introduction
14.2 Pistons
14.2.1 Introduction
14.2.2 Piston loading
14.2.3 Piston design
14.2.4 Piston types
14.2.5 Gudgeon pins
14.2.6 Piston design analysis
14.3 Rings
14.3.1 Introduction
14.3.2 Ring design
14.3.3 Ring types
14.3.4 Ring packs
14.3.5 Ring materials
14.3.6 Ring coatings
14.3.7 Oil consumption and blow-by
14.3.8 Scuffing
14.3.9 Ring research
14.4 Liners
14.4.1 Introduction
14.4.2 Dry liners
14.4.3 Wet liners
14.4.4 Liner shape and surface finish
14.4.5 Material
14.4.6 Bore polish

Auxiliaries

15.1 Governors and governor gear
15.1.1 Introduction
15.1.2 Basic principles
15.1.3 Basic governing terms
15.1.4 Typical governors
15.1.5 Application requirements and governor
selection
15.1.6 Typical applications
15.1.7 Conclusion
15.2 Starting gear and starting aids
15.2.1 Introduction
15.2.2 Unaided cold starting ability
15.2.3 Improving the unaided cold starting ability
15.2.4 Engine cranking requirements
15.2.5 Methods of starting
15.2.6 Starting aids
15.3 Heat exchangers
15.3.1 Introduction
15.3.2 Operating conditions
15.3.3 Water-cooled systems
15.3.4 Evaporative systems
15.3.5 Temperature control
15.3.6 Air-cooled systems
15.3.7 Heat transfer
15.3.8 Construction and design
15.3.9 Materials
15.3.10 Corrosion
15.3.11 Maintenance
15.3.12 Water treatment

Aircooled engines

16.1 Introduction
16.2 Design features and functional aspects
16.2.1 Crankcase
16.2.2 Cylinder unit
16.2.3 Heat exchangers
16.2.4 Fan control
16.3 Cooling fan
16.3.1 General aspects
16.3.2 Layout and design of axial fans
16.3.3 Stators
16.3.4 Fan noise and its reduction
16.3.5 Other design considerations
16.3.6 Manufacturing considerations
16.4 Environmental aspects
16.4.1 Exhaust emissions
16.4.2 Engine noise
16.4.3 Noise characteristics of aircooled engines
16.4.4 Noise attenuation by secondary measures
16.5 Applications

Crankcase explosions

17.1 Introduction
17.2 Oil mist in crankcases
17.3 Explosion effects
17.4 Incidence of crankcase explosions
17.5 Prevention of explosions
17.6 Design aspects
17.7 Explosion relief valves
17.8 Crankcase monitoring systems
17.9 Oil mist detectors
17.9.1 Graviner systems
17.9.2 Schaller Visatron systems
17.9.3 Location of sampling points
17.10 Practical aspects

 

BOOK 4 Environmental aspects

Exhaust smoke, measurement and regulation

18.1 General considerations
18.2 Instrumentation
18.2.1 Comparators
18.2.2 Filter-soiling ‘spot’ meters
18.2.3 Opacimeters
18.3 Calibration and correlation of smoke meters
18.4 Optical system—spectral response
18.5 Opacimeter specifications
18.6 Visibility criterion—public objection
18.7 Test methods and procedures
18.8 Typical smoke regulations
18.8.1 Road vehicle applications
18.8.2 Regulations other than for road vehicles
18.9 Conclusions—future legislation

Exhaust emissions Contents

19.1 Introduction
19.2 Legislation
19.2.1 USA
19.2.2 Europe
19.2.3 Japan
19.2.4 Concluding remarks
19.3 Analysers
19.3.1 Carbon dioxide
19.3.2 Carbon monoxide
19.3.3 Nitric oxide
19.3.4 Hydrocarbons
19.3.5 Oxygen
19.3.6 Particulates
19.4 Formation and control
19.4.1 Carbon dioxide
19.4.2 Carbon monoxide
19.4.3 Unburnt hydrocarbons
19.4.4 Nitrogen oxides
19.4.5 Odour
19.4.6 Particulates
19.5 Unregulated emissions
19.5.1 Aldehydes
19.5.2 Polycyclic aromatic hydrocarbons
19.5.3 Nitrated polycyclic aromatic hydrocarbons
19.5.4 Vapour-phase hydrocarbons
19.5.5 Particle size
19.6 Conclusions

Engine noise Contents

20.1 Introduction
20.2 Theory and definitions
20.2.1 Amplitude
20.2.2 Effect of distance on sound pressure level
20.2.3 Frequency and wavelength
20.2.4 Sound power level
20.2.5 Addition and subtraction of sound sources
20.2.6 Averaging decibel levels
20.2.7 Calculating relative levels
20.2.8 Weighting curves
20.2.9 Noise dose level
20.3 Legislation
20.3.1 On-highway vehicles
20.3.2 Off-highway machines
20.4 Measurement and analysis of noise
20.4.1 Measurement environments
20.4.2 Equipment
20.4.3 Frequency analysis
20.4.4 Tracking analysis
20.4.5 Sound quality analysis
20.5 Noise characteristics of diesel engines
20.5.1 Engine overall noise levels
20.5.2 Assessment of combustion noise
20.5.3 Assessment of mechanical noise
20.5.4 Engine radiated noise
20.5.5 Vehicle and machine noise assessment
20.6 Methods for control of diesel engine noise
20.6.1 Combustion noise
20.6.2 Mechanical noise
20.6.3 Predictive analysis
20.6.4 Palliative treatments and enclosures
20.6.5 Vehicle and machine refinement
20.7 Conclusion

Larger engine noise and vibration control

21.1 Introduction
21.2 Noise
21.3 Vibration

 

BOOK 5 Applications

Passenger car engines

22.1 Introduction
22.2 Vehicle specific requirements
22.3 Current engine technology
22.3.1 Combustion systems
22.3.2 Design features
22.3.3 Fuel injection equipment
22.3.4 Exhaust gas aftertreatment
22.3.5 Electronic control systems
22.4 Performance and emissions characteristics
22.4.1 Power and torque
22.4.2 Fuel consumption
22.4.3 Exhaust emissions
22.4.4 Noise, vibration, and harshness
22.5 Future developments

Trucks and buses

23.1 Market demands
23.1.1 Size and physical constraints
23.1.2 Weight
23.1.3 Cost
23.1.4 Durability and reliability
23.1.5 Performance
23.1.6 Fuel economy
23.1.7 Gaseous and noise emissions
23.1.8 Electronics
23.1.9 Product support
23.2 Starting point
23.2.1 Cylinder block and head
23.3 Cylinder kit components
23.3.1 Pistons
23.3.2 Piston rings
23.3.3 Cylinder liner
23.4 Connecting rod assembly
23.4.1 Connecting rods and bearing caps
23.4.2 Piston pin bearings and connecting rod-to-crankshaft bearings
23.5 Crankshaft assembly
23.5.1 Crankshaft
23.5.2 Crankshaft oil seals
23.5.3 Crankshaft main bearings
23.5.4 Crankshaft pulley
23.5.5 Crankshaft vibration damper
23.6 Camshaft assembly
23.6.1 Camshaft
23.6.2 Camshaft bearings and caps
23.6.3 Camshaft drive gear
23.7 Overhead components
23.7.1 Valve train assembly
23.7.2 Rocker assemblies
23.7.3 Rocker cover assembly
23.7.4 Engine retarders
23.8 Flywheel
23.9 Flywheel housing
23.10 Geartrain
23.11 Gear case and cover
23.12 Electronic control system
23.12.1 ECM
23.12.2 Sensors
23.12.3 Interconnections and wiring
23.12.4 Communications
23.13 Fuel injection system
23.13.1 Electronic fuel injection devices
23.13.2 Fuel (transfer) pump
23.13.3 Fuel lines
23.13.4 Fuel filters
23.13.5 Fuel heaters and coolers
23.13.6 Fuel and water separators
23.14 Air system
23.14.1 Turbocharger
23.14.2 Charge cooler
23.14.3 Intake and exhaust manifolds
23.15 Lubrication system
23.15.1 Oil pump
23.15.2 Regulator
23.15.3 Relief valve
23.15.4 Filters
23.15.5 Oil cooler
23.15.6 Dipstick
23.15.7 Oil pan
23.15.8 Crankcase ventilation
23.15.9 Oil quality
23.16 Coolant system
23.16.1 Coolant
23.16.2 Coolant filter and conditioner
23.16.3 Water pumps
23.16.4 Thermostats
23.17 Typical engines
23.17.1 Product overview
23.17.2 Caterpillar engines
23.17.3 Cummins engines
23.17.4 Detroit diesel engines
23.17.5 Mack engines
23.17.6 Mercedes-Benz engines
23.17.7 Navistar engines
23.17.8 VarityPerkins engines
23.17.9 Volvo engines

Locomotives

24.1 Introduction
24.2 Development trends
24.2.1 Emissions
24.2.2 Engine weight
24.2.3 Reliability and durability
24.3 Engine descriptions
24.3.1 Caterpillar 3500
24.3.2 Caterpillar 3600
24.3.3 Dalian 240 ZD
24 3.4 General Electric 7FDL™
24.3.5 General Electric 7HDL™
24.3.6 General Motors EMD 645 and 710
24.3.7 General Motors EMD H engine
24.3.8 Kolomna D 49
24.3.9 MTU/DDC 4000 series
24.3.10 Paxman VP 185
24.3.11 Pielstick PA4 200 VG
24.3.12 Pielstick PA6B
24.3.13 Ruston RK215
24.4 Summary of engine design features and future trends
24.5 Railcar engines
24.5.1 Cummins
24.5.2 MAN
24.5.3 MTU
24.5.4 Niigata

Dual fuel engines

25.1 What is a dual fuel engine?
25.2 Combustion in dual fuel engines
25.3 Gas properties and their effects
25.3.1 Heat value of a stoichiometric mixture volume
25.3.2 Net heating value (kJ/m3)
25.3.3 Anti-detonation properties
25.3.4 Pre-ignition tendency
25.3.5 Flame speed
25.4 Combustion system
25.4.1 The ‘conventional’ dual fuel engine
25.4.2 The ‘low NOx’ dual fuel engine
25.4.3 The ‘gas diesel’ engine
25.4.4 Other combustion systems
25.5 Air-fuel ratio control systems
25.5.1 Intake throttle
25.5.2 Exhaust by-pass
25.5.3 Compressor by-pass
25.6 Safety systems
25.7 Applications
25.7.1 Automotive
25.7.2 Locomotive
25.7.3 Stationary (power generation and mechanical drive)
25.7.4 Marine and offshore

Marine engine applications

26.1 High speed engines
26.1.1 Caterpillar
26.1.2 Cummins
26.1.3 Deutz MWM
26.1.4 GMT
26.1.5 Isotta Fraschini
26.1.6 MAN B&W Holeby
26.1.7 Mitsubishi
26.1.8 MTU
26.1.9 MTU/DDC designs
26.1.10 Niigata
26.1.11 Paxman
26.1.12 SEMT-Pielstick
26.1.13 Wärtsilä diesel
26.1.14 Automotive-derived engines
26.2 Low speed engines
26.2.1 Introduction
26.2.2 Intelligent engines

 

BOOK 6 Operation

Condition monitoring

27.1 Introduction
27.2 A typical condition monitoring system
27.3 Instrumentation for condition monitoring
27.3.1 Vibration monitoring
27.3.2 Temperature measurements
27.4 Instrumentation for condition monitoring indirect methods
27.5 Fuel monitoring
27.6 Exhaust emissions
27.7 Conclusion

 

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