DIESEL ENGINE MAINTENANCE PLAN

MANGOSUTHU UNIVERSITY OF
TECHNOLOGY

STUDENT NAME STUDENT NUMBER SIGNITURE

1 MAPHALALA V.S 21000901 P
2. MALULEKA Z.F 21526932
3. MAPHUMULO S.C 21322031
4. MANQELE K.G 21537241

Maintenance Plan for Centrifugal pump

INTRODUCTION
This maintenance plan is designed to provide guidance on maintaining centrifugal pump in the maintenance
department. Centrifugal pump problems leading to shorten pump life and high operating costs, are usually the
results of poor operation or improper maintenance. Proper maintenance will assist in maximising the life of the
centrifugal pump, and thus make the operation smooth.

Centrifugal pump are the primary pump type in the class of pumps called kinetic pumps. All centrifugal pumps
includes a shaft-driven impellers that rotates inside a casing. Liquid flows into a suction port (inlet) of the casing
and is thrown outside of the casing and then exit the discharge port. The velocity transferred to the liquid by the
impeller is converted to pressure energy.

AIM
To ensure that the centrifugal pump runs smooth at all time with max efficiency to meet with adequate levels of
reliability and operate at an acceptable cost.

OBJECTIVES

To design the maintenance plan that will be used in a centrifugal pump, it will show how to maintain a
centrifugal pump, how often the maintenance should be carried out and the cost of maintenance.

BACKGROUND
In the 1890s Rudolf Diesel invented an efficient compression ignition, internal combustion engine that bears his
name. Early diesel engines were large and operated at low speeds due to the limitations of their compressed air
assisted fuel injection systems. In its early years the diesel engine was competing with another heavy fuel oil
engine concept the hot bulb engine invented by Akroyd Stuart. High Speed diesel engines were introduced in the
1920s for commercial vehicle applications and in the 1930s for passenger cars.

Diesel idea was to compress the air so tightly that the temperature of the air would exceed that of combustion. In
his 1892 US patent granted in 1895 diesel describes the compression required for his cycle:

Pure atmospheric air is compressed according to curve 1 2, to such a degree that, before ignition takes place, the
highest pressure of diagram and the highest temperature are obtained that is to say the temperature at which the
subsequent combustion has to take place, not the burning or igniting point. To make this clearer, let it be
assumed that the subsequent combustion shall take place at a temperature of 700˚. Then in the case the initial
pressure must be sixty four atmospheres or for 800˚ centigrade the pressure must be ninety atmospheres. Into the
air thus compressed is then gradually introduced from the exterior finely divided fuel, which ignites on
introduction, since the air is at a temperature far above the igniting point of the fuel.

PROBLEM STATEMENT
The vehicle is the common used way of transport in everyday life and 93% of vehicle use engines as the brain of
the vehicle, for these transportation to take place, the vehicles engine must be serviced and maintained at regular
intervals and, in the event of a breakdown, action must be taken to repair the vehicle so as to restore it to good
working condition, as quickly as possible. The diesel engine failures / faults occurs due to:

 Poor maintenance plan

 Not reading operation manuals
 Oil mixing with coolant with results in engine overheating
 Improper lubrication non-oil circulating
 Detonation abnormal combustion that results from too much heat and pressure
 Misassemble when replacing/ repairing an engine component
 Not replacing worn part

METHODOLOGY
For our maintenance plan to be successful, we need to inspect the failure modes of centrifugal pump to be
maintained. All failures have been grouped into four failure modes. It can be seen that from here the dominant
failure mode is due to component damage. The damage components includes

Step 1

Selecting failure modes for a centrifugal pump maintenance plan

Prioritisation of plant items

The pumps block

The pumps block is made of a lots of plant items, but the ones that are the most important in terms of
contribution to profit of the plant are listed below:

-suction pipes

-delivery pipes

-reservoir tanks

-centrifugal pumps

Suction pipe

The function of suction piping is to supply an evenly distributed flow of liquid to the pump suction, with
sufficient pressure to the pump to avoid excessive turbulence in the pump impeller. The suction pipe is usually
located below the centre line of the pump. The suction pipe brings water from the sump to the pump, there is a
strainer mounted at the bottom of the pipe so as to separate liquid from order solid substance that may affect the
performance of the pump. The suction pipe also have the foot valve which is a one way valve and prevent liquid
from falling back to the sump.

Delivery pipe

The function of the delivery pipe is to supply an evenly distributed flow of liquid to the reservoir tanks from the
pump. The delivery pipe is located above the pump centre line, there is delivery valve which is also a one way
valve making sure liquid from the pump to the tank does not fall back causing the liquid flow to be turbulent.

Reservoir tank

Pump reservoir tank stations use a large fluid reservoir and circulating pumps to move water through the plants
distribution system. The delivery pipe delivers liquid to the pump tank straight from the pump, the tank is also
connected above the centre line of the pump.

Centrifugal Pump
Plant item break down

delivery nozzle

nozzles
suction nozzle

oil ring
bearing
centrifugal pum p

thrust bearing
stuffing box
shaf sleeve

shaf Motor

seals
volute

cover plate
casing impeller
vanes

casing wear ring

Compo Functio Functional Failure mode Possible cause of Maintenance Consequ Mainten
nent n failure failure Strategy ence ance
task
Impeller Centrifu The impeller is  Broken  Contaminated  Strengthen Operatio On
gal a series of delivery fuel the nal condition
pump vanes molded  Valve  Local maintenance
come around a hub, springs pressure falls of clean
with an the tips of the  Choked below diesel filter,
impeller impeller vanes fuel saturated clean or
. This wear out from valves vapour replace the
impeller it use and in the  Capitation pressure of filter in
when case a foreign fuel. timely
spins, it objects enters manner.
transfer the pump. This  Complete
energy result in the removal of
to the impeller not the bottom
fluid being0 0able to of the tank
using transmit of oil sludge
the enough energy and water,
centrifu to the fluid. diesel fuel
gal injection
force. It pump of any
directs impurities.
water to  Check the
the oil tanks of
discharg oil injection
e point. pump
volume and
quantity
compliance
requirement
s.
 Check the
quantity of
the oil
situation to
ensure
sufficient oil
quantity and
quality.

Shaft Centrifu Vibration  Incorrect  Choked Operatio On

gal harmonics puts atomizatio atomizer due nal condition
pump extra stress on n to
impeller the pump  Cavitation contaminated
s are shafts, causing fuel debris
connect it to flex and and hot gas
ed to the eventually fail. from cylinder
drive Imbalance also forming
shaft. creates carbon.
The problems in the  Low pressure
 main pump shaft caused by
function because it’s a pressure
of the source of waves that
shaft in vibration. move
a Misalignment between
centrifu creates bending injector and
gal moments for fuel pump at
pump is the shaft, end of fuel
to weakening it injection,
transmit over time. delivery valve
the breakage also
input aggravates
power cavitations.
from the
driver
into the
impeller
.

Bearing The High heat often Reduced heater Age and wear of Replace Operatio On
function caused by too performance at the electric motor. thermostat, the nal condition
of the much bearing low speeds and water pump or
bearing lubrication, as at idle. the heater core
is to well as
support contamination
the of the bearing
weight lubricant
of the (mostly by
shaft water or
assembl moisture).
y, to
carry
the
loads
acting
on the
shaft,
and to
keep the
pump
shaft
aligned
to the
shaft of
the
driver.

Seals The gasket not  Engine  Check Operatio On

compressed compone injectio nal condition
sufficiently in nts not n
the destroyed that adjustm
section because sealing ent
the specified web  Check
bolt tightening deforme injectio
torque not d on the n valve
observed. engine carefull
block y and
and test
cylinder leakage
head. .
 Engine
not
properly
adjusted,
resulting
in
 overheati
ng.
Oil rings .  Engi  Engi  Cranksh  Diagno Operatio On
ne ne aft sis the nal condition
block over damage cylinde
erosi heati  Overheat r head
on ng ing can  Rearran
 Brok dama cause ge the
en ges piston cranksh
cylin the melting aft for
der cylin due to timing.
gaske der cylinder  Use
t head. head coolant
 Pisto  Crac failure. and
ns ks  Power not
failur insid loss due pure
e e the to engine water
cylin timing. for
der cooling
head down
due an
to engine
over to
heati avoid
ng. overhea
ting.
casing The Functional  Oil  Seizing of the  Clean the Operatio On
casing failure in the consumpti piston in the engine block nal condition
contains casing is on cylinder liner. for any
the caused by leaks  Loss of  Failing of erosion.
liquid in casing power crankshaft  Lubricates
and acts resulting to it  Engine bearings due the piston
as a not being able noise to lubricating rings and
pressure to retain  Excessive oil being make sure
contain pressure inside blow-by diluted by their are
ment the pump. fuel. tight.
vessel  The injector  Position the
that failure in piston
directs turn , were accordingly
the flow caused by into the
of liquid poor quality crankshaft.
in and fuel.
out of
the
centrifu
gal
pump
and
prevent
leakage.

Nozzles   

LITERATURE REVIEW
The diesel engine is a type of internal combustion engine. The injector injects diesel into the combustion
chamber above the piston the piston directly. Diesel engines are also commonly knowns as compression ignition
engine since the diesel is burned due to hot compressed air. The temperature of the air inside the combustion
chamber rises to above 400˚c to 800˚c, which in turn, ignites the diesel which was injected into the combustion
chamber. It’s a 4 stroke diesel cycle operation

 Suction stroke

With the piston moving downwards and opening of the inlet valve creates suction of clean air into the cylinder
  Compression stroke

Compression stroke

With closing of the inlets valve the area above the piston gets closed. The piston moves up resulting in
compression of the air in a confined space under higher compression ratio. Combustion process at this stage the
injector sprays the diesel into the combustion chamber. The rise in temperature of the air caused by its
compression results in instantaneous burning of diesel with in an explosion. This causes heat to release resulting
in generation of expanding forces known as power

 Power stroke

These forces again push the piston downwards resulting in their reciprocating motion.

 Exhaust stroke

On their way up piston push the exhaust gases above them thru the exhaust valve which opens during exhaust
valve which opens during exhaust stroke.

PLAN AND TIME LINE

Resource activities start dates end date duration

Maluleka ZF introduction 1-Apr-17 3-Apr-17 2

Maphalala VS background 3-Apr-17 5-Apr-17 2

Manqele KG problem statement 5-Apr-17 7-Apr-17 3

prioritisation of plant
Maphalala VS item 7-Apr-17 11-Apr-17 5
Maphumulo SC item breakdown 11-Apr-17 14-Apr-17 4

Maluleka ZF most significant items 11-Apr-17 17-Apr-17 6

Maphumulo SC literature review 17-Apr-17 19-Apr-17 2

Manqele KG conclussion 17-Apr-17 19-Apr-17 2

1-Apr-17 8-Apr-17 15-Apr-17 22-Apr-17

introduction

background

problem statement

prioritisation of plant item duration

start dates
item breakdown

most significant items

literature review

conclussion
DISCUSSION
The information in the maintenance plan highlight that there critical components on the machine that need
regular maintenance as compare to other. The diesel engine are subjected to too much friction and heat at high
temperature this results in the engine during operation such that wear of component my occur when the engine
is not been lubricated/serviced properly. This wear may be reduce by regular maintenance and servicing of the
diesel engine, the following procedure can be used to maintain the diesel engine.

Kind of service work Interval

Check for oil, diesel and coolant leaks Daily before operation
Drain and replace the engine oil 500 hours of operation
Change the diesel , oil and air filter 500 hours of operation
Change the diesel water separator 500 hours of operation
Drain and top up coolant 500 hours of operation
Check for loose bolts and mountings 3 monthly
Change the fan belt 1000 hours of operation
Visual inspection on the diesel pump 500 hours of operation
Check the alternator and pulley condition 500 hours of operation
Monitor the timing belt set if timing is not set Annually
accordingly
Perform the pressure test Annually
Visual inspection on the water pump 500 hours of operation
Clean the radiator when still in good condition 500 hours of operation
Visual inspection on the engine Daily before operation
Check the pulley for good condition 1000 hours of operation

CONCLUSION

The diesel engine maintenance report gives steps and guidelines that when carefully followed the maintenance
will be successful and the engine will operate at 100% efficiency as well as the engine life will be maximized.

REFERENCES

1. Maintenance, maintenance Pty ltd South Africa 1998 Jasper I Coetzee

2. Practical approach to Motor Vehicle Engineering and Maintenance, Integra Software Services Pty. Ltd,
Pondicherry, India 2002
3. http://www.howstuffwork.com/entry/14639/1/Engine-maintenance.html
4. www.mtzequipment.com/sites/default/files/manuals/operation%maintenance%20manual
%20d260%202014.pdf

http://www.spabfim.org.uk/pages/understanding_why_maintenance_is_importantat.html