MILITARY SEALIFT COMMAND

Diesel Doctor Training

Reciprocating Engine Analysis
 Learning Objectives

Upon Finishing this Training, the student will be able to

• List Benefits of Performing Reciprocating Analysis

• Connect the Doctor Dk-2 cables correctly

• Explain How to Find Engine DTAG information

• Explain the Operating Parameters necessary for a Valid

Doctor Reading

• Explain the required Safety Precautions

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 Learning Objectives
Upon Finishing this Training, the student will be able to
• Specify the correct starting cylinder and cylinder order for
data collection

• Explain Doctor DK-2 Pressure Reading memory management

• Explain Crank Pickup functionality

• Demonstrate how to take Pressure Readings correctly

• Demonstrate how to verify a good reading before moving on

to the next cylinder

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 Learning Objectives

Upon Finishing this Training, the student will be able to

• Explain accessing the SAMM Reciprocating Analysis Module

• Explain editing an Engine Setup

• Explain correctly transferring the Doctor DK-2 Data to SAMM

correctly

• Verifying the data downloaded is valid data for the Engine

selected

• Analyze the data effectively

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 Why is Engine Analysis important?

Marine Engines are complex machines

Engines are not built from clear

materials

We can take a pressure sample of the

combustion chamber to find out what’s
happening inside.

2 – Stroke Engine

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 Why is Engine Analysis important?
Reciprocating Analysis tools show the pressure curve
inside the cylinder

• Demonstrating status of engine before and after

servicing
• Troubleshoot anything affecting cylinder pressure
• Injectors
• Valves
• Timing issues
• Etc..
• Reduce catastrophic failures by seeing problems early
• Balancing the cylinder load
• Have better fuel savings
• Less Vibration
• Reduce wear on components

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 Historical Context
• Analyzing pressure in steam reciprocating engines
• Check valve timing
• Condensation in Cylinders
• Pressure inflow and outflow
• Calculate Cylinder Power

Example Steam
Indicator card

Barton and Stickney, Naval Reciprocating Engines and Auxiliary Machinery, 1914, pgs 214, 215, 225

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 Historical Context
• Higher Temperatures
/Pressures
• Polar Planimeter for
Measuring Manual
Power Calculations
• Analyzing Combustion

Indicator Card

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 Modern Electronic Indicator Card
With modern technology comes modern
solutions

• Repeatability
• Less prone to mechanical errors
• Digital database storage
• Precise calculations
• Compare trending over time
• Historical Data easily searched and
accessed

Military Sealift Command has chosen the

Diesel Doctor System, units maintained,
calibrated and data analyzed by Emprise
Corporation.

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 Analysis Ashore

• Analysis Ashore requires valid data

• Capture errors before you download the data into SAMM

• Shore Analyst
• Provides data analysis within 72 hours
• Entered into Notepad for each data sample
• Significant issues will generate Work Requests
• Shore Analyst can only provide a recommendation!
• Vessel Engineers are the ultimate authorities for the
operation and maintenance of their assets
• Continuously improve the process with communication

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 RA Shore Analyst

Emprise Analysts
(PM 1,2,3) Joseph Muchulsky:
[email protected]
(PM 4,5,6) Michael Wilson:
[email protected]

• Review data within 24 hours

• Can be reached by email for specific analysis
• Engine Balancing/tuning
• Overhaul QA

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 Pressure Sensor

Kiestler Pressure Sensor

Pressure Sensor

Piezo-electric Crystal Extension Cable

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 Crank Sensor
Gap 3mm

Magnetic Proximity Sensor

Gap 3mm

Bolt head to be clear of flywheel surface by a minimum of 8mm

(for 18mm pickup)

Picture Showing Dual Pickup Installation

Proximity Sensor installation 4-strokes have 1 sensor

2-strokes have 2 sensors

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 Junction Boxes

Crank Interface Cable

Junction Boxes
• Connecting Crank Interface Cable
• Large Engines may have 2+

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Diesel Doctor Installation

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 Diesel Doctor DK-2 Interface

Cylinder Pressure Battery Charger

Input LCD
Displa Input and Power
y Circuit Indicators.

RS-232
Communication 100 - 240 VAC Input -
Output -- 9 VDC Output
Battery Charger

ON/OFF Switch

User Keypad
Inductive Crank
Pickup Input
RS 232 Computer Communication Cable
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(Null Cable, not just any RS 232 Cable)
Diesel Doctor DK-20 Interface

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 Diesel Doctor DK-20

Diesel Doctor DK-2 Units are obsolete

• Currently most Vessels in MSC have the DK-2
• Not supported by OEM, Emprise has been maintaining current stock
• No longer feasible due to lack of parts and spare units

DK-20 is the drop-in replacement unit

• DK-20 uses same sensors as DK-2
• DK-20 uses same Charging Cable
• Only difference is connection to Workstation (Mini-USB instead of RS-232)

Transition Process
• All MSC ships are being phased from DK-2 to DK20
• New Software needs to be installed

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 Engine DTAG Information
• What is DTAG and Where do I find it?
• DTAG = Diesel Test and Analysis Guide
1: Open Machinery History

2: Expand Hull

5: Select Most Recent “VTAG/DTAG” Entry

3: Expand Certificates and

Documentation
5: Double Click on the VTAG or DTAG
to open

4: Select “Vibration and Diesel Test Analysis

Guides

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 Engine DTAG Information
Engine Cylinder and Power Info
Characteristics

Operating Conditions Doctor Dk-2 Recommended

For Taking Readings Memory Management

Pressure Readings
Cylinder Order Starting
Cylinder

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 Engine Examples

• Example: Hershel-Williams

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 Engine Examples
• Example: Kanawha Main Propulsion

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 Safety
WHEN TAKING COMPRESSION READINGS FROM A RUNNING ENGINE,
WEAR YOUR PPE!

Face Shield/Goggles Hearing Protection Safety Shoes Gloves Protective Clothing

Significant Hazards:

Rotating Machinery Hot Surfaces Airborne Particles Slips, Trips, Falls

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 Doctor Dk-2 Setup
Dk-2 can be used for standalone analysis
For MSC Ships, SAMM is used for the analysis
Dk-2 setup is simplified for downloading into SAMM

Data Collector should already be setup before being sent to the ship

4 Stroke Engine: 40 Average Samples

2 Stroke Engine: 20 Average Samples

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 Doctor Dk-20 Setup
Charge the DK-20 fully before using
To Set Up the DK-20, plug in included Mini-USB standard Cable

Login To SAMM using your CAC

card

Right Click SAMM Icon in System Tray

(You may need to click^ First)

Select “SAMM DK-20”

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 Doctor Dk-20 Setup
DK-20 will clear out any prior engine configuration and upload your
vessel’s engine configuration

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 Taking Pressure Readings
• Verify Two ways
• 1: Crank Setup mode
• Displays RPM, useful for engine testing

• 2: Emprise TDC Sensor

• Verify at slow speeds /
slow rolling engine

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DK-2 Memory Management
Engine 1 Memory Engine 2 Memory
Cylinder 1A 1 Cylinder 1A 21
Cylinder 2A 2 Cylinder 2A 22
Cylinder 3A 3 Cylinder 3A 23
Cylinder 4A 4 Cylinder 4A 24
Cylinder 5A 5 Cylinder 5A 25
Cylinder 6A 6 Cylinder 6A 26
Cylinder 7A 7 Cylinder 7A 27
Cylinder 8A 8 Cylinder 8A 28
Cylinder 1B 9 Cylinder 1B 29
Cylinder 2B 10 Cylinder 2B 30
Cylinder 3B 11 Cylinder 3B 31
Cylinder 4B 12 Cylinder 4B 32
Cylinder 5B 13 Cylinder 5B 33
Cylinder 6B 14 Cylinder 6B 34
Cylinder 7B 15 Cylinder 7B 35
Cylinder 8B 16 Cylinder 8B 36

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 Error Capturing
Unlike ViPre, no software requirement time limit.
Test Conditions should remain constant throughout the duration of the test
(Speed/Load), and often take at least a moderate amount of time.

Tests are usually planned events due to vessel operations interference

• Machinery Startup may affect Generator Engine Tests
• Vessel Course/Speed changes may affect Propulsion Engine Tests

Once you Download the Data, often the “Planned Event Time” for Engine Testing is done

Its best to Capture and Correct errors before you download:

• Verify Consistent RPM Signal before you start
• Normal Engine fluctuations
• Crank Signal connection is good

• Verify individual cylinder readings are good before moving to next cylinder
• If the problem needs to be addressed, close Indicator Valve to protect Sensor
• Verify 2 Green Thumbs up before pressing “Go”

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 Data Validation

Wait for This Screen to Finish Bad Cylinder Reading

If this is what you see, correct the
issue, press “Main”, select previous
memory and press “Go” Again.

Correct Memory
For Cylinder Pmax is good

DK-2 DEFAULTS TO NEXT

Pressure Curve is MEMORY NUMBER FOR
valid
PRESSING “GO”
Verify Good Reading for that Cylinder

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 DK-20 Engine Readings

Review Collected Data

Take individual Readings

Start a full set of
readings of an Engine

Extra Functions

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 DK-20 Engine Readings

Select the Engine Enter Scavenge Pressure

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 DK-20 Engine Readings

DK-20 Collection Screen

Selected Engine Abort Readings and go
to Home Screen
Cylinder Selection
View Graph

Status Indicator View Table

Pressure Sensor check

Cylinder Navigation

Crank Sensor check

Collection Data Summary

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 DK-20 Engine Readings
Sensor Errors

Sensor or Cylinder errors

will indicate onscreen and
the Go Button will “Blink”

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DK-20 Engine Readings

Click the “Ready” Window or “Go” button

(when solid green) to take the reading

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 DK-20 Engine Readings

Interrupting the Test Finished with Readings

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 Emprise RA Simulator
Diesel Engine Simulator/RA Signal Generator
• Produced for simulation purposes
• Powered by 9V battery
• Memory points 1-8 for Diesel Doctor Test engine

Provided to MSC Vessels with Diesel Doctor Kits

Training Use
• Can be used to simulate collecting data in a more forgiving
environment
• Conducive to Training

Testing Use
• Test the full collection process with Diesel Doctor Units

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 DK-20 Engine Readings

Intermission to take Sample Readings

• Simulate In-Line 8 Cyl Eng with Diesel Doctor Test Engine

• Simulate common collection issues with sample Indicator valve and sensors

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 DK-20 Engine Data
To Download Data, plug in included
Mini-USB standard Cable

Login To SAMM

Right Click SAMM

Icon in System Tray

Select “SAMM DK-20”

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 DK-20 Engine Data
Transfer Screen

Reading Selection Engine Load Selection

Process Steps

Process Selected Reading

Delete Selected Reading
*DELETES PERMANENTLY – DATA UNRECOVERABLE

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 Diesel Doctor Software
Reciprocating Analysis Software
Included in CMS “Condition Monitoring Software”
Multiple ways to Access “RA” software:

SAMM Utilities “RA” Link from Workbook From Within CMS Module

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 Diesel Doctor Software

Graph View Table View

Bar Graph
Download View
Data

Measurement
Engine Selection
Select

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 Diesel Doctor Software

Cylinder Firing Order

Right Click on Selected

Engine click “Edit Engine” Engine Setup Screen

This is where you can

include important additional Table Fields
readings that have to be
obtained seperately
User Data

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 Downloading Data
IMPORTANT – Make Sure Correct Engine is Selected
Click “Download Data” Icon
Select Cylinder 1 and 1st Memory on Dk-2 Click Auto Connect

If Connection Error, adjust COM port

under “Download” Menu

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 Finishing Transfer

Fuel Pump Rack

Readings

Scavenge Air Pressure

Click Save

Click Transfer
Fuel Pump Index
(Rack Readings)
After Transfer, and entering Rack
Readings, Click Close

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 Adding User Values

Select Cylinder

Click User Values

Right click on Measurement

Click “Edit Sample”
Enter Exhaust Temp and Fuel
Pump Index For Each Cylinder

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 Adding Extra Data
Diesel Doctor only captures RPM and Cylinder Pressure information from engine.
Additional Engine Condition Parameters should be taken to facilitate a more
complete “snapshot” of the running condition of the Engine.
• Fuel Pressure
• Jacket Water Temp
• Scavenge Air (Boost) Pressure (per Bank)
• Intercooler Temperatures
• Intercooler Pressure Drop (usually manometer)
• Turbocharger RPM
• Invidual Cylinder Rack Readings
• Individual Cylinder Exh Temps
• Etc…

This can be done multiple ways:

• Picture of Console
• Screenshot of Console screens
• Spreadsheet with included information (Rounds sheet)
• Etc…

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 Adding Extra Data

For Selected Engine, Selected Test, Attach File

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 Diesel Doctor Software

Double Click on the downloaded data

By Default Crank Angle Based

Pressure Plot Appears

Crank Angle Based Pressure Diagram

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 Is My Data Valid?

Good Data Cylinders Taken out of order

Banks Taken out of Order of a Vee Engine One Bank Good, One Bank out of order

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Data Collection Errors
Flat Line

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Data Collection Errors
Spikes in Trace

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Data Collection Errors
Pressure Sensor Connector

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Data Collection Errors
Intermittent TDC

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 Different Data Views

Data Table Pressure Derivative Plot

Bar Graph P-V Diagram

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Analyzing Table Data

How you can compare

variations of values like
peak pressures, exhaust
temps, power, etc..
Peak pressures +/- 5%
for good balance

Another Way to Add User

Values, Double Click on
“???”

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Analyzing the Bar Graph

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Pressure Curve

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 Pressure Curve Cycle
Peak Fire Pressure

Maximum Pressure Rise (combustion)

Start Combustion

Comb
ustio
n Per
iod
Peak Fire Pressure Angle Intake Open
Compression Reference
Exhaust Open

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 Intake
Close

Injectio
n Start

Ignition Star
t

Injectio
n End
Ignition
End

Exhaust Open

Intake and Exhaust Open

4 Stroke Engine Diagram

Exhaust Close
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 Intake and Exhaust Ports Open

Compression Stroke, Ports Closed

Start Injection

Start Combustion

End Injection

End C
ombu
stion

Exhau
st Po
rt Op
en

Intak
e Por
t Ope
n
2 Stroke Engine Diagram

Intake and Exhaust Ports Open

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Analyzing Pressure Curve
Late Injection

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Analyzing Pressure Curve
Late Injection

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Analyzing Pressure Curve
Late Injection w/ Derivative Plot

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Analyzing Pressure Curve
Clogged Injector

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Analyzing Pressure Curve
No Combustion

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Analyzing Pressure Curve
Early Injection

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Analyzing Pressure Curve
Early Injection

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Analyzing Pressure Curve
Early Injection w/ Derivative Plot

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Analyzing Pressure Curve
Low Compression

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Analyzing Pressure Curve
Indicator Valve Leak

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 Injector Spray Problems

GOOD FAIR BAD BAD BAD BAD

Even Cone Weak Split Spray Jetting on Feathering at Dribble
One Side Top of Spray

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Analyzing Pressure Curve
Clogged Injectors

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Analyzing Pressure Curve
Replaced Injectors, Still Engine Imbalance

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Analyzing Pressure Curve
Bank Imbalance

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Analyzing Pressure Curve
Indicator Valve Restriction

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 Analyzing Pressure Curve
Indicator Valve Restriction

Indicator Valve partially open Problem corrected, data retaken

(significantly reduced and graph shifted to the right)

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Data Collection Errors
Flat Line

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Data Collection Errors
Spikes in Trace

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Data Collection Errors
Pressure Sensor Connector

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Data Collection Errors
Intermittent TDC

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 Shore Analysis
Shore Analyst reviews the data when data replicates ashore
• Data is entered into the Notepad for each Test
• Analysis is emailed directly to the Chief Engineer

Cylinder Balance Index

• Compares all Cylinder Peak Pressures on a Standard Deviation Curve
• Quick Summary Indicator for how well balanced an engine is
(All cylinders to each other)
• CBI, when compared over time, can be used to trend the material
degradation of an engine since its last overhaul.

GOOD FAIR POOR

CBI < 0.036* 0.036 ≤ CBI < 0.050 0.050 ≤ CBI

*Differences between Good/Fair/Poor started off as educated guesses but over

time and hundreds or thousands of engine data downloads and analysis’ have
solidified the estimate. It’s just a summation, not a deep analysis.

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 USNS Montford Point

Derivative Curve
Depressed PFP
• USNS Montford Point showed poor CBI
• 2 Cylinders significant PFP depression
• Analyst put in Work Request
• Vessel Engineers Investigated.
• All but 1 Cylinder demonstrated broken Injector
Spring (highest PFP in above curves)
• Spring Failure Rate was corrected due to running
hours
Broken Inj Springs

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 Final Thoughts

• This is a tool! Use it to keep engines running in top shape

• Use it as part of Engine Overhaul Q/A Process
• Minimize Errors during data collection
• We see the data as it arrives. If there is a problem, C/E will get an
email.
• Any problems, contact us as soon as they happen

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