FAULTS OF FUEL INJECTORS:

1. Over heating OR under cooling:

If cooling of the injector is reduced, either by fuel valve cooling system or poor
heat transfer to the cylinder head, then the working temperature of the injector
will rise. This can cause:-
Softening of the needle and seat which increases the possibility of nozzle
leakage and/or,
Fuel to expand/boil out of the fuel sac, leading to carbon trumpet formation,
and increased levels of HC and smoke in the exhaust gases.
2. Over cooling:
More common on older vessels with separate fuel valve water cooling systems.
When the injector is over cooled, the tip of the injector falls below the
condensation temperature and acid corrosion due to the sulphur in the fuel oil
occurs. This can severely corrode the injector tip, causing the spray pattern to be
affected.
3. leakage from Nozzle:
This fault will produce carbon trumpets as the dribble of fuel burns close to the
tip and the carbon deposits remain. The formation of the trumpets will have a
progressive affect by influencing the spray pattern of the fuel, and this can be
detected in the increased exhaust gas temps and smoke levels.
Nozzle leakage can sometimes be identified by a seat defect(the seat is no longer
narrow in appearance, and is caused by):-
Insufficient cooling,
Dirt within the fuel damaging/abrading the seating area,
Excessive needle valve hammering, due to excessive time in service, excessive
needle lift or spring force.
4. Weak spring:
This will cause the injector to open and close at a lower pressure. Thus the size of
the fuel droplets will increase during these injection periods.
Increased droplet size at the start of combustion will decrease the maximum
cylinder pressure (late combustion), whilst increased droplet size at the end of
combustion will increase the exhaust temperature and smoke (afterburning).
Causes of a weak spring are usually metal fatigue, due to an excessive number of
operations.
5. Slack needle:
Slight leakage between the needle valve and its body is required to provide
lubrication of the moving parts. However excess leakage due to a slack needle
will allow a greater quantity, and larger size of fuel particle to pass between the
valve and body.
The quantity of leakage should not influence injector performance unless
excessive, but dirt particles between the needle and body can increase friction
and make the needle action sluggish.
The cause of a slack needle is usually poor filtration of the fuel causing wear
between needle and body.
6. Poor atomisation:
This will increase the size of the fuel droplets, which will increase the time
required for combustion. Thus engine noise, exhaust smoke, exhaust
temperatures, etc will increase. Poor atomisation can be caused by low injection
pressure (fuel pump wear), high fuel viscosity and nozzle hole obstruction such as
carbon trumpets.
7. Poor penetration
This will reduce the mixing which occurs between the fuel and air, and will
increase the over-rich areas in the centre area of the cylinder. Thus only following
combustion in the centre area will the expanding gases move the fuel charge into
the air rich outer ring of the cylinder where the greatest mass of air is present.
This will increase the time required for combustion as the fuel/air mixture is not
correct in many areas, and hence afterburning, exhaust temps, and smoke will
increase.
Causes of poor penetration is reduced injection pressure, and nozzle hole
blockage such as trumpets or sac deposits.
8. Over penetration
This will occur when the air density within the cylinder is reduced, or with over-
size holes. The liquid stream travels too far into the cylinder, so that a high level
of liquid impingement on the liner wall takes place. This will remove the liner
lubrication, and once burning will greatly increase the liner wall temperature, and
its thermal stress.
If this over penetration is caused by prolonged low power operations, then slow
speed nozzles should be fitted.
Slow steaming nozzles can be used when regular and prolonged engine operation
is required between 20-50% power.
The nozzle hole diameter is reduced to
i. Reduce the penetration that will occur into the less dense cylinder air
ii. Keep the atomisation level and injection pressure sufficient, as mass flow rate
is reduced.
If the engine is operated for long period on low levels of power/speed with
`normal size injector nozzles, then the atomisation will reduce, thus engine
noise, mechanical loading, exhaust smoke, exhaust temps, and fuel consumption
will increase.
EFFECT OF FAULTY FUEL INJECTORS:
1. Greatly enlarged holes cause overheating, perhaps burning of piston upper
surface, also cause carbon deposits in the piston cooling space, if oil cooled. It
may also cause increased cylinder and piston ring wear
2. If the holes are chocked, the fuel sprays will be effected to the extent that
imperfect combustion will result. This in turn may reduce the power output quite
considerably and bring about all the mechanical troubles usually associated with
after burning.
3. If the injectors leaky or spring is damaged, burning of piston upper surface,
also cause carbon deposits in the piston cooling space, if oil cooled. It may also
cause increased cylinder and piston ring wear and can lead to scavenge fire.
INDICATION OF FAULTS:
1. Early injection is usually evidenced by knocking in the cylinder. On the power
diagram the maximum pressure will be considerably in excess. Exhaust
temperature will be low.
2. Leaky valve can be detected through indicator diagram, which show reduced
combustion pressure. This will be some reduction in power output, increasing in
exhaust temperature about 10oC and smoky gases. Chocking of atomizer and
exhaust ports. Surging in turbo-blower are also some of the indication
3. After burning will cause higher exhaust temperature and pressure. The
maximum height of both the power and draw diagram would be reduced. Other
indications are smoky exhaust, possible fires in uptake, fouling of exhaust
system, surging of turbo-blower
4. Choked fuel injectors combustion efficiency of an engine depends on fuel
atomization, shape and direction of the fuel sprays. So the holes should be clear
and clean. First outward indication of accumulation of carbon deposits will be
increase in the exhaust temperature due to fuel not mixing properly with the air,
consequently not burning completely in the allocated time. Power output is
reduced and the exhaust is smoky.
MAINTENANCE
o Fuel injectors must be kept in good condition to maintain optimum
efficiency, and to prevent conditions arising which could lead to damage
within the cylinder.
o Injectors should be changed in line with manufacturers
recommendations, overhauled and tested.
o Springs can weaken with repeated operation leading to the injector
opening at a lower pressure than designed.
o The needle valve and seat can wear which together with worn
nozzle holes will lead to incorrect atomization and dribbling.
o Proper cooling should be made during operation. Cooling passages
to be cleaned during overhaul.
o Proper grade of fuel oil should be used and it should be used after
proper purification to prevent atomized holes become enlarged, conical
and oval due to abrasive materials.
o The valve body and valve needle should always be considered as a
unit, not as two separate pieces and they should be renewed together.
o The holes should be cleaned and cleared properly without damaging
by blown with compressed air.
o The valve needle must be perfectly fluid tight when in the closed
position and must open and close smartly.
o The cam operating the fuel valves or the fuel pump, as the case may
be, should effect opening and closing in the shortest time practicable.