Quality Improvement of Oil and Fuel Leakage in Diesel Engine by using Semi Automatic Setup

Quality Improvement of Oil and Fuel Leakage in Diesel Engine by using Semi Automatic Setup

Surajkumar Hamane1

P.G. Student1

Mechanical Engineering Department

Deogiri Institute of Engineering and Management Studies Aurangabad, Maharashtra

R.V. Chavan2

Assistant Professor2 Mechanical Engineering Department

Deogiri Institute of Engineering and Management Studies Aurangabad, Maharashtra

Sujit P. Khairkar3 Student3

Mechanical Engineering Department Deogiri Institute of Engineering and Management

Studies Aurangabad, Maharashtra

Abstract – Before engine goes to the testing department semi- automatic setup is installed on assembly line conveyor for oil and fuel leakage testing in diesel engine. Trials were taken on various engines by using methodology which includes ATEQ D520 unit and air pressure regulator for finding out leakage quantity. The ATEQ D520 is a flow meter which measures a drop in pressure with a differential sensor. Pressurized air is supplied into the engine through Breather plug and overflow pipe. If leakage not found engine will dispatched to testing department and if leakage is found the problem may solve by spraying soap water in leak area where the bubbles comes out. This work which emphasize on the analysis of problems due to which engine rejects from testing department and also time and cost saving analysis for one month. Due to this setup improvement in PQCDSM, PPM and reduction in cost of poor quality supplied to customers from 28% to 18% of cost per benefit, better Customer satisfaction.

Keywords: ATEQ D520 Sensor, Leakage Detection, Leakage Location, Oil and Fuel connection, PQCDSM, PPM

1. INTRODUCTION

   Leak detection is the process of finding leakages from oil/gas pipelines or from engines may create environmental hazards. Very small leakages may create a big problem. So, the System where leak may occur should possess following terms-Sensitivity-The system should detect minor leaks within a short period. Precision The system should be able to locate leakages precisely. Robustness The leak detection system should have active monitoring in unsteady or non- ideal conditions. Reliability The system should not generate false alarms, even it is highly sensitive.

   The aim of this experimental setup study is 100% leak detection in the system. Leakage may from Oil/gas pipelines, engine oil or fuel leakage to avoid explosions and environmental hazards and safety leak proof system is most important.

   To compensate false alarms when there is no leak in the pipeline, to reduce the response time and Increase the accuracy of leakage location. The idea of Semi-Automatic setup used in such a way that the leakage in the engine is tested on assembly line conveyor before engine goes for

   testing in testing department. Due to this work, Productivity, Quality, Delivery, Safety and Moral of operator is increased. Reduced overall cost of engine considering rejection cost, Labor, transportation, Diesel, oil, Rework cost.

   Many researchers work on this area of leakage testing and they found the computational methodology which permits to detect and locate leakage is based on the on-line analysis of signals originated from pressure, flow and temperature acquired by SCADA. Zhao yang, Mingliang Liu, Min ShaoIngjie Ji Computational method is used which permits to detect and locate leakage based on the online analysis of signals Acquired by SCADA. It is approximate method for leak detection (1).

   Jasper Agbakwuru examines the advances in pipeline third party encroachment alert systems and leak control methods in oil/gas industry. Also highlights extent of spill/pollution issue in Niger Delta region due to intended /unintended damages & suggest possible method of control (2).

   Agbakwuru Jasper Paper suggests that use of optical eye (3D camera) as main tool for managing the challenges in underwater pipeline repairs in unclear water conditions (3).

   Agbakwuru Ahamefula, Jasper, Gudmestad Tobias Ove, Bilstad Torleiv invented the leak response with time when upstream & downstream valves are operated is taken internal diameter of pipeline considered holding and flowing characteristics are find out. This characteristic has been discussed with oil industry operations (4).

   Ali Nasirian result has shown that novel method is used which is step by step elimination method which has capability of detecting leakage In terms of its location and quantity (5).

   1.1.PROBLEM STATEMENT

   Traditionally, Engine leakage testing was conducted by using pressure gauge, applying compressed air on the engine, chalk powder and use of ultraviolent lamp. So from this testing leakage may occur and it was not possible to get 100% leak detection.

   The problem was Engineer will not able to test leakage easily due to overheating of engine joints in fuel line and oil leakage from the engine because these problems are

   not easily detectable. This method was not 100% leak detectable. So instead of dispatching engine to application department it was rejected from testing to assembly for rework on the leakage. Loss of time & cost of engine for rework reduces companies profit & productivity with no customer satisfaction.

2. METHODOLOGY

The semi-automatic set up includes ATEQ D520 unit & air pressure regulator for finding out leakage quantity. The ATEQ D520 is a flow meter which measures a drop in pressure with a differential sensor (transducer).

Pressurized air at 1 bar supplyy to engine Control valve

Filter

Pressure regulator Dryer

ATEQ D520 Unit

Engine to be tested

Flow chart of air supply

1. EXPERIMENTAL SETUP

   The setup consists of ATEQ D520 sensor, Pressure regulator, Air and Fuel line connections for oil and fuel leakage testing. Pressurized air at 1 bar is supplied into the engine through Breather plug & overflow pipe. Supply of air will be 30 seconds stabilization time. If pressure doesn't drops (within 20 seconds) engine is ok and no leak found indicated by green light. If pressure gets dropped in fuel line, engine will get rejected that means engine is not ok & ATEQ D520 indicates Red light. So engine leakage testing is done by spraying soap water on that leak portion due to which bubbles May come out which will indicate leakage at that point.

   Figure 2 Leakage Testing Setup

2. PRINCIPLE OF A CYCLE

   The ATEQ D520 is a flow meter which measures a drop in pressure with a differential sensor (transducer) which is placed at the extremities of a calibrated flow tube. When fluid (air) moves through a calibrated flow tube (laminar flow), a drop in pressure occurs, the value of which is proportional to flow.

   Figure 2.1Principle of a Cycle

   Figure 2.2 Fuel line Air Supply circuit diagram

   Figure 2.3 Air supply through rocker cover & overflow pipe

   Figure 2.4 Leakage findings in the engine whether engine is Ok or Not Ok

3. SEQUENCE OF OPERATIONS

   1. Assembled engines from the trolleys of the line conveyor will come for the leak testing on leak test station for every 90 seconds

   2. Operator has to select air circuit on selector switch provided on set up

   3. Operator can see the respective program on ATEQ D520 sensor which is provided by that ATEQ Company

   4. Remove the rocker cover with the gasket on which breather hole is there

   5. Mount standard rocker cover gauge made to fill air into the engine one supply of airline is given to breather plug hole & other is given to fuel line through oerflow pipe

   6. Deep stick is inserted which measures oil level of engine Oil filter bolt is tightened

   7. Now there is no any phenomenon from where leakage will occur, start the cycle

   8. ATEQ will start Air leak testing cycle- Start, The fill time, the stabilization Time, The test time, Reset, End of Cycle.

   9. ATEQ will give results Ok or Not Ok depending on leakage found or not & the indication of this Ok or Not Ok is presented on lamp

   10. Green light indicates the engine is Ok i.e.no leakage found in the engine. Red light indicate engine is not ok i.e. leakage phenomenon occurred in the engine. mark Ok or Not Ok on engine

   11. Leakage may be from Governor Support O-ring, oil pan, PTO (power take off), push rod tube rubber bush, various Banjo joints of fuel line.

   12. Remove all the plugs from the engine & send engine for next station for next operation i.e. Inspection. Repeat this cycle for next engine

   13. If engine is ok no leakage found dispatched for testing department. If not ok leakage is found hold for a while and clear this problem in rectification.

3. ANALYSIS OF PROBLEMS Implementation on problem analysis is done to minimize cost of engine, rework time, customer complaints, and no. of engine rejection from testing. Outcomes to solve the leakage Phenomenons problems occurrence is captured and listed below for making analysis easier.

Figure 3 Major problem occurring phenomenon analyses

Following are problems while detecting leakage

1. Governor support Stop lever and O-ring leakage

2. Oil pan oil leak due to discontinuous loctite profile

3. Power takes off (PTO) enlarged loctite size

4. 400WG Cylinder head leakage due to water seals.

5. Leakage from FIP (Fuel Injector Pump) NRV (Non Return Valve) Banjo bolt

6. Leakage from diesel filter

7. Leakage from deep stick

   All these problems analysed and tried to improve companys profit, productivity and 100% customers satisfaction with goods supplied to customers.

   The Pareto chart shows that the no. of engines is rejected due to oil or fuel leakage & the Maximum rejection quantity is 30 engines from governor support O-ring & stop lever. Governor support stop lever leakage is supplier problem because stop lever portion has welded joint over it when it is connected to linkage setting lever for fuel supply. Other problem is of Governor Support O-ring which cuts while inserting governor support into the assembly fitment.

   Chart 1 Pareto chart for analysis of leakages

   PARETO CHART

   3.2. TIME SAVING ANALYSIS

   Table No.2- Time saving Analysis

   35

   30

   30

   25

   25

   20

   20 18

   15 13

   10

   10 7

   5

   0

   100.0

   Operation	Time (min)
   Engine loading	5
   Running time	30
   Unloading time	5
   Transport time from Testing to Assembly	5
   Rework time	20(due to overheating )
   Again Transport time from Assembly to Testing	5
   Engine Testing time	40(loading+setting+unloading)
   Total time	110

   Operation	Time (min)
   Engine loading	5
   Running time	30
   Unloading time	5
   Transport time from Testing to Assembly	5
   Rework time	20(due to overheating )
   Again Transport time from Assembly to Testing	5
   Engine Testing time	40(loading+setting+unloading)
   Total time	110

   90.0

   80.0

   70.0

   60.0

   50.0

   40.0

   30.0

   5 20.0

   10.0

   0.0 Series1

   oil leak

   Governor

   oil leak

   FIP NRV Diesel filter oil leak

   leakk from oil pan oil

   from G.S

   Support from inlet

   banjo

   banjo

   from

   oil filter

   leakage

   In 110 minutes 3 engines are tested but due to rejection of

   O- ring

   stop lever port

   rocker cover

   Series2

   engine there is loss of time. Operator tests 12 engines daily on each test bed. If engine is rejected due to leakage there is

   3.1. COST SAVINGS ANALYSIS

   Material	Quantity	Cost
   Diesel	1 Liter	45
   Oil	1.75 Liter	Re-filtration cost
   Tooling	–	–
   Rework material	–	–
   Electricity	_	_
   Blower(compressed air)	_	_

   Material	Quantity	Cost
   Diesel	1 Liter	45
   Oil	1.75 Liter	Re-filtration cost
   Tooling	–	–
   Rework material	–	–
   Electricity	_	_
   Blower(compressed air)	_	_

   Table No.3.1-Cost saving analysis

   loss of one engine. Operator will not consider this engine as rejected and we have to test again he will test the engine as a new. Instead of testing 13 engines he will test only his target engines so loss is there. Real cycle time for testing of engine in testing department is 40 minutes. But, due to leakage problem it becomes 110 Minutes.

   1. DEFECTS BEFORE AND AFTER SETUP IN MARCH 2016

      Chart 3.1 -Cost saving analysis

      Cost saving analysis

      Table No.3-Defect before and after setup

      30,00,000

      25,00,000

      20,00,000

      15,00,000

      25,20,000

      Sr. No.	Leakage problems	Defect Before	Defect After
      1	Rocker Shaft G.S O Ring Cut	30	0
      2	Governor Support	25	0
      3	Oil Leak From Inlet Port	20	0
      4	FIP NRV Banjo	18	0
      5	Diesel Filter Banjo	13	2
      6	Oil Leak From Rocker Cover	10	4
      7	Leak From Oil Filter	07	3
      8	Oil Pan Oil Leak	05	1
      	Defect Quantity	120	10
      	Total Production	7400	7400
      	Total PPM	16217	1351

      Sr. No.	Leakage problems	Defect Before	Defect After
      1	Rocker Shaft G.S O Ring Cut	30	0
      2	Governor Support	25	0
      <>3	Oil Leak From Inlet Port	20	0
      4	FIP NRV Banjo	18	0
      5	Diesel Filter Banjo	13	2
      6	Oil Leak From Rocker Cover	10	4
      7	Leak From Oil Filter	07	3
      8	Oil Pan Oil Leak	05	1
      	Defect Quantity	120	10
      	Total Production	7400	7400
      	Total PPM	16217	1351

      cost saving 23,10,000/-rupees

      10,00,000

      5,00,000

      0

      2,10,000

      BEFORE AFTER

   2. PARTS PER MILLION ANALYSES BEFORE AND AFTER SET UP – MARCH-2016

      Table No.4- Parts per Million Analyses

      PPM for Engine Quality defect	Before setup	After setup
      (Defect) X10,	120 X 1000000/ (7400)	10 X 1000000/
      00,000/ (Total		(7400)
      Production)
      	16,217	1351

      PPM for Engine Quality defect	Before setup	After setup
      (Defect) X10,	120 X 1000000/ (7400)	10 X 1000000/
      00,000/ (Total		(7400)
      Production)
      	16,217	1351

      Cost saving of 435 series Diesel engine is 23, 10, 000/-rupees before and after the setup because earlier 120 rejections per month now this is reduced to 10. Parts per million is calculated for one month and from that respective cost saving.

   3. SET UP IMPACT

      This criterion describes the main goal of this project that was to reduce the problems at PDI Line due to Engine Quality Issue and to improve the sigma level. After calculation Sigma level was found to be improved considerably and Quality improvement in PPM for Engine Quality Defect = 1351ppm from 16,217ppm in month march 2016. It is clear that the setup is more profitable.

      Chart 2 PPM Level

      PPM LEVEL

      PPM LEVEL

      18000

      16217

      18000

      16217

      16000

      14000

      12000

      10000

      8000

      PPM LEVEL

      16000

      14000

      12000

      10000

      8000

      PPM LEVEL

      6000

      4000

      2000

      1351

      6000

      4000

      2000

      1351

      0

      0

      BEFORE

      AFTER

      BEFORE

      AFTER

   4. COST PER BENEFIT IMPACT

      Cost of poor quality (COPQ) has been significantly reduced from 28% to 18% of sale that means if company is supplying 1000 engines to the customer and apart from that 5 engines are rejected due to leakage complaints this loss is reduced by setup which will provide 100% leakage free engines to the customers.

      Chart 3.6.1 – Cost of poor quality

      Cost of poor quality per annum

      	18%

      	18%

      30% 28%

      20%

      10%

      0%

      BEFORE AFTER

   5. CUSTOMER SATISFACTION IMPACT

      Engine assembly/Testing line Department was able to assemble/test more defect free engines than the earlier period. Problem at PDI engine line due to Defects related to Engine quality issues reduce from Avg. 16217 PPM to 1351 PPM per month. The benefit is that there are no single defects reported at Buy off testing stage after implementation of action plan.

   6. OVERALL ANALYSIS

   Ho-Defectives proportion before solution implementation = Defectives proportion after solution implementation

   Ha-Defectives proportion before solution implementation > Defectives proportion after solution implementation

   Table No.5- Overall Analysis

   Sample	X	N	Samples
   1	120	7400	0.01621
   2	10	7400	0.0013

   Difference = p (1) – p (2) Estimate for difference: 0.01491,

   95% lower bound for difference: 0.00539415

   Test for difference = 0 (vs. > 0): Z = 9.77 P-Value = 0.000 Result: P value is <0.05, OR

   (Z at 0=9.77) > (Z at 0.05=1.645)

   So, Ho is rejected.

   It shows that after implementation of solutions on assembly line conveyor Engine manufacturing there is significant improvement by this set up of Oil & Fuel leakage.

   1. CONCLUSION

      1. Improvements in PQCDSM, 100% leak detection in engines. Due to this The tendency of operator/Engineer to work is increased, Customer satisfaction increased, Cost saving due to in-house manufacturing Rs. 6.5 Lac, Reduction in rework cost by Rs. 21,000/ engine.

      2. Cost saving of 23, 10, 000/- rupees in one month as per the engine rejection due to leakage from PPM of March 2016. Time saving upto110 Minutes which was waste for rework of engine.

      3. Before the setup Parts per million was 16,217 and now it is 1351 after the setup. Rejection of engines reduced from 120 nos. to 10 nos. and thus ppm is calculated it clears that setup is more profitable.

      4. The Fuel & Oil leakage testing improvement methodology project Setup shows that the performance of the company is increased to a better level as regards to enhancement in customers (both internal and external) satisfaction, adherence of delivery schedules, development of specific methods to redesign and reorganize a process with a view to reduce or eliminate errors, defects; development of more efficient, capable, reliable and consistent manufacturing process and more better overall process performance, creation of continuous improvement and do it right the first time mind set.

   2. ACKNOWLEDGEMENTS

      We express our gratitude to DIEMS Aurangabad and Greaves cotton ltd. chikalthana, Aurangabad Company which has provided us lot of background information & literature for this study. We are grateful to Mr. Abhijeet Bulge Industrys Head of the department, all managers & supervisors who helped us for making this work successful.

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