Wet stacking is a condition in diesel engines in which unburned fuel passes on into the exhaust system. [1] The word "stacking" comes from the term "stack" for exhaust pipe or chimney stack. The oily exhaust pipe is therefore a "wet stack".
This condition can have several causes. The most common cause is idling the engine for long intervals, which does not generate enough heat in the cylinder for a complete burn. "Idling" may be running at full rated operating speed, but with very little load applied. Another is excessive fueling. That may be caused by weak or leaky injectors, fuel settings turned up too high or over fueling for the given rpms. Cold weather running or other causes that prevent the engine from reaching proper operating temperature can cause a buildup of fuel due to incomplete burn that can result in 'wet stacking'. [2] [3] In diesel generators, it is usually because the diesel engine is running at only a small percentage of its rated output. For efficient combustion, a diesel engine should not be run under at least 60 percent of its rated power output. [4]
Wet stacking is detectable by the presence of a black ooze around the exhaust manifold, piping and turbocharger, if fitted. It can be mistaken for lubricating oil in some cases, but it consists of the "heavy ends" of the diesel fuel which do not burn when combustion temperature is too low. The heavier, more oily components of diesel fuel contain more stored energy than a comparable quantity of gasoline, but diesel requires an adequate loading of the engine in order to keep combustion temperature high enough to make use of it. Often, one can hear a slight miss in the engine due to fuel buildup. When the engine is first placed under a load after long periods of idling and wet stacking, it may blow some black exhaust out as it burns that excess fuel off. Continuous black exhaust from the stack when under a constant load is also an indication that some of the fuel is not being burned. [5] Additionally, wet stacking can result in a build up of diesel fuel in the engine which does not combust due to the low temperature in the engine. This results in a reduced fuel economy. This fuel leaks through the cylinders and dilutes the engine oil. If not frequently changed, this diluted oil can lead to increased wear on the cylinder and premature engine failure. [4]
The diesel engine, named after the German engineer Rudolf Diesel, is an internal combustion engine in which ignition of the fuel is caused by the elevated temperature of the air in the cylinder due to mechanical compression; thus, the diesel engine is called a compression-ignition engine. This contrasts with engines using spark plug-ignition of the air-fuel mixture, such as a petrol engine or a gas engine.
A carburetor is a device used by a gasoline internal combustion engine to control and mix air and fuel entering the engine. The primary method of adding fuel to the intake air is through the Venturi tube in the main metering circuit, though various other components are also used to provide extra fuel or air in specific circumstances.
In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide (NOx) emissions reduction technique used in petrol/gasoline, diesel engines and some hydrogen engines. EGR works by recirculating a portion of an engine's exhaust gas back to the engine cylinders. The exhaust gas displaces atmospheric air and reduces O2 in the combustion chamber. Reducing the amount of oxygen reduces the amount of fuel that can burn in the cylinder thereby reducing peak in-cylinder temperatures. The actual amount of recirculated exhaust gas varies with the engine operating parameters.
Motor oil, engine oil, or engine lubricant is any one of various substances used for the lubrication of internal combustion engines. They typically consist of base oils enhanced with various additives, particularly antiwear additives, detergents, dispersants, and, for multi-grade oils, viscosity index improvers. The main function of motor oil is to reduce friction and wear on moving parts and to clean the engine from sludge and varnish (detergents). It also neutralizes acids that originate from fuel and from oxidation of the lubricant (detergents), improves the sealing of piston rings, and cools the engine by carrying heat away from moving parts.
An oxygen sensor (or lambda sensor, where lambda refers to air–fuel equivalence ratio, usually denoted by λ) or probe or sond, is an electronic device that measures the proportion of oxygen (O2) in the gas or liquid being analyzed.
The Trionic 8 is an advanced engine management system in the Trionic series, created by Saab Automobile. It is used in both Saab 9-3 and Opel Vectra vehicles, and is available with 150, 175 and 210 horsepower (160 kW) engines. It will also be used for a flexifuel version starting production spring 2007. Saab Trionic T8 has been developed by Saab and is a very advanced engine management system. The Engine Control Module (ECM) is used principally to regulated the air mass, fuel and ignition timing.
Homogeneous Charge Compression Ignition (HCCI) is a form of internal combustion in which well-mixed fuel and oxidizer are compressed to the point of auto-ignition. As in other forms of combustion, this exothermic reaction produces heat that can be transformed into work in a heat engine.
A crankcase is the housing in a piston engine that surrounds the crankshaft. In most modern engines, the crankcase is integrated into the engine block.
A diesel particulate filter (DPF) is a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine.
A diesel generator (DG) (also known as a diesel GenSet) is the combination of a diesel engine with an electric generator (often an alternator) to generate electrical energy. This is a specific case of an engine generator. A diesel compression-ignition engine is usually designed to run on diesel fuel, but some types are adapted for other liquid fuels or natural gas (CNG).
The hot-bulb engine, also known as a semi-diesel or Akroyd engine, is a type of internal combustion engine in which fuel ignites by coming in contact with a red-hot metal surface inside a bulb, followed by the introduction of air (oxygen) compressed into the hot-bulb chamber by the rising piston. There is some ignition when the fuel is introduced, but it quickly uses up the available oxygen in the bulb. Vigorous ignition takes place only when sufficient oxygen is supplied to the hot-bulb chamber on the compression stroke of the engine.
In a spark ignition internal combustion engine, ignition timing is the timing, relative to the current piston position and crankshaft angle, of the release of a spark in the combustion chamber near the end of the compression stroke.
Engine efficiency of thermal engines is the relationship between the total energy contained in the fuel, and the amount of energy used to perform useful work. There are two classifications of thermal engines-
A glow plug engine, or glow engine, is a type of small internal combustion engine typically used in model aircraft, model cars and similar applications. The ignition is accomplished by a combination of heating from compression, heating from a glow plug and the catalytic effect of the platinum within the glow plug on the methanol within the fuel.
A free-piston engine is a linear, 'crankless' internal combustion engine, in which the piston motion is not controlled by a crankshaft but determined by the interaction of forces from the combustion chamber gases, a rebound device and a load device.
Crankcase dilution is a phenomenon of internal combustion engines in which unburned diesel or gasoline accumulates in the crankcase. Excessively rich fuel mixture or incomplete combustion allows a certain amount of fuel to pass down between the pistons and cylinder walls and dilute the engine oil. It is more common in situations where fuel is injected at a very high pressure, such as in a direct-injected diesel engine.
Internal combustion engines come in a wide variety of types, but have certain family resemblances, and thus share many common types of components.
Wärtsilä Vasa is an engine series built by Finnish diesel engine manufacturer Wärtsilä. It was released in 1977 and remained in production until 2010. These medium speed diesels were produced in and named after Vasa, Finland. The lead designer of the first engine was Wilmer Wahlstedt. The series comprises three models, the Vasa 22, 32, and 46, with the number denoting the bore size of the engine.
Four-stroking is a condition of two-stroke engines where combustion occurs every four strokes or more, rather than every two. Though normal in some instances at idle, extremely high engine speeds, and when letting off the throttle, such firing is uneven, noisy and may, in cases of malfunction, damage the engine if allowed to continue unabated.
An internal combustion engine is a heat engine in which the combustion of a fuel occurs with an oxidizer in a combustion chamber that is an integral part of the working fluid flow circuit. In an internal combustion engine, the expansion of the high-temperature and high-pressure gases produced by combustion applies direct force to some component of the engine. The force is typically applied to pistons, turbine blades, a rotor, or a nozzle. This force moves the component over a distance. This process transforms chemical energy into kinetic energy which is used to propel, move or power whatever the engine is attached to.
In order to avoid failures from either type of wetstacking, the conventional advice is that the engine should never be operated for extended periods of time at less than half-load. In order to assure that the engine operates at a load of at least 50%, artificial loads are sometimes applied... Wetstacking also occurs when solid carbon or nonvolatile liquids accumulate along the cylinder wall or in the piston ring grooves and inhibit expansion and sealing of the ring against the cylinder wall. The cylinder can become glazed which further contributes to poor charge air compression heating and poor combustion of fuel. The performance of the engine continues to deteriorate until charge air compression heating is no longer sufficient for the engine to operate.
It is already well known that when the diesel engine is operated for long periods at a partial load, a condition known as ‘wet-stacking’ occurs (Donaldson, 2005). This is mainly attributed to incomplete combustion of fuel when the engine runs at low operating temperature. This results in reduced fuel efficiency and, simultaneously, shortening of engine operating life, and the time interval between routine maintenance calls.
Operating the engine without an electrical load for prolonged periods of time (one hour or more) will eventually cause damage to the diesel engine (sometimes called wet stacking which is NOT covered by the engine manufacturer’s warranty) or damage to the rings, fuel oil entering the lubricating oil and excessive vibration. Breaking in the diesel engine can require 5 to 10 hours of operation. It is extremely important to have electrical loads of at least 25% to 50% of the rated capacity of the generator’s nameplate rating to have the valves properly seat.