Training Manual

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS
IM BA TOR
E MARINE
E LL CO
G E
GME & BS TRAINING MANUAL
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OPERATIONAL LEVEL TRAINING MANUAL REFERENCE
Function: Operate Main and Auxiliary Machinery and Associated Control Systems Pumps & Pumping Systems Maintenance & Repairs
CREDIT : MR.A.RAMASWAMY COMPILED BY B.K.KUMAR ( GME HOD )
COMPETENCE NO- 6 Function: Operate Main and Auxiliary Machinery and Associated Control Systems.
ASSIGNMENT NO: 4
Que1-Name the parts of four stroke engine and write down briefly the function of each? Ans1- The parts of four stroke engine are: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) Cylinder head Piston Liner Connecting Rod Crank shaft Bottom end bearing Main Bearing. Bottom end bearing bolts Exhaust valve Inlet valve Push rod Rocker arm. Jacket Turbocharger. Fuel Valve Air Starting valve Relief valve Fuel pump.
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ASSIGNMENT NO: 8 Que1- Write notes on bottom end bearings, working clearances and lubrication? Ans1- Bottom end bearing transmit similar loads to those in the crosshead, but there is the benefit of continuous sliding movement between crank pin and bearing surfaces which establish an oil wedge and fluid film lubrication. Working clearance of bottom end bearing is 0.3mm. Lubrication is required to reduce friction and wear of metal surfaces. It keeps metal surfaces clean by carrying away possible deposit and providing a seal to keep out dirt. It also carries away the heat generated in bearing preventing over heating seizure and possible breakdown.
Que2- Write down the safety precautions, procedures for dismantling and assembling the bearings of 4 stroke engines? Ans2-Precautions to be taken:1. Isolate L.O, JCW, F.O and starting air lines. 2. Open indicator cock and engage turning gear. 3. Put a note Men Working on engine and control room.
Procedure for dismantling of bottom end bearings is down as follows: Please refer Engine Manufacturer manual and instructions given: 1. Drain the JCW from the particular unit. 2. Remove all the cylinder head connections (a. High pressure fuel pipe b. exhaust manifold connection c. scavenge manifold connection d. starting air line connections e. pilot air connection, etc.,) 3. Open the crank case door on both sides. 4. Remove all cylinder head holding down nuts. 5. Remove the push rods. 6. Lift the cylinder head from its place. Keep it on the floor on wooden piece. 7. Clean the piston lifting tools fitting groove on the piston (threaded passage) with proper tape and fit the lifting tool.
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8. Turn the engine to BDC. 9. Clean the liner top portion (remove the ridges and carbon). 10. Lock the liner with special tool. 11. Turn the piston and keep it in position of 300 after TDC. 12. Open the bottom end bearing bolts and remove the bottom end bearings bottom keep along with its shell bearing.
13. Now lift the piston carefully and slowly with the help of overhead crane and with chain block and place it on its working stand (during lifting, please take care of the bottom end bearing top shell.) 14. Clean the crankpin and take the diameter using a Micrometer. 15. Connect the bottom end bearings bottom keep to the top keep with bottom bearing bolts and tighten it to the proper torque. 16. Measure the inside diameter of the bottom end bearing at different position. 17. Using the crankpin diameter and the above measured diameter calculate the bottom end bearing clearance and compare it with manufactures data.
ASSIGNMENT NO: 9 Que1- How does a fuel valve work?
Ans1- The fuel is delivered by the fuel pumps to the fuel injectors or fuel valves. For the fuel to burn completely at the correct time it must be broken up into tiny droplets in a process known as atomization. These tiny droplets should penetrate far enough into the combustion space so that they mix with the oxygen. The temperature of the droplets rise rapidly as they absorb the heat energy from the hot air in the cylinder, and they ignite and burn before they can hit the relatively cold surface of the liner and piston.
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Fuel injectors achieve this by making use of a spring loaded needle valve. The fuel under pressure from the fuel pump is fed down the injector body to a chamber in the nozzle just above where the needle valve is held hard against its seat by a strong spring. As the fuel pump plunger rises in the barrel, pressure builds up in the chamber, acting on the underside of the needle as shown. When this force overcomes the downward force exerted by the spring, the needle valve starts to open. The fuel now acts on the seating area of the valve, and increases the lift. As this happens fuel flows into the space under the needle and is forced through the small holes in the nozzle where it emerges as an "atomized spray". At the end of delivery, the pressure drops sharply and the spring closes the needle valve smartly. Older loop scavenged engines may have a single injector mounted centrally in the cylinder head. Because the exhaust valve is in the centre of the cylinder head on modern uniflow scavenged engines the fuel valves (2 or 3) are arranged around the periphery of the head. The pressure at which the injector operates can be adjusted by adjusting the loading on the spring. The pressure at which the injectors operate vary depending on the engine, but is in the range of 280 ~ 320 bar. Some injectors have internal cooling passages in them extending into the nozzle through which cooling water is circulated. This is to prevent overheating and burning of the nozzle tip. Injectors on modern 2 stroke crosshead engines do not have internal water cooling passages. They are cooled by a combination of the intensive bore cooling in the cylinder head being close to the valve pockets and by the fuel which is recirculated through the injector when the follower is on the base of the cam or when the engine is stopped.
As well as cooling the injector, re circulating the fuel when the engine is stopped keeps the fuel at the correct viscosity for injection by preventing it from cooling down.
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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. Injectors should be changed in line with manufacturers recommendations, overhauled and tested. Springs can weaken with repeated operation leading to the injector opening at a lower pressure than designed. The needle valve and seat can wear which together with worn nozzle holes will lead to incorrect atomization and dribbling. .Que2- What do you understand by atomization? Ans2- Atomization is the process of increasing surface area of the droplets to obtain better mixture with the air. As the fuel passes into the fuel valve it approaches the lower chamber and forced out through tiny holes. The small holes are sized and arranged to atomize as break into tiny drops all of the fuel oil which will then radically burn.
Que3- What is the working pressure of fuel valve? Ans3- The working pressure of fuel valve is around 275kg/cm to 325 kg/cm.
Que4- What precaution to be taken while testing fuel valve? Ans4- The precaution to be taken while testing fuel valve is:1) Use proper testing equipment. 2) Dont allow the atomized fuel to fall on your body. 3) Do not put your hand bellow the fuel valve while testing which may cause blood poisoning. 4) Que5- What do you understand by dripping? Ans5- Dripping is the phenomenon of leaking of fuel injector before, during or after the injection of fuel without proper atomization. Dripping occurs due to the damage seat or needle valve struck due to carbonized fuel or due to loss of resilience of pressure spring. Que6- What is the meaning of blood poisoning? Ans6- The nozzle injects the fuel spray under very high pressure i.e. is about 250 bars. While testing if by mistake any part of body comes in contact with the spray, the fuel oil enters into the blood stream which may lead to blood poisoning.
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ASSIGNMENT NO 10 Que1- What is the difference between inlet and exhaust valve? Ans1- Inlet valve allows the charged air to enter the combustion chamber, where as the exhaust valve allows the exhaust gases to leave the combustion chamber. Inlet valve opens during intake stroke before TDC, and exhaust valve opens during exhaust stroke before BDC. Exhaust valve requires a cooling medium where as inlet valve do not require any cooling medium.
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Que2- What do you understand by tappet clearance? Ans2- The clearance between the valve spindle (edge) and the rocker arm is tappet clearance. The clearance is necessary to take the thermal expansion of the valve spindle. Excessive tappet clearance will cause the valve to open late and close early in the cycle and will reduce its maximum lift. It will also cause noise and eventually damage from the impact of working surface. If the tappet clearance is less it may result in improper closing of valve.
ASSIGNMENT NO: 11 Que1- How Does a Fuel Pump Work? Ans1- A fuel pump consists of a barrel in which a plunger reciprocates when driven by a cam shaft. When the plunger is at bottom of its stroke, the fuel flow through the inlet port into the barrel and fills the space above the plunger and also vertical grooves. As cam rotates it lifts the plunger through barrel. This will lead to the closing of barrel port. As it continues to move upwards the fuel is discharged through delivery valve into high pressure line. Delivery of fuel ceases when plunger has passed and opens the spill port. The delivery valve returns to its seat. Que2- What do you understand by plunger and barrel? Ans2- The pumping action in fuel pump is achieved by reciprocating plunger inside a barrel. The barrel consists of two readily opposite holes i.e. inlet port and spill port. A vertical channel extending from top face to plunger to an angular groove is provided on upper part of plunger. Pump barrel and plunger has very small clearance between them, such a lower clearance provide a perfect seating without special packing even at a high operating pressure and low speed.
Que3- How is the delivery of the fuel terminated and quantity of fuel delivered is regulated? Ans3- The plunger pressurizes the fuel trapped in space above the plunger during the upward movement, delivering the fuel to the injector. Injection process continues till the end of upward stroke of plunger. When lower end of helix uncover the spill port, with this pressure of fuel in barrel suddenly drops. Both spring loaded injector and delivery valves suddenly gets closed and injection process is terminated. Fuel Quantity Regulation: The amount of fuel delivered per stroke is controlled by rotating the plunger by means of a control rail. A plunger is rotated by means of a control rail which
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affects position of helix coming in front of inlet port, thus varying effective stroke of plunger, there by fuel regulation is done. Que4- What do you understand by helical groove and where will you find the same in a fuel pump? Ans4-The helical groove is provided on the fuel pump plunger top end portion in order to regulate the fuel.
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ASSIGNMENT NO
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Que1- What is the function of camshaft? Ans1- Camshaft is used on diesel engine to operate the mechanism connected with opening and closing exhaust valves, air inlet valves, air starting pilot valves, driving fuel pump etc, which control the engine cycle. Each valve or pump is activated by a cam follower, which rises or falls as the cam rotates beneath it. Camshaft is driven by power transmitted from the engine crankshaft through gears. Camshaft rotation must be accurately synchronized with the crankshaft and timing must be checked periodically and after any adjustment or repair is carried out.
Que2- How inlet and exhaust valves are opened? Ans2- The inlet and exhaust valve are mechanically actuated from a camshaft. The shape of the cam controls the timing and lift of the valves. The rotation of cam peak raising the follower and push rod to operate a valve spindle through a tappet and causes the valve to open.
Que3- How is the fuel pump operated? Ans3- A fuel cam is designed to raise the plunger at the rate required to build up fuel pressure and maintains this for the corresponding period to operate the fuel injected, since the pump only discharge on its upstroke only one flank of the cam operates the timing. The trailing flank of the cam returns to plunger at the bottom of the stroke to allow the chamber to refill. Timing is controlled by the relative angular position of the cam peak to the crankshaft. It can be adjusted by moving the cam with respect to the shaft.
Que4- What is the relationship between the rpm of crankshaft and camshaft? Ans4- For four stroke engine camshafts rotates at a speed half the speed of crankshaft, where as in two stroke engines cam shaft speed is same as that of crankshaft speed
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ASSIGNMENT NO
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Que1- How does lubrication in four stroke diesel engine takes place? Ans1- Lubrication in four stroke diesel engine is done by a shaft driven gear pump taking drive through the crankshaft through gears. Pump takes suction from sump and transmits it through bore in the crankshaft and connecting rod.
Que2- What are the materials used for gear? Ans2- Case hardened alloy steel is used for gears.
Que3- Before starting a diesel engine what precautions are taken regarding lube oil? Ans3- Following are the precautions to be taken for lube oil before starting the engine:3.1 Level of lube oil is checked in the sump by a dip stick. 3.2 Check the condition of the lube oil. 3.3 Check the turbocharger lube oil (turbine side and bearing side) 3.4 Check the Alternators pedestrian bearing lube oil level or flow of oil 3.5 Check the rocker arm lube oil level and condition of lube oil. 3.6 Check the crankcase doors venting line is clear.
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Que4- Sketch the lubricating oil pump and indicate the safety features of the oil pump? Ans4-
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ASSIGNMENT NO 15
Que1- How is fuel supplied to the fuel valve in a 4 stroke diesel engine? Ans1- In a 4 stroke diesel engine the primary fuel pump supplies oil to the individual fuel pump mounted on every unit, then the fuel pump again builds up the fuel oil pressure in order to supply to the fuel valve.
Que2- Sketch the complete fuel oil arrangement for a diesel engine? Ans2- Fuel oil system:-In the system shown in figure the oil is stored in tanks in the double bottom from which it is pumped to a settling tank and heated. After passing through centrifuges the cleaned, heated oil is pumped to a daily service tank. From the daily service tank the oil flows through a three-way valve to a mixing tank. A flow meter is fitted into the system to indicate fuel consumption. Booster pumps are used to pump the oil through heaters and a viscosity regulator to the engine-driven fuel pumps. The fuel pumps will discharge high-pressure fuel to their respective injectors. The viscosity regulator controls the fuel oil temperature in order to provide the correct viscosity for combustion. A pressure regulating valve ensures a constant-pressure supply to the engine-driven pumps, and a pre-warming bypass is used to heat up the fuel before starting the engine. A diesel oil daily service tank may be installed and is connected to the system via a three-way valve. The engine can be started up and manoeuvred on diesel oil or even a blend of diesel and heavy fuel oil. The mixing tank is used to collect re-circulated oil and also acts as a buffer or reserve tank as it will supply fuel when the daily service tank is empty. The system includes various safety devices such as low-level alarms and remotely operated tank outlet valves which can be closed in the event of a fire.
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Que3- Sketch and describe a fuel oil pump with its safety features? Ans3- There are two particular types of fuel pump in use, the valve controlled discharge type and the helix or helical edge pump. Valve-controlled pumps are used on slow-speed twostroke engines and the helix type for all medium- and high-speed four-stroke engines. Description: The injector pump is operated by a cam which drives the plunger up and down. The timing of the injection can be altered by raising or lowering the pump plunger in relation to the cam. The pump has a constant stroke and the amount of fuel delivered is regulated by rotating the pump plunger which has a specially arranged helical groove cut into it. The fuel is supplied to the pump through ports or openings at B. As the plunger moves down, fuel enters the cylinder. As the plunger moves up, the ports at B are closed and the fuel is pressurized and delivered to the injector nozzle at very high pressure. When the edge of the helix at C uncovers the spill port D pressure is lost and fuel delivery to the injector stops. A non-return valve on the delivery side of the pump closes to stop fuel oil returning from the injector. Fuel will again be drawn in on the plunger down stroke and the process will be repeated. The plunger may be rotated in the cylinder by a rack and pinion arrangement on a sleeve which is keyed to the plunger. This will move the edge C up or down to reduce or increase the amount of fuel pumped into the cylinder. The rack is connected to the throttle control or governor of the engine. This type of pump, with minor variations, is used on many four stroke diesel engines.
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Que4- How will you prime the fuel pump? Ans4- The fuel pump is primed by slackening the spill line valve and the priming pump is started. The air bubble is purged out and a continuous flow of oil is obtained, after this the spill valve is tightened.
Que5- What do you understand by air lock? Ans5- An air lock is formed when the air enters the fuel line and air bubble interrupts the continuous flow of oil.
Que6- How is fuel oil regulated in the diesel engine? Ans6- In a port controlled pump, the fuel oil is regulated by helical grooves in the plunger and can be isolated about its longitudinal axis, besides the vertical oscillating motion. Injector begins as soon as the suction port are covered by the plunger and it terminates when the helical edges of the grooves uncovers the ports. Rotation of plunger effects the regulation of fuel quantity. This is done by rack and pinion arrangement and the rack is connected to the fuel lever. In a valve controlled fuel pump the timing of the spill valve the controls the regulation of the fuel supplied, so it pushes the plunger and spill valve is controlled by a speed governor lined to the pump unit through a rack and pinion arrangement.
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ASSIGNMENT NO 16
Que1- Sketch a complete crankshaft and write down the function of each part or component? Ans1-
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Crankpin: Crankpin is used to connect the connecting rod to journal. The rubbing surface between crankpin and connecting rod is linked with metal or other similar bearing material known as big end bearing.
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Crank web: The crank web is supported or held by two crank web one on either side, which transmits the revolving motion of crankpin about crankshaft/journal axis to journal. Other end of the web is connected to journal. Journal: The journal lies along the axis of rotation of crankshaft. The journal rotates on this axis and it is supported by main bearing. Thus journal transmit drive to flywheel and is used to transmit gas load, to engine from bed plate through main bearing. Big End bearing: The connecting rod bearing on the crankshaft side located around crankpin is known as big end bearing
Que2- How is crankshaft supported in bed plate? Ans2- Crankshaft is supported in the bed plate by main bearing which is usually a bearing material like white metal backed by a steel block, bolted to bed plates. Main bearing transmits gas load to engine frame and bedplate
Que3- What is a white metal and where is it used? Ans3- White metal alloys represents majority or sliding bearing anti friction metal usually known as babbits. Babbits are divided into tin based and lead based alloys. A typical composition of white metal Tin- 87.65 % Antimony-7.5% Copper-4.5% Lead -0.35% White metal finds its application in main bearing, big end bearing and small end bearing of diesel engine etc.
Que4- What are balance weight with respect to crankshaft? Ans4- Balance weights are additional weight fitted to crankshaft to balance weight of piston, under stress rod assembly of various units to prevent under stress as condition of loading of crankshaft which in turn may accelerate wear down of main bearing. This may be an integral part of crankshaft or can be bolted to crankshaft, thus making it adjustable
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Que5- What do you understand by tri metal bearing? Ans5- Trimetal bearings are made of three different layers of materials instead of a single white metal shell; it usually consists of shell with a layer of brass like metal, over which a thin film of white metal spray is given
Que6- How reciprocating motion of piston is is transmitted to flywheel? Ans6- Reciprocating motion of piston is transmitted to flywheel through connecting rod and crankshaft assembly.
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ASSIGNMENT NO 17 Que1- Sketch the complete air starting line? Ans1-
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Que2- How is diesel engine started? What precautions are to be taken before starting a diesel engine? Ans2- Diesel engines are started by supplying compressed air into the cylinders in the appropriate sequence for the required direction. A supply of compressed air is stored in air reservoirs or 'bottles' ready for immediate use. Up to 12 starts are possible with the stored quantity of compressed air. The starting air system usually has interlocks to prevent starting if everything is not in order. Before starting a system, drain the air bottle in order to remove oil and moisture from starting air line. Master air starting valve must be open during starting. Follow Procedure of Starting Engine ( Main Engine & Aux Engine ) as per Checklist ASSIGNMENT NO 18
Que1- What is a cylinder liner, how it is fitted and how cooling is carried out? Ans1- cylinder liner is the replaceable part of the engine in which piston reciprocates. They are designed to give an extensive working life with long periods between overhauls. They must maintain low wear rates and friction losses from the sliding motion of the piston rings under fluctuating pressure and temperature. Materials for liners must provide adequate strength and fatigue life, readily transfer heat, resist abrasion and corrosion. Liners are cast in pearlite grey cast irons to which alloying elements such as vanadium and titanium are added to enhance strength, wear and corrosion resistance. The upper end of the liner forms a flange of sufficient strength to support it. This flange is secured between the cylinder cover and the jacket or engine entablature, leaving the lower end of the liner free for thermal expansion. Thickness may be reduced towards the lower end where pressures and temperatures are less, but external flanges and bossing may be added to accommodate seal rings, lubricator connections etc. Cylinder liner cooling is often referred to as jacket cooling and is carried out by circulating fresh water between the outer surface of the liner and the cylinder jacket or sleeve in which it is supported. The water space extends over the upper part length of the liner. Silicon rubber rings fitted into groves in the liner make a watertight seal at the lower end while still allowing freedom for thermal expansion of the liner. The upper end is sealed by the landing of the liner flange. Water enters at the lower end of the jacket, flowing upwards and leaving at the top to pass on to cool the cylinder cover.
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Que2- Why cooling water has to be treated? Ans2- The cooling water used for engine cooling should be properly treated with an approved cooling water inhibitor and alkaline agents to avoid corrosion attack, sludge formation and scale deposits. The commonly treatment used is 1. Sodium nitrite or sodium borate They are safe for handling, non toxic, not dangerous if over dosed and contain a pH buffer to provide protection against acidic corrosion Que3- With respect to liner Que3.1- What are the materials used for liner? Ans3.1 Cast iron with alloys of nickel, chromium, molybdenum, vanadium, copper and titanium is used.
Que3.2- What do you understand by liner wear and what is the maximum linear wear permitted? Ans3.2 There are three types of liner wear. Corrosive wear: It is the wear on the liner surface due to low temperature corrosion of sulphur. Sulphur oxides in the gaseous state combine with water, which has formed due to the condensation or sweating, when the temperature is low. Thus, acids are formed which lead to corrosion. Abrasive wear: It is due to hard particles of ash deposits and catalytic fines, which continuously cut, scratch and plough the liner surfaces. Friction or adhesive wear: Mechanical friction wear is due to the piston ring friction on the liner wall. This wear takes place usually where the oil film has depleted or broken down Maximum wear before renewal is usually limited to 0.6% 0.8% of original bore diameter or less when manufacturer advice. Wear rate may differ for different engines but on appropriate figure of 0.1 mm per 1000 hrs is acceptable for large engines.
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Que4- What is liner calibration? Ans4- The cylinder liner should be gauged internally at fixed interval during cylinder overhaul (60008000) to measure the increase in cylinder bore. Continuous record of gauging should be kept for each cylinder. Liner is gauged with an internal micrometer and extension bar which has been calibrated against a master gauge. The gauging is taken at a number of vertical positions (68) over area swept of piston. Readings are taken from aft and forward directions of the ship. To ensure readings are taken at corresponding parts, a template may be used. Que5- What is Ovality? Ans5- After some running hours, wear occurs in liner when measured with micrometer gauge at some parts, the internal diameter have to be in shape from cylinder to oval. This is known as ovality of cylinder. Que6- What is an indicator cock? Ans6- It is a valve mounted on cylinder head to accommodate indicator for measuring cylinder pressure and power developed. It is also used for blowing through the combustion gases, moisture from the cylinder before starting the engine.
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Que7- Sketch the cooling water systems of a diesel engine? Refer TAR Book exercise
SECTIONAL VIEW OF 2 STROKE ENGINE CYLINDER LINER
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4 Stroke Engine Cylinder Liner
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Two stroke Engine Liner
ASSIGNMENT NO:19
Que1- Sketch and describe a lube oil/ jacket cooler? Ans1- The heat produced by running machinery must be removed to ensure the satisfactory functioning of the equipment. Cooling is achieved primarily through circulation of water, oil and air but the abundant supply of sea water is normally reserved for use as an indirect coolant because the dissolved salts have a great potential for depositing scale and assisting in the setting up of galvanic corrosion cells Shell and tube coolers: shell and tube heat exchangers for engine cooling water and lubricating oil cooling are circulated with sea water. The sea water is in contact with the inside of the tubes, tube plates and water boxes. The oil or water being cooled is in contact with the outside of the tubes and the shell of the coolers. Baffles direct the liquid across the tubes as it flows through the cooler. The baffles also support the tubes and form with a structure which is referred to as the tube stack. The usual method of securing the tubes plates is to roll expand them
Que2- What are the types of coolers? Ans2- Heat exchangers used in marine diesel machinery installations are either of the multitubular type or plate types. Generally the multi-tubular type heat exchanger has been favored in the past but the plate type is now finding increasing usage particularly in high powered installations. There are various types of multi-tubular heat exchanger, classified by the flow arrangements, tube arrangements and the like. Plate type heat exchangers consist of a number of thin metal sheets (often made of titanium) which are sandwiched between cast header plates. By arranging the cast headers the flow of the liquids is such that the liquid to be cooled is passed between the one pair of sheets and the coolant between an adjacent pair of plate Sketches showing different type of heat exchangers:
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ASSIGNMENT NO 22 Que1- What do you understand by Oil mist and crankcase explosion? Ans1- Following are the conditions for crankcase explosion A) A source of heat or ignition which is required to vaporize the oil into a fine vapour: The source of ignition is mostly a hot spot due to a bearing running hot. This heat causes the lube oil in contact with the hot surface, to vaporize into a fine vapour. This oil vapour forms an oil mist in the presence of condensation in a relatively cooler section of the crankcase B) The correct air to fuel ratio required for explosion: When this fine oil mist ignites in the presence of a hot surface, pressure rise occurs which depends on the weakness or richness of the oil particle to air ratio. An explosion occurs if this mixture is in the explosive range
C) Fine oil vapour with a high surface area to mass ratio: A primary explosion is relatively slow as the crankcase atmosphere is too rich with oil vapour, but may cause a rupture of the crankcase allowing ingress of air. This ingress of air causes a very good air to oil-particle ratio and a secondary explosion occurs, which is more violent
Que2- What do you understand by hot spots? Ans2- Hot spots in a crankcase may arise due to overheating of bearings, piston rod gland , timing chain , hot combustion gas or sparks from piston blow past in engines where no diaphragm is fitted or from fires in spaces adjacent to the crankcase such as scavenge trunks etc.
Que3- What precautions are taken to avoid crankcase explosion? Ans3- In the event of a hot spot or explosive condition being detected , the engine must immediately be slowed and should be stopped a soon as possible to allow the overheated parts to cool down. It may be advisable to operate the engine turning gear, with indicator cocks open, to prevent seizure of overheated parts.
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Que4- Sketch and describe a crankcase relief door? Ans4- Crankcase pressure/ relief devices are of two main types. One type is hinged with a near horizontally placed, upward opening door. The door has a coiled spring fitted around the hinge pin, and is made self closing both by the action of gravity and the spring. The amount that the door can open is restricted by butts on the door. The other type consists of a circular door or valve disc mounted on a central spindle and spring loaded. The spring holds the valve shut and makes itself closing. Several thickness of wire gauze is sometimes fitted over the opening to the device on the inside of the crankcase to act as a flame trap. Naturally the free area through the meshed wires is kept well in excess of the area through the valve. Oil tightness on the spring loaded type door is maintained by having a joint or O ring of suitable non stick material fitted into a groove machined around the sealing face of the door.
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ASSIGNMENT NO 23 Que1- Why it is necessary to provide a filter on fuel oil/ lub oil line? Ans1- Contaminated fuel high in solids and other material, leads to problem with combustion and erosion of parts, to avoid the problems and risk of damage, filters are provided on the fuel / lub oil line. A filter is such a media that, contaminates down to minute size are prevented from going into circulation. The pressure drop across a clean filter will depend on the viscosity of the liquid being filtered, the size of the filter, the size of particles being removed and the flow rate through the filter.
Que2- Sketch and describe a duplex filter, how will you clean the filter? Ans2- Duplex filter are arranged in pairs so that one filter can be in use and the other ready for use or being cleaned. An arrangement of valves or cocks is usually fitted to duple filters so that as one filter is opened to flow the other is closed. Care must be taken with the change over interlocking arrangements on duplex filters to ensure that they are always in god working order. Extreme care must be exercised in removing the cover of a shut down filter. The air leak off and drain cocks must be opened to check that the filter is completely isolated before slackening the cover fastening.
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Que3- What is mesh size of the Duplex filter? Ans3- The mesh size of the duplex filter varies depending upon the fuel oil being used.
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ASSIGNMENT NO 64 Que1- What is a two stroke diesel engine? Ans1- A two stroke diesel engine is one in which the entire cycle of operation takes place in one revolution of the crank shaft. In one stroke two process takes place i.e. when piston moves upwards compression and ignition takes place and when piston moves downwards exhaust and inlet takes place.
Que2- What is the difference between two stroke and four stroke diesel engine in theory and construction? Ans2-In two stroke diesel engine one power stroke is obtained for each revolution of crankshaft where as in four stroke one power stroke is obtained for every two revolution of crankshaft. In two stroke the turning movement is more uniform so lighter flywheel is used, where as in four stroke the turning moment is not uniform so fly wheel is heavy. In two stroke power to weight ratio is less, where as in four stroke power to weight ratio is more. Two stroke engines are heavy and big in construction, where as four stroke engines are lighter and small in construction.
Que3- What is Scavenging? Ans3 - Scavenging is the process in which pressurized air is utilized to remove the exhaust gases in combustion chamber.
Que4- Explain in detail the types of scavenging? Ans4: - The types of scavenging are as follows:1. Uniflow scavenging 2. Loop scavenging
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Uniflow scavenging means flow of air in one/same direction. The scavenge air is allowed in at the bottom of the cylinder with slight rotation and exhaust gas is pushed out
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3. Cross scavenging
from the top of the cylinder through exhaust valve. Uniflow scavenging is required in modern engines to use advantages of slow speed and a long stroke. The scavenge efficiency is the highest. There is no exhaust and scavenge inter mixing. In loop scavenging, the flow of air and gas is in a loop path. The air inlet and exhaust ports are arranged on the same side of the cylinder. Modern engines with high strokebore ratios do not use the loop type method. In cross scavenging, the air and gas flow is in the across path i.e. air inlet and exhaust ports are situated on opposite sides of the cylinder.
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ASSIGNMENT NO 65 Que1- Name different parts of two stroke diesel engine? Ans1- Different parts of two stroke diesel engine are:1. Cylinder head 2. Exhaust valve 3. Fuel injector 4. Air starting valve 5. Indicator cock 6. Piston 7. Cylinder liner 8. Piston rod 9. Cross head 10. Connecting rod 11. Crank shaft
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Que2- What do you understand by piston skirt and what is the function of the same? Ans2- Composite pistons are made up of two materials/parts; the upper is crown and lower is skirt. The piston skirt is made up of cast iron. The function of skirt is to close the inlet and exhaust ports during the part of cycle when the piston is at TDC in the cylinder.
Que3- Which part of the piston requires cooling and how does it take place in two stroke engines? Ans3- The combustion side of the piston needs cooling in the piston crown. It is compulsory to remove the excess heat from combustion and to limit thermal stress. It also limits the thermal expansion to maintain correct working clearance between the piston and liner and even in between the piston ring grooves and rings. In two stroke engine cooling may be carried out by circulating oil or water. Mostly oil is preferred in modern engines for cooling of piston due to the absence of water corrosion, or scaling, or water leaks into the crankcase. The same oil and pressure can be used from the main lube oil system, thereby avoiding the necessity of separate piston cooling pumps.
ASSIGNMENT NO 66
Que1- What is a piston rod stuffing box? Ans1- A piston rod stuffing box is a seal between the scavenge spaces and the crankcase in the area of the piston rod penetration. It seals the crankcase oil entering into the scavenge space, and scavenge deposits or cylinder oil entering the crankcase. It is made up of two sections. Each section consists of segmented metal rings held against the piston rod by garter ring. Que2- Why stuffing box is required? Ans2- The stuffing box assembly is required to form a seal, to prevent the mixing of oil from crank case to enter in the cylinder liner. Que3- How is the stuffing box secured to the engine? Ans3- The stuffing box is mounted on a flange which is bolted to the underside of the double-bottom of scavenge air box. The stuffing box is removed together with the piston rod
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during piston inspection but can also be dismantled for inspection, in the crank case while the piston remains mounted in the engine.
Que4- How is the sealing of combustion product from the liner achieved? Ans4- The stuffing box housing is provided with some mechanical ring grooves, the three upper most of which are fitted with sealing rings to prevent scavenge air from passing downward along the piston rod.
Que5- What is a crank case and how is the oil from the crank case prevented from entering into the cylinder liner? Ans5- Crank case is an integral part of cylinder block. It is casted integrally to the cylinder block. The function of crank case is to provide support for the main journal and bearing of the camshaft rigidly maintaining the alignment of their axis of rotation under engine load. Crank case is shaped simply like a box having no bottom root being formed by the lower deck of cylinder block. The stuffing box assembly is used to prevent the mixing of oil from crank case to enter in the cylinder liner. The stuffing box is fitted at the bottom of the scavenge air box as a holder for two sets of rings. Near the top of the box is ring in two parts held together and pressed against the rod by a steel clamping ring which is resistant. The action prevents any air or oil escaping into crank case. The second ring is scrapper ring. Any oil clinging to the rod, while exposed in crankcase is scrapped off and return to the crank case by the passage.
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ASSIGNMENT NO 67
Que1- What is the difference between a four stroke and two stroke engine cylinder liners? Ans1- In two stroke engine, ports are available at the bottom of the cylinder liner and cooling space is provided on the top side of the cylinder liner. Whereas there are no ports available on cylinder liner in four stroke engines. Que2- What parts of the liner of two stroke engines require cooling? Ans2- The top part of liner in two stroke engines requires cooling.
Que3- How is the lubrication of liner achieved? Ans3- The lubrication of liner is achieved with the help of Cylinder Lubricator and Quills.
Que4-What is an oil film and how it is achieved in liner? Ans4- Oil film is a layer of oil maintained in between the moving parts. In liner it is achieved with the help of piston rings. The piston ring has a cut at a slight angle which causes a wedge shaped oil film to be maintained.
Que5- What are the properties of cylinder lubrication oil? Ans5- The properties of cylinder lubrication oil is:1. It should reduce sliding friction between rings and liner. 2. It should have proper viscosity at working temperature. 3. Oil should be able to spread evenly over working surface to form good oil film. 4. Ash content is zero. 5. No formation of deposit.
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Que6- What do you understand by cylinder oil consumption and how it is expressed? Ans6- The consumption of oil is more when cylinder is running due to following reason:1. High level temperature reduces lub properties. 2. Worn out metal has to be washed away. Amount of lubrication oil delivered into cylinder unit depends upon following factor:1. Stroke 2. Engine speed and bore 3. Type of fuel burned 4. Engine load 5. Portion of cylinder lubrication 6. Piston speed Que7- Sketch a liner? Ans7- Two stroke cylinder liner:-
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ASSIGNMENT NO 68
Que1-What are the mountings on cylinder head and function of same? Ans1- The mountings on cylinder head are:1. Fuel injector or valve 2. Exhaust valve 3. Relief valve 4. Indicator cock Fuel injector:-The function of fuel injector is to inject and disperse the fuel evenly into the engine cylinder in a finely atomized spray. Exhaust valve:-It is used to remove all the combusted gases into the exhaust manifold. The valve can be operated either by a rocker arm or a hydraulic/pneumatic system. Relief valve:-These are designed to reduce the pressure in excess of 10% above normal. A spring keeps the valve closed and its lifting pressure is adjusted by appropriate thickness. A small amount of lift is permitted and the escaping gases are direct to safe outlet. Air starting valve:-It is used to admit starting air into the cylinder. The timing for the opening and closing of valve is controlled by cams. Indicator cock:-It is used for measuring peak pressure indicator instrument. It is also used to blow through the engine before starting.
Que2-What is the main difference between the cylinder head of uniflow and reverse flow scavenged diesel engine? Ans2- The main difference between the cylinder head of uniflow flow scavenged engine is that there is an exhaust valve where as in reverse flow an engine there is no exhaust valve present.
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Que3- How are the combustion gases sealed between the cylinder head and liner? Ans3 - A copper and soft metal gasket is placed between the cylinder head and the cylinder liner is held down on the liner by studs.
Que4- What are the various methods used for tightening the cylinder head nuts? Ans4- The cylinder head of small engines are tightened using torque wrenches, and for large engines hydraulic jack is used for tightening. ASSIGNMENT NO 69 Que1- What is a connecting rod, cross head and state the function of same? Ans1-Connecting rod is the rod connecting the cross head and the bottom end bearing. Its purpose is to convert reciprocating motion of piston into rotary motion of the crank shaft. Cross head is usually found in only two stroke engines. The piston rod and the piston moves only in vertical direction, there is no side thrust, so the piston need not have an external trunk area to absorb the thrust. There is however crass head guides to take the side thrust, which results from the angularity of the connecting rod to crankshaft motion. Que2- What are guide and guide shoes? Ans2- The guides are fixed on a frame or column and provides alignment to the cross head. The guide shoe is made up of cast steel and liner with white metal, having grooves for lubrication which is supplied from the cross head bearing lubrication system. Que3- What is a cross head bearing and how lubrication is carried out? Ans3- The cross head pin is supported by two bearings which rest head on cross head bearing and are equipped with bearing shells linked with white steel. Lubrication of bearing is carried out by Elasto Hydrodynamic Lubrication in which the oil supply is the same as that of the bearing lubrication oil, whose main pressure is now boosted to 16 bar supplied via the lube oil articulated arm.
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ASSIGNMENT NO 70
Que1- What is a thrust block and why it is required on a main propulsion engine? Ans1- If a force of any sort acts axially along a shaft, some form of thrust bearing must be used to prevent the shaft sliding along in its bearings as it revolves. The magnitude of the force may be small, as might be experienced in electrical generators. A simple type of thrust bearing is then used. This consists of nothing more than the provision of some bearing surface on both ends of one of the engine crankshaft main bearing. The main bearing nearest the generator is the one used, one end of the main bearing contacts the side of the crank web, and the other may contact a collar on the shaft or the side of a camshaft drive wheel. The thrust from the propeller is taken up by the main thrust bearing which transmits the thrust to the ships hull and causes the ship to be propelled in the direction of the thrust. The main thrust bearing is always fitted at the aft end of the main engine crankshaft. The correct location of the crankpins relative to the centre of the cylinders is controlled by the main thrust bearing. Que2-What is the thrust pad? What is the meaning of ahead thrust pads and astern thrust pads? Ans2- In propulsion machinery, the thrust bearing is most commonly of the tilting pad type. In this type of baring a thrust collar is forged integrally with the thrust shaft. One the forward and aft sides of the thrust collar, the thrust pads are fitted, which are commonly known as ahead thrust pads and astern thrust pads. The thrust pads are lined with white metal and face on to the finely machined and polished surface of the thrust collar. The back of the pad has a radial ridge which forms a fulcrum on which the pad can tilt. The tilting fulcrum on the back of the pad comes in contact with a solidly constructed housing. Que3- How is thrust pads fitted to obtain the tapper oil wedge? Ans3- In tilting pad type thrust block bearing builds up an oil pressure between the white metal face of the thrust pad and the thrust collar when the shaft revolves. The oil pressure is due to the formation of an oil wedge which can build up only when the thrust collar is supplied with oil and is revolving. As the pad is able to tilt it becomes self adjusting to the shape of the wedge.
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Que4- What is a thrust collar? Ans4- When the thrust bearing is fitted forward of the main gearwheel the cost of the heavy forging for a normal thrust shaft with integrally forged collar can be reduced to that of a plain shaft. The forward end of the main gearwheel shaft is machined to a taper with a thread at the end. The thrust collar is machined from a flat forged disc, with a tapered hole which fits on the taper of the shaft end and is held in place with a heavy nut capable of taking the astern thrust. A key is fitted within the taper. The thrust housing is arranged so that the thrust collar can be removed without lifting the shaft, thus allowing the thrust collar to be removed for re machining without a lot of disturbance to other equipment.
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ASSIGNMENT NO 71
Que1- What is a chain drive? Why it is required on diesel engine? Ans1-Chain drive in diesel engine is used to transmit the power drive from the crankshaft to the camshaft. An intermediate wheel (for fuel pump and exhaust cam drives) serves as a guide, while an adjuster wheel serves to adjust the chain. The intermediate wheel may be connected to a separate chain for driving motion to the lubricators, governor, air distributor, etc.
Que2- How is the lubrication of gear and chain drive carried out? Ans2- Gear teeth are lubricated by means of oil spray nozzles from the main lubricating pump. The chain is lubricated by means of oil sprayer which diverts a continuous stream of lubricating oil in to the chain bearing. The oil will lubricate and cool the bearing and will reduce fluctuating loads.
Que3- How is the tightening of chain done and why is it required? Ans3- With course of time, the chain will become gradually elongated. A slack chain will vibrate imposing heavy additional mechanical loading which can result in failure of the chain. The wear of the chain can be measured by its extension. To avoid heavy vibration tightening is done. Procedures for tightening the chain are; A) By turning engine to that all the slackness is taken on the side of free length. B) Pull at the middle of the free length of the chain under normal conditions. The chain should vibrate by half to one chain link. C) By opening two locknuts on the chain, tighten bolt so that the bolt is free D) By measuring the free length of the spring. Tighten nut of the tensioning bolt until the free length of the spring has reduced by the number of minimum specified tightening up to. This ensures equal tensioning of the chain at all times.
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Que4- What do you understand by chain link? Ans4- Two identical roller chains run over chain sprocket, one being bolted with the camshaft and other with the crank shaft. An intermediate wheel and an adjuster wheel to perform their respective duties of guidelines and adjusting the chains. From intermediate wheel separate chain take the transmission.
Que5- What all parts are operated or rotated by chain drive? Ans5- Following are the engine parts operated by chain drive A) B) C) D) E) F) Governor Starting air distribution Lubrication Fuel oil pump Fresh water pump Rocker arm lub oil pump
Que6- What would be the alternative arrangement for chain drive? Ans6- The alternative arrangement for chain drive is gear drive. Helical gears and spur gear are used for this purpose. The tipping and fitting movements which normally occur in the wheel cancel each other. These result in good meshing contact.
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ASSIGNMENT NO 72
Que1- What is supercharging/turbo charging in diesel engine and how is it achieved? Ans1- Combustion and power depends on the amount of fuel and air supplied, since proper combustion requires a stoichiometric air fuel ratio of 14:1. The amount of fuel to be burnt is limited by the ratio of air that can be supplied. If mass of air is increased i.e. its density and pressure, more fuel can be used for burning. Hence supercharging or pressure charging of the combustion air supplied allows more power to be developed with proper combustion. Supercharging/turbo charging is the pressure charging of air supplied to the cylinder at the beginning of compression. In 2 stroke marine engines, in order to achieve correct combustion, good scavenging and effective cooling, thrice the amount of ideal combustion air quantity is supplied.
Que2-Why an auxiliary blower is required on turbocharged engine and under what circumstances it is used? Ans2- Auxiliary blowers which are of independently driven type are used turbocharged engines. These are used mostly in the first or second stage of a combined supercharging system only as scavenge assistance. They are used, during the starting of the engine, and when the engine running at low speed the turbo charger is not able to supply enough air for the engine process.
Que3- What is scavenging? How scavenge air is cooled and what are the advantages of higher scavenge air pressure? Ans3- Scavenging is the process in a diesel engine, in which low pressure air is utilizes to blow out the waste gases of combustion i.e. scavenging, and refill the cylinder with fresh pressurized air for the next compression stroke. Air cooler is used to cool the scavenge air. The cooler is designed with an air receiving chamber which incorporate a water mist catches built of a number of smaller units, which separate the condensate water from the scavenge air during the passage of flow. The separated water is collected in the bottle of the cooler housing from which it is removed by drain system. The scavenge efficiency is the highest. There is no exhaust and scavenge intermixing. Working temperatures are reduced. Costly cylinder lub oil consumption is reduced. Less residual exhaust gas remains in the cylinder after scavenging. The air loss during exhaust and
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scavenging is nil. Thermal stresses are also much less as compared to other scavenging methods.
Que4- Explain pulse and constant types of turbo charging? Ans4- Pulse turbo charging uses the pressure pulse wave to expand the gas further at the turbine nozzles and blades. Exhaust gas from each cylinder is directly leads to the turbine inlet. Pressure waves are created (pulses), when the exhaust valve suddenly opens and exhaust is blown down into the exhaust piping of smaller diameter, thereby pressurizing it. Work is done by exhaust gas expanding further at the turbine nozzle and blades. In Constant pressure turbo charging, exhaust gas from each cylinder is lead to a common exhaust manifold which then supplies exhaust gas to the turbocharger at a constant pressure. The exhaust manifold space is large enough for the volume of combined exhaust gases without any pressure rise. Hence, a constant pressure is available to the turbine.
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ASSIGNMENT NO 73
Que1- What is an exhaust valve and where it is fitted in 2 stroke diesel engine and why it is required? Ans1-The exhaust valve is an opening for the combustion gases to escape from the cylinder usually provided overhead. They are made up of special heat resisting steel. They consist of the valve, valve stem, valve face, valve seat, valve cage, valve rotator and valve gas deflector. They are required on an engine to expel the burnt used gases produced after the combustion.
Que2- How does an exhaust valve work? Ans2- Exhaust valve are usually poppet mushroom shaped valves. Opening and closing is done by mechanism such as valve springs and push rod- rocker arm arrangements, or hydraulic operation using camshaft lube oil pressure to open and spring air to close the valve.
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Working principle of hydraulically operated exhaust valve: The exhaust valve is closed by the pneumatically operated air piston. The air pressure applied to close the valve is provided through a non return valve. The exhaust valve is opened by the valve spindle being pressed down by the piston in the hydraulic cylinder fitted on top of the exhaust valve. The hydraulic piston is operated through a piping which communicates with a corresponding hydraulic cylinder on the roller guide housing above the camshaft. The piston in the latter cylinder is, through the roller guide, actuated by the exhaust cam on the camshaft. The system is kept filled with oil from the cam shaft lubricating system, and the upward movement of the roller guide is transmitted through the hydraulic cylinder on the roller guide housing to the hydraulic cylinder on the exhaust valve.
Que3- Sketch and describe an exhaust valve with all parts, special features particularly valve and valve seat. Ans3- Exhaust valve consist of the valve cage, valve spindle, valve seat, valve rotator and valve gas deflector as per given illustration ( Refer also MAN B&W Manual )
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ASSIGNMENT NO 74 Que1- Sketch and describe an Engine Indicator Instrument? Ans1- Engine indicator consist of a small bore cylinder containing a short stroke piston which is subjected to the same varying pressure that take place in the engine cylinder during a cycle operation. This is done by mounting the indicator cylinder to the top of the engine cylinder in case of single acting cylinder engine. The gas pressure pushes the indicator piston up against the resistance of spring. A spindle connects the indicator piston to system designed to produce a vertical straight line motion at the pencil on one end of the stylus parallel to motion indicator piston. The pencil is brought in contact with the indicator paper which is wrapped around a cylinder drum and clipped to it. The drum which has been built in recoil spring is actuated in a semi rotary manner by a card wrapped and a groove in the bottom of it, the card passing over a guide pulley is attached by a hook at its lower end.
Que2- What are the indicator card taken using indicator instrument and explain in detail with cards? What are the parameters and engine performances you study? Ans2- Indicated power The stylus draws out an indicator diagram which represents the gas pressure on the engine piston at different points of the stroke, and the area of the Indicator diagram produced represents the power developed in the particular cylinder.
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Typical indicator diagrams for a two-stroke and four-stroke engine are shown in Figure 2.8. The area within the diagram represents the work done within the measured cylinder in one
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cycle. The area can be measured by an instrument known as a planimeter or by the use of the mid-ordinate rule. The area is then divided by the length of the diagram in order to obtain a mean height. This mean height, when multiplied by the spring scale of the indicator mechanism, gives the indicated mean effective pressure for the cylinder. The mean effective or 'average pressure can now be used to determine the work done in the cylinder. To obtain a measure of power it is necessary to determine the rate of doing work, i.e. multiply by the number of power strokes in one second. For a four-stroke-cycle engine this will be rev/sec -r 2 and for a two-stroke-cycle engine simply rev/sec. Indicated power: ip= pm l a n Where pm=mean indicated pressure a= area of piston l=length of stroke n=revolution per second of engine. n=number of cylinder X revolution per second, for 2-st engines: n/2= number of cylinder X revolution per second / 2, for 4-st engine.
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ASSIGNMENT NO 75
Que1-What do you understand by running gear of a two stroke diesel engine? Ans1- The running gear consists of a piston, a piston rod and crosshead assembly and a forged steel connecting rod. The crosshead moves in guide shoes which are fitted on the frame box ends. The camshaft has several sections, each of which consists of a shaft piece with exhaust cams, fuel cams and couplings. It is driven by a chain drive from the exhaust gas from the engine is passed into a constant-pressure receiver and then into the turbochargers. Scavenging is uniflow, and electrically driven auxiliary blowers are automatically started during low-load operation. Lubricating oil is supplied to the various bearings and also to the pistons for cooling. Cylinder oil is supplied via lubricators from a high-level service tank. A separate lubrication system is provided for the camshaft bearings to prevent contamination of the main lubricating oil system. Fresh water cooling is provided for the cylinder jackets, cylinder covers and exhaust valves. The engine is designed to run on diesel oil or heavy fuel oil.
ASSIGNMENT NO 76 Que1- What is a Scavenge Fire? How it occurs, how it can be prevented, what are the indications of scavenge fire, what steps you take and how do you put back the engine to normal operation? Ans1- A scavenge fire may be caused by the ignition of unburned oil and carbon which has been blown from the engine cylinder into scavenge spaces. This may include unburned fuel or cylinder into the scavenge spaces. This may include unburned fuel or cylinder lubricating oil and may be due to incorrect combustion caused by a defective injector, faulty oil and may be due to incorrect combustion caused by a defective injector, faulty fuel pump timing, incorrect fuel condition, lack of scavenge air, partially choked exhaust, low compression, afterburning, by operating the engine at overload conditions, or due to defective piston rings, badly worn cylinder liner, or by wrongly timed or excessive cylinder lubrication. The oil will build up in scavenge spaces where it will become carbonized by further heating and will then reach a condition in which it can burn in the presence of air. It may be ignited by a hot gases and burning particles from blow past of piston rings. Indications of a scavenge fire are loss in power and irregular running of the engine, high exhaust temperatures of corresponding units, smoke in exhaust gas, high local temperature in scavenge trunk, surging of turbocharger, and sparks and smoke emitted from scavenge drains. If a fire is detected engine speed must be reduced, fuel shut off from the affected units, cylinder lubrication increased and scavenge drains shut. A minor fire may shortly burn out and conditions will gradually return to normal. The affected units should be run on reduced power until inspection of the scavenge trunking and overhaul of the cylinder and piston can be carried out at the earliest safe opportunity
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Que2- What will you check during scavenge space inspection? Ans2- During the scavenge space inspection: 2.1 Scavenge ports are inspected for deposition of carbon, cracks 2.2 Scavenge valve and under piston area is inspected 2.3 Scavenge drain should be opened and should be checked for any metal particles.
TAR BOOK COMPETENCE NO- 6 Function: Operate Main and Auxiliary Machinery and Associated Control Systems.
Que1- Define the following:Ans1- Cross head diesel engine: - In this type of two stroke engines, there is a crosshead which has shoes sliding over the cross head guides. Trunk type diesel engine: - These types of engines are much lighter and smaller than equivalent slow speed engines but require gearing or some other means to reduce the drive speed for ships propellers. Medium speed diesel engine:-the speed of these types of engines lies in between 400 and 750rpm. High speed diesel engine: - the speed of these types of engines lies in between 750and 2500rpm.
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Que2- Define the following:1. Two stroke engine with valve timing diagram: In two stroke diesel engine the piston goes up and down in one complete revolution of crank shaft and gives one power stroke. The processes are:1. Compression (scavenging and suction) strokes. 2. Power (expansion and exhaust) strokes.
2. Four stroke engines with valve timing diagram:-In four stroke engines the piston moves up and down twice in two complete revolution of crank shaft and gives a power stroke. The processes are:1. Suction stroke 2. Compression stroke 3. Power(expansion) stroke 4. Exhaust stroke
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3. Scavenging process and types of scavenging: - Scavenging is the process in which pressurized air is utilized to remove the exhaust gases in combustion chamber. Types of scavenging are: Uniflow scavenging Loop scavenging Cross scavenging
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Que3- What are the difference in Loop and Uniflow scavenging? Ans3-In loop scavenging there is no exhaust valve where as in uniflow there is exhaust valve on cylinder head. Que4- Explain the reason for super charging and indicate typical super charging pressures? Ans4 In order to burn more fuel oil to get more power, we have to supply large quantity of (scavenge) air. The typical super charging pressure is 2 Kg/cm2.
Que5- Sketch and describe diesel engine indicator and cards taken using indicator? Ans5- Engine indicator consist of a small bore cylinder containing a short stroke piston which is subjected to the same varying pressure that take place in the engine cylinder during a cycle operation. This is done by mounting the indicator cylinder to the top of the engine cylinder in case of single acting cylinder engine. The gas pressure pushes the indicator piston up against the resistance of spring. A spindle connects the indicator piston to system designed to produce a vertical straight line motion at the pencil on one end of the stylus parallel to motion indicator piston. The pencil is brought in contact with the indicator paper which is wrapped around a cylinder drum and clipped to it. The drum which has been built in recoil spring is actuated in a semi rotary manner by a card wrapped and a groove in the bottom of it, the card passing over a guide pulley is attached by a hook at its lower end.
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Que6- Describe fuel injector and reasons for using high pressure fuel? Ans6- Fuel injector consist of a spring loaded non return needle valve operated hydraulically by a high fuel pressure wave from fuel pump to discharge fuel at high pressure an atomizer nozzle. Que7-Define the follow:A) Brake thermal efficiency: - it is the ratio of energy in the brake power to the fuel energy. B) Mechanical efficiency: - it is the ratio of the brake power to the indicated power. C) Specific fuel consumption: - it is the ratio of the fuel consumed by the engine in generating 1KW of brake power per hour. It is expressed in gm/KW hour. Typical value of SFOC is 130 gm/BHP hrs.
Que8- Indicate heat balance diagrams of a diesel engine? Ans8- A diesel engine working on the basis of an air standard cycle is inherently incapable of utilizing all the heat that is liberated in the cylinder engine. Heat balance chart is a useful method of computing thermodynamic losses in the engine. 1. Maximum (heat) power utilized as engine power. 2. Heat transferred to jacket cooling water, utilized for producing fresh water from sea water using Fresh Water Generator. 3. This heat from the Main Engine exhaust is utilized to run the Turbo charger. 4. Heat from the Turbo Charger exhaust is utilized to generate steam on Composite Boiler / Exhaust Gas Boiler.
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Que9- Draw the line diagram for the following:Ans9- Line diagrams are given below a. Fuel Oil Supply System
b. Lube Oil Supply System
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c. Fresh Water Cooling System
d. Sea Water Cooling System
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e. Starting Air System
Que10- Sketch an air reservoir with its fittings, their typical air pressure? Ans10-Fittings required on air reservoir are: Safety valve Pressure gauge connection Filling valve Distribution valves: Main engine starting air valve, auxiliary engine starting air valve, air reducer valve, Air to ships whistle. Fusible plug Drain valve
Typical air pressure of air reservoir to be maintained is 30 bar.
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Schematic Starting Air line for Main Engine Que11- Explain the purpose of the following:a. Sheathing in high pressure fuel line: - This is to avoid the fire hazard of fuel finding a surface hot enough to ignite it, or of accumulating somewhere where it could be otherwise accidentally ignited. b. Lagging on hot surface: - It is used to avoid dissipation of heat. c. Guards over moving machinery: - the guards are provided on the moving parts like coupling etc to avoid accidents and to provide safety.
Que12- Explain the purpose of a turning gear and inter locks? Ans12- The purpose of a turning gear is: 1. to turn the engine & inspect the moving parts moves properly 2. in order to turn the engine during non operational period
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The purpose of interlock: To avoid accidental start of Engine .

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Que13- Describe how engine speed is varied and how over speeds are prevented? Ans13- Engine speed is varied with the help of governor whereas over speed is prevented with help of over speed trip.
Que14- Explain what is oil mist? When does it become dangerous? Sketch and describe an oil mist detector and what maintenance is required? Ans14- Oil mist is the result of oil vaporization caused by a hot spot. It becomes dangerous when the density of oil mist increases above a certain limit. Two basic methods of measuring the oil mist density. The first is the Comparator type where a sample taken from each crank chamber is compared in turn with the combined mist from the remaining chambers. The second method, called the Level type, involves comparing a sample from each crank chamber in turn with clear air. The first method is particularly applicable to crosshead type two stroke engines where there is a low background of oil mist, a sub-divided crankcase and relatively slow speeds. The second is used for engines where there is a high background of oil mist and little or no sub-division of the crankcase, i.e. high and medium speed trunk piston engines.
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Maintenance carried out on Oil Mist Detector:1. 2. 3. Cleaning of reference tube. Cleaning of rotary valve. Calibration of oil mist detector.
Que15- Define Turbocharger surging and explain why it occurs and action to be taken when it occurs? Ans15- Surging (variously known as coughing, barking etc.) is a vibration of audible level emanating from the compressor end of the rotating element. The turbocharger should be matched to the engine's air consumption rate and pressure across the whole operating range. Action to be taken when surging takes place: Slow down the engine. To reduce surging as far as possible the development of scale or deposits of any type, 'water washing' of the blades is frequently adopted. Clean the suction filter of turbo charger.
Que16- What is a Scavenge Fire? Explain why it occurs? What are the indication of scavenge fire? How to avoid it? What action to be taken when it occurs? Ans16- A scavenge fire may be caused by the ignition of unburned oil and carbon which has been blown from the engine cylinder into the scavenge spaces. This may include unburned fuel or cylinder lubricating oil and may be due to incorrect combustion caused by a defective injector, faulty fuel pump timing, incorrect fuel condition, lack of scavenge air, partially chocked exhaust, low compression, after burning, by operating the engine at overload conditions, or due to defective piston rings, badly worn cylinder liner, or by wrongly timed or excessive cylinder lubrication. The oil will build up in scavenge spaces where it will become carbonized by further heating and will then reach a condition in which it can burn in the presence of air. It may be ignited by hot gases and burning particles from blow fast of piston rings. Indication of a scavenge fire are loss in power and irregular running of engine, high exhaust temperatures of the scavenge drain shut. Reduce the speed of engine, cut off the fuel supply of that unit by lifting the plunger and increase the lubrication of the unit and shut the scavenge drain.
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Que17- Sketch and describe the construction and operation of turbo charger? Ans17- The turbocharger is driven by the exhaust gas leaving the cylinders of the diesel engine it serves. The gas has sufficient pressure and heat when released from the cylinder at exhaust opening, to drive the turbocharger. It is directed on to turbine blades by nozzles which are built into a nozzle ring in the axial flow type or into a radial turbine from the peripheral volute casing of smaller turbochargers.
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Que18- Sketch and describe a Governor? Ans18- When used for alternating current power generation, a diesel engine is normally fitted with a hydraulic governor. This incorporates a centrifugal speed sensing device (spring loaded flyweights) controlling a suitably damped oil operated servo-cylinder through a pilot valve. The governor has adjustable speed droop and load limit controls. A split field, electric motor-operated speeder gear to facilitate remote alteration of engine speed setting from the switchboard is incorporated. This alters the spring pressure usually through a screwed rod.
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Que19- Sketch and describe an over speed trip? Ans19- The 'Bolt' type over speed trip (Figure 1.31) consists essentially of a spring-loaded stainless steel bolt which, due to its special design, is heavier at one end than the other. The rotary motion of the turbine shaft tends to move the bolt outwards, while the spring retains it in its normal position until the turbine speed reaches a pre-determined safety level. At this speed the centrifugal force exerted by the heavier end of the bolt overcomes the spring opposing it and the bolt moves outwards to strike the trip trigger. This in turn disengages the trip gear, allowing the steam stop valve to shut.
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COMPETENCE 9
Function: Maintenance and Repairs at the Operational level.
Que1- How you prepare and overhaul a unit of a two stroke diesel engine? Ans1- Follow the following procedure before overhauling a particular unit: Take Immobilization certificate, from the Port Authority through the Master. Take Propeller Clearance from Deck Officer. Put a note Men Working on engine and control room. Open indicator cork and engage turning gear. Isolate LO, JCW, FO and starting air lines. Shut particular units JCW inlet/outlet and drain out the unit water to bilge water tank. Remove and disconnect all the pipe lines connections to the cylinder head mountings. Before doing the job, plan and go through the instruction manual of that engine (particularly give importance to the special tools used to carry out maintenance). Que2- How you prepare and overhaul a unit of a four stroke diesel engine? Ans2- Follow the following procedure before overhauling a particular unit: Take Immobilization certificate, from the Port Authority through the Master. Take Propeller Clearance from Deck Officer. Put a note Men Working on engine and control room. Open indicator cork and engage turning gear. Isolate LO, JCW, FO and starting air lines. Shut particular units JCW inlet/outlet and drain out the unit water to bilge water tank. Remove and disconnect all the pipe lines connections to the cylinder head mountings. Before doing the job, plan and go through the instruction manual of that engine (particularly give importance to the special tools used to carry out maintenance). Que3- How to prepare and do the Crankcase inspection? Ans3-To carry the crankcase inspection check the following items:ALL SAFETY PRECAUTIONS AS RECOMMENDED BY THE MANUFACTURER TO BE TAKEN PRIOR TO ENTERING THE CRANKCASE. White metal particles or foreign particles in the lube oil sump.
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Check for white metal squeezing at bearings.
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Colour of the lube oil and oil flow.
Check the crankcase walls for carbon deposits, leaking diaphragm. Check the crank pin and web alignment mark. Crankcase relief door. All bolts, nuts and locking marks. Any discolourisation signifying hot spots. Clearance of bearings.
Que4- How you prepare and take crankshaft deflection of a diesel engine? Ans4- The best method for crankshaft alignment is the dial gauge fitted between the adjacent webs, opposite the crankpin at half of the diameter from the shaft centre. The dial gauge measures the crank web spread at different angular position of the shaft. The first measurement is taken with the engine just beyond the bottom dead centre position with the gauge close to the side of connecting rod. It is usual to set the gauge to zero at this position. The engine is now rotated with the turning gear and stopped at each quarter from where gauge readings are taken plus or minus value. The final or fifth reading is being taken near bottom dead centre, with the connecting rod on the opposite side of the first reading. The first and last readings are averaged to use as an approximation of bottom position. The procedure is repeated for each unit. .
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Que5- Describe Propeller with its Maintenance? Ans5- Propeller with its maintenance:The propeller consists of a boss with several blades of helicoidally form attached to it. When rotated it 'screws' or thrusts its way through the water by giving momentum to the column of water passing through it. The thrust is transmitted along the shafting to the thrust block and finally to the ship's structure. Maintenance of propeller:When a ship is in dry dock the opportunity should be taken to thoroughly examine the propeller, and any repairs necessary should be carried out by skilled dockyard staff. A careful examination should be made around the blade edges for signs of cracks. Even the smallest of cracks should not be ignored as they act to increase stresses locally and can result in the loss of a blade if the propeller receives a sharp blow. Edge cracks should be welded up with suitable electrodes. Bent blades, particularly at the tips, should receive attention as soon as possible. Except for slight deformation the application of heat will be required. This must be followed by more general heating in order to stress relieve the area around the repair. Surface roughness caused by slight pitting can be lightly ground out and the area polished. More serious damage should be made good by welding and subsequent heat treatment. A temporary repair for deep pits or holes could be done with suitable resin filler. ENGINE DISTANCE = REVOLUTIONS x PROPELLOR PITCH
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Ques6- Define the following terms? Ans6- Rudder clearance: Top pintle: a head is fitted to the upper pintle to prevent undue vertical movement of the rudder. This is known as locking pintle. The locking pintle is called top pintle. Bottom pintle: The bearing pintle is called bottom pintle. Rudder drop: it is usually an indication of wear out of carrier bearing. This is taken by trammel gauge. Jumping clearances: jump is taken with feeler gauge or with a standard gauge, which indicates the distance by which the rudder can jump during pitching. Jump would usually be restricted to 6-7 mm but it exceeds then the jumping bar is renewed.
Que7-Sketch and describe a Viscotherm? Ans7- Viscotherm is used for viscosity measurement by maintaining the temperature of oil. Viscosity control of fuels is essential if correct atomization and combustion is to take place. Increasing the temperature of a fuel will reduce its viscosity, and vice-versa. As a result of the varying properties of marine fuels, often within one tank, actual viscosity must be continuously measured and then corrected by temperature adjustment. The sensing device is shown in figure. A small constant speed gear pump forces a fixed quantity of oil through a capillary (narrow bore) tube. The liquid flow in the capillary is such that the difference in pressure readings taken before the capillary and after it is related to the oil viscosity. A differential pressure gauge is calibrated to read viscosity and the pressure values are used to operate the heater control to maintain some set viscosity value.
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1. Stainless steel gear pump. 2. Oil chamber 3. Capillary tube 4. Differential pressure
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Figure: Viscosity Sensor

(a) diagrammatic
(b) actual
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COMPETENCY NO- 6 & 7

Function: TRAINING MANUAL
ASSIGNMENT NO: 27, 28, 29 &30 Que1- Sketch and describe a main air compressor? Ans1- A single stage compressor used to provide air at the high pressures required for diesel engine starting, would unfortunately generate compression temperatures of a level similar to those in a diesel. Such heat would be sufficient to ignite vaporized oil in the same way as in a compression-ignition engine. The heat produced in a single stage of compression would also be wasteful of energy. This heat of compression adds energy and produces a resultant rise in pressure apart from that pressure rise expected from the action of the piston. However, when the air cools the pressure rise due to the heat generated is lost. Only the pressure from compression remains. The extra pressure due to heat is of no use and actually demands greater power for the upward movement of the piston through the compression stroke.
Marine Auxiliary Machinery Pumps & Pumping Systems
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Que2- Sketch and describe the compressor suction and delivery valves? Ans2- A compressor is a rotary or reciprocating machine which compresses air or other gases. Valves- Air compressor use plate type valves which are designed to cover and uncover the valve seat, thus controlling flow of air in and out from the compressor. These are require small pressure differential to operate. For intake of air suction valve is used and for out take of air delivery valve is used.
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Ques3- What maintenance is required on Main Air compressor? How you prepare and carry out maintenance? Ans3- Complete overhaul of a Main Air Compressor:1. Put off the power to the compressor and put a note Men Working on the power panel. 2. Shut the air bottle filling valve and compressors delivery valve. 3. Isolate cooling water system. 4. Open crankcase door and drain out the oil from the sump. 5. Remove all connections like JCW outlet pipe, inlet pipe, pressure gauge line on cylinder head. 6. Remove cylinder head holding bolts, nuts. 7. Lift the cylinder head from its place and keep it on a wooden piece on floor. 8. Move piston to BDC and clean the circumference on liner top. 9. Move the piston to TDC and fit the piston lifting tool. 10. Open the bottom end bearings bottom half. 11. Remove the piston from its place and place it on its stand. 12. Clean the liner and calibrate the liner. 13. Clean the crank pin, bottom end bearing and calibrate. 14. Remove the piston rings; clean the piston, piston groove, old piston rings and new piston rings. 15. Calibrate piston ring grooves, old piston rings and new piston rings. 16. Put new piston rings on the piston. 17. Lubricate the liner, crank pin, bottom end bearing and fit back the piston and connect the bottom end bearing. 18. Clean the cylinder head landing area and renew the gasket. 19. Put back the cylinder head after cleaning its landing area and tighten it. 20. Clean L.O pump suction filter, clean crank case and take fresh L.O into the crankcase/ sump. 21. Give all cylinder head connections. 22. Clean the intercoolers S/W passages (tubes). Clean the J.C.W spaces with descaling liquids. 23. Open compressors delivery valve and air bottle filling valve. 24. Open intercooler drain. 25. Try out compressor.
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Ques4- Write down the starting stopping procedure for main air compressor? Ans4- Procedure for running air compressors:Special operation Before starting after overhaul or long periods of out of use carry out the following. 1. Check the oil level and also the quality of the oil. 2. Open the suction valve manually and turn the flywheel. 3. Check that the cooling water valves are open. 4. Check that all the valves in the discharge is set to the reservoir. And all auto drain valves are open. 5. Manually start the compressor and check lube oil pressure, cooling water pressure and the current drawn. Manual stopping 1. Open the water trap drain cock. 2. Stop the compressor. Auto starting 1. Check the oil level. 2. Check that all the valves in the discharge are set to the reservoir. 3. Check that the cooling water valves are open. 4. Check that the water trap auto drain valves are open. 5. Put the motor selector switch to auto position. 6. Press the start push button. 7. After starting make sure that all the parameters are within limits and the auto drain valves are functioning properly. 8. Check that the compressor cuts out at the correct pressure.
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Ques5- What do you meant by bursting disc? Ans5- Bursting discs or caps; These are relatively tamper proof provided that the correct materials and replacement caps are used. They do vent the manifold completely and, unlike the above relief valve, which resets once the pressure has dropped, require some form of blanking off if the engine is to be started again. For this reason, it is usual for several caps to be fitted to the engine (one per unit), unlike the relief valve where one or two valves are the norm. Bursting disc comprise of thin metal diaphragms designed to burst at a pressure equal to the maximum working pressure.
ASSIGNMENT NO 32, 33, 34 & 35 Que1- What is a clarifier and what principle does it work? Ans1- Clarifier separates liquid and solid phase such as impurities and small amount of water from oil. It does not have any gravity disc Top disc is without neck Only one outlet for liquid phase Its separation efficiency is maximum, since oil is subjected to centrifugal force
Que2- What is a purifier and what principle does it work? Ans-2.1 Purifier separates two liquids such as oil and water, which results in the formation of a cylindrical interface between the two. 2.2 It utilizes gravity disc at the time for getting interface between the two liquids. 2.3 Top disc has an extended neck. 2.4 It has two outlets in the bowl, one for heavy fluids and other for light fluids. 2.5 Separation efficiency is less due to pressure of gravity disc.
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Que-3 Describe briefly: A) Gravity disc: It is used to maintain on interface for separating the light and heavy liquids in the bowl. Gravity disc with different inner diameter are used according to specific gravity of fuel to be treated then by changing the interface position. B) Discharge collar: It acts as a guide for light liquid to pass through. C) Bowl head: It is a bowl body and looks like a large wing to form a housing for distillation and disc set through which the liquid is passed and separation takes place D) Top disc with neck: The top most disc stock is known as top disc and is heavier and has neck and collar fitted at top in case of purifier. It acts as a barrier between the two separator phases at the outlet. E) Top disc without neck: The top disc without neck is similar in function to that of a purifier but is used in clarifier F) Disc Set: It consists of a thin conical shaped disc of stainless steel. The separation tube is placed between the discs.
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Que4- Write down starting / stopping procedure of a self cleaning purifier? Ans4- Starting: 1. Check that the brake is disengaged. 2. Check the oil level in the gear case. 3. Confirm that the valves to & from the tank, pump, heater & purifier are set in the correct position. 4. Start the H.F.O. supply pump. 5. Start the H.O. purifier. Initially the current drawn will be almost full load current after some time the current will drop to 50% to 70% of the load i.e. 13 to 15 amps 6. Operate the fuel oil heater. 7. The heavy oil will be in circulation. Check the temperature of the oil is heated up to 980C. 8. Check that the epc control panel is on. When the purifier has attained its speed, press "feeding" (second) button. 9. Check the water level in the operating water tank and the control air supply. 10. After conforming that the purifying operation has started adjust the flow control valve to obtain the correct throughput. 11. Adjust the back pressure with the outlet valve to give a back pressure of about 1 to 1.5 kg/cm2 Stopping 1. Press push button "stop feeding" on the epc control panel the purifier will come to stop after doing a desludging. In case of an emergency, the push button emergency stop" can be pressed, but in this case the purifier will not do a desludging operation. 2. Close the sludge drain valve.
Que5- What is the rpm of a separator / clarifier? Ans5- The speed at which the bowl of the separator rotates is called the rpm of the separator. Its range is from 5000 7000 rpm. This can be measured with the aid of a revolution counter.
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Que6- Write the periodical maintenance for purifier? Ans6- The bowl and the disc stack will require periodical cleaning whether or not an ejection process is in operation. Care should be taken in stripping down the bowl, using only the special tools provided and noting that some left-hand threads are used. The centrifuge is a perfectly balanced piece of equipment, rotating at high speeds: all parts should therefore be handled and treated with care.
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Que7- Sketch a fuel oil service line Ans7-
Fig-Fuel oil supply system
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ASSIGNMENT NO 37, 38, & 39 Que1- Define a pump and what are the types of pumps? Ans1- Pump is a device which adds to the energy of fluid or gas causing an increase in its pressure and hence movement of the fluid. Mainly there are two types of pumps 1.1 Positive displacement pumps 1.2 Roto-dynamic pumps In positive displacement pump, the liquid or gas is displaced from suction to discharge by the mechanical variations of the volume of chamber or chambers. Rotodynamic pumps operate on a rotodynamic principle in that flow through the pump is induced by the centrifugal force imparted to the liquid by rotation of an impeller. Que2- Sketch and describe a Centrifugal Pump? Ans2-
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Centrifugal pump works through centrifugal action and the liquid receives energy from the impeller and due to continuous rotation of impeller the fluid moves radially with increasing the pressure and velocity.
Que3- Write short notes on: Ans31) Impeller: The rotation of centrifugal pump impeller causes the liquid it contains to move out wards from the centre to beyond the circumference of the impeller. Material used is aluminum bronze 2) Volute casing: This casing is known as volute casing because of its spiral shape. The casing section collects the liquid, discharged by the impeller and converts velocity energy into pressure energy 3) Stuffing box: Stuffing box has the primary function of protecting the pump against leakage at the point where the shaft passes out, through the pump casing. 4) Mechanical seal: A mechanical seal is similar to a bearing in that, it involves a close running clearance with the liquid film between the faces of the two dissimilar metals. The lubrication and cooling provided by the seal face material. 5) Bearing: Bearing transfer the load on the shaft and provide rotary relative movement minimizing the friction between the members. Bearing are usually roller bearing or ball bearing 6) Coupling: Coupling is used to connect the pump shaft to the prime mover shaft. Mostly flange or jaw type coupling are used. 7) Capacity: The capacity of a centrifugal pump determines its ability in particular condition. Capacity of a centrifugal pump is usually given by its flow rate in liters/hr or tones/hr. 8) Head: Head of a centrifugal pump is the height to which it can pump a particular fluid above the water level. 9) Priming Unit: The priming unit is used to handle the highly accelerated water that forms because of rolling and pitching even in moderate weather condition.
Que4- What do you understand by? Ans4-A) Water head: This is the vertical height from the suction of liquid level on highest point in delivery pipe. It determines the suitability of pump at given working condition. It gives height to which water can be pumped to a particular drawn. B) Kinetic energy: It is the total energy contained in a fluid owing to its vel;ocity. It is the energy content when the fluid is in motion. This energy is imparted to the fluid by rotation of impeller in a centrifugal pump. C) Pressure energy: It is the total energy contained in water owing to pressure difference between two points in pipe or between suction and discharge ends of pipe or pump.
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Que5- What is a multistage pump? Ans-5 In a multistage pump the fluid from one impeller is discharged via suitable passage to the eye of the impeller so that total head developed( or discharged) is the product of the head per stage and number of stage, such pumps are often used for high pressure discharge at alternative speed e.g. (turbo feed)
Que6- What is the difference between a Horizontal and a Vertical pump? Ans6 a)The pumps are differentiated on the type of sealing arrangement as in horizontal pump gland packing with rings is used for cooling of the shaft while vertical pump have mechanical seal mostly. b) Horizontal pump have bearing on both end for supporting the shaft whereas vertical pump have one pivot bearing to support the weight of the shaft and impeller c) In vertical pump, the motor is mounted on the top of the body, while the horizontal pump has its placed along axis, hence there is an advantage of space saving. Que7- Sketch and describe a Screw Pump? Ans7- Screw pumps are rotary type positive displacement pump in which the flow through the pump element is freely spaced. The liquid is passed between the screw thread and displaced axially as screw rotates. These pumps are self priming and are always fitted with a relief valve on the discharge side places.
Screw Displacement Pump

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Que8- What should be the safety features provided on a pump? Ans8- Each pump should be provided with a pass/relief valve to prevent overloading of the driving motor in case of unexpected increase in pressure during the operation. For this reason, bypass relief valve is to be designed at any determined pressure. The bypass valve connects the delivery side with suction side. It consists of a valve plate held against the valve sealing with a spring. The spring is designed for the working pressure. Que9- What defects will you normally look for in a pump? How will you check the correct direction of rotation of pump? Ans9- A) there should not be any leakage from mechanical seal of shaft B) Temperature of mechanical seal should not be high while working. C) Wear and tear of screws shaft arrangement of pump and motor should be checked. It is necessary to give attention to red arrow marking on pump outer casing, as it indicates the pump direction of rotation.
Que10- Sketch the Bilge and Ballast System of a Cargo Ship?
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ASSIGNMENT NO 40 & 41 Que1- How you prepare and carry out maintenance on Fresh Water Generator? Ans1- Maintenance on fresh water generator: 1. Open valves on the suction, discharge & overboard side of the ejector pump. 2. Close the vacuum breaker (air screw) valve on the fresh water generator. 3.Start ejector pump to create a vacuum of min. 90%, check the pressure at the combined air/ brine ejector inlet ( min 3 kg/cm2 ), check back pressure at combined air/brine ejector outlet ( min 0.6 kg/cm2 ). 4. Check that the two butterfly valves in the steam injector circuit are shut. 5. Open valve for feed water treatment, and adjust flow.
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6. Open heating (JCW) inlet and outlet valves; adjust heating by regulating the bypass valve step wise until the desired JCW temperature is reached. (approx. 10o c difference the boiling temperature will raise while the obtained vacuum drops to 85% this indicates evaporation has stated.) 7. Condenser CSW can be adjusted by regulating the bypass valve on the fresh water generator. 8. After approximate 3 minutes, the boiling temperature will drop again and normal vacuum is re-established. Open valve to fresh water tank and switch on the salinometer. 9. Start the distillate pump. Maintenance procedure for a Fresh Water Generator (Plate Type) 1. 2. 3. 4. 5. 6. 7. 8. Isolate Condenser cooling water (S/W) Evaporators heating water (JCW inlet and outlet) Ejector pumps feed water (shut all line valves of the Ejector) Distillate pump valves Open vacuum breaking cock Open evaporated drain Open the end cover Open the evaporated plates (Before opening, take measurement of the plates stack width at top, middle and bottom) 9. Clean the plates with descaling liquid / use Coir brush (Do not interchange any plates; take care of the plates lining rubber gaskets) 10. After thorough cleaning, clean with fresh water and assemble and tighten to the same width, measured before 11. Same way open the condenser plate and descale it and assemble it 12. Clean the demister with soap water 13. Start the heating water to evaporator(open the JCW inlet and outlet valve) and see that there is no leakage 14. Open the condenser cooling water (S/W inlet and outlet valve) and see that there is no leakage 15. Shut off the heating water (JCW ) to evaporator and cooling water (S/W) to condenser
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Que3-Sketch and describe a tube and shell type Fresh Water Generator? Ans3- The tube and shell type fresh Water Generator is designed to produce fresh water from sea water. This fresh water generator uses the engine coolant as heat source and produces fresh water by evaporating and condensing sea water. To evaporate sea water, it only uses the heat from coolant so, while a vessel is sailing, it uses main engine, and while a vessel is in port it uses auxiliary engine to produce fresh water. This Type fresh water generator can produce fresh water economically without any additional heat source (The coolant passes thorough the heat exchanger to transmit heat for evaporating sea water. At last, this heat goes back in to the engine).While the generator is running, the inner parts will be vacuum, so the boiling point of sea water will be dropped. The vapor become water drops by refrigeration from the cold sea water. When the water drops are collected in waterspout under the condenser, they are sent to the fresh water tank. If the salinity of the produced water exceeds the limitation, solenoid valve will operate to prevent the inflow of the water with high salinity. In conclusion, the produced water's solidity (salinity) is less than 10ppm, which is very pure, and also the produced water is soft water which can be used in many purposes.
FWG Schematic Sketch
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Que4- Sketch and describe plate type Fresh Water Generator? Ans4- The Plate Type Fresh Water Generator utilizes the heat from diesel engine coolant to evaporate sea water. Also, evaporation process occurs under high pressure to lower the boiling point under 48 degrees Celsius. Steam from evaporation can be used as heat source instead of hot coolant. It is based on two titanium plate heat exchangers acting as an evaporator and a condenser. The evaporation chamber maintains the vacuum condition by an ejector. Part of sea water from evaporation chamber is used as feed water for the evaporator. The feed water evaporates when entering the evaporating chamber due to the vacuum condition. Water particles and droplets are partly removed from water vapor by the built-in demister and the deflector mounted on the top evaporator. Separated droplets are brine, extracted at sump by an ejector pump. The desalted vapor passing through the demister is condensed by the plate condenser with incoming cold sea water. The pure distilled water is taken out by discharge pump. The pure water from condenser is controlled by the preinstalled salinometer to not exceed salinity level of 1-10ppm. If the salinity exceeded the specified level, solenoid valve in discharge line will automatically return the faulty distilled water to the feed line.
Pipe diagram for plate type Fresh Water Generator
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Que5- What is the basic principle for Fresh Water Generator? Ans5- The basic principle involved in the fresh water generator involves heating and evaporation of the sea water to produce fresh water by using the waste heat in the jacket cooling water of the diesel engine .The heat exchanger in the freshwater generator is connected to the jacket cooling water system of the Diesel engine, and is thus working as an extra cooler. Un-evaporated water is discharged as brine and that which is evaporated passes through the demister, where after condensation it is discharged to fresh water storage tank by fresh water pump. Que6- What are the faults which can occur that decrease the Fresh Water Generator? Ans6- The efficiency of fresh water generator is decreased by scale formation and frequency of the blowing down. Fouling is also a cause for decreasing the capacity of the fresh water generator. Thus decreases the heat transfer between the sea water and vapour and condensing liquids. If the sea water in the evaporator is heated to 800 c, CaCo3 scale predominates and if heated above 800 c magnesium hydroxide scale is deposited.
Que7- Sketch and describe a Salinometer.

Ans7-Salinometer
Water purity, in terms of the absence of salts, is essential where it is to be used as boiler feed. Pure water has a high resistance to the flow of electricity whereas salt water has a high electrical conductivity. A measure of conductivity, in Siemens, is a measure of purity. The salinity measuring unit shown in Figure 15.21 uses two small cells each containing a platinum and a gunmetal electrode. The liquid sample passes through the two cells and any current flow as a result of conductance is measured. Since conductivity rises with temperature a compensating resistor is incorporated in the measuring circuit. The insulating plunger varies the water flow in order to correct values to 200 C for a convenient measuring unit, the microsiemens/cm3 or dionic unit. A de-gassifier should be fitted upstream of this unit to remove dissolved carbon dioxide which will cause errors in measurement.
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ASSIGNMENT NO 60 Que1- What is a Heat Exchanger? Ans1-The application of heat exchangers to diesel engines is principally in the dissipation of heat to the environment, either to water or to atmospheric air. The functions which they fulfill can be classified as: (i) Engine cooling, to maintain within acceptable temperature limits such components as liners, pistons, and cylinder covers, etc. The pistons are cooled by a separate circuit in some larger engines. The materials used in the construction of engines are unable to withstand the thermal stresses that would be imposed upon them, for any appreciable length of time, without some form of forced cooling. (ii) Oil cooling, to control temperature and hence the viscosity of lubricating oil within the limits required to provide effective lubrication. The lubricating oil is sometimes used also for cooling the pistons. (iii) Charge air cooling in pressure-charged engines, to increase the density of the combustion air entering the cylinders as well as reduce its temperature, enabling engine power to be increased by burning more fuel on each piston firing stroke, whilst maintaining acceptable exhaust value temperatures.
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Que2-Sketch and describe a plate type heat exchanger? Ans2-The plate-type heat exchanger is made up of a number of pressed plates surrounded by seals and held together in a frame. The inlet and outlet branches for each liquid are attached to one end plate. The arrangement of seals between the plates provides passageways between adjacent plates for the cooling liquid and the hot liquid. The plates have various designs of corrugations to aid heat transfer and provide support for the large, flat surface. A double seal arrangement is provided at each branch point with a drain hole to detect leakage and prevent intermixing or contamination. Operation: Temperature control of coolers is usually achieved by adjusting the cooling liquid outlet valve. The inlet valve is left open and this ensures a constant pressure within the cooler. This is particularly important with sea water cooling where reducing pressure could lead to aeration or the collecting of air within the cooler. Air remaining in a cooler will considerably reduce the cooling effect. Vents are provided in the highest points of coolers which should be opened on first filling and occasionally afterwards. Vertical mounting of single pass coolers will ensure automatic venting. Positioning the inlet cooling water branch facing downwards and the outlet branch upwards will achieve automatic venting with horizontally mounted coolers. Drain plugs are also fitted at the lowest point in coolers.
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Plate type Heat Exchanger
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Que3- Sketch and describe a shell/tube type Heat Exchanger? Ans3- In the shell and tube design a tube bundle or stack is fitted into a shell. The end plates are sealed at either end of the shell and provision is made at one end for expansion. The tubes are sealed into the tube plate at either end and provide a passageway for the cooling liquid. Headers or water boxes surround the tube plates and enclose the shell. They are arranged for either a single pass or, for a double pass of cooling liquid. The tube bundle has baffles fitted which serve to direct the liquid to be cooled up and down over the tubes as it passes along the cooler. The joint arrangements at the tube plate ends are different. At the fixed end, gaskets are fitted between either side of the tube plate and the shell and end cover. At the other end, the tube plate is free to move with seals fitted either side of a safety expansion ring. Should either liquid leak past the seal it will pass out of the cooler and be visible. There will be no intermixing or contamination. Materials:Shell: Generally of cast iron or fabricated steel. Tubes: These are of aluminum-brass (76% copper, 22% zinc and 2% aluminum), or cupronickel or even stainless steel may be used. Tube-plates: The tube plate material should suit the tube material and the method of fixing. Naval-brass tube plates are used with aluminum-brass tubes. Water boxes: Cast iron or fabricated steel always designed to keep turbulence and coated for corrosion protection. Shell/Tube type Heat Exchanger
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Que4- Write the maintenance you do on Heat Exchanger? Ans4- Maintenance and testing procedure for a heat exchanger LO / JCW Cooler 1. 2. 3. 4. 5. 6. Isolate S/W cooling systems( shut inlet and outlet of the L.O / J.C.W) Isolate L.O/ J.C.W systems ( shut inlet and outlet of L.O/ J.C.W) Open the S/W side vent and open it drain and drain out S/W from the cooler Open the L.O/ J.C.W vent and its drain and drain out L.O/J.C.W from the L.O. cooler Open the end covers ( First cover should be of the side of Tube Heat- inserting point) Clean cooling water (S/W) passage tube, with wire, clean with fresh water; clean with compressed air 7. Now shut the L.O / J.C.W drain and fill up of cooler with fresh water and of the cooler with diluted descaling liquid 8. Heat the chemical added to the cooler with steam for few hours 9. Shut the heat steam and drain out the chemicals from the cooler (i.e., chemicals surrounding tubes) 10. Clean the space again fresh out till the chemicals surrounding the tubes comes out 11. Clean the end covers inner surface and give a coat of Apexier 12. Change / install new sacrificing anodes 13. Prepare new gasket for the end cover and fit back the end covers in reversing order with the way we opened the end cover 14. Now fill up the space surrounding tubes (I e., fill up the L.O / J.C.W passage area with fresh water and see that there is no leakages at both tube ends. If tube found leaking, plug the tube on both ends 15. Put back the end cover with new gasket 16. Shut all the drain 17. Start the S/W cooling system and vent it ( Purge out the air in the system ) 18. Start the L.O/ J.C.W system and vent it (Purge out the air in the system).
Que5- How leaky tubes are checked and how it can be plugged? Ans5- Tube leakage can result from corrosion. This can be checked for, or identified, by having the shell side of the cooler circulated while the cooling water is shut off and the end covers removed. Any seepage into the tubes will indicate the leak. It is also possible to introduce fluorescent dyes into the shell-side liquid: any seepage will show under an ultraviolet light as a bright green glow. Leaking tubes can be temporarily plugged at each end or removed and replaced with a new tube. Leaking tubes can be temporarily plugged at each end or removed and replaced with a new tube.
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ASSIGNMENT NO 48
Que1- What are the different types of valves? Ans1-There are many different types of valve; some used more extensively than others in the various systems found aboard ship. Valves will be of a type where the closing device consists of a circular disc with some arrangement of wings, or a centrally located guide rod on the base of the disc. The wings, or the guide rod, guide the disc in its up and down motion in the valve seat bush fitted in the body of the valve. Valves having this form of closing device are often referred to as globe valve. The energy wastage increases as the flow of fluid is restricted when the amount of valve opening is used to adjust flow rates.
Globe valve
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Gate valve: Another type of valve, a gate valve, uses a wedge shaped closing device. The wedge fits into a wedge shaped opening in the valve body. Fluids pass straight through this type of valve without a change in direction so there is less energy loss.
Gate Valve
Another type of valve uses a ball or spherical shaped closing device. A hole is made through the ball. When the axis of the hole is in line with the direction of flow the valve is open. When the hole in the ball is at 90 deg the fluid the valve is in the closed position The butterfly valve is also well suited as a closing device in pipelines and is used increasingly. Valves may be operated manually or by opening and closing devices known as valve actuators. Manually operated globe type valves have a screw and hand wheel to open or close the valve. The thread of this type of valve is usually a single start thread as this gives a rapid enough opening or closing speed when the valve wheel is turned.
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Butterfly Valve
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ASSIGNMENT NO 57 Que1- Why Auxiliary Boilers are required on ship? Ans1- A boiler in one form or another will be found on every type of ship. Where the main machinery is steam powered, one or more large water tube boilers will be fitted to produce steam at very high temperatures and pressures. On a diesel main machinery vessel, a smaller (usually fire tube type) boiler will be fitted to provide steam for the various ship services. A boiler is used to heat feed water in order to produce steam. The energy released by the burning fuel in the boiler furnace is stored (as temperature and pressure) in the steam produced. Que2- What are the types of Boiler? Ans2- Two basically different types of boiler exist, namely;1. The water tube 2. The fire tube In the water tube the feed water is passed through the tubes and the hot gases pass over them. In the fire tube boiler the hot gases pass through the tubes and the feed water surrounds them. Que3- Sketch and describe a Water Tube Boiler? Ans3- Water tube boilers The construction of water a tube boiler, which use small-diameter tubes and have a small steam drum, enables the generation or production of steam at high temperatures and pressures. The weight of the boiler is much less than an equivalent fire tube boiler and the steam raising process is much quicker. Design arrangements are flexible, efficiency is high and the feed water has a good natural circulation. These are some of the many reasons why the water tube boiler has replaced the fire tube boiler as the major steam producer. Early water tube boilers used a single drum. Headers were connected to the drum by short, bent pipes with straight tubes between the headers. The hot gases from the furnace passed over the tubes, often in a single pass, Que4- Sketch and describe a Smoke Tube Boiler? Ans4- The fire tube or smoke tube boiler is usually chosen for low-pressure steam production on vessels requiring steam for auxiliary purposes. Operation is simple and feed water of medium quality may be employed. The name tank boiler is sometimes used for fire tube boilers because of their large water capacity. The terms smoke tube and donkey boiler are also in use.
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Package Boilers Most fire tube boilers are now supplied as a completely packaged unit. This will include the oil burner, fuel pump, forced-draught fan, feed pumps and automatic controls for the system. The boiler will be fitted with all the appropriate boiler mountings. A singlefurnace three-pass design is shown in Figure 4.7. The first pass is through the partly corrugated furnace and into the cylindrical wetback combustion chamber. The second pass is back over the furnace through small-bore smoke tubes and then the flow divides at the front central smoke box. The third pass is through outer smoke tubes to the gas exit at the back of the boiler. There is no combustion chamber refractory lining other than a lining to the combustion chamber access door and the primary and secondary quart. Fully automatic controls are provided and located in a control panel at the side of the boiler.
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Que5- Sketch and describe a Composite/Cochran tube Boiler? Ans5- Composite boilers A composite boiler arrangement permits steam generation either by oil firing when necessary or by using the engine exhaust gases when the ship is at sea. Composite boilers are based on fire tube boiler designs. The Cochran boiler, for example, would have a section of the tube bank separately arranged for the engine exhaust gases to pass through and exit via their own exhaust duct.
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Que6- Sketch and describe a Safety Valve and how you set its pressure? Ans6. Safety valves Safety valves are fitted in pairs, usually on a single valve chest. Each valve must be able to release all the steam the boiler can produce without the pressure rising by more than 10% over a set period. Spring-loaded valves are always fitted on board ship because of their positive action at any inclination. They are positioned on the boiler drum in the steam space. The ordinary spring loaded safety valve is shown in Figure 4.13. The valve is held closed by the helical spring whose pressure is set by the compression nut at the top. The spring pressure, once set, is fixed and sealed by a Surveyor. When the steam exceeds this pressure the valve is opened and the spring compressed. The escaping steam is then led through a waste pipe up the funnel and out to atmosphere. The compression of the spring by the initial valve opening results in more pressure being necessary to compress the spring and open the valve further. To some extent this is countered by a lip arrangement on the valve lid which gives a greater area for the steam to act on once the valve is open. A manually operated easing gear enables the valve to be opened in an emergency. Various refinements to the ordinary spring-loaded safety valve have been designed to give a higher lift to the valve.
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Boiler safety valve are overhauled in dry dock workshop, lifting/floating pressure is set using nitrogen. However actual floating pressure is certified only using steam under working boiler conditions.
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Que7- Write down the starting/stopping procedure of the boiler? Ans7- Procedure for running auxiliary boiler 1. Manual firing. 2. Automatic firing. 3. Emergency firing Manual firing 1. Start forced draught fan keeping the switch on manual position. Fan should be run for at least 1 min before firing. 2. Start the boiler fuel oil pump keeping the switch on manual. Check that the recirculation valve is open and the temperature of the fuel is above 850. 3. Check that the atomizing steam valve is kept open. 4. Set the fuel oil controller to minimum i.e. about 1 kg/cm2 fuel oil pressure. 5. Check that all alarms are off and that there is sufficient water in the boiler. 6. Select low firing or high pressure. Press switch "burner start", 7. Automatic firing will start and the boiler will fire. The boiler will continue to fire in this mode and pressure will rise till the boiler is stopped manually. Automatic firing 1. Set the mode of the boiler to "low firing" or "high pressure" mode. Low or high pressure led will be lit 2. Check that the force draught fan switch is in "auto mode". 3. Check that the boiler fuel oil pump is in "auto and the steam pressure controller is on auto". 4. Check that the atomizing steam valve is open. 5. Check that there are no alarms on the boiler panel, and water level is normal. 6. Press button "burner start".
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7. After firing sequence is completed the boiler will fire and continue to fire till it reaches the cut out pressure of "low firing" mode or "high pressure mode.
Emergency mode firing Resort to emergency mode start up only when the burner sequence is out of order. 1. Switch over from auto to emergency operation 2. Set the load controller in manual. 3. Close the air damper completely. 4. Start the force draught fan. 5. Open the damper completely and purge the furnace for at least 50 second. 6. Close the air damper completely. 7. Press the ignition push button (maximum 10 second). Note: if the burner fails to start furnace must be re-purged positively prior to repeating the ignition sequence again.
Que8- What do you understand by boiler mountings? What are the mountings fitted on a boiler? Explain them? Ans8- Boiler mountings:Certain fittings are necessary on a boiler to ensure its safe operation. They are usually referred to as boiler mountings. The mountings usually found on a boiler are: Safety valves: These are mounted in pairs to protect the boiler against overpressure. Once the valve lifting pressure is set in the presence of a Surveyor it is locked and cannot be changed. The valve is arranged to open automatically at the pre-set blow-off pressure. Main steam stop valve: This valve is fitted in the main steam supply line and is usually of the non-return type. Auxiliary steam stop valve: This is a smaller valve fitted in the auxiliary steam supply line, and is usually of the non-return type. Feed check or control valve: A pair of valves is fitted: one is the main valve, the other the auxiliary or standby. They are non-return valves and must give an indication of their open and closed position. Water level gauge: Water level gauges or 'gauge glasses' are fitted in pairs, at opposite ends of the boiler. The construction of the level gauge depends upon the boiler pressure. Pressure gauge connection: Where necessary on the boiler drum, super heater, etc., pressure gauges are fitted to provide pressure readings. Air release cock: These are fitted in the headers, boiler drum, etc., to release air when filling the boiler or initially raising steam. Sampling connection: A water outlet cock and cooling arrangement is provided for the sampling and analysis of feed water. A provision may also be made for injecting water treatment chemicals.
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Blow down valve: This valve enables water to be blown down or emptied from the boiler. It may be used when partially or completely emptying the boiler. Scum valve: A shallow dish positioned at the normal water level is connected to the scum valve. This enables the blowing down or removal of scum and impurities from the water surface. Whistle stop valve: This is a small bore non-return valve which supplies the whistle with steam straight from the boiler drum.
Que10- Sketch and describe Exhaust Gas Boiler? Ans10-Exhaust gas boilers: The original exhaust gas boilers or economizers were of simple construction and produced, from the low powered engines of the time, a very moderate amount of steam. As large slow speed engine powers increased, the larger quantity of steam that could be generated from otherwise wasted exhaust energy, was sufficient finally for provision of the ships entire electrical power requirement through a turbo-alternator, plus any necessary heating steam. Slow-speed diesel power development has increased engine efficiency but actually reduced the waste heat available to an exhaust gas boiler. Waste heat systems have become more sophisticated (Figure 4.10) in order to continue to supply the electrical requirement and to obtain other economies.
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Que11- Sketch the fuel oil system for Auxiliary Boiler? Ans11- Boiler fuel-oil supply system:-
Que12- Sketch and describe an oil burner? Ans12-Fuel oil burning: The high-pressure fuel is supplied to a burner which it leaves as an atomized spray (Figure 4.16). The burner also rotates the fuel droplets by the use of a swirl plate. A rotating cone of tiny oil droplets thus leaves the burner and passes into the furnace. Various designs of burner exist, the one just described being known as a 'pressure jet burner' (Figure 4.16(a. The 'rotating cup burner' atomizes and swirls the fuel by throwing it off the edge of a rotating tapered cup. The 'steam blast jet burner', shown in Figure 4.16(c), atomizes and swirls the fuel by spraying it into a high-velocity jet of steam. The steam is supplied down a central inner barrel in the burner.
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The air register is a collection of flaps, vanes, etc., which surrounds each burner and is fitted between the boiler casings. The register provides an entry section through which air is admitted from the wind box. Air shut-off is achieved by means of a sliding sleeve or check. Air flows through parallel to the burner, and a swirled provides it with a rotating motion. The air is swirled in an opposite direction to the fuel to ensure adequate mixing. High-pressure, high-output marine water tube boilers are roof fired. This enables a long flame path and even heat transfer throughout the furnace. The fuel entering the furnace must be initially ignited in order to burn. Once ignited the lighter fuel elements burn first as a primary flame and provide heat to burn the heavier elements in the secondary flame. The primary and secondary air supplies feed their respective flames. The process of combustion in a boiler furnace is often referred to as suspended flame since the rate of supply of oil and air entering the furnace is equal to that of the products of combustion leaving.
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Que13- Write short notes on:Ans13- Super Heaters:With modest pressures and temperatures it was usually found sufficient to connect super heater tubes to the headers by expanding the tubes into tube holes in the header using a revolving mandrel expander. By revolving the tapered mandrel, rollers were forced against the tube bore, expanding it and squeezing the tube material against the metal of the header. The tube holes could be plain or were sometimes machined with one or more grooves. The tube end was also belled by an additional belling roller in the expander. As pressure and temperature advanced, difficulties were encountered with leaking at the expanded joints and in some cases this was countered by first expanding the tube and then running a light sealing weld around the tube end inside the header before lightly re-expanding. Each of these construction methods necessitated the provision of sufficient access handholes in the headers to permit the expanding and welding operations to be carried out.
Draught Fans:Fans used for boiler forced draught duty are usually of the centrifugal type, as are the fans for circulating air in air conditioning installations. Fans used for air supply to machinery and confined spaces are commonly of the axial flow type.
Water Treatment:Probably the single most important factor concerning safe, efficient and reliable operation of boiler plant is the maintenance of correct water conditions appropriate to the particular installation. Since raw water is insufficiently pure for use in boiler plant water treatment is used to produce the desired water conditions. The objectives of feed water treatment and chemical control can be listed as follows: 1. Prevention of corrosion/deposition within the boiler itself. 2. Prevention of corrosion/deposition of the feed and condensate systems. 3. Prevention of damage to machinery due to impure steam being generated. 4. Prevention of outage time due to failure of the boiler or its associated equipment. 5. Reduction of time for repair or maintenance. 6. Maintenance of a safe operating environment for personnel. Back Pressure:If the air were not removed by air ejector from the system it could cause corrosion problems in the boiler. Also, air present in the condenser would affect the condensing process and cause a back pressure in the condenser. The back pressure would increase the exhaust steam pressure and reduce the thermal efficiency of the plant. Blowing through of water gauge glass: Procedure should be followed. Referring to Figure 4.11, close the water cock B and open drain cock C. The boiler pressure should produce a strong jet of steam from the drain. Cock A is now closed and Cock B opened. A jet of water should now pass through the drain.
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The absence of a flow through the drain will indicate that the passage to the open cock is blocked.
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ASSIGNMENT NO 56 Que1- Sketch and describe a Refrigeration Plant? Ans1- Refrigeration works by removing heat from a product and transferring that heat to the outside air. REFRIGERATION SYSTEM COMPONENTS There are five basic components of a refrigeration system, these are: - Evaporator - Compressor - Condenser - Expansion Valve - Refrigerant; to conduct the heat from the product In order for the refrigeration cycle to operate successfully each component must be present within the refrigeration system. Evaporator: The purpose of the evaporator is to remove unwanted heat from the product, via the liquid refrigerant. The liquid refrigerant contained within the evaporator is boiling at a lowpressure. The level of this pressure is determined by two factors: - The rate at which the heat is absorbed from the product to the liquid refrigerant in the evaporator - The rate at which the low-pressure vapour is removed from the evaporator by the compressor To enable the transfer of heat, the temperature of the liquid refrigerant must be lower than the temperature of the product being cooled. Once transferred, the liquid refrigerant is drawn from the evaporator by the compressor via the suction line. When leaving the evaporator coil the liquid refrigerant is in vapour form. Compressor The purpose of the compressor is to draw the low-temperature, low-pressure vapour from the evaporator via the suction line. Once drawn, the vapour is compressed. When vapour is compressed it rises in temperature. Therefore, the compressor transforms the vapour from a low-temperature vapour to a high-temperature vapour, in turn increasing the pressure. The vapour is then released from the compressor in to the discharge line. Condenser The purpose of the condenser is to extract heat from the refrigerant to the outside air. The condenser is usually installed on the reinforced roof of the building, which enables the transfer of heat. Fans mounted above the condenser unit are used to draw air through the condenser coils. The temperature of the high-pressure vapour determines the temperature at which the condensation begins. As heat has to flow from the condenser to the air, the condensation temperature must be higher than that of the air; usually between -12C and 1C. The high-pressure vapour within the condenser is then cooled to the point where it becomes a liquid refrigerant once more, whilst retaining some heat. The liquid refrigerant then flows from the condenser in to the liquid line.
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Expansion Valve Within the refrigeration system, the expansion valve is located at the end of the liquid line, before the evaporator. The high-pressure liquid reaches the expansion valve, having come from the condenser. The valve then reduces the pressure of the refrigerant as it passes through the orifice, which is located inside the valve. On reducing the pressure, the temperature of the refrigerant also decreases to a level below the surrounding air. This lowpressure, low-temperature liquid is then pumped in to the evaporator.
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Que2- Sketch and describe an Expansion Valve? Ans2- Expansion Valves:The expansion valve is the regulator through which the refrigerant passes from the high pressure side of the system to the low pressure side. The pressure drop causes the evaporating temperature of the refrigerant to fall below that of the evaporator. Thus, for example, the refrigerant can be boiled off by an evaporator temperature of -18C because the pressure drop brings the evaporating temperature of the refrigerant down to say -24C The liquid refrigerant leaves the condenser with a temperature just above that of the sea-water inlet, say 15 C. As it passes through the expansion valve the evaporating temperature decreases to- 24C and some of the liquid boils off taking its latent heat from the remainder of the liquid and reducing its temperature to below that of the evaporator.
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Que3- What maintenance is carried out on Refrigeration System? Ans3- Daily maintenance:The daily maintenance for a R22 installation should be completed as follows:1. Check that condensing pressure and evaporating pressure are correct, and that the oil pressure drop across the oil filter is within the specified range. 2. Inspect the compressor unit and check that there are no abnormal noises or vibrations. 3. Check the discharge and suction temperatures, and the oil temperature. Discharge temperature depends on refrigerant and compressor type. 4. Check the oil level. 5. Check the tightness of the shaft seal. Oil leakage can be tolerated whereas gas leakage cannot. 6. If an oil separator is installed, check that oil is returned to the crankcase, and that the oil return line is warmer than the crankcase.
Que4- What is Defrosting and why we have to do it regularly? Ans4- Defrosting: - Another task which may be regarded as maintenance is to keep frost deposits on provision and cargo refrigerating plants under control. Frequent defrosting assures that the plant will cause few problems. The plant will need a minimum of care and maintenance if it is kept: A) Free of moisture; B) Free of impurities; C) Free of Freon leaks; D) Free of frost. The need for defrosting arises when operating with cargo temperatures close to 0C. The rise delivery air temperatures in cargo chambers under normal operating status of the entire cooling plant would be the first indication of the frost build up the air cooler coils.
Que5- What temperature are the food products like meat, fish, vegetable and dairy stored? Ans5- Carrying temperatures, C Apples 1-2 Bananas 11-14 Butter -9 Cheese 1-10 Eggs (Frozen) -9 (Chilled) 0-1 Fish -10
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Que6- How is the leak of refrigerant tested? Ans6- Leak detection Refrigerating plants must be gas-tight to prevent refrigerant leakage and air entering the low-pressure side when under a vacuum. Systems which been modified, or opened to the atmosphere during repairs, must be pressure tested for mechanical strength and leaks before charging with refrigerant. Pressure tested Leak detection equipment Leak detection equipment:Electronic leak detectors are the most sensitive and accurate method of leak detection. There are many instruments for detecting CFC and HCFC refrigerants and ammonia on the market. The most commonly employed operating principles are the semi-conductor, ionization or corona formation, and infrared detection. The detector contains an internal pump that draws air into a probe, or tube. If refrigerant gas is present in the sample, the electrodes in the sensing element generate a current, and an output signal is obtained. Que7- Write short notes on: Ans7- Oil Systems: The primary function of oil in a refrigeration compressor is to lubricate the bearings and other rubbing surfaces. It is also required to: a) Seal the clearance spaces between the discharge and suction sides of the compressor; b) Act as a coolant, removing the friction heat from the rubbing surfaces and, in the case of screw compressors, part of the heat of compression from the discharge gas; c) Actuate capacity control mechanisms, and in the case of screw compressors, load the balance pistons; d) Dampen the noise generated by the compressor. The oil for all these purposes is supplied from the crankcase or separate reservoir, and circulated under pressure by a pump or, in the case of some screw compressors, by the pressure difference existing across the compressor. Oil strainers and filters are fitted to prevent solid particles damaging the compressor and oil pump, and sludge blocking the system. Oil Separators: Some oil is always carried over with the compressed gas and must be removed. This is: a) To prevent it entering and fouling the internal surfaces of the evaporator and other heat exchangers; and b) To ensure its return to the crankcase or reservoir, preventing failure through the shortage of oil. Oil separators are placed in the line between compressor and condenser, and consist of a vessel fitted with internal baffles and screens. The separation of oil is mechanical, the slowing down and change of direction of the gas/oil stream throwing out the oil. The oil
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separated from the gas collects the bottom of the separator and is returned to crankcase or receiver through an automatic regulating valve. Filter Driers: The function of filter driers is to remove moisture from all refrigerant systems, with the exception of those using ammonia (R717), which has a high tolerance for moisture. Foreign particles, sediment, and the products of oil breakdown are also filtered out. The filter driers are fitted in the liquid refrigerant line from the condenser to prevent moisture and other contaminants entering and blocking the expansion valve. Filter driers contain a desiccant, which is a moisture absorbing substance which will eventually become saturated with moisture and have to be replaced. Two widely used desiccants are silica gel and molecular sieves. Where rechargeable units are fitted, the desiccant can be removed and the drier casing refitted with a fresh charge. Frost Bite: Direct contact with liquid refrigerant may result in frost-bite, due to the rapid evaporation of the liquid. Refrigerants are not usually caustic.
Eye Injuries: Refrigerant vapours are not usually harmful to the eyes. However, should liquid refrigerant squirt directly into the eyes, ensure that the injured person is taken to hospital or a doctor immediately? Avoid rubbing the eyes. The following first-aid should be administered. Drop the eyes with sterile mineral oil (refrigerating machine oil or liquid paraffin) and then rinse thoroughly with water. If the irritation continues, rinse the eyes with a weak boric acid solution.
Que8- What safety systems are provided in a Refrigeration Plant? Ans8- Safety provided on system: Compressor Crankcase Low Lube Oil Pressure Cut Out Low Refrigerant Suction Pressure Cut Out High Refrigerant Discharge Pressure Cut Out Relief Valve on Condenser for safe guarding against high pressure Shut off solenoid valves in respective refrigeration rooms Mechanical Hazards Personnel should be aware at all times that refrigeration systems contain liquids and vapours under pressure. Suitable precautions must be taken when working any part of the system to guard against the pressure hazard. Compressors must be operated within their design parameters, and should never be used as vacuum pumps or for compressing air. A) Guards on coupling, belts drives, and fans are in place, and other personnel are not in positions that might be hazardous when the plant is in operation. B) The compressor discharge stop valve is open.
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Opening up part of the system will necessitate the less of a certain amount of refrigerant to atmosphere. It is essential that the amount of refrigerant which escapes is kept to a minimum, and appropriate steps are taken to prevent hazardous concentrations of refrigerant accumulating. Under certain conditions, liquid refrigerant at low temperature may be present. Contact with this liquid must be avoided. When dismantling the compressor for maintenance, inspection or repair, the method of pumping out and opening up described in the operation manual should be followed with care. When it is necessary to open up the compressor, e.g. when cleaning the oil pump suction strainer changing the oil filter, caution must be exercised the lubricating oil will contain a certain amount refrigerant which will be released when subjected atmospheric condition Electrical Hazards The electrical power used in this equipment is at voltage high enough to endanger life. Before carrying out maintenance or repair procedures, persons concerned must ensure that equipment is isolated from the electrical supply and tests made to verify that isolation is complete. Whenever possible, precautions must be taken to prevent the circuit being inadvertently energized, i.e. withdraw the mains fuses, or, if this is not practicable, place a warning notice over the mains switch. When the supply cannot be disconnected, functional testing, maintenance and repair of the electrical units is to be undertaken only by persons who fully aware of the risk involved and who have taken adequate precautions to avoid direct contact with dangerous voltage. Que9: What are the trouble shootings which affect the refrigeration system? Ans9: Trouble Shooting: When problems are incurred in a refrigerating plant, these can be attributed in most cases to a shortage of refrigerant. Bearing this in mind, always commence troubleshooting by checking the refrigerant charge. For example, in the case of CFC and HCFC plants, too little refrigerant prevents the oil, which always circulates in the system, from being returned as the gas velocity is low, and this leads to various functional troubles. A trouble-shooting chart cannot be made complete until the design of the refrigerating plant is known. The comprehensive trouble-shooting chart should make it easier to locate the fault and its cause in the event of malfunction of a modern DX refrigerating plant. In investigating trouble, there are certain things to which attention should always be paid in the first instance: a) The temperature of the refrigerated space; b) Evaporating pressure; c) Condensing pressure; d) Suction pipe temperature; e) Discharge temperature; f) Liquid line temperature; g) Compressor running time; h) Noise from compressor, motor, expansion valve, etc.
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ASSIGNMENT NO 59
Que1: What is Steering Gear and why is it required on a ship? What is the maximum movement of rudder permitted and how much time it takes from hard port to hard starboard? Ans1: The steering gear provides a movement of the rudder in response to a signal from the bridge. The total system may be considered made up of three parts, control equipment, a power unit and a transmission to the rudder stock. The control equipment conveys a signal of desired rudder angle from the bridge and activates the power unit and transmission system until the desired angle is reached. The power unit provides the force, when required and with immediate effect, to move the rudder to the desired angle. The transmission system, the steering gear, is the means by which the movement of the rudder is accomplished. Certain requirements must currently be met by a ship's steering system. There must be two independent means of steering, although where two identical power units are provided an auxiliary unit is not required. The power and torque capability must be such that the rudder can be swung from 35 one side to 350 the other side with the ship at maximum speed, and also the time to swing from 35 one side to 30 the other side must not exceed 28 seconds. In brief, a steering gear is required to: a) Be continuously available; b) Move the rudder rapidly to any position in response to the orders from the bridge during maneuvering, and hold it in the required position; c) Have arrangements for relieving abnormal stress and returning the rudder to its required position; d) Maintain the ship on course regardless of wind and waves.
Que2- What is a Telemotor and what is the function of same and where it is located? Ans2- Telemotor control is a hydraulic control system employing a transmitter, a receiver, pipes and a charging unit. The transmitter, which is built into the steering wheel console, is located on the bridge and the receiver is mounted on the steering gear. The charging unit is located near to the receiver and the system is charged with a non-freezing fluid. The telemotor system is shown in Figure 12.4. Two rams are present in the transmitter which moves in opposite directions as the steering wheel is turned. The fluid is therefore pumped down one pipe line and drawn in from the other. The pumped fluid passes through piping to the receiver and forces the telemotor cylinder unit to move. The suction of fluid from the opposite cylinder enables this movement to take place. The cylinder unit has a control spindle connected to it by a pin. This control spindle operates the slipper ring or swash plate of the variable delivery pump. If the changeover pin is removed from the cylinder unit and inserted in the local hand wheel drive then manual control of the steering gear is possible. Stops are fitted on the receiver to limit movement to the maximum rudder angle required. The charging unit consists of a tank, a pump, and shut-off cocks for each and is fitted in the main piping between the transmitter and receiver.
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Que3- Sketch and describe a Electro Hydraulic Steering System with Hunting Lever Mechanism? How is the movement of Rudder obtained through steering gears? Ans3- A Two-Ram Steering Gear is shown in Figure. The rams acting in hydraulic cylinders operate the tiller by means of a swivel crosshead carried in a fork of the rams. A variable delivery pump is mounted on each cylinder and the slipper ring is linked by rods to the control spindle of the telemotor receiver. The variable delivery pump is piped to each cylinder to enable suction or discharge from either. A replenishing tank is mounted nearby and arranged with non-return suction valves which automatically provide make-up fluid to the pumps. A bypass valve is combined with spring-loaded shock valves which open in the event of a very heavy sea forcing the rudder over. In moving over, the pump is actuated and the steering gear will return the rudder to its original position once the heavy sea has passed. A spring-loaded return linkage on the tiller will prevent damage to the control gear during a shock movement. During normal operation one pump will be running. If a faster response is required, for instance in confined waters, both pump maybe in use. The pumps will be in the nodelivery state until a rudder movement is required by a signal from the bridge telemotor transmitter. The telemotor receiver cylinder will then move: this will result in a movement of the floating lever which will move the floating ring or slipper pad of the pump, causing a pumping action. Fluid will be drawn from one cylinder and pumped to the other, thus turning the tiller and the rudder. A return linkage or hunting gear mounted on the tiller will reposition the floating lever so that no pumping occurs when the required rudder angle is reached.
A Four-Ram Steering Gear is shown in Figure. The bask principles of operation are similar to the two-ram gear except that the pump will draw from two diagonally opposite
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cylinders and discharge to the other two. The four-ram arrangement provides greater torque and the flexibility of different arrangements in the event of component failure. Either pump can be used with all cylinders or with either the two port or two starboard cylinders. Various valves must be open or closed to provide these arrangements. The use of a control valve block incorporating rudder shock relief valves, pump isolating valves, ram isolating and bypass valves, offers greater flexibility with a four-ram steering gear. In normal operation one pump can operate all cylinders. In an emergency situation the motor or a pair of hand pumps could be used to operate two port rams, two starboard rams, two forward rams or two after rams.
Que4- What is hard port/hard starboard? Ans4Hard Port: when the position of the rudder is at 350 from the centre line toward port side. Hard Starboard: when the position of the rudder at 350 from the centre line toward starboard side.
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Que5- Incase of Steering Gear failure, what means are provided to steering system? Ans5- In case one steering gear system fails , second steering gear system ( on auto standby at all times ) comes into use . Emergency power supply is always ensured for at least one system from ESBD. If the telemotor fails a manually controlled system is provided for operating the solenoid valves associated with the steering gear control systems enabling the movement of the rudder..
Que6- What is a Ward-Leonard system and how it is used in steering system? Ans6- A Ward-Leonard arrangement is shown diagrammatically in Figure. A continuously running motor-generator set has a directly coupled exciter to provide the field current of the generator. The exciter field is part of a control circuit, although in some circuits control is directly to the field current of the generator with the exciter omitted, When the control system is balanced there is no exciter field, no exciter output and no generator output, although it is continuously running. The main motor which drives the rudder has no input and thus is stationary. When the wheel on the bridge is turned, and the rheostat contact moved, the control system is unbalanced and a voltage occurs in the exciter field, the exciter, and the generator field. The generator then produces power which turns the rudder motor and hence the rudder. As the rudder moves it returns the rudder rheostat contact to the same position as the bridge rheostat, bringing the system into balance and stopping all current flow.
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Que7- Write short notes on? Ans6- Hydraulic ram: Two cylinders for steering gear are of cast steel and to the rams compromise of one piece steel forging with integral pins to transmit the movement through load piece which slide in the jaws of a forced tiller and hydraulic press. It is supplied to cylinder by variable delivery pumps to move the ram. Swivel Block: This connects the hydraulic rams and the tiller. This purpose is to convert the liner movement of rams to rotary movement of the tiller arm as rudder stock. Rudder Tiller: It is keyed to the rudder stock. It is to transmit motion from the swivel block to rudder stock. There is no relative motion between the tiller and rudder stock Floating Lever: It is used to bring back the pump position to zero. It provides main feedback for the rudder stock to control the delivery pump so that the rudder comes to rest at desired position. Emergency Steering: By operating the solenoid valves manually thus ensuring rudder movement is NEVER immobilized. The drill is carried out prior arrival /departure port and out at sea as per SOLAS regulations.
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MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

OPERATIONAL LEVEL TRAINING MANUAL REFERENCE

CREDIT : MR.A.RAMASWAMY COMPILED BY B.K.KUMAR ( GME HOD )

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

ASSIGNMENT NO: 9 Que1- How does a fuel valve work?

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

ASSIGNMENT NO 17 Que1- Sketch the complete air starting line? Ans1-

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS

GME & BS TRAINING MANUAL

MAIN & AUXILIARY MACHINERY - TRAINING MANUAL ASSIGNMENTS