1. What is ovality of auxiliary engine crank pin?

Combined effect of reduced effectiveness of L.O and directional thrust of the con rod.

This is maximum at around 45 degree ATDC

Uneven loading of units and overloading

Max Allowed: 1/4th of the bearing clearance

Removed By: Insitu Grinding and polishing

Reference: Fillet of crank web

Max. Allowed Grinding: 2mm, because after grinding 2mm or more surface hardness reduces

drastically. Due to this maximum allowable grinding is 2mm.

Bottom bearing damage reason is the ovality, bearing clearance and condition of L.O supply

2. Why are concentric springs fitted for A/E cylinder head valves?

If the frequency of the natural vibration of air or exhaust valve springs is a harmonic of the

camshaft speed, then the spring may vibrate axially and are said to surge. Surge can be

avoided by modifying the sizes of springs by arranging the springs in pairs and fitting one

inside the other.

If one spring fails the valve is held up and is not damaged by striking the piston.

The thickness of individual springs can be reduced as against original thickness.

Normally two springs of different vibration characteristics are chosen.

Moreover, the stiffness requirements and the space congestion at this place warrants a

concentric springs arrangement. The net stiffness is equal to the sum of individual stiffness.

3. What is SQUAT Phenomenon?

It is a venturi effect while vessel is moving on shallow water. A vacuum is created due to

which the draught of the vessel is increased there by increasing the engine load.

Steering ability of the ship is reduced as a result.

4. What is a thermostatic expansion valve?

This is a regulator through which the refrigerant is metered from the high pressure side to

the low pressure side of the system. The pressure drop causes the evaporating temperature

(saturation temp.) of the refrigerant to fall below that of the evaporator.

a. Avoids liquid refrigerant return to the compressor suction.

b. Automatic expansion control and maintain 6 ~ 7 degree superheat.

5. What is the function of an L.P controller?

The LP controller stops the compressor at low suction pressure caused by the closure of all

compartmental solenoids. When the pressure in the compressor suction rises due to solenoid

opening, the LP controller restarts the compressor.

6. What is the function of an L.P cutout?

This is used to protect the compressor against the low suction pressure due to loss of

refrigerant or blockage. If the a/c compressor suction pressure is allowed to fall below

atmospheric pressure then there exists a risk of moisture and air ingress into the system.

7. What is a Coalescer?

A device consisting of a material whose surface provokes coalescence.

The process of combining of larger droplets of a liquid like oil into larger droplets is called

coalescing.

8. Why is there a starting air overlap provided in a diesel engine?

a. To give a positive starting in correct direction.

b. Starting ability from any position.

c. If any one of the valve is malfunctioning. Engine can still be started.

9. What is the significance of firing order?

a. Balancing of primary and secondary inertia forces.

b. To assist the exhaust grouping.

c. For distribution of stress over the length of crankshaft and optimum bearing loading.

d. A firing interval for even turning moment.

10. What are the reasons for foaming in refrigeration compressor crankcase?

Due to rapid boiling out of the refrigerant dissolved in the oil when the pressure is suddenly

reduced.

When the compressor starts operating, if a large quantity of refrigerant has been dissolved,

larger quantity of refrigerant boils out and can be carried through the refrigeration lines.

Reasons:

a. Liquid in the suction line (viz. TEV stuck open, incorrect super heat setting, sensing
bulb not closing, overcharge etc.,)

b. Crankcase heater not working.

c. Compressor capacity too high at the start.

d. Expansion valve giving too small superheat

e. Oil charge is less.

11. Explain the functions of lube oil in refrigeration system

a. Lubrication

b. Seal the clearance spaces between the discharge and suction sides of the compressor.

c. Act as a coolant.

d. Actuate capacity control.

e. Dampen the noise generated by the compressor.

12. What are the various windlass safeties?

ELECTRIC:

a. Electromagnetic brake.

b. Motor overload protection.

c. Short circuit protection.

d. Restart delay timer.

e. A Restart stop.

MANUAL:

a. Manual brake / mech. Brake.

b. Cable stopper.

c. Slipping clutch (torque limiter).

d. Relief valve.

13. What are the steering gear motor safeties?

a. Overload alarm.

b. 200% insulation in motor.

c. High temperature alarm.

d. Self-starting after power failure.

e. Short circuit trip.

f. Phase failure alarm.

g. One of the steering motor is fed from the emergency bus.

Hydraulic side there is two trips

a. Low level cutout

b. High lube oil temperature cutout.

14. What are the overhead crane safeties?

Current to motor’s field coils passes through solenoid coil of a brake which is magnetized and

holds a brake against spring and releases the rotor. Incase of power failure the solenoid is

demagnetized and brake is applied.

SAFETY:

a. Limit switch on the f’wd, aft, port, s’tbd, hoisting and lowering prevents movements

more than the allowed limits.

b. Overload trip.

c. Dead man’s handle.

d. Guards over the pulley.

e. Locking device on the lifting hook.

f. Mechanical locking (to avoid crane movement during heavy weather)

15. What is a critical pressure?

It is the pressure at which gas will just liquefy at its critical temperature.

16. What is a critical temperature?

It is the temperature above which the gas cannot be liquefied under isothermal compression.

17. What are the air bottle safeties?

a. Relief valve

b. Fusible plug

c. Drain

d. Low pressure alarm

18. What happens if fuel pump leaks?

a. Fuel quantity is reduced – loss of power, cylinder liner lubrication is affected.

b. Loss of cylinder power.

c. Late injection.

d. After burning.

e. High exhaust temperatures, smoky exhaust.

f. Power imbalance among units. Compiled by Eswara Arun Kishore

[email protected]

19. What are the constant tension winches?

It is a variation of the constant pressure and constant horsepower control for variable

capacity pumps. It is used to achieve constant tension winch system. In this case the pump

control is automatically operative across the neutral such that constant system pressure and

hence a constant motor torque is maintained whilst both drawing in and paying out.

20. What are the causes of turbocharger surging?

a. Rapid variation (reduction) in load.

b. Chocked exhaust and air passage like scavenge ports, valve or air cooler etc.,

c. Abnormal fuel system like a unit misfiring.

d. Chocked air suction filter, fouling of the turbocharger, unbalanced output from the

engine, damaged exhaust valve, scavenge fire.

21. What are the causes of cylinder head cracking?

a. Scale deposits

b. Inefficient cooling water

c. Uneven tightening of bolts and fuel valves

d. Fluctuating cooling water temperature (excessive temperature gradient)

e. Overloading or racing of engine

f. Faulty relief valve

g. Mechanical failure due to gas corrosion, acidic corrosion due to leaky exhaust valves

h. Water side corrosion

22. What is the normal relief valve setting of cylinder head in a diesel engine?

10 ~ 14.5% more than the working pressure about 120 bar (some what higher than

maximum pressure)

23. State the advantages of uniflow scavenging

a. Simple liner construction

b. Long skirt (for piston) not required

c. Stroke length can be increased

d. High scavenging efficiency

e. High thermal efficiency

f. Low grade of fuel can be burnt

g. Uniform wear of piston rings and liner

h. Less thermal stresses

i. Less intermixing of scavenging air with the exhaust gas

j. Exhaust valve can be made to open late – more work, close early – scavenge air is

more utilized.

24. Why cylinder liner wear is more at the top?

a. High temperature exposure due to the combustion gases

b. Loss of liner lubrication in low speed diesels

c. Corrosion, predominantly acidic due to combustion products

d. Fuel impingement, deposits

e. Change of direction of the piston, which causes to a step like formation at the reversal

point

25. What actions do you take incase of stern tube of the ship starts leaking?

a. Maintain low head.

b. Use higher viscous oil.

c. Replenish periodically to counter for the oil loss.

d. Drain off the water periodically.

e. Try to remove foreign particles by changing direction of shaft.

26. How do you test a fresh water generator plant for leaks?

a. Close the outlet of the distillate pump, vacuum breaker valve, bottom blow off valve

and feed water valve

b. Inject air into the evaporator shell

c. Keep the shell pressed up to about 1.0bar gauge

d. Sprinkle soap solution on to the jointings, packings, and suspected areas of the shell

27. What are the reasons for a piston crown to crack?

a. Casting defect

b. Thermal stresses due to cold starting air and scavenging air

c. Scavenge fire

d. Overheated piston(cooling failure, cooling side deposits due to oxidation of the cooling

oil)

e. After burning

f. Faulty fuel injection system (more penetration or loss of atomization)

28. What are the reasons for black smoke from a diesel engine?

a. Poor combustion due to faulty injection system

b. Low compression

c. Insufficient scavenging air

d. Fouled exhaust system

e. Broken piston rings

f. Ineffective lube oil seal

g. After burning, bad fuel and other fuel assisted faults

h. Faulty cylinder lubrication

i. During starting, it is inevitable as the engine maker sets the starting fuel index to a

fixed value. At this index there is insufficient air, low piston speed, cold combustion

chamber, low fuel injection pressure etc., each compounding the cause for black

smoke

29. What are the critical speed effects?

Resonance, torsional vibration, fatigue failure of components

Can be remedied by:

a. Detuners

b. Vibration dampers

c. Electric vibration compensator unit

30. What are the types of vibration in a diesel engine and which is the most
damaging?

Types of vibration:

a. Linear vibration

b. Torsional vibration

c. Resonant vibrations involving any two of the above or may be combinational

Most damaging form of vibration is the torsional vibration mode, affecting crankshaft and

propeller shafting.

31. What is a node?

A node is found where the deflection is zero and the amplitude changes its sign in a vibrating

medium. The more the nodes in a given length the higher the corresponding natural

frequency.

32. What is a forcing frequency?

W.r.t the crank shafts, the forcing frequencies are caused by the firing impulses in the

cylinders.

Firing impulses superimpose on one another and appear as a complex waveform represented

by harmonics –

1x cycle frequency: first order harmonics of firing

2x cycle frequency: second order harmonics

3x cycle frequency: third order harmonics and so on…

33. How can the frequency of resonance, the forcing impulses and the resultant

stresses adjusted?

a. By adjusting shaft sizes

b. Number of propeller blades

c. Firing order

d. Using viscous or other dampers

e. Using balancing weights

f. Detuning coupling

34. What is balancing?

Balancing is a way of controlling vibrations by arranging that the overall summation of the
out of balance forces and couples cancels out, or is reduced to a more acceptable amount.

35. Explain the vibration characteristics of low speed 2-S engines

a. External unbalanced moments

b. Guide force moments

c. Axial vibrations in the shafting system

d. Torsional vibrations in the shafting system

36. What is 1st order moment?

These moments acts in both vertical and horizontal directions. For engines with 5 cylinders

or more, the 1st order moments are of rare significance to the ship but it could be of a

disturbing magnitude in the 4 cylinder engines. Resonance with a 1st order moment may

occur for hull vibrations with two and/or three nodes. 1st order compensator can be

introduced in the chain tightener wheel. It comprises of two counter rotating masses

rotating at the same speed as the crankshaft.

37. What is a second order moment?

The second order moment acts only in the vertical direction and precaution needs only be

considered for 4, 5 and 6 cylinder engines. Resonance with the 2nd order moment may only

occur at hull vibrations with more than 3 nodes. A 2nd order moment compensator

comprises two counter rotating masses running at twice the engine speed.

38. What are the methods to cope up with the second order moments?

a. A compensator mounted on the aft end of the engine driven by the main engine chain

drive mechanism.

b. A compensator mounted on the fore end driven from the crankshaft thus a separate

chain drive.

c. A compensator on both aft and fore end completely eliminating the external 2nd order

moment.

39. What is an electric compensator?

It is electrically driven compensator preferably located in the steering gear compartment,

where deflections are the maximum and the effect of the compensator is maximum. Such a

compensator is synchronized to the correct phase relative to the external force or moment
and can neutralize the excitation. The compensator requires an extra seating to be fitted.

40. What are guide force moments and their types?

The origin of the guide force moment is the angularity of the connecting rod. It is the

vibration of the engine about the foundation bolts.

Guide force moments are caused by the transverse reaction forces acting on the cross head

due to the con rod crankshaft mechanism.

Guide force moments may excite engine vibrations moving the engine top arthwartships

causing a rocking (excited by the H moment) or twisting (excited by X moment) movement

of the engine.

Guide force moments are harmless except when the resonance occurs in the engine double

bottom system. As a precaution, top bracing is installed between the engine’s upper platform

brackets and the casing side for all its 2S models.

41. What are different types of the top bracing for a diesel engine?

a. It comprises of the stiff connections (links) either with friction plates which allows

adjustment to the loading conditions of the ship

b. A hydraulic top bracing – by using the top bracing natural frequency will increase to a

level where resonance will occur above the normal engine speed.

42. How are the axial vibrations caused in the crankshaft? How are they

remedied?

When the crank throw is loaded by the gas pressure through the conrod mechanism, the

arms of the crank throw deflect in the axial direction of the crankshaft, exciting axial

vibrations. These vibrations may be transferred to the ship’s hull through the thrust bearing.

Its remedy is to axially dampen the crankshaft vibrations.

43. How is torsional vibrations generated?

The varying gas pressure in the cylinders during the working cycle and the crankshaft /

conrod mechanism create a varying torque in the crankshaft. It is these variations that cause

the excitation of torsional vibration of the shafting system.

The torsional excitation also comes from the propeller through its interaction with the non

uniform wake field.

Remedy: modify crankshaft natural frequency by adjusting the diameter. Use a torsional

damper.

44. What is under critical running?

The natural frequency of the one node vibration is so adjusted that the resonance with the

main critical order occurs about 35~45% above the engine speed at specified maximum

continuous rating (MCR). The characteristics of an under critical system:

a. Relatively short shafting system

b. Probably no turning wheel

c. Turning wheel with low inertia

d. Large diameter of the shafting

e. Without barred speed range

45. What is overcritical running?

The natural frequency of the one node vibration is so adjusted that the resonance with the

main critical order occurs about 30~70% below the engine speed at the specified MCR. The

characteristics of the system are:

a. Turning wheel may be necessary on the crankshaft

b. Turning wheel with a relatively high inertia

c. Shaft with relatively small diameter (shaft material has to be of high UTS)

d. With a barred speed range of about +/- 10% w.r.t the critical engine speed

46. If resonance occurs, what is the solution?

The following modification(s) have to be carried:

a. Lanchester balancers, either on the engine or electrically driven units usually located

in the steering flat, compensated for ships vibration caused by the 2nd order vertical

moment

b. Counter balancing weights on the crankshaft to be adjusted for compensating the first

order vibrations

c. Combined primary and secondary balancers

d. Adjusting the side stays

47. How to prepare a DB fuel oil tank for a survey/inspection?

a. Empty the oil, strip with portable pumps if required

b. Clean the tank with sea water and pump it through the oily water separator

c. Ventilate the tank(s) with a blower specially provided for the purpose, always cross

ventilate i.e. there should be at least two openings, each for entry and exit for the air

d. Check the space for explosive gases at various points suitably, more sampling should

be carried out at the corners at the bottom most part of the tank

e. Obtain the necessary certificates and get the checklist completed

48. Why are the CO2 bottles provided with dip tubes?

It is to ensure that only liquid is drawn during release. The liquid expands after the nozzles

and assumes the gaseous state. This will prevent co2 freezing and blocking the nozzle

Also it achieves the 85% discharge in 2 Minutes as liquid part represents a large volume of

gas

The materials used in its construction are copper, stainless steel

49. Why a crankcase relief door is not fitted in the refrigeration compressor

crankcase?

a. Possibility of the contamination of the refrigeration system by air by leaks

b. Oxygen is not available in the compressor crankcase

c. The incoming refrigerant temperature is low and chances of hot spots is low

d. Crankcase forms the suction chamber of the compressor and chances exist that the

compressor may draw in air and moisture

50. Why heaters are provided in the crankcase of a refrigeration compressor?

a. To avoid carry over of the lube oil because at low temperature, the separation of the

refrigerant and the oil is difficult

b. To condition the lube oil, by maintaining the viscosity so that the lubrication is

effectively carried out.

c. This prevents the lube oil achieving its floc point which may cause narrowing or

chocking of the passages (flocculation)

51. What are the causes of a centrifugal pump reduced output?

a. Friction and leakage losses, loss of suction head, chocked suction filter, worn out wear
ring, air ingress in the suction side

b. Low voltage is applied to the pump motor

c. Cavitations on the impeller

d. Bad maintenance, incorrect fixing up of the parts after overhaul

52. What are the causes of vibration in the vertical centrifugal pump?

Misalignment of the shaft, worn out bearing, foundation bolts loose, hydraulic clearances -

not proper on the impeller, coupling bolts / seating damaged, bottom bush worn out, heavy

objects/debris deposits, and corrosion/erosion on the rotating parts

53. What is volumetric efficiency of air compressors?

Actual volume of air drawn in / swept volume

54. What is compression ratio?

(Swept volume + clearance volume)/clearance volume

55. What is brake thermal efficiency?

Ratio of the energy developed at the brake to the energy supplied. Amount of heat liberated

during the combustion to the heat equivalent at the brake

56. What is the function of a Solenoid valve in the refrigeration system?

There is an electric signal actuated valve in the liquid line of the refrigeration system just

before the thermostatic expansion valve. This is being actuated by the thermostat in the

refer compartment. The solenoid shuts off the refrigerant supply if the compartment is

sufficiently cooled to the lower set point of the thermostat. Also it connects the supply when

the temperature of the compartment goes high i.e. above the thermostat higher set point

57. What is the function of the back pressure valve in the refrigeration system?

Back pressure valve is fitted just at the exit of the refrigerant from the evaporator coil in a

multi temperature rooms system. This being fitted at the exit of the compartments whose

temperature is set higher (usually at about 4~5 degrees centigrade). The function of the

valve is to maintain equilibrium of the system as the pressure of the gas at the exit of each

compartment differs. More over the back pressure valve creates a back pressure on the

evaporator coil and ensures that most of the liquid refrigerant is made available to the lesser

temperature requirement compartments as their demand for the refrigerant is higher than
the compartments being maintained at a higher temperature. It is spring loaded non return

valve

58. What is the function of a H.P cut out in a refrigeration system?

This is a safety device (trip) provided in the discharge of the compressor. It functions to trip

the compressor if the pressure in the HP side goes high above the working level

59. What is the function of the driers in the refrigeration system?

The filter/drier is installed in the main liquid line of the system to absorb any moisture

present in the refrigerant. It consists of activated alumina or silica gel in a renewable

cartridge. It also accommodates the charging connection

60. What are the usual stern tube bearing clearances?

a. Water cooled stern bearing clearance: 8.0mm (8~12mm)

b. Oil cooled stern tube bearing: 1.87~2.0mm

61. What is a usual volumetric efficiency of a diesel engine?

a. Naturally aspirated engine: 0.85~0.95

b. Supercharged engine: up to 4.0

c. For 2S engine: 0.85~2.5

62. What is a usual propeller drop usual value?

1mm/160mm of the shaft diameter

63. What are the advantages of a thin shell bearing?

a. Increased fatigue resistant properties

b. High load carrying capacities

c. Embed ability

d. Conformability

e. Bedding not required

f. Easy storage, easy fitting, light in weight

g. Increased (enhanced) mechanical properties

h. Better heat transfer due to reduced thickness and uniformity of the contact with the

bearing housing

64. What are the typical bearing failures?

a. Fatigue failure (cracks)

b. Tin oxide encrustation (black SnO2 )

c. Wiping damage of the bearing surface

d. Tearing of the overlay

e. Acidic corrosion

f. Cavitations, erosion

g. Dross inclusion

h. Spark erosion

i. Bacterial attack damage (honey colored deposits on the bearing surface)

65. What are the advantages and disadvantages of the synthetic lube oils?

Advantages:

a. Better low temperature fluidity and pump ability, due to nil wax content

b. Better oil retention at high temperatures

c. Lower friction losses

d. Reduced thickening of the oil in service due to oxidation

e. Lower deposits at higher temperature due to resistance to oxidation properties and

thermal stability

Disadvantages:

a. Increased cost of the lube oil (about 6~12 times)

b. Poor availability

Uses:

a. Air compressors

b. Purifiers

c. Hydraulic units

66. What is the purpose of the lube oil analysis?

a. To determine any deterioration in lube oil properties or additives levels and assess its

suitability for further service

b. To determine the type and level of the contaminants held within the oil which indicate

the rate of contamination and effectiveness of the purification process

c. To predict the internal wear rate on the machinery components

d. To lengthen the time between overhauls or surveys

67. When is the lube oil said have deteriorated?

a. TBN reduces

b. Viscosity reduces

c. Flash point reduces

d. Oxidation increases

e. Water content high

f. Insolubles increase

g. Dispersancy increases

68. What are the problems in cast iron welding?

a. Brittleness (cracks easily)

b. High carbon content in the form of graphite

c. Close grain structure

d. Poor thermal conductivity and differential cooling

e. Possibility of stresses and distortion

69. How is a propeller drop measured?

a. Turn the engine to coincide with the mark on the liner and the stern tube or normal

reference is taken to be that the engine’s unit 1 will be in TDC prior measuring the

propeller drop

This could be also arranged as with a designated blade of the propeller up wards while

measuring this drop. Blades are assigned alphabets A, B, C, D and so on.

b. Take the poker gauge reading and the compare with the previous reading

c. Bearing clearance : 2mm (oil sealed)

: 8mm (sea water lubricated)

Bearing length is about 2xdia of the shaft for oil cooled stern tube bearing

4xdia of the shaft for sea water lubricated stern tube bearing

70. Compare an engine flywheel and its governor

a. A governor maintains the speed of the engine

b. A flywheel controls the cyclic fluctuations of the engine RPM

c. Flywheel works on the virtue of the inertia alone and the governor uses the inertia

principle to actuate the fuel linkages to counter the changes in the engine RPM

71. Why are tie rods provided?

Tie rods are provided to keep the whole engine structure in compression which:

a. Increases the fatigue strength of the engine structure as it is the tensile stress which

causes fatigue

b. Maintain running gear alignment to avoid fretting

The firing forces that press down the bearing saddle also attempt to push up the cylinder

covers, the net effect being to put the whole engine structure into tensile loading. So the tie

rods are tightened such that the engine structure is maintained in compression even during

the peak firing conditions and that the engine is not subjected to the tensile loading.

72. Why tie rods are placed close to the centerline of the crankshaft?

During firing, the transverse girders are subjected to a bending moment as the saddle is

pushed down by the crankshaft acting on the cylinder head. To limit this bending effect and

consequent distortion of the bearing housing the tie rods are positioned as close as possible

to the center-line of the crankshaft.

73. Where is a thrust bearing installed in an auxiliary engine? And why?

Axial location of the crankshaft may be required if the coupling does not incorporate a thrust

housing. This is achieved by forming white metal rings on the sides of one main bearing shell

that allows the shaft to run with a small clearance between running faces on the two

adjacent webs.

In some engines a small collar may be provided at one side of the bearing. It is important to

appreciate that only one such locating bearing should be fitted to any one shaft, otherwise

the differential thermal expansions of frame and the crankshaft may cause problems.

74. What are the environmental problems with the use of CFCs?

a. CFC released into the atmosphere are broken down by pyrolysis to release chlorine

atoms which catalytically destroy ozone layer.(this layer in the stratosphere acts as a

filter to the UV radiation from the sun)

b. Furthermore CFCs along with other greenhouse gases inhibit radiation from the

earth’s surface thereby contributing to the global warming.

75. What is a pH value?

It is the logarithm of the reciprocal of the hydrogen ion concentration expressed in gram ion

per liter.

Pure water at 25 degree centigrade consists of equal concentration of the hydrogen and the

hydroxyl ions and equal to 10

-14

gram ion per liter. If the hydroxyl ion concentration exceeds

the hydrogen ion concentration then the solution is basic and vice versa is acidic in nature.

pH value = log [1/H+]

If the water temperature is increased, the concentration of the hydrogen ion increases and

hence acidity.

76. Why is a man hole door elliptical in shape?

Any opening in a pressure vessel is kept to a minimum and for a man entry an elliptical hole

is lesser in size than the corresponding circular hole. More over it is prime concern to have a

smoothed generous radius at the corners to eliminate stress concentration. Hence other

geometrical shapes like rectangle and square are ruled out.

To compensate for the loss of material in the shell due to opening, a doubler ring has to be

provided around the opening. The thickness of the ring depends on the axis length along the

direction in which the stresses are maximum and the thickness of the shell. It is important to

align the minor axis along the length of the vessel, as the stress in this direction is

maximum.

Longitudinal stress: Pd/2t where P= pressure inside the vessel, d= diameter of the arc, t=

thickness of the shell plating

Circumferential stress: Pd/4t

More over a considerable material and weight saving is achieved as minor is along the

direction of maximum stress.

77. Why is the fridge compressor belt driven?

a. A slight misalignment is a problem or vibration of the electric motor may lead to shaft

seal leakage, leading to loss of the refrigerant. So minimize these the fridge

compressor is belt driven.

b. In case of the liquid entry into the refrigeration compressor, the belt drive gives a

limitation of the damage owing to the slip in the belt and flexibility of the belt

material.

78. Why intercooling is provided in an air compressor? And why is the

compression distributed into stages?

a. By employing the interstage cooling we are trying to achieve an isothermal

compression cycle. So least work is expended in the process.

b. The air outlet temperature after compression is lowered by intercooling. So oxidation

of the lube oil is prevented. Also good lubrication is achieved.

c. Lesser deposits in the air system.

d. Intercooling increases the air density and hence reduced volume of the HP

compression chambers is possible.

e. It facilitates removal of moisture by condensation at the intercoolers.

f. To facilitate intercooling the compression is distributed into stages. Also even load

distribution is achieved over the cycle.

79. What if the compressor motor connections are reversed after overhauling?

a. The lube oil pressure will not be sufficient for lubrication so the compressor may trip

on low lube oil pressure. The moving parts may get damaged due to the failure of the

lubrication.

b. The cooling water pump which is also shafted driven usually does not build up enough

flow/pressure hence the compressor may trip of the cool water non flow or high air

temperature.

80. If viscotherm is absent or damaged how do you maintain the fuel oil

viscosity?

The required viscosity prior injection and the viscosity of the fuel oil at 50°C are provided by

the fuel oil analysis report. Basing on the viscosity nomogram the required fuel oil heating is
determined. The steam inlet to the fuel oil heater is manually adjusted to maintain the

temperature and a close observation has to be maintained on the steam pressure and

temperature of the fuel oil at the outlet of the heater.

81. What are the reasons for the error between the helm order and the angle

shown locally on the steering gear unit?

a. Air in the hydraulic telemotor system

b. Buffer spring too weak or stiff, faulty hunting gear

c. Instrument error/defective

d. Worn out linkages

82. Why are the accumulators used in the hydraulic systems?

a. To absorb shock due to load variation or sudden change in the direction of flow,

impact loading

b. To maintain the circuit pressure by compensating for the loss due to leaks or pressure

increase due to rising temperature

c. To supplement the pump delivery where multiple circuit operations have wide flow

variations with a short term peak demand in excess of the pump capacity.

Accumulator charge can take place during low demand periods to meet maximum

demand later

83. Explain the cross head slipper lubrication

a. The lubricating oil is fed to the guide shoes by a pipe from the main lube oil system

b. The lubricating oil may also be fed from the drilled passages in the pin to the slipper

faces

84. What is the material of the CO2 bottle and its accessories?

CO2 bottle: solid drawn seamless manganese steel

Cable: phosphor bronze

Seal/bursting disc: thickness 0.3mm, phosphor bronze

Pipeline: solid drawn MS galvanized

Siphon tube: copper tube

Cutter: 120° /travel 19mm

85. How will you decide for reentry into the engine room after flooding it with

CO2

Re-entry is determined by

a. Heat build up due to the scale of the fire and the elapsed time after release

b. Has the fire been extinguished or chances of a smoldering fire exists

c. Ship’s position, condition and the prevailing weather (ship may be listing to the angle

of progressive flooding etc.,)

d. The location of the entry point

e. Risk analysis outcome

86. What is the quality of the vapor coming back to the compressor suction in

the refer system? In addition, how will you ensure that the vapor has adequate

degree of superheat?

a. The condition of the vapor coming to the compressor suction line should have

adequate degree of superheat

b. The condition is checked by reading the pressure of the returning vapor and its

corresponding temperature from the P-T chart provided for the specific refrigerant.

This temperature is compared with that of the evaporator outlet and the degree of

super heat is expressed as the difference in the temperature.

87. What is the length of the crank web?

Length of the crank web = stroke length/2

88. What is lignum vita?

In the traditional sea water lubricated stern tubes the bearing material consisted of the

staves of the wood called lignum vitae. This has a property of lubrication in the presence of

sea water. They are fitted with the grains in the axial direction for economy and are shaped

with V or U grooves between them at the surface to allow for access to water. They also act

as a debris collector points. The staves are held in place in the bronze boss by bronze keys

attached to the bush by counter sunk screws. Bearing length is equal to 4times the shaft

diameter.

89. What are the safeties in the fridge system?

a. HP cut out

b. Differential lube oil pressure cutout

c. LP cutout

d. Relief valve in the condenser

e. Belt driven

f. Cylinder head relief valve

g. Cooling water low flow/high temperature alarm

h. Motor overload

i. Oil separator

j. Drier

k. Mech. Seal

l. Unloaders /capacity controllers

m. Non return shut off valves

n. Sensors – temperature, pressure

90. How will you know the presence of air in the refrigeration system? Explain

the procedure for purging air

a. High condenser pressure

b. Small bubbles in the sight glass

c. Compressor discharge pressure high/running hot

d. More superheat

e. Pressure fluctuations

f. Inefficient working

PROCEDURE FOR PURGING AIR

a. In the normal operation of the system, measure the liquid refrigerant pressure,

temperature at the outlet of the condenser/reservoir

b. Check the corresponding saturation temperature for the recorded pressure of the

liquid refrigerant from the P-T chart for the same refrigerant

c. Compare the measured temperature with the determined saturation temperature for

any sub-cooling and adjust the flow of the cooling water through the condenser to
achieve near saturation condition inside the condenser,

Then,

d. With the condenser liquid refrigerant outlet valve closed, circulate cooling water, start

the compressor and pump down the liquid to the condenser/reservoir, checking the

pressure in the suction line. If this pressure is allowed to drop down below the

atmospheric pressure then there could be chances of air ingress into the system

e. Circulate the cooling water till the cooling water outlet and the inlet temperatures

equal, a check to ensure complete pump down operation

f. Check the condenser sea water out let temperature, check the refrigerant pressure

corresponding to its temperature from the P-T chart of same refrigerant

g. Due to the presence of air they don’t agree

h. Release air from the condenser, through the vent cock until the pressure of the

refrigerant in the condenser corresponds to the saturation pressure at the sea water

outlet temperature

91. What is the material of the boiler gauge glass?

The material used in the gauge glass is a special toughened glass containing

a. Silicon oxide or magnesium oxide

b. Borosilicate or lime soda glass

92. What is the material of a boiler tube?

Low carbon alloy steels containing chromium, nickel, molybdenum

93. What is the material of the ship side valve?

BODY: Nickel-Aluminium bronze / cast steel

Stem/Seat/Disc: Monel metal (cupro nickels of varying proportions are used popular being a

Cu:Ni = 2:1)

The cupronickels are known for their great resistance to the sea water corrosion, erosion by

the particles in the sea water, and strength.

94. What is the material of the propeller material?

a. Nickel aluminium bronze (nickalium)

Copper: 55~62%, Aluminium: 0.5~2.2%, Nickel: 0.5%, Manganese:

0.5~1.0%, Iron: 0.4~1.5%, balance is Zinc

b. Manganese bronze

Copper: 58%, Iron: 1%, Aluminium: 1%, Manganese: 1%, Nickel: 0.5%, Zinc:

38%, Tin: 0.5%

95. What is the general composition of the stainless steels?

Chromium: 18%, Nickel: 8%, Carbon: 0.12%

96. What is the material of the 4S engine conrod?

a. Forged steel: Open hearth plain carbon steel

UTS: 432~494 MN/m2

% Elongation: 25~30%

Fatigue limit: 208 MN/m2 (push pull)

b. Nickel steel, 3%Ni

UTS: 695 MN/m2

%Elongation: 20%

Fatigue limit: 309 MN/m2 (push pull)

METHODS OF TIGHTENING:

a. Measuring the extension of the bolts

b. Use of the calibrated torque wrenches

c. Hydraulic tensioning

d. Angle tightening

97. What is the material of the foundation bolts?

High tensile steel

98. What is the material of the tie rod?

High tensile steel

99. What is the material of the double bottom plug?

Silicon steels

100. What is the material of the crankshaft?

Forged low carbon alloy steel. Carbon: 0.12% and less

101. What are the materials used for the diesel engine’s liner and piston rings?
State their principle differences

Generally the materials used for the piston rings are harder than the liner material. This is

due to the fact that the rings are subjected to wear always during their operation but only

the portion of the liner in contact with the rings wears.

Material used for the liner is generally the nodular cast iron, which is tailored to have

expansion along the length and negligible expansion circumferentially. Alloying materials are

added to improve certain characteristics like vanadium and titanium.

Piston rings are cast and machined from graphite grey cast iron. This ring may include

chromium, nickel & copper as alloying substances.

The prime property which distinguishes it from the liner material is that it has to flex

circumferentially.

This is of primary concern for running in and to match the contour of the wearing liner

surface. Also they have to form an effective sealing of the combustion gases.

102. What are the liner wear rates? And how is it achieved?

Old engines: 0.1mm/1000hrs

Modern engines(2S): 0.03mm/1000hrs

Modern engines(4S): 0.12mm/1000hrs

This is achieved by:

a. Highly alkaline lube oil

b. Load dependant jacket cooling water temperature control

c. Good quality of cast iron with a hard face

d. Careful design of the piston ring profile

e. Improvement in lube oil

f. Multilevel cylinder lubrication

g. Condensate separation from the scavenging air

h. By use of the anti-polishing ring or the piston cleaning

103. Explain why stainless steel is resistant to corrosion?

Stainless steel depends on the formation of a protective oxide film, tenacious chromium

oxide for resisting corrosion. This film is formed spontaneously on exposure to air or well
aerated water. Compiled by Eswara Arun Kishore

[email protected]

Without this oxide film, their corrosion resistance is only slightly better than other

engineering steels.

104. What is the material of the fuel valve needle and body?

Needle: high speed steel

Body: case hardened steel

105. What is the material of the chain and its tightener arrangement?

High tensile steels

106. Quote some important clearances in the rudder system

Jumping clearance: 6mm

Clearance at raphson slide mechanism: 16~19mm

Propeller drop: 1mm/160mm diameter of the tail shaft

Pintle clearance: 1.1mm~3.3mm

107. What are the usual pressures to which the boilers are tested?

New boilers, if > 6.9bar working pressure, 1.5xdesign pressure

If < 6.9bar working pressure, 2.0xdesign pressure

After major repair, 1.25~1.5x working pressure, duration of the testing: 30Min.

108. Explain the purpose of the hunting gear

a. To put the pump on stroke gradually

b. To stop the pump at the end of the stroke gradually

c. To lock the rudder at desired position till further movement is given at helm

d. To transmit movement of telemotor to pump

e. Spring in the hunting gear store extra control movement to ensure that the pump

operates at the maximum capacity for major part of the turning operation

109. Differentiate between the terms priming and foaming with reference to their

occurrence in a steam boiler

Both refer to the carry over of water into the steam outlet. Priming is due to the

mechanical/physical aspects and the foaming refers to certain insouble/solubles in the boiler
water, which by the principle of increased surface tension cause priming.

The various reasons for priming:

a. High water level in the boiler

b. Rapid changes in the steam demand

c. Safety valve lifting frequently due to its malfunction

d. Rough weather causing heavy rolling/pitching

e. Rapidly raising steam

f. High salinity of the boiler water

Foaming is the formation of unbroken chain of bubbles on the surface of boiler water. A

common cause of the same is the oil contamination.

110. Mention some important mechanical properties of metals

a. Elasticity:

b. Hardness: Resistance to abrasion

c. Plasticity:

d. Toughness: Ability to absorb maximum energy before fracture

e. Ductility: Ability of the metals to deform plastically under tensile force

f. Stiffness: Ability to withstand deformation

g. Malleability: Ability of the materials to deform plastically under compressive force as

in forging or rolling

h. Resilience: Resist shock and impact

i. Brittleness: Tendency of the material towards brittle fracture. Brittle fracture is the

failure of the material without plastic deformation

j. Creep: Plastic flow under constant load application or heat

k. Weld ability:

l. Endurance: Ability to withstand alternating stresses

m. Cast ability:

n. Strength: Ability to withstand rupture

111. What is a tie rod bolt pinch screw? And what is its purpose?

Pinch screw is normally provided at the foot of the engine cylinder jacket to stop the tie rod
from vibrating during the normal service of the engine.

The pinch screw is fitted at the antinodal point of the tie rod to limit its transverse vibration

amplitude, thereby preventing its fracture due to vibrations. These can be arranged as a

group of three screws positioned equilaterally at the antinodal point. Each screw consists of a

stud, which is hand tightened by screwing the outer sleeve and held in place by a lock nut

which is tightened to a torque specified by the manufacturer.

112. What is the course of action after finding that a bottom end bolt is

slackened?

a. Check the length of the bolt

b. Check whether it is within the limits

c. Check for cracks / surface finish. Check the threads

d. The tie rod can be rolled over a flat surface coated with Prussian blue. Any twists in

the rod are revealed by the Prussian blue lines on the tie rod which get adhered along

the twisted plane

e. If found alright, tighten the bolt and check the remaining bolts

113. Define higher calorific value and the lower calorific value

[H2O formed by the hydrogen in the fuel oil cannot exist as water at the high temperatures

in an internal combustion engines. The water formed by the combination of hydrogen and

oxygen absorb the heat from the combustion and forms steam. Therefore, some amount of

available energy is lost in converting water into steam. This energy is not available to the

engine.

Therefore, the calorific value of the fuel reduced by this amount presents the actual calorific

value available to the engine.] -Æ This definition is given by reeds and I feel this has

to be altered after looking into the MANBW manual, which provides a graph to

calculate the Lower calorific value based on the Specific Gravity and Sulfur content.

Therefore, the amount of heat loss due to the inclusion of sulfur, which cannot be separated

by normal fuel oil treatment and its subsequent oxidation to SOx warrants the entire calorific

value to include correction for corresponding fuel content in a specific mass of fuel sample

and the energy loss due to sulfur oxidation. Corrections should also include for ash & water
content.

Therefore, to get the practical scenario two specific calorific values are mentioned Lower

calorific value and the higher calorific value.

Lower calorific value = higher calorific value – the energy loss in converting the mass of the

[water into steam] + sulfur to sulfur oxides + Loss of specific enthalpy due to ash content

present in unit mass of fuel.

114. Explain gear pumps w.r.t the materials used and the clearances

Rotors and shafts are integrally forged of Nitraalloy steel.

Gears are case hardened, medium carbon steel. They are hardened all over and ground

finished after hardening

Casing and bearing housing are close grained grey cast iron

Shafts are supported by white metal bearing or roller bearings or bronze bushes on the free

ends

Liquid being pumped is forced out after being carried around the gear teeth between the

gear teeth and the casing.

Backflow is limited by:

a. Minimizing the radial clearances between the teeth of the gears and the housing

b. Increasing the number of teeth

c. Optimizing the side tolerances /play

Gear pump suitable for operating up to 25bar and can achieve displacement volume of

0.35~1.0 liters/revolution

Clearances between the gear teeth and the housing are of the order 0.02~0.03mm

115. What are the advantages and disadvantages of resin chocks?

ADVANTAGES:

a. 100% contact on uneven surfaces

b. Cheaper to install as no hand fitting is required

c. Don’t corrode and are resistant to most of the chemicals

d. As they achieve good contact, there is little chance of fretting, thus cheaper, shorter,

non resilient bolts can be used. These permit a reduction in the bolt tension by a
factor of 4

e. Avoid vibrations

DISADVANTAGES:

a. Overstressing of the bolts causes the resin to shatter and break

b. Maximum temperature is limited to about 80°C

116. Explain the cavitation in the bearings

Vaporization due to oil pressure falling locally below vapor pressure causes bubbles in the oil,

which when goes to higher pressure region, collapses and shock wave is generated causing

heavy impingement. The causes:

a. High oil temperature

b. Low oil pressure

c. Vibration

d. Oil contamination

117. What are the Nimonic and Stellite coatings?

These are considered to be the hardened materials by the process of metallic cementation

Nimonic: carbon, chromium, Titanium, Aluminium, Cobalt, Molybdenum, Iron, Nickel

There could be other constituents such as Manganese, copper, silicon

Stellite: They are alloys of Cobalt, and Chromium, with the addition of varying amounts of

tungsten and other elements

They are very resistant to corrosion and abrasion. Retain their hardness at a red heat

Since they cannot be forged, they must be cast direct to shape or deposited by welding

118. Why is an equalizing line provided in the refrigeration system?

It is used in the installations where a large drop in pressure occurs in the evaporator. In the

expansion valve, the pressure acting outside (top) of the bellow corresponds to the

saturation pressure plus the degree of superheat of the refrigerant leaving the evaporator.

This pressure is trying to open the valve against the spring force from below the diaphragm.

The external equalizer connection has a saturation pressure of the refrigerant leaving

evaporator, to act below the diaphragm. Therefore the saturation pressure from the external

equalizer connection balances the saturation pressure of the sensing bulb leaving only the
pressure due to degree of super heat only to oppose the spring force. Therefore, this degree

of superheat is supposed to open the expansion valve.

By this method, we are getting a control over only the degree of superheat of the refrigerant

leaving the evaporator coil. This is important to ensure proper utilization of the refrigerant

and that no liquid refrigerant reaches the suction of the compressor.

119. What are the reasons for short cycling of a refrigerant compressor?

a. Refrigerant charge is too low

b. Frosting or clogging of the evaporator

c. Dirty suction strainer

d. Low pressure control differential too small

e. Wrongly adjusted capacity regulator

f. Refrigerant vapor in the liquid line

g. Too much cooling water

h. TEV faulty

i. Too high compressor capacity

120. What is viscosity? Differentiate between the kinematic viscosity and the

dynamic viscosity

Defined as the resistance of fluids to change of shape, being due to the internal molecular

friction of molecule with molecule of the fluid producing the frictional drag effect.

Absolute (Dynamic) viscosity is numerically equal to the force to shear a plane of fluid

surface of area of a unit square meter, over another plane surface at the rate of one meter

per sec, when the distance between the surfaces is one meter.

Kinematic viscosity is the ratio of the absolute viscosity to the density at the temperature of

viscosity measurement.

Viscosity index is a numerical value which measures the ability of the oil to resist the change

in viscosity with the change in temperature. A high viscosity index shows a good resistance

to the change in viscosity with change in temperature.

121. What is an Otto cycle or the constant volume cycle?

This is the constant volume cycle. Although no actual engine cycle operates strictly following
this ideal cycle, the analysis of this cycle provides a tool for comparison of performances of

actual engines under different operating conditions.

The most important noted difference between this ideal cycle and the normal cycle is that

this is a non-flow cycle involving an ideal gas whereas the actual cycle is a flow process and

the gases are real.

This cycle is explained as follows:

At the beginning of the process the cylinder is assumed to be full with a charge of fresh air.

The air is compressed isentropically following the law PV

= constant. Heat is then added to

the same mass of air at constant volume. This point represents the maximum pressure and

temperature in the cycle. From here the air is expanded isentropically to the initial volume

and then the heat is rejected at the constant volume.

122. What is a Diesel cycle?

This thermodynamic cycle is first analyzed by Rudolph Diesel. This is a slight variation of the

above constant volume cycle, the difference being that the heat addition in the cycle takes

place at constant pressure. The other processes during compression, expansion, and heat

rejection remain same as with the constant volume cycle.

123. What actions do you take incase of an EGB Soot fire?

The oxygen levels in the EG Boiler/Economizer is about 14~16%, so this can support

combustion.

The nature of combustible deposits include soot from the combustion of fuel in the plant as

well as some amount of unburnt oil (fuel and lube oil), particularly at low loads.

Ignition of soot may arise at sufficient high temperature of the layer of the soot whose

surface temperature may go up to 300~400˚C, but presence of unburnt oil may lower this

temperature to about 150˚C and under favorable conditions to about 120˚C.

SMALL SOOT FIRES: Mainly occurs during maneuvering with the engine being operated at

prolonged low loads. The situation may arise even at short low load running if the fuel is bad.

Indications:
a. High economizer exhaust gas outlet temperature

b. Sparks from the funnel

c. Engine running parameters showing deviations due to increased exhaust back

pressure

d. High steam pressure or outlet temperature from the super heater section if fitted

How to deal with this situation:

a. Stop the main engine so that the oxygen levels can be brought well below the fire

sustenance levels

b. Carry out the boundary cooling

c. Fire watch to be kept on deck due to the risk of the funnel sparks, fire hoses to be

kept charged

d. Continue running the circulating water pump

e. Never use the soot blowers for fire fighting

f. Stop the auxiliary blowers

g. Ensure that all the exhaust valves are positively closed (check the spring air pressure)

If the soot fire has now turned into metal fire (identified immediately by the loss of the

circulating water of the economizer), stop the circulating water pump. Carry out the

boundary cooling.

If means are provided, deluging the economizer fires with copious amounts of water should

be carried out to the seat of the fire. This is essential because, if lesser amount of water used

the fire is additionally supported by the production of steam sourcing hydrogen for the

situation to get worse.

Hydrogen fire: Occurs because of dissociation of water (steam) into hydrogen and oxygen or

carbon in connection with carbon monoxide and hydrogen

This occurs only above 1000˚C

Iron fire: Oxidation of the iron at high temperature occurs at a rate sufficiently high to make

the amount of hest release from the reactions sustain the process. These reactions may take

place at a temperature in excess of 1100˚C

124. How do you identify the symptoms of a crank case explosion? What action
would you take to minimize the hazard?

a. Engine noise

b. Oil mist detector alarm

c. High bearing temperature (alarm if fitted)

d. In case of minor explosions the crank case relief door releases the pressure

ACTION:

a. Slow down the engine, inform the bridge

b. Take permission from the bridge for stopping the engine

c. Continue running the engine lube oil pumps

d. In severe cases, it is prudent to open the engine room skylights and other vents and

abandoning the engine room. The doors from the engine room to the accommodation

should be kept shut. Return to the engine room only after carrying out risk

assessment

e. Turn the engine by turning gear with the indicator cock opened to prevent seizure of

the hot spots

f. Stay clear of the crank case specially in the region of the relief door to the

turbocharger suction

g. Don’t open the crank case door until sufficient time has elapsed

125. What are the various IG plant alarms and trips?

ALARMS:

a. O2 content high

b. Scrubber tower water level low

c. Deck seal water level high

d. Deck seal water level low

e. IG pressure low

f. IG pressure high

g. IG temperature high

h. Boiler uptake soot level high (Ringlemann)

TRIPS:
a. Scrubber tower water level high

b. Venturi water pressure low

c. Low IG cool sea water pressure

d. Scrubber cool sea water pump abnormal stop

e. Power failure

f. Incorrect mode of the boiler (mode set to NAV, GF.. etc)

g. IG temperature high high (more than alarm level)

h. IG blower abnormal stop

i. Deck seal water low flow

j. IG deck main extreme high pressure

126. Reciprocating pump is getting over heated, what checks should be carried

out?

a. Inlet and outlet valves are to be examined

b. Inspect the seat and lapping should be done if required

c. Valve lift should be checked

d. Inspect piston and piston rings

e. Spring (valves should be checked for tension and springing action)

f. Liner wear down should be checked

g. Driving belt should be checked for wear down or damage

127. Explain the various rudder inspections and testing in the dry dock

a. Visual examination of the rudder plating for cracks and distortion

b. Air plugs and drain plugs are to be opened in the presence of the class surveyor,

repair superintendent and chief officer. Water draining out indicates a breached

rudder and the breach to be located by air pressure testing and applying soap

solution, repairs to be planned

c. Check the rudder drop in the steering gear compartment (trammel gauge)

d. Check the pintle clearances, jumping bar clearance and the palm coupling bolts

tightness to be checked

e. Check the rudder stock for corrosion, erosion and any damage
f. The inspection plates in the way of the upper, the lower pintle to be cut open, and the

pintle nuts checked for proper securing. Later the plates to be welded and tested.

g. Hydraulic test the rudder for a static head of about 2.45m of sea water

h. After draining and re oiling the internals, plug the drain and check the effectiveness

by a vacuum check and cement the plug

i. The rudder stock gland packing has to be checked and renewed

128. What is caustic cracking or embrittlement? What is its cause? Suggest

remedy

This is a form of intercrystalline/intergrannular cracking and occurs when a specific corrodent

and sufficient tensile stress exists. Iron consists of ferritic granules bonded by iron carbide so

this gives a scope of the intergrannular corrosion. This can be found in water tubes, super

heater, reheat tubes, and in stressed components of the water drum. The stress may be due

to thermal, bending or residual stress (due to welding). This usually occurs as a localized

attack in the combination of NaOH, some soluble silica and a tensile stress. The mechanism

begins with the accumulation of the corrodent NaOH due to –

a. DNB (departure from nucleate boiling)

b. Deposition

c. Evaporation at the water line

d. Small leakage

e. High heat flux (rapid evaporation)

f. High pressure

This corrosion below 149˚C or with NaOH concentration below 5% is rare. Increased

susceptibility occurs at about 20~40%. This corrosion is difficult to identify in the beginning

and ND testing has to be carried out at the suspected areas. At some time after the initial

start of the corrosion, this manifests as a whitish highly alkaline deposits or sparkling

magnetite.

COUNTER MEASURES:

a. Applying heat treatment process to relieve stresses after fabrication/repairs (welding

etc)
b. Correct and accurate boiler water treatment

c. Avoid DNB

d. Avoid accumulation of the deposits

e. Prevent leakage of corrodents

f. Prevent carryover

g. Use of rifling in the water tubes

129. A shell & tube type cooler tubes are leaking, what is the procedure to rectify

the leaks?

Before jumping to any conclusions it is prudent to check where the leaks are from. It could

be from the breach on the tube (a hole etc) or from the origination of small gaps between

the tube plate and the expanded portion of the tube. The procedure should to be based on

the findings.

A holed tube should be plugged from both the sides; the plugs can be of cork, wood, rubber,

brass, or copper as supplied by the manufacturer. Care should be taken when plugging with

the metal plugs, not to damage the tube plate.

If the leaks are from the gaps between the tube plate and the tubes, slight flaring of the tube

may help preventing the leaks however this flaring, if excessive will damage the tube plate

and also the tube itself. Alternative methods are available by carrying out surface

preparation and applying metal repair putty, like Devcon’s brush able ceramic repair putty.

In the above process, if the plugging of the tubes is about 10% the tubes have to be

renewed.

130. Explain a tube renewal process

To remove the tube, first remove the flare on the tube by chiseling off the flare flush with the

tube plate and then split the tube taking care not to damage the tube plate. The tube can

then be cut by a tube cutter to drop the tube inside the shell. Fitting of a new tube is carried

out by first positioning the tube in place between the end tube plates and flaring to the

correct amount by a flaring tool after fixing the other end by a brass wedge. It could by

either hand operated, pneumatic or motor operated. The tube should have a protruding part

about 1/4”~1/8” and the flaring should be to about 1/8” + tube diameter at the tip.
131. What is a phosphate reserve? Why is it important in high-pressure boilers?

A reserve of phosphate should be present in the boiler water to neutralize any hardness

salts, which may enter. These salts would deposit as a scale on the heating surface if reserve

were too low while, too high a reserve leads to foaming and possible excess production of

sludge. It also gives alkalinity.

3CaCO3 + 2Na3PO4 ----Æ Ca3 (PO4)2 + Na2CO3

3CaSO4 + 2Na3PO4 ----Æ Ca3 (PO4)2 + Na2SO4

3CaCl2 + 2Na3PO4 ----Æ Ca3 (PO4)2 + 6NaCl

MgSO4 + 2Na3PO4 ----Æ Mg (PO4)2 + 3Na2SO4

Precipitates as Sludge

At high pressure and temperature, reaction from left to right will be more. Therefore, it is

very important in high pressure boilers to keep the reserve level up to required concentration

to avoid excessive caustic alkalinity and thus caustic cracking.

Na2CO3 + H2O Å---Æ 2NaOH + CO2

In high pressure boilers where there is a risk of caustic concentration and subsequent caustic

attack it is common to apply a coordinated or congruent phosphate control programme.

These control methods are based on the hydrolysis of tri-sodium phosphate (TSP) and

disodium Phosphate (DSP) in the boiler water.

Na3PO4 + H2O Å-----Æ Na2HPO4 + NaOH

Na2HPO4 + NaOH Å----Æ Na3PO4 + H2O

The objective is to maintain a desirable pH without the presence of free OH alkalinity. The

desired conditions are obtained by maintaining the relationship of the pH to phosphate

concentration in the boiler water at less than that of the equivalent stochiometric solution of

Na3PO4 (<3:1). This is achieved by the equilibrium reaction above. The congruent phosphate

approach utilizes mixtures of TSP and DSP to further ensure the absence of free OH alkalinity

and usually run with a Na:PO4 ratio of <2.8.

132. What is the routine anchor windlass maintenance?

a. Brake drum should be free of oil, grease and other deposits. The brake drum should

be cleaned periodically with a solvent prescribed by the maker

b. The brake drum and the disk should be checked for wearing out or damage

c. Gear oil should be checked for contaminants and level

d. The direction of tensioning should correspond to the correct operation of the brake. As

the reverse direction for tensioning would render the brake ineffective, check should

be carried out to ensure the same

e. Brake test of the windlass is to be carried out to the pressure mentioned by the

maker on the jack tool. If necessary, the spring tension adjusted. It should be done in

guidance of the instructions and in the tensioning direction. The number of turns on

the drum should also be checked and should be same as to the makers quote

f. The securing device of the tension spring adjust should be checked periodically for

any tamper

g. Anchor windlass testing should be carried out to check the efficiency of the windlass.

The windlass should raise the anchor with chain from 82.5m to 27.5m at a mean

speed of 9m/min

h. The foundation of the windlass should be checked

i. Other routines of the prime mover should also be carried out like for the windlass

electric motor or the hydraulic motor as the case may be

133. What are the cylinder lube oil properties?

a. SAE 50 or higher range oils

b. TBN about 70 for heavy oil burning engines with sulfur content of about 3%

c. Ability to burn completely and leave no deposits

d. Good detergency

e. Good load bearing property

f. Good spread ability

g. Incompressibility for accurate metering and timing the injection

h. High flash point

134. What is a pressure-vacuum valve and why can’t it be used to vent the cargo

vapors during loading?

PV valve is designed to compensate for the variations in the tank pressure conditions due to
variation of temperatures and the vapor quantity. A drop towards vacuum condition because

of condensation of steam will also be handled by this valve. Usual set point of the valve is

about +700mmHg and -350mmHg on the vacuum side.

This valve cannot cope up with the requirements of cargo loading, as its capacity of pressure

venting is small. Moreover it is not designed for this purpose.

The valves displace a weight that vents the tank in case of an overpressure or vacuum

condition. The valves are fitted with velocity vents that make sure that the inert gas is

ejected out of the tank with such a velocity that it clears the deck sufficiently rendering the

deck surface safe.

135. What is a high velocity vent?

Tank vapors can be sent clear of the deck in case of excess pressure or during cargo loading

operation by a high velocity vent. The usual construction of such a valve is incorporated in a

mast riser, which is a long tower for safely venting the excess pressure of the inert gas in the

tanks to the atmosphere. The control is affected through a valve. The height of the mast

riser is arranged to vent outside the hazardous zone, generally 9m or more. The valve

consists of a variable moving orifice held by a counter weight to seal around the batten of a

fixed cone. Pressure build up in the tank causes the moving orifice to lift. The small gap

between the orifice lip and the fixed cone gives high velocity. The escaping gases are made

to pass through a flame arrestor and a flame screen. The valve has a cover that is normally

closed during sailing.

136. Air bottle maintenance and inspection

a. Regularly drain the bottle of water and oil

b. Regular inspection to ensure that the internal condition of the bottle is good

c. Check for corrosion both externally and internally

d. Inside coating, COPAL varnish condition to be checked to ensure that it is unbroken

and no peeling is taking place

e. Welding seam to be checked, carry out dye-penetrant test at suspected areas

f. The tell tale hole between the lap welding seams of the doubler plate / ring to be

checked for leaks in service to ensure that the internal welding is intact
g. Face of the man hole is to be checked for pitting marks

h. Drain should be clear

i. All points of high stress and corrosion are to be thoroughly checked viz. welds,

supports braces, the bottom of the bottle where water/oil is collected. Pay attention

to the zone of water line.

j. Check for leaks at the mounted valve glands/flanges, carry out inspection of the valve

face and seat for wire drawing effect

k. A timing check with the air bottle completely charged and isolated will give a good

idea of the intactness of the pressure vessel

l. The safety/relief valve setting to be inspected as per the class requirement

m. Regularly check the alarms and monitoring equipment for proper functioning

137. Explain the air bottle entry procedure

a. Inspection is to be carried out when the receiver capacity is not required for

maneuvering

b. Receiver properly isolated, depressurized and notice pasted

c. The internal pressure is to be checked by the pressure gauge and by opening the

drain valve

d. Open the manhole door carefully and ventilate the air bottle

e. Obtain an enclosed space permit and comply with it

f. Ventilation is to be maintained during the entire time of enclosed space entry

138. What action should be taken in case of corrosion/wasting observed on air

bottle?

MINOR: clean the site of corrosion, observe the varnish manufacturer instructions for surface

finishing prior applying the coat. Apply new coat of the varnish.

MAJOR: The site has to be cleaned and revarnished as above. The air bottle has to be

derated.

Incase of excessive the entire bottle has to be replaced.

The derating procedure should be carried out as follows:

a. The extent of the derating is determined by the class surveyor to a value which
ensures the safe limit of the hoop stress at this reduced thickness of the shell plating

b. The derating should not violate the starting air requirements for consecutive starts of

the main propulsion engine

c. The setting of the safety/relief valve, should be set not exceeding 10% of the

maximum working pressure after derating

d. The cut in and cut out pressure switches for compressor automation should be

readjusted

For these reasons the air pressure vessels on board ship are fabricated to allow for derating

in future still complying with the consecutive start requirements of the propulsion engine

139. What is a PV breaker? Why is it fitted?

This is a U tube manometer filled with an ethylene glycol solution (as a measure against

freezing). The height of the manometer is manipulated such that the pressure on either side

may displace the solution, into tanks incase of vacuum inside cargo tanks and outside on to

the deck incase of over pressurization inside cargo tanks. Usual set values of PV breaker are

+1800mmHg on high pressure and -700mmHg on vacuum side.

Pressure-Vacuum breaker is fitted to the IG main line on the deck to protect cargo tanks

from the following:

a. Abnormal rise of pressure in the cargo tanks which occurs when cargo is loaded with

specified rate and that all gas outlets are closed

b. Abnormal drop of pressure in cargo tanks which occurs when cargo is unloaded with

the rated capacity of the cargo pumps and the inert gas blower fails

c. Abnormal rise or drop of pressure in cargo tanks which occurs, when the breather

valves fails to operate properly for the fluctuation of the pressure in cargo tanks, due

to variation in atmospheric and sea water temperatures, altering the vapor pressure

inside tanks

140. What is the routine maintenance, checks on the PV breaker?

CHECKS:

a. Check the seal liquid periodically and replenish the liquid in case

• Liquid levels of inner and outer pipes do not coincide

• “0” points of inner and outer pipes do not coincide when the pressure inside

the cargo tanks is atmospheric pressure

b. Clean the flame screen in the cover at the top when the ships makes a dock-in

CHECKING PROCEDURE:

a. Checking the liquid level of the inner pipe (open the vent cock located at most top of

the gauge, close the upper gauge cock and open the lower gauge cock) this is also

termed as “bigger range”

b. Checking the liquid level of the outer pipe (close the vent cock, open the upper gauge

cock also open the lower gauge cock) this is also termed as “smaller range”

Two distinct scales are provided for the liquid gauge one “higher” and other “lower” the

respective readings (as in ‘a’ and ‘b’) should match numerically

MAINTENANCE & INSPECTION IN DRYDOCK:

Disconnect and remove top cover with attached internal stand pipe. Disconnect and remove

Flame Arrestor Assembly. Remove flame screen. Thoroughly clean internal of flame arrestor.

Renew flame screen with shipyard supplied equivalent type mesh. Drain breaker liquid,

thoroughly clean internal breaker body, and stand pipe. Apply two coats of shipyard supplied

tar epoxy by hand brushing to all internal surfaces. Level gauges, cocks and protective

housing to be removed and transported to workshop for cleaning and overhaul. Dismantle

sight glass tubes and cocks for overhauling and cleaning. Upon completion, re-assemble and

re-install onboard with new shipyard supplied approved type jointings, studs, and nuts.

Prove filling and level cocks clear and free. Disconnect and remove PV Breaker valve.

Dismantle and clean surfaces. Lap valve and disc. Set valve to +0.21kg/cm2 and

0.07kg/cm2 in the presence of the attending superintendent. Record and submit calibration

of valve settings. Close on completion with new shipyard supplied approved type jointings

and sealing compound and bolts and nuts.

141. Explain the mounting arrangement of boiler feet

The alignment of boiler should incorporate provisions for thermal expansion at the boiler feet

(saddles) when the boiler is in hot operating condition. Expansion may be in the order of

10mm. Assuming a four-point support; one foot will be bolted down hard to the foundation,
while the other three feet will be bolted down so as to permit the feet to slide.

Holes for the fixed bolts will be reamed in place. The foundation bolts in way of the sliding

feet must be accurately located with respect to the elongated holes in the boiler feet to

enable the feet to slide clear of the bolts. The pipe sleeves prevent the bolts from tightening

down on the sliding feet. A brass liner or a lubricant such as molybdenum disulfide is

normally used to facilitate the sliding action. In some cases, the pipe sleeves are not used.

Instead, the bolts are tightened only slightly so that the boiler foot can slide.

FIXED FOOT

BOLT

ELONGATED

HOLE IN

BOILER FEET

SLIDING FEET

OUTLINE OF

BOILER

Lock Nut

Boiler Feet

Steel Liner

Foundation Bolt

Interference body bolt or fitted bolt

FIXED FOOTCompiled by Eswara Arun Kishore

[email protected]

142. What is a fitted bolt?

The answer lies above. This is a closely fitted bolt. The holes are initially drilled to undersize

and are reamed in the assembling place before the bolts are tightened in place. Accuracy is

required in the machining. These bolts could be of two types one having a slight taper of

about 1:100 on diameter and the other having a large taper of about 1:15 on diameter.

However, the holes in either case are reamed in final place.

Some times an oversized bolt is stretched hydraulically reducing the bolt diameter. When
tightened down and the hydraulic pressure is released the final exact fit in the bolt hole is

achieved, like a pilgrim nut on coupling shafts.

These bolts find place in engine / boiler mountings, coupling shafts etc. and form a rigid

fixture. On main engine mounting these are situated aft of the engine in the way of thrust

block. The foundation bolts towards the fore end (either side of the engine ‘P’ ‘S’) are

generally simple foundation bolts which are not fitted bolts. This system of foundation bolts

offers the rigid seating with provision for thermal expansion towards fore end.

143. What is the material of main steam piping and explain how it is supported?

Main steam piping is usually made of seamless low alloy steel. Where temperatures are

above 455˚C, the most widely used alloy contains 0.5% molybdenum, 1.25% chromium.

Gaskets between the flanges are made of thin stainless steel strips spiral wound with

insulating filler between successive layers.

There are three types of supporting to carry the weight of main steam piping.

a. Rod hangers

b. Variable spring hangers

c. Constant force spring hangers

Horizontal sway braces are often used to resist dynamic forces applied to the piping due to

rolling and pitching or due to vibrations transmitted to pipe anchor points. Sway braces could

be of the turnbuckle-rod type, the preloaded spring type or the hydraulically damped type.

At fixed anchor points, the pipe anchor brackets are separated from the anchor foundation

by insulating material to reduce the heat transfer from the steam piping to the hull structure.

144. Soon after complete overhauling a generator engine, its lube oil consumption

increases. What checks do you carry out in this regard?

a. Check that the lube oil system valves are set back to normal, and that the concerned

valves are correctly holding

b. Verify dip stick bottom for any blockage which can give erroneous results

c. Check for normal operation of the purifier

d. Ensure that the piston scraper ring is set correctly, if this ring is boxed back upside

down, the oil scraping action of the ring is lost and uncontrolled lube oil enters the
combustion chamber. This presents a significant oil loss

e. Ensure that the cylinder head valves are correctly boxed back. Misalignment of the

valve spindle with their guide also causes lube oil to enter the combustion chamber

causing oil loss

145. Generator lube oil sump level increases, what are the checks you would

carry out?

a. Check that the generator lube oil systems valves are correctly positioned and that the

sump filling valve is holding

b. Ask the personnel for if they have carried out any transfers just before, related to the

sump oil of the generator

c. Check the purifier for correct operation and that no water is being discharged with the

purified oil

d. Change over the generator concerned, isolate it and check the sump for any

contamination like water. Basing on the findings further inspections can be carried

out, like checking the cylinder liner jacket cooling water sealing O-ring etc.,

146. How do you prepare a boiler for survey?

Before a survey, the boiler must be prepared. The preparation process involves:

I. Water side preparation prior entry into the steam drum for internal inspection

II. Gas side preparation for external tubes inspection also the refractory condition can

be inspected

III. Electrical isolation

Electrical side isolation:

The power supply to the boiler control panel should be isolated. The power supply breakers

for the FD fan; burner pilot fuel oil pump should be switched off and caution tags put.

Gas side/Exhaust side:

a. If the boiler is an exhaust gas boiler, then the main engine should be isolated from

starting positively. The composite boiler should be isolated on the fuel side in addition

by manual isolation of the fuel line by a shut off valve and isolating the power of the

boiler control panel.

b. Oil fired boiler should be isolated on the fuel side by a manual shut off valve and

isolating the power of the boiler control panel

Waterside isolation:

a. The boiler should be taken out of service. With the boiler shut, isolate the boiler on

fuel/exhaust side electrical side and water side by isolating valves, power supply

breakers as the case may be

b. Empty the boiler of water by blowing down, after allowing sufficient time for the boiler

to cool gradually to prevent excessive thermal shock

c. When blowing down to sea, open the overboard valve first then the boiler valve to be

opened gradually. The nearing completion of the blowing down operation can be felt

by falling noise, pressure. At this point, care must be taken not to let the cold

seawater into the boiler. Start closing the boiler blow down valve when the boiler

pressure is low enough, and when it is down to the desired value, the valve must be

closed down tightly and the ships side cock closed. This is to be done to keep out the

seawater ingress positively even though the valves are usually of non-return type.

d. Allow the boiler to cool down further and loose all its pressure, and when the boiler

pressure is at atmospheric pressure open the air cock and gauge glass drains to

ensure the pressure is atmospheric inside the boiler

e. Either the top door or the bottom door can be opened at this stage but not both,

while removing bottom door care must be taken against any hot water if present can

cause injury to the personnel near it

After the boiler has sufficiently cooled the access points can be opened, the spaces well

ventilated, enclosed space entry/steam drum entry procedures should be followed.

The fire/exhaust side should be cleaned after initial examination

a. Open access doors in way of the uptake and front and rear walls and the burner

register and all hand holes

b. Hydro-jet all soot deposits on tubes. Allow for collection and disposal of fresh water

c. Mop up the fireside to dry. Neutralizing chemical can be added in order to avoid

corrosion. Heating lamps can be used to dry out the furnace

d. Scrape hard deposits on all generating and water wall tubes, sweep and remove all

carbon, soot and debris on the furnace floor

The waterside requires a similar approach for cleaning

a. Remove for access to steam drum and water drum manholes and headers

b. Allow for header blanks for water side survey

c. Remove all steam baffle plates in the steam drum

d. Hydro-jet cleaning of the internals of drums and tubes may be required to remove

mill scale and sediments

147. What are oxygen scavengers?

Oxygen scavengers are chemical compounds, which are added to the boiler feed water to

eliminate oxygen residuals and to assist in the passivation of metal surfaces.

There are a number of these chemicals available, and a selection is a function of the amount

of oxygen present, risk, feed system design, economics and any particular limitations

required by the process using the steam.

Some widely used oxygen scavengers are:

a. Sodium sulfite (Na2SO3)

Method of dosage: Dose the feed water continuously to maintain a desired

concentration. Where corrosion in the feed system is experienced, it is used as a

catalyzed form of sodium sulfite. The catalyst (usually a salt of cobalt) is to speed up

the following reaction, so that this is complete before the water gets into the boiler.

How is O2 Scavenged? : 2Na2SO3 + O2 ---------Æ 2Na2SO4

Limitations: The speed of the reaction is influenced by the pH of the feed water

which should be between 8.0~9.5. Sodium sulfite adds some solids to the feed water,

so it should not be overdosed or applied to the cold feed water. Otherwise, this may

lead to increased blow down requirement.

Sodium sulfite can be used in the boilers of pressures up to 62 bars. Above these

pressures, decomposition products such as H2S and SO2 can affect steam purity

b. Hydrazine (N2H4)

Method of dosage: Liquid hydrazine is injected at the earliest possible point in the
feed water system.

How is O2 Scavenged? : N2H4 + O2 --------Æ N2 + 2H2O

Limitations: Excess hydrazine should be controlled to avoid an undue rise in the

ammonia level in the steam; there is a danger of copper corrosion in the condensing

plant. (Ammonia is produced by the decomposition of excess of hydrazine can provide

a suitable alkaline condition in the steam and in the condensate system,

3N2H4 --------Æ 4NH3 + N2). Hydrazine is not permitted in the systems where steam

is in contact with the foodstuffs.

c. Carbohydrazide (Eliminox) (N2H3)2CO)

Carbohydrazide is a combined form of hydrazine. It is superior in performance and is

designed to minimize exposure to hydrazine vapors during handling. Carbohydrazide

reaction products will add no dissolved solids to water. This can be used as an oxygen

scavenger and a metal passivator at both high (230

C) and low (60

C) temperatures.

Carbohydrazide can be applied to boilers up to 170 bars.

How is O2 Scavenged? : (N2H3)2CO + 2O2 --------Æ 2N2 + 3H2O + CO2

Limitations: in boiler, Carbohydrazide decomposes to hydrazine as one of the

products, so it cannot be used in systems where the steam is used for humidification.

(FDA rules)

d. Tannins

Certain alkaline tannin solutions have good oxygen absorbing capability. A 6ppm of

certain tannins extracts can remove 1ppm of oxygen at a pH of 12. The oxygen

scavenging efficiency is better than that of sodium sulfite.

e. Erythorbic Acid (Sur-Gard) (R1-C(OH)=C(OH)-R2)

This is an effective oxygen scavenger and a metal passivator. This is the only non

volatile scavenger, which can be used for spray attemperation. This does not add
measurable solids to the boiler water; is non-volatile and will not hamper the steam

purity. Erythorbic acid can be used in boilers up to 122 bars. This is considered as a

safe substance by FDA.

How is O2 Scavenged? : R1-C(OH)=C(OH)-R2 + ½O2 --------Æ R1-(C=O)2-R2 + H2O

Limitations: Ammonia is produced in the boiler as a by-product. This is not

recommended for use for boiler lay-up. Good corrosion control requires a high boiler

water pH value since the magnetite film is at its most stable condition when the pH is

10.5~11.5.

147. What are the various control actions?

The basic controller actions can be grouped as

a. Two position or on-off controllers

b. Proportional controllers: It is also called corresponding control. The corrective action

of controller, C, bears a constant ratio to the error θ = ± (Measured Value – Desired

Value), Thus C = -Kθ (where K= constant of proportionality)

c. Integral controllers: It is also called the reset action control. The rate of change of

corrective action is proportional to the error. Mathematically, dC/dt = -Kθ or

C= -K∫θdt + k (where K= constant of proportionality, k= constant of integration, C=

control action)

d. Derivative controllers: It is also called the rate action control. The amount of

corrective action is proportional to the rate of change of error. It is never used alone

and is always used in conjunction with the integral and or proportional controllers. As

with a constant error, the control action being derivate becomes zero. C = -K dθ/dt,

(K= constant, C= control action)

e. Proportional-plus-Integral controllers

f. Proportional-plus-Derivative controllers

g. Proportional-plus-Integral-pus-Derivative controllers

148. How is the chain drive of a main engine inspected?

Chain inspection is to be carried out as follows:

a. Make a general inspection for loose screws and bolts

b. Inspect lube oil pipes for damage, and check oil jet nozzles for possible stoppages or

deformations

c. Examine the rubber track of the guideways for cracks or other damage, replace the

guideway bits if they have started to be plucked out of the rubber stack

d. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement

by placing a straight edge over the wear edges and measure the length of the wear

along the straight edge and the gap between the straight edge and the wear trough

e. Check the chains for cracks on possibly defective rollers and side plates

f. Check that for each chain link, chain rollers can run freely and that the chain links can

freely move on the pin and bushing

g. Check the chain wear by measuring the length of 10 chain links and compare the

result with the value in the data provided by the maker. If the parameter shows

abnormality then adjust the chain tightener

149. Explain the procedure of chain tightening

[Courtesy MANBW]

a. Loosen the nuts A, B, C and D to free the

chain tightener bolt

b. Turn the engine so that the slack part of the

chain is on the same side as the tightener

wheel. If balance weights are mounted, turn

the engine so that the weights hang vertically

downwards

c. With the balance weights in this position,

tighten the nut B on the chain tightener bolt

until there is a clearance of 0.1mm between

the shaft and the nut. then tighten the nut B

to a tightening angle of about 720

d. Tighten the nut C hard against the contact face of the shaft. Tighten the nut D, lock
nuts A and B with the tab washer

e. Measure the distance X, if the chain is worn (i.e. X>165mm) repeat the procedure

from ‘a’, but tighten the nut B only to a reduced tightening angle 600

f. If the distance exceeds the maximum distance 265mm, find and eliminate the cause

of this abnormal chain elongation, like a defective chain, damaged chain wheels or

bearings etc., repeat the procedure from ‘a’.

g. Repeated tightening of the chain will gradually alter the cam angle in relation to the

crankshaft. It is therefore necessary to readjust the camshaft to its initial angular

position after the lead angle has been increased by 2

. The camshaft is adjusted by

turning both halves at the coupling joint with the chain wheel

150. Why is a copper gasket annealed?

The essential qualities of a copper gasket are softness and toughness (provision for cold

working without fracture). In its place the copper gasket is subjected to considerable

mechanical stress, resulting from elastic strains internally balanced. These elastic strains are

due to jamming of dislocations, which occurred during cold deformation (during service). If

this cold worked gasket is heated to a sufficiently high temperature the total energy available

to the distorted regions will make possible the movement of atoms into positions of

equilibrium so that the elastic strains diminish and the locked-up energy associated with

them ‘escapes’. Tensile strength and hardness will fall to approximately their original values

and capacity for cold work will have returned.

151. What is the difference between a safety valve and a relief valve?

A safety valve is a pressure relief valve actuated by inlet static pressure and characterized by

rapid opening or pop action.

A relief valve is a pressure-relieving valve actuated by inlet static pressure and opens in

proportion to the increase in pressure over the opening pressure.

The terms ‘safety’ and ‘relief’ are synonymous; the safety valve is generally applied to valves

protecting any vessel, which could explode and endanger life whereas the relief valve is more

appropriate to the valve protecting system containing non-expansible liquid a burst causing

no violent explosion.

Another notable difference between these valves is that the vent of a safety valve is led to a

‘safe’ place (harmless to the working personnel) whereas a relief valve vents just outside the

valve.

152. What are the parameters of a lube oil analysis?

The parameters of a two stroke, heavy fuel oil engine circulating/system lube oil are

a. Specific gravity: Range 0.90~0.98. This is used for identification of the oil. Limits: 5%

of initial value

b. Viscosity: Viscosity increases with oxidation, contamination with cylinder oil, heavy

fuel or water. Diesel fuel contamination decreases viscosity. Limits: Max 40%, Min -

15% of initial value

c. Flash point: Gives an indication of possible dilution with diesel oil. Limits: Minimum:

180˚C

d. TAN (total acid number): Expresses the total content of organic and inorganic acids in

the oil. Organic acids are due to oxidation products. TAN = SAN + weak acid number.

Limits: TAN 2

e. SAN (strong acid number): This expresses the amount of inorganic acids in the lube

oil. Inorganic acids are usually sulfuric acid from the combustion chamber or

hydrochloric acid arising from seawater. This will be stated. SAN makes lube oil

corrosive (especially together with water) and should be zero. Limits: SAN = 0

f. Alkalinity/TBN (total base number): Gives the alkalinity levels in the lube oil

containing acid neutralizing additives. Limits: High = 100%, Low = -30% of initial

value

g. Water: Could be fresh water or sea water, will be stated. Limits: Fresh water: 0.2%

(0.5% for short period), saline water: Traces

h. Conradsen carbon: Residue from incomplete combustion, or cracked lubricating and

cylinder oil. Limits: Max 3%

i. Ash: May be used to indicate the amount of additives in the lube oil. It can also

consist of wear particles, sand and rust. It should always be evaluated by comparison

with the ash content of the unused oil. Limits: Max 2%

j. Insolubles: Stated as pentane/heptane and benzene insolubles. Equal parts of the oil

sample are diluted with benzene and normal pentane or heptane. As oxidized oil

(lacquer and varnish like constituents) is only soluble in benzene, and not in pentane

or heptane, the difference in the amount of insolubles is indicative of the degree of oil

oxidation. Benzene insolubles are the solid contaminants. Limits: Pentane insolubles

Max 2%, Benzene insolubles Max 1%

Apart from the primary parameters as stated above, the insolubles are usually stated as

percentage/ppm of individual constituents such as Vanadium, Sodium, Aluminium, Iron,

Silicon, Tin etc., which shows the engine wear and tear empirically.

153. Explain hot gas defrosting in a/c fridge system

A/C Com pressor

Electric Motor

Condenser

To Other Evaporators

Evaporator Re-evaporator

Suction solenoid v/v

Liquid Solenoid v/v

Hot Gas Solenoid v/v

Expansion v/v

R educing v/v

D rain

Sensing Line

Drain

Defrosting Circuit

From other Evaporators

Two kinds of hot gas defrosting systems by pass line are shown here.

A by pass line hot gas defrosting system as above. This can be carried out for one

evaporator coil when others are in use.

Below is another type of hot gas defrosting system which is also called reverse cycle

defrosting system and is used when all the evaporator coils have to be defrosted.

Condenser

A/C Compressor

Electric Motor

Evaporator

Drain

Expansion v/v

Check v/v

Expansion v/v

Check v/v

Reservoir

Four

way v/v

Defrost circuit

154. What is the difference between coagulation and coalescing?

A Coalescer filter element consists of some pre-filter for particulate removal followed by

compressed inorganic fiber coalescing unit in which water is collected into larger globules

Coalescing action is relatively complex and simply it can be said to be due to the molecular

attraction between the water droplets and the inorganic fibers is greater than that between

the oil and the fibers. When the water globules are large, enough they will move with the

stream out of the coalescing unit.

Coagulation is the process of agglomeration of smaller particles into larger particle due to

intermolecular attraction between similar molecules in preference

155. Why do we carry out boiler water treatment?

The objects of boiler water treatment are:

a. Prevention of scale formation and feed system by

i. Using distilled water

ii. Precipitating all scale forming salts into the form of a non-adherent sludge

b. Prevention of corrosion in the boiler and feed system by maintaining the boiler water

in an alkaline condition and free from dissolved gases

c. Control of the sludge formation and prevention of carry over with the steam

d. Prevention of entry into the boiler of foreign matter such as oil, waste, mill-scale,

iron oxides, copper particles, sand, weld spatter, etc., by careful use of oil heating

arrangements (close watch on the drains), effective pre-commission cleaning and

maintaining the steam and condensate systems in a non-corrosive condition

156. How do you indent a drill bit?

a. Order the drills in consultation with the personnel routinely working with the tools

b. Take the inventory of the drills, estimate the consumption of each drill, analyze to

ensure that excess inventory is not kept

d. Regarding the technical specifications follow the instructions as per the ordering book

viz. IMPA/ISSA

e. Some aspects should be looked into before arriving at a conclusion, these are:

a. Material of the tool and the intended nature of its work, like for light or heavy

duties

b. Industry specification like DIN, JIS, BIS etc.,

b. Length of the drill, normal or extra length

c. Cutting angle, standard angles are 118 & 135 degrees

d. Nature of twist, right handed, left handed, spiral etc.,

e. The shank shape, tapered, straight or ‘S’ cut

f. Number of flutes

g. Drills and counter sinks

h. Reputation of the company and cost

i. Any previous experience with the company’s tools

Most commonly used drills on board are jobber drills (drills without a shank, which are
gripped in the vice) for light duty, tapered shank drills for medium to heavy duty

157. What checks do you make if a compressor trips on low lube oil pressure?

Incase of reciprocating compressor

a. Direction of rotation, in case the motor is overhauled or some maintenance carried on

the motor

b. Suction filter should be cleaned

c. Check the pressure switch

d. Inspect the lube oil pump

e. Check if any lube oil pipe is holed

f. Check for excessive foaming

Incase of rotary compressor,

a. Check whether the lube oil pump is rotating with the compressor

b. Check the condition of vanes and the elliptical casing for scoring damage

c. Check the compressor is free to turn, no seizure of rotor, no wear on the vanes and

the casing

158. What are the reasons of piston seizure in a reciprocating air compressor?

a. Failure of lubrication

b. Failure of cooling water

c. Valve part broken and fell into the chamber

d. Piston ring breakage

159. What are the instructions you would give to the watchkeepers regarding

boiler?

a. Check the water level by gauge glass

b. Keep an eye on the steam pressure

c. Watch the flame pattern

d. Check the vicinity of the oil burning equipment for any traces of oil

e. Maintain the hot well temperature about 85C

f. Check the hot well level and maintain it

g. Atomizing steam pressure should be monitored

h. Fuel oil pressure, temperature, the fuel oil pump its suction pressure

i. Amperage drawn by the related motors like FD fan

160. What is the procedure of conrod removal from a main engine?

[Courtesy MANBW]

a. Turn the engine to BDC.

Dismount the nuts from the

crosshead bearing studs

b. Mount the shackles in the top

of the crankcase in the lifting

brackets, in the athwart ship

direction, and suspend two

tackles

c. Turn the crank to TDC.

Dismount the crankpin

bearing cap, and remove the

bearing cap from the engine

d. Mount the four supports

for guides shoes on the

crosshead guides, turn

the crank towards the

camshaft side, until the

guide shoes rest on the

supports. Adjust the

supports brackets to the

guide so that the weight

of the crosshead is evenly

distributed on the four

supports

e. Mount the lifting

attachments for securing the

connecting rod on the head of the

connecting rod. Fasten tackles to

the lifting brackets A and B on the

box wall, and attach the tackle

hooks to the mentioned lifting

attachments on the connecting rod

head. Haul the tackles tight. Also

mount a lifting attachment on the

lower end of the conrod, on the

exhaust side

f. Turn the crankthrow carefully

towards BDC while following with

the tackles, thus continuously

supporting the connecting rod.

The crosshead now rests on the

four supports. Turn the crankthrow to 90˚ before BDC

g. Shift tackle B from the lifting attachment on one

side of the connecting rod to the lifting attachment

on the other side. Dismount the lifting attachment

on the camshaft side of the connecting rod. Attach

a tackle to the lifting bracket C on the frame box

wall box and connect the tackle hook to the lifting

attachment on the lower end of the connecting rod.

Mount the wire guide on the doorframe. Turn the

crankthrow towards TDC while following with the

tackles thus continuously supporting and guiding

the connecting rod towards the doorway

h. Attach a tackle to the gallery-mounted lifting

bracket E, and hook on to the lifting attachment on

the connecting rod. Shift tackle A from the lifting

attachment on the head of the connecting rod to

the lifting attachment on the head of the connecting

rod to the lifting attachment at the bottom of the

connecting rod. Turn the crank upwards while

following with tackles A, B, C and E, guiding the

head of the connecting rod out of the doorway. Shift

the tackles from one lifting attachment to the other

as necessary

i. Mount a strap around the connecting rod and

suspend the connecting rod from the engine room

crane. Shift tackle B, from the lifting attachment on

the head of the connecting rod to the lifting

attachment at the bottom of the connecting rod.

Remove tackles A and E. continue turning upwards

till about 30˚ after TDC while following with the

tackles and the engine room crane

j. Shift tackle from lifting bracket C to A. lift the

connecting rod out of the engine, using the tackles

and the engine room crane. Remove the tackles by

means of the engine room crane.

161. What is the importance of starting air overlap? What should be the minimum

number of cylinders for a two-stroke engine for air starting? What is the

corresponding number for four-stroke engine?

Some overlap of the timing of starting air valves must be provided so that one cylinder air

start v/v opens as another closes. It is essential that there is no angular position of the

engine crankshaft with insufficient air turning moment to give a positive air start. The usual

minimum overlap provided is 15˚. Starting air is admitted in the working stroke of the
engine and the period of opening is governed by

a. The firing interval of the engine = No. of degrees in engine cycle/No. of cylinders

b. The valves must close before the exhaust commences. It is dangerous and a waste

blowing air to exhaust manifold.

c. The cylinder starting air valve should open after TDC to give a positive turning

moment in the correct direction.

The minimum number of cylinders for a two stroke engines is FOUR and that for a four

stroke engine it is SIX.

This can be concluded as follows:

For a two-stroke engine the air starting valve timing is

Air on 15˚ATDC, Air off 50˚BBDC (exhaust opens at about 40˚BBDC) therefore a net

starting angle of 115˚. At the end of this angle of a unit in power stroke, another unit of the

engine should be 15˚ATDC in the power stroke, for continuity of starting. For this to happen,

the maximum possible crank angle difference can be 115˚ between units.

A two-stroke engine has a complete cycle angle of 360˚, therefore the minimum number of

units ≥ (360˚/115˚) = 3.13….

Minimum possible number of units in a two-stroke engine is therefore FOUR.

Similar approach to four-stroke engines gives the following inference.

Air on 15˚ATDC, Air off 40˚BBDC (exhaust valve opens at 30˚BBDC) therefore a net starting

angle of 125˚. Therefore, maximum possible crank angle difference between units is 125˚.

A four-stroke engine has a complete cycle of 720˚

Therefore, the minimum number of units in a four-stroke engine ≥ (720˚/125˚) = 5.76

Minimum possible number of units in a four-stroke engine is therefore SIX

162. Show how the requirement of carbon dioxide in a ship’s installation is

calculated. How is the number of bottles required calculated?

Regulation stipulates the requirements of CO2 onboard ships as follows

a. For cargo space, 30% of gross volume of largest cargo space

b. CO2 of sufficient amount to give minimum value of free gas equal to larger of

following volumes
I. 40% of gross volume of largest machinery space excluding casing

II. 35% of gross volume of largest machinery space protected including casing

Regulation also states that, for machinery space, piping arrangement should be such that

85% of the gas can be discharged into the space protected including the casing with in 2min.

The following information about CO2 is important

Volume of free CO2 should be taken as 0.56m3/Kg (inverse of density)

CO2 content in a bottle is 45.4Kg (standard)

Water capacity of the bottle = 65.1 liters (standard)

For example, consider a ship in which

a. Engine room gross volume (to upper deck) = 4658m3

b. Engine room gross volume to top casing = 5358m3

c. Volume of the largest cargo hold = 6849m3

Calculation of the CO2 cylinder required as per the regulations for the volume of the air

reservoir = 375m3

Therefore, for engine room the CO2 bottle requirement is calculated as

For gross volume excluding casing,

(4658+375)*0.4/ (45.4x0.56) = 80 cylinders

For gross volume of engine room including casing,

(5358+375)*0.35/ (45.4*0.56) = 79 cylinders

For cargo hold, requirement is calculated as

(6849*0.30)/(45.4*0.56) = 81 cylinders

The requirement is the largest of the above values, which is 81 cylinders

163. What is a compensating ring in a boiler?

If any hole drilled in the boiler shell exceeds the value 2.5t + 75mm, where t = thickness of

boiler shell, the vessel should be compensated for the loss of strength (due to lost material)

by a stiffening ring around the hole (circumferentially). This is called a compensating ring.

164. What is BOD?

In sewage system, the effectiveness of the biological treatment of raw sewage is measured

by BOD, biochemical oxygen demand.

In a biological sewage treatment plant certain bacteria feeds on the raw sewage aerobically

there by rendering the sewage harmless and with reduced suspended solids. After complete

treatment the bacteria has no or little action.

Therefore, by measuring, the amount of oxygen consumed from a sample of treated sewage

the activity of these aerobic bacteria and hence the completeness of the treatment can be

estimated.

In actual check, 1Litre of the sample is collected in a measuring container and stored at

about 20˚C in water, which is well oxygenated and in a container and the amount of oxygen

consumed in a period of five days is measured and is expressed in mg/L or ppm as BOD.

165. What is the difference between a filter and a strainer?

A filter is a fine mesh insert in the pipeline of a fluid for the prime purpose of filtration. It is

normally positioned in the discharge line before the utility (equipment) or in the return line in

some hydraulic systems. The usual size of the mesh is mentioned in microns, which is the

smallest particle that can be filtered by the filter.

A strainer is a coarse mesh inserted usually in the pump suction. It is positioned for the

prime purpose of safeguarding pumps from ingress of heavy debris. In addition, this strainer

helps in preventing chocking of the pipeline in the upstream especially near sharp bends or

narrow passages like coolers. Its objective is not filtration. It is usually mentioned as ‘mesh’

and is the size of the holes of the mesh.

166. What is principle of viscotherm?

The principle of viscotherm is that a drop in pressure of a fluid of laminar flow, across a tube

is directly proportional to its viscosity.

In a viscotherm, a sample of the fuel is pumped at a constant rate through a fine capillary

tube. As the flow through the tube is laminar, pressure drop across the tube is proportional

to its viscosity. Tapping points are provided to enable the pressure difference to be

measured by means of a differential pressure gauge. The gauge is calibrated directly in

terms of viscosity. A differential pressure transmitter provides an analogue of viscosity to a

pneumatic controller, which regulates the supply of fuel heating.

167. What is a bore relief in a bearing?

The bearing sliding surface is machined at the mating faces of the upper and the lower shells

to create bore reliefs. Their main objective is to compensate for the misalignments, which

could result in a protruding edge (step) of the lower shell’s mating face to that of the upper

shell. Such a protruding edge can act as an oil scraper and cause oil starvation

168. What is microbial infestation of lube oil? What are its causes, effects?

Suggest remedies.

Microbial infestation of lube oil is the undesirable growth of bacteria, yeasts and/or moulds in

the oil.

Infestation of the oil can be due to contaminated seawater, hydrocarbon source already

onboard or due to poor housekeeping practices.

The problems are like tank washing with contaminated seawater, water ingress from leaks of

seals (as in a stern tube, CPP etc.,), leaking cooling water, microbe infested fuel oil

contamination, onboard contamination due badly maintained or stagnant tanks (long lay off),

bilge water etc.,

The effects of such microbial infestation can be

a. Slimy appearance of the oil; the slime tends to cling to the crankcase doors

b. Rust films

c. Honey-colored films on the journals, later associated with corrosion pitting

d. Black stains on white metal bearings, pins and journals

e. Brown or grey/black deposits on metallic parts

f. Corrosion of the purifier bowl and newly machined surface

g. Sludge accumulation in crankcase and excessive sludge at the purifier discharge

h. Paint stripping in the crankcase

i. Additive depletion

j. Rancid or sulfitic smells

k. Increase in oil acidity or sudden loss of alkalinity. (BN)

l. Stable water content in the oil, which is not resolved by the purifier

m. Filter plugging in heavy weather

n. Persistent demulsification problems

o. Reduction of heat transfer in coolers

To counter the problems of the microbial infestation, it is necessary to take steps to prevent

such infestation.

The microbial infestation is not possible without the presence of water. Some water in the oil

in inevitable due to leaks, condensation, etc., so it is necessary to constantly purify the oil.

Tanks should be provided with drain cocks at the bottom most part to regularly drain the

tank of water. The tanks should be designed to prevent any pockets where the flow is

minimal or stagnant. The oil should be stored outside the 15~35˚C range. This temperature

zone is very conducive for bacterial growth. Preferably, the tank should be kept at a higher

temperature to facilitate sterilization. Lube oils have a maximum risk of infestation in the

water-cooled pistons engine. Therefore, care must be taken not to allow any scope for water

leakage from the cooling system and the coolers should be kept leak free.

Once the oil is infested, it is necessary to kill the bacteria by physical, chemical or other

means.

PHYSICAL MEANS:

a. Settling: microbes settle the as they have a higher specific gravity (Sp.gr. 1.05)

b. Centrifuges: they can be separated by centrifuging

c. Filtration: microbes can be filtered by suitably staging filters

d. Heat: This is a function of both temperature and time at that temperature. A

temperature of over 70'C for 20 minutes is effective in killing the microbes. However

this is difficult to achieve at the plate surfaces and it may be necessary to sterilize the

tank first say by the use of steam lances before filling with oil for heat treatment

CHEMICAL MEANS:

Killing microbes using microbes is easy and effective, however the selection of chemicals

appropriate for the system application and should be done with care. Such things as

compatibility and hazards should be taken into account. However, if the infestation is acute,

higher concentration of dosage of the chemical is required. This may render the oil unusable

and has to be discharged to shore facilities.

Other means of combating the microbes are available like

a. Irradiation (UV Rays, Gamma Rays or X Rays)

b. By ultrasonic treatment of the infested oil

c. Using microwaves

d. Continuous pasteurization of the infested oil and heat control

169. What are the properties of gear oil?

Properties required for gear case oil:

a. High viscosity. This gives high film strength to prevent metal-to-metal contact. Also a

adhesive of the film to the metal is required to counter the sliding and centrifugal

force

b. It should prevent corrosion

c. It should have high specific heat to be a good coolant

d. High viscosity index

e. Antifoaming

f. Sound damping with good cushioning property to prevent pitting on the gear teeth

faces

g. Oil should be suitable for elasto-hydrodynamic lubrication

170. What is Osmosis? What is Osmotic head?

Osmosis describes the process whereby a fluid will pass from a more dense to a less dense

solution through a semi-permeable membrane. It is very important to the water absorption

processes of plants. Reverse Osmosis is a process, which uses a semi permeable membrane

that retains both salt and impurities from seawater while allowing water molecules to pass.

Filtration of up to 90% is possible thus making the produced water unsuitable for boiler feed

without further conditioning. Improved quality is possible using a two or more pass system.

The fig. shows an experiment to show the effect of Osmosis

(Osmotic head). When the jar is immersed in the

concentrated solution the liquid inside jar increases due to

diffusion of liquid from the concentrated solution to the clean

water inside the jar, which is reflected as an increase in the

water column. This increment in the water column is the

Osmotic head.

171. What are Detergency and Dispersancy properties of lube oil?

Detergency of lube oil is the property of the lubricant to keep engine parts clean. In motor oil

formulations, the most commonly used detergents are metallic soaps, usually of calcium

(metalloid-organic compounds) with a reserve of basicity to neutralize acids formed during

combustion.

Dispersancy of lube oil is the property of the lubricant to keep solid contaminants in a

colloidal suspension, preventing sludge and varnish deposits on engine parts. Usually the

additives used to impart this property are nonmetallic ("achless"), and used in combination

with detergents.

172. Why are air compressors and diesel generator engines not provided with

crankcase oil mist detectors?

Crankcase oil mist monitoring for engine protection are to be provided when:

a. When arrangements are provided to override the automatic stop for excessive

reduction of lubricating oil supply or pressure

b. Power rating is 2250 Kw or more

c. Having cylinders of more than 300mm bore

Air compressors and generator engines in a ship usually do not meet any of the above

criteria and hence are not provided with crankcase oil mist detectors.

173. What is the purpose of steam traps?

Steam traps are automatic valves that release condensed steam (condensate) from a steam

space while preventing the loss of live steam. They also remove air and non-condensable

gases from the steam space. Steam traps are designed to maintain steam energy efficiency

by performing specific tasks such as maintaining heat for process.

Once steam has transferred its energy, it becomes hot water and is removed by the trap

from the steam side as condensate and either returned to the boiler via condensate return

lines or discharged to atmosphere (a wasteful practice).

174. What is the importance of ‘Lip clearance’ in a boiler safety valve?

The boiler safety valves make

use of a special shaped valve

seat and a lip on the valve

which gives increased lift

against the increasing

downward force of the spring.

The action is as shown above.

And this lip value is of

importance and should be

checked during inspection.

Damage to this region can lead

to malfunctioning of the valve.

175. What are the reasons for a lot of deposits in the scavenge space of a marine

engine?

The usual reasons for a lot deposits in the scavenge space of a marine engine are

a. Chocking of the scavenge drains

b. Blow-by due to broken or sticking piston rings

c. Excessive liner wear

d. Faulty injection due to altered timing, bad fuel or incorrect atomization

e. Blow back of exhaust due to increased exhaust back pressure

f. Leaking piston stuffing box

g. Excessive cylinder liner lubrication

176. How does a leaky piston manifests as in an indicator diagram?

As shown above the loss of intactness of the combustion chamber due to leakages, increased

volume or fouling causes the compression pressure and peak pressure to drop.

177. What is the thermal efficiency of the main engine?

Thermal efficiency of a plant = Heat energy converted to work/Heat input

In a main engine heat input = (Fuel consumed x Calorific Value x reference time)

Heat energy converted to work = Brake power x Reference time

178. What is composition of thin shell bearings?

Thin shell bearings are broadly of

a. Tin based White Metal: Tin-based white metal is an alloy with minimum 88% tin (Sn),

the rest of the alloy composition is antimony (Sb), copper (Cu), cadmium (Cd) and

small amounts of other elements that are added to improve the fineness of the grain

structure and homogeneity during the solidification process.

b. Tin-Aluminium (AlSn40): Tin aluminium is a composition of aluminium (Al) and tin

(Sn) where the tin is trapped in a 3-dimensional mesh of aluminium. AlSn40 is a

composition with 40% tin.

179. How do you operate the main engine after a Turbocharger breakdown?

Some points are to be taken into consideration for engine operation with turbocharger out of

operation:

a. Air supply for amount of fuel injected

b. Adequate flow path of the exhaust gas produced

c. Cooling of the turbocharger casing, rotor or bearings

d. Isolation of air/gas/lubricating spaces in the event of no sealing air available

e. Securing damaged parts

The method of turbocharger isolation may be done in a number of ways depending on the

nature of damage.

Bypass arrangement: Turbocharger is bypassed of exhaust gases by a suitable bypass pipe.

Turbine inlet and outlet are isolated by fitting blanks and by pass pipe is fitted to give a

suitable gas path. The compressor side also requires isolation to prevent loss of scavenge air

due to back flow from the receiver. Cooling water and lubricating oil systems may also

require isolation if casing and or seal is damaged.

Rotor removal: If the rotor is damaged it should be removed for repairs. The openings of the

casings should be blanked to prevent internal and external leaks of exhaust gas or air.

Cooling of the casing should be effected as exhaust gases still pass through the casing.

Locking of rotor: If requirement of propulsion is of concern and time is limited, rotor is

locked into position by attaching the appropriate fixtures provided by the maker. An orifice

plate should be inserted on the compressor side to allow a controlled amount of scavenge air
to effect cooling. Cooling water to the casing should also be continued since exhaust gases

pass through the casing. Isolation of the lubrication system may be necessary due to lack of

sealing air.

LIMITATIONS OF OPERATION:

The limits of engine load depend on the actual configuration of the system and how many

turbochargers remain in operation.

A broad consideration of the following points should be made:

a. The actual operating temperatures should be taken into account and limits should not

be exceeded

b. Condition of the exhaust should be monitored to ensure acceptable combustion inside

the cylinder

c. Allowance should be given for rate of change of air supply during acceleration of the

engine

d. Remaining turbochargers should be also monitored for abnormal operation due to

altered gas flow

e. Auxiliary air supply should be provided where possible, but this may be effected by

remaining turbochargers in operation

Internal water leaks: In the event of a holed water jacket it is possible to operate the

turbocharger as an air cooled unit by supplying compressed air as the coolant after isolating

the water supply. Attention must be paid to the operating temperatures of the casing, and

bearings especially turbine end.

Four stroke engines with turbochargers out of service and no alternative air supply may be

operated as a naturally aspirated engine with suitable attention being paid to the operating

temperatures

In any case the engine load is to be limited a value specified by the engine maker for the

conditions of operation and usually for a two-stroke engine its value is about 15%MCR

180. What is the procedure of plugging boiler of boiler tubes?

Procedure of plugging water tubes

a. Clean the face of leaky tube remove all the scales and dirt both in steam and water
drum

b. Plug with brass plug, hammer tight and weld

c. Cover this tube on the furnace side with heat resisting material

Procedure of plugging smoke tubes

a. Brass plug with stud and tightened by nut at both the ends

181. What is the difference between a purifier and a clarifier?

Purifier Clarifier

A centrifuge for separation two liquids of

different densities

A centrifuge for separation of solid particles

from a liquid

Sealing water is added to a purifier to

establish a seal

No sealing water is added

Gravity disc needs to altered with the

changing density of the liquid to be purified

A smallest of the gravity discs provided,

called a clarifier disc is fitted and requires no

alteration

Interface is to be maintained and depends on

process variables viz. density, flow, viscosity

or temperature

Interface is not required but is established if

water is present and moves inwards

Water outlet is normally open Water outlet is normally closed by the

clarifier ring

Provided water seal is maintained particle

separation is also good

Provided no water, particle separation is

good

182. How do you detect a leakage in a bilge pump suction line?

With the main suction of the pump closed, start the pump with discharge open. Monitor the

vacuum in the pump suction, if the vacuum is maintained for sometime the pump is in good

condition.

Proceed for checking the integrity of the suction lines as follows:

With the discharge of the pump opened for delivery,

a. Set the pump to draw bilge from each particular well closing other suction lines valves

b. Start the pump and note the build up of vacuum

c. Repeat the operation for all other suction lines individually, closing other remaining

lines

Now conclusion can be drawn with above observations.

The pump does not achieve good vacuum for any well, in this case

The manifold intactness by opening the sea water valve on the suction side and check it for

the seawater leaking. Repair the line after identifying the location

Identify for the leaks on the suction lines for which the pump does not achieve good vacuum

This can be done by pressure testing the line by opening the seawater valve on the pump

suction. The non-return valve on the line has to be dismantled and the valve put back after

removing the valve disc.

The sealings on the strainers have to be checked, like renewing gaskets.

183. How is an engine lube oil sample collected?

Sampling points for an engine lube oil are clearly mentioned by the maker of the engine. In

any case, the following points are to be adhered to

a. Sample of lube oil should be drawn from the inlet to the engine

b. Before collecting a sample some amount of oil is to be drained from the sampling

point. Later sufficient amount of oil should be collected into a clean container,

decanted and collected in a clean sampling bottle

c. Engine should be in operation as close as possible to the MCR for some time before

collecting a sample
d. The sampling container should be unused one specially produced for lube oil sampling

e. After collecting a sample in the bottle, it should be stored in a cool dry place to let the

oil cool down before securing it with cap/seal. This is essential to prevent slight

condensation in the bottle

f. The sample should be fully identified with the date, vessel name, running hours of the

engine, lube oil running hours, sampling point identification

g. Each time the sample should be drawn from the same point

184. Explain onboard testing of lube oil

Some or all of the testing explained below is done onboard ship.

1. FLASH POINT (Pensky Martin Apparatus)

This method determines the flash point of the lube oil sample in a closed cup. This gives

the lowest possible ignition point of the oil.

A portion of the lube oil sample is slowly heated at a constant rate, whilst continual

stirring is provided. A small flame is directed through an open shutter at regular

temperature intervals, with simultaneous interruption of stirring.

The flash point is the lowest point at which the application of the test flame causes the

vapor above the test point to ignite. For a new oil the flash point should be above 220˚C,

and any reduction would indicate fuel oil contamination.

2. BASE NUMBER

BN tester kits are provided onboard to determine the alkaline properties of the lube oil.

These testers use the chemical reaction of a reagent with the alkaline lube oil additive

(calcium) to produce a pressure rise. 10ml of oil is mixed with equal volume of a reagent.

10ml of another reactive reagent is placed in a plastic cup, which is floated on top of the

oil and reagent. The testing unit is sealed and thoroughly mixed. The resultant pressure

rise is directly read on an calibrated pressure gauge against base number.

3. KINEMATIC VISCOSITY

Onboard testing lube oil for viscosity is by the use of a comparative flow stick. This

measures the relative flow between two oils, usually a sample of the in-use lube oil is

measured against a fresh unused sample of the same grade of lube oil.
The flow stick is filled with 3ml of each oil in each reservoir, once both the oils are at the

same temperature, the flow stick is tilted to cause both oil grades to flow down the

channels. Once the new oil has reached the reference mark, the position of used oil in the

channel is checked. The following inferences can be drawn

a. If the used oil has a low viscosity, due to light fuel dilution. Then oil will have

traveled further down the channel than the new oil.

b. If the used oil has a higher viscosity, due to oxidation or heavy fuel oil

contamination it would not have traveled as far as the new oil.

4. DENSITY

This method uses hydrometer to test the sample oil density. It is important to keep the

oil and the hydrometer at the same temperature and maintained throughout the

experiment.

5. WATER CONTENT

Onboard water content is tested by using a calcium carbide. The tested is carried out by

mixing 5ml of oil with 15ml of a petroleum reagent (paraffin, toluene). The two liquors

are thoroughly mixed and then a measured amount of reagent (calcium carbide) is placed

on floating on the oil/reagent surface. The test unit is sealed and thoroughly mixed to

bring all liquids together. If water is present the carbide will produce acetylene gas, and

the resultant pressure rise will indicate the level of water contamination.

185. What is the material of a boiler valve?

Valve body: Cast Steel

Spindle, valve seat, valve disc and other parts: Monel Metal, Bronze or stainless steel

186. What will be the effect of water in fuel oil?

The effects of water content on fuel oil are

a. Loss of calorific value of the fuel oil

b. Corrosion in the lines, fuel pump (plunger/barrel), injectors

c. Water in oil can lead to vapor lock in the line leading to fluctuating engine RPM,

seizure of fuel pumps

d. In case of seawater contamination, it would lead to high temperature corrosion in the

exhaust system

e. Results in increased cylinder liner wear

f. Cause increased fouling of the exhaust gas ways and turbocharger blades

187. What are actions you would take if a purifier starts overflowing?

Some or all of the following should be checked for in case the purifier overflowing:

a. Sealing water low

b. Excessive fuel back pressure

c. Low pressure, chocked water line (check the water filter)

d. Gravity disc oversized for the density of the fuel oil in question

e. Oil temperature high

f. Excessive sludge deposition inside the purifier bowl

g. Excessive feed rate

h. Sealing ring damaged (between the Bowl and Hood)

i. Check RPM and direction of rotation of bowl

j. Leaking three-way valve

188. How do you calculate the specific fuel oil consumption?

a. Take the fuel oil flow meter readings for a specific time interval usually for an hour

b. Calculate the volume (difference between the above readings)

c. Using the fuel oil sample test results provided by the shore facility, calculate the

density of the fuel oil at the temperature near the flow meter

d. Calculate the mass of the fuel consumed by multiplying the results in b and c

e. Calculate the shaft power of the engine during this interval of time, take an average

value

f. Specific fuel consumption is calculated by mass of fuel consumed/Avg.shaft power

developed by the engine in the time interval.

Express the result in the Units of specific fuel oil consumption: g/Kw-h

189. How do you calculate the shaft power of main engine?

[Procedure for MANBW Engines]

During an interval of time, 1Hour measure engine

a. Fuel index of each unit

b. Engine RPM

c. Scavenge Air temperature

d. Ambient air temperature (Engine Room Temp.)

e. Fuel oil preheating temperature

f. Obtain the specific gravity of the fuel oil at 15˚C, its sulfur content & Lower calorific

value

g. Obtain the cylinder constant (engine data)

Calculate the average fuel pump index, Pθ = sum of all individual fuel index/total number of

cylinders.

Corrected fuel index, Pθ’ = average fuel index x K

Where K = Correction factor for fuel pump index Compiled by Eswara Arun Kishore

[email protected]

= K1 X K2 X specific gravity of fuel @ 15˚C

An example of calculation is shown with the following data to calculate K, Hence Pθ’

Lower calorific value of fuel: 9700Kcal/Kg, Specific Gravity @ 15˚C: 0.947, Preheated

Temperature: 104˚C, Engine room temperature: 30˚C, Scavenge air temperature: 32˚C

K1 = 0.953, K2 = 0.926

K = K1 x K2 x Sp.Gr. @ 15˚C = 0.836. Hence Pθ’ = Pθ x K

Mean Effective Pressure Pe = Horizontal coordinate in the above graph

Brake Horse Power (BHP) = C x Pe x Ne

Where C = Cylinder coefficient = 8.811 for 6S60MC MANBW engine

Pe = Mean Effective Pressure

Ne = Engine RPM

OUT PUT OF THE ENGINE (Shaft Power in Kw) = BHP x 0.7355

190. What is P-Alkalinity and T-Alkalinity?

P-Alkalinity: phenolphthalein is less alkaline than hydroxides or carbonates, and when it is

added to a sample containing hydroxides and or carbonates it will first neutralize the

hydroxides forming salts, it will turn pink in color. The acid used after this coloration will first
neutralize the hydroxides forming salts, it will then react with the carbonate molecules

present forming bicarbonate molecules. Bicarbonate molecules are less alkaline than

phenolphthalein, hence, the pink coloration disappears once all the hydroxides and

carbonates have been dealt with by the acid. One bicarbonate molecule is formed from two

carbonate molecules, hence in the test the quantity of acid used is a measure of the

alkalinity due to the hydroxides (caustic) present and half the carbonates.

T-Alkalinity: Methyl-orange indicator is less alkaline than phenolphthalein and bicarbonates.

It can be used initially in place of phenolphthalein or in continuation after the alkalinity to

phenolphthalein test. If no yellow coloration results when the methyl-orange is added to the

alkalinity to phenolphthalein sample no bicarbonates are present. Hence no carbonates are

present. Therefore, the alkalinity as determined in the alkalinity to phenolphthalein test has

been due to hydroxides alone.

191. What is the difference between an over speed governor and a constant speed

governor?

If within a governor, an over speed detection/actuation mechanism is provided to trip the

engine in case of over speeding and or rapid increase of speed then the governor is called an

over speed governor. These were the obsolete governors and commonly had fly or bob

weights restrained by spring. When the engine exceeds a predetermined speed, the weight

moves out to strike some form of fuel cutoff.

Governors designed to maintain the engine speed at the set point are called constant speed

governors. These are also referred to as isochronous governors like the ones usually installed

on COPT and main engine.

192. What are the properties of steering gear lube oil?

a. Satisfactory flow properties

b. High viscosity index

c. Low compressibility

d. Good lubricating properties

e. Low vapor pressure

f. Compatibility with system materials

g. Chemical stability

h. Protection against corrosion

i. Rapid air-release and water separation

j. Good thermal conductivity

k. Fire resistance (desirable)

193. What is the material of connecting rod bolt? What is the importance of

elongation? What is the nature of stresses in this component and why should these

bolts be replaced after some time in service?

The connecting rod bolt in service is subjected to:

a. A dynamic tension loading due to centrifugal force of the mass of connecting rod

rotating with the crank pin

b. A dynamic tension loading owing to inertial forces of the reciprocating mass of the

piston which is fluctuating with angular displacement of the crank and having the

peak value at an instant of 360˚ after the firing TDC in a cycle of operation

c. A dynamic shear stress at the parting of the two halves of the bearing housing

Dowel pins with fitted bolts or serrations at the face or both are used to reduce shear loading

on bolts and possibility of fretting.

Bolts should be constructed of materials having high resilience and should not be stiffer w.r.t

bearing housing.

Pretension of the bolts should be regarded as the single most important factor which

contributes towards the fatigue life of the material of the bolt. Pretension must be kept high

enough, so that the increase in stress owing to dynamic loading remains within the range of

stress already given by pretension.

Some routine checks on this part are (rejection criteria of the bolt)

a. Check for corrosion by acidic lube oil, discard if any present on shanks

b. Check the length of the bolt against a new or bolt tolerances. If longer, yielding of

the material should have taken place. Renew the bolt in this circumstance

c. Check for mechanical damage, especially on shanks

d. Check for fractures by NDT

e. Check the landing faces for uneven tightening

f. Discard the bolt when either designated life, over speed failure or piston seizure has

occurred

194. What are the bunker specifications? What changes would you make in the

event of a bad bunker?

THE INTERNATIONAL STANDARD

In 1982 the working group responsible for the development of the international standard

issued a draft proposal which became ISO 8217 Petroleum products – Fuels (Class F) –

Specification of marine fuels. Another draft proposal was issued at the same time which

became ISO 8216 Petroleum products – Fuels (Class F) – Classification Part 1 – Marine

Fuels. In 1987 the first edition of the international standard was published followed by the

publication of BS MA 100 in 1989, which was identical to the International Standard. The

second edition of ISO 8217 was issued in 1996 and this is denoted as ISO 8217 : 1996.

Distillate Fuels

There are four grades of marine distillate fuels – DMX, DMA, DMB AND DMC. The ‘DM’

denotes ‘Distillate Marine’ and the third letter distinguishes the different grades.

Grade DMX is a pure distillate used for emergency equipment external to the machinery

space. Grade DMA is the equivalent of a gas oil and is also a pure distillate. Grade DMB is

equivalent of a clean diesel, although it may contain some residue giving it a black color.

This means that an appearance test cannot be used on DMB as it is for grades DMX and

DMA. Grade DMC relates to a blended diesel oil which contains a residual component,

normally up to 10 %

Viscosity

Grades DMX and DMA have a specified minimum viscosity to ensure the fuel has sufficient

lubricity.

Flash Point

The flash points for marine fuels is determined by the closed cup method corresponding to

the opening of a previously closed vessel. The minimum flash point is 60°C for all fuels
within the machinery space of a merchant ship classed for unrestricted service, as laid

down by SOLAS national and classification regulations. Grade DMX, used for emergency

equipment external to the machinery space, must have a flash point greater than 43°C. It

should be noted in some countries gas oil and diesel oil are produced for local land based

market to a national specification. A minimum flash point is usually included in such a

specification, however, this value may be below that required by international legislation for

normal marine use.

Pour and Cloud Point

The pour point parameter specifies a winter and summer quality temperature. Normally

vessels burning DMA, DMB, and DMC do not have tank heating. Purchasers should ensure

the pour point is suitable for the equipment on board, particularly if a vessel is operating in

both Northern and Southern hemispheres.

The cloud point is the temperature at which wax begins to crystallize from a clear distillate

fuel. These wax crystals will cause rapid filter blockage. This parameter is only applicable to

grade DMX and is a technical limitation so that emergency equipment can start and operate

at an ambient temperature of –15°C.

Ignition Quality

The Cetane number is the measure of the ease of ignition of a distillate fuel determined by

a special engine test with a variable compression ratio. The higher the number the easier it

is for fuel to ignite in the engine.

The Cetane index is an empirical measure of ignition quality for distillate grades of fuel.

This index is calculated in a number of ways, such as from the mid-boiling point and

density. Bear in mind, these empirical equations do not take account of any cetane index

improver which may have been added in the manufacture of the fuel.

Sediment

The sediment test for the DMB is sediment by extraction which defines the insoluble

residues remaining after extraction of the fuel by toluene. For the blended diesel grade

DMC, the sediment test specified is the Total Existent Sediment. This is the combination of

inorganic and hydrocarbon sediments existing in fuel when delivered. This test is aimed at
limiting the maximum amount of sludge present that could be separated by the filters or

centrifuges.

Catalyst Fines

In distillate fuels the elements vanadium and aluminium, plus silicon for grade DMC, relate

to he residual component of the blend.

RESIDUAL FUELS

From table 2, ISO 8217 : 1996, there are fifteen grades of residual fuel which are

distinguished by three letters and two numbers. The first two letters are common to all

residual grades, ‘RM’ denotes ‘Residual Marine’, and the third letter refers to the

characteristic of the fuel. The two numbers are the viscosity of the fuel at 100°C. Grade

RMA relates to a residual fuel which normally does not require tank heating because of the

defined low pour point. Other residual grades require tank heating as they may have a

considerably higher pour point as defined in the specification.

ISO FUEL STANDARD 8217, 1ST REVISION 1996, FOR MARINE RESIDUAL FUELS

CHARACTERISTIC UNITS LIMITRMA

Density

Grades RMA 10 to RMA 15 have a restricted density so as to give acceptable ignition quality

characteristics when empirically determined from either the Calculated Carbon Aromaticity

Index (CCAI) or Calculated Ignition Index (CII). The density limit of 991 kg/m³ at 15°C is

the technical limit for the efficient removal of water by a centrifuge set up as a purifier

operating with a water seal. Three grades (RMK 35, 45, 55) have a density limit of 1010

kg/m³ which are suitable for vessels with fuel treatment plant capable of receiving such

densities. The two grades with no density limit (RML 45, 55) are intended for machinery

installations where the fuel treatment plant does not include centrifuges, namely a steam

ship.

Viscosity

Carbon residue
The carbon residue of a fuel depends on the refining processes used in the manufacture.

Two grades have no defined carbon residue or density limit (RML 45 and RML 55), a

maximum of 22 per cent m / m applies to Rmh, RMK, 35, 45, and 55, while a limit of 18

per cent m / m applies to RMG 25. The lower limits for viscosity grades 10, 15 and 25

reflect the use of diluents to cut back heavy residual fuel to produce light intermediate fuel.

Ash

In general there is a relationship between the specified ash level in a residual fuel and that

for vanadium. This is because vanadium is the major ash forming component in residual

fuel.

Water

The specification limit for water in residual fuel is based on traditional limits. Excessive

water represents a loss of energy to the fuel purchaser, potential engine operational

problems and possible waste disposable problems.

Sulfur

Sulfur limits in residual fuel provides guidance to lubricant suppliers as to the level of

alkalinity required to neutralize corrosive compounds originating from the combustion of

sulfur.

Vanadium

The level of vanadium in residual fuel depends on the source of crude oil and the refining

process used in manufacture. On a global basis this varies considerably, from 50-100mg /

kg to over 500mg / kg, and the specification differentiates between low and high vanadium

fuels, such as RME 25 and RMF 25.

Catalyst Fines

The purpose of a control for aluminium and silicon is to limit the amount of catalyst fines

delivered with the fuel. Globally, the composition of catalyst fines varies considerably and

can be controlled using limits for aluminium and silicon, considered better than the

historical method of just controlling the level of aluminium.

Sediment

Total Sediment Potential (TSP) provides a measure of the stability of a fuel.

Following are the points to be looked at when using new bunker

a. Start consuming the fuel only after the fuel analysis report from a shore lab with

recommendations is available

b. Bunkers should be stored in the bunker tanks above the minimum transferable

temperature mentioned by the shore lab

c. A watch should be kept on the line filters/strainers soon after changing over. Clean

the filters and ensure no excessive debris

d. Ensure that fuel oil transfer pump is in good operating condition

e. Monitor the purifier / clarifier operation and make adjustments if problems arise like

considering another gravity disc if the purifier starts overflowing

f. Make adjustments like decreasing purifier throughput, preheating temperatures or

operating the purifiers in parallel / series inline with the analysis report

g. Frequently drain the settling and service tanks to asses the amount of water in the

fuel and take further steps in line with the findings like increasing / decreasing

desludging intervals

h. Monitor the line filters/strainers before pumps viz. purifier feed p/p, booster pump

and circulating pump

i. Adjust the back flushing interval of the automatic fuel oil filter based on the findings

j. Adjust the viscotherm to attain the recommended viscosity prior engine inlet

(altered preheating temperature)

k. Adjust VIT/FQS if required

l. Cylinder lubrication, sometimes the scavenge air and JCFW out let temperatures

may be required to be altered if the sulfur content warrants the changes

m. Low load operation of the engine should be limited incase the fuel report shows high

CCAI value

n. Exhaust gas economizer soot blowing & cleaning interval may have to be reduced if

the Conradsen number, CCAI, ash, water content is high. Boiler water circulating

temperature should be monitored so as to ensure that economizer operates above

pinch point
o. Fuel injectors/exhaust valve overhaul intervals may also be altered basing on high

ash, sodium/vanadium, Conradsen number, asphaltenes and CCAI values

p. Soon after the engine is put to consume new bunkers take the performance of the

engine with draw cards to ensure good health of the engine. Further changes in fuel

injection settings may have to be effected if the indicator card diagrams show

deviation

195. How do you select a gravity disc of a purifier?

Makers nomogram is an aid to select a tentative gravity disc in purification, when the

density of the oil at a temperature of 15˚C is known.

The hole diameter of the first gravity disc to be tried appears directly from the nomogram.

However, in practical operation the best result is obtained by using the gravity disc with the

largest hole diameter that will not cause a break of the liquid seal in the bowl or an

emulsification in the water outlet.

The presence of seawater may demand the use of a gravity disc with larger hole than

indicated in the nomogram. (the nomogram is based on the properties of fresh water)

The nomogram consists of two graphs arranged in series, one consists of density of fuel at

15˚C Vs Separating temperature and the other graph is divided into different zones of disc

hole diameters against through put of the purifier.

196. Explain running direction interlock

Running direction interlock is provided to withhold the fuel supply during maneuvering if

the running direction of the engine is not coincident with the setting of the engine telegraph

lever.

At the camshaft, forward end the shaft is coupled to the camshaft and carries round with it,

due to the key, a flanged bush and spring plates which cause an adjustable friction

pressure axially due to the springs and nut. This pressure acts on the coupling disc which

rotates through an angular travel until the stop pin prevents further rotation. This causes

angular rotation of a fork lever and the re-positioning of a control valve plug in a new

position within the sleeve. Oil pressure from the reversing valve can only pass to the valve

block valve (air) and unlock the air start lever and the fuel control if the rotation of the
direction interlock is correct. If the stop pin were to break, the fork lever would swing to

position M and the fuel supply would be blocked.

197. Explain capacity control in a refrigeration system

Automation provided to effect refrigerating compressor operation to meet to the varying

refrigerating load is called capacity control in a refrigeration system. The nature of

automation is dependant on the size, capacity of the refrigeration system.

Capacity control in refrigeration can be achieved by any of the following methods

a. On/off control: if the refrigeration load is absent, capacity control may be effected

by cutting out the compressor motor

b. Variable motor speed: during reduced load, capacity control may be effected by

reducing the throughput of the refrigerant by reducing compressor motor speed.

c. Cylinder unloading: during reduced load condition in a multi cylinder unit

compressor, capacity control may be effected by successively cutting in or out

cylinders or cylinder groups

d. Hot gas bypass: involves passing a portion of the discharge gas from the

compressor directly to the evaporator, bypassing the condenser

e. Hot gas injection to evaporator

f. Evaporator pressure control

198. Explain unloader of a refrigerating compressor, reciprocating type

Large reciprocating compressors are provided with an unloading system which enables the

compressor to start easily with no vapor pressure load in the cylinder, permitting the use of

electric motors with low starting torques. Unloading is effected by holding the suction

valves open, or by opening a by pass valve between the discharge and suction sides during

starting. The unloading mechanism is actuated hydraulically, mechanically or by solenoid

valve.

199. What are the reasons for engine running on air but failing to run on fuel?

a. Fuel pump valves are leaking: valve cages leaking, dirt in fuel, governor gear

jammed and holding valves off seats, faces require grinding

b. Fuel system not properly primed: water in fuel, air left in system, leaky valves,
priming connections left open

c. Fuel oil supply restricted: suction strainers dirty, gravity tank empty, vacuum in

gravity tank, valve in suction line not fully open

d. Fuel injection pressure too low: spill valve jammed, priming valves left open

e. Rotational speed on air too low: starting air pressure too low, starting air restricted,

cylinder head valve leaking, tight bearings

f. Compression pressure too low: piston rings leaking, indicator cocks open, cylinder

head valve leaking

g. Timing of fuel pumps incorrect: fuel pump plungers not functioning properly(spring

return type), incorrect spill valve timing

h. Speed governor jammed: inertial weight jammed, trip pawl not engaging,

connecting mechanism not properly adjusted

200. What are the lube oil properties of a diesel generator engine?

a. Dispersivity or capacity to the cold parts of an engine clean

b. Detergency or capacity to keep hot parts of an engine clean

c. Thermal strength or capacity to withstand temperature changes

d. Anti-oxidant or capacity to resist the action of oxygen

e. Anti-wear or capacity to contain wear

f. Anti-scuffing or capacity to preserve oil film even in the presence of high pressures

g. Alkalinity reserve or capacity to neutralize acids formed during combustion or other

sources thereby preventing corrosive wear

h. Demulsibility or capacity to separate contaminants

i. Resistance to hydrolysis or capacity to withstand the action of water which can affect

additives

j. Pump ability

k. Centrifugibility and filterability or capacity to separate insoluble elements

l. Anti-rust, corrosive and anti-foam are just some of the other properties required

201. Explain a torsion meter on a main engine shafting. How is engine power

calculated from the torsion meter?

Torsion meter is an instrument provided on the engine shafting to measure the torque

developed by the engine.

Torsion meter uses the principle that when a torque is applied to a shaft an angular twist θ is

produced which is dependant on the shaft material torsional rigidity. It is given by

T/r = Gθ/L where r= radius of the shaft, G= torsional rigidity, L= reference length of

the shaft. Where radius, length, and material of the shaft are constant, θ is directly

proportional to the angular twist.

A modern instrument is a contact less all electric instrument. It is as described below:

It based on the magnetic stress sensitivity principle, some ferromagnetic materials

reluctance is less along the plane of stress than across it. Magnetic fields are induced in a

shaft; the distortion of these fields gives an indication of the torque being transmitted.

It consists of three rings fitted on to the shaft each of which carries four electromagnetic

poles. The centre ring acts as a transformer primary with two outer rings acting as secondary

coils arranged at a phase of 45˚ to the primary but are in line with each other.

Poles for inducing currents in the shaft coils are held in a stator frame so that there exists no

contact between this stator and the shaft. A gap of about 3mm is usually maintained

between this stator and the shaft.

An alternating current is fed to the central ring (primary) generating a magnetic field. This

causes an induced currents in the outer secondary coils, which are connected in series such

that when there exists no twist (no torque condition, rpm=0) in the shaft, the induced

currents oppose each other and neutralize. When torque is applied to the shaft stress lines

are inclined to the axis. This distortion causes the induced current in the secondary coils to

increase on one side and decrease on the other side. Thus a resulting induced voltage is

developed in the secondary which is sensed by the secondary poles in the stator. The

magnitude of this induced voltage is proportional to the torque applied.

The signal out put from the instrument is directly calibrated in terms of torque developed by

the engine and read on the display.

Now as torque T is known, power developed by the engine can be calculated from the

following relation,
Shaft Power, P = 2 π NT/60 where N= RPM, π= 22/7 (PI)

202. Explain the procedure of setting a boiler safety valve

The safety valve is the sole safety device, which relieves the boiler of a dangerous excess

pressure. In the majority of designs the oil fired boiler and the exhaust gas boiler have a

common steam circuit, though separate heat input and flue gas paths. The oil fired section of

the oil fired boiler has a fuel cut out which is operated by the steam pressure limiting device,

whereas the exhaust gas boiler has to depend solely on its safety valve to protect it.

In a composite boiler as mentioned above the pair of safety valves can serve to protect the

common steam circuit. An additional pair of safety valves is provided in the outlet header of

the exhaust gas boiler, which has to be set separately.

The setting of the safety valve has to be done when the heat input and the rate of pressure

rise is maximum. The setting of the exhaust gas boiler safety valve to comply with the

above, shall be carried out as follows:

While at sea, with the main engine running at normal service speed and when all systems

are steady, the oil-fired section of the boiler can be fired to augment steam production (all

precautions such as adequate water level in the boiler, operator standing by the burner quick

shut off valve etc. are to be followed). With the safety valve on the steam receiver of the

boiler lightly gagged. The safety valve of the exhaust gas boiler section is set at slightly

higher pressure. In order to ensure that the economizer (or the exhaust gas boiler) operates

under flooded conditions at all times, it is customary to adjust the safety valves of the

economizer to a slightly higher pressure than the safety valves of the boiler steam receiver

of which they are connected.

After setting the safety valve as above to satisfaction locking it to make it tamper proof, the

oil-fired boiler firing is stopped, the steam receiver safety valves gags removed and all the

easing gear properly connected.

The exact lifting pressures are recorded in the logbook authenticated by the CEO and a copy

of the above is to be forwarded to the classification society upon arrival next port.

In the setting of the safety valve of a boiler, three items are of great importance. They are:

1. Setting pressure at which the valve should lift.

2. The accumulation of pressure, which will be above the former due to the valve spring

characteristics

3. “Blow down” which is a drop in pressure below the setting pressure after the valve has

lifted and reseated.

4. For example the following values are relevant:

a. Boiler working pressure: 7 bar.

b. Safety valve setting pressure: 9 bar.

c. Accumulation of pressure: Maximum of 10% of the setting pressure = 9.9 bar.

d. Blow down at 3% of lifting pressure.

Q.1 The precision engineering bearing inserts are manufactured with small portion of bearing ends
extending beyond the bearing housing or caps. The installation process of these bearings requires
sufficient

Ans. (b) crush.

The bearing shell itself is in two halves. The bearing shell halves are extended beyond the bearing
housing

by approximately 0.3mm. This is applicable in modern thin-shelled bearings. As these bearings are thin

shelled, they cannot support shaft on their own and hence need backing-up support of the bearing
housing.

Hence it is necessary to have full contact with the back of the bearing and the bearing keep. Hence crush
is

provided to achieve this. Also, it prevents the rotation of the shelf in the housing due to the rotation of
the

shaft.

Q.2 The method of piston cooling in which oil is delivered through the connecting rod to a
compartment within the piston, then distributed by the motion of the piston and allowed to drain to

the crankcase via one or more pipes or holes is termed as

Ans. shaker method of cooling of the piston.

In shaker method of piston cooling, it is actual movement of the piston which causes the movement of
oil
in the piston. The oil outlet from the piston crown cooling space is kept at higher level than that of inlet.

Hence some oil is always retained in cooling spaces. This oil is splashed against the underside of the hot

crown as the piston moves up and down so as to have better cooling of the piston crown. This spraying

action is done due to the movement of the piston. This is very efficient piston cooling method.
Nowadays,

new Sulzer engine is employing the combination of shaker and nozzle cooling method and has reported
to

have reduction in piston crown temperature.

Q.3 The piston rod scrapper box incorporated in two-strokes cycle crosshead diesel engine serves to

Ans. (c) prevent the sludge and dirty oil from entering the crankcase.

In two-stroke crosshead engines, under-piston scavenge space are separated from crankcase by use of

diaphragm. Under-piston scavenge space gets accumulated with unburnt carbon, unburnt fuel and
mixture

oil in the form of sludge. If this finds its way into crankcase, then crankcase oil will get deteriorated.
Hence

stuffing box with scrapper and sealing rings is mounted on the diaphragm through which reciprocating

piston rod passes thus scrapping off and preventing the entry of sludge into the crankcase. Also it
prevents

the crankcase oil into the under-piston space hence preventing the loss of crankcase oil.

Q.4 In large slow speed main propulsion diesel engines which of the parts listed is under tension

when the engine is running?

Ans. Tierods.

The job of the tierods is to hold bedplate column, entablature under compression so as to prevent the

relative movement between these parts. When the engine is running hence these parts are tied
together and

are kept under compression by use of tierods. While doing so, the tierods itself gets into tension. Hence
the

firing load is transferred to the bedplate and ship structure.

Q.5 The main advantage of unit injector over other fuel injection system is

Ans. lack of high pressure fuel lines.

In case of unit injectors, which is a combination of fuel pump and fuel valve, as the fuel valve is not
separately mounted away from the fuel pump, there is no need to provide a connecting high pressure
oil

carrying fuel between the fuel pump and fuel injector. This combination improves safety and chances of

high-pressure fuel leakages also reduces. Also the possibility of fire due to leaky high-pressure pipes is

reduced.

Q.6 The passages are drilled in the crankshaft of diesel engines to provide lubricating oil to

Ans. the main bearings, connecting rod bearings and piston pin bushings.

Crankshaft moves in the main bearings. At the same time the connecting rod big end bearings moves
over

the crankpin. Also the connecting rod top end bearing moves over the piston pin bushing. As there is

relative movement between these parts, friction always exists between them. In order to reduce the
friction

and remove the heat generated due to small amounts of film friction that may exist, it is necessary to
supply

sufficient quantity of lubricating oil to all these three parts so as to have a film lubrication which will

separate the moving parts from the stationary bearings. At the same time, it will provide sufficient
amount of lubricating oil for the purpose of cooling. This arrangement is utilized only in case of small
engines

where the drilling of the crankshaft is permitted. In case of big engines, there is possibility of stress

concentration due to the drilling in the crankshaft and there is a possibility of crankshaft breaking.

Therefore this type of system is not utilized in big engines. In big engines, main bearing lubricating oil is

supplied separately through the crosshead bearing which will be branched to the piston cooling as well
as

crosshead lubrication and through the connecting rods drilling it will go to the bottom end bearing

lubrication.

Q.7 When can the main crankcase ventilation pipes or oil drain pipes of two or more engines be

connected?

Ans. As far as possible no connection should be provided between the crankcase ventilation of

different engines.

Crankcase ventilation pipes or drain pipes of two or more engines should not be connected as in case of

crankcase explosion, the heat wave may enter other healthy engine crankcase causing explosion in that
engine also. Also if one engine crankcase oil is contaminated, other engine oil may also get
contaminated if

the drains are connected. Also this may occur due to the oil vapour getting mixed up.

Q.8 The main function of tierod in the construction of a large low speed diesel engine is to

Ans. absorb most of the tensile load that results from the firing forces during the operation.

The main function of the tierods is to keep the cylinder block, A-frame and bedplate tied together under

compression. At the same time it itself goes into tension. Also tierods accept most of the tensile loading

that results from the firing forces developed during operation and relieve the bedplate, entablature and

columns off these firing forces. Hence it can be seen that the tierods are always under tension so as to

maintain all other parts of the engine structure under compression and to prevent the relative
movement

between the parts when the engine is in operation.

Q.9 On most modern diesel engines, the main and connecting rod bearings receive their lubricating

oil by

Ans. (d) pressure feed.

On most modern diesel engines, where the load is comparatively high, it is necessary that the bearings

should be lubricated by lubricating oil. This lubricating oil will form a wedge type film between the

stationary bearing and the rotating shaft so as to prevent the metallic contact and the friction between
the

bearings and the journal. For this purpose, it is necessary to supply large quantity of oil so as to have a

continuous and uninterrupted supply of lubricating oil which is required to form the film as well as
cooling

purpose. In order to achieve this, it is necessary to continuously supply lubricating oil under pressure.
This

will overcome the piping friction and also it will maintain uninterrupted and sufficiently large quantity of

lubricating oil to the bearings.

Q.10 Fuel injection pump using the port and helix metering principle requires the use of a

Ans. (b) lapped plunger and barrel.

Due to lapped plunger and barrel, there is a good contact between the plunger and barrel. As the pump

develops very high pressure, there will be least amount of leakage between the plunger and barrel. Also
due
to the cutting of helix on the sliding surface of the plunger, the sealing area between the plunger and
barrel

reduces. As the area reduces, the possibilities of leakages increases. Hence in order to reduce the
leakages

at high pressure between the plunger and barrel, it is necessary to lap plunger and barrel together so as
to

have a perfect bearing between the plunger and barrel and to reduce the leakages. The plunger and
barrel

are to be replaced together as a set because they are lapped individually with each other and they
should not

be replaced individually as single unit.

Q.11 Lubricating oil is supplied to the crankshaft main bearing in a marine diesel engine by

Ans. internal crankshaft passages.

In small diesel engines where the crankshaft size is small and the engine pistons are trunk-type, oil is

supplied to the main bearing by a pipe. From there through the passage in the crankshaft it is fed to the

crankpin bearing thus avoiding complicated piping to supply lubricating oil to crankpin bearing. From

there, oil is led upward through the connecting rod holes. B004

Paresh

Q.11 The lubricating oil supplied to the crankpin bearing in a marine diesel engine

Ans. by internal crankshaft passages.

The internal passages in the crankshaft are made in such a manner, in case of small diesel

engines where crankshaft size is comparatively small, that oil is supplied to the main

bearing. From there to the passage in the crankshaft it is feed to the crank pin bearing.

Thus avoiding the complicated piping to supply oil to the crankpin bearing and gudgeon

pin bearing. This is applicable only in case of small crankshafts. Bigger crankshafts may

fail under fatigue if the holes are drilled out for the passage of the oil. Hence in case of

the bigger crankshafts, no drilling of the holes is done on the crankshaft and hence this

method of lubricating the bottom end bearing and gudgeon pin bearing is not applicable.

In that case, there is a separate supply of lubricating oil to main bearing and as well as to

the crosshead bearing, which will be further bifurcated into two: the crosshead bearing
and piston cooling, and the bottom end bearing, for lubricating.

Q.12 Gudgeon pin bearings are difficult to lubricate because of their oscillating

motion and

Ans. (d) their position in the lubricating system.

As a gudgeon gearing is fitted between the piston and the connecting rods.

B005

Paresh

Q.12 Gudgeon pin bearing are difficult to lubricate because of their oscillating

motion and

Ans. (d) their position in the lubricating system.

As the gudgeon pin is fitted between the piston and connecting rod, it is difficult to

convey oil to it. Also by the time oil reaches this bearing after passing through the main

bearing and bottom end bearing, there is a large amount of pressure drop as well as loss

of quantity of the lubricating oil. Thus this bearing is starved of the oil. Also load on this

bearing is acting downwards. Also the area of the bearing is less. All these factors

contributes to the difficulty in the lubricating the gudgeon pin bearing.

Q.13 The camshaft drive is designed to maintain the proper camshaft speed relative

to the crankshaft speed. In maintaining this relationship the camshaft drive causes

camshaft to rotate at

Ans. (b) crankshaft speed in a two-stroke diesel engine i.e. camshaft and crankshaft

speeds for two stroke engines are same.

In a two stroke engines for every revolution there is one power stroke. For every power

stroke, there is one fuel injection movement and one exhaust valve opening movement.

This fuel injection and exhaust valve opening is controlled by the camshaft rotation.

Hence it is necessary for camshaft to rotate at the same speed as the crankshaft, so as to

have fuel injection and exhaust to be carried out for every revolution of the crankshaft.

Q.14 Engine having bore exceeding 250 mm, but not exceeding 300 mm, are to have

at least

Ans. (c) one explosion relief door or one explosion relief valve in the way of each
alternate crank throw with a minimum of two valves.

This is a minimum requirement under the classification society rules. When arriving to

this requirement figures, the calculation of the crankcase volume and the rate at which the

explosive gases are released, in order to avoid the building of pressure and explosion of

the crankcase, atleast two safety valves are needed; in case one valve fails to open atleast

the second one will respond.

Q.15 The opening of an exhaust valve on a modern large two-stroke slow-speed

main propulsion diesel engine may be actuated by

Ans. (c) hydraulic “pushrods”.

The opening of exhaust valve on a modern engine of a large slow-speed main propulsion

diesel engine may be actuated by hydraulic pushrods as it eliminates the need of

mechanical pushrods and the rocker arms. Also it eliminates the problem encountered

due to the thermal expansion of the valve spindle. There is no need for checking and

adjustment of the tappet clearance. Also, closing and opening timing of the valve can be

adjusted depending upon the load, and the closing and opening action can be made

smooth with less hammering of the valve on the seat and hence less noisy. Thus hydraulic

pushrod is most convenient method for opening of exhaust valve. In modern engines,

closing is carried out by mechanical or air springs.

Q.16 Shaker/circulation and spray are the three general methods used in B005

Paresh

Ans. (d) piston cooling.

Q.16 The shaker, circulation, and the spray are the three general methods used in piston cooling.

As these three methods are the most effective and easier to be applied to the rapidly reciprocating
pistons

without providing any external methods and this the most convenient method of supplying lubricating
oil or

any other cooling medium to the piston cooling. At the same time, movement of the piston is utilized for

the splash-type shaker method of cooling for the under side of the piston crown. This method is highly

effective method.
Q.17 Speed of the camshaft of a two-stroke cycle diesel engine running at 950 rpm is

Ans. 950 rpm.

In two-stroke engine, it is necessary to run the camshaft at the same speed as that of the crankshaft. As
for

every revolution there is one power stroke and for every power stroke fuel has to be injected. Hence the

speed of the camshaft and the crankshaft should be equal.

Q.18 Explosion relief valve on diesel engine crankcase should relieve the pressure at not more than

Ans. 0.2 bar.

This rule is governed by the classification society and SOLAS regulations. When arriving to this figure, all

necessary calculations are done to reduce the severity of explosion. If the pressure is allowed to reach
more

than this value, the crankcase temperature will be higher and the chances of explosion and severity of

explosion is on higher side. Hence it is necessary to relieve the pressure from the crankcase if it exceeds

more than 0.2 bar

Q.19 Two-stroke diesel engine exhaust temperature will be lower than a

four-stroke diesel engine of same displacement because

(i) scavenging air cooling the exhaust gases.

(ii) exhaust cycle time is longer.

Ans. (i) scavenging air is cooling the exhaust gases.

In two stroke diesel engines, exhaust temperature is lower than the four stroke diesel engine of the
same

power because the scavenging air is cooling the exhaust gas while the incoming scavenge air is driving
out

the exhaust gas. During this process, some cool scavenge air mixes with the exhaust gases and the

thermometer fitted on the exhaust gas outlet measures the mean exhaust gas temperature. Hence it is
always

lower than the four-stroke engines where the exhaust gas is expelled due to the physical movement of
the

piston and not due to the incoming air.

Q.20 The sealing surface of a diesel engine piston rings which faces are considered to be in contact

with cylinder walls in addition to the ring grooves?

Ans. (a) Bottom.

The high pressure combustion gases goes behind the piston rings to push them hard against the liner to

have a good sealing effect between the liner and the piston rings. But the gas pressure behind the piston

rings should always be maintained and there should not be any leakage from the landing faces of the
rings

on the grooves of the piston; otherwise blowpast may take place. Hence the sealing, between the
contact

faces of the rings and the bottom surface of the grooves on which the ring rests, is important to
maintain

gas pressure behind the piston ring to give better sealing effect between the piston rings and the liner.

Q.21 Where is the fuel delivery check valve located in jerk type fuel injection system?

Ans. (c) In the injection pump housing discharge side.

As the valve job is to prevent the backflow of the fuel from the high-pressure piping and fuel valves into

the pump during the suction stroke of the pump and also at the end of delivery stroke when suction and

discharge gets short-circuited to terminate the delivery stroke. Otherwise the backflow of the oil from
the

fuel piping will take place. In that case, every time at the end of delivery the high-pressure side of the

piping will get partially empty and this will cause late beginning of injection for the next stroke. Hence it
is

necessary to maintain the high-pressure pipe between the fuel pump and fuel valve to be always filled
with

the oil. At the same time, they should be maintained at certain high pressure.

Q.22 How many crankcase relief valves are required for a 325mm bore, 8-cylinder in-line engine?

Ans. (d) 8 As the bore is 325mm as per classification society rules, each crankcase should have atleast
one relief valve

fitted. Hence in case of 8-cylinder engine, it is necessary to have 8 crankcase relief valves.

Q.23 Which of the air-intake system listed will result in lowest specific fuel oil consumption?

Ans. (b) Turbocharged.

The turbocharger will provide the extra air under pressure so that more quantity of air can be admitted
into

the cylinder so that more fuel can be burnt efficiently. For this, turbochargers are provided. As these

turbochargers are driven by waste exhaust gas without any power from the engine, it is the most fuel
efficient method of improving the performance of the engine. In all other methods of supercharging, the

power for driving the supercharger is taken from the engine crankshaft. Hence there is a loss of power
and

from the point of view of available power at the engine output, the specific fuel oil consumption will be
on

the higher side as compared to the turbocharged engine.

Q.24 In which of the area of the crosshead engine is a permanently connected fire extinguishing

system required?

Ans. (d) Scavenging space

In open connection to the cylinders i.e. it is required for the under piston scavenge space.

Under piston scavenge spaces are connected on the cylinder underside. As under side of the piston is

having fuel unburnt loops and carbon mixture. In case of blowpast in presence of plenty of availability of

air, this sludge may catch fire. This type of fire is called crankcase fire. In order to extinguish such type of

fire, permanently connected fire extinguishing system is required. This is possible by providing a

permanent connection of steam smothering or connection to extinguish scavenge fire because there are

circumstance under which most of the other fire fighting processes will fail. In such circumstances, there
is

no other alternative but to flood the under piston scavenge space weight smothering element such as

carbondioxide or steam.

Q.25 Camshafts are usually driven by timing gears or

Ans. (b) chain drive.

Chain drives is one of the reliable method of driving the camshaft with consumption of minimum
energy. It

is simple in construction and easy to maintain. By using the chain drive, it is easier to position the
camshaft

very near to the cylinder head along with the fuel pump placed near the head which reduces the fuel

injection delay and better combustion of fuel because it is injected exactly at time which is having the
best

combustion efficiency.

Q.26 The valve cam slope angle determines the

Ans. (b) opening and closing rate of the valve.

As the roller is always in contact with the camshaft, the profile of the camshaft plays an important role
in

deciding the time of opening and closing and the time for which the valve will remain open and the rate
of

opening and closing of the valve. The rate of opening and closing of the valve will depend upon the cam-
slope. As more

steeper the cam profile, faster the rate of opening and smarter the closing. This is

required for the valves in order to avoid the throttling effect when the valve is opening

very very slowly or when it is closing very slowly. If the valve opens or closes slowly, in

that case, there is always a possibility of improper scavenging taking place. In such

circumstances, the efficiency of the combustion is poor. This is mostly applicable to the

high-speed engines where the time available for the process of exhaustion and suction of

air is very very limited.

Q.27 Arrangement and shape of the cams on diesel engine camshaft directly

controls which of the listed group of operating condition?

Ans. (b) Firing order, valve timing and valve lift.

Justification: The position of the individual cam on the camshaft will decide the firing

order of the engine. At the same time exhaust and intake valve opening will be also

decided by the positioning of the respective cams on the camshaft. The position of the

cams on the camshaft with respective crankshaft will decide the opening and closing

timing for the fuel valve, exhaust valve and intake valve. The profile of the cam will also

decide the rate of opening and the rate of closing. Also the valve lift will depends upon

the roller lift which will be decide by the total cam lift.

Q.28 Carbon deposits building up in and around injection nozzles are least likely to

occur when using which of the listed type of the fuel injection nozzles?

Ans. (c) Pintle type of nozzles.

Justification: Pintle type of nozzles are mostly used in the low powered engines where

the temperature inside the cylinder is much lower. At the same time, because of its single

whole structure, there is least amount of leakages or dripping of the nozzle. Also it has

very very low sac volume and hence its dripping possibility reduces. All this will
contribute to the minimum amount of carbon deposit around the fuel nozzle.

Q.29 A port and helix fuel injection pump having upper and lower plunger helix is

designed to

Ans. (b) vary the beginning and end of injection timing.

Justification: When there are two helixes cut on the plunger one helix controls the

beginning of injection i.e. lower helix controls beginning of injection and upper helix

controls the end of injection. Thus it is a good old method of variable control which were

fitted on the previous generation of engines.

Q.30 Which of the following statements describes the fuel injection pump mark

timed for port closing.

Ans. (a)

Injection has a constant beginning and variable ending. The helix cuts on the plunger

surface and inlet port on the barrel. The time at which the upward moving pump covers

the suction port on the barrel is the beginning of injection as the fuel oil gives

compressed and it lift opens the fuel injection valve.

9nppffTill that time there is overflow of oil to the suction side. By moving upwards,

depending upon the load of engine, there is relative position of plunger helix with respect

to the suction. This will decide as to when the discharge side of the plunger will be in

connection with the suction side, hence ending the delivery. Also this will decide quantity

of fuel injected depending upon the load. This system has constant beginning but the end

and quantity of injection is controlled by the helix position.

Q.31 Same as Q.30

Q.32 An individual pump is designed for variable beginning and constant end of

injection. For diesel engine operating at constant speed, the start of injection will

Ans. advance as the load increases.

As the load increases, engine requires more fuel to inject and burn. As the speed is

constant, more fuel is to be injected in same time frame available, it is necessary to begin

the injection earlier, i.e. to advance the beginning of injection, so that the fuel can be

completely burnt, effectively and efficiently, within the time frame available thus giving
better thermal efficiency of the engine.

Q.33 Crankshaft whose center of gravity coincides with the centerline is said to be

Ans. (b) statically balanced.

B012

Ans. (b) increase the distance of heat travel from the crown to top ring groove.

As the first ring or the top ring is subjected to maximum amount of temperature and

pressure, it is difficult to maintain the film of lubrication between the top ring and liner.

Also there is every possibility that due to heat and high pressure, the top ring will get

broken or seized in the piston groove. Due to lack of lubricating oil film, there is

maximum weardown for the top ring and top end of the liner. In order to avoid this, it is

necessary that the piston ring should be maintained as far as away for the firing

temperature so that a good lubricating oil film can be maintained between the liner and

piston rings. In order to achieve this, a seat damp is utilized in the engine.

Q.40 Diesel engines are classifieds as internal reciprocating engines because they

Ans. (c) burn the fuel in chamber and their energy moves the piston back and forth.

As the fuel is burning in confined space which is sealed where fuel burning takes place

because of high temperature of compressed air. All the burning process is carried out

inside the cylinder liner between the top of the piston and bottom of the cylinder head.

The heat released is converted into mechanical energy by the movement of the piston

which is transmitted to the crankshaft. As the combustion takes place inside the cylinder,

it is called internal combustion engine.

B015

Q.53 Turbulence in diesel engine cylinder is of major importance in providing

Ans. (c) complete fuel air mixing. Turbulence is created due to the circular movement of air in the
cylinder. This turbulence

is created by the geometry of entry ports, scavenge air as well as the geometry of the

cylinder head and the piston crown. Due to turbulence there is thorough mixing and

homogenize mixture is produced between fuel and air. This mixture will burn efficiently

and hence the full quantity of air is available for the combustion of fuel. This gives higher
thermal efficiency of the engine and reduce the unburnt fuel going into the exhaust thus

reducing the specific fuel oil consumption and less smoke is formed in the exhaust. At the

same time, this will give the uniform distribution of heat over the combustion space.

B016

Q.54 Load is always placed on lower half of main bearing in

Ans. (a) two-stroke cycle engine.

In two-stroke engine, as there are two strokes for the complete cycle, the piston will

always be loaded downwards whether it is expansion or compression stroke. Hence for

first half revolution, the piston is loaded downwards due to expansion gases which is

transmitting load force to the crankshaft. When the piston is moving upwards it is

compressing the air to perform compression stroke. Due to this unidirectional downward

loading of the piston which is transmitted to the crankshaft, the main bearing of the two

stroke cycle engine is always loaded at bottom half. Also the pressure acting is varying

and hence difficulties are encountered in lubrication of bearings in case of two-stroke

engines rather than four-stroke engines.

B017

Q.55 Cavitation and corrosion in cooling water system of diesel engine usually

occurs at the pump impeller and the waterside of the

Ans. (c) cylinder liner.

When the water enters into the cylinder liner, it gets heated up. At the same time when

water passes through the cylinder liner, the velocity of water increases due to restricted

passages. As the velocity increases, as per Bernoulli’s theorem, pressure drop takes place.

As the pressure drop takes place, water tends to boil off at lower temperature due to

which steam bubbles are formed. These bubbles get bursted creating cavitation. Hence if

the liner is opened for inspection any time, especially at the places of restricted entries

and passages, cavitation is easily visible.

B018

Q.56 The main operating characteristics that distinguishes it from other internal

combustion engines is
Ans. (c) method of igniting the fuel.

In petrol engines, the ignition is carried out with the help of igniter or spark plug. Diesel

engine fully depends on compression ignition for the purpose of igniting the fuel. In

diesel engine the air is compressed. As the air is compressed its temperature increases to a temperature
which is more than the self-ignition temperature of the fuel. When fuel is

injected at this temperature, it vapourizes and mixes with air to form combustible

mixture. As the temperature is above the self-ignition temperature this mixture ignites

and produces a high pressure wave. This pressure wave and the heat is transmitted to the

crankshaft by the downcoming piston.

B019

Q.57 Which term describes piston pin having bearing surface in both piston bosses

and connecting rod eye?

Ans. (b) Full floating.

If the gudgeon pin is having a press-fit in the bosses of the piston and is free to move

over the top end bearing of the connecting rod, there is a possibility that misalignment

cannot be taken care off. Hence the pin is made to float or have bearing surface in the

piston boss and the connecting rod eye so that it can take care of misalignment. At the

same time the pin can have a rotating effect. When the pin has rotating effect, it will not

have continuous loading on one surface and the weardown of the bearing will be uniform

thus preventing the ovality of the bearing due to wear in only one place. In order to

prevent this pin from coming out when the piston is moving up and down, at the end of

bosses, circlips are provided which prevents the gudgeon pin from coming out and

touching the liner.

B0021

Q.58 Compared to other fuel injection systems, unit injection system operates with

virtually no

Ans. (a) injection lag.

In unit injection system, the fuel pump and the fuel valve consists of a single block.

Hence there is no fuel piping the valve and the pump. As there is no piping, the time
required for injection from the time the fuel pump plunger starts moving up is reduced

resulting in reduction of injection lag. In case of other types of fuel pumps, where the fuel

pump is connected to the injector by long high pressure pipes, some amount of pressure

drop takes place inside the fuel pump piping. Also due to the pressure wave created, the

fuel piping gets slightly expanded which can cause fuel injection delay. Hence in order to

avoid fuel injection delay, the best possible way is to fit the fuel pump very near to the

injector. In unit fuel injection system, this delay is nearly reduced to zero.

B0022

Q.59 Piston cooling fins are located

Ans. (b) underneath the piston crowns.

Piston cooling fins act like cooler. When the fins are provided, better heat transfer takes

place from the hot surface towards the pointed tips of the fins due to which the hot crown

remains comparatively cool and better heat transfer takes place across the cross-section crown. Hence
the piston crown induced thermal stresses are reduced to minimum. This

has resulted in less cracking of the piston crowns.

B0023

Q.60 Properly honed diesel engine cylinder liner will

Ans. (b) shorten the ring breaking in period.

When the liner and the piston rings are new, microscopic * and roughness is always

present in the liner wall and piston ring surface. During the breaking in period, these * are

grounded or broken up so that they will be smoothened. Running in can be done

afterwards to achieve complete bedding between the liner and piston rings. Hence

breaking in is importance process. If it is not done properly, there is a possibility of

scuffing and blowpast. The process of breaking in should be carried out as fast as

possible so that the engine load can be increased. In order to get fastest breaking in,

controlled fast weardown should be achieved. For this purpose, honing should be carried.

During honing process, the surface of the liner is made artificially rough. Thus

lubricating oil is retained at the surface of the liner. Also due to roughness, both piston

rings and liner will get worn out faster so that breaking in can be carried out fastly,
without causing blowpast or scuffing. Hence honing is important from the point of view

of breaking in.

B0025

Q.61 Besides the use of piston cooling, fins provides extra strength for the

Ans. (b) piston crowns.

As the fins are provided on the underside of the piston crown, the top portion of the

piston crown which is subjected to higher temperature and pressure is supported by the

fins from underside. As the support is provided by the fins, they give extra strength to the

piston crown. Hence it is possible to use the piston crown of thinner cross-section without

causing it to buckle under the influence of high temperature and pressure.

B0026

Q.62 Minimum fuel oil delivery pressure required for efficient fuel injection

depends primarily on

Ans. (b) maximum pressure in the engine cylinder during injection.

When the piston is approaching TDC on compression stroke, the fuel oil injected into the

cylinder. The fuel oil injected has to overcome the resistance or backpressure offered by

the high pressure compressed air. Hence the pressure of the fuel oil injected has to be

more than the pressure inside the cylinder head; otherwise it will not be possible for the

fuel to penetrate the mass of dense air available. This will result in improper combustion

of the fuel. Hence it is necessary to maintain minimum injection pressure higher than the

compression pressure existing at the time of injection.

B0027 Q.63 A thrust bearing is used in diesel propulsion engine to

Ans. (a) control axial movement of the crankshaft.

When the ship moves forward or aft, the propeller produces a thrust which is applied to

ship’s hull. At the same time this thrust is exerted on the propeller blades. As the

propeller is connected to the propeller shaft which is connected to the engine shaft, due to

the axial thrust created, there is a tendency for the crankshaft to move inside the engine

i.e. the crankshaft will have axial movement. If this axial movement is not prevented or

taken care off, there will be misalignment between the piston connecting rod and bottom
end bearing. Also the crankshaft webs may touch the A-frame and the main bearings

which may damage to the engine structure. Also the rest of the crankshaft will be

subjected to axial thrust and hence it may bend or break. Hence it is necessary to take

care of this axial thrust before it enters the engine and affects the moving parts of the

engine. For this purpose, thrust block is provided at the end of the last unit so that all

other units and crankshaft is protected from the axial thrust and the crankshaft alignment

will not be affected.

B0028

Q.64 The two strokes of the two-stroke cycle diesel engines are

Ans. (d) compression and power.

As any diesel cycle, the two-stroke cycle will also consist of all four major processes i.e.

suction, compression, power and exhaustion. In case of two-stroke engines, the process of

compression and power are distinct but air intake and exhaustion are combined together

and they form a part of the distinct compression and power stroke. Hence there is no

separate distinct stroke for intake and exhaustion as exhausting is carried out by intake of

air.

B0030

Q.65 Which of the following statements pertains to propulsion engines with bore

exceeding 200mm?

Ans. (c) The units will be fitted with means to display the exhaust temperature of

each cylinder.

When the piston diameter exceeds 200mm, the engines are considered as highly rated

engines. In such engines, the exhaust temperature of individual units will be on higher

side and sufficient amount of power is developed by the units. In order to have proper

running of the engine, it is necessary to have a balanced engine. The balanced engine can

be roughly described by comparing the individual unit temperature. If the exhaust

temperatures of the units are within prescribed range, one can consider that the engine is

properly balanced. It should also be noted that exhaust temperature is not the only

indication of power balance. For this purpose, the indicator card is taken and the power
developed by the individual unit is calculated the best method. It can be a rough

estimation of power balance.

B0031 Q.66 When engine bore exceed 230mm, a berthing disc or flame arrestor is fitted

Ans. (a) to the engine air supply inlet to the starting air supply manifold for non

reversing engines.

When the bore of the engine exceeds 230mm it is considered as highly rated engine as far

as power is concerned. These engines are mostly started with compressed air. If air inlet

valve or starting air valve on the cylinder leaks, high pressure exhaust gas will enter the

air manifold. As the pressure and the temperature is high, it will cause a air starting line

explosion. This will result in heavy damage to the engine and the personnel working.

Also the engine will be completely immobilized.

B0033 Q.67 What is the function of the main thrust bearing?

Ans. (b) Transmitting propeller thrust to the hull.

In case of thrust bearing, there is a thrust collar and a pad. Due to the power produced by the engine,
axial

thrust is produced because the power is transmitted to the propeller shaft and the load is taken by the

propeller blades. This loading of the propeller blades will try to push the propeller inwards and along
with

that the thrust will be transmitted in the form of axial thrust to the propeller shaft and then to the
crankshaft.

This thrust will be transmitted to the ship side through the collar which is an integrated part of the
propeller

shaft or the crankshaft and the pads which are fitted on the forward side during the forward running and
to

the aft side during the astern running. The thrust is transmitted to the ship’s hull as this is useful which

helps in moving the ship in the desired direction.

Q.68 The main function of compression ring is to

Ans. (c) seal the space between the piston and the liner.

High pressure gases due to combustion enters behind the piston rings. This pushes the piston rings in
the
outward direction to have a good contact between liner and the piston rings. At the same time, piston
rings

are also pushed downwards on the piston ring landing grooves. Thus it forms a complete sealed space

above the piston rings in between the liner and the piston. Hence the force of gas behind the piston
rings

which forces the piston rings outwards is of prime importance. If the piston rings are seized or the
grooves

are not clear i.e. it is obstructed with carbon, there is a possibility the piston rings will not have proper

contact with the liner and blowpast will take place which will cause breaking of piston rings and scuffing.

Q.69 The function of diesel engine piston compression ring is to

Ans. (c) to transmit heat from the piston to the cylinder liner.

As the cylinder liner is better cooled off than the piston and in order to keep the piston and the piston
rings

in cooled condition to have better lubrication between piston rings and the liner, it is necessary that the

piston rings should be kept as cool as possible. When the piston ring is in contact with the liner, some

amount of heat from the piston is transmitted to the liner via the piston rings thus keeping the piston
crown

and the rings in cool condition, thus promoting the lubrication between the liner and the piston rings.

Q.70 Diesel engine piston ring gaps can be straight-cut or angle-cut. In compression rings the angle

cutting

Ans. (d) decreases the combustion gas leakages.

Due to the angle-cut rings and if they are left and right cut, if they are fitted alternatively, the resistance

offered for the gas to flow through the gap between piston rings end i.e. butt clearance, is more. Hence
less

leakage takes place from the top of the piston rings to the bottom of the piston rings through the gap

between the piston rings. Hence angle cutting is more preferred than straight cut. But in angle-cut rings,
the

joint at the cut position will be slightly weaker than the straight-cut rings.

Q.71 Modern marine diesel engines equipped with mechanical fuel injection operates on combustion

space within the cycle which is

Ans. (c) combination of constant volume and constant pressure.

In the mechanical fuel injection system, when fuel is injected the piston is approaching TDC, but the fuel
is

not injected exactly at TDC but much earlier than TDC. During this time, the volume is changing. At the

same time, when the piston is at TDC when firing takes place though the pressure is increasing but as
the

piston is moving downwards the volume increases and the pressure remains constant. Thus there is a

combination of constant pressure and constant volume which helps to have a better thermal efficiency
as

compared to other fuel injection systems.

Q.72 Which of listed design is successfully used to provide the turbulence necessary for proper

combustion in the diesel engine cylinder?

Ans. (c) Precombustion chamber.

The precombustion chamber is a part of the cylinder head where fuel is injected and combustion takes
place

in this chamber. This chamber is made up of spherical shape and because of the geometry of the
chamber

better turbulence is achieved. If the fuel is injected in this condition, it is burnt effectively and thus
causing

better combustion and thermal efficiency increases. These engines were used in earlier days but at
presently

they are not utilized because the geometry of the combustion space is made in such a manner including
the piston top so as to have a turbulence created inside the main cylinder head rather than having

precombustion chamber.

Q.73 The purpose of counter-boring the top of the cylinder liner extending to the top of point of

travel of the top compression ring is to

Ans. (c) prevent wear of the liner to form ridge at the upper level of the ring crown.

Counter-boring is the word utilized to give the tapered shape to the top of the cylinder liner. Because of
the

tapered boring the formation of ridge is reduced or it will not take place as there is gradual change in
the

diameter of the liner. Hence if there is any ridge formation it will be removed and any metal will not be

allowed to form a ridge. If ridge formation takes place there is a possibility that the piston rings will hit
the
ridge which may cause the rings to crack and the liner to break.

Q.74 The most rapid period of fuel combustion in a diesel engine cycle should begin just before the

piston reaches the TDC and

Ans. (d) should be completed just after the TDC.

The maximum possible efficiency of any diesel can be achieved if the most of fuel is burnt near the TDC.

In order to burn it near TDC, it is necessary that it should be injected before the TDC so that combustion

mixture can be formed by the TDC. At the same time, complete combustion should be carried out
before

the expansion stroke begins so that no power is lost. If the combustion continues in the expansion
stroke, it

is called afterburning, in which there is loss of power and high exhaust temperature which gives lot of

problems to the engine and hence result in loss of thermal efficiency. Taking into consideration all these

things, it is necessary that the completion of the fuel burning should be shortly after the piston crosses
the

TDC position and should not be continued longer than this.

Q.75 Exhaust gas pyrometers are useful for

Ans. (a) detecting faulty combustion in an individual cylinder.

Pyrometers are fitted on the individual cylinders. The exhaust gas temperature is a direct indication of
any

fault in the combustion process. If the combustion is late, we have high exhaust temperature and low
power

developed. If the fuel injectors are dripping, it will be revealed by high exhaust temperature. Also, any

exhaust valve is leaking it will be also indicated by high exhaust temperature. This all indicates that the

exhaust gas pyrometers fitted on individual cylinders will give the complete picture of health of
combustion

process. Also if the fuel nozzles are choked or if the rack position is not proper or low in position, it will

also indicated on the pyrometer by low exhaust temperature. Also in case of liner crack near the top
dead

center position, because of water ingress the exhaust temperature will drop. Hence considering all these

problems which can be indicated by the use of exhaust temperatures it is necessary to installed an

individual exhaust gas pyrometer on each cylinder. This can be utilized as a diagnostic tool.
Q.78 Oil control rings functions to

(a) allow proper lubrication of cylinder and compression rings.

(b) reduce the amount of lubrication oil burnt in the combustion chamber.

(c) scrap the excess oil from the liner on the down stroke.

(d) All of the above.

Ans. (d) All of the above.

Oil scrapper or control ring’s job, in case of four stroke engines, as their edges are in downward
direction is

to scrap down the excess oil splashed onto the liner so as to prevent the excess lubricating oil
consumption

and burning of the excess lubricating oil along in the combustion process. Hence excess cylinder

lubrication oil is scrapped. In case the oil control rings are fitted wrongly, the lubrication oil consumption

will increase and the turbocharger and the exhaust manifold will get fouled.

Q.78 The main function of the oil control rings is to

Ans. (b) reduce the amount of lubrication oil burnt in the combustion chamber.

In case of trunk type four-stroke engines the cylinder lubrication is carried out by splash lubrication.
Hence

large amount of excessive lubrication oil is carried to the liner. This excess lubricating oil from the

crankcase which is coated onto the cylinder liner should be scrapped off so that only required amount of

lubricating oil should be available for lubrication and sealing between the piston and liner. If the excess
oil

is not scrapped, it will get burnt in combustion space resulting in turbocharger and exhaust passage
fouling and piston ring getting seized in the grooves due to excess carbon formation. In order to avoid all
these

problems, it is necessary to scrap the excess oil. This is done by the oil scrapper rings with sharp edge

pointing downwards so that when piston comes downwards the oil will be scrapped from the liner and
the

scrapped oil will be dropped in the crankcase.

Q.80 What is commonly used to create turbulence in a diesel engine combustion system?

Ans. (a) Shape of the piston crown.

As the air inlet valve opens, the piston is near TDC and exhaust valve also opens during the overlap
period.
The air entering from the air manifold through the air inlet valve hits over the crown and drives the
exhaust

gas from the cylinder through the already opened exhaust valve. As the incoming air is hitting the piston

crown, the shape of the piston crown very important to create the flow patterns of the air which will be

ultimately useful in creating turbulence for the better combustion of the fuel. Thus the shape of the
piston

crown is of prime importance. This shape will form a spherical combustion space which have better

combustion efficiency and better turbulence. Hence thermal efficiency will increase. In case of two-
stroke

engines, the liner scavenge port configuration and angle at which the scavenge ports are cut is also of

importance to create the turbulence.

Q.80 How many power strokes per crankshaft revolution are there in an 8-cylinder two-stroke cycle

diesel engine?

Ans. (d) 8.

As it is two-stroke engine, for every revolution there is a power stroke per cylinder. As there are 8
cylinders

there will be 8 power strokes per revolution. Hence there will 8 strokes of power.

Q.81 To shutdown a diesel engine after it exceeds the set maximum speed which type of device listed

below is used?

Ans. (c) Overspeed trip.

It is necessary for the engine to trip if the speed exceeds beyond the set speed as the inertia and the

centrifugal forces created because of high speed of the engine will give large amount of stresses onto
the

moving parts which may cause the failure of the moving parts and bottom end bearing bolts. Hence to

avoid these damages, it is necessary that as soon as the speed increases beyond the preset limit the fuel

should be cut-off and the engine should be made to stop. This is achieved either mechanically or

electrically depending upon the engine and the type of injection system fitted. Mostly it is at 10% above
the

normal running rpm. If the engine trips because of overspeed, the restarting of the engine is possible
only

after resetting the fuel lever to the start position and then starting the engine. This is provided so that
continuous stopping and starting of engine is prevented in case if the engine trips and overspeeds.

Q.82 Turbulence is created in the cylinder of diesel engines to

Ans. (b) help mixing of fuel and air.

Turbulence is the swirling movement of the air due to which the air sweeps the complete volume of the

liner and the combustion space. This causes the complete and efficient sweeping action thus leaving
behind

no exhaust gases from the previous stroke. Also because of the sweeping action, the fuel will be
properly

mixed with the air and complete air in the combustion chamber will be available for combustion rather
than

forming isolated pockets of combustion. This helps in better mixing between fuel and air and hence
better

combustion and hence thermal efficiency increases and fuel consumption decreases.

Q.83 To function properly oil control rings used on diesel engine must distribute sufficient oil to all

cylinder parts and also

Ans. (b) prevent excessive lubrication from reaching the combustion space.

The oil control rings or scrapper rings are used in the trunk type of diesel engines so that excessive

lubricating oil which is splashed on the liner walls should be removed and drained back into the
crankcase

so that excessive lubrication will not get carried away by the exhaust gas into the exhaust manifold and

turbocharger which may otherwise get fouled because of the lubricating oil burning in the exhaust
piping

and the combustion space. As this oil cannot withstand high temperature, it will get burnt and form
large

amount of carbon deposits. These carbon deposits will cause the piston rings to seize or turbocharger

efficiency to drop. Q.84 An important design characteristics of an explosion relief valve of a diesel

engine is its ability to

Ans. (a) close quickly inorder to prevent inrush of air.

Explosion relief valves or crankcase relief valves are non-return flap valves which opens against the
spring

pressure due to the formation of excess pressure inside the crankcase. When the pressure reaches in
the
region of about maximum upto 0.2bars, these valves must open and let the crankcase gases to get
relieved

into the engine room atmosphere. At the same time as soon as this release is carried out, the spring
should

close this relief valve onto the seat. In case of crankcase explosion, viz. the primary explosion and

secondary explosion, if the primary pressure wave created is not allowed to relieve, it will damage the

crankcase and the personnel. This primary explosion leads to the secondary explosion which takes place

due to ingress of fresh air into the crankcase from the atmosphere. If the ingress of air in the crankcase
is

prevented after the primary explosion in such condition a major secondary explosion can be avoided.

Hence inorder to relieve the excess pressure generated into the crankcase and to prevent the ingress of
fresh

air into the crankcase to avoid secondary explosion, the crankcase relief doors are made up of non-
return

type.

Q.85 In modern diesel engines which of the following is used as a support for main bearings?

Ans. (a) Bed plate.

In most of the modern engines, in case of conventional crankshaft, the crankshaft rests on the bottom
half

of the main bearing. The bottom half of the main bearing is resting over the saddle created in the
bedplate.

Thus the complete load of the engine will be transmitted via the main bearings to the bedplate and from

there to the ship structure. But in case of undershrunk crankshafts, the crankshaft will not be resting
over

the bedplate but it is overhanged or undershrunked from the bedplate. This is useful for the easy
removal of

the main bearing for inspection and replacement.

Q.86 Turbulence in the cylinder of two-stroke main propulsion diesel engine is mainly created by

Ans. (d) intake port design.

In case of two stroke engines, having the scavenge ports cut in the cylinder liner, the air enters through
the

scavenge ports. This air is responsible for sweeping clean the cylinder liner of any remaining exhaust
gases
and creating turbulence in the liner and combustion chamber. The entry of air through the scavenge
port is

made at some angle with respect to the circumference of the cylinder liner. In such condition,
turbulence

can be created in the cylinder liner and combustion space. Hence to have a tangential entry into the
cylinder

and to have the proper turbulence created by the scavenge air entering the cylinder liner, it is necessary
to

cut the cylinder liner intake ports at a specific design which will help in promoting the turbulence in the

cylinder of two-stroke engines. As sweeping action by the scavenge air is very important in case of two

stroke engine, the exhaust removal is carried out by the incoming air rather than the upward movement
of

the piston as in case of four-stroke engines.

Q.87 In internal combustion engine, which of the device listed will force the compression rings to seal

the compression gases in the space above the piston?

Ans. The gas pressure acting against the back of the rings

The gas pressure due to combustion of fuel and compression of gas will find its way through the piston
ring

groove clearance i.e. the vertical clearance between the piston ring and the groove. This high pressure
gases

will act on the piston rings from behind because of which the piston rings will be forced radially
outwards

and it will exert a pressure onto the liner thus forming a perfect seal between ring rubbing surface and
the

liner. At the same time, this piston ring will be forced downwards against the piston ring groove by the
gas

pressure thus preventing the leakage of gas between the landing face of the piston ring and the groove.
This

clearance is of very importance and for this the piston ring should be free in the groove so that gas can
find

its way behind the piston rings to form a best possible seal. If this seal is not maintained due to any
reason,

the piston ring will not seal effectively against the liner which will cause the blowpast and ultimately
lead
to scuffing due to the wiping out of lubricating oil film between the liner and piston ring. The gap
between

the groove and the piston ring is maximum for the top ring and it reduces as the piston rings are fitted
away

from the combustion space i.e. the topmost ring will have maximum clearance and the lowermost ring
will

have the least clearance.

Q.89 The size of the exhaust valve opening is

Ans. (b) most critical in two-stroke cycle diesel engines. In case of two-stroke engines the process of
exhausting is carried out with the help of incoming scavenge

air and not by physical movement of piston as in case of four-stroke engines. Hence in two-stroke
engines

the exhausting process is not effective as that in case of four-stroke engines. Hence in order to improve
the

efficiency of exhausting it is necessary that there is no backpressure created onto the exhausting system.
In

such cases, it is necessary to have a maximum exhaust opening possible so that there is no backpressure
on

the exhaust gas to flow. Hence the scavenging and sweeping action in the cylinder liner of the exhaust
gas

is carried out efficiently which ultimately improves the fuel oil combustion characteristics and also it

improves the thermal efficiency of the engine.

Q.90 Provision is to be made for ventilation of an enclosed diesel engine crankcase by means of a

Ans. (d) small breather or slight suction not exceeding 25mm of water.

By ventilating the enclosed crankcase of a diesel engine, the pressure inside the crankcase can be
reduced.

Thus preventing the excess pressure developed which may cause the leakage in the crankcase doors and

crankcase oil may finds its way out. At the same time, it will prevent the development of high

concentration of oil mist in the crankcase. Thus reducing the possibility of crankcase explosion. In
modern

engines mostly, the crankcase external fans are not provided but crankcase weld is provided which is led
to
a remote plate which prevents the excessive built up of pressure inside the crankcase. This pressure
should

not be above 25mm of water gauge otherwise the leakage from the crankcase and the loss of oil will be

very much.

Q.91 Which of the general advantages listed does electrical pyrometers have over mechanical

pyrometers?

Ans. (d) It can indicate temperature at a distant point from the source of heat.

In case of electrical pyrometer which works on the principle of thermocouple and the hot and cold
junction,

due to the temperature difference between the hot and cold junctions, an electric current is produced in
the

circuit. This current is directly proportional to the temperature difference between the cold and hot
junction.

This electric current which is produced due to the temperature difference can be amplified by use of

amplifier and can be relayed through the wire to a remote place from where it can be indicated in the
form

of temperature. Hence with electric pyrometer, it is possible to have a remote indication rather than in
case

of ordinary pyrometer. In ordinary pyrometer, it is not possible to have remote indication of

temperature.

Q.92 In large slow speed diesel engines the force applied to the crosshead is

Ans. (c) against the crosshead during the power and compression stroke.

In a crosshead engine, there is a crosshead shoe with two rubbing surfaces. At the same time, there are
two

crosshead guides one each at port side and starboard side. During the half revolution of the engine one
face

of the crosshead shoe rests against one side of the crosshead guides. This will continue upto BDC when
the

crank turns around the dead center and the piston starts moving upwards. In such condition, the
directional

forces of the crosshead changes and other face of the crosshead shoe will start resting against the other

crosshead guide. Hence for half the revolution one face of shoe and guides are coming in contact and for
the remaining half revolution other face of the shoe and guide are coming in contact. Hence both
crosshead

guides and shoes are required. Sometimes they are called ahead or astern shoes and guides. Hence even
the

engine may be unidirectional, it is necessary to have guides and shoes at both, port and starboard sides.

Q.93 A diesel engine is driving an alternator required to run at 1800rpm. The overspeed governor is

required to set within the range of

Ans. (a) 1980rpm to 2070rpm.

The overspeed governor is to be set at 10% of the rated rpm of the engine As the rated rpm of engine is

1800rpm the governor is to be set at 1980. If the rpm goes above this there is a possibility that excessive

damage can be caused to the running gear of the engine as well as the alternator due to the centrifugal
force

which is created. At the same time, the bottom end bearings may be sheered off. Also the alternator gap

between the stator and rotor. If the speed exceeds beyond particular limit because of centrifugal force,
the

mass of rotating poles on the rotor will try to move away from the center and reduce the air gap
between

the stator and rotor and the stator poles may touch the rotor and may cause severe damage. Hence it is

necessary to control the speed within 1980rpm to 2070rpm.

Q.94 A crankshaft whose center of gravity coincides with its centerline is said to be (a) statically
balanced

(b) dynamically balanced

Ans. (a) statically balanced only.

In case of statically balanced crankshaft the center of gravity through which all the load will pass will

coincide with the center line of the crankshaft. Hence it will not come to the standstill position at the
same

point again and again. In such condition, the entire weight of the crankshaft is evenly distributed but this

does not mean that when it starts rotating, the forces which are created at different planes are
balanced. The

vectors of forces created because of rotation of crankshaft may be in different planes and they may not

balanced though the crankshaft is statically balanced. For dynamic balance we have to carry out the
special
procedure of dynamic balancing so that the vectors created because of the rotation of masses will be

balanced with respect to each other and hence there is no unbalanced vector which is affecting the

crankshaft.

Q.95 & Q.96 MATHEMATICAL

Q.97 Diesel engine valve springs functions to

Ans. (c) close the valves.

Valves of a diesel engine always opens inside the cylinder and closes against the pressure inside the

cylinder. So cylinder pressure acts over the valve lid which helps in keeping the valve closed. In addition
to

this, springs are also utilized which keeps the valve closed because of its upward pressure on the valve.

These springs are of high importance to keep the valves closed onto the seat. The tension in the spring is

also of high importance. If the tension in the spring is too much, the valve will be held against the seat
with

great pressure which will prevent the leakage but it may damage the valve seat. At the same time, for

opening the valve excessive pressure will be required which will cause more amount of weardown to
roller

and cams. If the spring tension is not sufficient, the valve will not close properly on the seat and due to
its

own weight it may fall down and also cause leakage of the valve seat. Hence the spring is the most

important part of valve gear and must be used for properly closing the valve on the valve seat. But in

modern diesel engines, instead of springs of mechanical pressure, nowadays air springs are utilized due
to

various advantages it has over mechanical springs. Also it gives better rotation to the valve which will
keep

the valve seat clean and prevent the burning of the valve and extend the valve life.

Q.98 Built up exhaust valve is one thing in which

Ans. (a) stem and head are made of different material

In earlier days these types of valves were utilized. In these valves the valve spindle and valve head
material

can be selected properly depending on working conditions to which they are subjected. As the valve
seat
and the valve head are subjected to high temperature and corrosion they are made up of special
material

and coated with stelite. In case of valve stem, which is subjected to more amount of wear because of its

reciprocating movement in the valve spindle guide, valve spindle has to be wear-resistant. This is
achieved

by providing a wear-resistant material for the valve spindle. Hence in order to achieve best result from
all

aspect of the valve operating condition, it is necessary to make the valve part from the material which is

suitable for the working condition of that part.

Q.99 & Q100 MATHEMATICAL

Q.101 Between the periods of injection and ignition of a fuel a diesel engine crankshaft rotates

through the

Ans. c delay period.

The time between the injection and ignition is called delay period. This delay period is caused because as

the fuel enters the combustion space, it takes some time for it to mix up with the hot compressed air
and

evaporate and to form a combustible mixture. Hence it is not possible to ignite the fuel at the instant it

enters the cylinder, but it takes some time and by the time this delay period is lapsed, the combustion
space

is filled with thorough mixture of air and fuel so that the combustion can take place efficiently. This
delay

period depends on the quality of the fuel. If the fuel is of inferior quality the ignition delay increases. If
the

fuel is of superior quality the ignition delay is reduced. If the delay period is excessively high there is a

possibility of knocking as well as afterburning and loss of power. Q.102 The cylinder liner forming the
cylinder wall and the inside of the water jacket is called a

Ans. (b) wet liner

Wet liner is a liner which is cooled by water and, for cooling by water, it is necessary to form an annular

space between the jacket and outside of the liner so that water can be circulated through this space. For
this

purpose, annular space is provided between the liner outer wall and jacket so water can be circulated.
This
is called wet liner. Q.137 A diesel engine crankcase ventilation system is provided to

Ans. remove the combustible gases.

Inside the crankcase, the oil is getting spread all around due to the moving parts of the

engine. At the same time, this oil is coming in contact with the hot surfaces thus causing

evaporation of oil. If this evaporated oil is allowed to condense, it forms oil mist. This oil

mist is a potential hazard for the crankcase explosion. The only thing that lacks is a spark.

If there is any spark present due to the blowpast or running of any hot part, crankcase

explosion will take place. In order to avoid such occurrence, crankcase is fitted with

ventilation so as to remove the combustible gases which are formed.

Q.138 Most fuel injector nozzles are opened by

Ans. (a) fuel oil pressure.

Most of the fuel injector nozzles presently utilized on the internal combustion engines are

hydraulically operated. This hydraulic pressure is produced by the fuel itself which is

going to burn in the cylinder. Hence when the fuel pump plunger is moving upwards, oil

pressure is developed which acts on the underside annular space of the fuel valve needle.

This results in the lifting up of the needle and the oil, under high pressure, finds its way

through the already unseated fuel injector needle and is forced through the fuel injector

holes as a fine stream. As soon as the pressure drops, the spring pressure will be more

than the hydraulic pressure and the valve snap closes on the seat.

Q.139 The bearing used to support the crankshaft are generally called

Ans. (c) main bearings.

Main bearings are the bearings which support the crankshaft. The full load or the full

power developed by the engine is transmitted to the crankshaft through various moving

parts such as pistons, connecting bearing, crosshead bearing, bottom end bearing and

ultimately to the crankshaft. From crankshaft, it is transmitted to the propeller shaft. At

the same time, the downward forces acting on the crankshaft are taken care of by the

bearings which supports the crankshaft. Hence they are called the main bearings as they

are the most important bearing of the system. If they are not of proper strength or are

worn out, the crankshaft may get deflected and there is a possibility that the crankshaft
may crack. Also, the complete alignment of the engine is fully dependent on these

bearings; hence they are called main bearings.

Q.140 Injection pressure in a common rail fuel system is controlled

Ans. (d) by a bypass valve.

In common rail system of fuel injection, common piping supplies fuel to the individual

injectors by a branch pipe which is the feature of the common rail system. This pipe and

the full system is under high pressure i.e. the injection pressure. To control this, a bypass

valve is utilized which is fitted at the end of the common pipe. By closing or opening this

valve, more or less, the fuel is bypassed from the system back to the suction of the pump,

thus reducing the pressure.

Q.141 In internal combustion engines, the crankcase vent outlets must be equipped

with

Ans. (b) corrosion resistant flame screens.Corrosion resistant flame screens are required on the vent
outlets of the crankcase, in

internal combustion engines, in order to prevent spark from outside to enter the

crankcase. As the crankcase atmosphere is full of oil mist, it is only waiting for the spark

to come in contact to have an explosion. Under any circumstances, the spark must be

prevented from entering the crankcase. For this purpose, it is necessary to have the flame

arrester fitted on the crankcase breather. At the same time, this flame arrester should be

maintained in clean condition so that it should have better heat transfer property so that it

can extinguish the flame before entering the crankcase. It is therefore necessary that there

should be not any rust formation on the screen because of which the heat transfering

capacity and the efficiency of the arrester would be reduced. Taking into consideration

the above conditions, it is necessary to provide a rustproof flame arrester screen on the

crankcase vent outlet.

Q.142 What is to be installed on an internal combustion engine if a cylinder bore

exceeds 200mm?

Ans. (d) Explosion relief valves.

The engines having cylinder bore that exceeds 200mm are generally highly rated engines
with high peak pressures. At the same time, most of these engines are compressed air

started engines. Taking into consideration these conditions, it is necessary to prevent the

excessive build-up of pressure inside the cylinder as this excessive pressure may put the

parts of the engine under heavy stresses, which may cause mechanical failure of these

parts. Hence, in order to avoid this, it is necessary to provide a cylinder relief valve on

these engines.

Q.143 Cylinder lubricating oil for a low-speed main propulsion diesel engine is

admitted to each cylinder during

Ans. (b) the compression stroke.

Cylinder lubricating oil, for lubricating the piston rings and the liner, has to be admitted

when the piston, piston rings and the liner are in cool condition and the piston is moving

upward so that oil can be retained on the piston rings and sprayed by the piston rings on

the liner walls. This is only possible during the compression stroke. Otherwise, the piston

is hot and if the lubricating oil is sprayed on it, it will evaporate very fast and will not

carry out any work of lubrication. At the same time, if lubricating oil is injected during

the expansion stroke, i.e. when the piston is moving downwards, it will have a scrapping

effect rather than lubrication.

Q.144 What is the purpose of the window installed in the housing of an individual

jerk-type fuel pump?

Ans. (a) To allow the pump to be timed with the engine.

Through the window of the fuel pump housing, it is possible to see the movement of the

sleeve up and down. The sleeve has one marking only. At the same time, the sides of the

window also have one reference mark. When the reference mark on the sleeve starts

moving upward, it indicates that the plunger is moving upward. When the mark on the

upward moving sleeve coincides with the mark on the pump body, it indicates that the

upward moving plunger has closed the suction port of the fuel pump. This is the beginning of the
injection. This can be checked on the flywheel and, if required, can be

adjusted. The end of the injection will be dependent on the amount of fuel to be injected.

Q.145 Which of the following listed construction details of the internal combustion
engines is required?

Ans. (a) A warning notice of caution against the opening of a hot crankcase for a

specified period of time after shutdown.

On most of the modern engines, the crankcase doors has been put up with a warning or

notice as not to open before particular time has lapsed. The crankcase is full of oil spray.

This oil spray will be spread over the hot surfaces of the crankcase and will get

evaporated into oil mist. This oil mist, when comes in contact with the hotspots, causes

the explosion. Most of the times these crankcase explosions do not occur as the

atmosphere in there is too rich to cause an explosion. If the crankcase is hot due to some

reason and oil mist has been already formed, under such circumstances, if the crankcase

door is opened before allowing sufficient amount of cooling, there will be ingress of fresh

air. This will try to dilute the crankcase atmosphere and bring it into explosive range and

an explosion might occur. Thus it is necessary to wait for specified amount of time before

opening a crankcase door.

Q.146 Which statement regarding the arrangement and location of explosion relief

valve used on internal combustion engines is true?

Ans. (b) Minimising the danger from emission of flames is a key consideration.

When a crankcase explosion takes place, the crankcase relief door opens and allows the

hot gases to get relieved through the relief door. Along with this, there is a possibility of a

flame emerging from the crankcase relief door. An arrangement should be made on the

crankcase relief door so that this flame and hot gases will not emerge directly and create

danger for the personnel working in the engine room. Hence it has to be deflected to a

safer place. This is carried out by a deflector plate on the outside of the crankcase relief

doors. At the same time, inside of the crankcase relief door is provided with a flame

arrester valve which also cools the flame before it emerges in the engine room

atmosphere. Thus it prevents the spreading of fire in the engine room.

Q.147 The term “proper metering” as applied to a diesel engine injection system can

be best defined as

Ans. (a) delivering the same quantity of fuel to each cylinder for each power stroke
depending upon the engine load.

It is necessary to inject particular quantity of fuel oil, for a specified load, in order to have

proper combustion of the fuel and the best thermal efficiency of the engine. Also it is

necessary that this fuel oil should be injected at the right time. In addition, it is necessary

that all the units get equal quantity of fuel so that the engine will be mechanically and

thermally balanced. For this purpose metering is done. The process of injecting the right

quantity of oil at the right time and to distribute equally for all the cylinders so as to have

the full power balancing of the engine is called metering. Actually, metering is the word

used for measuring the fuel equally for all units.

Q.148 One function of the fuel pump delivery chest valve is to Ans. (c) help the injector needle reset
without dribbling at the injection nozzle holes.

The fuel pump delivery valve is designed in such a manner that it has got one portion of

the valve in the form of a piston. This piston form of the valve will help in preventing the

smart closing of the valve. In other words, it will delay the closing of the valve because

of the drag effect. This delayed closing of the valve will help in relieving the pressure

wave caused due to sudden closing of the fuel valve needle on the seat. As this pressure

wave is reduced, it will not have any effect on the fuel valve needle. If this pressure wave

is not reduced, then as the delivery valve of the fuel pump is closed, it will cause the fuel

injector to open for the second time thus causing secondary injection. This is not

desirable as it would increase the exhaust temperature and reduce the power generated

and increase the specific fuel oil consumption. Hence the fuel pump delivery valve does

this function quite efficiently.

Q.149 The rate of fuel injection in a diesel engine cylinder depends primarily on

Ans. (a) the size of holes in the fuel nozzle.

Taking into consideration the size of the holes, the volume of the fuel injected through

each hole will depend upon the diameter of the hole because the length of the hole is

constant for a particular fuel injector nozzle. Also, as the hole size of the injector

increases, the droplet size increases. As the droplet size increases, it has more penetration

into the cylinder volume. Hence it can overcome the compression pressure of the
cylinder. Taking into consideration both these aspects, the diameter of the hole of nozzle

will be the main governing factor for the rate of fuel injection.

Q.150 The fuel injection system meters, atomize, and

Ans. (c) inject the fuel at the right time.

Fuel injection system has many functions to perform. One of the functions is to inject the

proper amount of the fuel which is determined by load on the engine and through the

governor. Secondly, it has to atomize the fuel by passing the high-pressure fuel through

the fuel injector nozzle having tiny holes so that it would be spread in the form of oil

mist. One more important function of the system is to inject the fuel at the proper time.

Right time fuel injection is the most important aspect of the efficient burning of the fuel.

This is carried out by the helix cut on the plunger or with the help of the * spring valve.

Hence, in most of the engines, the proper timing is the beginning of injection time

because the end of the injection timing is governed by the quantity of the fuel injected.

This is achieved by the time when the upward moving plunger closes the inlet port of the

fuel pump or when the fuel pump plunger moves upward and the suction valve closes.

Q.151 The valve cam slope angle determines the

Ans. (b) acceleration rate of valve closing and opening.

As steeper the slope angle of the valve, more abrupt is the opening and closing of the

valve. At the same time, this gives lot of stresses on the operating mechanism of the

cams, the rollers and the pushrods. The best possible efficiency can be obtained from the

cam when the flank of the cam is kept tangential to the base surface which gives snap

opening and snap closing, without undue stresses on the operating mechanism of the

cams. Especially in the case of the inlet and exhaust valves, the closing and opening should be fast
enough to avoid the throttling effect which may be encountered during the

opening and closing. Steeper the angle, the valve will open and close faster.

Q.152 The engine displacement is equal to the cylinder

Ans. (b) area x stroke x the number of the cylinder.

The displacement of the engine is the displacement volume caused by the engine or the

swept volume of the engine piston, together for all units. Hence the displacement is
calculated by multiplying the cross-sectional area of the cylinder and the stroke of the

piston which gives the swept volume for one cylinder. When this is multiplied by the

number of cylinders, it gives the total swept volume for the engine.

Q.153 Cylinder diameters greater than 230mm require additional safety devices

when the scavenging spaces are openly connected to the cylinders. Which of the

following devices will be used to protect such spaces?

Ans. (b) Explosion relief valves.

When the under piston scavenge spaces are directly connected to the cylinder, in such conditions if
there is

blowpast due to the any reasons (such as broken piston rings, excessive liner wear, seized piston rings in

the groove), it will cause scavenge fire. When scavenge fire takes place, there is a possibility of explosion

occurring inside the scavenge space because of the availability of combustible material, hot gases or
sparks

blowing past and plenty air available in the scavenge space. In order to avoid such explosion, it is
necessary

to relieve the pressure if it gets generated. This is carried out by the explosion relief valves.

Q.154 A loop or cross scavenge engines utilizes the motion of its piston and turbocharger to provide

scavenge air. Which of the listed mechanical design prevents the air under the piston from being
pumped

back through the scavenge ports during the piston travel?

Ans. (b) length of the piston skirt.

Q.159 The duration of fuel injection developed by the individual port and helix fuel injection pump is

determined by

Ans. (b) effective pump stroke.

Effective pump stroke is the stroke when fuel is delivered by the pump. It will not take into
consideration

the idle stroke before the up-moving fuel pump plunger covers the suction port or the movement of the
fuel

pump plunger after the completion of the delivery stroke. Hence the position the fuel pump will be
decided

by the time through which the fuel is actually delivered. When the fuel pump plunger is moving
upwards,
as soon as it covers the ports, fuel injection is started. This is the beginning of the effective delivery
stroke.

As the plunger moves upwards, depending upon the load on the engine, the rack position of fuel pump
will

rotate the fuel pump plunger. Thus, for every load, there will be a definite disruptive position between
the

helix cut on the fuel pump plunger surface and the suction port. When the plunger is moving upwards, a

point will come when the top of the plunger, i.e. the high pressure side, will get connected to the
suction

side thus relieving the high pressure and causing the end of injection. This is the end of effective delivery

stroke. The quantity of the fuel injected will vary as per the effective delivery stroke which is controlled
by

the governor through fuel pump rack.

Q.160 The plunger in a jerk pump is rotated until the release port is uncovered. If the port remains

uncovered all the time which of the listed operation will occur?

Ans. (a) no fuel.

When the plunger is moving upwards, the fuel pump as soon as the top of plunger covers the suction
port,

the oil on top of the plunger will get compressed and pressure will be developed and injection will

commence. As soon as the top of the plunger will get connected through the helix to the suction port,
the

suction and the delivery side will get short-circuited and hence no pressure will be developed on top of
the

plunger which will cause the end of the delivery stroke. If the rack position is nearly zero, even though
the

plunger is moving upwards and is covering the suction port, the helix position is such that it will always
connect the discharge side of the pump with the suction side of the pump thus causing the short-
circuiting

and no pressure will be developed throughout the stroke of the plunger. If no pressure is developed

throughout the stroke of the plunger in that case there will be no delivery of the fuel throughout the
stroke

of the plunger. This is called as a zero delivery stroke.

Q.161 When the lower edge of the spiral begins to uncover the release port, in a jerk pump,
Ans. (b) effective pumping stroke of the plunger ends.

As the plunger is moving upwards and the fuel is getting compressed, the pressure is developed and it
will

cause the fuel injector nozzle to get lifted and the fuel is injected. Depending on the position of the rack

which governs the position of the helix with respect to the suction port, a point will come when the helix

bottom portion will come in contact with the suction port. This will cause the short-circuiting of the fuel
oil

between the high pressure and the low-pressure side i.e. between the top of the plunger and the
suction side.

This will cause a sudden drop in the delivery pressure due to which the fuel valve will close under the

spring pressure thus causing the end of fuel injection and hence the end of effective delivery stroke.

Q.162 The amount of fuel delivered by a helical plunger fuel injection pump is controlled by

Ans. (c) the rotation of the pump plunger.

The surface of the pump plunger has a helix cut on it. These helical grooves on the surface will be

responsible for changing the effective delivery stroke of the plunger. The moment at which the helical

groove connects the delivery side of the plunger with the suction side will be the end of injection. The

position of the helical groove can be changed with respect to the fuel pump barrel suction hole by
means of

rotating the fuel pump plunger while it is moving up and down in vertical position. This movement of the

plunger with respect to the pump barrel is due the fuel pump rack which is connected to the governor.

Hence depending upon the fuel load, the governor will change the position of the rack. Due to this, the
fuel

pump plunger will rotate and change the position of the helix with respect to the suction holes. Hence
the

quantity of fuel delivered will vary as this causes change in the end of injection timing.

Q.163 Which of the following will occur when lower edge of the spiral on the plunger of a jerk pump

uncovers the spill ports?

Ans. The pressure drops and the fuel delivery stops.

When the lower spiral edge cut of the helix cut on the fuel pump plunger surface uncovers the suction
port

or the spill port, it will have a short-circuiting effect between the top of the plunger and the suction side.
As
the top of the plunger is high-pressure side, when it is connected to suction low-pressure side the
pressure

will drop suddenly on the delivery side. As a result, the fuel pump will have the end of effective delivery

stroke and the fuel valve will close smartly.

Q.164 In a diesel engine, the pistons are attached to the crankshaft by

Ans. (c) connecting rods.

The transfer of the power from a piston to the crankshaft is achieved by the use of connecting rod and

gudgeon pin assembly or connecting rod and crosshead assembly. This connecting rod also helps in

converting the reciprocating motion of the piston into rotary movements of the crankshaft. This part of

engine connects the piston to the crankshaft hence it is called the connecting rod.

Q.165 Which of the component listed is not found in a single acting engine?

Ans. (b) Double crankshaft.

In single acting engine, the action of the fuel burning and load transmission is carried out only on the top
of

the piston and during the downward movement of the piston Hence it requires only one crankshaft to

transfer the power.

Q.166 In diesel engines designed with a crosshead the motion of the engine can be described as

Ans. (c) straight reciprocating.

In an engine with crosshead, the piston has a piston rod which is rigidly connected to the bottom of the

piston and the other end is connected to the crosshead. Hence when the piston moves up and down,
the

piston rod also moves in a vertical direction thus causing the reciprocating movement which follows the

movement of the piston. At the same time it is passes through a stuffing box which separates the
scavenge space from the crankcase space. This vertical movement of the piston rod is converted into the
rotary

movement by the use of crosshead and connecting rod combination.

Q.167 Cast iron piston used in large propulsion diesel engines are constructed with

Ans. (d) the crown being tapered and smaller than the skirt.

The crown of a large engine is always subjected to more heat rather than the skirt and hence the
expansion

of the crown is higher than the skirt. Clearance is provided for the expansion. Otherwise, the crown will
expand to such an extent that it may start to touch the liner and it may cause a damage. In order to
avoid

such things, clearance is kept at higher valve at the top of the piston. This is achieved by using a tapered

crown so that the clearance is maximized at the top of the crown where the temperature is maximum
and

reduced at the bottom where the temperature is minimum.

Q.168 Which of the manufacturing method is recommended diesel engine fuel injection line piping?

Ans. (c) Seamless drawn.

The diesel engine fuel injection piping is subjected to very high pressure, in the range of about 1200bar.

Also, there is sudden increase and decrease of pressure which causes the fatigue in the material. Taking
into

consideration these two things it is necessary that the material and the manufacturing process of the
piping

should be such that it should be able to withstand the high pressure and fatigue. It is also of prime

importance, from the point of view of safety of the ship and fire hazard, that the fuel pipe should not get

cracked under these high pressures. In order to achieve these requirements, it is necessary to use fuel
pump

pipes made up of seamless, solid drawn tubes.

Q.169 The surface of combustion in the cylinder of a diesel engine depends on

(i) fine atomizing.

(ii) high temperature.

(iii) good mixing of fuel and air.

(iv) All of the above.

Ans. (iv) All of the above.

The efficient combustion of fuel will depend on the proper mixing of the fuel and air in the combustion

space and evaporation of the fuel as fast as possible so as to form a combustible mixture. This is
achieved

by breaking the fuel into fine particles and to spread the fuel in the entire combustion space available.
This

is carried out by the fuel injector which will atomize the fuel into fine spray due to which the fuel
droplets
will be broken down into small particles and cause the evaporation of the fuel. Higher the temperature
of

the fuel or the compressed air, the time required for the fuel to evaporate and form a combustible
mixture

reduces and hence greater combustion effect is achieved. As good mixing of fuel and air takes place,
entire

volume of air is available for combustion. Hence full quantity of fuel can be burnt effectively as there are

no pocket formations which will cause local combustion.

Q.170 Which of the combustion parameters listed is use in diesel engine but not related to the

injection system?

Ans. (c) Effective stroke.

Effective stroke is not directly related with the injection system. It will control only the quantity of fuel

which is injected. It will not be related to any of the parameters required for efficient combustion such
as

atomization, metering or penetration.

Q.171 Fuel oil penetration in the cylinder of a diesel engine is

Ans. (b) reduced by the finer atomization.

Atomization is carried out by injecting the fuel with high pressure through the fuel injector nozzle holes

and it breaks the fuel into very minute particles. If the atomization is too much, the particle size will be

very small which will have less weight and hence it will not have sufficient amount of kinetic energy to

overcome the pressure of compression which is existing inside the cylinder at the time of injection.
Hence

it will not be possible for the fuel to penetrate deep into the combustion space, which is filled with high

pressure compressed air, at the end of compression stroke. This may cause the improper burning of the
fuel

as pockets of high concentration of fuel will be created and complete amount of air available will not be
use

for combustion. Q.172 Proper atomization of fuel in the diesel engine combustion chamber will

Ans. (b) improve the combustion.

Proper atomization means breaking the fuel oil droplets into fine particles or to inject the fuel under the

influence of high pressure which will convert the fuel oil into fine spray. This will cause more surface
area
of the fuel available for the contact with air. As the surface area increases, the fuel and air mixing will be

properly done. At the same time, because of availability of more area, the fuel will evaporate fast and
will

form the combustible mixture which is the main important point from the point of view of greater

combustion of the fuel and increasing the thermal efficiency of the engine.

Q.173 What is required for crosshead type engines that have a scavenging space in open connection

to the cylinder?

Ans. (c) The scavenge space to be permanently connected through an approved fire extinguishing

system, entirely separated from the extinguishing system of the engine room.

When the scavenge space is connected to the under side of the piston, there is every possibility of
scavenge

fire if the blowpast of the hot exhaust gas takes place due to worn out cylinder liner or broken piston
rings

or piston ring cut off in the groove. In such circumstances, the hot gases or the spark, entering the
scavenge

space, will start burning the sludge and accumulated oil inside the scavenge space. As plenty amount of
air

is available this scavenge fire may continue for a longer period and it may also go beyond control. Hence
it

is necessary that a permanent arrangement must be provided so that if all other means, such as
stopping of

the engine and covering the exhaust and the turbocharger suction filter with a cloth, fail. In such

circumstances, it should be possible to extinguish the fire by the use of a permanent extinguishing
medium

which is connected to the underside of the piston scavenge space mostly CO2 or steam is utilized. The

requirement for this is very small and it should be independent of the engine room system because if it
is

connected to the engine room fire fighting system, it may possible that you may discharge the complete

safe battery of the cylinder which are actually kept for the engine room fire. In such condition, engine
room

fire fighting equipment capacity will be reduced. Hence the scavenge space fire fighting installation
should

be entirely independent of the engine room fire fighting installation.

Q. 174 Which of the following statement is an accurate description of the fuel injection piping used in

a diesel engine with a cylinder bore of 250mm and above?

Ans. (b) The piping is to be effectively shielded and secured to prevent fuel or the fuel mist from

reaching the source of ignition on the engine or the surrounding.

In case of engines of high capacity or those utilized in UMS ships, it is necessary that if the high-pressure

pipe do burst, the oil or the oil mist should not come in contact with hot surfaces such as exhaust
manifold

so as to prevent the fire. For this purpose, it is necessary to double-walled the high pressure injection
piping

between the fuel pump and the fuel valve. Hence in case of any rupture in the pipe, the outcoming high

pressure oil will not get injected directly over the hot surfaces and will not cause fire in the engine room.

Also in the double-walled pipes, the outer portion of the pipes is connected to a leak-off tank whereby if

any high pressure pipe does crack, the leak-off will led to the leak-off tank where it will give an alarm

which indicates that there is a crack in the fuel piping Q. 223 The rate of pressure rise during the period
following fuel ignition in a diesel engine is

influenced by the length of ignition delay period due to the

Ans. (c) turbulence of the air charge

The turbulence of air charge is of most important as it results in thorough mixing of fuel and air due to

which the fuel oil will evaporate faster and form a combustible mixture in a shortest possible time.
Hence

the ignition delay will be reduced as the turbulence increases.

Q.224 Lower water seal on a diesel engine wet cylinder must allow for liner axial movement. This

seal is most commonly a

Ans. (a) neoprene o-ring.

Neoprene o-ring is fitted at the bottom of the cylinder jacket which seal the cooling spaces from the

crankcase. Hence prevents the cooling water which is circulating around the liner from entering the

crankcase. At the same time, because of the heat generated due to running of the engine there is always
a

linear expansion of the liner; so this should also be taken careof. So neoprene is the right rubber
material
which will allow the rings to expand in the axial direction. At the same time, it will do the sealing job so
as

to prevent the water from the jacket enter the crankcase. Hence it forms a flexible and movable seal

between the jacket and the liner.

Q.225 Which of the device listed is installed in a diesel engine to isolate some of the crankshaft

vibration created by rotational and reciprocating process?

Ans. (b) Torsional vibration dampener.

Torsional vibration dampener is fitted either on the engine crankshaft and driven by it or it separately
fitted

in the engine room platform or in the steering room are controlled by electric motors. These torsional

vibration dampeners consists of rotating masses. The frequency of the vibration caused by these masses

will be out-of-phase with the original frequency of vibration. Hence it will nullify the frequency caused
by

the rotation of the crankshaft thus total frequency of vibration is reduced.

Q.226 Differential type fuel oil nozzle in diesel engine are closed directly by

(a) spring pressure

(b) fuel oil pressure

Ans. (a) spring pressure only

In a fuel injection nozzle, which operates on hydraulic pressure of the fuel oil, the opening of the nozzle
is

carried out by fuel pressure which is developed by the fuel pump. This pressure will lift the nozzle
against

the spring pressure and thus injection will take place. As soon as injection pressure drops in order to
have

the efficient and positive sealing between the needle and landing face. it is necessary to close the needle
by

use of spring force against the seat so it will prevent the dripping. At the same time, the hot gases will
be

prevented from entering the fuel valve nozzle from the combustion space.

Q.227 Modern marine diesel engines equipped with mechanical injection operates on a combustion

cycle which is

Ans. (c) a combination of constant volume and constant pressure.

In diesel engines when the fuel is injected near to the TDC the piston is nearly in a standstill condition
and

change of volume is very low. During that time, when the fuel is injected it burns under the constant

volume condition. This results in sudden increase of pressure near the TDC. Hence the volume is kept

constant but the pressure increases. When the fuel starts burning and piston starts to move towards the
BDC

position, during this period the fuel burns and the pressure rises. Even though the volume increases due
to

the movement of the piston, the pressure remains constant though the volume changes. So the fuel
injection

and burning process is divided in constant volume and constant pressure phase.

Q.228 An efficient seal between cylinder block and cylinder head on many diesel engines is obtained

with

Ans. (d) gasket.

It is necessary to form a gas-tight combustion space between the top side of the piston and the
underside of

the cylinder head. This space has to seal high-pressure gases and this is possible only if the seal is perfect

and without any leakage. For that purpose, it is necessary to have some sealing arrangement between
the

cylinder head and liner. In earlier days this used to be a metal-to-metal contact but to maintain a high-
pressure seal with this is a difficult process. Also, there is a possibility that some leakage may take place

and the liner and the cylinder head landing face may get damaged. In order to avoid this, a soft metal
gasket

is utilized which is fitted between the cylinder head and liner. When the cylinder head is tightened
against

the liner flange, the softness of the gasket will allow it to flow into the small deformities which will be

formed between the cylinder head and liner, thus forming a perfect seal.

Q.229 Oil for piston cooling is delivered through the connecting rod to a compartment in the piston

head. Then, it is distributed as a result of piston motion and finally drained to the crankcase through

one or more holes or pipe. This process is known as

Ans. (c) shaker method.

In the piston cooling, the cooling medium, the oil or water, is conveyed to the underside of the piston
crown by the pipes. There are two pipes for inlet and outlet. The outlet pipe is kept slightly higher so
that

the piston cooling face will always be having some amount of cooling medium places. This cooling

medium gathers the momentum of the piston when the piston moves up and down. Due to this, the
medium

gets the agitating movement and because of this it splashes against the hot piston crown underside and

gives better cooling effect rather than only jet or any other method. At present, most of the engines are

using a combination of jet and agitation method, also called the shaker method, for piston cooling. This

combination gives better cooling efficiency and better running.

Q.232 The breaking up of fuel oil as it enters the diesel engine cylinder is known as

Ans. (c) atomization.

When the fuel enters the cylinder, it is at high pressure and it passes through the small holes of the
nozzle

tip. Due to this, when it is injected through the nozzle tip, it gets broken up into tiny particles which are

useful in efficient burning of the fuel. This is known as atomization.

Q.233 The exhaust ports of a diesel engine using the crossflow scavenging method are closed by

Ans. (c) the reciprocating motion of the piston.

Scavenge and exhaust ports, on a cross flow scavenging system, are cut on the wall of the liner at
different

level. When they are cut on the liner wall at different level, the opening and closing of these ports are

carried out with the piston movement. As the piston moves downward towards BDC, the piston top will

uncover the exhaust ports first and exhausting takes place. When it moves further it will open the
scavenge

ports and scavenging will take place and scavenge air will enter the units. This is called unit injection.

Q.234 Which of the bearing listed below is most widely used for main and connecting rod bearing of

a modern high-speed diesel engine?

Ans. (b) Precision insert.

The precision insert bearings are factory made bearing which are just to be inserted into the bearing
keep

and no scrapping or * of the bearing is required. These bearings are mostly thin shelled white metal
bearing
and they have got better fatigue resistance and high load carrying capacity. Hence they are called
precision

insert bearings. Most of the engines and bearings, where there is fluctuation of load and heavy loading
such

as crosshead bearings and the bottom end bearing, the thin shelled aluminium bearings are utilized.
Even

on many engines, main bearings are also made up of thin shelled bearings.

Q.235 Valve rotors are commonly used on which of the listed diesel engine cylinder head valves?

Ans. (c) Exhaust valve.

When the exhaust gas pass through the exhaust valves it is having some unburnt carbon particles. This

particles will get lodged or get in between. So when the exhaust valve closes there is a possibility that
the

carbon particles may get lodged between the valve and the valve seat. If the carbon particles remains

continuously in that same position, there is a possibility that carbon will burn on the valve seat and
valve.

Due to this, the valve and the valve seat will get damaged and dents will be formed on the valve seat
and

life of the valve will be reduced. In order to avoid this, it is necessary that the valve should be rotated so

that it will have a self cleaning effect and whatever carbon is deposited between the valve and the valve

seat, it will get removed due to the rotation of the valve. This will increase the life of the valve. Hence it
is

necessary to fit a valve rotor on the exhaust valve so as to keep the valve rotating while it is opening and

closing. Q.236 Exhaust valve opening in a diesel engine cylinder head are made as large as practical to

Ans. (c) reduce the pumping loses associated with scavenging.

When the exhaust valve is opened and the piston is moving in upwards on exhaustion stroke, there
should

not be any backpressure on the piston. When there is backpressure on the piston, it will consume the
energy

from the engine for exhausting the gas from the engine through the exhaust valve. Hence in order to
reduce

these pumping losses, it is necessary that there should be no restriction for the exhaust gas to flow
through
and there should not be any backpressure on the piston because of the exhaust gases. This is possible
only

by providing sufficiently large exhaust valve area so as to avoid backpressure and loss of power because
of

pumping effect.

Q.237 Piston cooling fins are located

Ans. (c) beneath the piston crown.

The underside of the piston acts like a cooling area for the piston crown. In this area the cooling medium
is

circulated and the heat transfer takes place at the underside of the piston crown. If the underside of the

piston crown is provided with the fins, as the fins have better cooling effect with sufficiently thickened

crown, we can have better cooling of the crown the thickened crown have more strength. At the same
time

the fin effect will be utilized for better cooling. Hence both, more strength and better cooling effect, is

achieved by having a thicker crown and fins.

Q.238 Diesel engine muffler reduces the noise by

Ans. (d) changing exhaust gas direction.

In the muffler, there are plates which are fitted so that gas passes in a zigzag manner when the gas
passes in

such way there is continuous change in the direction of exhaust gas. Due to this, the dampening effect is

imparted to the waves which are created by the exhaust gas. This causes the reduction in the noise as
well

as vibration caused by the exhaust gas.

Q.239 In the cylinder head of two-stroke diesel engine valves are used for

Ans. (d) exhausting combustion gas.

The two-stroke engine mostly works on uniflow scavenging system. In uniflow scavenging system, the

exhaust valve is fitted on the cylinder head and the inlet ports are cut on the cylinder liner at much
lower

position. The cylinder head valves are only used to take out the exhaust gas. The inlet of air is from the

bottom position so that there will be complete sweeping action of cylinder liner will take place and there
is

a less possibility of exhaust gas mixing with the incoming air. Hence unidirectional scavenging will give
better efficiency. Therefore exhaust valves are fitted on the cylinder head and the inlet ports are cut in
the

liner walls.

Q.241 The intake ports of two-stroke diesel engines are opened and closed by the action of the

Ans. (b) piston movement.

On a two-stroke cycle diesel engine, the exhaust and inlet or only inlet ports are cut in the walls of the

cylinder liner at much lower height from the cylinder top. Hence the opening and closing of these ports
are

controlled by the vertical movement of the piston. When the piston moves down and uncovers the
ports,

scavenge air enters the cylinder. At the same time, when the piston is moving upwards and closes the

scavenge ports, the scavenging process stops. If the exhaust valve is also closed, compression stroke
starts.

Q.242 Compared to four-stroke diesel engines two-stroke diesel engines have the disadvantage of

Ans. (b) high cylinder head temperature.

In two-stroke engine, for every revolution there is one power stroke i.e. for every revolution there is one

fuel firing. This means that the total power developed in individual cylinder head is more. This
contributes

to more heat being developed by the engine as compared to the four-stroke engine. So the cylinder
head

temperature in two-stroke engine is more than that of four-stroke engine. In reality, the exhaust
temperature

of a two-stroke engine is lower than the four-stroke engine because during the scavenging process the
air is

driving the exhaust gas. Along with exhaust gas, some amount of cold air is expelled from the cylinder
due

to which the mean temperature recorded by the exhaust gas thermometer will always be lower, in case
of

two stroke engines as compared with four stroke engines. Theoretically the exhaust temperature will be
on

the higher side in two-stroke engines than four-stroke engines. Q.243 Which of the listed conditions
will affect the mean effective pressure the most in a diesel engine

cylinder?
Ans. (c) Completeness in the mixing of fuel and air.

When the fuel and air is completely mixed and fuel is fully vaporized, the combustion efficiency will

always be better because the fuel will burn efficiently in the allocated time and resulting in high peak

pressure. When the peak pressure increases automatically, the mean indicated pressure also increases
and

more power will be developed by the engine.

Q.244 In comparing engines of equal horse power higher exhaust gas temperature occurs in a

Ans. (d) four-stroke cycle diesel engine.

In four-stroke cycle diesel engines, the mixing of the incoming air and outgoing exhaust gas through the

exhaust valve is less because the expelling of the exhaust gas is carried out by the movement of the
piston

and not by the incoming air in case of two-stroke cycle engine. In two-stroke cycle engine, the expelling
of

the exhaust gas is carried out by the incoming air. Hence, there is mixing of fresh air with the exhaust
gas

and some amount of incoming air is being exhausted along with the exhaust gas through the opened

exhaust valve. Therefore exhaust temperature registered by the thermometer always drops. But, in case
of

four stroke engines, the exhausting is carried out by the upward movement of the piston and it is not
much

assisted by the incoming air. So in the exhaust manifold less amount of incoming air is exhausted. Hence

the exhaust temperature of four-stroke cycle diesel engine is more than two-stroke cycle diesel engine
for

the same amount of power developed.

Q.246 Which of the bearing listed are most widely used for the connecting rod and main bearing of a

diesel engine?

Ans. (c) Precision insert.

Q.247 Which of the following is an example of a solid bearing?

Ans. Piston pin bushing.

Piston pin bushing, i.e. the gudgeon pin bearing, is a solid bearing as it is not in two halves. It is bush
which

is shrunk-fit into the boss of the connecting rod top end thus forming a solid bearing.
Q.248 The upper section of piston is called the

Ans. (c) crown.

It is the portion of the piston which takes the full load of the combustion. It is subjected to highest

temperature and pressure, and wear down.

Q.249 In a diesel engine, the main bearings are used between

Ans. the crankshaft and the engine block.

The main bearings are used for supporting the crankshaft on the engine blocks. Thus it is necessary to
use

the main bearings in between the crankpin bearings so that the crankshaft will be properly supported
over

the entire length by the bearings at equal distance. This will prevent the bending and sagging of the

crankshaft and it will transfer the power to the bedplate. This will help in having a rigid bedplate which
will

support the crankshaft and have a proper alignment of the crankshaft.

Q.250 Which of the listed bearing installation is subjected to swinging motion?

Ans. (c) Gudgeon pin bearings.

In the gudgeon pin bearing, there is no relative movement between the pin and the bearing and there is
only

swinging motion which takes place. The swinging is on one side when the piston is moving downwards.

The swinging comes to zero at TDC and BDC and the swinging action turns over the other side as the

piston turns over the dead center and starts moving upwards. Thus there is a swinging action between
the

two extremities which will cause the oscillating swinging of the connecting rod which ultimately gives
the

oscillating movement to the gudgeon pin bearing.

Q.251 Which of the bearing listed is widely used as connecting rod and main bearing on a modern

diesel engine?

Ans. (d) Precision bearing. Precision bearing are thin shelled bearings having more load bearing capacity
and resistance to fatigue.

These are factory manufactured with precision clearance maintained having thin layer of bearing
materials.

Q.252 The proper location for journal bearing oil groove is

Ans. (b) at the side relief where the two shelves meet.

If oil is supplied to the grooves, it can be conveyed very easily and without any pressure drop on the
loaded

bearing, i.e. bottom half of main bearing. Hence for the pumping action of the rotating journal, it is

necessary to supply oil at the side of the journal, at the junction of the bottom and top half, so that the

rotating movement of the journal the oil will be drawn and pressure will be created. This pressure will

cause the wedge type lubricating oil film due to which the hydrodynamic lubrication will be possible. At

the same time, as the grooves are not in the loaded area, it will not reduce the load carrying capacity of
the

bearings.

Q.253 Fuel is admitted to the diesel engine cylinder through the

Ans. fuel injector valve.

The fuel injector valve injects the fuel at high pressure against the compression pressure developed
inside

the cylinder so as to form a combustible mixture and ignite the fuel.

Q.254 Directional intake ports in diesel engines are used to

Ans. (b) induce air swirl.

The intake ports are cut at an angle to the periphery on the cylinder wall so that when air enters through

these ports into the cylinder they get a swirling action. Due to this, the complete mass of air, which
enters

the cylinder, will go on rotating. This rotational air mass will be useful for complete sweeping action of
the

liner. At the same time, it will aid in thorough mixing of air and fuel in the cylinder thus forming a better

combustion mixture and improving the thermal efficiency of the engine.

Q.255 Telescopic pipes to the piston of a large slow speed main propulsion diesel engine are designed

to prevent

Ans. (c) contamination of lubricating oil by water.

When the piston is water-cooled and water is conveyed to the underside of the piston crown, it has to
be

conveyed through the telescopic pipes because there is a continuous vertical movement of the piston.
To
achieve this, telescopic pipes are utilized which will give the sliding sealing between the stationary pipes

and reciprocating piston. For this, there is telescopic and gland packing is utilized in order to prevent
water

from leaking into the crankcase; otherwise crankcase contamination will take place in crankcase.

Telescopic pipes, arrangement along with the carbon seal provided, will prevent water from
contaminating

the crankcase oil.

Q.257 Large slow speed main propulsion diesel engine uses sea water to directly cool

the

Ans. (c) scavenging air.

Scavenging air temperature before cooling is in the range of more than 100°C which is to

be cooled to about 40°C. At the same time, the quantity of air available is also very large

and air is having a low thermal conductivity. Hence to cool such large quantity of air

through such a large temperature difference it is necessary that cooling medium should

have a good cooling efficiency. Otherwise if it is cooled by any other medium in such

cases the cooler has to be very big. Also, seawater being a convenient medium can be

thrown overboard after cooling and new abundant cooling medium is available. Hence

cooling is carried out by seawater directly rather than indirect cooling or by using any

other medium. Seawater cooling is most efficient method of cooling scavenge air.

Q.258 The purpose of mist detector in a main propulsion diesel engine is to warn of

Ans. (a) excessive mist density in the crankcase.

Oil mist detector continuously samples the atmosphere of the crankcase and compares it

with the average atmosphere or the atmosphere in the engine room. Hence any change in

the density of oil mist will be immediately revealed or brought to notice by means of

audio and visual indication. The high density in the crankcase is a direct indication that

there is hotspot present in the crankcase because of which the oil is getting evaporated

forming oil mist which may lead to crankcase explosion if ignored. Hence high oil mist

density alarm which is given by oil mist detector is a safety alarm and immediate action

should be taken inorder to avoid future destruction to the engine as well as the danger to
personnel working in the engine room.

Q.259 One method of constructing large marine diesel engine and reducing the

frame weight is through

Ans. (b) welding plates to form the section for assembly.

In earlier days the frame and the bed plate assembly were made up of casting. Compared

to the casting the plates which are rolled has got more strength and by assembling it

properly and proper welding, it is possible to construct a structure which has got more

strength for the same weight. Hence it is possible to use a welded structure so that the

weight of the structure is reduced and its strength is increased. Hence in present

generation of engines, the longitudinal girders are made up of steel plates. They are

welded in between with the transverse girders which are made from the casting because

their intrinsic structure is difficult to fabricate. The total welding of these two different

parts of bedplate has been generated into a box type bedplate which has high strength and

low weight.

Q.260 Which of the fuel injection system listed below uses a spring-loaded

differential spray needle valve and an individual pump for each cylinder?

Ans. (c) Jerk pump fuel injection.

In the jerk pump fuel injection, a sudden pressure rise of fuel is achieved. This rise is

conveyed to the needle valve where the high-pressure wave acts under the conical surface

of the needle because of which the needle gets lifted against the spring compression.

Hence the oil is conveyed through the spray holes and it is injected inside the cylinder. As soon as the
suction and delivery of the pump are short-circuited the sudden drop in

pressure of fuel in the pump takes place and hence the pressure in the fuel valve drops.

Under such circumstances the spring pressure is more than the oil pressure and because

of the spring pressure the valve snap closes over the seat and prevents further injection of

fuel or leakage of the fuel. This is one of the best methods of injecting the fuel at right

time and without unnecessary dripping of the fuel from the engine.

Q.261 Concerning diesel propelled vessel the astern power is provided for

continuous operation astern

Ans. (b) at 70% of ahead rpm at the rated speed.

Most of the diesel engines are designed from the point of view of running ahead. The fuel

pump timing, the exhaust valve timing and the distribution of the weight of the rotating

parts is made in such a way that there is a balance in ahead direction. Hence the best

possible efficiency of the engine as far as fuel is concerned is in the ahead direction due

to proper timing for the exhaust and fuel valve. At the same time, there is minimum

torsional vibration because of dynamic balancing which is taken care off at the design

stage from the point of view of ahead running. If the engine is runned at astern direction,

the combustion efficiency reduces. At the same time, because of unbalanced forces, there

will be more amount of vibration. Due to profile of the ship and the efficiency of the

propeller, for the same rpm, the power required for running astern is always more than

that of what is required for running ahead. If the engine is runned at 100% rated rpm in

the astern direction it may be excessively overloaded. Hence it is always provided to give

astern power at 70% of ahead rpm at the rated speed

Q.262 The crankcase of many diesel engine are kept at slightly vacuum by

Ans. (b) crankcase exhaust fans.

(In the olden days, this was very practice but not utilized presently.) By keeping the

crankcase ventilated by use of exhaust fans fitted on the crankcase, the atmosphere in the

crankcase is kept slightly under vacuum. By this, we are depriving the oil mist of air. If

even little oil mist is present it will not cause any major explosion as it may be

excessively rich and it will lack of air and hence possibility of explosion will be reduced

because of excessively rich mixture which will be above high explosive limit. But this

method is no more used as if there is any leakage there is every possibility that air may

enter through the leaky crankcase doors. At the same time, because of the vacuum in the

crankcase, more amount of air may leak through the under-piston scavenge through the

stuffing box into the crankcase or excessive blowpast may take place in case of four

stroke engines.

Q.263 Which of the fuel injection system combines the fuel pump and nozzle in one

housing?
Ans. (b) unit injector.

Unit injector is a combination of fuel pump and injector without any high-pressure pipe

connected between fuel injector and fuel valve. Hence some advantages such as

elimination of pipes and reducing injection delay are achieved. Q.264 In unit injector upper and lower
helix are machined in the lower part of

plunger for

Ans. (c) accurate metering of fuel oil.

By having the helix cut on the plunger and suction hole on the barrel, and positioning the

suction hole with respect to helix by means of rotating the plunger with the help of fuel

pump rack controlled by the governor, it is possible to control the fuel injection timings.

Due to the double helix cut on the plunger surface, it is possible to control the beginning

of injection and end of injection. Thus both the beginning and end of injection is

controlled thus controlling the quantity of fuel injected. Thus proper metering of quantity

of fuel depending upon the load and changing the fuel injection timing with respect to

load is achieved by the double helix cut over each other in the fuel pump plunger surface

of unit injector.

Q.265 Regarding the diesel engine crankcase the general arrangement and

installation should preclude the possibility of

Ans. (a) free entry of air to the crankcase.

The crankcase atmosphere of a diesel engine is full of large amount of small oil droplets

floating in the atmosphere. At the same time, if any hotspot is created in the crankcase oil

mist may also be formed which is susceptible to burning, if sufficient amount of air is

available. As hotspot and oil mist is present, only air is required so that explosion can

occur. If the entire atmosphere of crankcase is entirely filled and because of oil mist,

formed due to evaporation of oil, is rich in concentration and is above the upper

explosion limit and the chances of explosion are less. But if air is allowed to enter the

crankcase, through the crankcase doors or by any other means, then dilution of the oil

mist will take place and it passes through the upper and lower explosive limit. When it

passes through this range, in presence of hotspot, this oil mist may explode and chances
of explosion are very high. This is the main reason that notices are put on the crankcase

doors that the door should not be opened for atleast half hour after the engine has been

stopped.

Q.266 In a diesel engine, internal combustion causes the piston to be moved by

Ans. (a) the pressure of the gases developed.

When the piston is near to TDC fuel is injected. This fuel injected will burn and produce

the heat and pressure wave. This pressure wave will act over the piston. By the time this

pressure wave is created, the piston has already passed the TDC position. As it is turned

over the TDC position, these high-pressure gas acting over the piston forces it

downwards. This phase of the cycle is called power or expansion stroke. Under this

stroke the piston is forced downwards. When the pressure acts over the area of the piston

it produces the force. This force when is multiplied by the distance traveled by the piston,

i.e. the stroke, will give the actual work done by the engine. This work done is taken from

the fuel and is transferred after burning, due to the high-pressure gases produced, by

acting on the cross section of the piston and forcing it downwards. Thus producing the

work or the power developed by the engine inside the cylinder which is termed as

indicated horsepower. Q.267 What function is provided by the crankcase ventilation system on some
diesel

engines?

Ans. To reduce the pressure in the crankcase.

Crankcase ventilation system, whether it is forced or ordinary ventilator with a flame

arrestor fitted, its job is to produce pressure inside the crankcase because in the crankcase

oil in the form of droplets and numerous hot places, such as bearings and pistons, are

always present. Due to this, continuous evaporation of oil is taking place. If these vapors

are not removed from the crankcase, then the crankcase starts getting pressurised. In that

case, oil starts leaking from the crankcase doors. At the same time, consumption of

crankcase oil will increase. If oil mist increases continuously there is a possibility that it

may pass through the explosive range and cause explosion. Hence to avoid this things it

is necessary that the crankcase of the internal combustion engine should always be
ventilated so that whatever gases or oil mist are accumulated will be reduced to safe limit.

Q.268 For diesel engine piston cooling lubricating oil can be supplied to the piston

by

Ans. (a) oil spray.

For cooling of the piston, lubricating oil is the best and convenient medium. Oil is

conveyed to the underside of the piston by different methods: In case of four stroke

engines, it passes from the main bearing to the bottom end bearing; from bottom end

bearing through the drilled passages in the connecting rod, it will be supplied to the top

end bearing where the nozzle is fitted which will inject the oil to the underside of the

piston. In case of two stroke engines, the oil may be supplied through the crosshead and

the telescopic pipe, which are fitted inside the piston rods, the oil is supplied to the

underside of the piston where it will be injected through the drill passages or nozzle so

that efficient cooling can be done rather than any other method. In present engines,

combination of nozzle and shaker method of cooling rather than normal single nozzle or

shaker method is used which gives efficient cooling of the piston. (At present *RTI

engine is using the combination of spray and shaker method.)

Q.269 The purpose of delivery check valve used in a diesel fuel injection jerk pump

is

Ans. to prevent the backflow of oil from the pipe to the pump and also to prevent

the emptying of the delivery.

This pipe has to be filled every time so that pressure is built up resulting in delayed fuel

injection and the injection timing will not be proper. This valve shuts at the end of

injection stroke thus preventing the emptying of injection pipe and backflow of fuel to the

pump. At the same time, the valve is designed in such a manner that the closing action of

the valve under the spring and returning oil is delayed slightly. Due to sudden closing of

the valve, backpressure and the pressure wave created is allowed to get released and

prevents the secondary injection. Also this valve prevents the fuel from entering the fuel

valve till sufficient pressure is developed. Thus in general the valve job is to avoid the

backflow and secondary injection and delivery of fuel to the fuel injector before the
pressure is sufficiently high.

Q.270 In a two-stroke diesel engine the cam shaft rotates at Ans. (c) the same speed as the crankshaft.

In two-stroke engine for every stroke there is one power and one exhaust and inlet stroke.

This power stroke is controlled by the fuel injection and the opening of exhaust valve is

controlled by camshaft. Hence for every revolution fuel has to be injected once and this is

possible only if the camshaft rotates at the same speed as that of crankshaft.

Q.271 The primary function of a delivery check valve assembly is to

Ans. 269

Q.272 For any piston ring to operate smoothly without scuffing, the ring must be

Ans. (b) properly lubricated.

In a diesel engine, when in operation the piston moves up and down vertically. During

this motion the piston rings are forced radially outward to have very high contact pressure

between liner and piston rings thus forming a sealed combustion space. Under this

extreme pressure between the piston rings and liner, it is necessary to have a thin film of

lubricating oil so as to reduce the coefficient of friction between them. If the lubricating

oil film is not present the coefficient of friction will become excessively high because of

which, under extreme pressure, excessive heat will be generated and due to this heat,

instantaneous welding between the liner and piston will take place. At the same time, due

to the vertical movement of the piston ring, this weld will get worn out thus causing the

scuffing. In order to avoid this scuffing, it is necessary that the coefficient of friction

should be reduced. This is only possible if sufficient amount of lubricating oil is spread

over the liner.

Q.273 The upper piston ring in large two stroke cycle main propulsion diesel engine

are most efficiently lubricated by oil

Ans. (a) fed from a mechanical lubricator.

In a large slow speed engine, the stroke of the piston is large. At the same time the piston

is separated from the crankcase by a diaphragm and a stuffing box. Also the oil required

for the cylinder lubrication is of different characteristics, i.e. high TBN, as compared to

crankcase lubricating oil. Hence taking into consideration all these aspect it is not
possible to have the flash lubrication as it is carried out in the small (four stroke) diesel

engines. Also as it is slow speed, it is difficult to splash oil to such a height. In case of

two stroke engines, the oil has to be injected into the cylinder at appropriate time so that

it can be spread over the liner wall and it will be burnt and go out as exhaust. For this

process the necessary timed lubrication is possible only with the help of mechanical

lubricator which are controlled by the camshaft and crankshaft. Thus it is best method of

lubricating the piston ring and in latest engines, like Sulzer RTA, the mechanical

lubricator are in conjunction with the accumulator principle. Some of the modern engines

have electronically controlled cylinder lubrication to give a minimum quantity of

lubricating oil with best possible effect and prevent excessive burning of oil. At the same

time, it avoids weardown because of lack of lubrication. All this is possible because of

mechanical or electronic controlled cylinder lubricating system.

Q.274 Fuel injector nozzles are usually of the multi-orifice type with the number

and placement of the holes arranged according to the Ans. (d) design of the combustion chamber.

Design and geometry of the combustion chamber and the placement of the fuel injector in

the combustion chamber is so that oil can be sprayed evenly in the combustion chamber

and it will be injected deep into the combustion chamber so that it can completely mix

with the amount of air available in the combustion chamber. At the same time, it should

not be injected so deep that it will not burn over the wall of the liner or on the piston top.

This can be achieved only be achieved by taking into consideration the geometry of the

combustion chamber and the number of holes in the fuel injector and the angle at which

oil is injected so that the best thermal and fuel combustion efficiency is achieved without

harming the engine. For this, it is necessary to take into consideration the geometry of the

combustion chamber and design before deciding the number and diameter of holes and

the angle at which the holes are drilled in the fuel injector nozzles.

Q.275 The delivery valve installed in the port and helix fuel injection pump is

designed to

Ans. (b) maintain the column of fuel in the line.

The delivery valve is fitted at the delivery side of the fuel pump and it opens against the
spring force when the plunger is moving upwards in the delivery stroke. As soon as the

delivery stroke ends i.e. the short-circuiting takes place between the suction and delivery

side of the fuel pump, sudden pressure drop takes place on the top of the plunger. As a

result, the fuel from the pipe connecting the pump to the injector will return back to the

suction side. Hence it may be possible that this pipe becomes empty and everytime, for

the next stroke again, you will have to fill this pipe before the fuel injection starts which

will cause the excessive delay in fuel injection. Hence inorder to avoid this, it is

necessary to maintain a column of oil at a slight pressure inside the pipe connecting the

fuel pump to the injector. This is carried out by the shutting of the delivery valve fitted on

the pump so as to avoid the back-flow of fuel from the injector to the pump. Also, this

valve is made in such a manner that there is slight delay in closing time that it will

prevent the excessive development of the secondary pressure wave and secondary

injection is also avoided.

Q.276 The shape of a diesel engine cam determines the

(a) point of opening and closing of valves.

(b) velocity of opening and closing of valve.

(c). amount of valve lift from its seat.

(d). All of the above.

Ans. (d) All of the above.

By taking into consideration the profile of the cam and drawing the figure of the cam, we

can see that the cam is divided into base circle, riding flange, following flange and the

dwell of the cam. The height difference between the base circle and the dwell is the total

lift of the cam. Thus when the cam is rotating, depending upon the profile of the cam,

when the roller comes in contact with the rising side of the flange, this is time when the

roller starts to rise upwards and push the pushrod upwards and it will open the valve. The

lift of the valve will depend upon the movement of the roller and this is decided by the

total lift of the cam. It will remain open till the roller is on the dwell of the cam. Due to

the movement of the cam, when the roller comes at the end of the dwell i.e. it will come on the
following flange or receding flange, this is the time when the roller will start
descending and it will start riding over the receding flange of the cam. This will be the

beginning of the closing of valve. When the roller completely crosses the receding flange

and comes in contact with the base circle, this will indicate the complete closure of the

valve. Thus the profile of the cam decides the opening and closure of valve and the lift of

the valve from its seat. Also, the angle between the base circle and receding or rising

flange will decide the rate of opening and closure of valve. The best possible effect is

achieved when the rising and receding flange will be at tangent to the base circle.

Q.277 Additional explosion relief valve are fitted in separate spaces in the crankcase

such as gear or chain case for camshaft or similar drives when the

Ans. the gross volume of such place exceeds 0.6d x .340m3

Q.278 If all the conditions such as bore, stroke, speed and mean effective pressures

are equal, a two-stroke cycle diesel engine will develop approximately

Ans. (c) twice the indicated horsepower as developed by four-stroke engine.

This is because in two-stroke diesel engine, for every revolution of the engine there will

be a power stroke. The power stroke is responsible for the development of the

horsepower. Hence if all the parameters are equal then it is the number of power strokes

which governs the power developed by the engine. For every power stroke of a four

stroke engine, it will have two revolutions of the crankshaft whereas a two-stroke engine

produces power strokes for each of its revolution. Hence two-stroke engine with all equal

parameters will develop twice the power developed by four-stroke engine.

Q.279 In order to reverse the rotation of the two-stroke cycle loop scavenging direct

reversing propulsion diesel engine the cam position must be changed for

Ans. (a) starting air fuel pumps.

For reversing the engines, it is necessary that it must be started in reverse direction. For

that purpose it is necessary to admit the starting air on the piston before TDC rather than

after TDC. Once the air is admitted before TDC, the engine will run in the reverse

direction. This is possible by changing the air starting distributor timing so that the air

starting valve will open much early TDC and hence the engine will start in reverse

direction. In order to keep the engine running in reverse direction, it is necessary to alter
the fuel injection timing also because fuel pump injection timing is not symmetrical over

the dead center position. It is also necessary to adjust the timing of inlet and exhaust

valve but being a loop scavenging or cross scavenging engine, where the inlet and

exhaust valves are absent and the opening and closing of the ports is controlled by the

movement of the piston, this alteration is not required.

Q.280 Viscous damper as used on a marine diesel engine is a sealed precision built

device which dampens the torsional vibration in the

Ans. (c) crankshaft.

By providing the viscous fluid inside the sealed chamber, the vibration which are created

by the firing frequency of the units on the crankshaft is dampened by providing an equal

and opposite dampening frequency so that total torsional vibrations are reduced. In order to reduce the
torsional vibration, the fluid gives an opposite torque to the vibrations,

which has the dampening effect on the vibrations.

Q.281 The rotary motion of the crankshaft is obtained from the up and down

motion of the piston via the

Ans. connecting rod or crosshead and piston rod assembly.

The vertical movement of the piston has to be converted into rotational movement of

crankshaft. This is achieved by providing a connecting rod which is connected at one end

to the gudgeon or crosshead pin and at the other end to the crank pin which is eccentric

with respect to the arrangement of the crankshaft. Because of this arrangement whenever

the piston moves up and down the crankpin makes a complete rotation and thus converts

the vertical movement of the piston to the rotary movement of the crankshaft.

Q.282 Indirect cooling of a fuel injector nozzle holder of a diesel engine is

accomplished primarily by

Ans. (b) heat conducted into the water jacket wall.

Most of the system cylinder nowadays are made to cool by bore cooling systems. In the

bore cooling system, the water for cooling is brought very near to the combustion space.

Due to this water comes very near to the bore in the cylinder where the injector is fitted

and it is circulated very near the to the seat in the cylinder head where the injector is
fitted. Thus this water is brought so close to the tip of the nozzle and with sufficient

amount of water circulation, heat can be taken out indirectly from the injector through the

cylinder cooling water and thus cooling of the injector is carried out. Also, the circulating

fuel oil helps in carrying out the cooling of injector.

Q.283 Diesel engine main and connecting rod precision bearing are made in two

half. Each half exceeds one-half bearing circumference by a small amount. The

small amount is termed

Ans. (b) the crush.

This crush is highly essential so that when two halves of the bearing are fitted over each

other and has been tightened by bolts the bearing halves, they will have easy flow into the

bearing housing and will have a good first contact with the back side of the bearing

housing thus preventing rotation of bearing in the bearing housing. At the same time, the

load of the shaft is transmitted on the bearing because thin shelled bearing due to its

thinness they are unable to carry out load on their own and so they require some backing

and this backing is possible through the crush. Also due to this crush, there is a perfect

contact between the back of the bearing and the bearing housing and this provides

thermal conductivity between the bearing and the housing. Thus it keeps the bearing cool.

This crush provides the interference fit between the bearing and that of the housing.

Q.284 The port and helix metering pump used in diesel injection systems are usually

designed to produce a constant beginning and variable ending of injection. These

pumps are usually

Ans. (b) timed for port closing and are controlled by the rack movement.

In helix controlled pump, when the plunger is moving upwards and the plunger top closes

the suction port in the barrel, the further movement of plunger upwards will create a hydraulic pressure
on top of the plunger which will cause the fuel valve to open and fuel

injection starts. Thus the fuel injection starts when the plunger closes the ports. At the

end of injection even the port is covered by the plunger which is connected with the

discharge side of plunger by means of helix and that terminates the delivery. The quantity

of the fuel depending upon the load of the engine will depend upon the variable end of
the delivery. The later the end of delivery, more is the fuel injected. This is controlled by

the rack which controls the position of the plunger helix with respect to the suction port

on the barrel thus it controls the quantity of the fuel injected.

Q.285 The end of injection in a port and helix metering pump is controlled by

Ans. short cycling or connecting the delivery ports with the suction ports in the

barrel.

When the piston is upwards and it has already covered the suction port the fuel is being

injected. As it is moving upward, a time comes because of the helix cut on the plunger

surface which short-circuits the discharge side of the pump with that of suction side and it

will cause the end of the delivery. Hence the combination of helix, which is cut, and the

suction port will decide quantity and point of termination of fuel injection. The position

of helix with the port cut in the barrel will be decided by the rack position which will

rotate the fuel pump plunger with that of the barrel.

Q.286 The main reason counterweights are added to crankshaft is to

Ans. (c) provide uniform loading and wear of the main bearing.

Counterweights are provided so as to properly balance the engine statically. At the same

time, an effort is made to balance it dynamically. Though it is not possible to completely

balance the engine dynamically, some efforts are made by counterweights to produce

proper dynamic balance of the engine. When the balancing of engine is proper the load is

equally distributed on all bearings. At the same time vibration is also reduced. This two

automatically reduces the weardown of the bearings and cause uniform distribution of

load on the bearing.

Q.287 For a given size, the two-stroke diesel engine will deliver more power than a

four-stroke diesel engine because

Ans. (c) it develops more power stroke at the same speed.

It is wellknown fact that in case of two-stroke engines for every revolution there is one

power stroke whereas in four stroke engines for every two revolution there is one power

stroke. Hence it is natural that, with same size of the engine and same parameters, it is

only the number of strokes which will be responsible for the quantity of the power
developed. As two-stroke engines have more power strokes compared to the four-stroke

engines, it will atleast theoretically produce more power than a four-stroke engine.

Q.288 In a jerk pump, the amount of fuel that is forced through the spray nozzle on

each upward stroke depends on

Ans. (c) how the plunger is rotated.

In a jerk type fuel injection pump, the quantity of fuel delivered by the injector into the

combustion chamber will depend on the effective delivery stroke i.e. the beginning of the delivery
stroke is mostly constant and the end of the delivery stroke is responsible for the

quantity of the fuel which is delivered. The quantity of fuel delivered will depend on the

load of the engine. Hence more the load more fuel is required and vice-versa. Under such

circumstances, it is the plunger which is rotated by means of rack connected to the

governor. Due to the position of governor, the rack position changes depending upon the

load on the engine. As the rack position changes the rack will make the plunger to rotate

with respect to the barrel and under such circumstances the helix which is cut on the

plunger surface will change its position with respect to the suction port on the barrel. This

relative position of the helix to the plunger surface with respect the suction hole on the

barrel will decide quantity of fuel injected which decides by the termination of the

delivery stroke of plunger of fuel pump.

Q.289 Modern marine engines using mechanical fuel injectors operates on a

combustion cycle which is

Ans. (a) combination of constant volume and constant pressure.

When mechanical fuel injectors are fitted on diesel engines, as soon as the fuel injection

starts, i.e. when the main piston is near to TDC, the volume is nearly constant as there is

no much vertical movement of the piston. When the fuel is ignited, it catches fire and as

the volume constant it develops high pressure. In this condition, the pressure is kept

constant as the volume increases. So part of fuel ignition takes place at constant volume.

As the piston turns over the TDC and start moving downwards, some amount of fuel is

still injected. During this time, the fuel is injected and is burnt, the pressure rises which

pushes the piston downwards. As the piston moves from TDC to BDC, though the
volume increases, the pressure is kept constant. Hence the ignition of fuel is carried out

partly at constant volume and partly at constant pressure. This combination method gives

better thermal efficiency.

Q.290 The amount of fuel oil delivered by the fuel injector is controlled by the

Ans. (c) rack position.

Unit type of fuel injector pump is nothing but a jerk type of fuel pump and a fuel injector

together. Hence whatever is applicable to the jerk type of fuel pump is applicable to the

unit type of system. In unit injector, it is the rack position which will control the position

of helix on the plunger with respect to the suction hole on the barrel. Hence the quantity

of the fuel decided by the position of the rack which will decide the position of helix on

plunger surface with that of suction port on the barrel.

Q.291 The diesel engine valve which is subjected to most severe condition of service

is

Ans. (a) the cylinder exhaust valve.

It is wellknown fact that the exhaust valve is subjected to very high temperature and

pressure of the exhaust gas. At the same time these exhaust gas which passes over the

exhaust valve will consist of some unburnt particles of carbon, ash, silica, or alumina

from the fuel. Under such circumstances, when these gases pass over the exhaust valve,

they try to settle over the valve because of which it will cause the valve to burn or severe

dent may be formed on the valve seat. At the same time, the heat to which this valve is

subjected the strength of the material will reduce and hence there is a possibility of deformation of
valve and valve seat. Hence taking into consideration all these aspects, it

is necessary that proper care of the valve should be taken. If the engine is burning heavy

fuel oil where the concentration of contamination such as ash, alumina, silica, unburnt

carbon is bound to be more, for self cleaning purpose and uniform thermal distribution on

the seat of the valve, it is necessary to make the valve rotate on the seat.

Q.292 For a given fuel, a change in compression ratio will affect the ignition lag by

which of the listed means?

Ans. (b) An increase in compression ratio will decrease the ignition lag.
As the compression ration increases, the quantity of air available for combustion also

increases. At the same time, the temperature of air at the end of compression stroke will

also increase. Due to this the fuel which is injected will vaporize faster and mix properly

with the air and thus it will ignite instantaneously and thus reduce the ignition lag.

Q.293 The lower section of the piston is called the skirt of the piston. This skirt of

the piston is utilized in case of four stroke engine to transfer the

Ans. athwart ship thrust to the liner wall and also guides the piston in the liner.

In case of two-stroke engine, the skirt is very small and it is only in the initial stages that

this skirt is utilized as a rubbing guide which are used only when the piston and liner are

new.

Q.294 What is the function of stationary parts of the engine?

Ans. (c) To keep the moving parts of the engine in their proper relative position.

Engine moving parts are supported by the stationary parts. As long as the stationary parts

of engines, such as bedplate A-frame and cylinder block, are rigid and firm, and they do

not have movement relative to each other, in such circumstances it is possible to give a

support to the rotating parts and to maintain the alignment between the different rotating

parts so as to prevent the malfunctioning and breakdown of the engine. Hence the

strength of the stationary parts is the most important aspect of engine performance.

Q.295 Fuel oil discharged to the diesel engine cylinder is atomized at the

Ans. (b) fuel injector nozzle tips.

As the high-pressure oil passes through the fuel injector nozzle tips, which are having the

very small holes, they are broken up into tiny particles. This process is called

atomization. This is possible by passing the fuel through the holes of the injector under

high pressure. Thus converting the pressure energy of the fuel into kinetic energy partly

and thus breaking the fuel into tiny particles which is responsible for rapid evaporation

and mixing with air in the cylinder and better thermal efficiency of the engine.

Q.296 Proper dispersion of fuel in diesel engine cylinder is dependent on

Ans. injection pressure, shape of combustion space and turbulence pattern in the

combustion space.
Proper distribution and mixing of the fuel with the air in combustion space will ultimately

depend upon how finely the fuel is atomized which is carried out by injection pressure.

Also the depth to which the fuel is distributed in the cylinder volume is also important so

that it can be fully mixed with volume of air which is available and no pockets will be created. This is
possible with the help of the pressure. At the same time, shape and

geometry of the combustion space will also important part in the formation of sphere on

top of the piston so that fuel can be mixed properly with the air. Also turbulence of the

cylinder is also significant for proper combustion of fuel as the motion of air helps in

proper mixing of the air and fuel. Hence for increasing the thermal efficiency of the

engine all the listed factors play an important role.

Q.297 In a diesel engine, crosshatch on the liner surface aids in

(a) rapid ring sealing.

(b) retention of lubricating oil.

Ans. both (a) and (b).

Cross hatch on the liner surface is honing. In this, there is cross honing so that it will

form microscopic cells over the liner wall. These microscopic cells will help in retaining

oil in the cell as well as it will use this oil for rapid sealing and spreading of the oil. The

unevenness which is intentionally caused because of the honing will also be useful in the

rapid weardown of the liner in running-in process. Due to honing the running and

breaking in process of the liner will be shortened and hence better sealing between liner

and piston ring will be achieved in the shortest possible time. At the same time, during

this process of breaking and running, this tiny cells which are formed on the surface of

liner due to honing will act like a oil retaining cells.

Q.298 Why is it necessary to compress the air charge in the cylinder of a diesel

engine?

Ans. (a) To ignite the fuel.

When the air is compressed in the cylinder of a diesel engine, it is compressed

adiabetically. Due to this the temperature at the end of compression increases to the self

ignition temperature of the fuel. Under such circumstances, if the fuel is injected in a
highly atomized condition inside the combustion space, the fuel will ignite immediately

and convert the chemical energy of fuel into mechanical energy of the engine.

Q.299 Which of the following statement concerning a closed type fuel injection

nozzle is true?

Ans. (c) The most closed nozzle open inwards under the pressure acting on the

differential area of the needle valve.

In the fuel injector, the needle sits over the seat by the spring pressure. When high

pressure fuel oil enters the fuel nozzle, it acts over the annular space and the differential

area of the needle valve. As this fuel pressure acts over a greater area, an upward force is

created which overcomes the downward force of the spring thus lifting the needle

upwards. As the needle is lifted, the fuel will pass between the needle and the seat. It will

further act over the needle area thus increasing the area of pressure acting and lifting it

further up and because of this, the full lift of the needle is possible. Under such

circumstances, the fuel under high pressure will pass between the needle and seat and

inject through the nozzle holes. As soon as at the end of injection when the pressure

drops, the spring force will be greater than the hydraulic pressure acting on the

differential area of the needle and the needle will snap close because of the action of the

spring. Q.300 In many diesel engines exhaust valves are being constructed with hollow stem

filled with sodium in order to

Ans. (c) assist in dissipating heat due to the extreme operating temperature.

Sodium is a good conductor of heat and as it does not evaporates easily there is less

possibility of gas or vapour pocket formation taking place and obstructing the cooling

process. Thus when the stem is filled up with sodium the liquid sodium will transfer the

heat in a better way and keep the valve cool. Hence in the older engine this method was

utilized but at presently it is not utilized due to the development taken place in the

material of the exhaust valve and the cooling of the exhaust valve seat with water.

Q.301 Turbulence of the compressed air charge in the diesel engine cylinder

increases

Ans. (c) the efficiency of the engine.

When the turbulence of the compressed air increases, it increases the movement of the air

in the combustion. Due to this, the air sweeps the complete volume of the cylinder with

that of the exhaust gas and hence all the exhaust gas from the cylinder will be removed

and there will not be any gas in the cylinder. Thus the cylinder will be charged with pure

quality of air. Secondly, this motion of air will aide in thorough mixing of air and fuel.

Thus creating a homogenous mixture throughout the combustion space. Hence having a

better combustion of the fuel and increase in the thermal efficiency of the engine.

Q.302 Thin brass rings are inserted in the face of some chromium-plated piston

rings to

Ans. (a) promote the piston ring sealing in the cylinder.

Piston rings are coated in order to prevent corrosion. At the same time, because of

chromium coating the surface of the piston rings become hard and it takes long time to

weardown and form a proper sealing between the cylinder wall and piston ring sliding

surface. Hence there is a possibility of improper sealing between the piston and liner

surface and because of this blowpast of hot gases will take place. Also the chromium

coating will increase the time for breaking-in and running-in period. Hence in order to

have better sealing between piston rings and liner and give corrosion resistance to the

piston rings, they are coated with chromium and an insert of brass is put inside the sliding

surface so that the brass insert will wear down fast and have a proper bearing with the

liner and provide a good sealing.

Q.303 In the Otto cycle the oil fuel is ignited at what time and by what means?

Ans. (c) Just before TDC by spark ignition.

In Otto cycle, the compression pressure is very low and hence it is not possible to achieve

the air temperature to that of the self-ignition temperature of the fuel. Hence it is

necessary to ignite the fuel by means of spark ignition just before TDC.

Q.304 The critical speed in diesel engine occurs when engine torque pulsation

becomes

Ans. (b) resonant with the crankshaft natural frequency. Engine torque pulsation takes place due to the
units firing at different positions of the
crankshaft. Lesser the number of units, less pulsation will take place and higher the

number of units higher the pulsation will take place because the angular difference

between the two firing strokes will be quite large. Also it will depend on the size of the

flywheel. Bigger the flywheel, lesser will be the pulsation on the engine torque. In

addition to this, there is a natural frequency of vibration in the crankshaft. If the natural

frequency of vibration of crankshaft and torsional vibration coincides, these two

frequencies will resonate and total frequency will be excessively high causing excessive

vibration and damage to the engine. Hence the speed at which this happens is called

critical speed.

Q.305 A diesel engine piston ring pitting face is in direct contact with

Ans. (b) cylinder liner oil film and bottom of ring groove.

The sliding face of the piston ring will be in direct contact with the vertical face of the

cylinder liner wall. In order to reduce the coefficient of friction between these surfaces

and to avoid the scuffing and blowpast, it is necessary to maintain the lubrication

between the surfaces which is carried out by cylinder lubrication or splash lubrication.

Also when the cylinder is moving downwards, the pressure acts over the piston ring and

it forces the piston ring radially outward against the liner walls. At the same time, it

forces the bottom of the piston ring against the bottom portion of the ring groove. This

sealing is also important to maintain the pressure behind the piston rings. If this sealing is

not maintained, the piston ring will not seal properly and blowpast will take place.

Q.306 The secondary function of the diesel engine piston ring is to

Ans. (d) prevent excess lubrication from reaching the combustion space.

The primary function of the piston ring is to forms a sealing between piston and the liner

surface. One of its secondary function is to transfer the heat from the piston to the

cylinder wall and thus keeping the piston cool. Also, it has to spread oil over the cylinder

wall so as to spread oil uniformly over the wall and thus reduce the friction between the

piston and the liner. Also due to this, the piston ring and liner wear is reduced. Also, if

excess lubricating oil is given, it will be scrapped downwards by means of scrapper rings

rather than by piston rings. Hence scrapper rings are more useful for scrapping the excess
oil than piston rings and send it back to the crankcase. In case of two stroke engines,

there are no scrapper. In such condition, the quantity of lubrication injected oil is so less

that is only necessary to spread over the liner walls than scrapping.

Q.307 The fuel is ignited in diesel engine cylinder by

Ans. (c) heat of compression.

In a diesel engine, air is compressed adiabetically so that by the end of compression the

temperature and pressure of air increases which reaches about 250°C which is more than

the self-ignition temperature of the fuel oil. Hence at this high temperature when the fuel

injected being at highly atomized condition will ignite and produce power in the cylinder

Q.308 Barrel faced, tapper faced grooved and chromium platted are all types of

diesel engine Ans. (b) piston rings

These are different shape and coatings of piston rings. They are provided to spread the

lubricating oil over the liner walls, to have a scrapping effect of excess lubricating oil or

to reduce the corrosion effect of fuel on the piston rings. They provide sealing between

the piston and liner and accelerate the process of sealing between the liner and piston

rings when they in new condition i.e. to reduce the breaking and running in time.

Q.309 Injectors that use heavy fuel oil must be cooled by water or light oil to

Ans. (d) avoid carbonization of nozzle tips.

When engine is burning heavy fuel oil it is necessary to cool the piston and nozzle tips.

As the nozzle tips becomes hot the seat and needle looses its strength and because of this

the proper sealing between seat and nozzle is not achieved and the fuel injector will start

leaking. Under such circumstances even after the completion of injection, when the

needle is sitted on its seat, some amount of minute drops of fuel will leak through nozzle

holes and it will get accumulated on the nozzle tips. This accumulated oil will burn at

high temperature and, due the local burning, form a carbon formation in the form of like a

flower near the tip of the injector thus damaging the injector and fuel injection pattern.

Hence it is necessary to maintain the temperature of the fuel injection nozzle tips within

certain limit so as to avoid loss of strength and leakage of fuel through the tips. Hence

cooling is an important factor of fuel injector nozzle burning heavy fuel oil. Also as the
fuel oil itself is heated to high temperature and hence the cooling effect of the fuel oil is

comparatively low than in case of diesel engine fuel injector burning diesel oil where the

fuel oil injected during every stroke does the cooling job.

Q.310 Which of the equal power diesel engine listed running at the same speed is

least affected by the exhaust gas backpressure?

Ans. (a) Four-stroke cycle V-type of engine.

In case of four-stroke engine, for every two revolution there is a power stroke so that the

time between two power stroke is more so that the exhaust gas, which is discharged into

the exhaust manifold, will get dissipated through the turbocharger before the next unit

exhaust valve opens. Hence there is a less possibility of backpressure. In addition, if we

are using V-type of engines, where there are two banks of cylinders, they are exhausting

alternatively into the two banks of exhaust manifold. Hence there is a further delay in the

exhausting of two cylinders in the same exhaust manifold. Hence less amount of

backpressure is created in four-stroke V-type engines as compared to two-stroke engine

with any configuration (in-line, or V-type).

Q.311 In a diesel engine, the time taken to heat the fuel particles turned into vapors

and bring about combustion is called

Ans. ignition delay.

The time from which the first particle of the fuel enters the combustion space through the

fuel injector till the time the first ignition starts is called the ignition delay. During this

process, the fuel is atomized, vaporized, mixed with the available air so as to forms a

combustible mixture is called ignition delay. It will depend on the compression pressure

and the quality of the fuel. If the compression pressure is low or the fuel quantity is bad, the ignition
delay will be more. Higher the ignition delay there will be more amount of

power loss due to afterburning effect.

Q.312 In a diesel engine the contact surface of a piston compression ring are those in

contact with

(a) back of the ring groove.

(b) bottom of the ring groove.

Ans. (b) bottom of the ring groove.

For sealing between piston ring and liner, the high pressure gases has to find its way

behind the piston rings and has to force the piston rings against the cylinder wall. This

pressure behind the piston rings is to be maintained in order to get the proper sealing

between them. This is possible if there is proper sealing between the bottom of piston

ring and bottom of the ring groove. If the sealing between them is not properly

maintained, the gas which is acting from behind the piston ring will get leaked off. As

this pressure is lost, there will not be sufficient pressure between the piston ring and the

liner wall and the high pressure gasses will force the rings inwards will cause the

blowpass and ring to collapse and break. Hence sealing between the between the bottom

of groove and bottom of piston rings is also of prime importance.

Q.313 The thermal energy produced by internal combustion engine is transformed

into

Ans. (d) mechanical energy.

When the fuel burns on top of the piston inside the cylinder, it is the chemical energy of

the fuel which is converted into heat energy. This heat energy and the pressure energy

together is acting over the piston thus forcing the piston downwards, thus converting this

energy into mechanical energy to the crankshaft. Thus it is the thermal energy which is

converted into mechanical energy by the engine.

Q.314 The reason that some two-stroke diesel engine piston rings are pinned to

prevent rotation is

Ans. (c) to keep the ring ends from catching in the scavenge ports.

When the rings are pinned in the ring grooves, they are prevented from rotation. The

rings can be initially set up in such a manner so that the ends of piston rings will not

come in way of scavenge and exhaust ports and thus it will be prevented from being

damaged because of getting entangled with the scavenge and exhaust ports and thus

avoid their breaking of the piston rings. Hence in older engines the pinning was done to

prevent the rotation of the rings and to keep the rings in their original position (at which

they are fitted) when they are removed for overhauling and the rings are in new
condition. In modern engines, the ends of the rings are turned slightly inwards so that

when they expand due to heat, they will not get entangled with the scavenge and exhaust

ports and will not break. At the same time, the rings are allowed to rotate in the groove to

give the self-cleaning effect of the groove and to have the even distribution of heat over

the entire circumference of the groove. Hence the pinning arrangement is no longer in

use.

Q.315 Oil control rings are designed with slotted holes to Ans. (d) permit excess oil to drain in the
sump.

The job of the oil control rings is to scrap the excess oil that has been splashed over the

liner walls to prevent the excess lubrication oil consumption and to prevent the excessive

burning of the lubricating oil into the combustion space. Hence it is necessary to scrap

this oil. For this, the scrapping edges are provided onto the oil control rings. As the oil is

getting scrapped, it should get drained into crankcase * and that is carried out by

providing the oil control rings and the small holes in the grooves of the piston rings. Thus

the oil being scrapped will find its way through these slotted holes in the grooves and into

the crankcase sump.

Q.316 Precombustion chamber differs from turbulence chambers as the

precombustion

Ans. (d) contains a small portion of the total clearance volume.

Precombustion chamber is an extension of combustion chamber and fuel is injected into

it. Precombustion chamber is very small chamber in which the fuel is injected. When

firing takes place in the precombustion chamber, due to restricted area, a high-pressure

wave is developed. This forces the remaining fuel and air mixture in the combustion

chamber thus having a proper mixing of fuel and air in main combustion chamber and

have better burning of fuel in the main combustion chamber. Presently, the

precombustion chamber is utilized only in very small engines where the compression

pressure is not sufficient to ignite the fuel efficiently.

Q.317 The primary purpose of oil control rings on a diesel engine piston is to

Ans. (c) prevent excessive lubricating oil consumption.

In a four stroke trunk piston diesel engine the liner lubrication is carried out with the help

of splash lubrication and large quantities of lubricating oil is splashed by the waves of the

crankshaft onto the liner walls. This oil is necessary to spread properly on the cylinder

liner and farther lubrication between the piston rings and liner wall. At the same time,

excess oil is returned back to the crankcase otherwise it will get burnt along with the

exhaust and lubricating oil consumption will increase. At the same time, fouling of

turbocharger and manifold will also take place. Inorder to avoid this things, oil control

rings are provided the job of which is to scrap the oil and send it back to the crankcase

and to avoid excess consumption of the crankcase oil.

Q.318 The compression ratio of a diesel engine refers to the ratio between the

Ans. (b) cylinder volume at top dead center and that of the bottom dead center.

At the bottom dead center, there is large amount of volume available in the cylinder and

air is charged into the cylinder at this volume. If the piston moves upward, due to the

proper sealing of the compression space, the air will get compressed. At near TDC, the

volume of air will be reduced but its pressure will increase. The ratio between the

cylinder volume at TDC and BDC is called compression ratio.

Q.319 In describing basic diesel engine operation the term events refers to

(a) production of high pressure gases .

(b) removal of expanded combustion gases.

(c) admission of air to the cylinder. (d) All of the above.

Ans. (d) All of the above.

In any diesel cycle, there are four events: fuel firing and high pressure gas is produced

which will drive the piston downwards thus producing the power stroke. At the end of

power stroke, the exhaust valve will open and exhausting will take place by which the

exhaust gas will be removed which is the exhaust stroke. After completion of exhaust

stroke, when the piston is moving downwards the cylinder will be filled with fresh air

charge which is called the suction or induction stroke. This continues till the piston

reaches TDC. When the piston is moving upwards all the valves are in closed condition

the air which is available on top of the piston will get compressed to produce high
pressure and high temperature air in which the fuel will be burnt. This is the fourth event

or the compression stroke. All these events together will form one cycle. This cycle can

be completed in one revolution (two-stroke) or two revolutions (four-stroke) of the

engine.

Q.320 The ratio brake horsepower to the indicated horsepower is its

Ans. (b) mechanical efficiency.

Mechanical movement of the piston and the mechanical movement taking place inside

the cylinder and the bearings will result in mechanical loses. The power which the output

of the engine will be the difference between the power which is generated inside the

engine i.e. indicated horsepower minus the mechanical losses. Hence it will be ratio of

losses and indicated loss power. The output of the engine is called the brake horsepower.

Hence the ratio of brake horsepower and indicated horsepower will determine the

mechanical efficiency. More the brake horsepower more the engine will be efficient from

the mechanical point of view.

Q.321 The slots are provided in the diesel engine piston oil scrapper rings to remove

excess oil from the cylinder liner and to scrap and send it back to the crankcase.317

Q.322 The function of piston compression rings used in diesel engines is

(a) to seal the space between the piston and liner.

(b) transmit the heat from the piston to the liner.

(c) reduce the amount of combustion gases blowby.

(d) All of the above.

Ans. (d) All of the above.

The primary function of the piston rings is to form a sealing space between the piston and

liner. This is carried out by the seal between the piston ring sliding surface and the liner.

This is achieved by the gas pressure finding its way behind the piston and forcing the

piston rings against the cylinder liner. Thus forming the gas-tight combustion space. At

the same time, when the piston is in hard contact with the liner and the piston. The piston

is always running at higher temperature than the liner, hence the piston rings does the job

of transmitting heat from the piston to the liner. Also because of the sealing between the
liner and piston, gas-tight combustion space is formed which prevents the blowing out of

the high-pressure gas through the gap between the liner and the piston rings. All these are

carried out efficiently by the piston rings. Q.323 How are the temperature and pressure affected in a
diesel engine cylinder

during compression?

Ans. In the diesel engine adiabatic compression takes place because of which the pressure

of air inside the cylinder increases. Theoretically as there is no heat transfer the

temperature also increases to the surrounding hence they both increase during

compression.

Q.324 Modern diesel engine using mechanical fuel injection operates on combustion

cycle which is

Ans. a combination of constant volume and constant pressure.

Q.325 If the compression ratio is increased on any diesel engine

Ans. (b) the thermal efficiency will increase.

Thermal efficiency will depend upon how efficiently the fuel is burnt and efficient

burning of fuel will depend on the compression ratio. If the compression ratio is high,

more amount of air will be available which will be higher temperature. Hence more

amount of air at higher temperature will give better combustion and minimum ignition

delay. Thus maximum pressure will be developed in the cylinder near the TDC and

because of this, automatically the thermal efficiency will increase.

Q.326 The piston compression rings used in diesel engine functions to

Ans. (c) seal the combustion space from the crankcase.

In case of trunk piston engine, the bottom of the piston is directly connected to the

crankcase and top of the piston is connected to the combustion space. Hence the piston

ring does the sealing between the liner and the ring surface and thus forming a gas-tight

combustion space above piston ring which if properly sealed will prevent the blowing of

the hot gases from the combustion space into the crankcase.

Q.327 At bottom dead center the centerline of the connecting rod usually coincides

with the
Ans. (c) centerline of the cylinder.

At the bottom dead center position the connecting rod will be exactly vertical and the

piston will be at the lowest position of the cylinder liner. Under this position, the

centerline of the connecting rod and the cylinder must coincide to get the proper

alignment between the liner and the piston. If this does not take place, there is a

possibility that the liner will weardown on one side and the piston rings will weardown

on one side and the piston may get seized in the liner. Hence the most important part is to

have coincide the liner and connecting centerline when at TDC of BDC.

Q.328 A diesel engine exhaust valve spring is under compression when

(a) the valve is open

(b) the piston is at TDC

(c) the valve is closed

(d) All of the above.

Ans. (d) all of the above. When the exhaust valve is opened the spring is forced downwards by the
rocker arm and

the spring is under compression. When the piston is at TDC, the exhaust valve is opened

and the spring is under compression. When the valve is closed, due to the initial

compression which is given to the spring it gives equal upward force to the valve and

keeps the valve in closed condition. Hence even under closed condition, the spring is

under initial compression given during the boxing up of the valve and to make sure that

the valve sits on the valve seat properly and without any leakage.

Q.329 The piston is said to be at TDC when it is

Ans. (d) nearest to the cylinder head.

When the piston is moving upwards and the crankpin is at topmost position, at this point

it will start taking turn and start moving downwards. Hence the position where it

momentarily stops and changes its direction is the position of TDC. As there is no

possibility of piston moving upwards further than this position, there will be minimum

space between the cylinder head and the piston top.

Q.330 The purpose of flywheel is to

Ans. (a) provide energy to operate the engine between the power pulses.

In a diesel engine, the firing is not continuous. The firing of the fuel in different units

depends upon the crank position and it is in the form of pulse. Hence depending upon the

number of units, and whether the engine is two-stroke or four-stroke, there is time

difference between the firing of fuel in the two consecutive units in the firing order. In

between two firing strokes, there is a time delay. During this time, the engine will try to

slow down because lack of power available on crankshaft. Hence there will be fluctuation

in the rpm of the engine. In order to avoid, this a heavy flywheel is fitted on the

crankshaft. This flywheel will store the energy during the firing stroke when the energy

level is above the average level and it will give back the energy to the crankshaft when

the energy level is below the average when no unit is firing thus maintaining a constant

torque and constant rpm over the entire load range of the engine. The size and weight of

the flywheel will depend upon the number of units and whether the engine is four-stroke

or two-stroke. If the number of units is more, the flywheel will be smaller size as

compared to engine with less number of units.

Q.331 A 7-cylinder two-stroke cycle single acting diesel engine with cylinder

indicated horsepower calculated to 1350kW and the brake horse power measured at

7466kW has a mechanical efficiency of

Q.332

Q.333 In diesel engine pistons are attached to the crankshaft by

Ans. (c) connecting rods.

The connecting rod or the crosshead and connecting rod assembly will convert the

reciprocating movement of the piston into rotary movement of the crankshaft with the

help of eccentrically situated crankpin on the crankshaft. Q.334 One advantage dry cylinder liner used
in a diesel engine is

Ans. (d) procedure to replace it is simpler than the wet liner.

As in case of dry liner, there is no cooling provided and hence there is no provision for

o-rings at the bottom of the liner and the jacket hence it is easier to replace it than wet

liner
Q.335 Vibration from the diesel engine and engine driven equipments are isolated

from the hull structure by

Ans. (d) flexible engine mountings.

Flexible engine mountings consist of shock absorbing material, such as rubberized cork,

so that it will absorb the vibration created by the machines and those vibrations will not

be transferred to the ship structures or vice-versa. They are known as elastomount and

they have got the property of dampening the vibrations. Only care should be taken while

tightening them that they should not be overtightened; otherwise they will burst. Hence

the tightening of the bolts should be carried out with the help of torque

Q.336 Which of the following statements in a fuel atomization in a diesel engine

cylinder is correct?

Ans. (b) Greater the atomization lesser the penetration.

For greater atomization, it is necessary to break the fuel droplets into microscopic

particles. When they are reduced in such manner their weight reduces and hence their

inertia also reduces thus reducing the force at which it will drill through the dense

atmosphere of air reduces. Thus the potential energy of the particle reduces and it cannot

penetrate the dense atmosphere of the air in the combustion chamber. Hence as the

atomization increases the penetration decreases and vice-versa.

Q337 The most rapid period of fuel injection occurring in a diesel engine cylinder

should begin just before the piston reaches the TDC position

Ans. (d) should be completed after the TDC.

In diesel engine, the best possible efficiency is obtained if the fuel is burnt partially at

constant volume and constant pressure. For achieving this, the fuel injection and ignition

must start just before TDC and it should completed after the TDC. During this time, the

quantity required as per the load should be injected and burnt efficiently. If the complete

combustion takes place before or after TDC, the thermal efficiency will reduce.

Q.338 When comparing different fuel for different engines the ignition quality of

diesel fuel oil becomes a less critical consideration as

Ans. (d) the engine speed decreases.

As the engine speed decrease the time for the fuel to atomize evaporate and mix with air

to form a combustible mixture is ample. When ample time is available, it is possible to

burn lower grade of the fuel with low speed engine. Hence when low grade of fuel is

utilized, less critical consideration is given to the speed of the engine because lesser the

speed of the engine inferior is the quality of fuel which can be burnt efficiently. Q. 359 The power
developed by slow speed main propulsion diesel engine

depends upon the:

(a) quantity of air takes in and retains in the cylinder during a given time period.

(b) proportion of trapped air that is utilized in the combustion process.

(c) thermodynamic efficiency of the engine cycle.

(d) All of the above.

Ans. (d) All of the above.

The power developed by diesel engine depends upon the how efficiently the fuel is

burnt. The quantity of the fuel that burns will depend upon the quantity of the air

which is available at the end of operation stroke. This depends upon the how much

quantity of air taken inside during the suction stroke. At the same time, it will depend

upon the efficiency. Secondly when air is compressed whatever the quantity of air that

is retained at the end of the operation is also important factor. Otherwise if the piston

rings are leaking or broken or stuck up, the quantity of air is taken during the

induction stroke will be higher. The retention of the air at the end of compression

stroke will be low. Under these circumstances, the power developed will be reduced.

Hence the power develop will depend upon the quantity of air taken during the

induction stroke and quantity of air which is available at the end of compression

stroke in the combustion chamber. Lastly, it depends upon the thermodynamic

efficiency of the engine because higher the thermodynamic efficiency of the engine,

the more efficient burning of the fuel and more power develops for the same quantity

of fuel. Hence it can very well be said that all three are most important factors which

will decide the power development.

Q.340 An indicator card or pressure volume diagram shows graphically the:

(a) relation between pressure and the volume during the stroke of the engine.

(b) relation between pressure and volume during one cycle of the engine .

(c) volume of the engine.

(d) the compression ratio of the engine.

Ans. (b) relation between pressure and the volume during one cycle of the

engine.

It shows the relationship between the pressure and volume during one cycle of the

engine. When indicator card is taken, it is drawn with x-axis as volume and y-axis as

pressure. It is drawn for the complete one revolution of the engine. So in case of a

two-stroke engine, it is a two stroke it will represent on the indicator card. Hence it is

a relationship between a volume and pressure for a complete cycle of a engine

because by measuring the area of the diagram of the indicator card, you will be in a

position to estimate the power development in the engine. Power development of the

engine is taken into consideration for the first cycle and not for the first stroke

because for every cycle there may be two strokes or four strokes. The power

developed will be considered for entire cycle, not for particular stroke as such.

Q.341 The cylinder lining constructed as an integral part of a block are

characterized by which of the following disadvantages.

(a) They conduct heat poorly

(b) They are expensive

(c) They cannot be replaced and

(d) They require special tools for removal.

Ans. (d) They require special tools for removal Now when the cylinder liner becomes an integral part of
a cylinder block, it is not

possible to replace the liner in case it is worn out. It is a complete part of the cylinder

block and in such condition, you may have to replace a complete cylinder block or

recondition the complete cylinder block in the way of liner bore.

Q.342 One end of diesel engine cylinder is sealed with the hot air and the other

end by the
Ans. (b) piston.

Air is present on top of the piston and this air is compressed between the cylinder

head and top of the piston thus forming a combustion space holding high pressure and

high temperature air where the fuel injected will burn and produce the power. Hence

the sealing for the compressed air is possible because of the heat which is existing

between the cylinder head and the piston.

Q.343 Where is a charge for an air starting system is stored.

Ans. (b) Presurise tank.

For starting the engine, it is necessary to have large quantity of air at a different

minimum pressure in order to get a large quantity of air at different pressure. It is

therefore necessary that the compressor should be in a position to store the quantity of

air and hence it will be easily available. Also, as per the regulation it is necessary to

have 12 consecutive starts, 6 ahead followed by 6 astern alternatively. Under such

circumstances, unless storage of air is not available, it is not possible to the starting to

many starts for the engine. Hence starting air is highly essential from the of manually

and safety point of view of the engine so that it is possible to maneuver the ship

continuously without even if it has designed very moderate size of the compressor.

Thus the air bottle acts as source of stored energy for the engine to turn during

starting.

Q.344 Maximum power of the diesel engine is attended

Ans. (b) at rated engine speed.

When the engine is designed, all parameters are considered and calculated. During

this time, the rpm is also taken into consideration for calculating a maximum power

which can be developed and given by

Power developed = PLAS.

In this, rpm is most the important part. If rpm is low and the power developed is high,

it may possible that the engine may get thermally overloaded and maximum pressure

may exceed the safe limit. It may also give the cracking to the engine part. Hence it is

necessary that the engine maximum power output can be calculated and attended only
at the rated rpm and not at the lower rpm.

Q.346 During fuel injection period the fuel pressure must exceed cylinder gas

pressure to

Ans. (a) insure penetration and distribution of fuel in the combustion chamber.

When the fuel is injected by opening the nozzle of the fuel injector, the flow of the

fuel is into the high-pressure air. This high pressure air will try to oppose the entry of

the fuel. Hence the fuel, which is entering, has to drill through the dense atmosphere

to move in further away from the tip and mix up with the complete quantity of the air

available in the combustion space. For that purpose, the pressure at which it is injected should be
always more than the compression pressure in the cylinder so that

penetration deep into the dense atmosphere is possible.

Q.348 Telescopic pipe through the piston of a large of a slow speed main

propulsion diesel engine are designed to prevent

Ans. (c) contamination of the lubricating oil by water.

As the telescopic pipe has to convey the water to the piston, it has to pass through the

crankcase or scavenge space. By having the telescopic pipe, it is possible to convey

between the stationery part of the pipe to the reciprocating part of the compressor.

This is possible with the help of telescopic pipe and the gland.

Q.349 The exhaust system for a turbocharged two-stroke diesel engine functions

to

(a) discharge exhaust gases and smoke.

(b) permit energy to turbocharger.

(c) reduce the engine room noise.

(d) All the above.

Ans. (d) All of the above.

As the exhaust valve opens, the high pressure exhaust gas, which is slightly higher

than the atmospheric pressure, will get release from the exhaust from the cylinder. It

will pass through the exhaust valve towards the turbocharger. Thus it does the

function of removing the exhaust gas and the smoke from the unit. Secondly, this
energy which is available in the exhaust gas can be utilized which may be

combination of pressure and heat energy can be utilized for driving the turbocharger

so as to supply the pressure as per the engine. Thirdly, when the exhaust gas is

released from the exhaust of the engine unit it enters the exhaust manifold, which is

also bigger size, dampening of the exhaust gas will take place in the manifold and

because of this it will reduce the noise created by the engine.

Q. 350 Which of the diesel engine exhaust muffler listed is usually equipped with

spark arrester?

Ans. (c) A dry-type exhaust muffler.

Dry-type exhaust muffler has been fitted with a flame or spark arrestor in the form of

a copper. This will cool down the exhaust gas coming out and prevent any flame or

spark from the engine to get distributed on the desk.

Q.351 When monitoring diesel engine performance the most useful instrument to

be used is

Ans. (b) exhaust gas pyrometer.

Exhaust gas pyrometer gives rough estimation of the power developed by the engine.

Higher the power developed by the engine more the exhaust temperature. At the same

time, it can also monitor any discrepancies or problems encountered by the engine. If

the fuel valve is dripping or the fuel nozzle is not spraying properly or the fuel

ignition timing is not proper, even then large variation in temperature will take place.

If the pistol rings are leaking, immediately compression pressure and the peak

pressure will reduce but the exhaust temperature will be high. The exhaust

temperature can be considered as a most important tool to determine the performance

of the engine and diagnose the possible cause of the malfunctioning of the engine or

dropping of the performance of the engine. Q.352 The exhaust system of the diesel engine usually
designed to remove

exhaust gases and to

Ans. (d) muffer the exhaust gas noise.

The pressure waves when the exhaust gas is released from the cylinder has been
dampened by the use of muffler where in the direction of the exhaust gas changes.

This causes the dampening of the noise wave and causing the total dampening of the

exhaust gas noise.

Q.353 The water jacket is placed around the exhaust manifold of propulsion

diesel engine to

Ans. (a) reduce the radiation of the engine room.

When the exhaust gas manufold is water cooled, heat is carried out by water and less

amount of heat is radiated from the exhaust manifold into the engine room. Thus

keeping the engine room cool. At the same time it protects the engine from exhaust

manifold fire because the temperature of the exhaust manifold here is less than 240º C

thus the chances of fire is reduced and hence it acts like a safety device.

Q.354 In a two-stroke cycle diesel engine the exhaust gases are expelled from the

cylinder by

Ans. (c) pressure of the fresh air charge.

In two stroke cycle engine the exhausting is carried out with the help of incoming air

and not by the movement of the piston as in case of four stroke engine. When the

piston is moving down and when the exhaust valve opens, after certain lapse of time

the scavenge ports open. By time the scavenge ports open, the gas pressure inside the

cylinder has dropped sufficiently. When the scavenge air under the pressure higher

than the exhaust enters the cylinder through the scavenge ports, at the same time, the

exhaust valve is also opened. This incoming air from the exhaust manifold will drive

the exhaust gas out through the already opened up exhaust valve.

Q.355 Diesel engine muffler or silencers reduce the engine exhaust noise by

Ans. (d) reducing the exhaust gas velocity.

When the exhaust gas is passed through the muffler it is made to pass in the zigzag

manner. When passing in this manner, everytime it changes the direction and it’s

velocity drops. As a result, vibration caused by the exhaust gas also reduces and hence

the noise is dampened and the muffler effect is carried out.

Q.356 is a repetition of Q.354.

Q.357 Exhaust gases in two-stroke cycle diesel engine are discharged through

Ans. (c) exhaust ports or valve.

When the piston is moving downward and the exhaust ports are cut on the liner. As

soon as the downward moving piston uncovers the exhaust ports, the exhausting takes

place. This will continue till the time the piston when it is moving up again closes the

exhaust ports. This process is the combination of exhausting and scavenging. In case

of the engines in which valves are fitted in the cylinder head, the exhausting is carried

out by opening the valve when the piston is moving down. As soon as the valve opens

the pressure in the cylinder drops and further movement of the piston downward opens the scavenge
ports through which the scavenge air enters the cylinder liner and

forces the exhaust gas upward through the already opened up exhaust valve.

Q.358 The disadvantage of a two stroke cycle diesel engine is a

Ans. (b) high working temperature of a piston and cylinder.

In two stroke cycle diesel engine, for every revolution there is one power stroke. The

amount of fuel engine burnt is more and amount of power develop is more and

because of this the liner and the temperature is more. In general, the exhaust

temperature is lower than the four stroke engine because of the mixing of the

incoming scavenge air thus giving a cooling effect on to the outgoing exhaust gas.

The main temperature is always less than the maximum temperature which will be

encountered.

Q.359 Many diesel engines have piston with concave heads to

Ans. (b) increase the air turbulence and improve the fuel mixing.

The formation of concave top of the piston, in combination with the cylinder head, it forms a spherical

combustion space between the piston and cylinder head. Because of this spherical geometry of the

combustion space, good turbulence is achieved due to which there is good mixing of fuel and air,
resulting

efficient burning of the fuel and the thermal efficiency increases and the fuel consumption can be
reduced.

At the same time, concave surface of the piston top acts as a self-supporting surface even with the
thinner
wall of the piston crown and without any support from the cooling water side, it can withstand high

temperature and high pressure without any external supports.

Q.360 In a single acting diesel engine, the cylinder liner area that is most difficulty to lubricate is

Ans. (c) the top circumference

Combustion of fuel takes place near the TDC. Hence this portion of liner is very hot. At the same time, it
is

subjected to large amount of pressures from the piston rings because of high-pressure gases acting
behind

the piston. Also whatever lubricating oil reaches this place gets evaporated quickly because of
temperature

and the contact pressure between the piston rings and cylinder liner. Hence taking into consideration all

these aspects it is very difficult to lubricate this top portion. On the contrary, there is a possibility of loss
of

lubricating oil and scuffing may takes place.

Q.361 repeated

Q.362 Which of the following design features will reduce the possibility of overheating the top

compression ring of cast iron piston?

Ans. (d) Heat damp design is sometimes used in the piston head.

Due to the heat damp design which is incorporated in the piston, the piston rings are not directly
subjected

to heat from combustion. As a result, the life of the piston rings increases and lubrication between the
liner

and piston rings increases and the weardown of the piston ring and the liner reduces. This is used to

prolong the life and overheating of the top piston ring.

Q.363 Which of the following statements concerning the factors affecting ignition delay is correct?

Ans. (b) An increase in coolant temperature will decrease the ignition delay.

The coolant surrounds the liner and it takes out all the heat from the compressed air at the end of

compression stroke through the liner wall. If the jacket cooling water temperature is maintained at
higher

level, the heat transfer from the compressed air to the cooling medium reduces automatically. When
this

happens, the temperature of the air at the end of compression stroke remains at higher level. If the air
temperature remains at higher level, it helps in fast evaporation of fuel and good mixing of fuel and air

instantaneously and ignite it. Hence the delay period is reduced.

Q.364 Which of the following statement is a description of combustion cycle?

Ans. (c) The heat of process which produces the force to initiate the movement of engine parts.

Internal combustion engine is a heat engine. In this, the heat of combustion is converted into
mechanical

energy. For this conversion, the increase of heat energy will increase the pressure and the heat energy is

converted into pressure energy. This pressure energy acts on the piston and moves the piston
downwards

and converts into mechanical energy. During combustion cycle, the heat generated is converted into

mechanical energy on the crankshaft.

Q.365 In a large slow speed propulsion diesel engine the force applied to the engine piston is

Ans. (c) against the crosshead during the power and compression stroke.

During two-stroke cycle engine compression for every revolution there is one compression and power

stroke. During the power stroke the piston is moving downwards under the force of high-pressure gases

produced on the top of the piston due to the combustion of fuel. Hence the force acts downwards and it
is

taken by the bottom half of the crosshead bearing. When the piston is moving upwards, during
compression

stroke, there is another half revolution of the engine and the piston is moving towards TDC. During this

time, the exhaust valve is closed scavenge ports are closed and the air on top of the piston gets
compressed

so that next power stroke can commence. Hence during the compression stroke, because of
compression of the air, the force acts downwards on the crosshead bearings. As both, during
compression as well as power

stroke, the force acts downwards, it is difficult to lubricate the crosshead bearing

Q.366 One of the advantage in the use of dry liner over wet liner

Ans. (c) there is likely leakage of water into the combustion space,

In case of dry liner, there is no cooling medium involved around the liner or in between the liner and

cylinder block. As there is no cooling medium involved, there is no possibility of water leaking into

crankcase and contaminating the lubricating oil, as in case of wet liner because in wet liner there are O
rings which seals the water space around the liner with that of the crankcase.

Q.367 Which of the construction technique listed is used on new piston rings to facilitate running or

seating?

Ans. (a) Special ring facing such as thin bearing surface of anti-friction metal.

When the piston rings are new, their sliding surfaces are not even which may cause long time to get

properly worn out and having a proper bedding between the liner and the piston rings. Hence there is a

possibility of blowpast and scuffing may take place. For this purpose, it is necessary to increase the

cylinder lubrication when new piston rings are used and running in is carried out. Inorder to accelerate
the

running-in process and to have better sealing between the piston rings and liner, the piston ring sliding

surface is coated with anti-friction material such as tin-aluminium, aluminium-bronze and nickel-
graphite.

These materials being soft will weardown faster and will form a good seal between the piston ring
sliding

surface and liner surface. This coating will get worn out over the number of hours slowly, and in the

meantime, there will be proper bedding of liner and piston ring because the liner will worn out to form a

good surface sealing between the liner and the piston ring. Hence by providing the anti-friction coating
on

the sliding surface, the running in time will be reduced. At the same time the requirement of cylinder

lubrication is reduced.

Q.368 In diesel engines the four basic events: suction, compression, power and exhaust are formed

once in

Ans. (a) one complete revolution in two-stroke engines and two revolutions in four-stroke engines.

In two-stroke cycle engine, the complete cycle is completed in two strokes or one revolution of the
engine.

For this purpose, the four basic events are completed in one revolution or two stroke so that, for every

revolution there will be one power stroke.

Q.369 The intake air ducting in diesel engine should not drop from an area on deck where flammable

vapours released from tanks are present because

Ans. (b) the engine may overspeed and normal governor or overspeed trips will not be able to stop or
secure the engine.

When engine is drawing air rich in hydrocarbons, it acts like additional fuel to the engine. Thus whatever

the governor has allowed the fuel pump to admit, in addition to the fuel vapours present in air suction,
will

also act as additional fuel. This fuel will cause the overspeeding of the engine. Under such
circumstances,

even though the governor will try to reduce the engine speed by reducing the fuel, the fuel coming
along

with air intake, on which we don’t have any control, will continue to burn and the engine will rotate at
the

overspeed irrespective of the governor cutting off the fuel supply. Hence the governor will not be able to

control the speed. Even if the overspeed trip operates and cuts off the fuel supply, as the engine is still

rotating, it will draw air from the atmosphere which is rich in hydrocarbons and continue burning inside
the

cylinder and cause the continuation of running of engine irrespective of overspeed trip.

Q.371 The purpose of delivery check valve used in the diesel engine fuel injection jerk pump is to

(a) assist in quick cut-off of fuel injection .

(b) prevent fuel oil backflow from the injection pump.

Ans. (b) prevent fuel oil flow from the injection pump.

Quick cutting off of the fuel injection is carried out with the help of seal valve or the helix cut on the side
of

the fuel injector pump. Hence the delivery valve will not come into picture. Delivery valve will only

prevent the backflow of the fuel from the fuel pump and fuel valve into the suction side of the fuel
injection

pump. Q.372 In a diesel engine, the advantage of precombustion chamber over the open-type
combustion

chamber is that

(a) it permits coarser fuel atomization

(b) it allows low fuel injection pressure

Ans. Both (a) and (b) possible.

As the precombustion chamber is a small chamber hence the atomization is not proper. The quantity of
air
entered with which the amount of fuel has to mix up is also very small and proper mixing is not done.

When precombustion takes place, the ignition wave, formed because of precombustion, will form a

turbulence effect in the combustion chamber that will allow the proper mixing of air and fuel. Hence
even

though the atomization in the initial stage is not proper or it is coarse, it will not have much affect on the

performance of the engine. As the precombustion chamber is a small chamber, there is no necessity of

penetrating the air deep into the chamber and hence requires low injection pressure as compared to
open

type combustion chamber as the depth of penetration is low.

Q.373 A large slow speed main propulsion diesel engine must be operated with one cylinder secured

when the engine stops the affected cylinder stranded in the position preventing the engine from being

started. Which of the following actions must be taken?

Ans. (c) Admit the starting air in the position opposite to the desired direction.

There is a possibility that when one unit is cut-off the maneuverability of the engine reduces and when
the

engine stops it stops in such a position that the affected unit may come under the starting position.
Under

such circumstances, air will not be admitting to that unit and it is not possible to start the engine. Under

such circumstances, it is better to reverse the engine i.e. to start the engine in reverse direction, some
other

unit may come under starting position and air will be admitted to the unit and the engine can be started.

When the engine starts, it must be stopped and restarted in the desired direction. There is a possibility
that

the engine might be stopped in such a position that air will not be admitted to the affected unit but air
can

be admitted to other units and the engine can be started in the desired direction.

Q.374 The average exhaust temperature of a two-stroke cycle diesel engine with a turbine-driven

turbocharger is lower than a similar four-stroke diesel engine running at equal load because

Ans. (d) the opening of two stroke cycle diesel exhaust ports or the valves occurs much later than in

case of four stroke cycle diesel engines.

In two stroke cycle diesel engines, the exhaust opens much later than the four-stroke cycle engine.
Hence
the speed of the engine is low, and hence to get more amount of power, more amount of heat energy is

released from the exhaust gas on top of the piston to convert into power. Hence when the exhaust valve

opens late, as in case of long and superlong stroke engines, the temperature has been sufficiently
dropped

down so as to have lower temperature at the exhaust valve.

Q.375 Oil control rings used in two-stroke diesel cycle engines are located near the bottom of the

piston skirt inorder to

Ans. (c) keep the excess oil away from the intake and exhaust ports.

In two-stroke engines, the oil rings or scrapper rings are provided so as to distribute the oil over the
surface

of the liner rather than scrapping effect which is required in case of four-stroke engines. Hence the oil

should be spread upwards over the liner walls and it should not get washed away into the exhaust or

scavenge ports. Hence the oil control ring is provided. They increase the liner area covered by the oil
film

because the lower scrapper rings, which are provided, will spread the oil over the entire length of the
liner

and hence it will cover the entire length of liner. These rings were provided in the older MAN engines

where there was long skirt was present and because of proper spreading of lubricating oil over the liner,
it

was possible to have some amount of lubricating oil between skirt and liner. Thus when the skirt and
liner

have a mechanical contact the friction is reduced because of the presence of the oil film but in modern

engines these rings are no more utilized.

Q.376 Which of the following statement represent the function of the compression rings installed in

the top of the diesel engine piston?

Ans. (a) Transmit the heat from the top of the piston to the cylinder liner.

The piston is always running hotter than the cylinder liner and the cooling of piston is a difficult task.

Hence when the piston rings are keeping sliding contact over the liner surface, some amount of heat is
also transferred from the piston rings to the liner. While doing so, the piston gets itself cooled and is
prevented

from overheating and this reduces the piston ring weardown.

Q.377 In a diesel engine the time period between the fuel injection and fuel ignition is usually defined
as

Ans. (d) ignition delay.

It is the time difference from the time the fuel is injected into the combustion space till the time the
actual

fuel firing takes place. This will depend upon quality of fuel, compression pressure and the atomization
and

penetration of the fuel.

MOTOR OPERATION

Q.378 A loose crosshead plunger assembly in a metering or proportionating pump

will cause

Ans. (c) rapid wear on the plunger packing.

If there is excessive clearance between the plunger and barrel, there will be radial

movement of the plunger in the barrel due to which the packing between the plunger and

barrel will get worn out on one side, thus causing the damage and rapid weardown of the

packing. Hence this plunger clearance has to be kept as low as possible and the plunger

and barrel assembly should be replaced when the clearance exceeds the limit.

Q.379 In a naturally aspirated diesel engine the volume of air intake is directly

related to the engine

Ans. (b) valve size.

Valve size will govern the cross sectional area of the intake port. If the valve assembly is

of bigger size more area will be available for the air to enter and less amount of resistance

will be available for air to enter because of which the quantity of air drawn will be more.

Hence volumetric efficiency of the engine will increase.

Q.380 A naturally aspirated diesel engine running at full throttle will have an intake

manifold pressure

Ans. (a) slightly less than the atmospheric pressure.

When the piston is moving downwards in a naturally aspirated engine and the air intake

valve is open, air enters with a velocity inside the cylinder. As a result, there will be

movement of air which will increase the velocity of air which passes through the air
intake manifold to the cylinder. When the velocity increases, as per Bernoulli’s theorem,

there is a pressure drop. As the pressure in the intake manifold is lower than the

atmospheric pressure, the atmospheric pressure will drive the outside air into the intake

manifold and hence to the piston top through the opened inlet valve.

Q.381 An increase in air inlet manifold pressure of a diesel engine will result in a

Ans. (c) decrease in fuel consumption per kW.

When large amount of air is admitted into the cylinder of a engine under pressure the

large quantity of air can burn large quantity of fuel in more efficient manner. Hence

complete and efficient combustion of fuel is possible because of the availability of larger

quantity of air. Due to this, the thermal efficiency of the engine increases and thus

quantity of fuel consumed per kW per hour reduces i.e. the specific fuel oil consumption

of oil reduces. Q.382 On a large diesel engine installation, crankshaft axial alignment is maintained

by the

Ans. (b) engine thrust bearings.

In a large diesel engines, which is used for propulsion purpose, because of the axial thrust

created by the propeller the entire engine shafting will get pushed inwards inside the

engine. Due to this there will be misalignment with the piston, piston rod, connecting rod

and bottom-end bearing positions. At the same time, there is a possibility that due to the

axial movement of the crankshaft, the crankshaft web will move and touch the transverse

girder of the bedplate thus causing damage to the bedplate.

Q.383 The crankcase of many diesel engines are kept under slight vacuum

Ans. (c) reduce the risk the explosion.

If the crankcase is kept slightly under vacuum the quantity of air in the crankcase

reduces. Under such circumstances, if the fuel mist is formed it will be rich and it will not

fall within the lower or higher explosive limit. On the contrary, it will be on the higher

side of the explosive limit and hence there is less possibility of it getting ignited.

Q.384 Maintaining a lowest scavenge air temperature at all times is not

recommended due to the possibility of

Ans. (c) the formation of excessive quantity of condensate.

If the air temperature is dropped too much then excessive condensate will be formed

which will interfere with proper burning of the fuel. At the same time, it will wash out the

cylinder lubrication. This condensate, along with the sulphur present, will burn and form

sulphuric acid. Hence it will give more amount of wear because of corrosion. At the same

time, the scavenge spaces and the lower part of the piston may get rusted.

Q.385 On a turbocharged medium speed diesel engine which of the following

problems is an indication of restricted air inlet passage?

Ans. (a) Engine is hard to start.

In case of turbocharged engine, if the inlet passage is choked or the turbocharger air

suction filter is choked, at the time of starting or during running, sufficient amount of air

will not reach the engine cylinder and a point may reach that the combustion will not be

possible and thus the engine will have difficulty in starting on fuel. It will turn on air, but

as soon as it changes on to fuel, because of lack of availability of air it will stop.

Q.386 An indication of a diesel engine air intake being partially clogged is

Ans. low firing pressure and high exhaust temperature.

As the air intake is partially choked the quantity of air admitted during the suction will be

restricted. If the quantity of fuel remains same, the fuel will be starved off the air and in

such condition the fuel will not burn fully. If the fuel does not burn in proper time, the

peak pressure will drop but this fuel burn during the exhausting time and there is a

possibility that the exhaust temperature will go up but the peak pressure will decrease. If

the air inlet filter is excessively choked, peak pressure and the exhaust temperature will

also drop down because the available air will be so low that it will not be possible for the

fuel to burn during exhaustion stroke also. Q.387 The lower control on a diesel engine is accomplished
by

Ans. (b) rotating the fuel injector pump plunger.

By rotating the fuel injector pump plunger, the effective delivery of the pump is changed.

This means the total time at which the fuel is injected and the total quantity of fuel

injected will automatically depend upon the helix position on the fuel pump plunger

surface with that of the fuel pump suction port. This position can be changed by rotating
the plunger by means of rack and pinion arrangement. This rack is controlled by the

governor which is controlled by the load of the engine.

Q.388 Operating a diesel engine for a prolonged period with a closed fresh water

cooling system at temperature lower than the normal designed temperature can

cause

Ans. (a) formation of sulphuric acid.

If the engine is burning heavy fuel oil which has high amount of sulphur content and the

cylinder jacket cooling water temperature is low, then because of the low temperature of

cylinder wall of the liner the sulphuric acid, which is formed due to burning of sulphur

from the fuel, will get condensed. It will get deposited over the liner walls and the liner

will have corrosive effect of sulphuric acid. Hence it is necessary to maintain the jacket

water temperature at a prescribed higher limit rather than running the engine at low jacket

water temperature for a longer period.

Q.389 The air supplied to the diesel engine is compressed to provide heat for

ignition of the fuel or to decrease injection delay

Ans. (a) ignition of the fuel.

The air supplied to the engine during the induction or suction stroke is compressed by

piston moving upwards with the inlet and exhaust valves closed so as to compress the air

and increase the temperature. This compression is done adiabetically so that at the end of

the compression the pressure and the temperature will be high so that when the fuel is

injected, because of the air temperature being higher than the self-ignition temperature of

the fuel, the fuel will ignite instantaneously and convert the chemical energy of fuel into

pressure and heat energy to be converted into mechanical energy.

Q.390 Fuel droplets injected into a diesel engine cylinder must have adequate

penetration to

Ans. (c) thoroughly utilize the air charge.

The fuel injected should mix up properly with the available air in the combustion space.

For this purpose, it is necessary that the fuel should be atomized properly. At the same

time, it should penetrate deep into the dense atmosphere of the compressed air in the
combustion space. Otherwise, if the penetration is not sufficient, local burning will be

caused and the high density air which is available away from the nozzle tip will not be

utilized efficiently. Hence under such circumstances fuel will not burn properly which

will result in afterburning, loss of power and high exhaust temperature.

Q.391 Loss of lubricating oil pressure to a main propulsion diesel engine will actuate

a audible/visual alarm. Loss of lubricating oil pressure is a most dangerous thing which can happen to
the engine

as it may damage the bearings and cause severe damage to the engine and the crankshaft.

Inorder to avoid this thing, a prewarning should be given as the drop of the pressure takes

place and action has to initiated immediately by getting audible/visual alarm. If the

pressure drops still further, there is immediate danger to the engine. In addition to the

audible visual alarm, there will be tripping of the engine and the engine will stop.

Q.392 The amount of fuel injected into cylinder by unit injector is controlled by

Ans. (b) metering helix.

Metering helix will control the end of fuel injection and thus it will determine the

effective delivery stroke of the plunger. This is possible by having a proper angular

relation between the helix on the plunger surface and the suction ports. This is possible

by rotating the plunger with respect to the barrel by use of rack and pinion arrangement.

The position of rack is controlled by the governor.

Q.393 The dripping of fuel from an injector nozzle after injection terminates often

results in

Ans. (c) choking and blocking of the injection nozzles.

Once the injection terminates the fuel injection pump pressure drops. At the same time

the fuel injector needle valve closes. If the fuel injector needle valve still leaks, some

amount of oil ooze out between the nozzle and seat this oil will get accumulated over the

tip of the nozzle. As it in not in the atomized condition or it has not penetrated inside the

combustion space, this oil as a droplet will burn on the hot nozzle during the combustion

process. Due to improper combustion of the dripping oil it will form a * and this * is

mostly because of asphalt present in the fuel because asphalt being a heavier hydrocarbon
requires more time for burning and it requires more quantity and thorough mixing of fuel

with the air. All this is not possible when the dripping droplets accumulate on the nozzle

tip thus causing the * on the nozzle tip.

Q.394 The amount of fuel delivered in each cycle must be in accordance with engine

load and the same quantity of fuel must be delivered to each cylinder for each power

stroke as the load. Which of the following statements describes the requirements?

Ans. (b) Accurate metering

The complete fuel delivered to the engine will depend on the load. Hence for particular

load particular amount of fuel has to be burnt in the engine. At the same time, the total

fuel given to the engine must be distributed equally to the units so that all cylinders will

produce equal power for the balancing of the engine. This two process requires a proper

quantity of fuel to be measured and delivered equally. Hence this process is called

metering.

Q.395 The knock occurring when a cold diesel engine is started and continues while

running at low speed but stops when the engine reaches the normal operating speed

and temperature is

Ans. (d) normal for this condition.

When the engine is started from cold, the temperature at the end of compression stroke is

not sufficiently high. When the fuel is injected in combustion space, it takes some time for it to ignite i.e.
the ignition delay is more. When the ignition delay is more, the total

quantity of fuel accumulated inside the cylinder before the ignition actually starts will go

on increasing. When the accumulated fuel gets ignited, it produces a knocking sound and

knock wave. As the temperature goes on increasing, the temperature of the air at the end

of compression stroke also goes on increasing. When this happens, the fuel injected will

reach the self-ignition temperature much faster and hence there will not be much

accumulation of fuel before it starts to ignite. Automatically the knocking sound and the

wave will reduce as the temperature reaches the normal operating temperature.

Q.396 The most critical time for any bearing with regards to lubrication is

Ans. (c) during starting.

Most of the bearings used on the engines work on the principle of hydrodynamic

lubrication. During hydrodynamic lubrication, there is no metal-to-metal contact between

the bearing and the shaft. The bearing and shaft is separated by lubricating oil film. This

oil film is formed due to the rotation of the shaft inside the bearing. As the speed of the

shaft increases, more oil is drawn between the shaft and the bearing and thicker

lubricating oil film is formed. During starting of the engine, the speed is very low. Hence

it is difficult to form a hydrodynamic lubrication between the shaft and the bearing.

During this time, for a short period, there is metal-to-metal contact between the shaft and

the bearing surface. Hence this is the most crucial period as the characteristics of the

lubricating oil (oiliness) comes into use and this is time when more wiping out of the

bearing takes place. Hence it is necessary to coat the bearings with anti-friction material

to reduce the friction between the bearing and the shaft at the time of starting because

once the engine is started and the engine has achieved the speed, the white metal does not

play an important role because there is no metal-to-metal contact and it is pure

hydrodynamic lubrication. Hence white soft coating is useful for the boundary lubrication

which is existing at the time of starting the engine.

Q.397 Which of the listed diesel engine operating conditions should be checked

immediately after any diesel engine is started?

Ans. (c) Lubricating oil pressure.

Lubricating oil system is one of the most important system and if malfunctioning of

lubricating oil takes place the failure of engine is immediate and severe. Hence it is

necessary to check the lubricating oil pressure and the lubricating oil sump as soon as the

engine is started. Otherwise, it will be too late and there will be irrecoverable and

irreparable damage to the engine. Nozzle tip will get damaged because of sulphuric acid corrosion. That
is the main reason most of the

engines cooling water temperature of the nozzle cooling is kept at 85°C and in modern engines the
cooling

of the nozzle by separate cooling system has been abandoned.

Q.399 What occurs in the combustion space of a diesel engine cylinder shortly after ignition and
before piston reaches TDC?

Ans. (c) Rapid increase in the pressure and temperature.

When the piston is nearing the TDC and the fuel is injected, the temperature inside the combustion
space is

sufficiently high near the self-ignition temperature of the fuel. Hence the fuel catches fire and because
of

this, sudden increase in the pressure and temperature takes place. The initial stage of ignition takes
place

under constant volume therefore the temperature and the pressure increases. In the later stage, the

combustion takes place under constant pressure because the piston is moving downwards and the
volume is

increasing.

Q.400 The effective pump stroke of a port and helix fuel injection pump is determined by

Ans. (c) plunger control rack position.

The rack position will determine the position of the plunger helix with respect to the suction port of the

barrel. This angular position will determine the quantity and time for which the fuel is injected. Hence
more

the quantity of fuel more the load and lesser the fuel lower the load. The time for which the fuel is
actually

injected into the cylinder is called effective delivery stroke of the plunger which is decided by the helix

position and the position of plunger with respect to the barrel.

Q.404 Which of the listed conditions occur if a diesel engine cylinder exhaust valve is leaking?

(a) loss of compression for the cylinder.

(b) misfiring or rough engine running.

(c) damaged valve.

(d) All of the above.

Ans. (d) All of the above.

When the exhaust valve is leaking automatically, the compression pressure drops. When the
compression

pressure drops the fuel will not ignite properly. Hence there is a possibility that misfiring takes place. At
the same time, due to low compression pressure the fuel will not burn properly which may cause high
exhaust temperature and loss of the peak pressure. When the valve starts to leak, the high-pressure gas
at

high temperature will start to pass through the leaky portion of the valve. This will result in wear or wire

drawing effect on the valve and valve seat. Thus causing excessive damage to the valve and valve seat
and

excessive high exhaust temperature which increases fast.

Q.405 High firing pressure and low exhaust temperature in a diesel engine may result from

Ans. (c) early fuel injection timing.

In case of v.i.t. controlled injection, the early injection cause the fuel to mix up better with the quantity
of

air available it will have more time to mix up and form combustible mixture. Due to this, fuel will burn

efficiently and very near to the TDC which will cause high peak pressure and low exhaust temperature.

Q.406 Exhaust pyrometer reading provides an indication of

Ans. (b) distribution of the load between the engine cylinders.

Exhaust gas pyrometer reading which gives the exhaust temperature of individual unit is a rough
estimation

of power developed by the individual unit. As a thumb rule, higher the exhaust temperature more is the

power developed and lesser the temperature less is the power developed but this may not be always
true. If

the exhaust temperatures are nearly equal, it indicates that all units are developing equal powers and
hence

the engine is properly balanced as far as power is concerned.

Q.407 A change in the degree of fuel atomization in a diesel engine cylinder has the greatest effect on

the

Ans. (d) combustion of fuel in the cylinder.

The more degree of atomization, with proper penetration, will cause better fuel efficiency because the
fuel

will be divided into very minute particles which will have more surface area available and the
evaporation

of the fuel will be faster so as to form a combustible mixture. Hence the mixture will burn efficiently and

promptly due to which the combustion inside the cylinder will be efficient.
Q.408 Diesel engine oil having low cetane number can result in

Ans. (c) combustion knock.

Lower cetane number of the fuel low is the grade of the fuel and because of that ignition delay will

increase. Hence more fuel will get accumulated inside the cylinder before it catches fire. When it catches

fire it will give knocking effect because of sudden formation of pressure wave. This knocking effect is

called diesel knock which directly depends on the quality of the fuel.

Q.409 To successfully reduce an excessively high diesel engine exhaust gas temperature

Ans. (d) you should reduce the load on the engine.

As a general rule more the load on the engine more will be the exhaust temperature. Hence the first
action

to be taken if high exhaust temperature is noted is to reduce the quantity of fuel which is burnt. This is

possible by reducing the load on the engine which reduces the quantity of fuel burnt and the exhaust

temperature reduces immediately.

Q.410 High exhaust temperature and black smoke exhausting from an engine can be caused by

Ans. (a) engine overload.

When engine overload takes place, the amount of fuel burnt is always higher than the quantity of the air

supplied. At the same time, high quantity of fuel is injected. This high quantity of fuel injected cannot
burn

in the available time. Under such circumstances, afterburning takes and along with lack of proper
quantity

of air it will have higher exhaust temperature and black smoke.

Q.411 Combustion gas venting through the expansion tank can be caused by a

Ans. (b) cracked cylinder head.

When the cylinder head is cracked, during compression stroke when high peak pressure and high
exhaust

temperature takes place, these high pressure combustion gas will enter through the cracked cylinder
head

valve into the water space. This gas being lighter it will try to rise upwards and get accumulated inside
the

expansion tank and it will come out through the expansion tank weld. The gas coming out through the
expansion tank weld will have exhaust gas smell and water in the expansion tank will get discoloured.
Also

if the crack is big, more quantity of exhaust gas will find its way into the expansion tank, the expansion
tank may get bubbled out and may get empty due to trapped exhaust gas. Also, the jacket cooling outlet

temperature of that particular unit will also be high.

Q.412 Which of the following problems can cause fluctuating pressures in the closed cooling system

of a main propulsion diesel engine?

Ans. (b) Cavitation in the cooling water pump.

If the inlet in the cooling water pump is restricted or the water is having high temperature, cavitation
will

take place in the form of bubble at the suction of pump. Due to this, there will be partial loss of suction.

This will cause the variation in discharge pressure which will result in fluctuations in the pressures of

closed cooling water system.

Q.413 A fuel leak occurs in a high pressure piping between the fuel pump and fuel nozzle. This

requires immediate repairs because of the

Ans. (b) serious fire hazard.

The high pressure pipe leakage will cause the high pressure fuel to leak through the cracked portion of
the

fuel pipe. Due to this, the oil coming out through the cracked portion will be in the form of a fine mist.
This

mist when it comes in contact with the exhaust manifold or hot surface of the engine, as there is
sufficient

amount of air in the engine, it will result in fire in the engine room. Hence immediate repair is necessary
to

avoid this fire.

Q.414 Individual cylinder performance in the diesel engine is routinely determined by the exhaust

gas

Ans. (c) pyrometer readings.

As a general rule, the exhaust temperature will give a fairly good idea of power developed by the
individual

units. The exhaust gas temperature from individual unit is taken into consideration as a measure to
determine the power developed by the individual unit. Hence as long as all units’s temperatures are
equal

or they are within a prescribed limit, this indicates that all units are developing nearly same power and
the

engine is properly balanced.

Q.415 Excessive diesel engine cylinder exhaust backpressure will be caused by

Ans. (c) an obstruction in the exhaust silencer.

When the exhaust valve opens and exhausting takes place through the exhaust valve, if the exhaust gas

silencer valve is blocked or choked, there will not be easy flow of exhaust gas and complete emptying of

the exhaust gas from the cylinder will not possible. Under such circumstances, when the piston is on the

upward stroke it will give a backpressure over the piston and there will be loss of power in overcoming
this

backpressure.

Q.416 The injection pressure of a hydraulic fuel injection nozzle can be increased by

Ans. (d) increasing compression on the pressure spring.

The fuel is injected when the pressure developed by the fuel injection pump will act on the annular
space

around the fuel injection nozzle will overcome the spring compression from top on the fuel injection

nozzle. As the compression pressure increases, more pressure will be required by the fuel injector nozzle
to

lift up against the spring compression. Hence more the compression pressure more will be pressure

required for the fuel injector to open. Hence the injection pressure will increase as the compression
pressure

of the spring increases.

Q.417 The combustion knock occurring in a diesel engine can be caused by

Ans. (d) prolonged ignition lag.

Due to prolonged ignition lag the time between the fuel injection and fuel ignition will be large. During
this

time, large amount of fuel will get accumulated into the combustion space. When this accumulated fuel

suddenly gets ignited it will cause an explosive pressure wave which will create the knocking effect.

Q.418 Which of the following problems could develop due to the accumulation of oil vapours into the
crankcase of diesel engine?

Ans. Crankcase explosion. Accumulation of oil vapours in the crankcase and presence of hot spot will
cause the vapour to convert into

oil mist. When the oil mist comes in contact with the hot spot in presence of large quantity of air, which
is

available in the crankcase, it will form a lethal combustible mixture and it will cause a crankcase
explosion.

Q.419 One problem resulting in a diesel engine fuel injector opening pressure being lower than

specified by the engine manufacturer is

Ans. (d) quantity of fuel injected tends to increase.

As the fuel injection pressure is lower than recommended by the engine manufacturer, the fuel injector

valve will open much earlier but the closing will not alter. Due to this, the quantity of fuel injected will
be

more than what is required.

Q.420 Which of the listed reasons is the most likely cause of a sudden drop in compression pressure

in one diesel engine cylinder?

Ans. (b) Malfunctioning of the valves.

Malfunctioning of the valves may be because of improper adjustment of the tappet clearance or the
valves

may be sticky or leaky. Under all these conditions, during compression, the compressed air will leak

through the leaky valve and automatically the compression pressure will drop.

Q.421 repeated in Q.420

Q.422 Failure to open the diesel engine test cock after a long period of shutdown prior to starting

may result in

Ans. (b) damage to cylinder head and piston.

If the test cock or the indicator cock is not opened and the engine is started and due to any reason there
is

accumulation of fluid on top of the piston, this fluid will get compressed. As the fluid is incompressible,

excessive pressure will be developed between the piston top and cylinder head bottom portion. This will

cause the cracking of the cylinder head, damage to the piston, bending of the connecting rod or in worse

case it may cause damage to the crankshaft in the way of slippage.

Q.423 Which of the listed conditions is most likely to cause a crankcase explosion?

Ans. (b) Fuel dilation of lubricating oil.

When fuel dilation of lubricating oil takes place, automatically the flash point of the lubricating oil
reduces.

Under such circumstances, if there is any hot spot present in the crankcase and the oil mist is formed
along

with the oil mist there will mist of the fuel present. This mist of the fuel will be more prone to explosion

and hence explosion will be caused much early.

Q.424 repeated

Q.425 A diesel engine is operating with excessively high exhaust temperature in all cylinders. In

order to correct this condition, you should first

Ans. (a) reduce the engine load.

As a general rule if the load is more on the entire engine, the entire engine will be using more quantity
of

fuel. When more quantity of fuel is burnt, automatically more heat will be generated. This will give
higher

exhaust temperature for entire engine. Hence to reduce this exhaust temperature the quantity of fuel

injected is reduced and to reduce to quantity of fuel injected, you have to reduce the load on the
engine.

Q.426 The overspeed trip installed on most diesel engines will stop the engine by shutting off the

Ans. (b) fuel oil supply.

When overspeed takes place in order to prevent the damage to the engine it is necessary to stop the
engine.

For instantaneous stopping of the engine. the best possible way is to shut off the fuel immediately. This
is

done by the overspeed trip which will bring the position of the fuel rack of all the fuel pump to zero

position and no fuel will be injected and the engine will be immediately stopped.

Q.427 White smoke exhausting from a operating diesel engine may be due to

Ans. (a) cracked liner. Especially if the liner is cracked at the lower position, the water will enter into the
combustion space. This

water when it gets evaporated, during the combustion stroke because of combustion of fuel, will form
steam. This steam will come along with the exhaust gas into the atmosphere through the funnel of the
ship.

When it comes out it will get cooled down by the atmospheric temperature. This steam will be visible
due

to water present in it and it will form white mist when it comes out of the funnel.

Q.428 Black smoke exhausting from an operating diesel engine can be caused by

Ans. (a) fuel dribbling from leaky fuel injector.

When the fuel is dribbling from leaky fuel injector it is actually coming into the combustion space when
it

is not required. At the same time, it is not in atomized condition. Under such conditions, afterburning
will

take place and fuel which is dribbling will not mix properly with the air. Hence the improper combustion
of

this fuel will take place during the exhausting stroke of the engine and hence black smoke and higher

exhaust temperature will be indicated.

Q.429 A device which functions to bring a diesel engine to fullstop to protect it from damage is

known as

Ans. (b) overspeed trip.

If the due to any reason the engine gets into overspeed, due to the centrifugal force caused by rotation,
there

will be excessive damage may take place to the engine to the extend that the piston may come out from
the

cylinder or from the crankcase or the bottom end bearings may break. In order to prevent such heavy

damage, it is necessary that the engine should stop immediately. This is possible by installing the
overspeed

trip which will sense the overspeed and immediately shut off the fuel.

Q.430 Which of the following conditions can cause oil to accumulate in the cooling system of a diesel

engine?

Ans. (b) Defective oil cooler core.

If the lubricating oil cooler, in which the cooling is carried out by jacket cooling water especially in case
of

small engines, is leaking the lubricating oil will find its way into the jacket cooling water. This system is
utilized in the engines working in the cold weather where the lubricating oil is cooled by jacket cooling

water in a cooler.

Q.431 Lubricating oil accumulating in the cooling water system of a diesel engine will result in

Ans. (b) poor heat transfer.

When the lubricating oil find its way into the jacket cooling system it will coat over the heat transfer

surface. As lubricating oil is poor conductor of heat, it will effect the efficient heat transfer and will cause

the overheating of the liner and the cylinder head due to the overheat transfer.

Q.432 When the opening pressure of a diesel engine fuel injector is greater than that specified by the

engine manufacturer

Ans. (a) the quantity of the fuel injected decreases.

If the opening pressure of fuel injector is more than that specified by the engine manufacturer, the fuel

injector will open late and it will close at particular time depending upon the load. Hence the
automatically

the quantity of the fuel injected will be reduced because of the opening of the fuel injector is late.

Q.433 Black smoke exhausting from an operating diesel engine is an indication of poor combustion

which may be caused by

Ans. (c) clogged air intake passage.

If the air intake passage is clogged, automatically the engine will be starved off the air. The quantity of
fuel

injected will not burn efficiently because of lack of sufficient amount of air. If the fuel does not burn

efficiently, it will be indicated by black smoke and high exhaust temperature.

Q.434 The highest pressure in a diesel engine cylinder normally occurs

Ans. (c) after TDC.

As is indicated by the draw card the fuel is injected slightly before TDC. Depending upon the quality of
the

fuel, the fuel will mix with the hot air which is available to convert itself into a combustible mixture. This

combustible mixture will ignite to give a sudden maximum pressure denoted by Pmax. For this process
to take place, there is some time lag between fuel injection and fuel ignition. Hence by the time
complete fuel

burning starts, the piston has already passed the TDC and it is slightly on its downward stroke. This is the
time when complete fuel will burn and high pressure wave will be formed. Thus the maximum pressure
in a

diesel engine will be always after TDC.

Q.435 Diesel engine lubricating oil dilation with fuel oil is indicated by

Ans. (a) decreased viscosity.

If the lubricating oil is getting contaminated due to fuel oil, the viscosity of the lubricating oil will drop

down because the viscosity of the fuel oil is much lesser than the viscosity of lubricating oil. Hence when

they get mixed together, the viscosity of lubricating oil will drop down depending upon the quantity of
fuel

which is contaminating the lubricating oil. This is easily checked by the flow stick which are supplied for

the on-board testing of the lubricating oil. Also, it will drop the flash point of the lubricating oil. This is
the

most dangerous situation and action should be taken immediately otherwise bearing damage will also
take

place.

Q.436 A broken pintle in a fuel injector usually causes

Ans. (c) distortion of the spray pattern.

When the pintle breaks or gets eroded, as it is controlling the single hole in the center of the nozzle,
when

the needle gets lifted up under the high pressure of the fuel oil. When the fuel oil passes around the
pintle

the distribution pattern of the fuel oil changes.

Q.437 Diesel engine cylinder head test cocks are used

Ans. to remove the accumulated oil or moisture from the top of the piston.

In order to avoid the hydraulic pressure developed during starting of the engine which may otherwise
cause

damage to the cylinder head, liner, piston, connecting rod and the crankshaft, it is necessary to blow

through the engine just before starting it on air and fuel.

Q.438 A classical way of checking for excessive fuel injection in one cylinder of an operating diesel

engine is

Ans. (c) frequently checking the cylinder exhaust temperature.

As a general rule, the cylinder exhaust temperature is an indication of the quantity of fuel burnt in that
unit.

Hence higher the fuel burnt higher is the exhaust temperature. Hence by checking the exhaust
temperature

we can get a rough idea as how the distribution of fuel is taking place for individual cylinder. If the

temperature is at higher level by rough estimation we can assume that the quantity of fuel delivered to
that

unit is higher than as compared to any other units.

Q.439 A diesel engine emits a blue exhaust smoke as a result of

Ans. (c) excessive cylinder lubrication.

If the cylinder lubrication is excessive in that case the cylinder lubricating oil will burn along with the
fuel.

When the lubrication oil burns it gives a blue tinge to the exhaust gas from the funnel.

Q.440 Which of the following problems could cause misalignment between the needle valve and fuel

injection nozzle?

(a) A bad fuel needle.

(b) A defective nozzle tip seat.

(c) Distorted valve body.

(d) All of the above.

Ans. All of the above.

If the needle is bad it will not sit squarely on the valve seat. If the valve seat itself is distorted then the

needle will not sit properly on the valve. At the same time, if the complete body is distorted, then along

with the body, the cylinder in which the needle moves will also get distorted and hence needle will not
sit

squarely onto the seat. This will also cause the distortion and misalignment of the needle and valve seat.

Q. 443 The highest load applied to the diesel engine crankshaft main bearings are

Ans. (c) firing loads. During the firing of the fuel, the piston is nearly at TDC position and the piston rod,
connecting rod and the

connecting rod bearings are nearly in the same vertical plane because of which full load of firing is

transmitted to the crankshaft. When the load is transmitted to the crankshaft, the crankshaft is
supported by
the main bearings. Thus the load is transmitted to the main bearings and ultimately to the bed plate and

transverse girder.

Q.444 If the diesel engine fuel injection timing is changed to delay the start of injection until the

pistons are at TDC, the engine will

Ans. (b) develop less power under load.

If the fuel is injected when the piston is at TDC, by the time it mixes up with air and forms a combustible

mixture, the piston has already passed TDC and is moving downwards. Under such circumstances, the

firing of the engine will take place when the piston is moving towards BDC. In this condition, the firing

will take place under increasing volume instead of constant volume so the pressure cannot be
developed

onto the piston. As the pressure on the piston top is most important from the point of view of power

developed considering the power developed is given by

Power developed = PLAN

In this condition, power developed by the engine will reduce and whatever fuel is burnt will be wasted
due

to afterburning resulting in high exhaust temperature but low power.

Q.445 Increase in compression ratio of a diesel engine while maintaining designated rate of fuel flow

will result in

Ans. (a) increase in the horsepower.

If the compression ratio increases, the air in the cylinder will be more dense and the quantity of air

increases. At the same time, the temperature of the air at the end of compression increases. As a result,
the

fuel injected will burn efficiently and promptly. All this will result in more power being developed by the

engine because more heat can be released from the fuel which is burnt.

Q.446 If the jacket water temperature in a diesel engine rises rapidly above normal, you should

Ans. (b) first reduce engine load.

Jacket cooling water temperature will also roughly estimate the engine load. Higher the engine load,
higher

will be the heat absorbed by the jacket water and hence the temperature will increase. Hence jacket
water
temperature is a rough estimation of power or load on the engine. If the jacket water temperature is

excessively high and it is not because of any other reason such as malfunctioning of jacket water cooler,

then it is necessary to reduce the load and carry out the further investigation and rectify the fault.

Q.447 During which of the listed piston stroke of a four-stroke cycle diesel engine is the piston

moving downwards?

Ans. (a) Intake stroke.

In a four-stroke cycle diesel engines, the piston will move downwards two times: one during the
expansion

stroke and one during which air will be drawn inside the cylinder called the intake stroke. During the
intake

stroke, the intake valve is open and the piston is moving downwards so whatever increase in volume is

there, due to downward movement of the piston, will be filled up by the incoming air under intake
stroke.

Q.448 In operating diesel engine, preignition can be caused by

Ans. (b) oil in the air charge.

Preignition is caused because ignition takes place before the fuel is injected. This is possible only if the
fuel

vapours are present in the air suction. When this air is compressed these vapours will get ignite before
the

fuel is injected and will cause the preignition.

Q.449 Significant retardation of diesel engine fuel injection timing will result in

Ans. (d) reduced engine power.

Retardation of fuel injection timing will cause the fuel injection to occur late during the compression

stroke. As the fuel injection is late, by the time it forms a combustible mixture with the compressed air,
the

piston will be near to TDC or it might have already passed the TDC. If it has already passed the TDC and if

fuel ignition takes place, the pressure is increasing; also the volume is increasing as the piston is moving
downwards, hence the maximum peak pressure reduces which will cause loss of power. Also,
afterburning

will take place and the exhaust temperature will be high but the power developed by the engine will be
low.

Q.450 When fuel is injected late into diesel engine cylinder

Ans. (d) fuel consumption will be high.

When the fuel is injected late into the diesel engine cylinder the combustion will take place late and

afterburning effect will take place. The maximum pressure will reduce due to which the mean effective

pressure will be reduced. Ultimately the power developed by the engine will be less but the quantity of
the

fuel burnt will be same. Hence the specific fuel oil consumption of the engine will increase and the
thermal

efficiency of the engine will drop. Q.452 If a single cylinder relief valve on a diesel engine lifts
frequently while the engine is running,

the cause can be

Ans. (c) an incorrectly adjusted fuel injector.

If the fuel injector is incorrectly adjusted it means that the fuel injection pressure is low or if the fuel

injector is leaking, excessive amount of fuel will find its way inside the unit and excessive amount of fuel

burns inside the unit. Automatically, the peak pressure will increase and it may increase pressure and lift

the relief valve. At the same time, relief valve may lift if the rack position is stuck up in full load
condition.

The valve may also lift if the injection timing is advanced too much. If excessive amount of injection

timing is advanced, the peak pressure increases Also if the v.i.t. (variable injection timing) which is

suppose to start reducing too much after 85% to 100% is stuck up in full position and it is not reducing as

it is required to do because of this the pressure will be excessively high.

Q.453 When one cylinder has low compression pressure and high exhaust temperature than any of

the engine cylinders which of the conditions listed will be indicated?

Ans. (c) Leaky exhaust valve.

If the exhaust valve is leaking, the compression pressure will drop because the compressed air will get

leaked out from the leaky exhaust valve. At the same time, because of low compression pressure, the
fuel

which is injected will not burn properly which will give high exhaust temperature. Also when
compression

is taking place and the fuel is injected and as the fuel starts burning, as the fuel valve is leaky, high

temperature and high pressure gas will leak through the leaky exhaust valve and the exhaust
temperature
will rise. Hence low compression pressure, high exhaust temperature, low peak pressure and loss of
power

all of them will be indicated by leaky exhaust valve.

Q.454 A distorted spray pattern from a fuel injector can cause a diesel engine to have

Ans. (d) less power output.

The fuel should be distributed equally and evenly around the entire combustion space available. If the
spray

pattern of the injector has been distorted due to any reason, the fuel will not mix properly with the air
and

the complete use of the air available inside the combustion space will not be possible by the fuel. At the

same time, concentration of fuel at one particular point in the combustion space will be more than the
other.

Due to this, the availability of air will not be uniform for the fuel to burn in the entire combustion space
and

because of this there is a possibility that the exhaust temperature will be high and power loss will take

place.

Q.455 If a few injector spray holes becomes plugged the reason could be

(a) excessive surging under governor speed.

(b)combustion knock under load.

(c) poor fuel combustion.

(d) All of the above.

Ans. (d) All of the above.

When few holes of the injector are plugged, the fuel distribution for the units in which the holes are

plugged will get disturbed. Hence the power balance of engine will change. As there is change in power

balance, the governor will try to continuously try to maintain the speed and hence it will give surging
effect

to the engine speed. So engine speed will continuously fluctuating. Secondly, as the distribution of fuel is

not proper and penetration and atomization will also get affected the fuel will not burn properly and
hence

it may cause the fuel knock and poor fuel combustion resulting in knocking sound, black smoke, and loss

of power.
Q.456 A diesel engine fails to start because of water in the fuel. Inorder to start the engine we should

Ans. (d) drain the filter and stainer and bled off the water at each of the injection pump.

All methods should be taken to remove the water content from the entire fuel injection system upto the

nozzle tip. This is carried out by bleeding off the water content at different position including the fuel
pump

and injector so that water will not be injected during the injection stroke, resulting in stopping of the
engine

or incomplete combustion or fluctuation in the rpm. In such cases, if water is present engine may fail to

start also.

Q.457 A diesel engine piston crown can crack from (a) excessive piston to liner clearance.

(b) excessive dirt beneath the piston crown that reduces the heat transfer.

(c) faulty nozzle springs

(d) All of the above.

Ans. (d) All of the above

If there is excessive clearance between piston and liner because of liner wear, the piston ring may get

over hanged as the radial clearance increases. Hence there is a possibility that the piston rings may get

broken or twisted. Under such circumstances, blow past will take place and the liner and the piston will
get

damaged. Also, in four-stroke engine the piston will snap against the liner if the clearance is excessively

high and in that case the piston crown will hit against the liner and it may crack. The piston crown may
also

crack as a result of formation of carbon deposit or scale in the cooling space of the piston. Due to faulty

fuel injector nozzle, the fuel will get penetrated too much and it may directly burn over the piston
crown.

When this happens, the piston crown may also crack.

Q.458 Permitting a daytime fuel tank to run dry can cause

Ans. (d) air in the fuel.

It is natural that if the engine is running and the fuel tank is allowed to run dry then it will suck air in the

system and the engine will stop.

Q.459 Air in the fuel line through a fuel injection nozzle of a diesel engine will cause the engine to
Ans. (c) operate with reduce power or stop.

If there is air in the fuel injection system, there is a possibility that the quantity of fuel injected will get

reduced or there is intermittent firing. If the air ingress in the system is excessively high, air being a

compressible medium, the fuel injection nozzle will not open and no fuel is injected into the cylinder and

hence the engine may stop.

Q.460 Which of the following problems will occur if needle valve of an injector stick in open

position?

Ans. (a) Fuel injection timing may change.

If the fuel injection valve get stuck up in open position, during the suction stroke of the engine, the
pressure

inside the cylinder drops. At that time, the fuel will drip through the open needle valve into the
combustion

space and some part of fuel will be emptied off from the system. Hence for the next injection stroke it is

necessary to fill up the space and because of that the fuel injection timing will change. At the same time,

because the valve is staying in the open condition, the fuel will be injected as soon as the plunger covers
the

suction port. Hence too much fuel will be injected which will not be under sufficient pressure resulting in

the dripping of the fuel and not spraying properly. All this will cause excessively high exhaust
temperature

or the relief valve will lift resulting in loss of power and black smoke.

Q.461 A dry type exhaust muffler clogged with soot will cause

Ans. (c) loss of engine power.

When the exhaust gas muffler gets clogged, it will cause excessive backpressure on the exhausting
system.

In case of turbocharged engine, the turbocharger will not attain sufficient speed and it will not supply

sufficient air for the combustion. Even in case of naturally aspirated engine because of the backpressure

when the piston is moving upwards on the induction stroke it is to force the exhaust gas out of the unit.

This will cause the loss of power developed by the engine and hence the power developed will be less.

Q.463 In a diesel engine cylinder head, test cocks are used

Ans. (b) to connect the pressure indicator.

Pressure indicators are connected to the exhaust gas so that the indicator device piston will have the
exact

duplicate movement as that of the main piston. Hence the indicator device is connected to the indicator

cock.

Q.463 Air may be bled from fuel system by

Ans. (b) loosening the compression nut at the injector Q 464 Which of the terms listed below
represent the operational speed at which excessive engine

vibration is created?

Ans. Critical speed.

Critical speed is that speed at which the natural frequency of vibration of the shafting will coincide with
the

frequency of vibration caused because of the firing of the fuel in the cylinder i.e. firing frequency. If they

coincide, there will be resonance frequency and excessive vibration of engine will take place. The
condition

when this occurs is called critical condition. If this persists for longer period, there is a possibility that the

crankshaft and the connecting rod may get cracked. Also the tierods may get cracked or the foundation

bolts may get loose.

Q.465 If the needle valve in a fuel injection nozzle sticks open

Ans. (c) the valve will get overheated.

If the fuel valve will get stuck open then during the firing stroke the pressure inside the cylinder will be

high enough for the high temperature and high pressure gas to find its way to the nozzle and the nozzle
may

get overheated and it might be damaged.

Q.466 Which of the condition listed below would cause simultaneous high cylinder pressure and low

exhaust temperature?

Ans. (c) Excessively early injection timing

Earlier the injection more is the pressure developed. If the injection is too early the pressure developed
will

be excessively high and there is a possibility that the relief valve on the cylinder head will get lifted up to

relieve the pressure. Also early fuel injection will result in high maximum cylinder pressure but the
exhaust
temperature will be low.

Q.467 Early injection timing is indicated by cylinder pressure being

Ans. (a) above normal firing pressure and below normal exhaust temperatures.

Due to early injection, there is more time for the fuel and air to mix properly resulting in better
combustion

which will produce high firing pressure and low exhaust temperature.

Q.468 If fuel injection occurs too early the diesel engine will lose power because of

Ans. (b) ignition will be delayed due to low compression pressure

Early fuel injection is better for the proper combustion of fuel as we derive more power, high peak

pressures, and low exhaust temperature. If the fuel is injected too early, the compression pressure and
the

temperature of the air is not sufficiently high enough. The fuel will only get accumulated and it will not

catch fire immediately due to which knocking will take place and since the fuel will not burn properly
there

will be loss of power. Hence the timing should be properly adjusted it should not be too early or too
late.

Q.469 Diesel engine air starting valve timing is controlled by

Ans. air distributor.

The diesel engine air starting valve timing is controlled by air distributor which has got sets of cam; one
set

is used for ahead and other is used for astern These cams are rotated by shaft which is connected to the

main camshaft. Also individual air distributor valve will have a spring loaded double acting valve and

because of this the pilot air will be conveyed to the main air starting valve fitted on the cylinder
depending

upon the position of the piston in the starting condition.

Q.470 A diesel engine fails to start due to water in the injection system. Before engine is started water

should be removed from the

Ans. (a) fuel line.

If water is present it cannot ignite due to which the engine will not start.

Q.471 If you are suspecting misfiring due to air leakage into the air system,

Ans. (d) you should be looking for a leak on the suction side of the fuel transfer pump or booster
pump.

As the fuel in the suction side of booster pump will always be lower as compared to its delivery side, it is

necessary to check at the suction side of pump for any ingress of air. In order to avoid this, there should
be sufficient height of fuel in the service tank so that possibility of ingress of air through the suction
glands is

minimized.

Q.472 An increase in the load of a turbocharged diesel engine operating at constant speed will result

in an increase in

(a) exhaust temperature

(b) air box pressure

(c) brake mean effective pressure

(d) All of the above

Ans. (d) All of the above.

If the load on the turbocharger is increased the speed of the turbocharger increases. As the load on the

turbocharger increases more amount of fuel burnt increases. Because more quantity of fuel is burnt the

exhaust temperature increases. At the same time, more amount of exhaust gas is produced. This high

quantity and high temperature gas will drive the turbocharger at higher speed due to which more
amount of

air will enter the inlet manifold through the turbocharger and hence scavenge air pressure will increase.
As

the scavenge air pressure increases, more amount of air will enter the cylinder. As a result, compression

pressure will increase and peak pressure will increase because of firing of more quantity of fuel and

burning the fuel efficiently.

Q.473 When a diesel engine is operated at partial load as compared to full load, a decrease will occur

average

(a) in air quantity aspirated.

(b) fuel injection pressure

(c) combustion pressure on power stroke

(d) compression pressure on the compression stroke

Ans. (a) in air quantity aspirated.

If it is naturally aspirated engines the quantity of air aspirated will reduce. In case of turbocharged
engines,

the turbocharger at partial load will supply less quantity of air. In this respect the quantity of aspirated
air

will reduce. As the quantity of air admitted into the cylinder reduces, the compression pressure during
the

compression stroke will also reduce. When the compression pressure reduces at part load, the quantity
of

fuel burnt will also reduce ultimately the firing pressure and mean indicated pressure, which is acting
over

the piston when it is moving downwards on expansion stroke, will also reduce.

Q.474 Air in the fuel can cause

Ans. the engine to stop.

If there is air in the fuel there will be discontinuity of fuel injection will take place. If there is

discontinuation of fuel injection the engine will stop.

Q.475 Early injection timing is indicated

Ans. (b) low exhaust temperature.

Q.476 Which of the following operating procedures should be carried out immediately before any

diesel engine is started?

Ans. (c) Verify proper lubricating oil pressure.

Verification of proper lubricating oil pressure is most important part when the engine is started because
if

there is insufficient lubricating oil pressure and if the engine is allowed to run even for smallest possible

time, severe damage will occur to the crankshaft and the complete engine will be damaged beyond
repair.

Q.477 The most common diesel engine fuel injection system problems are caused by

Ans. (b) dirty fuel.

If the fuel is dirty the fuel filter will get choked. The fuel injector nozzle will get choked. There will be

excessive weardown of fuel pump barrel and plunger. All this will lead to deterioration of fuel injection

system.

Q.478 If sludge accumulation on the underside of the diesel engine piston it will
Ans. affect the heat transfer. If there is sludge accumulation on the underside of the diesel engine
piston in the cooling space it will

affect the heat transfer. When the heat transfer is affected ,there will less amount of heat transfer which
will

cause the piston crown to overheated and ultimately it may crack.

Q.479 Faulty operation of diesel engine fuel injection nozzle can be a direct cause of

Ans. sedimentation in the fuel supply.

If the fuel supply is having sedimentation, sludge or hard particles the injection nozzle will get seized or

there will excessive wear of injection nozzle and needle and guide and because of this the spray pattern
will

change and there will be faulty operation of diesel engine. Also the sludge may enter the combustion
space

and cause the weardown of the liner and piston rings.

Q.480 Low cylinder compression pressure and high exhaust temperature may indicate

Ans. (b) leaky valve.

When the valves are leaking during compression the air will leak out and because of this the
compression

pressure will reduce. When this happens sufficient amount of air will not be available for the fuel to
burn

and under such circumstances there will loss of power and high exhaust temperature and black smoke.
All

this is result of leaky valve.

Q.481 The loss of diesel engine cylinder air charge through leaky valves, piston rings, worned or

scorned liner will be indicated by which of the following sets of conditions?

Ans. Low compression pressure and high exhaust temperature

Due to loss of air during compression stroke, the compression pressure will drop. As the quantity of air

available for combustion is less, incomplete combustion will take place which will cause high exhaust

temperature, afterburning and loss of power and black smoke. As the compression pressure is low and
the

power is lost, the firing pressure will also drop with increase in the exhaust temperature.

Q.482 During diesel engine warm-up which type of tappet clearance adjuster listed below for a

change in length of exhaust valve?

Ans. (c) Hydraulic tappet clearance adjuster.

In hydraulic tappet clearance adjuster, there is no metal-to-metal contact between the pushrod and the
stem

of the valve. The opening of the valve is carried out by the hydraulic piston and hence it replaces the

pushrod and rocker-arm combination. Hence whatever expansion of the valve and spindle takes place

because of temperature, it will be taken care off by the hydraulic oil and hydraulic cylinder that is on the

top of the valve. This cylinder is connected to the lubricating oil system through a throttle valve which
will

also allow for the excess oil to be drained off and the valve will close positively.

Q.484 Worn cylinder head valve seat in a diesel engine will cause

Ans. (a) less cold tappet clearance.

As the valve will sit over the worn valve seat there will be more amount of vertical displacement of valve

spindle. As a result, the clearance between the spindle and pushrod or rocker-arm will reduce and
therefore

the cold tappet clearance will reduce.

Q.485 Which operating condition of a diesel engine is indicated by excessive firing pressure?

Ans. (b) Overload.

If the engine is overloaded and if the fuel pump timings are proper, more fuel will be burnt in the engine
to

accommodate for the increased load. When more fuel is burnt, automatically the firing pressure will be
on

the higher side.

Q.486 If the jacket water temperature rises rapidly above normal in a diesel engine you should first

Ans. (b) reduce the engine load.

As a thumb rule, it is essential that for any rise in temperature of jacket cooling or exhaust the main
reason

may be either overloading of the engine or lack of cooling. Before diagnosing or rectifying the cause it is

better to reduce the load and then carry out the necessary investigation and rectify the fault. Otherwise,
time

will be wasted in diagnosing and rectifying the cause and during that time the engine may damaged. As

soon as we reduce the load, the heat generated inside the engine is released and this will help in
reducing
the jacket cooling temperature or atleast maintaining it and not allowing it to reach more dangerous
limit. Also if the temperature is excessively high and if immediate action is taken to reduce the heat by
increasing

the flow of water, there is a possibility that the liner may crack due to sudden change in temperature.

Inorder to avoid this, it is advisable to reduce the load and then carry out investigation.

Q.487 A substantial increase in crankcase pressure could be an indication of

Ans. worn cylinder liner.

Especially in case of four stroke engine with trunk-type piston when liner worn out is excessive there is

improper sealing between the liner and piston rings resulting in blowpast which will cause the high

pressure gas to enter into the crankcase. This high pressure gas will cause the higher pressure in the

crankcase.

Q.488 Which of the following procedures should be carried out when large slow speed diesel engine is

operated with one cylinder secured i.e. one cylinder is cut-off from the fuel?

Ans. (d) The engine speed should be reduced.

When the engine is operated with one unit cut-off the other unit may get over loaded and because of
this

the other units may get damaged and there will be severe damage to the entire engine. At the same
time,

there will be excessive vibration. In order to avoid all these things, it is necessary that when one unit is
cut

off the load on engine be reduced so that the other units will not get overloaded and the engine will
work

moderately over a period of time.

Q.489 The most practical way of detecting the overload in one cylinder of an operating large low

speed main propulsion diesel engine is to

Ans. (d) check the cylinder exhaust frequently.

The exhaust temperature of the cylinder is a rough indication of power developed by the units. If the

exhaust temperature is excessively high for a particular unit and other operating conditions are normal,
it

can be easily determined that the unit is overloaded. Hence the continuous observation of exhaust

temperature of the units will indicate whether the units are properly loaded or they are overloaded and
whether they are equally sharing the power or not

Q.490 A diesel engine can fail to start because of

Ans. incorrect fuel injection timing.

If the fuel injection timing is too much out of the way, i.e. if the injection timing is too much earlier, the

fuel will be injected so early without sufficient compression pressure that it will fail to ignite. If the fuel

injection timing is excessively late then when the fuel is injected the compression pressure is sufficiently

dropped down so that the fuel will not be properly ignited and the engine will fail to start.

Q.491 One cause of diesel engine piston ring blowby is

Ans. excessive lubrication

Excessive lubrication will cause the lubrication oil to burn in the combustion space and top of the piston

and excessive carbon deposits will be formed. They will get deposited on the piston rings which will
cause

the rings to seize inside the groove and thus the blowpast will take place. If the lubricating oil supply is
too

low there will be metal-to-metal contact between the piston rings an the liner causing scuffing between
the

liner and the piston rings and cause excessive weardown of the liner and the blowpast.

Q.492 If you notice smoke coming out from crankcase exhaust fans outlet of an operating diesel

engines you should suspect

Ans. broken piston rings.

In case of trunk-type piston if the piston rings are broken, high temperature and high pressure
combustion

gases will enter into the crankcase because of blowpast. Due to this, the crankcase atmosphere will be
filled

with high temperature, high pressure exhaust gases. This can be seen from the exhaust of the crankcase

when gas comes out of the exhaust fan outlet.

Q.493 Which of the following conditions may need to be reduced when operating a large low speed

main propulsion diesel engine at low load?

Ans. (c) Cooling water flow through aftercooler. The cooling water flow through the aftercooler has to
be reduced in order to maintain the scavenge air
temperature above the dew point; otherwise condensation of moisture will take place which will
damage

the lubricating oil film which will cause the excessive weardown of the liner and the piston rings.

Q.494 A restricted diesel engine exhaust manifold operating under a normal load is indicated by

Ans. (b) low firing pressure and high exhaust temperature.

Due to the restriction in the exhaust manifold, the turbocharger rpm will be reduced and because of
that less

amount of air will be pumped by the turbocharger into the engine and hence it will cause lower

compression pressure. As the complete removal of exhaust gases from the cylinder does not takes
place,

there will be mixing of the exhaust gas with the incoming fresh air thus diluting it which will cause the

improper combustion of the fuel and hence low firing pressure and high exhaust temperature.

Q.495 Excessive exhaust temperature in two-stroke diesel engine can be caused by

Ans. (b) carbon built up in the exhaust ports.

If carbon is built-up in the exhaust ports, the exhausting process is restricted. Due to this complete
removal

of exhaust gas from the cylinder is not achieved. As a result, the incoming fresh air will get mixed up
with

the cylinder thus diluting or contaminating the fresh air which will cause the improper combustion of
the

fuel. Hence exhaust temperature will increase and the peak pressure will drop and cause afterburning
and

black smoke.

Q.496 What colour exhaust will be exhibited when a low speed two stroke main propulsion diesel

engine designated to operate on light and heavy fuel oil is operated on insufficiently preheated heavy

fuel oil?

Ans. (b) Black

When the heavy fuel oil is insufficiently heated up viscosity of the fuel oil will be high because of which

when it is injected it will not properly atomize. At the same time the penetration will be high and
because

of all this reasons the fuel will not properly mix with the air. It will not evaporate neatly in the
combustion
space to form a combustion mixture which will ultimately result in high exhaust temperature, black
smoke

and loss of power.

Q.497 Immediately after starting a diesel engine normal raw water and jacket water pressures are

indicated, however jacket water temperature continues to rise. If there is no change in the seawater

temperature, you should suspect

Ans. jammed up three-way thermostatic valve.

If the engine load and sea-water temperature is not changing still if the jacket water temperature is
rising, it

definitely indicates that the three-way valve which controls the flow of water through the coolers so as
to

maintain the jacket water temperature may be stuck up in such a manner that the jacket cooling water
is

getting by-passed and is not passing through the cooler. Thus the temperature will continuously go on

increasing.

Q.498 Before starting a diesel engine which has an engine-driven lubricating oil pump the engine

should

Ans. (c) pressurize the lubricating oil system.

When the lubricating oil for the engine is supplied by an engine-driven pump, there will be some time
delay

till the attached lubricating oil pump will take the suction and develop sufficient pressure to provide the

lubricating oil. During this transient time there is a possibility that engine bearings may get damaged.

Hence it is necessary that an externally electrically driven lubricating oil priming pump has to be started

earlier and proper lubrication of the bearings should be carried out and to keep the lubricating system
under

pressure. When the engine starts, the attached lubricating oil pump will have achieved high enough

pressure and the electrically driven lubricating oil pump can be cut-off safely without causing any
damage

to the engine.

Q.499 Collapsed hydraulic valve lifter in a diesel engine will result in

Ans. (c) excessive valve clearance.

Due to the collapse of the valve lifter the valve will not be lifted sufficiently high enough and it will not

seat properly on the seat and it will leak. At the same time, the tappet clearance will also
increase. Q.500 Prolonged operation of a diesel engine with a closed cooling water system at low
operating

temperature than designed will result in

Ans. (d) sulphuric acid formation.

If the engine is operated with the fuel having high sulphur content and low jacket cooling water

temperature, the sulphuric acid formed because of burning of sulphur will reach its dew point. As a
result

the sulphuric acid will coat over the liner wall and this will cause corrosive wear to the liner and hence
total

liner weardown will increase. Hence it is necessary to maintain a sufficiently high temperature if the fuel
is

expected to have more amount of sulphur content. Q.501 A large slow speed main propulsion diesel
engine may become overloaded by

(a) heavily fouled hull.

(b) strong head wind and heavy seas.

Ans. (c) both of the above.

When the hull is fouled, the resistance offered by the ship for the movement increases.

Hence for the same rpm, the engine will be overloaded as it will have to produce more

power to overcome the resistance. Similarly, when there is strong head wind, the ship

will have to work against the head wind and overcome the force created by the headwind.

In this condition also, the engine will be overloaded to maintain the same revolution on

the engine shaft.

Q.502 Immediately after any diesel engine is started, the engineer should check the

Ans. (b) lubricating oil pressure.

Lubricating oil is the most important component of the engine. If the lubricating oil

pressure is lost, even for a fraction of a second, there will be metal-to-metal contact

between the bearing and the shaft, and they will get damaged. Hence the lubricating oil

pressure should be checked as soon as the engine is started.

Q.503 In a diesel engine lubricating oil system, which of the following part should be
lubricated first?

Ans. (b) Main bearings.

In case of the four stroke engines, the oil is first supplied to the main bearings. From the

main bearings, through the holes of the crankshaft, it comes to the bottom end bearings.

From the bottom end bearings, through an oil passage, it passes to the top end bearing.

This passage shows that the main bearing is lubricated first. In case of large two-stroke

engines, where separate lubrication is given to the crosshead bearing, both the main

bearing and the crosshead bearing get the lubrication together.

Q.504 Poor combustion in a diesel engine can be caused by

Ans. (b) low intake air temperature.

If the intake air temperature is low, then the temperature of the air at the end of

compression stroke will also be low. In such condition, if the fuel is injected it will have

improper combustion because it will take more time for the oil to evaporate and form a

combustible mixture. Due to this, there will be more amount of fuel combustion and loss

of thermal efficiency.

Q.505 Diesel engine exhaust gas temperature can be used to determine individual

cylinder

Ans. (a) performance.

The exhaust gas temperature gives the approximate power developed by the engine.

Hence if the exhaust temperature is higher, we can consider that the power developed by

that unit is more than the other units. This may not true always because if there is any

discrepancy developed during the fuel injection, the exhaust temperature will be more but

the power will be less. Hence the combination of exhaust temperature and the indicator diagram will
indicate the exact problem. So exhaust temperature is a rough indication of

the performance of the unit.

Q.506 Which of the following problem may occur if the opening pressure of a fuel

injection nozzle is greater than specified by the fuel injection manufacturer?

If the nozzle opening pressure is higher than specified, the nozzle will open late because

the fuel pump has to develop higher pressure to lift the nozzle and open the fuel injection
valve. In such circumstances, the injection will be delayed.

Q.507 All the diesel engine firing cylinder pressures are normal; yet all exhaust

temperatures are low. Which of the following situation is responsible for this

condition?

Ans. (d) Light load.

When the temperature of all the units are low and the peak pressures are equal, it means

that all units are sharing equal power. If the exhaust temperature is low, it also indicates

that all units are producing less power. When all units are producing less power, then the

total load on the engine is reduced. Hence low exhaust temperature is a cause of low

loading of the engine.

Q.508 Insufficient piston cooling of a large low-speed main propulsion diesel engine

burning heavy fuel may result in

Ans. (c) high temperature corrosion and burning of piston crown metal.

If insufficient cooling takes place, the piston crown temperature will increase. When the

crown temperature increases above 470°C, the vanadium present in the fuel, along with

calcium, will be melted. This molten vanadium will form vanadium pentoxide, which is a

highly corrosive compound. This will get coated over the piston crown and cause

excessive high temperature corrosion of the crown.

Q.509 Which of the following factors tends to increase scale formation on the salt

water side of a heat exchanger used in a diesel engine cooling water system?

Ans. (c) Operating the engine while maintaining a high sea-water outlet

temperature.

The sea water outlet temperature of a cooler can be high because of restricted sea-water

inlet or reduced quantity of the sea water inlet due to some reason. Under such

circumstances, the flow of water through the heat exchanger will get reduced and will get

overheated resulting in high sea-water outlet temperature. This high outlet temperature

will cause the calcium and magnesium salts to get deposited inside the tube of the heat

exchanger causing the more amount scale formation.

Q.510 High exhaust backpressure will result in increase in

Ans. (c) carbon deposits on injector.

Q.511 Any increase in exhaust gas backpressure in a four-stroke cycle diesel engine

will

Ans. (a) reduce diesel engine power output. High backpressure will cause the piston to push the
exhaust gas out of the cylinder with

the backpressure acting over it from the exhaust manifold. This will cause loss of power

because the power required to drive out the exhaust gas from the cylinder will be taken

from other units which are firing. Thus the total power output of the engine will be

reduced because of the pumping effect of the trapped exhaust gas by the use of the piston.

Q.512 In diesel engine, blowby

Ans. (b) causes excessive crankcase pressure.

Especially, in case of four-stroke engine, if there is blowpast, high-pressure gases will

enter the crankcase by blowing through across the piston rings. This will cause increase

in the crankcase pressure.

Q.513 A crack in the cylinder liner can be caused by

Ans. (b) restricted cooling water passage.

Due to the restricted cooling water passages, the cooling of the liner flange on top will

get affected. The liner will run at the higher temperature and because of that the material

of the liner will lose its strength. Hence the liner will crack under the load.

Q.514 A cracked cylinder head may be indicated by

Ans. (c) combustion gases vented in expansion tank.

When the cylinder head is cracked and, under the compression stroke, when the fuel is

injected at high pressure, the combustion gases produced will find its way into the

cooling space through the cracks (in the cylinder head). Those gases which are lighter

will come out of the cooling water from the expansion tank vent.

Q.515 A direct cause of crankcase explosion can be attributed to

Ans. (c) an overheated bearing.

Crankcase explosion will take place only if there is hotspot present inside the crankcase.

If the bearing gets heated, due to various reasons, it will act as a hotspot and crankcase
explosion may take place.

Q.516 Crankcase explosion in propulsion diesel engine results from

Ans. (d) the ignition of unburnt fuel and air in the crankcase.

If there is unburnt fuel oil in the crankcase due to contamination of lubricating oil with

fuel oil, the crankcase will consist of lubricating oil as well as fuel oil vapors. This fuel

oil will ignite in presence of large amount of air present in the crankcase and thus cause

crankcase explosion.

Q.517 Combustion knock occurring in a diesel engine can be caused by

Ans. (a) low coolant temperature.

If the coolant temperature is low, it will take large amount of heat from the compressed

air at the end of the compression stroke. As a result, the temperature of the air will drop

and ignition will be delayed. When the ignition gets delayed, fuel will get accumulated

and get ignited resulting in knocking in the unit. Q.518 Persistent knocking of one cylinder of a diesel
engine ceases when the fuel

supply of that cylinder is secured. This problem may be a result of

Ans. (b) faulty combustion in that cylinder.

When the engine cylinder is knocking, and after shutting of the fuel if the knocking stops,

it is a clear indication that the knocking was a result of problem related to fuel injection

or quality. If the knocking persisted even after the fuel injection was cut-off, it indicates

that the knocking is a mechanical knocking which is a serious problem.

Q.519 Which of the condition will occur when in an operating diesel engine if air

pockets are formed within a cylinder head circulating water passage?

Ans. Hotspots will be developed.

If the air pocket is formed, as air is a low conductor of heat, the heat will not be

conducted form the hot surface and it will not be carried away by water. Hence that

particular spot will get overheated and hotspot will be developed.

Q.520 If a diesel engine exhaust temperature is abnormally higher, the cause could

be

Ans. overload of the engine or the compression pressure would be too low.
If the engine is overloaded, the exhaust temperature of all units will be higher. If the

temperature of only one unit goes up, it is an indication that there is some thing wrong

with that particular unit i.e. either incomplete fuel combustion or improper timing

adjustment of that unit or too low compression pressure of that unit due to worn out

cylinder liner or leaky piston ring.

Q.521 Heat damage to the fuel injection nozzle can be prevented by avoiding

(a) excessive fuel oil temperature.

(b) long period of engine overload.

(c) hard carbon deposits and varnish on the nozzles.

(d) All of the above

Ans. (d) All of the above.

If excessive fuel oil temperature is permitted and if there is no separate cooling is given

to the injector and the circulating fuel itself is part of cooling system, in such conditions

the hot fuel oil will keep the nozzle at high temperature. This will cause damage to the

fuel injector because at higher temperature the fuel injector nozzle and the valve seats

will lose its strength and it will fail. Secondly, if the engine is working at high load for

long time, the fuel injector nozzle will be subjected to high temperature from the

combustion space due to which the fuel injector nozzle may get damaged. Thirdly, if the

quality of the fuel is bad, there is a possibility that hard carbon deposits may be formed.

Also the needle guide may get coated with hard varnish and because of this the fuel oil

nozzle operation may get affected and it would ultimately cause to seep in place or have

excessive weardown and it will get damaged.

Q.522 The main propulsion diesel engine is normally shutdown by

Ans. (c) securing the fuel supply.

Under normal circumstances, the fuel oil supply supplied to the engine is stopped. Q.523 Excessive
diesel engine backpressure may be indication of

Ans. (a) carbon built up in exhaust manifold.

When the carbon is built up in exhaust manifold the exhaust gas will have to overcome

resistance of the built up carbon to pass through the exhaust manifold. Due to this there
will be excessive backpressure. In order to overcome this backpressure, the piston has to

work against the exhaust gas and hence there will be loss of power.

Q.524 White smoke from the exhaust of diesel engine can result from

Ans. (b) low cooling water temperature.

Due to low cooling water temperature, the entire atmosphere inside the cylinder liner will

be at lower temperature because of which the exhaust gas temperature will drop down.

When the exhaust gas temperature will drop down, the water vapor in the exhaust gas

will get condensed to form white smoke.

Q.525 What is the best way of stopping an overspeeding diesel engine?

Ans. (d) secure the fuel supply and block the air intake.

The best way to stop an overspeeding engine is to cut-off the fuel to all the units

simultaneously and immediately. If the fuel cannot be cut-off, then even if the air intake

suction filter or the turbocharger suction filter is blanketed, it will prevent the air entry

into the engine. Hence due to lack of availability of air fuel, combustion will not take

place and the speed of the engine will drop and ultimately it will stop.

Q526 By comparing the exhaust gas outlet of each cylinder in a diesel engine, one

method of determining if the engine load is balanced is by the use of

Ans. (d) pyrometer.

Pyrometer will show the exhaust gas temperature of each unit. Generally and roughly, it

is accepted that the exhaust gas temperature is the measure of power developed by

individual unit. Hence higher the exhaust temperature, higher will be the power

developed and lower the exhaust temperature lower is the power developed. This is a

rough estimation and cannot be utilized unless it is backed up by other parameters such as

* compression and * maximum.

Q.527 One cylinder of a diesel engine is persistently knocking and does not ceases

when the fuel oil supplied to the cylinder is secured. What is the following problem

which can cause this?

Ans. (d) A mechanical defect in working part.

If the diesel engine one cylinder is knocking the knocking may fuel related or mechanical
In order to know the exact cause of knocking first the fuel is cut-off. If after cutting of the

fuel the knocking stops, it indicates that the knocking is due to the fuel timing or the fuel

quality. But if the knocking continues even after the fuel is cut-off, it is a clear indication

that somewhere metal-to-metal contact is taking place and there is mechanical defect in

the working parts.

Q.528 A diesel engine is warmed up and white vapor is noted in the exhaust. What

does it indicate?

Ans. leaky cylinder liner. If engine is properly warmed up and is working at proper load and under such

circumstances if there white vapour is indicated in the exhaust, it is an indication that at

some point water is finding its way into the combustion space. This may be due to a liner

or cylinder head crack.

Q.529 A smoky exhaust from an operating diesel engine could be caused by

Ans. (c) late fuel injection.

In case the fuel injection is too late, there will be afterburning. When afterburning takes

place the efficiency of combustion reduces and excessive black smoke may occur.

Q.530 Oil accumulating in exhaust gas piping or manifold of a diesel engine can be

caused by

Ans. (b) worn valve guide.

If the valve guide is worn out, the clearance between the valve guide and valve stem will

increase and the valve guide will be lubricated by the use of rocker lubrication oil. If the

clearance will be more, then the finer particles of oil will, along the stem of the valve,

enter into the exhaust manifold.

Q.531 Diesel engine operating conditions are indicated by color of exhaust smoke.

Blue smoke can indicate

Ans. (c) clogged drain holes in the oil control ring.

If the drain holes in the oil control ring get clogged, the oil which is trapped in the oil

control link will not get drained into the crankcase but it will remain on the cylinder liner

and it will get burnt with the exhaust gas. This burnt oil vapor will find its way along

with the exhaust gas and hence the exhaust gas will have a blue tinge.
Q.532 If the diesel engine is smoking excessively under load, the cause could be

Ans. (d) plugged injection holes or low compression pressure.

If the compression pressure in one of the cylinder is low, the fuel will not burn efficiently

and black smoke will be emitted by the engine. Also if the injector holes are plugged or

are choked, there will not be proper penetration and the engine will have late ignition and

because of this, there will be excessive black smoke.

Q.533 Sticking of diesel engine compression rings may be caused by

Ans. (c) excessive cylinder lubrication.

If the cylinder lubrication is excessive and the excessive oil is not been scrapped by the

oil control rings, the excessive lubricating oil will get burnt and form carbon or calcium

carbonate due to which the piston ring will get stuck up in the grooves. Also the improper

rotation of the rings may cause them to get stuck up in the grooves because rotation of the

piston rings give the self-cleaning effect for the piton rings. If they are not allowed to

rotate, the carbon may get deposited and get choked up or stick the piston ring in the

groove

Q.534 Which of the following condition can cause excessive lubricating oil

consumption in a diesel engine?

Ans. (d) High lubricating oil temperature. If the lubricating oil temperature is high, excessive
vaporization of the lubricating oil will

take place and ultimately it will cause excessive lubricating oil consumption.

Q.535 Late fuel oil injection in a diesel engine may result in

Ans. (d) high exhaust temperature.

When the fuel oil injection is late, there is little time for fuel and air to mix properly.

Hence there is improper combustion will take place. Also there will be afterburning and

hence the exhaust temperature will be on the higher side.

Q.536 Which of following condition is likely to develop if the thermocouple element

of a pyrometer becomes coated with excessive amount of combustion byproducts?

Ans. (b) Pyrometer response will be retarded.

The carbon deposits around the pyrometer sensor will retard the heat transfer because that
coating will form an insulating material and hence heat transfer will be affected. Also the

heat transfer will take more time. Due to this, the response in change in temperature will

be retarded and the change in temperature will be registered not immediately but

comparatively late.

Q.537 When the opening pressure injector is greater than specified by the engine

manufacturer which of the following problem can be expected?

Ans. (a) quantity of fuel to be injected tends to decrease.

The effective delivery stroke of the pump plunger will reduce because it will take more

time for the plunger to travel before the sufficient pressure is developed. Hence as the

effective delivery stroke is reduced, it will automatically reduce the quantity of the fuel

injected.

Q.538 Late fuel injection occurring, at or after TDC, is indicated by excessive

exhaust smoke and

Ans. low firing pressure.

When the injection is late, the fuel will get ignited late when the piston is already on its

downward travel and because of this the firing pressure will reduce and afterburning will

take place.

Q.539 In a diesel engine, late fuel injection is indicated by black or gray exhaust

smoke with

Ans. (a) low firing pressure.

As the firing is late, the combustion of the fuel is late when the piston is moving

downwards and because of that the volume will increase. Hence the firing pressure will

reduce.

Q.540 If a crankcase explosion occurs in a diesel engine you should stop the engine

and

Ans. (b) allow the engine to cool naturally .

The crankcase doors should not be opened immediately as if they are opened there is a

possibility that outside air may enter the crankcase and result in secondary explosion. In
order to avoid the secondary explosion, which is of higher intensity and it will cause large scale
destruction, it is necessary to allow the engine to cool down naturally and not by

forced ventilation.

Q.541A diesel engine will lose power if the injection occurs too late in a cycle

because of

Ans. (c) maximum expansion of burnt fuel cannot take place in the cylinder.

If the fuel injection occurs too late then in such conditions the maximum pressure will be

reduced. At the same time, when the actual burning of the fuel takes place, the piston will

be on its downward movement under which the volume will increase and the pressure

cannot be increased. Ultimately, the power developed by the engine will reduce because

the power developed by the engine will be given by

Power developed = PLAN

In the above formula as P reduces the power developed is reduced

Q.542 Which of the following condition will be developed when unburnt fuel

contaminates the crankcase of a diesel engine?

Ans.

When the unburnt fuel oil finds its way into the crankcase, it will mix with the lubricating

oil from the crankcase and bring down the viscosity of the lubricating oil. Also it will

bring down the flash point and fire point of the lubricating oil

Q.543 Same as 539.

Q.544 The ignition quality of diesel oil becomes less critical as

Ans. (d) the engine speed decreases.

As the engine speed decreases, there is ample amount of time available for the fuel and

air to mix and form a good combustion mixture. Hence the quality of the fuel does not

matter much under the low speed engine as compared to medium or high-speed engines.

Q.545 Higher than normal temperature air passing through the intake of a diesel

engine will result in

Ans. (c) low horse power .

If the air entering the cylinder is at high temperature, the volumetric efficiency of the
cylinder will reduce because the quantity of the air which enters the cylinder reduces.

When this happens, automatically the fuel injected will not burn properly. Hence the

thermal efficiency will drop down and will cause black smoke and higher exhaust

temperature and low power is developed.

Q.546 When the fuel injector nozzle overheats which of the following problems may

developed?

Ans. (a) The fuel metering will vary.

When the nozzle gets overheated, the clearance between nozzle and needle guide will

change due to which there will excessive leakage pass the needle. Also the needle will

not seat properly on the seat and there will leakage pass the seat. Due to all this the total

quantity of fuel which is injected will vary. Q.547.An increase in fuel injection pump discharge pressure
can be caused by

Ans. (c) plugged fuel injector spray holes.

When the fuel injector spray holes are choked, it will develop excessive backpressure on

the fuel pump. This will cause excessive fuel injection discharge pressure.

Q.548 If fuel injection in a diesel engine begins earlier than designed start of

injection, ignition may be delayed because of

Ans.

If there is excessive early fuel injection, as the compression pressure in the cylinder has

not sufficiently reached to cause the ignition of the fuel and because of this the fuel will

get accumulated and burn with a heavy knock. This is the reason for not advising early

injection of fuel.

Q.549 Prior to starting, the purpose of turning over the main propulsion diesel

engine with a cylinder test cock open is to

Ans. (b) remove the condensation from the cylinder.

When condensation takes place of the moisture in the air on the top of the piston or if

there is any water or fuel accumulation and an attempt is made to start the engine, as the

liquid is incompressible, there will be hydraulic pressure developed which will act over

the piston, cylinder head, connecting rod and crankshaft thus causing them to bend, break
or fracture. Hence it is advisable everytime to blow through the engine before starting

after a long stoppage.

Q.550 A fuel injection valve opening at pressure below than normal will result in

Ans. (b) early fuel injection.

If the fuel injection valve opening pressure is low, the pressure required to lift open the

needle valve will be less. This low pressure can be reached with a very little upward

movement of the plunger and because of this fuel may enter the chamber too early and

this may also cause knocking.

Q.551 Faulty operation of diesel engine fuel injection nozzle can be directly caused

by

Ans. water in the fuel oil supply or excessive fuel nozzle holder cooling or distorted

fuel pattern or leakage past the plunger into the oil drain.

(All the above noted things are possible for the faulty operation of diesel engine fuel

nozzle.) Water will cause sticking of the needle in the guide and excessive weardown of

between nozzle and guide and missing of the firing in between and so it will cause the

improper combustion and surging of the engine. Excessive cooling of the nozzle will

cause the formation of sulfuric acid and it will get corroded. Due to the corrosion of

nozzle, the spray pattern of fuel which is injected will change. If the plunger and barrel

clearance is more then also there will be excessive leakage between the plunger and

barrel and this will also cause the late opening of the fuel injector. At the same time,

because of the drop in pressure, the spray will not be proper and atomization and

penetration will not be good. Q.552 Water in the fuel can prevent the engine from starting, preventing
it to

develop full power or run at full speed.

Ans.

If there is water in the fuel the power developed by the engine will be reduced and it will

miss firing. When missing of firing takes place, the rpm will go on fluctuating

continuously and smooth running of the engine will get hampered.

Q.553 Air in fuel lines of a diesel engine can cause

Ans. ignition failure.

As air is compressible fluid, it will get compressed and will not transfer the pressure to

the fuel injector valve. Hence it will not get lifted up and there will be loss of power and

ignition failure.

Q.554 Before starting a diesel engine you should always check

Ans. (b) crankcase oil level.

As oil is the most important part of the engine, it is necessary to check the oil level. If the

oil level is less and the engine is started, the oil level will go down and lubricating oil

pump may lose suction. If the lubricating oil pump loses suction, even for a fraction of a

second, the bearing will get damaged.

Q.555 Dirt in a fuel oil system of a diesel engine may cause

Ans. (d) to the fuel oil injector damage.

Due to the dirt, there will excessive weardown between the needle and guide. At the same

time, there will be scratching on the needle and the guide. The fuel injector may get worn

out faster or the dirt may also cause the needle to stuck up. All this will lead to damage to

the fuel injector. Q.556 If cooling water flow through after cooler is interrupted the power output of a

turbocharged diesel engine will drop because the

Ans. (b) density of the air will decrease.

When the water flow through the after cooler is interrupted, the air temperature increases.

Automatically, the volume of the air increases and the density decreases. Hence for the

same said volume, the quantity of the air from the point of view of weight, as concerned,

will be always less than what it would be if the temperature was lower. Higher the

temperature, the weight of the air reduces. When the weight of the air reduces, the fuel

injected will not burn efficiently. Hence, there is automatically a drop in the power output

of the engine.

Q.557 Operating a propulsion diesel engine at less than 30% of designed normal

load for prolonged periods will result in

Ans. (d) carbon formation on the combustion chamber surfaces.

When an engine is operated at such low loads, the turbocharger efficiency drops. When
the turbocharger efficiency drops, less quantity of air is supplied to the cylinder. Hence

the quantity of air available in the cylinder for combustion is reduced. This will

automatically reduce the quantity of fuel which is burnt. At the same time, the fuel will

not burn efficiently. Thus unburnt fuel will lead to carbon formation and the combustion

chamber surfaces will get coated with the carbon deposits.

Q.558 Diesel engine fuel oil contamination often results in

Ans. (b) fuel injection system malfunction.

The fuel oil of diesel engine will get contaminated with water or with solid particles such

as silica, rust, or allumina. All these three components will result in improper functioning

of the fuel combustion injection equipments. Because of the water, there will be rusting

and lots of misfiring in the combustion stroke. Also if there is a hard particle, silica or

allumina, present then it will give abrasion on the needle and guide and cause the leakage

of fuel. Any catalysts and fines entering the clearance spaces of part of fuel injection

equipments can lead to accelerated wear of these parts. The wear may be extensive with

few days of operation with contaminated fuel. Also it will block the injection holes on the

nozzle and cause complete malfunctioning of the fuel injection system.

Q.559 Operating a diesel engine under light load and at lower temperatures for

extended period can result in

Ans. (a) formation of carbon on the inlet and exhaust valves.

When the engine is operated at low load and low temperature for a longer time, the

turbocharger efficiency drops. When the turbocharger efficiency drops, the quantity of air

supplied to the engine reduces. This results in improper combustion and hence large

amount of carbon formation takes place in the combustion chamber. When running at low

load, the exhaust gas pressure and exhaust gas energy are not sufficient. Hence there will

be backpressure exerted on the exhaust. If the same overlap is maintained between

exhaust and inlet valve is maintained during that time, then when the inlet valve opens

the exhaust pressure is not sufficiently dropped. Under such circumstances, momentarily

there will be back-flow of exhaust gas from the cylinder into the air inlet valve before the actual flow of
the inlet air to the unit starts. During this time, the formation of carbon
takes place in the air inlet valve.

Q.560 Which of the conditions listed occurring in the diesel engine would cause

carbon deposits to develop in the piston ring belt.

Ans. (d) all above i.e. faulty combustion, excessive ring temperature, over

lubrication.

The carbon deposits develops in the piston ring belt because of

1. Improper combustion: The improper combustion of fuel results in carbon being

deposited.

2. Excessive ring temperature: If ring temperatures are excessive, then lubricating oil

will get burnt which also leads to the formation of carbon.

3. Over lubrication: The excessive lubricating oil that is supplied to the piston ring

will get burnt and convert into ash or carbon thus forming the excessive coating of

the carbon on the ring.

Q.561 If a crankcase explosion occurs in a diesel engine which of the listed action

should be taken.

Ans. (c) Allow the engine to cool before opening the crankcase.

There will be two kinds of crankcase explosion, one a primary explosion and other the

secondary explosion. When the primary explosion takes place because of the oil mist and

the appearance of hot spot in the crankcase, there is a high-pressure rise in the crankcase

which is released into the engine room atmosphere with the help of crankcase relief

valves. At the same time, the non-return valve will shut and not allow the new air to enter

into the crankcase. The crankcase atmosphere will be highly rich and hence there is a less

possibility of exposure. Under such circumstances if by mistake the crankcase door is

opened, fresh air will enter the crankcase and bring the crankcase atmosphere in the range

of explosive limit. When this happens, there will be heavy explosion and a secondary

explosion may take place. So the best thing to do is to allow the engine to cool down

before opening the crankcase doors.

Q.562 The burning of fuel oil in a diesel engine having a high sodium content will

cause
Ans. corrosion and grooving of exhaust valves.

In general, fuels leaving the refinery have sodium content well below 50mg/kg. If the

sodium content increases, which is normally caused due to seawater contamination. A 1%

seawater contamination represents potentially a 100mg/kg increase. Vanadium is also

present in the fuel oil, which combines with oxygen to form V2O5 (vanadium pentoxide),

which combines with sodium to form sodium/vanadium complexes. It is well known that

there are low melting temperatures of sodium/vanadium complexes of certain critical

ratios. The most critical sodium/vanadium ratio is about 1:3. This will form a

sodium/vanadium complex with a low melting point which will flow with the exhaust

gases. It will get deposited as a hard and brittle layer on the cold surfaces such as exhaust

valve spindles, turbocharger nozzles and turbine blades. This layer is highly corrosive

and corrodes the metal. It is also brittle and breaks away exposing the metal for fresh

attack especially when they get deposited on exhaust valve seats. The hard layer breaks and gives a
cutting effect on the seat. Preventive measures can be taken such as keeping

the temperature of the exhaust below the melting point of V2O5 and removal of sodium

by proper purification and proper draining of the settling tanks. Therefore high sodium

content in the fuel oil will result in corrosion and grooving of exhaust valves.

Q.563 The longer the ignition delay period resulting from improper use of low

cetane fuel, the

Ans. more rapid the rise in the combustion pressure.

Longer the period of ignition delay, more quantity of fuel will accumulate before the

actual firing will takes place. As a result, there will be sudden increase in the combustion

pressure. When the large quantity of accumulated fuel ignites, there is a sudden

development of the high-pressure wave. At the same time if the ignition delay is too

much, there will afterburning. When afterburning takes place, there will be high enforced

temperature.

Q.564 If the relief valve on the diesel engine cylinder lifts, the cause could be

Ans. (a) liquid in the cylinder.

When there is a liquid in the cylinder, the piston is moves upward. Hydraulic pressure
will develop because of the presence of liquid. As liquid is incompressible, large amount

of hydraulic pressure is developed. In order to save the engine components from damage,

the relief valve will lift and release the pressure.

Q.565 The substantial increase in the crankcase pressure could be an indication of

Ans. (c) a worn cylinder liner.

When the pressure in the crankcase of a diesel engine increases, it could indicate

blow-past by the piston. This could be due to worn out cylinder liner or the piston rings

are leaking or piston rings are broken. In that case large amount of high-pressure gas will

enter into the crankcase and produce high pressure in a crankcase. Hence the substantial

increase in the crankcase pressure could be an indication of a worn out cylinder liner.

Q.566 An indication of an overloaded main propulsion engine.

Ans. (b) High exhaust pyrometer readings.

As a general rule the exhaust temperature is related with the load of the engine. Higher

the load, higher the exhaust temperature of the engine. Hence it is the direct indication of

the load on the engine. Hence if the exhaust temperature is higher, then the engine is

overloaded.

Q.567 The dry-type exhaust silencer clogged with soot will cause

Ans. (b) loss of engine power.

When the dry-type exhaust gas silencer gets clogged with soot, there will be large amount

of exhaust gas to flow and because of that the exhaust gas pressure will be higher. Hence

the complete removal of exhaust gas will not be possible which will cause the mixing of

the exhaust gas with the incoming air. Thus it dilutes the incoming air with the exhaust

gas. This will cause improper combustion because of the starvation of the oxygen for the combustion of
the fuel. The exhaust temperatures will increase and consequently there

will be loss of power in the engine.

Q.570 The color of the exhaust from the diesel engine should be

Ans. (a) clear.

The clear color of the exhaust gas from the engine exhaust will indicate the best possible

combustion without any carry over of the fuel, lubricating oil, water in the fuel or
improper combustion. So it should be noted that the colour of the exhaust indicates the

health of the engine or any defects in the combustion. If the colour of the exhaust is

black, it indicates improper combustion that may be due to some fuel system

malfunctions or an overloaded engine. If the colour of the exhaust is white, it is consists

of water. If the colour of the exhaust is bluish, then it indicates the burning of lubricating

oil in the engine. So clear exhaust is an indication that the combustion is perfect.

Q.571 Engine operating conditions maybe indicated by the colour of the exhaust

smoke. Black smoke could indicate.

Ans. (b) an overloaded engine.

If the engine is overloaded beyond particular limit then, the quantity of the fuel will be

more but comparatively the quantity of the air will be less. Hence larger quantity of fuel,

which is injected into the unit, will be difficult to burn in allotted time and so

after-burning will occur. This will increase the exhaust temperature and black smoke will

be formed.

Q.572 Restricted air intake to a diesel engine may result in

Ans. (a) engine failing to reach the rated speed.

When the air intake to the engine is restricted, automatically the fuel will not burn

properly. Hence power generated by the engine will be less. When power generated by

the engine is less, it may be possible that it will fail to reach the rated speed at a lower

condition.

Q.573 Color of engine exhaust form diesel engine should be

Ans. (a) clear. (Refer to Q.570)

Q.574 With regards to diesel engine crankcase explosion, the most violent is

(i) secondary explosion.

(ii) primary explosion.

Ans. (ii) only. Q.576 Some diesel engines are fitted with thermometer in cooling water outlet of each

cylinder. The cooling water temperature from all the cylinder being risen above the normal,

you should suspect

Ans. overloading of all the cylinders i.e. overloading of the engine.

If overloading of engine takes place, then the quantity of heat taken out by the cooling water will

be very high and in that case jacket cooling water temperature will increase. Also, it may increase

due to the malfunctioning of the control valve fitted on the water cooling system.

Q.577 Some diesel engines are fitted with thermometers in the cylinder. If the cooling water

temperature from an individual cylinder begins to rise you should suspect

Ans. (b) overloading of that cylinder.

If the heat generated in that cylinder is excessively high, heat carried out by water from that unit

will be very high and hence the jacket cooling temperature of that unit will increase. It is an

indication that there is a overloading of that particular unit. This may be because of leaky fuel

valve, or fuel pump rack stuck up in the high fuel condition.

Q.578 A diesel engine using lubricating oil having too high viscosity will exhibit

Ans. increase in starting difficulty in cold weather.

If we are using high viscosity oil and having low viscosity index, because of the excessively high

viscosity, there will be too much of drag and excessive friction between the bearing. The loss of

power to overcome this drag will be so high that it will be difficult to start the engine from the

cold and most of the power, which is used for starting and turning the engine, will be wasted to

overcome this friction caused by the high viscosity.

Q.579 One result of operating a diesel engine at light load with excessively low cooling water

temperature is

Ans. (b) increase in the cylinder misfiring.

If the engine is operating at low load and with low cooling water temperature, the compression

temperature and compression pressure will be very low. If the fuel is injected, then it may stop

igniting and may cause misfiring of the engine.

Q.580 Which of the following condition may tend to increase the ignition delay period of

combustion in a compression ignition engine?

Ans. (b) Decreasing the charge air temperature.

If the charge air temperature is decreased, automatically the temperature at the end of

compression stroke will also decrease. When the temperature at the end of compression decreases

beyond certain limit, it will be difficult for the fuel which is injected to convert into combustible
mixture and large amount of time will be required to achieve this process. In this situation, the

time delay will increase, especially in compression ignition engines

Q.581 In a diesel engine excessive cylinder liner wear will cause

(i) increase blow-by.

(ii) wear between the piston ring and the groove.

Ans. Both answers are correct.

If there is excessive cylinder liner wear, there will be blowpast because piston ring will not seal

the liner properly. When the piston rings will be sliding over the worn surface of the liner, which are not
evenly worn-out, in order to keep the contact with the liner, the piston ring will move in

radial direction in and out continuously. Due to this, piston rings will slide over bottom surface of

the ring groove thus causing the excessive wear of the bottom of the ring groove.

Q.582 The change in the degree of fuel atomization in a fuel diesel engine will mostly affect

Ans. (b) fuel penetration.

Penetration and atomization are inversely proportional to each other. Hence if there is excessive

penetration there will be less atomization and if there is excessive atomization there will be less

penetration. When atomization takes place, the fuel particles are divided into very small minute

microscopic particles which will have less amount of energy to overcome the dense atmosphere in

the combustion chamber and hence it will not penetrate deep into the combustion space. On the

other hand, if the atomization is less the particle size will be bigger and their mass will be higher

and hence they will have high amount of kinetic energy to penetrate into the dense atmosphere air

deep into the combustion chamber.

Q.583 The longer the ignition period occur in a diesel engine the more rapid rise in the

combustion pressure.

More delay will give more accumulation of the fuel in the combustion space before the actual

firing of the fuel takes place. As a result, the accumulated fuel will get ignited. When the

accumulated fuel will get ignited suddenly or instantaneously, it will cause excessive amount of

pressure rise in the cylinder.

Q.584 Diesel engine exhaust temperature may be used to indicate

(a) leaky exhaust valve.

(b) overloaded cylinder.

(c) clogged injector nozzle.

(d) All of the above.

Ans. All of the above.

The leaky exhaust valve will indicate increase in temperature because of the high-pressure gases

leaking past the exhaust valve. An overloaded cylinder will be indicated by excessive exhaust

temperature as higher the load, more will be the quantity of fuel which is injected. When the

quantity of fuel injected increases, automatically the temperature of the exhaust gas increases.

Thirdly, as the injector nozzle is clogged automatically the quantity of the fuel injected will be

decreased. In that case, the temperature may drop down for that particular unit but it may increase

for the other units. Also, if one or two holes of the injector are clogged, there is a possibility that

more fuel will be injected through the other holes resulting in unbalanced distribution of the fuel

in the combustion chamber which may cause the afterburning effect and increase the temperature.

Q.585 Maintaining proper fuel oil temperature will result in

Ans. (b) improved atomization.

Maintaining proper fuel oil temperature will maintain proper viscosity and viscosity is important

from point of view of atomization. If viscosity is properly maintained, there will be proper

atomization and proper penetration. Hence there will be proper balance between penetration and

atomization, and there will be better combustion. Q.586 Combustion knock can occur in the cylinder of
a diesel engine under any condition

permitting

Ans. (c) excess fuel in the combustion chamber.

Excessive fuel in the combustion chamber may be due to ignition delay and cause sudden increase

in the pressure. This excessive pressure will cause excessive knocking effect in the engine.

Q.587 Persistent knocking in one cylinder of a 8-cylinder diesel engine is most likely to be

caused by

Whether the knocking in the cylinder is by fuel oil or not, it can be checked by cutting of the fuel

oil and checking whether the knock persists or not. Even if the knock persist after cutting the fuel

oil it indicates that there is some excessive clearance in some of the running parts. Most possible
place is badly worn piston pin and bush. Hence every time when the piston is changing its

direction from upwards to downwards it will give the knocking effect.

Q.588 A crack cylinder head in an operating engine may be indicated by

Ans. (b) combustion gases venting from expansion tank.

Due to the crack, high-pressure gases will enter through the cracks into the water space during the

exhaust stroke and these gases may come out of from the expansion tank or the expansion tank

may overflow. At the same time, this will be indicated by high jacket cooling temperature of that

particular unit.

Q.589 Coolant can be lost from jacket cooling water system by leakage from

(a) cracked cylinder head.

(b) piping joints.

(c) pump seal leaking .

(d) All of the above.

Ans. (d) All of the above.

Water can be lost if there is crack in the cylinder liner or head during the suction stroke when the

pressure inside the cylinder is low. When the pressure in the cylinder is low, water will leak into

the combustion space. When during the compression and ignition stroke there is high pressure gas

in the cylinder it will enter the cooling space. Thus there will be loss of water. The water loss can

also be due to leaking piping joints that can be seen externally. The pump sealing leakage will

also result in loss of water and it may enter the crankcase or it may come out of the * hole fitted

between the crankcase and the pump.

Q.590 When oil vapors, oxygen and hotspots are present at the same time with in a

crankcase which of the following hazards could develop?

Ans. (a) Explosion.

When oil vapor, hotspot and oxygen is present the triangle is completed for fire resulting in

explosion. This is called primary explosion which will be followed by secondary explosion.

Q.591A possible cause for an individual piston to knock when at TDC on a slow speed two

stroke diesel engine could be due to

(a) early fuel injection.

(b) excessive bearing play between the gears.

(c) overloading of the cylinder. (d) All of the above.

Ans. (d) all of the above.

The main reason is that if there is excessive early fuel injection, fuel will get accumulated and

there will be sudden firing of the cylinder and cause the knock. Excessive bearing clearance will

cause the mechanical knocking. Also excessive bearing clearance between the running gears will

cause low compression pressure. Due to low compression pressure automatically the ignition will

get delayed and knocking will take place. Also because of overloading of engine, excessive fuel

will be loaded in the engine and the time available to burn will be less. Hence more fuel will

accumulate and that accumulated fuel will ignite violently to give knocking. In other words,

knocking will generally be because of increase in the ignition lag.

Q.592 An automated diesel engine should normally shut down due to

Ans. (c) low lubricating oil pressure.

Lubricating oil is the most important element of the engine. If there is low lubrication oil

pressure, the engine will not run even for short time and may cause excessive damage. Hence the

first and foremost important thing for the engine is low lubrication oil pressure cut-off.

Q.593 Routine monitoring of a diesel engine should include

(i) checking for leak.

(ii) checking for temperature and pressure.

(iii) listening for abnormal noise.

(iv) All of the above.

Ans. (d) All of the above.

All of the above aspects will indicate proper running of the engine and to ensure proper running

of the engine, all the parameters should be continuously monitored and checked, and noted in the

log book.

Q.594 One remedy for a high firing pressure, in addition to high exhaust temperature, in

one cylinder of a diesel engine is to

Ans. (c) adjust the fuel rack.

If both the exhaust temperature and peak pressure is high, it indicates that the quantity of fuel
injected is more. Hence it is necessary to reduce the quantity of fuel in the cylinder. This is done

by adjusting the position of fuel rack. Due to this the quantity of fuel injected will automatically

get reduced and knocking will be stopped.

Q.595 If a diesel engine is difficult to start and operates at engine temperature lower than

normal you should suspect that

Ans. (a) compression pressures are below normal.

If the compression pressure is below normal, it will be difficult to start the engine immediately as

the fuel does not burn immediately. As the engine is cold and compression pressure is low, it will

be difficult to start the engine.

Q.596 A distorted spray pattern of a fuel injector can cause

Ans. (d) loss of power.

When there is distorted pattern of fuel injector, there will not be a proper distribution in the

combustion space. Hence fuel and air will not mix properly and complete air will not be available for
combustion. This will cause the improper combustion of fuel and because of this there will be

loss of power and high exhaust temperature.

Q.597 White smoke issuing from exhaust of an auxilary diesel engine would mean

Ans. (b) engine is cold.

If the engine is cold, the exhaust will have condensation of the moisture. At the same time, the

exhaust gas generated will cool down and the moisture in the exhaust gas will also get condensed.

This will result in white smoke from the exhaust gas outlet.

Q.598 White smoke in the exhaust of a diesel engine can be caused by

Ans. low combustion temperature.

Same as 597

Q.599 Bluish smoke in the exhaust of an operating diesel engine can be caused by

Ans. (b) cold cylinder liner

When the cylinder liner is cold, lubricating oil will not get scrapped out of the liner into the

crankcase but it will get burnt along with the fuel into exhaust gas. This will result in blue smoke

emitting from the exhaust manifold

Q.600 One of the factors limiting the amount of load which can be put on a modern diesel
engine is

Ans. (b) exhaust temperature.

Exhaust temperature is a criteria for loading the engine because higher the exhaust temperature,

the higher the temperature to which the components of machinery in combustion chamber are

subjected. Higher the temperature the components are subjected to, they lose their strength much

earlier and hence their load carrying capacity decreases. Hence the components fail under the

influence of higher temperature and pressure.

Q.601 White smoke exhausting from a diesel engine can be caused by

Ans. (c) cracked cylinder liner.

If the cylinder liner is cracked, especially at the lower end, water will enter the cylinder. This

water will be evaporated during the burning of the fuel and this evaporation will cause the steam

which will give white smoke in exhaust gas.

Q.602 If a diesel engine runs roughly, which one of the system listed is likely to be at fault?

Ans. (a) Fuel system.

If the fuel is of bad quality, it may have misfiring. When misfiring takes place, there will be

fluctuation in the load and rpm of the engine.

Q.603 One cause of diesel engine surging can be result of

Ans. (a) injection pump plunger stuck or worn.

The surging, in question, is that of turbocharger. When one unit fuel pump plunger is stuck or

worn out, there will be no injection in that unit. Due to this, there will be unbalance of the engine

power sharing. At the same time, there will be excessive fluctuation in the rpm and this will cause

the turbocharger to surge. Q.604 Which of the listed prestart procedures should be carried before
starting a crosshead

type diesel engine after an overhaul?

(a) pre-lubrication of the cylinder with hand crank.

(b) open all air space drain cock.

(c) open all indicator drain cocks.

(d) All of the above.

Ans. (d) All of the above.

Before starting engine, it should be necessary that there should not be any accumulation of water

or fuel on top of the piston. Otherwise, there will be hydraulic pressure developed and cause

damage to the engine. It is therefore necessary to open the indicator cock and turn the engine on

turning gear. Also, the indicator cock should be kept open before starting and do blow-through

with air. Secondly, when the engine is in standstill condition, the cylinder liner and the valve seats

are dry. Hence it is necessary to supplement it with the lubricating oil so that initially during few

strokes, when the cylinder lubricator is not injecting, sufficient amount of lubrication oil is

available on the cylinder liner wall. This is carried out by the lubricator turning by hand. Also, it

is necessary in order to avoid the entry of water through the air which may be because of

condensation of moisture in the air, it is necessary to drain the air manifold.

Q.605 Plugged spray hole in a diesel engine fuel injector will

Ans. cause excessive smoking at idling speed or when the engine is on load.

When the engine is at idling speed or on load, due to the plugged injector spray holes there will be

uneven distribution of fuel inside the combustion space. When there is uneven distribution of fuel

in the cylinder, the complete combustion of fuel will not take place because of unavailability of

air to the fuel. As a result, air pockets will be created and because of lack of oxygen, the

combustion will deteriorate and will form carbon formation and smoking.

Q.606 Late fuel injection in a diesel engine is indicated by low firing pressure with

Ans. (c) black or grey exhaust smoke.

When the fuel injection firing is late there will be afterburning. When afterburning takes place,

the exhaust temperature will be high and as the burning takes place under increase in volume

condition, the pressure will drop. At the same time, there will be large amount of black smoke.

Q.607 Distortion of spring pattern of nozzle may be indicated by

Ans. (c) smoky exhaust.

Refer to above.

Q.608 An incorrect spray pattern of a diesel injector nozzle can be directly caused by

Ans. overheating or overcooling of the nozzle or carbon blockage of spray holes.

Under all the three condition, there will be distortion of fuel pattern and loss of power and high

exhaust temperature. If there is overheating, the needle will not sit properly on the seat. At the
same time, the clearance between the needle and guide will change which will cause the leaking

and because of which the spray pattern will change because of drop in pressure and leaking of the

needle valve. In case of overcooling, the nozzle will get distorted because of corrosion and

because of which the spray pattern will change. Thirdly, carbon blockage of spray holes will

cause the distortion of the spray as the fuel will hit the carbon deposits and it will be distorted. Q.609
High cylinder pressure accompanied by low exhaust temperature can result from

Ans. (d) excessively injection timing.

If the fuel is injected early, there will high firing pressures but low exhaust temperature because

enough amount of time will be available for the fuel to mix properly and form a combustible

mixture. Hence the combustion will be perfect. When combustion is perfect, it will produce more

amount of power and there will not be any afterburning. Hence the exhaust temperature will be

low but the firing pressure will be high.

Q.610 A leaky diesel engine fuel injector will cause

Ans. (d) incomplete combustion.

Leaky fuel injector will cause alteration in the fuel injection timing because there will be loss of

fuel from the system. At the same time, the fuel that leaks in the combustion chamber will be in

the form of droplets and not in atomized condition and hence it will not burn properly and it will

form a * and it will cause incomplete combustion which will give black smoke.

Q.611 Diesel engine piston seizure can be caused by

(a) poor cooling of the cylinder wall.

(b) improper cooling of piston.

(c) insufficient piston lubrication.

(d) All of the above.

Ans. (d) All of the above.

If there is insufficient cooling of the cylinder liner, the cylinder liner wall temperature will be

very high. Under such circumstances, the lubricating oil over the wall will get evaporated faster.

Hence excessive friction will be developed between the piston and the cylinder wall causing the

high temperature which may cause the piston to get welded and cause the seizure of the piston.

Because of improper cooling of the piston, it will expand in radial direction and that will cause
the seizure of the liner. Insufficient lubrication will also cause excessive friction between the

piston rings and the liner, resulting in large amount of heat being developed. This will cause the

piston to get welded resulting in the seizure of the piston.

Q.612 A diesel engine will lose power if the fuel injection occurs too early because

Ans. (b) the ignition will be delayed due to low ignition temperature.

If the injection is too early, the compression temperature and compression pressure will not be

sufficient to ignite the fuel. Hence fuel will get accumulated and the fuel will burn with explosive

pressure that will give the knocking effect. At the same time, there will be afterburning and this

would cause excessive loss of power.

Q.613 When the fuel is injected in a diesel engine cylinder too early

Same as 612.

The ignition will be delayed because the temperature of air will not rich the

self-ignition temperature of the fuel. Also, there will be excess of fuel in the cylinder

resulting in too rich mixture and hence improper combustion will take place and hence

there will be loss of power.

Q.614 Which of the following should always be checked prior to starting a diesel engine?

Ans. (c) crankcase oil level. Q.615 When high firing pressure and low exhaust temperature occurs
simultaneously in a

diesel engine it may be because of

Ans. early timing of the fuel injection.

If the injection is not too early, there will be sufficient time for fuel and air to mix properly. At the

same time, there will be sufficient ignition temperature so that the fuel will burn completely and

efficiently, and produce more power. As there is no afterburning, the exhaust temperature will

drop and the firing pressure will be high.

Q.616 If the firing pressure in a diesel engine is high, although the exhaust temperature is

normal, the cause may be

Ans. (b) high compression pressure and high scavenge air pressure.

If the scavenge air pressure and compression pressure is high, the firing pressure will be high. As

good quantity of the air is available, at slightly low temperature, it will not effect any rise in the
temperature but the firing pressure will be definitely high.

Q.618 Which of the following statement represent a rolling of a diesel engine with a cylinder

indicator cock open prior to starting?

Ans. (b) To ensure foreign material, such as water or lubricating oil or fuel, is not present in

the cylinder.

If liquid, such as water, lubricating oil, or fuel, is present on top of the piston due to any reason, as

these liquids are incompressible, they may produce large amount of pressure which will cause

breaking of the piston rings, liner, cylinder head and in worst case it may damage the crankcase.

In order to avoid this, the engine must be turned by turning gear with the indicator cock open so

that if there is any pressure developed or liquid on the top of the piston, it would be released from

the cylinder and would not be able to develop any excessive pressure in the cylinder.

Q.619 In order to start a large slow speed diesel engine, on high viscosity fuel oil after an

extended shutdown, the

Ans. the fuel must be preheated.

Fuel has to be preheated so as to bring its viscosity down so that it can be injected. This is done

by preheating of fuel. When the viscosity is excessively high, there will be excessive drag and the

atomization will suffer. When atomization suffers, the combustion will not be proper and

sometimes, the fuel may not get fired at all. Under such circumstances, it is necessary to preheat

the fuel before starting the engine after prolonged shutdown

Q.620 After starting a diesel engine which of the listed operating condition should be

checked first?

Ans. lubricating oil temperature.

Q.621 What harmful condition could result in if a diesel engine is operated at very light load

for a long time?

Ans. (a) increase carbon built-up.

If a diesel engine is operated at very light load for a long period of time, the combustion is

inefficient because of low compression temperature and pressure. Also the quantity of air will be less
and under such circumstances, there will be improper combustion of fuel and improper

combustion of fuel will cause the formation of carbon deposits in the combustion chamber.
Q.622 A diesel engine should not be operated at low load for a long period of time because

(a) heavy carbon deposit will be built up on the exhaust valve and exhaust manifold.

(b) fuel dilation is increased at low load.

(c) exhaust valve may get damaged.

(d) All of the above.

Ans. (iv) All of the above.

Due to lack of air available, the combustion will be affected and this will cause the improper

combustion and carbon deposition will take place. Secondly, as sufficient amount of air is not

available for combustion, some amount of fuel will remain unburnt which will get coated over the

cylinder walls and will be scrapped downwards by the oil scrapper rings and it may finds its way

to the crankcase. The excessive fuel along the cylinder wall may get scrapped along with the

excessive lubricator oil and finds its way in the crankcase and the crankcase oil will get

contaminated. At the same time, the carbon deposits formed due to improper burning may get

logged on the exhaust valve seat and because of that local burning of the seat and the valve will

take place which may damage the valve. At the same time, when the exhaust valve does not close

properly, there will be wiredrawing effect and the cutting effect on the exhaust valve seat and this

will cause the exhaust temperature to rise.

Q.623 The possibility of diesel engine crankcase explosion will increase by operating the

engine

Ans. (b) by a leaking crankcase inspection cover gasket.

If the crankcase inspection cover gasket is leaking, there is a possibility of air entering into the

crankcase thus causing more amount of air available for the explosion to take place. This will be

primary explosion. When primary explosion takes place, the crankcase relief door will be opened

and it will release the excess pressure. As soon as the pressure is relieved, due to the leaky gasket,

fresh air will enter into it and cause the secondary explosion. Hence these chances of severe

explosions are more in case of leaky crankcase inspection cover gasket.

Q.624 Main propulsion diesel engine continuous running after shutdown, you should now

attempt to

Ans. (a) stop the air supply.

There is may be a possibility that if the fuel pump racks are stuck-up in one position, then even if

the stop signals are given by the governor to the engine, some of the fuel pump rack may not be

brought back to the stop condition and the engine will continue running. For this purpose,

puncture valves are provided to avoid this situation. Under such condition, if the engine keeps

running and it is necessary to bring it to stop condition, the blanketing of the suction filter of the

turbocharger is the best method. By this method, the blanketing will deprive the engine of the air.

When the engine is deprived of the air the fuel will not ignite and the engine will stop.

Q.625 Low compression pressure in the diesel engine can be caused by

Ans. (d) carbon deposits on the piston and piston rings. Due to this, the piston will get seized inside the
liner and they will not exert sufficient pressure on

the liner walls. As a result, there will be excessive blowpast and the compression pressure will

automatically drop because of lack of proper sealing between the piston and the liner.

Q.626 If the diesel engine has been stopped due to piston seizure due to severe overheating,

the crankcase inspection cover should not be opened

Ans. until the engine is cooled

Under such circumstances as the piston is hot, there will be hotspot present inside the crankcase

and there is already possibility of high amount of fuel mist. If at this moment the crankcase door

is opened for cooling purpose, the fresh air will rush inside the crankcase. When sufficient

amount of air is available along with the mist and the hotspot is present, there will be severe

explosion and severe damage.

Q.627 Which of the following condition indicate dilution of diesel engine lubricating oil by

fuel?

Ans. Drop of viscosity.

The dilution of diesel engine lubricating oil by fuel can be indicated by the drop in viscosity

because fuel acts like solvent. When the fuel acts like solvent, then automatically the lubricating

will be become thinner and hence its viscosity will drop. Also, its flash point will drop.

Q.628 Already done.

Q.629 A large slow speed diesel marine engine is operating at rated load and speed while the

vessel is in calm seas. As the intensity of the sea increases, the engine speed governor
indicates same rpm, although the load indicator indicates an

Ans. decrease in the load limit setting.

If the governor is rpm-dependent governor, it will try to maintain constant rpm irrespective of the

load change. In order to avoid the excessive loading of the engine and to keep the rpm constant, it

is necessary to set low load limit. Under such circumstances, the fuel will be given only to

maintain the rpm and the load will be reduced. (To keep the rpm constant at higher load we have

to give more fuel. Hence main engines which are directly coupled to the propeller, the governors

are mainly constant load governors where they try to keep the load constant and avoid loading

resulting in drop of rpm.)

Q.630 A drop in compression pressure of a diesel engine can caused by

Ans. (d) burnt valves.

If the compression pressure of only a particular unit is dropping, the problem is only of that

particular unit and not of the whole engine. Under such circumstances, it is necessary to

investigate the possible causes for that unit. In this case, the possible causes may be: the piston

ring may be sticky or the piston rings may be worn out or liner may worn out or there is a

possibility that valves (exhaust or inlet) are leaking.

Q.631 Which of condition listed could cause the cylinder relief valve on a large low speed

propulsion diesel engine to lift?

Ans. (b) Excessive fuel injection. When there is excessive fuel injection, there will be excessive rise in
the firing pressure. When

the firing pressure reaches above the setting of the relief valve, the relief valve lifts.

Q.632 An increase in crankcase pressure generally indicates

Ans. (b) worn cylinder liner.

If the cylinder liner is worn out or piston rings are worn out or stuck up, in all these conditions,

the high pressure gases will find its way between the liner and piston rings, into the crankcase and

the crankcase pressure will increase in case of the trunk type of engines.

Q.633 An increase in diesel engine crankcase pressure indicates generally the excessive

Ans. d excessive piston ring blowby. (Already explained)

Q.634 If the diesel engine was running at 20% overload with a smoky exhaust, you should
Ans. (c) slow the engine, allowing it to cool gradually.

You have to reduce the load on the engine so that it will be brought slowly into the normal

working temperature and hence there will no increase in the temperature. Hence sudden stoppage

should not be done; otherwise, there is a possibility that the liner or the piston may crack due to

sudden cooling.

Q.635 The starting air rotates a diesel engine at a proper speed but the engine fails to start,

you should check

(a) overspeed trip

(b) for an obstruction in an air filter

(c) air in the fuel line

(d) All of the above.

Ans. (d) All of the above.

If the overspeed trip has taken previously, fuel lever has gone in blocking condition and hence it

will not be released unless you reset it. In such condition, even if the engine starts up on air, it will

not pick up on fuel. Secondly, if there is air in the fuel system, the fuel pump will not inject the

fuel into the cylinder and hence the engine will not start on fuel. If there is obstruction in the air

filter, engine will not change over from air to fuel because the fuel will not burn due to lack of air.

Q.636 If the diesel engine turns over at normal crank * speed but fail to start the cause

could be late fuel injection or

Ans.(c) inadequate fuel injection.

If the fuel injection is inadequate, during starting the engine has to overcome the inertia of

rotating parts and from standstill it has to speedup the engine to the full speed. For this purpose,

you require excessive amount of power. Hence it is necessary that initially while starting the

amount of fuel injected should be more than the normal running fuel. If the fuel injected is less,

the engine will not pickup on the fuel.

Q.637 An increase in power output of a turbocharged diesel engine operating at constant

engine speed results in

(a) high exhaust temperature.

(b) increased turbocharged speed.

(c) high air box pressure. (d) All of the above.

Ans. (d) All of the above.

As the power output of the engine increases, more amount of thermal energy is available in the

exhaust gas which can be utilized by the turbocharger. Hence the exhaust temperature will

increase and more heat is available at the turbocharger hence the turbocharger speed will increase.

When the turbocharger speed increases, it will increase provide more quantity of air and hence the

scavenge air pressure will increase.

Q.638 An accumulation of carbon on one of the thermocouple of an exhaust gas pyrometer

will

Ans. read low temperature due to the insulation effect of the carbon deposits.

The carbon deposited on the thermocouple will act as an insulator and the actual temperature will

not be read. At the same time, the response to the temperature will also be low.

Q.639 Which of the listed state of condition indicate early fuel injection timing?

Ans. (b) High firing pressure and low exhaust temperature.

Early injection will induce a high firing pressure but low exhaust temperature

(DISCUSSED EARLIER)

Q.640 Black smoke exhaust in a diesel engine indicates

Ans. (c) incomplete combustion.

Incomplete combustion will form unburnt carbon in the exhaust which will be black in

color. (DISCUSSED EARLIER)

Q.641 Clogged or partially obstructed exhaust port on a diesel engine can cause

Ans. high exhaust temperature.

As the exhaust ports are clogged or partially obstructed, the exhausting will be affected and hence

complete removal of exhaust gas from the cylinder will not take place. Hence the sweeping

complete action of the exhaust gas by the incoming scavenge air will not take place. The

incoming scavenge will get mixed with the exhaust gas and there will be dilution of the air charge

with the remaining exhaust gas of the cylinder liner. Due to this, improper combustion will take

place which will cause the black smoke and loss of power will take place and high exhaust

temperature because of the afterburning effect.

Q.642 Combustion knock is likely to appear as a result of fuel with

Ans. low ignition quality.

If the fuel with low ignition quality is utilized there will be increase in ignition lag. When ignition

lag is higher then more amount fuel is accumulated before actual combustion ignition begins. This

high amount of fuel accumulated when catches fire, it will instantaneously produce heavy

knocking effect.

Q.643 Black smoke exhausting from a diesel engine may be caused by

Ans. (d) clogged air cleaner.

If the air cleaner is clogged, less quantity of air will enter the cylinder. When less quantity of air

enters the cylinder because of that the fuel will not burn properly. Due to this, unburnt carbon

deposits will remain in the exhaust which will give the black smoke. Q.644 If two-stroke diesel engine is
overspeeding due to lubricating oil leakage of the

cylinder what should you do to stop the engine?

Ans. (c) Shut of the fuel injector and block the flow of intake air.

By shutting of the supply of intake air the speed will be reduced. But if the lubricating oil is

igniting, which is causing the running of engine even after shutting the air supply, then under such

circumstances, the only possible way of stopping the engine is to stuck off the air supply by

covering the suction filter with blanket.

Q.645 Two stroke diesel engine operates electrically, overspeeds and fails to restart when

the crankcase at normal speeds Which of the following problems is likely the cause for the

engine failing to restart?

Ans. (c) Failure to reset overspeed trip.

Overspeed trip is a type of switch. This is provided for a safety purpose so that the engine speed

will reduce after the overspeed trip operates. It should not restart unless it is resetted manually. To

reset the overspeed trip manually, we have to bring the fuel lever to stop condition and we have to

restart. If this is done properly, then even if we try to start the engine on air, it will turn but it will

not come on fuel because the fuel is blocked because the overspeed is already operated. Hence it

is necessary to reset the overspeed trip.

Q.646 When running a large slow speed main propulsion diesel engine on heavy fuel which
of the following precautions should be observed when switching back to diesel?

Ans. (b) the temperature of fuel from the preheater should be gradually retarded after

switching over to the three way valve.

Whenever the changing from diesel oil to heavy oil or vice-versa is to be taken place, it is

necessary that the temperature of oil heated or lowered should be carried out gradually so that

there is no sudden shock thermal loading of the components of the fuel injection system. At the

same, it will allow proper expansion and contraction of different parts thus maintaining the proper

clearance between the running parts of the system. Otherwise there is a possibility that one part

will cool at a faster rate than other. In that case, there is seizure of the plunger in the fuel pump or

needle in the guide and there will be heavy damage.

Q.647 If it becomes necessary to cut-out an individual cylinder of a large low speed main

propulsion diesel engine

Ans. the fuel oil to the cylinder should be secured and its fuel oil rate should be reduced.

As the unit is not firing, there is no need of cylinder lubrication. Otherwise, the excessive

lubrication will go along with the exhaust and damage the turbocharger and it may catch fire in

the exhaust manifold causing the overspeeding of the turbocharger.

Q.648 Late fuel injection is indicated by

Ans. (b) lower normal cylinder pressure and high exhaust temperature

This will happen because of afterburning not due to burning the fuel at right time. Due to burning

during the expansion stroke there will loss of pressure and increase of temperature MOTOR
MAINTAINENCE

Q.649 Bearing wear on sleeve type bearing is measured with

(a) ball anvil micrometer.

(b) pair of outside caliper and dial indicator.

(c) pair of inside caliper.

(d) depth micrometer.

Ans. (a) ball anvil micrometer.

The ball anvil micrometer has got a ball end, instead of flat, end so that it can measure the curved
surface
thickness. Bearing being curved surface, ball anvil micrometer can be used for measuring the thickness
and

after measuring the thickness of the bearing it is possible to measure the weardown of the bearing.

Q.650 Wear occurring at the tip of the reduction gear teeth is usually the result of

Ans. (d) gear misalignment.

The tip of the gear teeth gets worn out entirely because of gear misalignment. When there is
misalignment

between gear, the tip of the gear will rub against the bottom of the gear teeth and cause excessive

weardown. This also gives the excessive axial thrust and radial thrust which will cause the weardown of
the

gear teeth.

Q.651 While inspecting the main bearings on a diesel engines you find impregnated dirt and

scratches. You would therefore suspect that

Ans. (c) the lubricating oil was not properly filtered.

If the lubricating oil is not properly filtered, dirt and hard particles will find its way between the bearing

and the shafting. Due to this, there will be scratching marks on the white metal of the bearing. At the
same

time, the hard dirt will get impregnated inside the soft surface of the bearing.

Q.652 When nozzle tester is being used to test a closed type fuel injection nozzle a clogged nozzle

orifice will be indicated by a

Ans. (a) distorted spray pattern.

When the nozzle hole is clogged the spray pattern will be distorted because that particular hole will not

have any injection but same quantity of fuel will be injected by remaining holes. Hence complete pattern
of

fuel will be distorted and that can be checked by the use of a plate which is held under the nozzle and
the

nozzle is tested.

Q.653 The spray holes in the diesel engine fuel injection valve should be cleaned using carbon solvent

and

Ans. (b) a special cleaning wire.

The carbon solvent will dissolve only carbon but hard particles such as silica or alumina cannot be
dissolved in the solvent. Hence it is necessary to remove them with special cleaning wire which is

provided. This cleaning wire will clean the hole but it will not damage the holes. Hence cleaning should
be

carried out by special cleaning wires.

Q.654 When dissembling or assembling an injection pump plunger and barrel, you must

(a) keep the parts immersed in diesel oil.

(b) always keep the plunger and barrel together.

(c) work over a linoleum type surface.

(d) All of the above.

Ans. (d) All of the above.

When dismantling pump plunger and barrel, if we keep them in the diesel oil there is less possibility that
of

any rusting taking place on the surface and thus surface finish will be maintained. Secondly, they should

always be kept together because they are lapped surface so that no dirt will enter in between them. At
the

same time, because of their better sealing effect, they should always be replaced as a pair and should

always assembled as a pair. Also, it should be worked over a linoleum type surface as it is smooth and
dirt

free surface. Due to this, there is a less possibility this surface will attract any foreign dirt or any hard

particles in the surface. So linoleum type surface can be kept clean by just wiping it out and the fuel

injector can be kept clean without getting the scratching due to the hard particles. Q.655 Visual
inspection of fuel injector valve removed during overhaul shows heat discoloration of

lower end of the valve. This is indicative of

Ans. (a) valve leakage.

Fuel injector valve is a non-return valve and it seals the nozzle against the high temperature and high

pressure gases. When the fuel injector needle valve is leaking, high temperature gases from the cylinder

will enter the nozzle because of which the nozzle will get overheated and it will get discolored.

Q.656 A visual examination of chrome plated piston compression ring at the liner port reveals

vertical brown strip on the face of the rings. This condition indicates

Ans. (c) ring blowby.

When ring blowby takes place the lubrication oil film between the piston and the cylinder liner gets

distorted resulting in the piston rings being coated with the brown tinge of the exhaust gas. At the same

time, when this happens because of lack of lubrication between the piston ring and the liner the
excessive

heat is generated. This will also give discoloration of the liner and the piston rings, and vertical lining on

the surface of the piston ring called scuffing

Q.657 Uneven bolt tightening during the installation of fuel injection pump can result in

Ans. variation of clearance between the plunger and the barrel.

Due to the uneven tightening of the bolts during the installation, it will result in variation of clearance

between the plunger and the barrel. Hence the clearance between them will not be uniform all around
the

circumference. There is a possibility that seizure may take place between the moving parts of the pump

where there is less clearance; therefore it is necessary to have uniform tightening.

Q.658 In a diesel engine a cylinder liner should be replaced if it is

Ans. (b) scoured.

Actually speaking, the liner should be replaced if it is badly scoured or scuffed because scuffing will also

give the distortion in the geometry of piston and the liner. At the same time, the scratches will prevent
good

sealing between the liner and the piston rings. Hence it should be replaced if it is badly scuffed or
scoured.

Q.659 If the plunger or barrel of a fuel injection jerk pump gets damaged

Ans. (a) the entire pump must be replaced.

As the pump plunger and barrel is manufactured as an assembly, there is good sealing between the
plunger

and barrel and both surfaces are lapped together to form air-metallic seal. Hence it should be replaced
as an

assembly and because good bearing between the two surfaces is possible if they are replaced together
and

not replaced individually.

Q.660 Which of the listed devices could be used as a substitute for a ring-grooving tool?

Ans. (c) Section of removed compression ring.

Q.661 Cracking of diesel piston crown can result from

Ans. (b) the under side piston crown being excessively dirty lowering the rate of heat transfer.

If the cooling space of the piston crown becomes excessively dirty due to the deposition of the carbon or

scale, proper transfer of heat will not take place from the crown to the cooling space. Hence the piston

crown will become excessively hot and it will loose its strength and it will crack.

Q.662 It is easier to replace a dry cylinder liner than wet liner because

Ans. (c) water seals are not required.

In case of dry cylinder liner as there are no water seals or o-rings to seal the water spaces and hence

replacement of the liner becomes very easy. In case of water cooled liner the sealing rings has to be

properly fitted. At the same time, the surface on which the sealing rings are to rest should be properly

cleaned; otherwise the leakage possibilities are more which is not applicable in case of dry liner.

Q.663 To facilitate early ring seating of newly installed piston rings while still providing extended

rings wear Ans. (c) a tapered faced ring can be used.

A tapered face ring can be utilized for faster running in of the cylinder liner and the rings due to which

sealing between the cylinder liner surface and the piston can be obtained in a shortest possible time.
Due to

tapered face, the surface contact area is reduced and because of this the pressure between the ring and

cylinder liner increases which causes the faster weardown of the piston rings and cylinder liner, which

ultimately results in better sealing between them in a shortest possible time.

Q.654 Insufficient end clearance on newly fitted piston rings on a diesel engine will cause the rings to

Ans. (a) jam in the least worn part of the cylinder liner when the ring expands.

The end clearance, also called the butt clearance, is less when the piston ring expands, the two ends of
the

piston rings will butt against each other. As there is no further expansion possible in the circumferential

direction, they will have to expand in the radial direction. In doing so, it will give excessive pressure over

the liner wall and cause the seizure of the piston rings into the cylinder liner.

Q.665 Heavy fuel oil will generally have an upper average ash content of .1% by weight. Which of the

following condition will occur if the ash content exceeds the above amount?

Ans. (b) Increase valve wear.

The ash which is present in the fuel oil is mostly in the form of heavy metals. Hence when the
percentage

of ash increases, this ash will get deposited on the valve seat. Due to this, the valve will not get properly

seated on the valve seat and there will be increase in the weardown. At the same time, there will be
burning

of valve and valve slip may occur.

Q.666 The face surface appearance of shallow groove stainless steel chrome plated compression ring

should exhibit through its operating life

Ans. (a) smooth shallow groove chrome surface.

Q.667 To determine the main bearing clearance of a propulsion diesel engine, you should measure

the shell by using ball anvil outside micrometer and measure the crankshaft journal using the

Ans. (a) outside micrometer.

The weardown of the bearing can be measured by using a ball anvil outside micrometer so that it can
the

thickness of curved surface of the bearings. By determining this, the total weardown of the bearing can
be

found out which can be utilized to find the inner diameter of the bearing. By measuring the pin
diameter, by

using an outside micrometer; it is possible to measure the clearance of the bearing by knowing the inner

diameter of the bearing and the pin diameter.

Q.668 Visual inspection of chrome plated piston compression rings reveals a black ring face at the

position of the cylinder ports. This condition indicates

Ans. the ring which has excessive blowby.

When excessive blowby takes place the ring surface which is in contact with the liner will get discolored.
It

will become blackish and dry as the lubricating oil will get burnt. This is especially present in case of first

piston ring because first ring is subjected to high temperature and pressure and so blowpast is maximum
on

the first piston ring which will make the ring surface into black.

Q.669 The consistent burning of fuel oil in a diesel engine with high sulphur content will result in

Ans. (d) increased cylinder liner wear.

The excessive sulphur in the fuel which is burnt will form sulphuric acid in the cylinder. When this acid

gets condensed on the liner wall excessive corrosion of the liner will take place. In order to avoid this, it
is

necessary to use cylinder oil with a high TBN value or to keep the liner wall temperature high by using
the

jacket cooling water temperature at a higher range.

Q.670 Burning fuel with high sulphur content in a diesel engine will

Ans. (d) produce corrosion in the cylinder and the exhaust system at low load.

Burning fuel with high sulphur content will produce sulphuric acid and at low load the temperature of
the

exhaust gas and inside the cylinder is low. During this low load operation the sulphuric acid will get
condensed over the liner wall. Hence excessive corrosion wear will take place when fuel with high
sulphur

content is used at low load operation. Q.671 Which of the following statement concerning cylinder
liner wear is true?

Ans. (b) Excessive liner wear causes the wear the between the piston ring and the

grooves.

Due of excessive and non-uniform liner wear, the piston rings will try to maintain the

contact with the liner wall. As a result, there is continuous radial movement of the piston

rings over the groove in the piston because of which there will be friction between the

piston rings and the groove. Hence the bottom of the groove will get worn out faster if the

cylinder liner is worn out excessively and non-uniformly.

Q.672 Generally where you should find the greatest amount of wear on the cylinder

liner?

Ans. (c) Opposite the top ring shortly after the piston travel has ended the

compression stroke.

The liner wear is maximum when the piston is at TDC. It is time when the piston is

subjected to high temperature and low lubrication. As a result, the cylinder liner is worn

out excessively along with the piston rings because of the excessive pressure between the

liner and the piston rings and lack of lubrication due to high temperature.

Q.673 Worn main bearing will cause the compression ratio of an auxillary diesel
engine

Ans. (b) to decrease.

When the main bearings are worn out, automatically the crankshaft inorder to keep

contact with the bottom half of the main bearing will try to sink downwards. Due to this,

the clearance volume between the piston and cylinder head, when the piston is at TDC,

will increase. This will cause the loss of compression pressure.

Q.674 Insertion shims in the main marine diesel engine between the connecting and

the bearing box would result in

Ans. (a) increase in compression ratio.

The marine type of connecting rod has a * and if that * is fitted over the bottom end

bearing housing and by inserting the shims between the palm and the bearing housing

automatically the piston is raised up and when the piston is raised up the compression

ratio increases

Q.675 Diesel engine crankshaft deflections are taken at four crankshaft positions.

Good engineering practice require the deflection gauges are indicated to be

Ans. left in place for all four readings.

When the crankshaft deflection is taken it is done at four position of the piston. As a

matter of fact actually five positions of piston. During this, we are checking the distance

between the two webs. Inorder to check the distance between the two webs, it is

necessary that the dial gauge fitted between the two webs should be continuously kept in

position to get the correct reading all around the cycle.

Q.676 An acceptable method of measuring the correct rotational force applied to the

connecting rod and main bearing bush is to use a

Ans. torque range. The tightening of the bottom end bearing bush can be done safely and properly by
use of

torque range. It has got silicon clutch and hence it will never get overtightened. When a

particular torque is reached it will give a sound which will indicate proper tightening

without over stressing or over tightening of the bolts. Hence torque range is the better

method of tightening the bottom end bearing bolts. At present, there are other methods
such as angle and hydraulic methods which are much better than the torque method.

Q.677 Small cracks in the surface of diesel engine crankshaft bearings are an

indication of

Ans. fatigue failure.

When the crankshaft bearing is subjected to fatigue, the strength at which it will crack

will lower down and hence the cracks appear. These cracks are quiet significant and are

not because of corrosion or insufficient lubrication or abnormal wear. This will not give

the cracking. Cracking is due to the material which is under stress due to fatigue.

Q.678 If water is found in the crankcase of a diesel engine the cause may be

Ans. due to cracked cylinder head, cracked cylinder liner and leaky cylinder gasket.

In case of four-stroke engine if the cylinder head is cracked, there is a possibility that

water may enter the crankcase when the engine is in stopped condition. If the cylinder

liner is cracked water may enter from the cylinder head through the gap between piston

rings and it will enter into the crankcase.

Q.679 Diesel engine piston ring blowby is usually caused by

Ans. excessive ring clearance at the ring gap

Ring gap clearance is also called as butt clearance. If this butt clearance is excessive, it

finds an easy assess for the hot and high pressure gases to pass through and it will give

more amount of blowpast

Q.680 Diesel engine blowby into crankcase is caused by

Ans. excessive ring gap clearance.

Q.681 The wear is usually greatest at the top of the cylinder in a diesel engine due to

Ans. the highest pressure being exerted.

At the TDC, when the fuel is injected, high pressure is developed. This high pressure

finds its way behind the piston rings and they are forced against the liner walls with great

contact pressure and thus more amount of weardown will take place. At the same time,

near TDC because of the high temperature, the lubricating effect is reduced and hence

there is more amount of wear of the liner and the piston rings.

Q.682 Which of the following operation will have a direct impact on the rate of wear
of cylinder liner?

Ans. (b) Quality of the fuel injected.

If the quality of the fuel injected is bad i.e. it has more amount of sulphur or vanadium or

sodium or abrasive particles, excessive wear down of the liner will take place due to

corrosive effect. At the same time, the wear down may also take place due to abrasive

effect. Q.683 Failure to remove the carbon ridge from the top of the cylinder when

replacing the piston ring will result in

Ans. damaged upper piston ring and the ring landing surface.

If the carbon ridge is not removed and new piston rings are replaced, the top most ring

will hit at the ridge and may get damaged. At the same time, it will damage the ring

landing surface. Hence it is necessary to grind off the ridge when the piston is removed

and the rings are replaced (repressed).

Q.684 Scuffed cylinder liner bearing surface in a diesel engine can result from

Ans. (c) operating the engine on overheating.

When the engine is operating on overheating condition (which can exist due to blowpast),

the lubrication between the piston and the liner is not effective because the lubricating oil

will evaporate faster. Under such circumstances, because of loss of lubrication oil, the

sliding friction between the piston and liner walls will cause great amount of heat which

will ultimately cause the scuffing of the liner walls.

Q.685 Water accumulation in the cylinder of a secured engine will indicate

Ans. cracked cylinder liner.

When the engine is secured, i.e. it is standstill, if there is water accumulation on the top

of the piston it is an indication that the liner is cracked or the cylinder head may be

cracked. Hence there is a possibility that water may get accumulated on the top of the

piston through these cracks.

Q.686 The formation of carbonmonoxide in diesel exhaust gas can be reduced by

Ans. (c) maintaining proper combustion and scavenging.

Carbonmonoxide gas is produced because of lack of oxygen during the burning process.

Hence if proper combustion and scavenging process is maintained, fuel will burn
efficiently and because of proper scavenging the amount of air will be sufficient and

hence better combustion and no starvation and no formation of carbonmonoxide.

Q.687 The amount of wear on a speed precision main bearing can be accurately

determined by comparing the data from previous reading to the present reading

taken with ball anvil outside micrometer.

Ball anvil outside micrometer can be utilized to measure the thickness of curved surface.

So by comparing the thickness (previous and present) of the shell bearing, we will be able

to find out the degree of wear of the bearing.

Q.688 On diesel engine equipped with individual jerk type fuel pumps, adjustments

should be made to the tappet push rods of the pump to

Ans. equalize effective delivery stroke.

The effective delivery stroke of all units can be equalized when the upward moving

plunger will close the suction ports of all the fuel pumps at the same crank angle. This

can be achieved by adjusting the tappet of the plunger under the jerk pump so that the

effective delivery stroke can be adjusted equally. Q.689 The amount of wear on a split fixed sleeve type
main diesel bearing can be

accurately determined with a

Ans. (c) ball anvil outside micrometer. (ALREADY DISCUSSED)

Q.690 Friction, engine wear, and oil consuming in a diesel engine are directly

related to the

Ans. viscosity of the oil.

In case of lubricating oil, viscosity of the oil place an important role in reducing the

friction wear and wear down of different components of the engine because the formation

of film lubrication depends on the viscosity of the oil. The viscosity of oil has to

maintained in a preset condition so as to have proper film thickness and to reduce the

friction between the rotating parts and to take out the heat generated due to friction.

Hence viscosity plays an important part in determining the engine wear and friction. At

the same time, if the viscosity is too low there is possibility that excessive consumption

will take place because of leakage of oil and more amount of evaporation will take place.
Q.691 Improper cooling of diesel engine cylinder liner due to the accumulation of

scale deposits may cause

Ans. increased piston ring wear.

When the liner wall temperature is high, the lubrication between the liner and piston will

get evaporated. Hence less amount of lubrication oil film will be there between the liner

and piston rings thus causing excessive friction between liner and piston rings causing

excessive weardown of the piston rings.

Q.692 The nuts of main bearing, connecting rod bolts and all other moving parts are

to be secured by

Ans. split pins or other effective means.

All the nuts of these parts after tightening should be locked by means of locking washers,

star washers or split pins so that they will not tend to loosen out. This is a safety measure

in addition to hydraulic tightening.

Q.693 The easiest way to locate a defective diesel engine exhaust valve is

Ans. by comparing the exhaust pyrometer readings.

By comparing the exhaust pyrometer readings, leaky exhaust valves can be easily

detected because exhaust gas temperature will be high. It will be on the continuous rise

and it will indicate that the exhaust valve is leaking. This could be found out by taking a

compression and peak pressure curves where we find that both the compression and peak

pressure curves for that particular unit is reduced.

Q.694 Engine coolant accumulating in diesel engine lubricating oil can result from a

Ans. cracked cylinder head or liner.

The cooling water finding its way into the engine lubricating oil in the crankcase is only

possible because of the cylinder or liner crack or the O-ring which seals the space

between the liner and cylinder block are leaking and hence water is finding its way into

the crankcase. Q.695 If it becomes necessary to clean the spray holes in a diesel engine fuel injector

Ans. you should use a suitable sized * wire and carbon solvent.

The carbon solvent will dissolve the hard particles around the holes. Hence the hard

particles because of which the holes are clogged get dissolved and it would be easy to
remove the dissolved carbon particles by use of wire and hence carbon solvent is

necessary to clean the clogged spray holes.

Q.696 While over-oiling a jerk type fuel pump it is necessary to replace pump

plunger which of the part listed below must also be replaced?

Ans. pump barrel

The pump barrel and plunger are lapped together and they form a single unit. They

cannot be replaced individually because perfect surface finish can be achieved between

the two surfaces. Hence it is not possible to replace them individually. If it is necessary to

replace the plunger the barrel also has to be replaced.

Q.697 An acceptable means of tightening connecting rods and main bearing cap

bolts is

(a) to measure the torque applied to each nut and bolt assembly

(b) stretch up each nut before and after tightening

Ans. (a) to measure the torque applied to each nut and bolt assembly.

The torque should be measured so that they are tightened to the required torque and they

will not be overtightened. Hence it is necessary to measure the torque applied to each bolt

at the time of tightening. At the same time, the elongation can also be checked to

countermeasure to confirm the proper tightening.

Q.698 In a diesel engine when refitting piston rings you should

(a) change the ring gap at the smallest diameter of the cylinder liner

(b) remove carbon from ring grooves

Ans. both (a) and (b).

When fitting new piston rings it is necessary to check the butt clearance and that is

possibly checked by fitting the rings at the least worn out position of the liner and

checking the gap at the end of the piston rings. At the same time it is necessary to make

sure that the ring groove is properly cleaned and there is no dirt or carbon deposits in the

groove otherwise the rings will collapse and blowpast will take place. Hence it is

necessary to check both i.e. the ring gap and carbon deposits.

Q.699 Problems with the diesel engine fuel injection pumps are usually caused by
Ans. (b) contaminated fuel.

When the fuel is contaminated with water or insoluble hard particles under, the fuel pump

plunger and barrel will get excessively wornout because of the abrasive wear and the

corrosive wear and all the problems related to the jerk type pump will start from here

onwards.

Q.700 Dirt lodged on the nozzle valve seat of a fuel injector nozzle will cause

Ans. (c) fuel leakage after and before injection. If the dirt will be lodged at the seat, the seat will not be
leak-proof. Hence whenever

there is low pressure inside the cylinder liner or in combustion space, oil will leak from

the seat and it will drip in the combustion space thus causing the high exhaust

temperature and loss of power.

Q.701 When a diesel engine is operated having a piston ring cold gap clearance less

than that recommended by that manufacturer, the ring will

Ans. seize and buckle.

If the ring gap clearance is less, the ring will expand. Thus ends of the rings will butt

against each other hard. As there is no way to expand, the rings will expand radially and

ultimately the rings will crack and it will collapse and break. At the same time, due to the

excessive heat, which is generated due to pressure between the piston and the liner, the

piston ring will get seized inside the liner.

Q.702 Due to excessive water in the fuel diesel engine fails to start. Before engine is

started the water must be removed from the fuel pump fuel stainer.

If excessive water is developed in the fuel in that case the engine will not start. In that

case, it is necessary to remove the water from the fuel oil at settling tanks, service tanks

through the filter so that when fuel injection starts the engine will pick up on fuel

immediately.

Q.703 Failure to remove the carbon ridge at the top of the piston while removing the

piston may result in

Ans. seizure of piston and rings inside the liner.

It will be difficult to remove the liner due to the carbon ridge at the top which results in
the seizure of the piston and rings. Hence it is necessary to grind the carbon ridge in order

to facilitate the removal of the liner. Otherwise, the top most ring will get jammed up

between the ridge and hence the liner may come out with the liner or the piston may get

jammed up in the liner. Hence it will not be possible to push it either upwards or

downwards and this is the most critical condition we can reach to. Hence it is necessary

to grind it before attempting removal of piston.

Q.704 If the piston ring gap remains insufficient when installing new rings, you

should

Ans. file the ends of the rings.

Ends of the rings are to filed to have a proper butt clearance if required. As far as possible

this should not be done because it may damage the profile of the piston rings or it may

cause the excessive weardown of the liner or vertical scratching of the liner may take

place because of the alteration of the profile of the piston ring. Hence as far as possible

when new rings are to fitted the original methods must be utilized where the end gap

clearance is always maintained.

Q.705 When inspecting piston rings through the ports of two stroke diesel engines

black areas on the sealing surface are

Ans. result of blowpast Black areas are because of the blowpast where the lubricating oil get washed
away. Due

to blowpast and heat and the carbon deposit this particular portion of the ring as well as

liner wall there will be a new patch of black surface. If this is happening, cylinder

lubricating oil has to be increased or checked whether the piston rings are free in the

grooves.

Q.706 An examination of the piston compression rings of an efficiently operated

diesel engine should appear with a

Ans. (a) shiny face end bottom and black end at the top.

If the engine is efficiently operated when the piston rings are in very good condition, then

the sliding surface of the piston rings over the liner should be shining without any black

markings or scratching. At the same time the piston ring is rubbing at the bottom end of
the groove so that the bottom end of the groove should also be shinning. As the gas goes

behind the piston rings into the backside some carbon get deposited on the top and hence

the top end of the piston ring may become black.

Q.707 Excessive side clearance between the side and the groove will cause

Ans. the ring to hammer the piston land below the ring.

Excessive groove clearance will cause the ring to hammer on the piston ring groove

bottom surface. This will especially happen when the piston is changing its direction, i.e.

when the piston is at TDC and BDC, and the piston ring may break due to this. At the

same time, the piston ring groove will wear faster.

Q.708 In certain cases the cylinder liner can be refinished rather than replaced

when the properly honned

Ans. liner surface should have a crosshatched pattern.

When the liner surface have excessive scuffing or polishing effect and is not possible to

retain the lubricating oil film on the liner surface then in that case it is necessary

artificially to make it roughened out under the controlled condition. This is done by

honing which is a method of cross pattern which will have the roughening carried out in

two direction so that there will be tiny cavities on the liner surface which will retain the

lubricating oil on the liner surface thus reducing the liner and the ring wear.

Q.709 One method of determining crankshaft misalignment is by

Ans. (d) taking micrometer readings between the crank webs opposite the crank pin

every 90 degrees or the crank angle rotation.

This means that we are actually measuring the distance between the two crank webs at

every 90 degrees position of the crank. The distance between the webs will change

according to the misalignment of the crankshaft centerline. If the crankshaft centerline is

misaligned because of weardown of the main bearings, the gap between the webs may

increase at particular crank position and it may decrease excessively at particular crank

position. Hence by comparing the web reading between these two positions, it is possible

to find out the misalignment of the crankshaft.

Q.710 Which of the following statements concerning the cylinder liner wear in a
single acting diesel engine is correct? Ans. (c) Excessive liner wear causes wear between the piston
rings and the groove.

Excessive liner wear will cause the radial movement of the piston rings inorder to

maintain the contact between the liner wall and piston ring surface. This continuous

radial movement of the piston ring over the entire stroke of the piston will cause the

piston ring to slide on the bottom of the piston groove. Hence there will be excessive

weardown of the piston ring groove as well as the piston ring landing surface if the liner

wornout is excessive.

Q.711 On large slow speed main propulsion diesel engine lower main bearing wear

is usually measured by using

Ans. bridge gauge.

Considering that the crankshaft is sufficiently flexible and heavy enough, it will always

keep the contact with the bottom half of the main bearing. If the bottom half main bearing

wears down, the centerline of the crankshaft moves downward inorder to keep the contact

with the bearing. Hence automatically the bridge gauge reading which measures the

position of the crankshaft centerline with the fixed machine surface transverse girder. If

this increases it indicates that weardown has taken place. This reading has to be

compared with the previous reading so as to measure the weardown of the main bearing

bottom half.

Q.712 The rate of wear on a cylinder liner depends on the

(a) quality of air filtration.

(b) effectiveness of lubrication.

(c) type of fuel used.

(d) All of the above.

Ans. (d) All of the above.

If the air is not properly filtered, along with air, sand and hard particles from the air will

be drawn into the cylinder liner which will give the abrasive wear. If the effectiveness of

lubrication is not proper, i.e. the quantity of lubricating oil is less or the lubricating oil is

not injected at proper time, the effectiveness of lubricating oil is reduced because of
which friction will increase and more weardown will take place. If the fuel contains more

amount of sulphur, the liner will weardown because of corrosive effect. If the fuel

contains more amount of abrasive particles such as silica, alumina then it will cause the

abrasive wear and if the fuel contains more amount of vanadium, sodium then it will

cause excessive amount of weardown because of hot corrosion.

Q.713 Abnormal crankpin bearing and piston skirt surface wear indicates

Ans. incorrect connecting rod alignment.

The connecting rod is to be aligned perfectly with the center of the liner and piston. If this

alignment is not carried out properly, the centerline of the piston with respect to the liner

will get altered. Under such circumstances, the piston will start rubbing against the liner

wall thus giving excessive weardown of piston skirt. At the same time, it will cause

alteration in the lubricating oil film produced in the bottom end bearing and hence bottom

end bearing weardown will be non-uniform and excessive.

Q.714 To determine the main bearing clearances in a diesel engine, you should use Ans. (c) plastic
gauge.

Plastic gauges are like lead wire in the form of stripes. These stripes are to flexed

between the top half of the main bearing and the journal and the main bearing is to be

tightened. When this is done the plastic will flow and the thickness of the plastic will get

reduced and the width of the plastic will increase. This increase in the width of plastic is

directly calibrated with the clearance in the bearing and hence the bearing clearance can

be checked with the help of plastic gauges. These are more accurate and safe than any

other method of checking.

Q.715 The ring land on a large low speed main propulsion diesel engine piston may

crack due to

Ans. insufficient ring groove clearance.

If the ring groove clearance is insufficient in that case the ring will expand and get

jammed up into the ring groove. As there is no further expansion possible it will exert

excessive pressure over the land of the piston ring groove and because of this the stress

concentration on the piston ring groove will exceed and cracks will originate on piston
ring groove.

Q.718 A condition contributing to diesel engine piston ring sticking into the ring

grooves is Ans. insufficient ring clearance at the ring sides i.e. the groove clearance.

If the groove clearance is insufficient, the piston ring will expand because of heat and it

will occupy the complete clearance which is available. As there is no clearance left, it

will get jammed up in the piston ring grooves and hence it will get seized up in the piston

ring grooves.

Q.719 Low compression in diesel engines could be caused by

Ans. (c) worn or broken piston rings.

When the piston rings are worn out or broken the sealing effect of rings with liner will

get affected considerably. Hence during compression compressed air will get leaked out

past the piston ring and it will blowback into the crank space or under scavenge space.

This will result in loss of compression pressure.

Q.722 Which of the listed problems can be caused by low compression pressure in

diesel engine?

Ans. Combustion will not be proper.

Actually due to low compression pressure, combustion will not be proper and when

combustion is not proper there is a possibility that more carbon will be formed on the

exhaust valve. The exhaust valve may start leaking, black smoke and turbocharger may

get fouled and because of that the scavenge pressure may drop. All this things may

happen because of the low compression pressure.

Q.723 Low compression pressure in a diesel engine may be a result of

Ans. (b) excessive mechanical clearance between the piston crown and the cylinder

head.

When the clearance between the piston crown and cylinder head increases the clearance

volume increases. Automatically the compression pressure at the end of stroke reduces due of which
the temperature and pressure of air will reduce which will cause improper

combustion of fuel and may cause afterburning and high exhaust temperature.

Q.724 When a nozzle tester is used to check the spray pattern of an injector nozzle
Ans. (d) the oil spray could cause blood poisoning if the spray penetrates the skin of

the operator.

It is well-known fact that with the high-pressure injection of the fuel, the fuel in highly

atomized condition will penetrate the skin and the diesel will go into the blood and it will

cause the blood poisoning. Hence during checking of a fuel injector valve on a test bed, it

is not advisable to put your palm under the nozzle.

Q.725 When the piston is removed from a diesel engine for maintenance the piston

should be examined for

Ans. scouring, crack, burned spots, gummy deposits and sticky rings.

The piston should be checked for whether the rings are free. If the rings are free then the

ring grooves should be checked for formation of carbon and ash. At the same time, the

piston rings and the landing site of the piston rings should be checked for cracks and any

gummy deposits which are there on the piston rings and the grooves. This all will indicate

if the lubrication is proper and quantity and quality of the oil is in good indication.

Q.726 To reduce the load during jacking operations which of the listed device

should be operated?

Ans. Indicator valve or cylinder test valve.

During jacking operations i.e. turning the engine with turning gear it is necessary to open

the indicator valve.

Q.727 After removing the old set of rings which of the following conditions is

indicated if a bright spot is found on each end of broken rings?

Ans. Butt clearance was not sufficient.

If broken piston rings are to be examined and the broken ends are found out to be

polished and shining, it indicates that the butt clearance was not sufficient. The main

cause of piston ring breakage is the lack of butt clearance. Once the crack takes place,

some amount of material will get removed and the clearance will automatically come into

existence. This will cause the two ends of the rings to move over each other and hence

the broken ends will get polished and automatically it will become shining.

Q.728 After an engine has been started using a * drive unit the drive gear or pinion
disengage from the flywheel due to

Ans. the high rotational speed of the flywheel.

In the * drive when the engine starts because of high speed of the flywheel, the pinion

speed becomes excessively high. As a result, the disengagement of the pinion from the

flywheel takes place and which avoids the damage caused to the pinion.

Q.729 Bearing crush as applied to diesel engine main bearing will result in

Ans. (a) positive sitting of the bearing in the housing. Due to the crush there is interference fit between
the housing and the bearing. The back

side of the bearing will have frictional contact or interference contact or interference fit

with the housing which will prevent the rotation of the bearing in the housing when the

shaft is rotating. Thus it will give positive sitting of the bearing in the housing.

Q.730 Crank web deflection readings will give a positive indication of

Ans. (a) worn main bearing journal.

Whether the main bearing journal is worn out or the main bearing itself is wornout

because of the wear down, the shaft will deflect downwards to maintain the contact with

the bearing surface. Due to this the centerline of crankshaft will get sagged. Hence where

the deflection is taken it will indicate an excessive crankshaft deflection. This will

indicate that the bearing or the journal is wornout or the bearing housing has sagged

because of the transverse girder of bedplate is sagged or distorted.

Q.731 When accumulated carbon at the air inlet port of two-stroke cycle diesel

engine is removed you should take care

Ans. to avoid carbon entering the cylinder.

If carbon enters the cylinder, it may get lodged between the piston and the cylinder and

cause the sticking of the piston rings. Ultimately it will cause the breaking of the piston

ring and blowpast. Hence it is necessary that carbon should not enter the cylinder

especially between the cylinder and the piston.

Q.732 Replacement piping for the diesel engine high pressure fuel system must be of

same length and diameter as the original piping to

Ans. avoid excessive amount of ignition delay.

Q.733 The burnt exhaust gas valve may be burnt by

Ans. higher than normal exhaust gas temperature from a particular cylinder.

If the exhaust valve is burnt out, the high temperature and pressure gases may leak past

between the valve and the seat and which will ultimately give rise to the temperature of

the exhaust gas after the valve. At the same time, the exhaust valve will start burning and

hence there will be continuous rise in the exhaust gas temperature. Also there will be

drop in the compression pressure which will cause afterburning and high exhaust

temperature.

Q.734 In diesel engine a leaky exhaust valve can cause

Ans. misfiring.

Leaky exhaust valve will give rise to the drop in the compression pressure which will

result in decrease in compression temperature due to which fuel may not ignite and which

will cause misfiring of the fuel.

Q.735 The most severe cavitation corrosion occurring on the water side of a diesel

engine wet cylinder liner normally occurs

Ans. (d) near the middle of the thrust side of the liner.

Thrust side of the liner is the side which has got the maximum thrust because thrust side

of the liner, in case of two stroke engine, is on both side of the thrust side. In case of four stroke engine,
the thrust is taken by the liner depending upon the rotation one side will be

thrust side which has got excessive amount of thrust transmitted to the liner wall by the

piston skirt. This excessive thrust will cause the variation of the pressure and because of

the variation of the pressure, the water pressure will fluctuate and because of fluctuation

of water pressure, bubbling will start. At high temperature, bubble formation will take

place which will cause the cavitation.

Q.736 Exhaust valve grooving and corrosion is caused by certain component of the

residual fuel oil. These components are

Ans. sodium, sulphur and vanadium.

Vanadium, in presence of sodium, will give the hot corrosion because in presence of

sodium, vanadium pentoxide which is formed because of burning of the vanadium will
melt at much lower temperature in the range of about 500°C. This molten vanadium

pentoxide is highly corrosive and it will give the corrosive effect. Hence the combination

of sodium and vanadium in the ratio of 1:3 is the most dangerous combination which will

cause the grooving. Both sodium and vanadium are present in the residual fuel.

Q.737 Which of the listed cylinder liner surface condition indicates proper

lubrication?

Ans. Bright appearance.

The liner surface should be dull white without excessive brightness or black spots or

bright spots. Black spots indicate the blowpast and excessive bright spots indicates

scuffing. Hence well runned and properly lubricated liner will have a dull silvery finish

on the liner surface.

Q.738 Well lubricated bearing surface always appears

Ans. dull white.

Dull white is the colour of the overlay of tin which the topmost layer of bearing surface.

Below this is the layer of nickle barrier which is hard and shining layer. Hence if the

bearing is properly running and there is no wiping then the bearing surface must be dull

silvery white.

Q.741 You are inspecting a lower main precision bearing on a diesel engine You

observe that about half the thin babbit lining are of milky white color The condition

is caused by

Ans. wiping out.

If wiping out takes place, the top layer of tin i.e. overlay is wiped out. When overlay is

wiped out there is bright nickel barrier will be seen as shiny spots. Hence half the babbit

is already visible in a milky white color which indicates that wiping has taken place

because of lack of lubrication or lubricating oil having water content or excessive loading

of the bearing.

Q.742 You are testing a non-popping closed fuel injector diesel nozzle using a nozzle

tester. A pressure less than the designed valve opening pressure is applied. If no fuel

appear in the spray tip this indicates

Ans. the needle valve is sitting properly and is not leaking. The needle valve must only allow the fuel to
inject when the injection pressure is reached

and not below it. If the pressure is raised to less than injection pressure and if there is no

leakage, it means that the injector is in very good condition and it is leak proof.

Q.743 Because of closed tolerance used in diesel engines fuel oil pump a worn

plunger requires

Ans. (b) replacement of pump plunger and barrel.

The plunger and barrel are lapped to form a best sealing surface between them and hence

it manufactured and lapped as a pair and it should be replaced as a pair. Replacing a

single unit will cause excessive leakage or may cause seizure of plunger in the barrel.

Hence it should be avoided and complete unit should be replaced, i.e. both plunger and

barrel, should be replaced.

Q.744 Which of fuel nozzle listed requires the least maintenance?

Ans. Pintle type nozzle.

Pintle type nozzle will have a center hole and the hole is comparatively bigger one and it

is completely covered by the pin at the tip of the needle. The needle sits squarely on the

pin and hence there is less possibility of any distortion taking place between the needle

seat and the valve seat and hence least amount of maintenance is required.

Q.745 When inspecting pistons, liner and rings of a large two-stroke diesel engine

through cylinder ports a wet piston crown could indicate

Ans. (a) leaky fuel injector.

If the oil is accumulated on the top of the piston crown there is no other way that the oil

can come on top of the piston other than a leaky fuel injector. When engine is in stopped

condition, because of leaky fuel injector, the oil is accumulated on top of the piston.

Under such circumstances, immediate action of replacing the fuel injector is most

appreciated.

Q.746 Which of the listed devices could be used as a substitute for a ring grooving

tools used to remove hard carbon deposits from the groove in preparation for

installing new rings?

Ans. (a) Section of removed compression ring.

A section of a removed compression ring can be wrapped all around by a thin Emery

paper and the ring section to be moved in the groove so that all around cleaning of the

groove can be possible with the help of Emery paper which is wrapped around the section

of the compression ring just removed.

Q.747 If the plunger or barrel of a fuel injection jerk pump becomes damaged

Ans. The pump and barrel of the pump must be replaced as a unit.

Q.748 Surface irregularities such as erosion and pitting on the injection pump

plunger will

Ans. effect the fuel oil metering.

If there is excessive erosion or pitting on the plunger then the integrity of the sealing

between the plunger and barrel will be affected. As a result, the high-pressure oil will leak past the
plunger. Hence the quantity of oil injected into the engine will reduce and

which will affect the metering of fuel to the engine.

Q.749 Side clearance (groove clearance) of the compression rings on a diesel engine

piston is necessary to

Ans. for the gas to have easy access to the back of the piston rings.

Due to the easy access, it will force the piston rings against the liner walls. Hence this

clearance is very important. If this clearance is less or the space between the ring and

groove gets clogged or deposited with carbon, sufficient amount of gas will not find its

way behind the piston rings. Hence the contact pressure between the piston rings and

liner will reduce which will cause the blowpast and weardown of liner and breakage of

liner and piston rings.

Q.750 If lost motion is present in a individual fuel injection pump which of the

following problem will occur?

Ans. The fuel injection will occur late.

Due to the lost motion, the exact motion of cam will not be transferred to the plunger

movement and hence there will be late injection because the position of plunger with

respect to the cam will be retarded.

Q.751 In a large low speed propulsion diesel engine if the injectors have formed

carbon around the nozzle holes which of the following would help avoid further

building up?

Ans. Decrease the injection cooling water temperature.

This may be happening because of the excessively hot fuel injector nozzle due to which

the sealing between the nozzle and the seat is affected and nozzle will start leaking. If the

nozzle starts leaking, formation of carbon deposit takes place.

Q.752 A condition contributing to diesel engine piston ring sticking in the ring

grooves is

Ans. insufficient ring clearance at the ring gap or side clearance.

If the groove clearance of the piston ring i.e. axial clearance between the piston rings and

the ring groove if it is less then in that case the piston ring will expand. At the same time

some carbon deposit may take place between the groove and the piston ring will cause

the piston ring to get seized or stick up in the groove. Hence sufficient clearance has to be

maintained between the groove and the ring.

Q.753 In diesel engine when installing new piston rings it is important to check

(a) ring gap clearance.

(b) side clearance .

Ans. Both (a) and (b).

It is necessary to check both the butt clearance and groove clearance. If any of the

clearance is less, it will cause the breaking of the piston ring or seizing of the piston in

the groove which will ultimately cause the malfunctioning or improper combustion of the

fuel and which may cause liner breakage, scuffing, piston ring breakage or loss of power. Q.754 The
purpose of interference angle in a diesel engine exhaust valve is to

(a) work in conjunction with valve to rotate the valve.

(b) break up the seat deposits.

Ans. (b) break up the seat deposits.

Actually interference angle of about ½ degree is given between the seat and the valve so

that when the actual operating temperature reached it will expand. It will have a proper
contact with the seat. At the same time, when this action is taking place, any carbon

deposition that is present between the seat and valve will get crushed and removed.

Hence it acts like a self cleaning method of the seat.

Q.755 When accumulated carbon at air inlet port of a two stroke diesel engine is

being removed you should take care to avoid carbon particles

Ans. entering the cylinder.

(ALREADY DISCUSSED)

Q.756 You are installing new piston rings on a single acting diesel engine piston. To

check the ring gap clearance, the ring should be placed

Ans. at the point of minimum cylinder wear.

At the point of minimum cylinder wear you will have the minimum gap clearance which

will be your yardstick for the proper operation of the engine. If the clearance is

satisfactory at the position of minimum weardown then it can be surely assured that when

the piston is at top position where the weardown of the liner is maximum there will be

sufficient clearance between the ends of the piston. Hence during entire stroke of piston

there will not be a single position where the piston ring ends will butt against each other

and cause cracking of the piston rings, seizure of the piston ring or cracking of the liner.

Hence as a safety measure, butt clearance is always measured where there is minimum

weardown.

Q.757 A defective injector nozzle in a propulsion diesel engine can cause

(a) engine power loss.

(b) smoking due to unburnt fuel.

(c) high exhaust temperature reading.

(d) All of the above.

Ans. (d) All of the above.

If the fuel injector nozzle is defective i.e. it is not spraying properly or if it is not

penetrating properly or if the nozzle is leaking or if the holes are choked, the fuel will not

be atomized properly and penetrated which will result in improper combustion. Because

of improper combustion, there will be loss of power, afterburnining, and hence unburnt
fuel and smoke in the exhaust and the exhaust temperature will rise.

Q.758 Which of the following problems is the main source of fuel pump and

injection system malfunctioning?

Ans. Improper adjustment.

Improper timing adjustment of fuel pump will ultimately lead to improper functioning of

the fuel injector and fuel pump which will ultimately lead to loss of power, excessive

weardown of the piston rings, black smoke, excessive carbon deposits, turbocharger surging. All these
problems will be because of improper adjustment of the fuel pump

which will ultimately cause the improper adjustment or improper spraying of nozzle

holes.

Q.760 If you have determined that entrained air in fuel nozzle system is causing a

diesel engine to stall you should first check for

Ans. a loose fitting in the booster fuel pump suction piping.

If there is loose fitting on the fuel booster suction piping, the fuel booster pump will draw

the air. This air will cause the problem of air traps in the fuel injection system because

booster pump suction side is the only low pressure side in the entire fuel injection system

and hence possibility of air leakage is more.

Q.761 In a large low speed diesel engine excessive piston clearance can be restored

by

Ans. inserting shims between crankpin bearing box and connecting rod foot.

By inserting shims between the bearing box and connecting rod foot the piston position

can be raised in the liner. When the piston position is raised in the liner automatically the

clearance volume reduces and the compression pressure increases. It can be restored back

to the original.

Q.762 Which of the following procedures should be carried out to permit the use of

crosshead engines with an inoperable aftercooler?

Ans. Run the engine at reduced speed until the cooler can be repaired or renewed If

the cooler is not working then the temperature of the air which is admitted to the engine

will be very high. When the admitted air is high the density reduces and hence the
quantity of air admitted will be less and the quantity of fuel that can be burnt will have to

be reduced. At the same time, as the air temperature increases the exhaust temperature

will also increases. Hence complete thermal loading of the engine will take place and at

the same time because of higher temperature in the cylinder lubrication will also get

affected. Hence in order to avoid all these things it is better to run the engine at lower

load.

Q.763 A faulty injector in one cylinder of an operating diesel engine can be located

by

Ans. (a) cutting out the individual injector and noting the engine performance.

Faulty injector in general can be detected by exhaust temperature of the unit but it is not a

reliable method. Hence one has to take the draw card. By draw card you can find out the

compression pressure and peak pressure. If the compression pressure is satisfactory and

peak pressure is varying, it clearly indicates that the injector is bad.

Q.764 Which of the following conditions will cause carbon deposit to form in the

piston ring belt of a diesel engine?

Carbon deposit on the piston ring belt can be caused because of faulty combustion,

excessive ring temperature or over lubrication. All this will lead to carbon formation.

If the combustion is not proper, more amount of carbon deposits will be formed on the

piston rings. If excessive lubrication is given the excess oil will get burnt, it will form carbon and ash and
they will also lead to carbon deposits on the piston ring. Also if the

ring temperature is excessively high i.e. the cooling of the piston is not properly done in

that case the lubricating will burn which will form carbon deposits on the piston rings.

Q.767 A change in the degree of fuel atomization will affect

Ans. (b) fuel penetration.

Penetration and atomization both depends on the hole size of the nozzle as well as the

injection pressure. But as they are opposite to each other if excessive penetration takes

place which occurs because of the increase in diameter of the injection holes the

atomization reduces. On the other hand, if the holes are of very small size which will

cause more amount of atomization. In this case, because of the pressure drop during
atomization, the penetration will reduce. Hence as they are opposite to each other as

atomization increases penetration decreases and vice-versa.

Q.768 Which of the following problems may occur if the clearance between the

piston and the cylinder is insufficient?

Ans. Excessive wear, scuffing of the liner and piston seizure.

There will be excessive wear of the liner as well as the piston as excessive pressure is

developed by the rings over the liner walls. At the same time, the skirt of the piston will

come in contact with the liner wall and wiping out of the lubrication oil will take place

which will also cause excessive wear of the liner. At the same time, as the expanded

piston will come in contact of the liner wall it will wipe out the lubricating oil film. When

the lubricating film is wiped out because of metal-to-metal contact between the piston

and liner wall there will be scuffing of the liner and blowpast. If the clearance is

excessively low and the piston expands beyond that clearance, the piston will get seized

in the liner.

Q.769 Black areas on the sealing surface of the piston rings indicates

Ans. passage of hot gases or blowpast.

Black areas is an indication of blowpast and the lubricating oil is wiped out between the

ring and liner and the areas get coated with carbon deposits from the exhaust gas or high

pressure gas.

Q.770 A bright side on the compression ring of a diesel engine indicates

Ans. properly functioning of the rings.

The job of the rings is to seal the surface between the liner and piston against the high

pressure and high temperature gases. When the piston and the liner surfaces are rubbing

against each other it will give a polishing effect as long as there is no blowpast and the

surface remains polished. This indicates that the sealing between the piston rings and the

liner is proper and the piston rings are functioning properly and the cylinder lubrication is

also proper to maintain the seal between the liner and piston rings.

Q.771 The best tool to remove the carbon ridge at the top of engine cylinder prior to

removing the piston is to use

Ans. metal scrapper. Metal scrapper is used to remove to ridge formed because of carbon. If the ridge is

formed because of the weardown of liner and it is a metal ridge, it is to be removed by

use of hand grinder as it cannot be removed by metal scrapper.

Q.772 Which of the following devices is commonly used to measure the clearance

between the main engine bearing and crankshaft?

Ans. (a) Plastic gauge.

Plastic gauge are utilized like lead wire and they are made to compress between the

bearing and the journal and because of the compression the thickness will reduce and the

width will be increase and the increase in width can be directly calibrated in terms of

clearance.

Q.773 Which of the following condition can result in cracking of the piston land?

Ans. Insufficient ring groove clearance.

If the ring groove clearance is insufficient, the ring will expand and it will occupy the

complete space in the ring groove. Further expansion of the ring in the groove will cause

excessive stresses induced on the piston ring groove which will cause cracking of piston

land.

Q.774 Which of the following conditions may occur while using fuel with high

sulphur content?

Ans. (d) Corrosion

If fuel with high sulphur content is used, sulphur will burn and it will convert into sulphur

trioxide and in presence of water and moisture it will convert into sulphuric acid which is

highly corrosive. This will give the corrosive wear on the liner.

Q.775 If the back clearance of a piston ring is excessive

There will be excessive amount of carbon deposits behind the piston rings and there will

not be enough support for the piston rings. Under such circumstances the piston rings will

protrude more from the ring groove and it will cause the piston ring to collapse or twist

and break.

Q.776 Which of the following conditions could contribute to the cracking of diesel

engine cylinder head?

Ans. Blocked cooling water passages to the head.

If the cooling water passages to the head are blocked or scale formation takes place in the

cooling water spaces, the cooling of the cylinder head is reduced and it is subjected to

very high temperature and pressure. Because of this high temperature and pressure, in

order to maintain the strength of the cylinder head, it is necessary to cool the cylinder

head and maintain the temperature of cylinder head. If the cooling is not carried properly,

the strength of cylinder head will reduce which will ultimately cause the cracking of the

cylinder head.

Q.777 A properly honed diesel engine cylinder liner will

Ans. shorten the breaking in period. A cross honing is carried out so as to give controlled roughness on
the cylinder liner

surface. At the same time to have the retention capacity of the lubricating oil on the

cylinder head surface. Both of this will contribute to the faster running and faster

breaking in period so as to prevent scuffing or blowpast. Hence honing is done at the

initial stages on new liner or if the liner is excessively glazed and the surface is too

smooth to retain the lubricating oil.

Q.778 A scoured diesel engine cylinder liner will cause

Ans. rapid wear of the piston rings.

If excessive scouring is present on the cylinder liner blowpast will take place. When

blowpast takes place the lubricating oil film between the liner and piston will get

distorted and there will be excessive metal-to-metal friction between the liner and the

piston rings due to which excessive weardown of the piston ring will take place.

Q.779 Which of the following operating conditions can occur when shims are

removed from the joint between marine type diesel engine gearing box and the foot

of connecting rod?

Ans. The piston position will move downwards with respect to the cylinder head.

When the shims are removed, the piston will move downwards with respect to the

cylinder head. Hence the compression pressure and clearance volume will increase and

compression ratio will reduce.

Q.780 After long period of operation a wear ridge caused by piston ring action will

developed near the top of the cylinder liner This ridge must be removed when piston

rings are removed inorder to

Ans. prevent breaking of the top ring and land or both.

If the ridge is not removed while removing the piston it may happen that the rings may

get jammed up in the ridge and it may cause the seizure of the piston in the liner. When

new rings are fitted and the piston is lowered and the ridge is not removed, the piston

rings will hammer against the ridge which will cause the breaking of the piston rings and

damage the landing face of the piston ring groove.

Q.781 Crank lead can be adjusted to change which of the listed operating

conditions?

Ans. Longer combustion event.

When the crank lead is adjusted the injection timing gets adjusted. When the injection

timing gets adjusted, the combustion can be delayed or advanced.

Q.782 When hydraulic valve lifter is on the base circle of the cam, zero tappet

clearance is maintained by

Ans. plunger spring.

When the hydraulic valve lifter is on the base circle the plunger springs will lift it against

the base circle and hence the tappet clearance is maintained. During this time, due to the

spring action on the valve plunger, the plunger will be pushed downwards and the roller

will keep contact with the base circle of the cam. Hence zero tappet clearance will be

maintained. Q.783 In a diesel engine blowby is generally a result of

Ans. worn compression ring.

Blowby or blowpast is because of improper sealing between the cylinder liner walls and

the piston rings. This is because of the excessive weardown of the liner wall and piston

rings or improper or uneven weardown of liner wall and piston rings so that the sealing

gets affected and blowpast will take place.

Q.784 Which of the listed condition can cause lacquer to be deposited on the piston

skirt?
Ans. High lubricating oil temperature.

Because of high lubricating oil temperature, the lubricating oil will burn over the piston

skirt. When the lubricating oil burns a lacquer like formation will take place and

deposition will take place on the skirt.

Q.785 Scuffed diesel engine cylinder liner wearing surface in a diesel engine can

result from

Ans. applying load to cold diesel engine.

When the engine is cold it will take some time to form a good sealing between the piston

rings and the liner. Hence the load should be kept low initially and increased gradually. If

the load is suddenly increased, blowpast will take place between the piston ring and the

cylinder liner wall. When blowpast takes place it will wipe out the lubricating oil

between the liner and piston ring and which will cause the excessive friction between the

liner and piston ring which will ultimately cause excessive scuffing of the liner.

Q.786 If a diesel engine driving a generator turns over freely but fails to fire

properly, the cause could be

Ans. air in the fuel.

If the engine can accelerate sufficiently to the firing speed and the fuel is released by the

governor but the engine does not pick up on fuel, this indicates that the fuel is of bad

quality and one of the reason is that the fuel contains air or water.

Q.787 When diesel engine compression pressure is checked

Ans. the indicator cork is kept open.

When the indicator cork is connected to the cylinder head, the indicator cork is kept open

so whatever the change of pressure is taking place inside the cylinder at different

positions or movements of the crank or the main piston will be directly indicated by the

stylus movement of the indicator piston.

Q.788 In a diesel engine exhaust system the cooling of the exhaust gases below their

dew point will result in

Ans. sulphuric acid corrosion.

If the fuel contains sulphur it will form sulphuric acid and if this sulphuric acid is in the
form of vapour but if this vapours are allowed to cool below the dew point then it will

convert into liquid form and it will cause excessive corrosion of the liner. Q.789 Which of the following
statements is true regarding the installation of piston

rings on two-stroke diesel engine as compared to four stroke diesel engines?

Ans. Some provisions must be made in two stroke diesel engines to prevent the rings

from bending in the ports.

In two-stroke engines, there will be ports in the liner walls over which the piston rings

will slide. Hence it is necessary to make sure that the ends of the piston rings will not get

entangled with the ports and the piston rings will not break. In order to avoid such things

the ends of the piston rings, in two-stroke engines, are slightly curved inside so that

during the operating temperature they will not get entangled with the ports and get

broken.

Q.790 In a large low speed diesel engine the clearance between the piston crown and

cylinder head is found to be excessive. Inorder to correct this

Ans. shims should be inserted between the crankpin bearing box and connecting rod

foot.

In case of marine type of connecting rod, where connecting rod is fitted on top of bottom

end bearing, it is possible to insert the shims between the crankpin bearing box and

connecting rod foot so that the position of the piston in the cylinder liner with respect to

the cylinder head can be altered. Hence the compression pressure and clearance volume

can be changed.

Q.791 Bouncing of valve gear in a diesel engine can be caused by

Ans. spring surge.

If the spring is not getting released or if it is not following the action of rockerarm when

the rockerarm moves upward, the spring will not push the valve upward. After sometime,

it will cause the valve to push upwards in the gap between the valve and rockerarm.

During this time, the movement of the spring will be abrupt due the stored compressed

energy in the spring and this will cause the surging effect of the spring and the valve.

This will cause the valve and the spring to get damaged. This can also be caused because
of sticky valve in the guide.

Question Bank and Answers

Section A

Unit 1

1. What are the functions of Mooring winch .

Mooring winch

A mooring winch is a marine equipment used during mooring operations to hold the ship or boat in
place at a pier or similar fixture.

2. What are the functions of Deck crane.

Deck crane

Vessel deck cranes equipment gives the possibilities of loading and unloading cargo without help of port
equipment’s ensuring efficiency in any port of call.

3. What are the functions of Gangway.

Gangway

A gangway is a platform or passage which allows people to move from one point to another. The term is
most classically used in reference to the ramps which are lowered to allow people to board ships.

4. What are the functions of Hatch cover.

Hatch cover

Cargo holds are fitted with hatch covers to prevent the contact of cargo with outer atmosphere i.e. air,
moisture, weather and water and to avoid cargo from getting wet.

5. What are the deck machineries fitted on ship?

Anchor (Windlass and Capstans)

Mooring (Winches and Capstans)

Cargo handling (Winches and Cranes)

Life boat gear (Davits and Winches).

Unit 2

1. Name the materials used for plate & gasket in Plate type heat exchanger.

Titanium,nitrile rubber

2. Name the materials of water box, shell-ms, tubes & tube plate in shell and

tube type heat exchanger.

Copper

3. Name the different types of flow pattern in shell and tube type heat exchanger.

Counter, Doublesingle, Parallel

4. Why lantern ring is provided with tell-tale holes?

To avoid leakage

5. What provision is provided in heat exchanger to prevent corrosion by sea water?

Sacrificial anode

Unit 3

1. What is the purpose of gravity disc?

It determines interface between high and low density medium and maintains it. To control water flow
through water port outlet

(Size of the gravity disc is selected according to specific gravity of oil).

2. How is the capacity of separator decided for a ship? What are the types of oil separators present on
board a vessel?

· 20% more than the consumption of the ship for heavy oil and 3 times the daily consumption of lube oil.

· Clarifier and purifier.

3. Define operating bowl, sliding bowl, spindle height, Bowl body, and Disc stack in a separator.

Sliding bowl

Sliding bowl is located below the top hood and sludge accumulates on the periphery on the sliding bowl.
It’s kept lifted by makeup water. Sliding bowl is provided with Teflon seal. (it seals tightly with the top
hood)

Operating slide

Operating slide is kept held in position by springs and to prevent the discharge of makeup water while
purifier is running and it’s pushed down by operating water then drains the makeup water then de
sludging process taken place

4. What is interface? What will happen if gravity disc size is more or less?

· Interface is nothing but a the line of separation between the oil and water which is controlled by
gravity disc

Unit 4

1. What are all the places centrifugal pump requires priming and why?

Suction head is negative, non self priming.

2. Name the types of pumps ?

dynamic pumps -centrifugal pumps, axial flow pumps

positive displacement pumps-reciprocrating pumps, gear pumps ,screw pumps.

3. What is the definition of pump?

v A pump is a device used to lift a liquid or gas from a low level to a high level, to transport a liquid or
gas from one place to another.

v To do this work it is usually driven by either a Steam engine, an Electric motor.

v Sometimes the pumps are driven direct by a separate Internal Combustion Engine or the main engine
or a Hydraulic motor.

4. Static Suction Head or Lift?

v This is the vertical head through the liquid has to be raised or the vertical height from the liquid level
to the center of the pump, neglecting friction.

5. How Pumps are classified?

v Positive Displacement pumps Ex reciprocating pump, gear pump,etc..

v Dynamic pressure pumps. Ex centrifugal pump.

6. Enumerate the various mountings fitted to the air compressor.

The following mountings are fitted to the air compressors to ensure safe and efficient operations:

1) Air Filters

2) Intercoolers

3) Drain Valves

4) Relief Valves

5) Bursting Discs

6) Fusible Plug

Unit 5

1. Name the certificate requirement of sewage discharge.

ISPP CERTIFICATE (INTERNATIONAL SEWAGE POLLUTION PREVENTION

CERTIFICATE).

2. Which ship needs the ISPP certificate.

All ships.

3. What is MEPC.
Marine Environement protection Committee

4. Expand the term IOPP.

International oil pollution Prevention

5. Under what MARPOL Annex does the incinerator come into picture.

Annex 5

Section -B

Unit 1

1. What are the safety equipments fitted on board ?

Consists of Life-saving Appliances (LSA), such as :

Lifebuoys and Life-jackets

Freefall Lifeboats

Rocket Parachute flares

Immersion suits, Anti-exposure suits and Thermal protective aids.

2. What are the different types of Marine propulsion Machineries?

a. Diesel propulsion system

b. Wind propulsion system

c. Nuclear propulsion system

d. Gas turbine propulsion system

e. Fuel Cell propulsion system

f. Biodiesel fuel propulsion system

g. Steam turbine propulsion system

h. Diesel-electric propulsion system

i. Water-jet propulsion system

j. Gas fuel or tri-fuel propulsion system

3. What do you understand by UMS class vessels.?

UMS class vessel or the Unmanned Machinery Space Class vessels are a term used in reference to the
ships engine rooms

4. What is SWL with regard to engine room crane ?

SWL stands for Safe Working Load. It is the maximum load for which the crane has been designed to lift.
Exceeding the SWL range is strictly prohibited and might lead to failure of the crane.

5. What is a Bouble bottom tank? Why is it called so?

The lowermost part of the ship, which comprises of the bottom shell in the bottom and tank top in the
above, is called as Double Bottom(DB) Tank. This feature was mainly added for extra strength
considerations of a ship. But to avoid wastage of space, this structure is used as a tank to carry
Oil/Ballast. It is longitudinally divided by the centre girder into portside DB and starboard side DB.

Unit 2

1. What are the types of valves used in ship?

v Screw lift valve (globe valve)

v Non – return valves

v Screw down non return valve

v Swing check valve

v Gate valve

v Butterfly valve

v Relief valve

v Quick closing valve

2. Where the screw lift globe valve used in ship ?

v boiler and air reservoir main stop valves

v pump inlet and discharge shut-off valves

v tank filling and outlet valves

v sea suction valves

3. What is the purpose of packing and seals ?

PACKING:-

v To prevent fluid, eg. water, lubricating oil, fuel oil, etc., from escaping from a system.

v To prevent gases and vapours from escaping from a system.

v To prevent undesirable entry of gases, fluids and dirt into a system.

SEALS:

v Seals are used to prevent the leakages thereby avoiding loss of liquid / gas from a system and damage
to components it is intended to protect.
v Seal can form an effective barrier against contamination.

Seals protects the bearings from moisture and dust and prevent lubrication (grease) leakage from inside.

4. Name some of the important characteristics for selecting a packing or seal ?

v When selecting a packing material some of the important characteristics to be taken into
consideration, they are :-

· Strength.

· Elasticity.

· Resistance to chemical influences.

· Resistance to high or low temperatures.

· Coefficient of expansion.

· Thermal conductivity.

· Density.

· Frictional properties.

5. Name three types of seals ?

Various types of seals are.

· Radial lip seal ( with garter spring inside ) - Oil seals are used in gearboxes, hydraulic pumps, etc where
a shaft connected to oil filled components from outside.

· Ring seal ( felt, leather, PTFE),

· ‘O’ Ring ( nitrile rubber)

· Packing box ( vegetable fiber, flexible graphite foil)

· Axial lip seal ( nitrile rubber)

· Mechanical seal, etc.,

Unit 3

1. What is the constructional difference between purifier and clarifier?

Gravity disc which determines the interface between the two liquids is present in purifier whereas there
is no gravity disc in a clarifier , instead there is a discharge collar which seals water outlet.

A top disc with neck separates the oil and water passage in purifier. A top disc without neck throws
water and other heavy particles outwards at the peripheryallowing only oil to pass through.

2. What is principle of operation of the purifier?

Centrifugal force is the fundamental operatingprinciple used in the purification of fluid. Centrifugalforce
is that force exerted on a body or substance byrotation. Centrifugal force impels the body or
substanceout ward from the axis of rotation.

Difference in specific gravity of liquids.

3. What is the purpose of Gravity disc and how do you select the gravity disc?

Gravity disc

It determines interface between high and low density medium and maintains it.

To control water flow through water port outlet

(Size of the gravity disc is selected according to specific gravity of oil)

The gravity disc is selected by using nomogram which is provided by manufacturer

The nomogram consists of

· Specific gravity of oil

· Temperature

· Feed rate

Depending on that a graph is drawn .based on that gravity disc is selected.

4. What will happen if gravity disc size is more or less?

If the diameter of gravity disc is large, the interface moves out towards the periphery and as a result
some oil is discharged with water from the water outlet. Also, if the diameter is small, the interface
formed will be more inwards and water will be discharged with the oil from the oil outlet.

Unit 4

1. What are the different types of pumps used on board the ship?

Positive displacement Pumps:

Reciprocating Pump

Screw pump

Gear pump

Piston pump

Ram type pump

Vane pump

Dynamic pressure pumps:

Centrifugal pumps
Axial flow pumps

Submersible pump

Centrifugal-axial (mixed) pump.

2. Describe the use of service air facility on board the ship?

The uses of service air are as follows :-

For deck equipments like air whistles, gangways, lifeboat winches.

For maintenance work like pneumatic tools, chipping machines, etc.

3. What are materials used for plunger, casing, shaft and cylinder body of a hele Shaw pump?

Materials used in the hele shaw pump:

* Casing: Cast Iron.

* Cylinder body: Ph. Bronze or Barrel.

* Shaft: Stainless steel.

* Plungers: Hardened steel. Well polished.

* Slippers: Ph. Bronze.

4. What are the various safety devices fitted on a marine compressor

1. Lubricating oil low pressure trip

2. Cooling water high temperature trip

3. Motor overload trip and Motor overheating trip

FUNCTIONS:

(a)Lubricating oil low pressure trip: in the event of lub oil low pressure it trips the compressor

causes :can be leakage in pipes, suction strainer choked, oil grade wrong, gear pump faulty, faulty
pressure gauge, increased clearances of the bearings, and oil level low.

(b)Cooling water high temperature trip: when the cooling of the compressor is not efficient due to rise
in cooling water temperature then in that case it trips the running compressor.

causes : can be cooling water valves closed, cooling water piping blocked, cooling water pump belt lose
or broken, cooling water pump faulty, no flow of cooling water, and low level of cooling water in the
expansion tank.

5. What are the safety devices fitted to an air compressor? Mention their requirements.

Safety devices

Relief valve
Fitted to each stages on air side and set to lift at pressure 10% more than stage pressure.

Bursting disc / Bursting Valve

Fitted to water side on coolers, will relieve excess pressure in the water casing in the event of failure of
an air tube.

Oil relief valve (Inside Crankcase)

Fitted in the oil system to relieve pr. more than 25% of normal working pr. to protect oil pump from
overloading, during cold start up.

Fusible plug

On air delivery pipe or on air reservoir a fusible plug is also fitted which melts at 121*c, this ensures the
safety of after machine system against temperature rise.

L.O.Pr.cut out switches –

Protects the compressor machine from damage due to loss of lubrication oil.

Air high temperature cut out switches

Protects compressor and air system from damages due to high temperature air.

Unit 5

1. What is the function of Hunting gear in Steering gear?

It is a return linkage mechanism mounted on the tiller arm to reposition the floating lever so that no
more pumping occurs ( by the variable delivery pump, which normally draws in fluid from one hydraulic
cylinder and pumps into another to move the rudder) when the required rudder angle is reached.

2. What is an Incinerator? What part of MARPOL governs the specifications of this equipment?

Incinerator

It is an equipment fitted on board a ship to incinerate solid waste, house hold waste & liquid waste
arising from the operation of the ship. E.g.: domestic waste, cargo associated waste, maintenance
waste, operational waste & cargo residue.

MARPOL Annex-1.REGULATION FOR THE PREVENTION OF POLLUTION BY OIL.

Annex- 5. REGULATION FOR THE PREVENTION OF POLLUTION BY GARBAGE FROM SHIPS.

Annex-6. REGULATION FOR THE PREVENTION OF AIRPOLLUTION FROM SHIPS, governs the specifications
of this equipment.

3. Explain classifications of fire?

Section-C

Unit 1

1. What is the purpose of the following on board the ship

a. Main engine .

b. Auxiliary engine .

c. Boiler ,

d. Fresh water generator .

e. Refrigeration Machinery .

f. Air-conditioning system .

Main engine: The purpose of main engine onboard a ship is to generate the power required to drive the
propeller for creating thrust force which causes the ship to move.

B) Auxiliary engines are large engines which drive electrical generators that provide power for the ship's
electrical systems. Large ships typically have three or more synchronized generators to ensure smooth
operation. The combined output of a ship's generators is well above the actual power requirement to
accommodate maintenance or the loss of one generator.

C)Boiler: The main purpose of a boiler onboard a ship is to produce High-pressure steam, which is of
vital use in Steam engine ships or nuclear powered ships, or might be used in Steam turbines, to
generate power.

There are basically two type of boilers

- Fire /smoke tube boiler – water present around the tubes

- Water tube boiler - water present in the tubes surrounded by fire.

D)Fresh water generator:

A device used to produce fresh water onboard a ship.

· Considerable amount of fresh water on board is needed for the maintenance of machinery, for use by
crew/passenger and other purposes.

· If huge quantity of fresh water is procured and stored in a ship for the planned voyage, it adds up the
displacement of the ship, so reduction in cargo carrying capacity. So it is advisable to produce F.W
onboard as it is required and consumed. It is common practice to take on only minimum quantity.

It is done using

Distillation system

Production of pure water from sea water by evaporation and condensing.

Evaporation can reduce dissolved solids in seawater from 32000 ppm to 2 ppm or even less.

In this there are two process, namely

1.Boiling process

2. Flash Process
E) Refrigeration: The objective of refrigeration is to prolong the storage life of a perishable product by
lowering its temperature so that metabolic deterioration and decay caused by micro-organisms is
retarded. The cargo could comprise of Frozen produces, meat, seafood, diary produce such as flowering
bulbs and fresh flowers, confectionary, chemicals, pharmaceuticals and photographic materials, all
perishables. Such perishable cargo is hence transported under refrigeration in refrigerated vessels and in
containers

F)Air conditioning: It is the control of temperature and humidity in a space together with the circulation,
filtering and refreshing of the air, aimed at Human Comfort. In Each environmental situation the
organism loses a certain quantity of energy due to emission of sensible heat by convection and radiation
to the latent heat by respiration, the quantity of emitted heat depending on the temperature and
humidity of the environment. The recommended

air conditioning temperature range : 22 - 26 degree Celsius

Humidity range : 40 – 60 % relative humidity in occupied space

2. Describe the different systems available for the main propulsion of a ship.

MAIN PROPULSION SYSTEM

This system comprises of a main engine (diesel or steam), boiler, shafting, thrust block, support bearings
and propeller.

The most common propulsion system used are shown below.

1. The general arrangement of a direct drive slow speed diesel engine is shown below.

This arrangement is having the following components.

A. Main Engine.

The main power to drive the propeller is supplied from a internal combustion engine (diesel engine)
which produces mechanical power by burning heavy fuel oil / diesel oil in it. This engine can run either
at clockwise direction or anticlockwise as required. There by the screw (propeller) is rotated, thrust is
produced by propeller so that the vessel can be moved in ahead or astern direction.

B. Flywheel

Flywheel is located is located at one end of the engine crankshaft and serves three purposes.

First, through its inertia, it reduces vibrations by smoothing out the power strokes as each cylinder fires.

Second, it is the mounting surface used to connect the engine to the shafting and propeller.

Third, to allow the engine to be turned by means of gear teeth arranged around its perimeter.
C. Thrust block

Thrust block absorbs the thrust forces created by the rotating propeller and transmits this force
to the ship’s structure.

D. Plummer block

This block only supports the weight of the intermediate shafting. Thus they have only lower half
bearing shells, except the aftermost bearing which has a top and bottom bearing shells.

E. Stern bearing

The stern tube bearing serves two important purposes. It supports the tail shaft (propeller shaft)
and a considerable proportion of the propeller weight. It also acts as a gland to prevent the entry of sea
water into the machinery spaces (engine room).

F. Propeller

It looks similar to a fan and consists of a boss with several blades of helicoidal 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.

3. General arrangement of an indirect drive, geared, medium speed diesel

( reversible by gears)

4. Sketch & describe the fuel oil system of a large main engine, indicating the important components
and the flow directions.

Ans:

Sketch

Description:

The fuel oil is stored in double bottom tanks after bunkering. While proper steam heating is provided
to increase the viscosity of iol if ship sails in tropical zones.

Fuel oil from doublebottom tank is sent to transfer pump through subsequient valves .

Transfer Pump

A transfer pump normally is installed to move fuel oil from storage tanks to settling tanks. One

positive displacement transfer pump, protected by suction strainers and a pressure relief valve, and a

pump bypass line, is normally fitted. The transfer pump flow rate is dependent upon engine fuel

consumption rate and service and settling tank size.

Settling tank

They provide a settling function for gross water and solids, a heating function, a deaeration function,
and a thermal stabilizing function. Ships’ settling tanks are designed to accept fuel oils with a 60
degrees Centigrade minimum flash point. As soon as a settling tank is filled, it is heated to 72 degrees
Centigrade, or 6 degrees Centigrade below the flash point, whichever is lower. The tanks should be
insulated where possible to reduce heat loss. Settling tanks should have bottom drains for water and
sludge stripping. And, water and sludge should be removed on a regular basis by means of these
drains

Centrifuge:

There are several types of centrifuges used to remove water and particles from the fuel and lube oil; the
most popular being the disc type as made by DeLaval .purifier and clarifier are used

Purifier – oil water seperator

Clarifier-soild water sepearator

Filters:

The higher ash, solids, and catalyst particle content

being found more frequently in heavy fuels make such an installation prudent. A properly designed

filtration system would positively control solids that can damage high pressure pumps, injection

systems, and the cylinder bores of diesel engines.

Service tank:

Service tanks, or day tanks, have a very important function in the overall treatment of heavy fuel oil

for diesel engines. They provide a final settling function for water and solids, a heating function and a

thermal stabilizing function. The settling function is primarily a backup in the event of a performance

failure of the separators and/or during a by-pass of the filtration system. Two service tanks are

normally provided.

Mixing Tank

The mixing tank is usually a narrow, cylindrical insulated tank into which clean, heavy fuel oil flows

from the fuel oil service tank. It also functions as a return tank for recirculated fuel oil from the engine

injection pump return rail. A primary function of the tank is to stabilize service fuel oil temperature by

mixing hotter return oil with cooler service tank fuel oil. The mixing tank is fitted with a bottom

drain. Steam heating coils maintain stable temperature during start-up.

From the mixing tank fuel oil is transferred to booster pump to increase the pressure(10 bar) to
reduce the viscosity of fuel oil. It is sent to heater and heated to 120 deg.

To check whether proper viscosity is maintained before it is sent to main engine it is done by viscosity
regulator.
The pressure in the fuel pump is 800 to 1800 bar and delivered to fuel injector and it injects in fine
atomised form for proper combustion

Unit 2

1. Sketch and describe an Heat Exchanger.

Sketch and

A heat exchanger is an equipment in which two fluids are separately circulated in adjacent spaces so
that some of the heat in the fluid at the higher temperature is transferred into the fluid at the lower
temperature. The fluid having the higher temperature is therefore cooled and the fluid having the lower
temperature is heated.

Heat exchangers – cooler and heaters

Most coolers used on board ship transfer heat from a hot fluid to sea water.

For the main propulsion engine of the motor ship, the engine jacket water, lubricating oil and charge air
must be cooled and generally also water or oil used in cooling the pistons.

Steam heated heat exchangers include heavy fuel oil heaters, boiler air pre-heaters, units to heat sea
water for tank washing, evaporators, feed heaters and calorifiers.

2. Sketch and Describe a globe valve?

v It has a bulbous body, valve seat screwed in / interference fit/ grub screw.

v Seat can be hard faced – stelited, face may be flat or tappered.

v Spindle square threaded, normally above stuffing box.

v Spindle may be fitted to valve disc by a lock nut and button or button locates in a simple horseshoe.

v Leakage along the spindle is prevented by a stuffing box, packed with a suitable material and a gland.

v The flow is from below the valve seat, so that the gland is always on the low pressure side.

v Spindle not connected (SDNR), it allows flow in one direction only. Wings or a stem must guide the
disc.

v The greatest lift required is one-quarter of the bore.

v If no spindle (check valve), body formed as change in direction of flow (angle valve)

v Screw lift valve (globe valve) used in ships are:

· Boiler and air reservoir main stop valves

· pump inlet and discharge shut-off valves

· tank filling and outlet valves

· sea suction valves

3. What examination to be carried out Valves, Seat & Spindle While Overhauling?

v Valves should be examined to see whether any cupping has taken place.

v If it has , the valves should be inverted or replaced.

v If the seats have been eroded, they should be either scraped by hand of if the erosion is too deep,
skimmed in a lathe.

v Where group valves are of the meter type, the valves and valve-seats should be examined and the
valves ground in as necessary to make them perfectly tight.

v In general, the lift of valves should be the minimum, which will give satisfactory operation. Greater lifts
than necessary increase wear and tear.

v Valve seats to be lapped in case of any scoring marks or leakage by using various types of lapping
paste.

v Valve spindle is to be checked for the straightness material worn out.

v The shaft should be carefully examined, especially the stuffing-box area, and if excessive wear has
taken place, the quality of the packing used should be investigated and a larger amount of lubricant
used while running.

A temporary repair with plastic white metal tinned on can be made to a shaft worn at the stuffing box
area.

Unit 3

1. Sketch and describe a flash type evaporator.

Flash water evaporator – a device working with the principle of Flash Process.

Flash process - this the water is heated in one compartment and released into second compartment in
which the process is substantially lower, causing some of the water to flash off into vapour – wherein
sensible heat is added.

Working :

SW is heated in one compartment and released into evaporator in which the pressure is substantially
lower, causing some of the water to flash off into vapour.

Evaporated vapour passed through demister to vapour condenser

To prevent carryover of saline droplets the distillate pump outlet is continuously monitored for purity
(salinometer)

2. Sketch and describe an Auto clean filter.

3. With reference to Purifier/Clarifier, explain the following

(a) Gravity disc

(b) Water seal

(c) Paring disc

(d) Sliding bowl

(e) Operating slide

(f) Damping springs.

a. Gravity disc

It determines interface between high and low density medium and maintains it. To control water flow
through water port outlet

(Size of the gravity disc is selected according to specific gravity of oil)

b. Water seal

A quantity of water remains in the bowl through the running period and these forms the complete seal
around under side of the top disc and confines the oil within the outside diameter of the top disc. Thus a
column of water balancing a column of oil and thus prevents oil going back into the water side. This is
called water seal.

c. Paring disc

It pumps out the separated (clean) oil through the outlet pipe. It works on the principle of centripetal
force.

d. Sliding bowl

Sliding bowl is located below the top hood and sludge accumulates on the periphery on the sliding bowl.
Its kept lifted by make up water. Sliding bowl is provided with Teflon seal.(it seals tightly with the
tophood)

e. Operating slide

Operating slide is kept held in position by springs and to prevent the discharge of makeup water while
purifier is running and its pushed down by operating water then drains the make up water then de
sludging process taken place

f. Damping spring.

It is used to absorb the vibrations in the system axially.

4. With reference to Purifier and Clarifier write the differences in the components and operation. How
will you improve the efficiency of performance of separators?

PURIFIER

1. In a purifier, the interface or the line of separation between the oil and water is created using a
gravity disc. The position of the dam ring plays an important role in the generation of interface. the
diameter of gravty disc is large, the interface moves out towards the periphery and as a result some oil is
discharged with water from the water outlet. Also, if the diameter is small, the interface formed will be
more inwards and water will be discharged with the oil from the oil outlet.

2. It has feed holes in the conical disc for effective cleaning.

3. Another difference between a clarifier and purifier is that a purifier needs to be filled completely with
water for the generation of a seal that prevents the oil to leave from the water outlet.

4. Purifiers are used for filtering lubricating oil whereas clarifiers are not used for the same unless the oil
is completely devoid of water.

CLARIFIER

clarifiers do not have a gravity disc but have a sealing ring which seals the water outlet. This prevents
the impurities and water to remain inside the bowl unless they are discharged automatically or manually
by opening the cleansing bowl.

the conical discs in a clarifier usually don’t have feed holes in them but if they do, then a disc without
any holes is fitted at the bottom of the stack.

Whereas a clarifier doesn’t needs to be filled up with water.

A clarifier used to remove solid particles.

1.) Purifiers are used for filtering lubricating oil whereas clarifiers are not used for the same unless the
oil is completely devoid of water.

2.) Supplying oil at higher*Celsius to purifier ensures efficient separation.

3.) Putting appropriate gravity disc for the oil of particular density ensures good efficiency.

4.) Seal between the sliding bowl and the bowl body should be maintained to maintain a good efficiency.

5.) Desludging operation should be periodically done.

Keep the throughput as low as possible.

5. With reference to centrifugal separator, give reasons for:

a. Vibrations, Inclusion of clutch in bowl drive.

b. Contamination of gear case oil

c. De-sludging operation not taking place

d. Separator not picking speed.

a. Vibration will occur due to over speed of the separator

· imbalance in the separator parts

· slackening of bowl while rotating.

· Paring chamber cover and lock nut are not correctly installed
· Insufficient or incorrect cleaning

· Bearing wear down

· Foundation bolts not tightened properly

· Worm and worm wheel is nor matches correctly

Motor and shaft is coupled by friction clutch ,if there is no clutch motor will overload while starting, so
friction clutch is necessary to reduce the load while starting, once motor attained particular rpm the
friction clutch will engage to the shaft.

b. operating water leaking ,water dripping from the bowl nozzle will contaminate the gear case oil if the
casing is cracked

c. Operating water not available, malfunction of valves, malfunction of solenoid valve for de-sludging,
bowl is not fully opened.

d. Brake is not released properly, friction clutch is slipping(if the pad is polished or worn out more). If
belt driven there may be slackness.

Motor r.p.m might be less.The bowl assembly due for cleaning.

Unit 4

1. Sketch and describe a centrifugal pump .

Flow through the pump is induced by the centrifugal force imparted to the liquid by the rotation of an
impeller or impellers.

The impeller construction has two discs joined at in between surface by a set of internal curved vanes.

Centrifugal pumps are not self-priming pumps. These pumps must be primed by gravity supply or by
priming equipment external or internal with the pump.

These pumps are basically radial flow or axial flow type.

Example: Emergency fire pump. Bilge and ballast pump

2. Sketch and describe a gear pump.

v This simplest type of rotary pumps is the spur gear pump. It consists of two meshing spur gears
enclosed in a casing. A close tolerance between the gears and the casing are important for the proper
functioning of this pump.

v It is very important to maintain a fine working clearance between:

· The axial end faces of the casing and gears.

· The gear teeth in mesh.

· The gear teeth tips and the casing.

v Two gears in mesh rotate within a housing. One gear shaft is driven with an external power source and
the other idles.

v An inside view of this pumps is shown below to explain its working.

v On the suction side the fluid flows into the casing when the gear teeth disengage.

v During the further rotation of the gears the fluid occupies the space, between two adjacent teeth and
carried over to the discharge side.

v At the discharge side as they mesh, each tooth forces an amount of liquid, equivalent to its own
volume.

v If the clearances are maintained small, this pump, can take air, and thus can take suction on the fluid
pumped.

v The viscosity of the fluid is unimportant in the functioning of this pump.

v Therefore, it is suited for pumping fuel and lubricating oil.

v These pumps should not be run dry or else they will overheat and seize up.

v Usually the pump is electric motor driven through a chain or wheel drive.

v Control of flow rate is achieved by a by-pass valve or by controlling speed of prime-mover.

v These pumps are used for duties as a lube oil pump, boiler fuel oil pump, fuel oil transfer pump, main
engine driven lube oil pump.

3. Explain with a neat sketch of Mechanical seal ?

v Due to undesirable characteristics of a conventional stuffing box, especially when the leakage has to be
an absolute minimum and under high pressures,

v An entire different type of seal had been designed, with wearing surfaces other than the axial surfaces
of the shaft and the packing. This form of seal is called a “mechanical seal” and has proved to be very
suitable in almost all extreme conditions.

v The design of mechanical seals may differ in various physical respects, but all are fundamentally the
same in principle.

v The sealing surfaces are located in a plane perpendicular to the shaft and usually consist of two highly
polished surfaces running adjacently, one surface being in contact with the shaft and the other to the
stationary portion of the pump.

4. Describe a two stage air compressor with a line diagram.

The two-stage compressor arrangements below show the single acting pistons acting in conjunction with
an intercooler.

Lubricating oil for air compressors should have, among many other properties, a flash point minimum of
above
2000C for safety.

High temperatures can carbonise the oil and form a “gritty” deposit which will cause severe wear on
piston rings, and cylinder liners, -- expensive replacement parts. This also causes the compressor valves
to “coke up” which can restrict their operation and sealing, thus reducing the compressor efficiency.

Modern practice is to use a synthetic oil for lubrication.

By using intercooling and cylinder cooling (usually ‘Air’ or ‘Water’ with air compressors) the oil is kept in
a

fluid condition (i.e. it does not vaporise or carbonise) so it may lubricate properly.

Operation

On the downward stroke of the piston in a single cylinder compressor, air is drawn in through the
suction filter and the suction valve, to fill the cylinder. The downward motion of the piston causes a
partial vacuum in the cylinder so the atmospheric pressure of the outside air pushes the suction valve
open against the light force of the spring that holds it closed when the machine is stopped.

As the piston begins its upward stroke the suction valve is pressed shut as the air pressure inside the
cylinder rises. Continued upward motion further raises the pressure until at a designed pressure the
discharge valve is pushed open against the larger spring force that holds it closed when the machine is
stopped, and the compressed air will then pass through an intercooler to a second stage.

The piston-reciprocating compressor has a more positive sealing arrangement (rings) than any other
type of compressor and consequently it can achieve higher compression ratios than any other form of
compressor.

The two-stage compressor arrangements below show the single acting pistons acting in conjunction with
an intercooler.

Lubricating oil for air compressors should have, among many other properties, a flash point minimum of
above

2000C for safety.

High temperatures can carbonise the oil and form a “gritty” deposit which will cause severe wear on
piston rings, and cylinder liners, -- expensive replacement parts. This also causes the compressor valves
to “coke up” which can restrict their operation and sealing, thus reducing the compressor efficiency.

Modern practice is to use a synthetic oil for lubrication.

By using intercooling and cylinder cooling (usually ‘Air’ or ‘Water’ with air compressors) the oil is kept in
a

fluid condition (i.e. it does not vaporise or carbonise) so it may lubricate properly. Multi-stage air
compression have the following advantages:

1. They can maintain a moderate range of air temperature by cooling the air between stages.

Cylinder cooling also assists this to a smaller extent.

2. By cooling between stages (and cylinder cooling), less work input (i.e. less electric motor or diesel
power) is required to compress a given quantity of air to a specific pressure.

3. Lubrication difficulties can be minimised by keeping the air temperatures as low as possible, (above
200°C the oil tends to carbonise onto piston rings and in delivery valves, seriously impairing their
operational efficiency).

It is common practice to use synthetic oils rather than mineral based oils to avoid carbonisation, despite
their much higher prices.

Unit 5

2. Sketch and describe two ram system of steering gear.

Consider the telemotor receiver cylinder moving from left to right. This movement moves the lever,
which has a fulcrum at the centre in a clockwise direction. The floating lever top moves to the left and
along with it pull the control lever of the pump out, pivoting at the bottom point. Since the Hele Shaw
Pump is running,, oil is sent to the right hand cylinder & sucked from the left hand cylinder. The stbd
ram is pushed from right to left, which in turn pushes the port ram, as both are connected by a
crosshead

The tiller arm, which is at right angles to the centre line of the rams and fitted to the crosshead, thus
moves to the left. The other end of the tiller arm is keyed to the rudder stock which then rotates and
turns the rudder to stbd. The tiller arm is connected to the bottom portion of the floating lever by a
buffer spring and link. This is called the hunting gear.

3. Sketch a sprinkler line for accomadation system. Explain briefly on different

colour bulb used in this system.

Light red ampoules release already with 57 0C,

red with 680C and violet only with 820C.

Between them the categories yellow (79 0C),

green (930C) and

blue (410C).

4. Sketch and describe an international shore coupling.

• Outside Dia 178 mm

• Inside Dia 64 mm

• Bolt Circle Dia 132mm

• Slots in Flanges: 4 holes, 19 mm in dia, spaced equidistantly on a bolt circle of the above dia, slotted to
the flange periphery.

• Flange thickness: 14.5 mm minimum

• Bolts & Nuts: 4-each of 16 mm dia, 50 mm in length, with washers.

4. Describe the procedure for the regular maintenance routines to be carried out on the total flooding
CO2 system.

Maintenance and Testing

Ensure that all moving parts are kept clean, free and well lubricated. Wires must be checked for
tightness, toggles and pulleys must be greased. With the use of compressed air the CO2 distribution
pipes could be blown through periodically. CO2 bottles must be weighed regularly to check contents (an
ultrasonic or radioactive isotope unit detector could be used to check liquid level).exhaust is working or
not . co2 alarm.

Note;

The CO2 storage bottles have seals which also act as bursting discs. Should there be a CO2 leakage from
one or more of the starting bottles this cannot result in CO2 discharge into the engine room from the
battery because of the cable-operated safety valve. When leakage occurs either in the starting section or
main battery a pressure switch in the lines will cause alarms to be sounded. Vents to atmosphere can
then be opened.