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1. WATCH KBEPING

I. EXPLAIN TFIE TERN{ *WATCH' ' .

Ternr watclr nreans1. Group ofpersonnel conrposing the rvatch.2. Per iod of responsib i l i t l , .Airn of lvatchl. For the safetl ' of l i fe anC irropefty at sea.2. Plevention of pollution of the marine environment

2. EXPLAIN ROUTINB WATCH KEEPING - TAKING OVER ANDACCEPTTNG A WATCH (CKL)The Engineer officer in charge of the watch should not hand over the watch to therelieving engineer officer ifhe has reason to believe that the latter is obviously notcapable of carrying out his duties effectively in which case he should notify the chiefengineer offi cer accordingly.

The relieving engirreer ofi lcer should not take over the r.vatch unti l he has exatnined theengine room log and checked tl iat it is in accordance with his orvn observations.

Prior to taking ovcr tlte rvatch l ie should satisfy hinrself regarding;1. Standing olders arrcl special irrstructions of the chief engineel officer.2" The nrerr rbers of h is r i 'a tch are apparent ly ' f i r l l l ' capable of per fbnning t l re i r dLr t ieseffbctivelv.3. Nature of all rvorli being perfbrrnecl, personnel involvecl and potential hazards.4. Level and rvhcre appl icable,i. the condition ol'rvater or residues in bilge. ballast tanks. slop tanks, reservetanks, fresh rvater tanks, sewage tanks, andii. special requirernents for use or disposirl of contertts there of.5. Level and rvhere applicable the conditions of fuel in all fLrel storage facil i t ies.6. Condi t ion and mode of onerat ion of

Various main ancl auxil iary systenls,I r4oni tor ing and contro l console equiprnent ,

i i i . Auto lnat ic boi ler corr t ro ls .1. Potcnt ia l ly adverse condi t ions resul t ing l l 'or r bad u 'eat l teL, ice, cc lntaur inated orshallorv rvater.8. Reports of engine roonr la t inss le lat ing to thei r ass igned dut ies.9. Avai labi l i ty of f i re f ight ing appl iances ancl thei r tnost c f l 'ect ive use.

In port: (CKL)l . Arry por t regtr l r t ions pel tu in iug t t r

Ship afflucnts,f-ire fi ghting requirernents,

i i i " Sh ip read i r t ess .2. L ines of corrnrunicat ion avai lable between the ship and shore s ide personnel ,i r rc luding por t authol i t ies.

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3. Procedures for notifuing the appropriate authority of envit 'onmental pollutiolr

resulting fi 'orn engineering activit ies.

3. EXPLAIN ENGINEERING WATCH UNDERWAY. (WFL)

l. Primary responsibil i ty at all t irnes is

i. Safe and efficient operation and upkeep of machinery'

ii. Bridge orclers relating to changes in speed or direction ofoperation are

immediate ly implemented.2" Should keep the nrain propulsion plant and auxil iary systeuls under constant

supervision unti l properly relieved.

3. he should ensure that adequate tours ofthe machinery and steering gear spaces are

made lor the purPose ofi. observing and reporting equipment malfunctions or breakdowns,

ii. performing or directing routine adjustments,

i i i . required upkeep and any other necessary tasks'

4. Take the action necessary to contain the effects of damage resulting from equipment

breakdown, fire, f looding etc.5. Ensure that all metnbers of the watch are familiarwith the location, type of f ire

fighting equipment, their use and the various safety precautions to be observed.

6. Oi1.eci any other member of the watch to inforrn of potentially hazardous conditions.

l. Arrange ior substitute personrrel in the event of incapacity of any watch personnel'

8. Be awire of potential hazards in the rnachinery spaces and be able to administer

f i rs t a id.9. Continue to be responsible for machinery space operations despite the presence ot

chief engineer officer in the machinery spaces.

10. Cheik i 'dicator diagra'ts to obtain power and pressures in cylinders.

In por t :1. Be fami l iar wi thi. Ship's ballast systelr and its controls

ii. All ship board detection and alarm systems and the appropriate response to the

activation of those systell ls.2. Be aware ofi . Cargo oPerat ions and

ii. Operational water suPPlie

3. Be ready to prepare the ship and its machinery for stand-by or ell lergency condltlons

as requi red.

He shouldl. ln eprergelcies, sound the alarm and take all possible measures to prevent damage'

2. Be aware of cargo officer's needs relating to

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i i .Equipnrent required in the loading and unloading of the cargo'

Ballast and other ship stabil ity control systems.

3 .Ensu re tha tp recau t i onsa re taken top reven tacc iden tso rdamage to theVar touselectr ica ll rydraul icpneumatic andMechanical systen'ls of the shiP.

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4. Ensure that all imporlant events affecting the operation, adjustment or repair ofship's rnachinery are satisfactori ly recorded. (For the benefit of relieving engineerofficer and for record purposes.)

05. WRITE A NOTE ON BRIDGE NOTIFICATTON. (WFL)The bridge should be irnmediately notif ied in the event of1. F i re.2. Of impending actions in rnachinery spaces that may cause reduction in ship's speed.3. Imminent steering failure or stoppage of ship's propulsion systern.4. Any alteration in the generation of electric power.5. Any other similar threat to safety.This notif ication where possible should be accomplished before changes are made inorder to afford the bridge the maximum available time to take whatever actions arepossible to avoid a potential marine casualty.

6. EXPLAIN NAVIGATION IN CONGESTED WATERS.The engineer officer in charge ofthe rvatch should ensure thatl. All machinery involved with the maneuvering of the ship can immediately be placedin rnanual nrodes of operation when notif ied that the ship is in congested waters.2. An adequate reserve of por.ver is available tbr steering.3. Emergency steering and other auxil iary equipment are ready for irnmediateoperation.

7. EXPLAIN NAVIGATION DURING RESTRICTED VISIBLITY.During navigation in restricted visibil i ty. the engineer officer in charge of the rvatchshouldL Ensure a pemanent air or steam pressure for fog sound signals.2. Be ready to respond to any bridge orders.3. Ensure that auxil iary machinery used for ntaneuvering is readily available.

8. WTIEN DO YOU CALL CHIEF ENGINEER? (WFL)I. When engine damage or malfunctions occur.2. When damage or breakdown of propulsion machinery, auxil iary rnachinery,rnonitoring and governing systems occur.3. In emergencies or in situations when he is in doubt as to what decision or lneasuresto take such as engine room flooding.4 . The engineer otl-icel in charge of the watch should in addition not hesitate to takeimmediate act ion.

9. EXPLAIN WATCH AT AN UNSHELTERED ANCHORAGE.The engineer officer in charge of the watch should ensLrre thatL Periodic inspection is nrade of all operating arrd stand-by machinery.2. Main and auxil iary machinery is maintained in a state of readiness.3. Measures are taken to protect the environment from pollution by the ship.4. All darnage control and fire fighting systems are in readiness.

IO. ENGINE ROONI WATCH KEEPING ROUTINt is .NIAII,'] EIYGINE

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Top platform levelL Fuel injection equipment for leakage.2. Fuel inject<lrs ( all are working )3. Exhaust gas temperatures after each unit ( 380 deg C )4. Ai rs tar t ingvalvepipes. I f leakingthey arehot .5. Cylinder cooling water F.W. outlet temperatures.6. Turbochargers.

air f i l ters (clean)

air discharge pressurecooling water F.W. outlet temperatureexhausf gas temperature inlet / outletLubricating oil f low, inlet / outlet temperature.Oil level inL.O. gravity tank for T/CL.O. drain tank for T/C

Middle platform levell . Scavenge a i r cooler

2. cy l inder lubr icatoro i lde l i veryoil level in cylinder oil tank for lubricator

3. Rocker arnt lubricator

Air inlet / outlet temperature.S.W. inlet / outlet temDerature

oi ldel iveryoil level in feeder oil tank

return temperatureoil f low in sight glasses

2. Feel terrperature ofcrank case doorsthrust bearing casing

3. Running gear noise level4. Line shaft bearing

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4. M/E scavenge space drains ( crack open )5. Oi l level in

M/E governorM/E governor amplif ier unit

Bottom platforrn levelL Piston cool ing o i l

telxperatureo i l l eve l

5. Stern tubeL.O. tenrperatureL.O. pressureOi l level inL.O. drain tank for S.T.Upper L.O. gravity tank

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ALower L.O. gravity tankL.O. tank for S.T sealing

CAM.SHAFT LUBRICATIONl. Turn discharge fi l ter element2. Level in camshaft lubricating oil tank3. Camshaft lubricating oil pump

mechanical seal for leakaseii. bearing ternperatureiii. discharge pressure

FUEL YALVE COOLINGl. Oil level in fuel valve cooling oil tank2. Oil temperature to fuel valves3. Fuel valve cooling oil pumpi. mechanical seal for leakageii. bearingtemperatureii i . discharge pressure

JACI(ET WATER SYSTEMl. Main and auxi l iary F.W. cooler

F.W. inlet / outlet temperatureii. S.W inlet / outlet telnperature2. F.W expansion tank level3. Main F.W. cool ing o i I punrpi. mechanical seal for leakagei i . bear ingtemperatureii i . discharge pressure

LUBE. OIL SYSTEMl. Pressure differential across fl l ters2 . O i l l eve l i ni . M/E L.O. dra in tankii. Lorver L.O. drain tank for M/E stuffing box3 . Ma in L .O . coo l i ng o i l pumpi. mechanical seal for leakagei i her l ins lernneraturei i i . d ischarge pressure4. Purif ieri. oil level in worm gear housingl l .

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bowl speed / oil f lowwater discharges for oil content

iv. oil inlet telnperaturesuction and discharge pressure

vi . s ludge tank levelvii. operating rvater tank level5. L.O. cooler

L.O. inlet / outlet temDerature

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FUEL OIL SYSTEM1. Pressure differential across secondary filters2. Purif ier (WFL')

i. oil level irr worm gear lrousingii. bowl speed / oil f lowii i. water discharges for oil content

vi. sludge tank levelvii. operating water tank level3. Fuel oil viscosity / temperature to engine4. Back wash F.O. secondarv filters5. F.O. primary pump

oil inlet temperaturesuction and discharge pressure

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Mechanical seal for leakageBearing tenlperature

i i i . Discharee l t l ter '6. F.O. settl ing and service tanksi. Drain water fi'om tankii. F.O. temperatr-rrei i i . Oi l level in tank

PURIFTER ROOX( (WFL)l. F.O. supply l irres fbr leakage2. Steam lines and valves for leakage3. Operating water leakage4. Purif ier room air supply5. Check that the exhaust fan is running6. Load on purif ier motors

AIR SYSTEMS (tr/FL)l . A i r compressors

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oil level in crankcasef-eel ternperature of crank casedrain inter-coolers and after-coolersL.P and H.P discharge pressureL.O. pressure, air delivery temperatureCooling water temperature and pressure

2. Drain water frorni. rnain air reservoiri i . contro l a i r reservoi ri i i . sh ip serv ice a i r reservoi riv. compressed air oil separator3. Main air reservoir pressure ( pump up if low )4. One reservoir should be kept closed at full pressure while the other is in

STEERING GEAR ( t ' ,FL)

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I . Feel temperature of motor and pump bearings

2. Hydraulic pump replenishing tank level

3. Telemotor pump replenishing tank level4. Ammeter for load5. All glands for leakage6. Lubrication of moving parls and oil fbeds

1 . A visual inspection of tl.re steering gear and its connecting linkageg. Operatiorr of the means of comnrunication between the navigating bridge and the

steering gear comPaftment9. Check for leakage from the system10. Check that sliding surfaces are properly lubricated

I l. Check fhat the individual grease nipples or central greasing system are full and

providing lubrication

AUXILIARY BOILER (WFL)l. Blorv through the water level gauges.2. Feel F.D. fan bearing telnperature3. Boi ler drumi. water leveli i. test water level alarmsii i. stealn pressure4. Cornbustion of f irel in furnace (clean bright f lame, no sparking )5. Fuel oil supply l ines for leakage6. Fuel oil temperature ( I l0 deg C ) / pressure

1 . Oily drain inspection tanki . leveli i . check for t races ofo i l8. Steam lines and valves for leakage9. Boiler blow dorvn l ines temperature10. Boiler safety valve l ines terrrperatureI l . Boi ler feed purnpsi. mechanical seal for leakageii. bearing tetnperatureii i . discharge pressure12. Funnel s tnoke color13. Carry out boiler water tests

ECONO]IIISER1. Boi ler water c i rcu lat ing punlp

glands fbr leakageii. bearing tentperatureii i . discharge pressure2. Exhaust gas temperature inlet / outlet -

3. Exhaust gas pressure droP

ELECTRICAL PLANTl. All rrtotors, t-eel2. bearingtemperattlre

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3. stator casing

SWITCH BOARD (WFL)1. Voltage and frequency2. Free from water drips or leaks3. Load on pump and compressor motors, Diesel generators4. Load on lighting and navigation circuits5. Purnps and diesel generator for stand-by status

C0NTROL ROOM PANEL (WFL)l. Alarm enunciators2. Equipment state enunciators3. Provision refiigerated roont temperatures4. Boiler drum remote level indicators5. Pumps and diesel generator for stand-by status

FRESH WATER GENERATOR (CKL, U/FL)l. Condensate level in condenser2. Temperature change acrossl .

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heat exchanger ( 70 - 62:8 deg C )condense r ( 30 -36 - 6 degC )

3. Shell tenrperature4 . Vacuun r (72 cn o fHg )5. Fresh water outpLrt quantity6. Salinonreter readings ( 4 - 6 p.p.m. sea salt )l. Over flows ll 'orn F.W. tanks( Donrestic )8. Ejector and condensate pumpsi. glands for leakageii. bearingternperaturei i i . d ischarge pressure

DIESEL GENERATORl. Oil level in clank case, R/A L.O. tank level2. Lube oil pressure / temperature3. Cooling water temperature I pressure4. Rocker arm L.O. pressure5. Erhaust gas tenrperature after each unit6. Turbochargerl .

i i .air f i l tersair discharge pressure

ii i. exliaust gas temperature inlet / outletiv . lubr icat ing o i l level7. Inlet air temperature8. Sea u,ater circulation tlrrouglr coolers / plessure9. Fuel injection equiprnent for leakage10. Feel temperature ofcrank case doorsI 1. Govelnor o i l level

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REF. AND AIR CONDITIONING aNITS (ryFL)1. Conrpressor and cfank case oil level / noise2. Feeli. compressor bearing tetnperaturesii. condenser S.W. inlet / outlet temperatures3. Compressori. suction pressure ( 3 bars) /temperature ( 0 degC )/i i . Discharge pressure ( 12 bars) / temperature ( 130 deg C max. )i i i . L .O. pressure (akglcm2)/ temperature (45 deg C ) ( 60 degC rnax. )4. Cooling water pumpi. mechanical seal for leakageii. bearing temperatureiii. discharge pressure5. Conrpressor shaft seal for leakage6. Oil separator : check that the oil return line is warmer than the crank case ,7. Temperature of the refrigerated space8. Cornpressor running hours

MISCELLA]VEOUSl. Bi lge and o i ly b i lge levels2. Potable and sanitary system hydrophores3. F i re and G.S. pump pressure

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WHAT OBSERVATTONS DO YOU MAKE IN CONTROL ROOM? (WFL)M.E. L.O. SYSTEXT

L.O. in let T.Bear ing L.O. in let P.Piston cool ing o i l in let P.L.O. f i l ter in let P.Camshaft L.O. inlet P.T/C L.O. in let P.

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M.E. COOLING IYATER SYSTE\TCool ing F.W. in let P.Cool ing F.W. out le t T.Sea water T.F.V. cool ing o i l out le t P.Cool ing S.W. a i r cooler in let P.

]IT.E. AIR SYSTE]ITStar t ing a i r P.Main a i r reservoi r P.T/C scavenge air outlet P.Scavenge air rranifold P.Speed control air P. to PG governor'Control air reservoir P.Ship serv ice a i r P.

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5. M.E. FUEL OIL SYSTEMi. F.O. in let T, P.i i. F.O. viscosityii i . H.O. service and Stand-by service tank T. and leveliv. H.O. settl ing tank level6. DIESEL GEIIERATOR SYSTEMi. Gen. Engine L.O. outlet T.i i. Cen. Engine cooling F.W. outlet T.7. STEAM GENERATI]VG SYSTEMi. Steam T.ii. Steam drum P.ii i . Exh. Gas economiser Header P.

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2. AIR COMPRESSORS

1. NAME THREE USES OF COMPRESSED AIR IN THE ENGINE ROOM.l Starting both rnain and auxil iary engines.2. For control equipment and instrumentation purposes.3. To drive pneumatic tools.4. Paint spraying equipmerrt.

2. WHAT PRESSURE IS REQUIRED FOR EACH OF THE COMPRESSEDAIR USES.l . 25 - 30 Kgf / cmZ.2 . SKg f / cm2 .3 . SKg f / cm2 .4 . 4Kg f / cm2 .

3. NAME 2 TYPES OF AIR COMPRESSORSl. Reciprocat ing2. Rotary vane3. Rotary screrv4. L iquid r ing

4. LIST ANY SAFETY FEATURES FOUND ON AIR COMPRESSORSl. L.P. and H.P. safety valve.2. Jacket water burstins disc or relief valve3. Compressor trip at4. L.O. low pressure5. Cooling water high temperature6. Conrpressed air outlet(H.P.) high tenrperature

5. LIST THE MOUNTINGS ON AIR RESERVOIRl . Ai r in let va lve2. Ai r orr t le t va lve lor rnain engine3. Air outlet valve fbr A/8, control air, ship service air4. Fusib le p lLrgs ( mel t a t l2 I deg C)5. Drain valves6. Safety valve7. Pressure gauge connection isolating valve

6. HOW AND WHY IS MOISTURE REMOVED FROM COMPRESSED AIR?Because, the rnois tu le in a i r wi l l causel. lt rvil l rvash the oil f i lm off the cylinder wall2. Starting air system explosion3. Excessive cy l inder l ine l and p is ton r ing wear4. Corrosion

7 . IS THERE ANY RULE GOVERNING THE S IZE OF MAIN ENCINESTARTI NG A I TT RESERVOIRS?

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| ' I . Single / Twin screw propeller engine: 12 starts without refi l l ing

L , 2. Controllable pitch propeller: 6 stafis without refi l l ingt -IL . 8. WHY SAFETY VALVE CONNECTION PIPE IS LEAD TO FUNNEL?

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Because\ 1. Air will air contbustion of any burning materialI

- 2. lt will cause CO2 discharged in the engine room to be displaced or rveakened by| " '

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l-- 9. wHAT ARE THE RESuLTS oF sLUGGTSH sucrtoN AND DELT'ERyI -I VALVES?_ ,

1t - , . S luggish suct ion valve:

l_. i. Part of the air drawn into the cylinder wil l be returned through the defective

!-= suction valve during the first part of delivery stroke.! - s U L t l U I l V d l v g U t l l l l l g r l l g t l l J (

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I -- i. Part of the air compressed and delivered during the delivery stroke wil l return

\ to the cylinder dtrring the first part ofthe suction stroke.a Jl -l - . 10. WHY AIR COMPRESSORS ARE PRONE TO VALVE TROUBLE?

I - L It operates once every revolution and the valve movements are extremely frequent.

l- , 2. Carbon deposits fiom the oil causes valve wear and breakage.I - 3. Due to presence of foreign particles.1-I ' I I . wHAT ATTENTION DO THE AIR BOTTLES NEED DURING THEI " '. . WATCH?I

- L The drain on the receiver should be 'bloln' periodically.

l-I t 12. WHAT ARE THE LIKELY CAUSES OF LOW DELTVERY FROM AN AIR

l_ COMPRESSOR?

a ) L lncreased clearance volume.

L 2. Sluggish opening and c los ing ofsuct ion and del ivery valves.

f I i . Leakage past compressor piston rings.

l- 4. Too high cooling water inlet temperature.

| ,. l 5. Too high air inlet temperature.

l - 6 . Diny a i r in let s t ra incrs.

l tl - rJ . WHAT TypE oF vALVES IS FITTED oN AIR coMPRESSoRS?

I - Spring loaded plate type non-return valves.

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I J 14. WHY CONTROL AIR DE-HYDRATOR IS FITTED?f-- In control air dehydrator, air is f i l tered and dried ir.r order to rernove virtually all traces

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| ' 15. wHy JACKET COOLTNG tS NECESSARY rN AIR COMPRESSORS?

l- L It lorvers the rvorkdone in conrpressing the air.

| " 2. Prevents a lot of mechanical problems, which could arise if the ternperature were '

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3. Less dift iculty is experienced with the lubrication of the pistons and cylinders.4. Suction and delivery valves remain in a cleaner condition without becoming fouledwi th carbonized o i l .

I6 . DESCRIBE THE PROCEDURE FOR MAINTAINING VALVES ON ARECIPROCATING COM PRESSOR.Compressor valves must be exarnined at regular intervals1. Dismantle the valve.2. Clean all parts with a cleaning fluid using a soft brush.3. Check the condition of all components especially fori. wearii. damage to the seat faceii i. the platesiv. fatigue ofsprings4. Repair all parts and replace all parts, which are worn or show any cracks.5. Reassemble the valve.

I7. HOW DO YOU RUN UP AN AIR COMPRESSOR? (WFL)l . Open a l l va lves in the a i r p ipe.2. Check the oil level in the crankcase.3. Remove one of the valves in each cylinder and insert a l itt le oil into the cylinder.4. Turn the compressor a few revolutions.5. Ensure that the cooling water is re-circulating.6. Open blow-off valves on coolers' water separators to drain off all moisture. Closethe valves after a shor-t period.7. When starting the L.P. suction valve must always be in the open position. This isdone rnanually or automatically by tneans of pneumatic controls.8. Check load on diesel generator.9. Norv, start the compressor.

RUN]VI IVGl. When the compressor is well under way,i . L .P. d ischarge: 4.5 to 5 Kgf / cm2.i i . H.P. d ischarge: 25 to 30 Kgf / cm2.2. During operation, open the blorv off valves on the coolers' water separators for amoment at intervals.

STOPPII,IG1. Open the blorv off valves on the coolers'water separators slightly to drain off allmoisture.2. Set the unloader lever in the vertical position and stop the printe tnover.3. Close the charging valve on the air bottle.4. Then open the blow off valves on the coolers' water separators fully

I8. WHAT ROUTINE MAINTENANCE WORK YOU WILL CARRY OUT ONMAIN AIR COMPRESSORS?l. Clean air inlet f-i l ter and oil f i l ter.2. Clean and inspect suct ion and d ischarge valves.

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3. Drain and renew crankcase oil.4. Clean coolers.5. Check for water leakage.6. lnspect and reneu p is ton r i r rgs.1. Check operation ofalarm devices.8. Check operation ofunloaders.9. Grease bearings on electric motors.

19. WHAT ARE THE CAUSES AND PREVENTION OF STARTING AIRSYSTEM EXPLOSION? (WFL)CAUSESl. Continuous leaking of a defective cylinder air-starting valve while the engine isoperating.2. Cylinder air starting valves sticking in the open position during maneuvering.3. Discharge of Iubricating oil mist to air starting system from air compressors.

DETECTIONl. By local overheating of the air starl ing valve pipe.

ACTIO]VL The main engine must be stopped and the air starting valve should be changedimmediately to l imit the darnage.

PREVENTIONl. Air starting valves rnust be correctly maintained and lubricated.2. Oil in the systenr must be kept in a minimum byi. regular draining andii. good air compressor maintenance.

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3. PURIFIERS

I. WHAT IS THE DIFFERENCE BETWEEN PURIFICATION ANDCLARIFICATION?I. PURIFICATIOIY:Liquid / Liquid / Solids separation

Clean oilDirry oil ---------water

Sludge2, CLARIFICATION:Liquid I Sol ids separat ion

Clean oilDirty oil --------Sludge

2. EXPLATN LIQUID FLOW IN PURIFTCATION.1. From the inlet, the dity oil florvs througlr the distributor into the space between thebowl discs where separation takes place. Water and sludge wil l move towards the bowlperiphery.2. The water leaves the bowl by the outlet through the gravity disc and the paring disc.3. The clean oil is moved towards the bowl center and proceeds to the outlet throughthe level ring and the paring disc.4. The gravity disc deternines the free water level in the bowl andthe position of theinterface.5. The level ring deternrines the fi 'ee oil level in the bowl.6. Parins disc is stationery purnps wheel, which dips into a l iquid ring confined in arotary paft and pares out l iquid.

3. WHY DO YOU PURIFY F.O. AND L.O.?By pur i fy ing the F.O. .L Large decreases in maintenance costs ofinjectors and exhaust valves.2. Wear on fuel pumps is very muclr reduced.3. Cylinder Iiners are not subject to the abrasive action ofsnrall particles ofsolidmatter, rvhich are normally present in oil.4. Redr.rced specific fuel consumption.5. lt is possible to use the lubricating oil practically indefinitely so that costs are verymuch reduced.

. I . WHY ARE THE HEAVIER FUEL O ILS USED TODAY MORE D IFF ICULTTO SEPARATE?L As the density ofthe oil increases, the difference in the separating forces betweenthe oil, the fbreign rnatter and the u,atel is leduced. The abil ity of the centrifugalpurif ier to function correctly is then inrpaired.2. Limits (0.991) on the density of the fuel oil are fixed by the density, it rvil l have atthe operating temperature ofthe centrifugal separator.3. The operating tenrperature of the separator must be less than the boil ine point ofu'ater due to ploblern of loosing the water seal.

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5. WFIY DO YOU PROVIDE LTQUID SEAL IN PURIFICATION?To prevent the oil f iom passing the outer edge ofthe top disc and escaping the outer waywith the water. a l iquid seal must be provided in the bowl. To this end. the borvl nrust befi l led with water before the contaminated oil is supplied. The oil rvil l then force thewater towards the borvl periphery. An interface will forrn between the water and oil. Itsposition can be adjusted by exchanging the gravity disc.

6. EXPLAIN FACTORS INFLUENCING SEPARATION.l . V iscosi ty

Densiry difference (specific gravity ratio)Separating temperatureRate ofthroughputOptimum utilization of machinePosition of interface

oi l v iscosi ry and densi tythroughput and back-pressulegravity disc

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The bowl has been properly cleaned and is correctly assembled with suitable parts.Brake has been released.Oil level in work gear housing is correct.Operating water tank is kept full and shut-off valves are open.Re-circulation to tank has been arranged. --

Control valve ahead of the pump is slightly open to prevent the pump from running

Valves between separator and tank are open.

STARTINGl. Staft the motor and after some time,2. Check the speed, check the load on purif ier motor.3. Close the bowl by opening valve for bowl closing operating water. Wait for someten seconds unti l the bowl is closed. Fil l ing can now take place.

FILLINGl. Open valve and add sealing l iquid.2. Close the valve when sealing l iquid is visible in water outlet pipe.3. Set 3-way valve for supply of un-separated oil to the machine.4. Set a suitable flow with control valve ahead of the pump. Check with flow meter.5. Check the separating temperature.

BOWL DISCHARGE DaRING OPERATTON CKL)1. Shut offthe supply ofun-separated oil.2. Displace the oil by opening the valve for adding sealing l iquid for about l5 to 20secs. Then close the valve.3. Open the valve for bowl opening operating water. Wait in this position unti l anemptying sound can be heard. Close the valve imrnediately after this.4. Wait some ten seconds unti l the bowl is closed.5. Refil l the bowl.

STOPPING AFTER SL(IDGE DISCHARGEl. Open the valve and add sealing l iquid.2. CIose the valve when l iqu id is v is ib le in water out le t p ipe.3. Stop the motor.4. Apply the brake.5. Close the valve for the bowl closing operating water.6. Release the brake when the bowl has stopped.

8. EXPLAIN THE WORKING PRINCIPLE OF PURIFTER.l. Separation takes place in a bowl of self-cleaningtype. Clean oil and separatedwater are discharged continuously under pressure by built in paring disc pumps.2. The separated sludge is discharged intermittently while the sepafator is running atfull soeed.

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3. A hydraulic system incorporating a sliding bowl bottom is used to open and closethe bowl allowing the sludge to discharge through a number of slots at its perimeter.4. This discharge cycle is normally controlled by an automatic timing device, but canalso be init iated manually.5. The bowl can be arranged either as a purif ier for oils containing sludge and anappreciable quantity of water or,6. As a clarifier for oils containing sludge and a very small quantity of water which isdischarged together with the sludge.

9. STATE THE ALARM FUNCTIONS OF PURIFIERS.Purifier motor trip at:l. High pressure in oil outlet2. Low pressure in oil outlet3. No discharge4. High oil temperature after pre-heater5. Low oil temperature after pre-heater6. Emergency stopping or vibration7. Logically wrong signal from purif ier

IO. WHAT WILL YOU DO IN THE EVENT OF PURIFIER OVERFLOW?(cKL, WFL)A. Heavy phase contains l ight phaseL The quantity of sealing l iquid is too small2. Sealing and displacement water f low solenoid valve defective3. The valve in the l ight phase outlet is closed4. The throughput is too large5. Back plessure too high6. The operating temperature of the purification oil has changed1 . A gravity disc with too large a hole diameter has been chosen

B. Sludge contains too rruch process l iquidl . The borv l is not ent i re ly c losed2. The seal ring around the sliding bowl bottom does not seal3. Drain nozzle in operating slide is clogged4. Valve plugs defective5. Borvl closing operating water solenoid valve defective (closed position)6. Bowl opening operating water solenoid valve def'ective (open position)7. Bo'uvl hood seal ring defective8. Defective operating slide springs(). Operating water tank is ernpty10. The process l iquid is not turned offduring sludge discharge

l t . EXPLATN INTERFACE CONTROL PROCEDURE. (CKL, WFL)l. After ensuring that the correct gravity disc for the fuel being purif ied is f itted to thepurif ier, the machine is started up.2. As soon as the rvater seal has been established and the dirly fuel supplied at thecorrect telnperature and throughput rate, the back-pressure is increased gradually unti lthe water discharge contains sorne oil.

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3. The back-pressure as indicated upon a pressure gauge is then reduced some 0.5 Kg i

cm2. At this stage the interface will be at its optimum position.

4. This combination ofi. correct gravity discii. correcttemperatureii i . correct throughput (l Kg / cm2)iv. most suitable back-pressure ensures a maximum operating efficiency.

12. GIVE INTERFACE CONTROL SUGGESTIONS.l. The interface between oil and water must be correctly positioned just outside the

disc stack in order to obtain maximum separating efficiency.2. The biggest gravity disc, which does not cause broken water seal, is the mostsuitable.3. A back pressure on l ighter phase (oil) wil l result in moving the interface outwards,towards the bowl periphery. Conversely if back pressure is applied to the heavier phase(water) discharge, the interface wil l move inwards.4. The nraxirnum separating temperature irrespective of viscosity is 98 deg C.5. The main cause of poor combustion problems is inefficient operation of the purif ier.

l'his can often be traced to an incorrect gravity disc and incorrect adjustment of tl-reinterface control.

I3 . WHAT ARE THE CAUSES IF LIGHT PHASE CONTAINS HEAVYPHASE?l . Seal ing l iqu id is suppl ied conf inuously.2. The valve in the heavy phase outlet is closed.3. The throughput is too large.4. Back-pressure is too low.5. Longer interval betrveen sludge discharges.6. The sludge space is overfi l led or clogged.7. A gravity disc with too small a hole dianreter has been chosen.

I4. EXPLAIN THE VALVE POSITIONS OF A L.O. PURIFIER.BOIVL OPEl,i, SLLlDGE DISCHARGEl. Borvl closing operating water: ON2. Bor.vl opening operating rvater: ON3. Sealing and displacentent water: OFF4. Status Time: Til l the report is heard, i.e. the sludge is throrvn out of t lre borvl.

BOII/L OPENl. Bowl closing operating rvater: ON2. Borvl opening operating water: ON3. Seal ing and d isplacement water : OFF4. Status Tinre: For 5 - 6 seconds, t i l l the discharge mechanism is emptied through

drain nozzle in the operating slide.

BOWL CLOSEDl. Borvl closing operating water: ON2. Borvl opening operating water: OFF

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3. Sealing and displacement water: ON4. Status Time: Til l sealing l iquid flows through the indication pipe.

OPERATING POSITIOI,{l . Bowl c los ing operat ing water : ON2. Bowl opening operating water: OFF3. Sealing and displacement water: OFF4. Status Time: I 2 hours. Sealing liquid is present in the purifier.

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4. PUMPS

I. GIVE 4 APPLICATIONS OF CENTRIFUCAL PUMPS IN THE ENGINEROOM.1. Sea water and fi'esh rvater coolins.2. Bilge and ballast.3. Cargo oil pumps on oil takers.4. F i re and general serv ice.

2. DESCRIBE THE PRINCTPLE OF OPERATION OF CENTRIFUGALPUMPS.In centrifugal punrp, the pressure is developed principally by the action ofcentrifugalforce and the flow through tlie impeller is radialy outwards.

3. NAME THE MAJOR COMPONENTS OF CENTRTFUGAL PUMPS.L Pump casing and cover2. Impel ler3. Top and bottom casing ring + locking pins4. Coupl ing5. Purnp shaft6. Gland ' packing . lantern r ing7. Neck bush and bottorn bush8. Water service pipes to stuffing box, bottom bush

4. WHAT POINTS WOULD YOU CHECK WHEN OPENING UP ACENTRIFUGAL PUMP FOR OVERHAUL?l. Porver supply to the pump has been isolated.2. Suction and discharge valves are shut.3. The gland nuts are rernoved and the gtand lifted clear off the studs and secured.4. Pressure in the Iine has been released.

5. WHAT POINTS WOULD YOU CHECK DURING INSPECTION OFCENTRIFUGAL PUMP?l. The rotor and rotor shaft are first exarnined. Give narticular attention to:

i. rotor sealing surfacesi i . g land packing locat ioni i i . ro tor b ladesiv. journal surfaces ofthe bearingsExanrine impeller casing rings and impeller fori. wear and erosionii. clearances betrveen them using feeler gaugesIf there is considerable wear on gland packing location, f it new packing sleeves on

rotor shaft.Mechanical seal / gland packing - adjusted or replaced.Examine journal surfaces of the bearings fori. condition and clearanceExarnine purnp casing for

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general deteriorationcasing ring location for wear

6. EXPLAIN THE PURPOSE OF WEAR RINGS IN A CENTRIFUGAL PUMP.1. To protect the casing and impeller from wear and fi ' iction.

7. HOW WILL YOU START A CENTRIFUGAL PUMP AFTER ANOVERHAUL?l. Ensure pipelines are free from dirt or other foreign matter.2. Add a l itt le lubricant to the gland packing or mechanical seal.3. Check that the discharge valve is shut and suction valve is fully open.4. Vent any trapped air from the pump by means of the air cock.5. Turn the pump shaft by lrand to ensure that it is free to rotate.6. Start the motor and check the rotation of pump.7. Slowly open the discharge valve.8. To stop the pump, shut the discharge valve and stop the motor.

8. WHAT IS THE REASON FOR STARTING CENTRIFUGAL PUMPS WITHTHE DISCHARGE VALVE CLOSED?l. By starting the pump with the discharge valve closed, the power demand made bythe pump on the pump motor is kept to the very minimum.2. After the pump has started and the momentary high motor current demand hasstabil ized, the discharge valve is opened.

9. LIST THE FAULTS ASSOCIATED WITH CENTRIFUGAL PUMPS.l. Failure to staft

i. Power supply to the pump being isolated.i i. The shaft assembly may be seized.

2. Fai lure to pr in tei. leakage at the pump glandii. all joints should be checked for t ightness

3. Failure to nraintain required discharge pressurei. purnp running at a speed below norrnali i . choked sucl ion st ra ineri i i . an a i r leak in the suct ion l ineiv. excessive wear on the impeller casing rings

4. Excessive noise or vibratiorri . cav i tat ion due to unsui table suct ion condi t ionsi i . loss of impel ler balanceii i. pump neck bush or bottorn bearing bush liner worn excessively

IO . WHY ARE CENTRIFUGAL PUMPS USED FOR THE SEA AND COOLINGWATER SERVICES?l. They are snall and l ight for the volumes of water they can handle.2. Except for pump bearings, casing rings and gland packing, there is no mechanicalcontact between the fixed and moving parts of the pump. So wear is l imited to the partsmentioned.3. Maintenance necessarv is verv small.

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4. The only drawback to these pumps is the fact that if they are empty, they cannotproduce a vacuum and so prime themselves.

I I . WHAT IS THE FUNCTION OF A CENTRAL PRIMING SYSTEM?l. On a vessel where priming is needed for a number of pumps, the use of centralpriming system would reduce the number of air pumps and the running time for them.

HOW IS AIR DEALT WITH IN A CENTRIFUGAL PUMP?For small pump: purging cockFor large pump: self priming pump

13. STATE PUMP CLASSIFICATION.l. Centrifugal pumps2. Axial f low propeller pumps3. Reciprocating positive displacement pumps4. Rotary positive displacement pumps5. Ejectors

I4. WHAT CAUSES THE MOTOR TO RUN HOT?1. Excessive casing ring clearance.2. Liquid heavier and more viscous tlran rating.3. Stuffing boxes too tight.4 . Head lorver than rating allowing pump to handle too rnuch liquid.

Defects in motor.

NAME 3 TYPES OF POSITIVE DISPLACEMENT PUMPS?Reciprocating punrpsGear pumpScrerv pumpLobe purnpVane purnpEccentric purnp

15.t .2 .3 .4 .5 .6 .

I6. DESCRIBE THE PRINCIPLE OF OPERATION OF RECIPROCATINGPUMP.1. The purnp is double acting, that is l iquid is admitted to either side of the pistonwhere it is alternatively drawn in and discharged.

I7. WHY ARE POSITIVE DISPLACEMENT PUMP PREFERRED FORLUBRICATING OIL SERVICES?l. Their characteristics are ntore suitable than those of centrifugal purnps.2. Being of positive displacement type they are inherently self priming.

I8. WHAT POINTS WOULD YOU CHECK WHEN OPENING UP A POSITIVEDISPLACEMENT PUMP FOR OVERHAUL?l . Exarnine

i. all nroving partsi i . o is ton

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i i i . piston ringsiv . cy l inder l iner

2. Ridges wil l eventually develop at thebe removed.3. Suction and discharge valves must be

limit of the piston ring travel and these must

refaced or ground in as required.

19. WHY IS AN AIR VESSEL IS NEEDED ON A RECIPROCATING POSITIVEDISPLACEMENT PUMP?1. To dampen out the pressure variations during discharge.2. As the discharge pressure rises, the air is compressed in the vessel, and as thepressure falls, the air expands.3. The peak pressure energy is thus stored in the air and returned to the system whenthe pressure falls.

20. WHAT INSPECTION WILL YOU CARRY OUT ON POSITIVEDISPLACEMENT LUBRICATING OIL PUMP?l. In gear pumps: End and radial clearances of the rotors within their housing.2. In pumps with helical form rotors: Examine

i. surfaces ofthe helices on the rotorsii. contact pattern between the rotors helicesiii. non-uniformity of contact indicates unequal wear in the rotor bearings which

rvil l require correction

2I . L IST THE FAULTS ASSOCIATED WITH RECIPROCATING PUMP.l. Gradual reduction in output over a prolonged period. General wear and tear ofmoving parls especially

i. Suction and delivery valvesii. Piston rings and cylinder l iner

2. Reduction in output over a relatively shoft periodi. breaking, sticking or disassembly of the suction and / or discharge valvesii. choked suction strainer

3. Purnp refuses to stafti. misalignment of any parts replacedii. r ings too tight, glands too tighti i i . foreign object rnay have left insideiv . incorrect ly set va lve gear

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5. ELECTRICALI SAFETY

I. WHAT PRECAUTIONS YOU WILL TAKE BEFORE WORKING ONELECTRICAL EQUIPMENT? (CKL)Before any rvork is done on electrical equipment,1. Fuses should be renroved or circuit breakers opened to ensure that ali relatedcircuits are dead.2. Switches and circuit breakers should be locked open or altematively a "NOT TOBE CLOSED" notice attached.3. Where a fuse has been removed, the nran working on the eqLripurent unti l the job isfinished should retain it4. The circuit should be checked with a suitable voltage indicator.

2. WHAT PRECAUTIONS YOU WILL TAKE BEFORE WORKING ONSTORAGE BATTBRIES COMPARTMENT? (WFL)l. Space thoroughly ventilated.2. Atnrosphere tested and tbund safe.3. All equipment to be used is of approved type.4. Responsible person in attendance at entrance.5. Any type of open flame should be prohibited.6. All battery connections should be kept clean and tight.'l . The battery charges and all circu its fed by the battery should be switched olf rvhenleads ale being connected or disconnected.8. Goggles, rubber gloves and protective apron should be rvom rvhen acid is handled.

3. WHAT IMMEDIATE ACTION WILL YOU TAKE IN CASES OFELECTRIC SHOCK?ACTIO]Vl. Switch otf the current2. Renrove the inlured person fiom the danger zone.3. Put out any fire, rvhich may have started with suitable fire extinguishers.4. The alarrn should be raised and the bridge informed immediately.5. Deterrrine the nature of injuries.i. l fthe respiration and circulation are functioning and that the patient is n a stateof shock, the injured person must be laid flat on his back and his legs should be raisedup so that blood flows back to his body (recovery position).i i . In case of respiratory failLrre, begin artif icial respiration (mouth to mouth l0 /nr in . ) .i i i . ln case ofrespiratory and circulatory failure. begin cardio-puhnonaryresuscitation (5 cornpression and I inflation). That is Mouth to mouth resuscitationin the flrst place (16 - l 8 / min.), as rvell as lreart massage in the second (60 - 90 / min.).Speed is ofessence here, because the absence ofoxygen supply results in the death ofthe brain cells after about 4 minutes.

1. WHY IS IT UNSAFE TO ENTER AN ENCLOSED SPACE WITHOUTTAKING ADEQUATE PRECAUTIONS? (WFL)

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The atntosphere ofany enclosed space may put at risk the health or l i fe ofany person

entering it. tt *uy be deficient in oxygen and / or contain flamrnable or toxic fumes,

gases or vapors.

5. NAME AT LEAST 5 ENCLOSED SPACES TO BE FOUND ON YOUR STIIP'

l. Cargo holds, cargo tanks.

2. pump rooms, compressor rooms, battery lockers, and storage rooms for co2,

Halons.3. Ballast tanks, double bottom tanks.

4. Coffer dams, void spaces, inter-barrier spaces' duct keels'

5. Fuel tanks, sewage tanks, pressure vessels'

6. Cable trunks, PiPe trunks.

7. Inert gas plant scrubber, blower spaces.

6. WHAT INSTRUMENTATION IS AVAILABLE TO ASSIST IN MEASURING

A N Y o F T H E H A Z A R D S T H A T C O U L D B E F O U N D I N A N E N C L O S E DSPACE? (WFL)l. Oxygen content meter (analyzer)

2. Explosirneter (combustible gas indicator)

3. Chemical stain tubes

1. WHAT IS THE PURPOSE, OF A PERMIT TO WORK?

l. permit to work sets out the rvork to be done and the precattt ions to be taken in doing

it.2. lt consists basically ofan organized and pre defined safety procedure.

3. It forms a clear record of all the foreseeable hazards arld shows the correct sequence

of operations and precautions.

8. WHAT ARE THE MINIMUM PRECAUTIONS YOU MUST TAKE I }EFORE

ENTERING AN ENCLOSED SPACE? (WFL)

l. A competent person should make an assessment of the space'

2. A responsible officer to take charge of the operation should be identil led.

3. The potential hazards should be identif led'

4. The space should be prepared and secured for entry'

5. The airnosphere ofthe space should be tested using oxygen analyser

6. A 'perrnit to work' system should be used.

7. Procedtrres before and during the entry should be instituted'

9 . S T A T E 6 | M P O R T A N T F E A T U R E S T H A T S H O U L D B E S H o w N o N APERMIT TO WORK. (WFL)

l . RecordWork to be done (descriPtion)

ii. Authorized Person in charge

i i i . Per iod of va l id i tY of Permi tiv . Autholizing officer

I-ocationvi. Crew detailed (names)

ENTRY INTO ENCLOSED SPACES

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Ensurel. Space thoroughly ventilated.2. Atmosphere tested and found safe.3. Rescue and resuscitation equipment available at entrance.4. Responsible person in attendance at entrance.5. Communication arrangements made between person at entrance and those entering.6. Access and il lumination adequate.'1

. All equipment to be used is of approved fype.8. When breathing apparatus is to be used,

Familiarity of user with apparatus is confirmed.ii. Apparatus has been tested and found to be satisfactory.MACHINERY OR EQUIPMENTl. Before working on machinery or equipment, ensure

Removed from service and isolated from sources of power or heat (steam).i i. All relevant personnel informed.ii i . Warning notices displayed.HOT WORKl. Ifhot work is to be carried out. ensurel . Areas clear to dangerous material and gas freeii. Ventilation adequate.i i i . Equipment in good order.iv. Fire fighting appliances in good order.v. Adjacent spaces clear of combustible material and gas free. (loh vol HC - LFL,l0% vol FIC - UFL)

10. NAME PERSONAL EQUIPMENT FOR PROTECTTON.l. Head protection: safety helmets.2. Hearing protection: ear muffs3. Face and eye protection: facial shields, goggles.4. Respiratory protective equipment: breathing apparatus.5. I land and foot protection: gloves, safety shoes.6. Body protection: safety suits, safety belts.1. Protection against drorvning: l i fejackets, l i fe buoys.

I I . WHAT CHECKS WILL YOU CARRY OUT ON BREATHINCAPPARATUS? (CKL)l. Pressure gauge and capacity ofair supply.2. Low pressure audible alarm.3. Face mask air supply and tightness.

I2. WHAT IS THE GENERAL EMERGENCY ALARM SIGNAL?Seven or more shorl blast followed by one long blast on the ship's whistle or siren andadditionally on an electrically operated bell.

13. WHAT PRECAUTIONS WILL YOU TAKE BEFORE WORKINC ONAUXILIARY MACHINERY?l. Removed from service and isolated from sources of power.2. The starting air valve or sirri lar device should be secured.

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3. Warning notices displayed rvarning that neither machine is to be started, nor theturning gear used.4. Switches and circuit breakers should be locked open or alternatively a "NOT TOBE CLOSED" notice attached.

I4. WHAT PRECAUTIONS WILL YOU TAKE BEFORE WORKING ONMAINENGINE?l. Main engine turning gear should be engaged and a warning notice displayed at thestarting position.2. Cut off starting air.3. Before the main engine turning gear is used, check:i. Indicator cocks are openI t .

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All personnel are clear offthe crankcase and offany moving part ofthe engine.Chain blocks and engine room crane are not attached to any ofthe runnins

All rnountings are isolated safely fronr any l ive feed or steatn.Cooled sufficiently.Adequately venti lated.Atmosohere tested and found safe.

gear.iv. The deck duty officer has confinned that the propeller is clear.4. Ifa hot bearing has been detected in a closed crankcase,

Do not open crankcase unti l 20 minutes after stopping the engine. Whenopening up, keep clear offpossible flantes.i i. The opened crankcase should be well venti lated to expel all f lammable gases.5. Before main engine is restafted,

A responsible engineer officer should check that the shaft is clear.Duty deck ofl ' icer should confirm that the propeller is clear.

I5. WHAT PRECAUTIONS WILL YOU TAKE WHILE TAKINGCRANKSHAFT DE FLECTION?l. Whenever possible, use a gauge that shorvs negative readings in compression andpositive on expansion.2. Watch the arxperage as the engine is turning to get an idea of resistance ro turning.Any sudden changes in reading should be investigated imrrrediately.

I6. WHAT PRECAUTIONS WILL YOU TAKE BEFORE WORKING ONBOILER?l. Personnel should stand clear offhot vapor when doors are opened.2. No person should enter any boiler unti l:i .i i .i i iiv .3. A responsible person should rentain in attendance at entlance, rvhile persons remainins ide.

I7. WHAT PRECAUTIONS WILL YOU TAKE BEFORE WORKING ONSTEERING GEAR? (WFL)l. Work should not be done on steering gear when a ship is under way.2. lf i t is necessary to wolk when the vessel is at sea,

The ship should be stopped.

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ii. Suitable steps taken to immobilize the rudder by closing the valves on thehydraulic cylinders.

I8. WHAT PRECAUTIONS WILL YOU TAKE BEFORE LIFTING MAINENGINE PISTON?1. Weight should be ascerlained to ensure that tlre working loads are not exceeded.2. Pistoni. Screw holes for l i ft ing bolts in piston crown should be cleaned.ii. Threads checked.3. Eyebolts should be checked to ensure that

iii. Eyebolts are screwed hard down on to their collars before lifting.

I9. WHAT PRECAUTIONS WILL YOU TAKE WHEN WORKING BELOWFLOOR PLATES.l. Lift ing handles should be used.2. Warning notices should be displayed.3. The openings should bei. Effectively fenced or guarded.ii. The area well i l luminated.

20. WHAT PERIODIC SAFETY ROUTINES WILL YOU CARRYOUT?I.

They have collarsThreads are in good condition

E.mergency generatorEmergency air compressorEmergency fire pumpAll l i fe boat enginesRun for a reasonable periodCheck fuel oil, lubricating oil, cooling rvater supplies and tank levelsCheck all operating parameters.

2. CO2 cylinder storoge room (CKL)

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i i .V isual ly exanl ined.Test the alarm and check that the machinel soace

3. One smoke detector irt eoclr circuitTest to ensureoperationcorrect indication on the alarm panel

Fire puslr buttott alarnt sltoultl be tesledMocltinery space uentilutors or skyligltts

Operated and greased.

Fire extinguishersFire hoses and nozzlesIn their correct location.Checked to ensure they are operable.Defective hose or nozzle should be replaces

Entergency butteries

pumps stop.

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i. Examine starting.i i. Specific gravity checked and topped up.8. All quick closing valvesi. Checked for operalion.9. Wiler ligltt tloorsi. Opened and closed by hand and power.i i. Guides should be checked.

2I . WHAT PRECAUTIONS WILL YOU TAKE BEFORE ENTERINC AREFRTG ERATED COMPARTMENT? (WFL)L No person should enter a refrigerated chamber without first infornring a responsibleofficer.2. lfrefrigerant leakage is known or suspected, then ensure:i. Space thoroughly ventilated.ii. Atmosphere tested and found safe.

22. EXPLAIN THE PRINCIPLE OF EXPLOSIMETER.The conbustible gas indicator consists of a Wheatstone bridge with cr.rrrent suppliedfrom a battery.i. When the bridge resistances are balanced, no curent flows through the meter.i i . One resistance is a hot f i lament in a combustion chamber.l. An aspirator bulb and flexible tube are used to draw a gas sample into the chamber.2. The gas rvil l burn in presence of the red-hot f i lament causing the temperature of thefi larrent to rise.3. Rise of ternperature increases the resistance of the fi lament and this change ofresistance unbalances the bridge.4. Current f low registers on the meter, which is scaled in percentage of the lowerflammable l irnit ol P.P.M.. for hvdrocarbons.l .

i i .i i i .

HC: 2.1 - 9.5 (LFL - FIFL) for hydrocarbons02: l l -21 % dangerousI . G : 3 - 8 % o f 0 2 i n l . G .

5. False readings are l ikely when,i. Oxygen content of the sample is low (< I l %)i i . iner t gas is present or .i i i . with rich mixture above the lower flammable l imit.

23. EXPLAIN THE PRINCIPLE OF OXYGEN ANALYZER. (WFL)L Oxygen is paramagnetic. So a magnetic f ield is intensified by the presence ofoxygen and its intensity wil l vary with the quantity of oxygen.2. Most other gases are diamagnetic.3. Thus glass spheres fi l led with nitrogen and mounted atthe ends of a barto form adumb-bell wil l tend to be pushed out from a strong symmetrical, non-unifonn magneticfield in which they are horizontally suspended.4. When the surrounding gas contains oxygen, the dunrb-bell spheres are pushedfurther out ofthe freld due to the change produced by the paramagnetic oxygen.5. Torque acting on the dunrlr-bell is proportional to the oxygen concenlration andtherefore the restoring force necessary to bring the dumb-bell back to the zero position isalso proportional to the oxygen concentration.

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6. Oxygen percentage is read from the meter, which measures the restoring current.

24. WHAT PRECAUTIONS WILL YOU TAKE WHILE TAKING READINGSoF oxYGEN ANALYZER? (WFL)l. The instrument and batteries must be tested before use.2. Samples must be taken from as many places as possible, particularly from the tankbottom.3. Accurate calibration is obtained by using,i. pure nitrogen or CO2 for zero check andii. Normal air at2loh oxygen for span.

25. WHAT ARE CHEMICAL STAIN TUBES? EXPLAIN IN DETAIL.

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6. FIRE FIGHTING

I. EXPLAIN FIRE FIGHTING "ENGINE ROOM" TOTAL FLOODING. (CKL.

wFL)l. By fire in engine room every second counls.

i. Stopi i . Main engineii i. Auxil iary engineiv. F.O. prirnary pumpv. Fuel valve cooling oil punrpvi . Main L.O. pumpvii. L.O. pump for camshaft, turbocharger, stern tubeviii. Engine room fans, forced and induced draught fansix. Purifier room exhaust fanx. Accomnrodation fans

2. Closei. Engine room skylights, quick closing valvesii. Funnel venti lators, venti lator dampers, blower flaps, exh. Fan flapsi i i . A l l openings lo engine roorn

3. Open door to release locker for engine room CO2 fire extinguishing system. Thiswil l autonratically start alarm siren in engine roorn.4" Open CO2 master valve to engine room.

i. Pull all valve levers in release locker outwards, pull CO2 release handle,where-after CO2 gas wil l f i l l engine room in about 2 minutes.5. Proceed to CO2 roorn and check that all CO2 cylinders for engine room have beenreleased. Ifnecessary open extra CO2 cylinders by hand.6. After a fire, take care that all machinery pafts have been cooled dor.vn beforeventilating engine room.7. Before entering engine room after CO2 fire extinguishing, use a breathing apparatuswith l ifeline attached. Cany a safety lamp and an insulated fire axe.

2. EXPLAIN CO2 FIRE EXTINGUISHTNG CARGO SPACES. (WFL)1 . Loca tespace in f l r e . Besu re tha tnobody i s l e f t i n f i r espace . S topven t i l a t i onandblock all air passages.2. Open stop valve outside hold on fire. Check that, those stop valves for all otherholds are closed.3. Open CO2 master valve in CO2 room nrarked "CO2 TO CARGO SPACES".4. Then open by hand, required number of CO2 cylinder valves.5. Use water hoses for cooling down accessible decks and bulkheads tending to beoverheated.6. Take care that nobody gives access for air to fire space by opening hatches forinspection.7. CO2 gas should remain in fire space for a minirnurn of 48 hours. Do not venti latespace unti l vessel has reached harbor where sufficient f ire assistance is available.8. Release additional CO2 gas according to best juclgement at intervals depending onnature offlre and distance to nearest harbor.9. lnd icat ions (WFL)?

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(cKL)l. Ensure that all moving parts are kept clean, free and well lubricated.2. Wires must be checked for tightness.3. Toggles and pulleys must be greased.4. With the use of cornpressed air, the CO2 distribution pipes could be blown throughaccordingly.5. Weigh the CO2 cylinders.

4. EXPLATN CO2 FLOODING SEQUENCE. (WFL)l. The machinery space SECTOR VALVES and STARTING VALVES are openedand the OPERATING HANDLE pulled to open the head valves on the pilot cylinders.2. Gas from the pilot cylinders, on entering the operating cylinder pushes the workingpiston down, thus operating all the cylinder head valves coupled to the wire.3. Gas then flows into the ntachinery space via the CO2 rnain, sector valve and variousdistributors.

5. GIVE A LIST OF FIXED FIRE EXTINGUISHING INSTALLATIONS.l. A pressurized rvater spraying system.2. A fire smothering CO2 installation.3. A fixed foarn installation.4. A fixed system discharging Halon 1301 (BTM)

6. EXPLAIN YOUR ACTIONS IN THE EVENT OF FIRE IN PURIFIERROOM.A fire in its f irst few rninutes can be readily extinguished. Prompt and correct actiorr isessential.1 . I f f i re breaks out

i. Tlre alann should be raised.i i. The bridge should be infbrmed immediately.i i i . An atternpt should be made to extinguish or l imit the fire using suitable

portable fire extinguishers or by smothering the fire.2. Limiting the fire

i. All openings to the space should be shut to reduce the supply of air to the fire.i i . Any fuel l ines feeding the fire or threatened by it should be isolated.i i i . Cornbustible materials adjacent to the fire should be removed.

3. If a fire is f i l l ing witlr snroke and fumes, any personnel not properly equipped withbreathing apparatus should get out ofthe space rvithout delay.4. Use water hoses for cooling down accessible decks and bulkheads tending to beoverheated.5. After a fire has been extinguished, precautions should be taken against itsspontaneous re-ignition.

3. WHAT ATTENTION WILL YOU GIVE TO CO2 FLOODING SYSTEM?

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7. WRITE A NOTE ON FIRE EXTINGUISHERS.EXTINGAISHERCARTRIDGE

OUTER CARTRIDGE

L Water - CO2 water (9 L)

2. Soda - acid water (9L) +bottle

3. Chemical foarnsulphate

4. Mech. Foam water (9 L) +

5. D.C.P.

6. CO2

EXTINGUISHERl. Soda acid

2. Chemical IMech. Foam Blanket ins

3. D.C.P.

4. CO2

Sod ium bicarbonate (454Gms.)

water (7 t/z L) +

Sodium bicarbonate (8 %) +

Foam stabilizer (3 %)

EFFECTCool ing

INNER

CO2 (60 Gms.)

H2SO4 Acid

(57 Gms.)

Aluntinium

( t y , L )

CLASS

CO2 (60 Gms.)AFFF (270 ml.) 3 % conc.

A. Ammonium phosphateB. Sodium / potassium bicarbonate (6 Kg.) CO2 (60 Cms.)C. Sodium / potassium / bariumChloride mixture

+Magnesium stearate to prevent powderfrom caking

4.5 Kg. at 5l bars

7. Haf on B.C.F. 7.0 Kg. at l0 Kg I cm2

B , C , D

5. Halon B.C.F. Enveloping,Breaking the chain ReactionInhib i t ing

8. DESCRIBE I.G. SYSTEM BRIEFLY. WHAT ACTION TO BE TAKEN INCASE OF BREAK DOWN OF I.G. PLANT?I.C. SYSTEM

Inhib i t ing

Envelopng with CO? andDiluting the supply of Oxygerr B , C

B , C

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1. The exhaust gas is cleaned in a scrubbing tower, dried and filtered before beingpassed to the deck mains for distribution.2. The gas wil l contain less than 5 %o oxygen and is t lrerefore considered safe.3. It is distributed along the deck pipes by fans and passes into the various cargo tanks.4. Seals in the system act as non-return valves to prevent a reverse flow ofgas.5. In the event ofa failure ofthe inert gas system, all tank operations should bestopped and the deck-isolating valve closed.

9. WHAT CHECKS W|LL yOU CARRY OUT ON CO2 CYLTNDER? (WFL)l. Check pressure : 52 bars2. Weigh the CO2 cylinder and if a weight difference of 10 Yo or more is observed, itshould be sent for recharging.

i. Weieht of CO2 sas : 45 Ks.i i. Weight full : 154 Kg.i i i . Weightenrpfy :109 Kg.

3. An ultrasonic or radioactive level indicator detector could be used to check l iquidlevel.

EXPLAIN CHEMICALS IN FIRE EXTINGUISHERS. (WFL)WATER -CO2

i. Outer container contains 9L of water.i i . 60 gms. of CO2 cartridge"ii i . Discharge time 60 sec.SODA - ACIDi. Outer container contains: 454 gms of sodiunr bicarbonate mixed in water to

make 9L of solution.i i. 57 gms of sulphuric acid bottle in cage.iii. Discharge time I 1/, - 2 min, range 6 m.

3. CFIEMICAL FOAMi. Outer container contains: 8 %o sodium bicarbonate and,3 o/o foarn stabil izer

mixed in water to nrake 7 % L of solutionii. lnner contaitrer contains: l3 % aluminium sulphate mixed in rvater to make 1 t/z

L of solutioniii. Discharge time rvithin 1 t/zmin, range 6 m.

4, MECHANICAL FOAMi. Outer container contains: 270 ml of 3 o/o cono. AFFF mixed in water to make

9L of foam solution.i i. 120 gns of CO2 cartridge.i i i . Discharge time within I min (about 50 sec).

5. DRY CHEMICAL POWDERi. Outer container contains 4;5 Kg. Of sodium bicarbonate rnixed with very small

quantity of magnesiunt stearate.i i. 60 gms of CO2 cartridge.i i i . Discharge t ime wi th in l5 sec.

6. CO2i. 4.-5 Kg. CO2 at 5l bars.i i. Discharge tinre 20 sec.

7. HALON

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7 Kg . o f BCF (1211 ) a t l 0 Kg / cn2Discharge time 20 sec., range 4.5 m

I1. HOW DO YOU OPERATE WATER TYPE OR D.C.P. FIREEXTINGUISHER?l. Remove the safety clip2. Strike the knob or plunger located in the cap to actuate the piercing mechanism,which in turn breaks the sealing disc of the cartridge.3. Direct the jet at the base of the flame, with a side to side rapid sweeping motion.

I2. HOW DO YOU OPERATE CHEMICAL FOAM EXTINGUISHER?L Pull the plunger, rest it on the notch provided and2. Tum the extinguisher over shaking well, to ensure the mixing of the two liquids,rvith a finger blocking the outlet nozzle.3. Direct the foam to some nearly vefiical surface so that the foam runs down the sideand blankets the l iquid.4. Where no veftical surface is available, adjust the distance such that the dischargedfoam falls gently on the l iquid surface.

I3. GIVE THE DISCHARGE TIME OF FIRE EXTINGUISHERS. (WFL)l . D .C .P . - 15 sec .2. Halon - l7 sec.3. CO2 - 20 sec.4. Mech. foam - 50 sec.5. Water CO2 - 60 sec.6. Soda acid i chem. foam - 1 Vz min.7 . 136-L chem. Foam - l5 nt in .

I4. WHAT EACH FIRE DRILL STIALL CONSISTS OPTl. Reporting to stations and preparing for the duties described in the muster l ist.2. Starting a fire pump using at least 2 jets of water to show that the system is in properwork ing order .3. Checking

i. Fireman's outfits and other personal rescue equipment.i i . The relevant communication equipment.iii. The operation of watertight doors, fire doors and fire dampers.iv. The necessary arrangements for subsequent abandonment ofthe ship.

I5. WHAT EACH ABANDON SHIP DRILL SHALL INCLUDE?1. Repofting to stations and preparing for the duties described in the muster l ist.2. Checking

i. That the cretv are suitably dressed.ii. That l i fe jackets are correctly donned.Lowering ofat least one life boat after any necessary preparation for laLrnching.Starting and operating the l ife boat engine.Operation of davits used for launching l ife rafts.

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7. ANTI-POLLUTION

1. STATE THE PRINCIPLE OF OTLY WATER SEPARATOR IN BRIEF.l. Separation of oil droplets fronr water is seen as a result of 3 steps.i. The suspended droplets must coll ide with each other.ii. Upon colliding, the droplets must merge to form larger drops.iii. The larger drops must float upward by their buoyancy.

2. DESCRIBE THE PRINCIPLE OF OPERATION OF THE OILY WATERSEPARATOR FITTED ON YOUR LAST SHIP.PRINCIPLE: The gravity differential between oil and water.1. In oily water mixtures the oil exists as a collection of almost spherical globules ofvarious sizes.2. The force acting on such a globule causing it to move in the water is proportional tothe difference in weight between the oil par-ticle and a particle of water of equal volume.

p rFs: - - - D3 (RHOw - RHOo) g

6Fs : separating forceD: D ia . O f o i l g l obu le

The resistance to the movement of the globule depends on itssizeviscosity of the l iquidFor small particles moving under stream line flow. by Stokes law

F r : 3 p i m u v DFr : resistance to movementnru: Viscosity of f luidv : terminal velosity of particleD : d ia . O f o i l pa r t i c l e

5. During separatiorr, Fs : Fr6. The terrninal velocity of oil globule is

gRising velosity, v: --- (RHOw - RHOo) D2

l 8 m uHigh rate of separation is favored byLarge size of oil globule.E,levated tenrperature of the system.Laminar or streanl l ine florv.

3. EXPLAIN THE OPERATION OF OILY WATER SEPARATORS. (CKL,

wFL)A. Prior to opefationl. Open the follorving valves.i. The valve between the bilge pump and the separatorii. The valve between the I and Il chambersii i . The overboard valveiv. Stearl inlet and condensate outlet valves (to heat the accurnulated oil in the oilcollecting charnber to 30 deg. C.v. Clean water f lr.rshinq valve to oil contel.lt neter

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Close the following valves.the sludge outlet valve in the I chamberoil outlet valve on the II chamber

B. Operation1. Feed sea water to the separator to fi l l i t up with the bilge pump, and run it forabout at least 5 minutes. To confirm that the separator is full of seawater, open test cocksattached to the upper body ofboth chambers and observe pressure gauges rise.2. Change the sea water valve to the bilge valve, so that the bilge water may befed into the separator.3. Continue the operation.C. Stoppage of operation1. Before the bilge is emptied, stop the bilge pump.2. Feed sea water into the separator for a post purge for about 5 - 10 minutes.3. It is essential to keep the separator full of water even while the running issuspended.

4. EXPLAIN CONTROL OF DISCHARGE OF OIL FROM CARGO TANKAREAS OF OIL TANKERS.A. Wirhin 50 N.M. from landl. No discharges except clean or segregated ballast.B. Outside a special area and more than 50 N.M. from landl. No discharge except either clean or segregated ballast or wheni. The tanker is en route and,ii. the instantaneous rate of discharge of oil does not exceed 30 l itres / N.M. andii i. the quantity ofoil discharged does not exceed 1/15000 (for existing ships) or1/30000 (for new ships or tankers) of the total quantity of cargo which was carried onthe previous voyage.iv. The tanker has in operation, an oil discharge monitoring and control system andslop tank arrangements.C. Within a special area1. No discharges except clean or segregated ballast.D. Special areas: In relation to its oceonographic and ecological condition andparlicular character of its traffic.L the Mediterranean sea

2. the black sea3. the Bal t ic sea4. the gulfs area5. the gulf of Aden6. the Antarctic7. Red sea8. UK and NW europe

5. EXPLAIN THE CONTROL OF DISCHARGE OF OIL FROM MACHINERYSPACES OF ALL SHIPS. (CKL, WFL)Before discharging bilges frorn machinery spaces, Marpol 13 l l8 regulations must bestrictly followed.A. When the ship is at more than l2 N.M. from landl. No discharge except wheni. the ship is proceeding en route and

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ii. The oil content of the effluent is I00 p.p.m. or less andii i. The ship has in operation oily water separating equipment of a design approvedby the administration.B. Anywhere outside a special areal .i .i i .i i i

No discharge except whenthe ship is proceeding en routeThe oil content of the effluent is l5 p.p.nl. or less andthe ship has in operation, an oil discharge monitoring and control system, oily

i i .l t l .

water separating or f i l tering equipment; andiv. On oil tankers, the bilge water does not originate from cargo pump room bilge,or is not mixed with oil cargo residue.C. Any where within a special areas

No discharge except whenthe ship is proceeding en routeThe oil content of the effluent without dilution does not exceed l5 p.p.m. andThe ship has in operation oil f i l tering equipment with automatic l5 p.p.m.

stopping device. And,iv. On oil tankers, the bilge water does not originate from cargo pump room bilgeor is not mixed with oil cargo residue.D. Antarctic1. Al l sh ips no d ischarge.

6. EXPLAIN MARPOL 73 /78 REGULATION FOR DISPOSAL OF GARBAGENNEX - VADistancefrom land

Outside special areas Inside special areas

Type ofgarbase

0 - 3N. M.

3 - 1 2 t 2 - 2 5 25 inf 0 - t 2 t 2 - . . .

All plasticsincludingsyntheticrope,fishing nets,garbagebaqs.

--Prohibited-- --------Prohibited--------

Dunnage.l in ing,Packingrnaterials.

---------Prohibited if i t wil l f loat----- --------Prohibited-------

Foodwastes. Prohibited

Ground orComminuted

Prohibited

Othergarbageinc ludingPaperproducts,rags,Metals.

Prohibited Ground orComminuted

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7. EXPLAIN MARPOL 73178 REGULATIONS FOR DISCHARGE OFSEWAGE (ANNEX IV)1. Distance from land 0 - 4 N.M.i. Discharge prohibited unless ship has in operation a sewage treatment plantapproved by the administration to standards developed by I.M.O. and the effluent doesnot produce visible floating solids or discoloration of the surrounding water.2. Distance from land 4 - l2 N.M.i. Discharge prohibited unless the ship has in operation a sewage treatment plantto comminute and disinfect the sewage of a type approved by the administration.3. Distance from land over 12 N.M.i. From holding tanks at a moderate rate when ship is en route and proceeding atnot less than 4 knots. Procedures to be approved by the administration.NOTE:I . Faecal coliforms should not exceed 250 / 100 ml.2. Total suspended solids content should not exceed 50 mg./l

8 . DESCRIBE THE PRINCIPLE OF OPERATION OF THE BIOLOGICALSEWAGE TREATMENT PLANT FITTED ON YOUR LAST SHIP.1. The treatment plant uses a tank, which is divided into 3 watertight compartments.i

i i .An aeration compartmentSettl ing compaftment

ii i . Chlorine contact compartment2. In an aeration compartment, aerobic bacteria whose existence is aided byatmospheric oxygen, which is pumped in, digest sewage.3. In settling compaftment, the activated sludge is settled out from the sewage.4. In chlorinator, the sewage is treated to kil l any remaining bacteria and then it isdischarged.POINTSl. The activated sludge in the settl ing tank is continuously recycled and builds up. Thissludge must be discharged for every 2 - 3 months only in a decontrolled area.2. Tablets are placed in the chlorinator and require replacement as they are used up.

9. WHAT PRECAUTIONS MUST THE WATCH KEEPER TAKE TO ENSURETHAT OILY WATER SEPARATOR DISCHARGE OVERBOARD IS CLEAR?(cKL, WFL)1. At suitable intervals, test cocks can be used to asceftain the levels of oil and waterapproximately as a check for the automatic detection.2. Ensure correct functioning of automatic 15 p.p.m. stopping device.

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8. BOILERS

1. EXPLAIN PROCBDURE FOR BLOWINC THROUGH A BOILER GAUGEGLASS.l. Close steam and water cocks, then open the drain.2. Open and close water cock to check that the water cock connection to the boiler isclear.3. Open and close stearn cock to check that the steam cock connection to the boiler isclear.4. Close the drain.5. Open the water cock. Water should then gradually rise up to the top of the gaugeglass.6. Open the steam cock and the water in the gauge glass should fall to the level of the'rvater in the boiler.

2. WHAT ARE THE CONSEQUENCES OF ABNORMAL WATER LEVEL.A. Ifthe rvater level falls to an extent where the sas/water heat transfer surface isreduced.

l. The steam pressure wil l tend to fall.2. The fuel burning rate wil l be automatically increased to restore the steam

pressure.3. The heating surfaces rvill distort.4. The brick rvork wil l get darnaged.5. Casings wil l be warped and,6. Pressure parts wil l leak.

B. For tlre high water level conditiorr.l . The boi ler wi l l pr ine.2. The carry over ofwater will danrage the superheater and hazard the turbines.

3. WHAT ARE THE THINGS TO BE CHECKED BEFORE TAKING WATERIN THE BOILER?A. When rvater cock is opened and water does not f low up the gauge glass.

l. Water level: Below the water cock connection to the boiler2. Fil l ing: It is unsafe to put feed water into the boiler.

B. When rvater cock has been opened, the rvater f lows to the top of the gauge glass,and rvhen the steam cock is opened, the water florv down and oLlt of the gauge glass.

l. Water level: Between the water cock connection to the boiler and the bottom ofthe gauge glass.

2. Fil l ing: lt is safe to put feed water into the boiler.C. I f after open ing the water cock, when the gauge glass is full of water; the steam cockis opened and the water does not descend in the glass,

I " Water level: Above the steam cock connection to the boiler.2. Fil l ing: There is a danger of prirr irrg the boiler if any add it ional feed is put into

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4 . NAME THB BOILER MOUNTINGS.1. Safety valves.

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2. Steam stop valve.3. Feed check valves (Main and Auxil iary).4. Feed controller isolating valves.5. Gauge glass isolating valves.6. Level alarms cutout isolating valves.7. Pressure gauge connection valve.8. Air vent cock.9. Blow down valves

i. Scum blow-downii. Bottom blorv-down

10. Running down or drain valves.I l. Sampling valve.12. E.G.E. steam raisins circulatins valves.

5. HOW WOULD YOU USE THE SURFACE BLOW?l. Raise the water level in the boiler to above the scum pan.2. Open the surface blow-down valve quickly and close it; when the water level in thegau-ee glass ceases to drop.3. Blow out the gauge glass and note the condition of the water which appears in thegauge glass after blowing it.4. If there are any signs of floating matter repeat the surface blow-down until the watershows clean.

6. WHAT IS THE PURPOSE OF BOTTOM BLOW-DOWN VALVE?L For removing sedinrent. mud, bits of scale etc., from the bottorn of the boiler.2. To reduce the concentration of impurit ies in the boiler rvater.

i. By removing some of the impure water through the bottom blow, and replacing\\ rt i\\r trrr ',\ \\ 'rr,\ l\\ \\\' i i ' Jur! \\htul .

7. EXPLAIN THE PURPOSE OF OILY DRAIN INSPECTION TANK.l. Ifthere is any appearance offuel oil on the surface ofthe water, due to a leak in the

heater, the inspection tank is inmediately drained to the bilge unti l the trouble is

remedied.2. Observation tank with cascade type oil filter is a most important safety device.

protecting the boilers against serious damage or an explosion, as it prevents the oil frorn

getting carried over into the boiler.

8. WHAT COLOR SMOKE INDICATES?1. Efficient cornbustion: A l ight brown haze at the stack.2. lnsufficient air: Black smoke.3. Excess air: White smoke.

9. DESCRIBE THE LAYOUT OF THE AUXILIARY BOILER.Type:l. AQ3 Aalborg vertical water tube boiler,2. working presstlre 7 bar.

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B.

1. Lower or water charnber2. Upper or steam-water chamber3. Vertical water tubesi. Two large down comersii. Stay tubes (l/3)i i i . P la in tubes.4. Shell crown plate5. Uppel tube platei. large center bar stay6. Lower tube plate7. Furnace crowni. Small center bar stay.

l. Cylindrical furnace or fire box2. Ell iptical f lue pipe3. Smoke box4. Baffle plates5. Uptake

NAME THE BOILER AUXILIARIES.F.D. fanF.O. pumps and fuel burning equiprnent.F.O. heatersF.O. burnersFeed purrpsE.G.E,. circulating pumpsSoot blowersSteam pressrrre reducing valves

I I . HOW WILL YOU CARRY OUT SOOT BLOWING?l. The stearrr l ine to the soot blower should be thoroughly drained ofl 'moisture.2. Blow steanr line down well before operating.3. Never stop rotating soot blower while steam is flowing through the unit.4. Have a regular schedule for operating soot blowers.5. Regular inspections should be made to soot blower nozzles.

I2. EXPLAIN HYDRAULIC TEST ON BOILERS.l. Hydraulic test is carried out

i. After rnajor shell repairsii. When testing in l ieu of an internal examination

2. When carrying out hydraulic test,i. The safety valves are gagged.ii. All valves are firmly closed.ii i . It is preferable to use wanr water and the pressure should be applied by rneans

of a small ram hand pump.iv. Maximunr pressure : 1.25 to 1.5 X working pressure.

3. The pressure should be applied gradually and held at the required level for aboutone hour. unti l the surveyor has courpleted his examination.

10 .1 .2 .

4 .5 .6 .7 .8 .

I3 . EXPLAIN BOILING OUT OR DEGREASING.l. Remove as much oil as possible by wiping out the end of tubes, the drums and theheaders.2. Make sure no tools and rags are left in the boiler.3. Chemicals required per ton of boiler water;

i. 25 Ltrs. of l iquid alkaline cleaner (LAC)ii. 5 Ltrs of liquid coagulant

4. Fill up the boiler with water to normal working level and at the same time add 2i3 ofthe chemicals (LAC and liquid coagulant)5. Fire the boiler raising the pressure gradually up to 7 KglCm26. Upon reaching pressure of 7 KglCm2,

i. Bottom blow down at intervals of 2 Hrs.,ii. Blow down from water wall headers at intervals of 3 Hrs. Each blow down

should be approximately 2" on the gauge glass.7. Raise the water level by the feed pump after each blow-down procedure and at thesame time add the remaining l/3 LAC and liquid coagulant divided equally by l0 blow-downs over l2 hours period.8. Fire the boiler again to raise pressure to 7 KglCm2, and repeat procedure 6 & 7.9. When boiling out procedure is cornpleted after 12 Hrs. period, fire should besecured and boiler allowed to cool down.10. When temperature of steam drum drops to 65 deg. C., the solution should bedumped overboard.

14. HOW DO YOU START AN EXHAUST GAS BOILER?l. Ensure adequate make-up feed is available and check boiler water level ismaintained.2. Open air vents on economiser headers.3. Circulate cooling coils on circulating pump gland.4. Open E.G.E. steam raising circulating valves.5. Open suction and discharge valves on circulating pump.6. Start circulating pump.l. Expel all air and close air vents or.l econontiser headers.8. Test casing/gas trunk drains for water leakage.9. Repeat air venting to expel residual air.10. When main engine is stafted and power level increases, equalise steam pressures.I l. Light off boiler f ires rvhen steatn pressure is stable.12. Purge boiler furnaces with air for 3 to 5 minutes and stop forced draught fan.13. Keep good boi ler water level .

15. HOW WILL YOU SHUT DOWN AND SECURE A BOILER.l. Carry out soot blowing if permissible.2. Change combustion control from automatic to manual.3. Change fuel supply to diesel oil.4. Shut steam offfuel heaters and trace heating.5. Close burner supply valves and main fuel shut off valve.6. Purge boiler turnaces rvith air for 3 to 5 nrinutes; stop forced draught lan.'1

. Close stearn stop valves on boiler when pressure is reduced.

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8. Drain boiler when it has cooled down or fill with treated water.

16. HOW WILL YOU BLOW DOWN AND OPEN UP A BOILER? (WFL)l. The ship side blow-down valve must be opened first, then the blow-down valve onthe boiler can be gradually opened up.2. Start closing the boiler blow-down valve when the pressure is low enough, andwhen it is down to the desired value, the valve must be closed down tightly and the shipside valve closed.3. Allow as much time as possible for the boiler to cool down and loose all i tspressure, and when the pressure is atmospheric, open the air vent and gauge glass drainsto ensure pressure inside boiler is atmospheric.

I7. HOW WILL YOU DETECT BOILER'TUBE FAILURE?A. Slight leakage of a boiler tube may be diff icult to trace as the escaping water isvaporised and is unlikely to be seen amidst the funnel gases. Such leakage may besuspected by

l. Unusually high rnake up feed requirements.2. Boiler water sampling readings are not as expected.

B. In the event ofa tube rupturing,l. Indicationsi . Noiseii. Furnace flame distorl ionii i . Appearance offunnel gasesiv. Loss of water level2. The Engineer's alarm should be operated to call assistance and fuel shut off

from the burners ofthe affected boiler.3. The forced draught fan must be kept running.4. The boiler steam stop valve should be closed.5. Maintain normal water level in the defective boiler unti l the boiler cools down.6. If the amount of leakage exceeds the flow capacity of the water level indicator,

discontinue the feed water supply.7 . Lift the safety valves of the boiler to reduce the pressure quickly only if it

seems likely that the steam leakage will endanger personnel.8. Stop the forced draught fan after the steam pressure has decreased.9. When cool, the boiler should be emptied through the bottom blow down valve.

18. WHAT WILL YOU DO TF THERE IS PRESENCE OF WATER IN FUELOIL?A. Indications

l. Unstable flame shape2. The flame being extinguished3. Fluctuating fuel oil pressure

B. Causesl. From contamination when the fuel was delivered.2. From water entering through tank vents in rough weather.3. Failure of steam heating coils in the tank.4. Careless use ofwash deck hoses.

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C. Actionl. Stop fuel oil pressure pump.2. Change fuel suction over to stand by fuel tank, which lras been checked for

freedom lrom water contamination.3. Drain offwater from fuel oil heater, and burner fuel hoses.4. Start the fuel oil pressure pump and open the re-circulation valve on the burner

fuel oil rail to discharge contaminated fuel to the waste oil tank.5. Clreck furnace is clear of un-burnt fuel, purge furnace and re-light boiler fire.6. Operate soot blowers as soon as possible after boilers are on normal loads.7. Identify source of water in contaminated tank and drain off water.

I9. WHAT SAFETY DEVICES ARE PROVIDED FOR BOILER CONTROLPANEL? (WFL)A. Water

l. High, low and too low water level in boiler drum.2. Low nrain feed water pressure.3. High condensate and feed rvater salinity.

B. Steaml. High superheater steam outlet temperature.2. Hish steam pressure.3. Lorv pressure in burner stearn assistance lines.

C. Fuel1. Enrergency trip.2. Forced draught fan failure.3^ Oil burner motor failure. '-

4 . Oi l pump motor fa i lure. - ' -

5. Flame failure.6. High and low oil temperature.7. Boiler fuel oil inlet low pressure.

D. Oily drain inspection tank rvith cascade type fi l ter.

20. EXPLAIN BOILER SOOT FIRES.lgnition of an accumulation of soot rich in carbon when supplied with the necessaryoxygen can be the source of f ire sufficiently intense to rnelt and burn steel.A. Causes

l. Poor combustion.2. Operating at low power for prolonged periods.

2 I . EXPLAIN HYDROGEN F IRE.l. When overheating of a superheater due to insufficient steanr circulation is verysevere, the tube rnaterial rnay ignite at about 700 deg. C and burning in the steanrproduce free hydrogen.2. The iron u,i l l continue burning in steam independently of any supply of oxygenfionr the air.3. The hydrogen produced by the reaction wil l burn, on coming into contact with air.4. Once such a fire has started there are Iikely to be 2 fires burning instantaneously

i. Iron burning in steatni i . Hydrogen burning in a i r

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5 . The conrbined fire wil l continue unti l the supply of steam is exhausted.

EXPLAIN FURNACE EXPLOSIONS OR BLOW BACKS.CAUSESl. When volumes of oily vapour and air present in a furnace in explosive

proportions are ignited.2. Sudden admission of air to a fuel rich burner mav well oroduce the same result.

B. Preventionl. Ensure adequate purging before ignition2. Failure to obtain ignition at tlre first attempt rnust be followed by adequate

purging.

23. WHAT WILL YOU DO IF THERE IS A FIRE IN EXH. GAS BOILER?,A. If sparking is reporled or if the observed temperature rise is say l4 deg. C at thefunnel, the engine speed should be reduced until sparks cease and the temperature fallsto a level consistent with the engine power. Thereafter speed may be again increaseduntil the conditions are observed to be norrnal at the required porver level.

P;. If the funnel temperature continues to rise or if the observed temperature rise is say28 deg. C it indicates that a fire is present.

l. The main engine should be stopped immediately.2. Water circulation should be maintained unless there is an evidence of internal

leakage.3. The outside of the casing may be cooled with water if there is a risk of

overheating.4. Do not use soot blowers or apply water to the fire.5. lnspection doors should not be removed wlri le a fire is burning.6. Water may be used inside the casing for cooling purposes only after any fire is

extinguished.1. The unit must be thoroughly cleaned and a careful inspection made for water

leakage.

24. HOW WILL YOU PREVENT FIRES IN ECONOMISERS?l . By mainta in ing

i . Good combust ion of fuel in the rnain engine.i i. Circulation of water througlr the unit.

2. By keeping exhaust gas economiser clear of soot deposits byi. Water washing.i i. Regular use of soot blowers.

25. WHAT ARE THE REQUIREMENTS OF EFFICIENT OIL BURNING IN ABOILER?l. Proper arnount ofoil at sufficient pressure.2. Proper anrount of air rvith minimurn excess air (20 %).3. Proper atomisation for good mixture of air and oil.4. Proper oil temperature.5. High furnace temperature.

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26. WHAT ARE THE PARTS OF A BURNER? WHAT IS THE FUNCTION OFEACH PART?The burner consists of an atomiser and a register.l. The atomiser breaks the oil into fine fog like pafticles which cornpletely fill thefurnace opening in the form of a hollow cone.2.

'fhe register allows entry of a strong blast of whirling air, which catches the oil fog,

mixes with it and enters the furnace where combustion takes olace.

27. EXPLAIN THE OPERATION OF COMBUSTION SYSTEM. (WFL)A. The electric circuit system will

l . Heat up and circulate the fuel.2. Purge the combustion space ofunburnt gas.3. Ignite the flame and by controll ing it, naintain the steam pressure.

B. Operation1. Ensurei. Adequate make up feed is available andii. Boiler water level is maintained.2. When the boiler is stafted, cuffent is supplied first to the fuel heater. 'lhe

electric heating elements are thermostatically controlled.3. When oil in the heater reaches the required atomising temperature, another

thennostat switches in the fan and oil circulating purnp.4. Air frorn the fan purges the combustion space for a set tirne.5. The recirculation process takes place during the entire pre-purge period. This

ensures that the oil in the burner is hot and thin enough to atomise.6. After the pre purge period, a voltage is applied to the solenoid valve I which

closes.7. Oi l pressure bui lds up and opens the p is ton valve in the burnerat l0 to l2

I(g/Cm2.8. The oil reaches the nozzle, gets atomised and ignited by a spark from porlable

electric igniter.9 . The oil which penetrates in to the piston space return back to the tank via the

leakage oil l ine.10. At further loading ofthe boiler, a voltage is applied to the solenoid valve 2

which opens.I 1. The fuel now also reaches the nozzle 2 and the burner operates with full load.

The fan damper is operated at the same time to adjust the air delivery to the requirement.12. The solenoids are controlled bv a pressure switch acted on bv boiler steam

pressure.

28. HOW WATER LEVEL IS CONTROLLED IN A BOILER?1. Water level is rnaintained by a feed pump controlled by a float operated ON/OFFswi tch.2. The float chamber is f itted erternal to the boiler and connected by pipes to thesteam and water spaces. There is a drain at the bottom of the float chamber.3. A similar f loat switch is f ined to activate an alarm and shut down in the event of lowwater level because float chambers and gauge glasses are at the water level.

29. LIST FUEL BURNING FAULTS.

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White funnel smoke, burner flame brilliant with ragged edges and sparks at tips.1. Causei. Excess air pressure2. Actioni. Reduce air supply to furnaceBlack funnel smoke, burner flame ends dull red.l . Causei. Low air pressure2. Actioni. Increase air supply to furnaceBlack smoke with black streaks in oil spray.l . Causei. Dirfy fuel atomisersii. Carbon deposits on air registers -n2. Actioni. Increase air supplyi i . Change atomisersHissing and spluttering of f iresl . Causei. Water in fuel2. Actioni. Drain and change over fuel suctionAtomisers carbonised on tip1. Causei. Fuel too hot2. Actioni. Adjust fuel temperature

30. HOW DO YOU ADJUST A BOILER SAFETY VALVE?Type: Full l i ft ing spring safety valve with closed spring housing.l. Safety valves must be set at a pressure not exceeding 3 Yo above the approvedworking pressure of the boiler.2. Verily the accuracy of the boiler pressure gauge.3. Each set of valves then adjusted independently using gags with the main steam stopvalve ofthe boiler closed4. The pressure was brought up to within 0.2 or 0.3 bar of the desired blow offpressure.5. Arrangements were then made to keep this pressure constant whilst the valves werebeing adjusted.6. At this stage. the compression nut of the valve that was lifting was screwed downuntil the valve seated.1. The valve was subsequently adjusted in turn by slacking back its compression nutunti l the valve l ifted.8. The compression nut was then screwed down sufficiently so that, when the valvespindle , 'vas l ightly tapped down, the valve returned to its seat and remained closed.

3I . WHAT IS THE EFFECT OF OIL OR GREASE IN BOILER WATER?Oil or grease in boiler water causes

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1. Foaming and priming.2. Poor heat transfer.3. Overheating and damage.4. Corrosion.

32. WHAT EFFECT HAS SCALE ON THE HEATING SURFACES OF ABOILER?l Scale in a boiler fbrms an insulating layer on the water side of the heating surfaces.2. This insulating layer of scale resists the transfer of heat fiom the fire and hotconrbustion gases to the water, and the heat which would normally pass into the waterremains in the metal and heats it.3 . If the layer of scale is sufficiently thick and resists the transfer of heat sufficiently,the metal will overheat, become rveak and bag, blister or rupture.

-33. HOW SCALE IS FORMED?L When a steam bubble is formed on a heating surface, all the salts in the bubble wiltflow toward the hottest paft, which is the heating surface metal.2. Since slightly soluble salts become insoluble at high ternperatures, scale wil l beforrned at the base of the bubble.3 . When the bubble leaves the heating surface, a ring of scales is left. These ringsinterlace and scale is formed.

34. GIVE A LIST OF CHEMICALS AND MINERALS THAT CAUSEPROBLEMS OF A BOILER SYSTEM.A. Source of corros ion

L CO22. Oxygeni . ch lor ide

B. Source of scalel . Calc iunt2. Magnesium3 . S i l i ca

C. Source of solids contentl . Sulphate2. Chloride3. Ni t rate

35. WHY DO YOU MAINTAIN HIGH ALKALINITY IN BOILER WATER?(CKL)l. The most common chemicals used to precipitate calcium salts are- sodiurn

j]fgipha1g{Tri sodium phosphate and disodium phosphate).2. These chemicals react rvith calcium salts to fonn tricalcium phosphate, a flocculentprecipitate.3. To ensure that this reaction takes place. a high alkalinity must be maintained in theboi ler .4. At a pH of 9.5 or less, the calcium salts rvil l not be precipitated properly.5. Magnesium is readily precipitated by the alkalinity of boiler water as sludge in theform of magnesium hydroxide.

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36. GIVE A BRIEF ACCOUNT OF RECOMMENDED WATER TREATMENT.(CKL)L To prevent scale

i. Sodium phosphates2. To give aikalinity and minimise aorosion

3 .

i. Sodium hydroxideii. Sodium carbonateTo condition sludge (coagulants)i. Starchii. Sodiurn alunrinateii i . TanninsTo remove traces of oxygeni. Mechanical deaeratorii. Sodium sulphiteii i . HydrazineTo reduce risk ofcaustic crackinsi. Sodium sulphatei i . Sodium ni ( rateTo reduce risk ofcarry over offoami. Anti foamsTo protect feed and condensate systems from corrosioni. Filrning aminesi i . Neutra l is ingamines

1 .

37. HOW IS SCALE FORMATION PREVENTED IN A BOILER?By adding a soluble chemical to the boiler water which wil l react with the calciumsulphate, the most conrmon scale forming salt, to form a highly soluble salt and ahannless sludge.A. For low pressure boilers

i. Calcium hydroxide (l irne)ii. Sodium carbonate (soda)ii i . Sodium hydroxide (caustic soda)

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Na2CO3 + CaSO4Na2SO4

chenrical scale forming salt sludge

B. For high pressure boilersi . Tr i -sodiumphosphatei i . Di -sodiumphosphate

3CaS043Na2S04

scale forming salt

2Na3PO4

boiler compound sludge

soluble salt

so luble sal t

C. Coagulants are then added to prevent sludge from sticking to the boiler surfaces.

38. WHY IS BOILER FEED WATER TREATMENT REQUIRED? (WFL)

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t . To prevent scale formation byi . Using d is t i l led water ori i. Precipitating all scale lbrming salts into the forrn of a non adherent sludge.iii. Reducing the loss of feed water.To prevent corrosioni. By maintaining alkalinityTo control sludge formation and prevention of carry over with the steam.

39. DEFINE THE TERMS: CARRY OVER, PRIMING.l. Carry over: Phenomenon of water droplets being carried over with the steam intothe steam syslem.2. Prirning: Contamination of the steam by the injection of gross quantities of water.

i. Remedy: Corect chemical treatment of feed water and boiler water should becanied out.

40. WHY DO YOU TEST BOILER WATER DAILY?Aim: To control the chemical treatment and blow-down.l. Hardness: is the sum of calcium and magnesiunr salts in the water.2. Alkal in i ty :

i. To prevent acidic corrosionii. To assist in the precipitation of calcium and magnesium salts.

3. Chloridesi. To calculate rate of blorv-dorvnii. To determine condenser leakage into the steam space.ii i . % blorv-down - Cl in Feed water X 100 / Cl in Boiler water

4. Sulphitei. To maintain residual sulphite concentrations in the boiler water to be sure that

all oxygen is scavenged.i i . 2Na2SO3 + 02

5 . pH (no rma l pH : 10 .5 )i. As a check on alkalinity testi i. pH - 7 means neutral, pH t 7 means more alkaline

6. Total dissolved solidsi. To ensure complete boiler water controli i . To determine blow-down rate.

41. WHAT ALL TESTS ARE DONE ON BOTLER WATER? (CKL)For water tube boi lers upto 17.5 barl . A lkal in i ty test

i . A lkal in i ty to phenolphthale in (150 - 300 ppm as CaCO3)i i . To ta la l ka l i n i t li i i . Caustic alkalinity (75 -200 ppm as CaCO3)

2. Chloride test (300 ppm CaCO3)3. Sulphi te test (50 - 100 ppm as Na2SO3)4. Plrosphate test (30 - 70 ppm as PO4)5. Hardness test (5 pprn CaCO3)6 . pH va lue (10 .5 - l l )'7.

Dissolved oxygen test (0.02 Cm3 / Litre for feed tvater)

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8. Total dissolved solids (500 - 1000 ppm) or 2250 micro-siemen/cm9. Hydrazine test (0.1 - 0.3 ppm N2H4)

42. WHAT IS YOUR ACTION IN THE EVENT OF VERY LOW WATERLEVEL?1. The fuel should be shut offfrom the burners ofthe affected boiler.2. The forced draught fan must be kept running. , .

3. If the water level is between the water cock connection to the boiler and the bottomof the gauge glass, it is safe to put feed water into the boiler.4. If the water level falls to an extent where the gas-water heat transfer surface isreduced; steam pressure wil l tend to fall. Then the boiler steam stop valve should beclosed.5. If the operating boiler is exhaust boiler, it is safe to put feed water into the auxiliaryboiler.6. The boilers must be immediately secured unti l the water level is established andcorrected.

43. EXPLAIN CONVERSION FROM CaCO3.l. From CaCO3 to ppm

i . Nac l X by 1 .17i i . c l X by 0 .71i i i . NaOH X by 0.80

2. From PO4 to ppmi. P2O5 X by 0.75

44. EXPLAIN CHANGES IN TEST RESULTSTEST SEA WATER CONTAMINATION

1. Hardness Increases2. T.D.Solids content Increases3. Chloride Increases4. Alkalinity Decreases5. Phosphate Decreases

WHAT IS THE PERMISSIBLE CHLORIDE LEVEL? (CKL)45.

B .

Upto 17.5 barsL Scotch2. Verlical f ire tube3. Package4. Water tube17 .5 - 31 ba rsL Water tube

ppm CaCO3 (chloride level)3000

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300

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46. WHAT IS THE PERMISSIBLE ALKALINITY TO PHENOLPHTHALEIN?(wFL)

P-alkalinity Caustic1. Scotch 300 - 700 l 50 - 5002. Vertical fire tube 300 - 500 150 - 4003. Package 150 - 300 75 -200

4. Water tube 150 - 300 15 -200

WHAT IS THE PERMISSIBLE TOTAL DISSOLVED SOLIDSMicro-Siemen/Cm at 25 deg. C.I 0000

2250

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I. EXPLAIN OPERATION OF FRESH WATER CENERATOR.BEFORE STARTING,A. Open the follorving valves

l. Suction and discharge valves for ejector pump2. Overboard valve for ejector system3. Inlet and outlet valves ofsea cooling water to condenser4. F.W. tank fi l l ing valve

B. Close the following valves1. Close inlet and outlet valves ofjacket cooling water to heat exchanger.2. Vacuum breaker valve3. Test cock4. Drain valve from the heat excharrger5. Fresh water discharse valve

STARTINGl. The ejector pump is stafted and it should be ascertained that the pump yields apressure of 4 - 4.5 kglcm22. The evacuation of the plant is now started and at the same time the heat exchangeris autornatically fed rvith the correct amount of feed water.3. When the vaclrum meter shows aboLrt 90% vacuum, the jacket cooling water iscirculated through the heat exchanger, thus starl ing boil ing in the heat exchanger.

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Boiling point (deg. C)26.411.46

4. Switch ON the salinometer. This unit rvil l function automatically once the alarmlevel has been set at 8 ppm sea salt.5. When the evaporation and condensation have commenced and the condenser isabout quaner full of produced fi 'esh water, the condensate pump is started andthe fresh water discharge valve opened. When F.W.G is well under way, check alloperating parameters.

STOPPINGl. Stopjacket cooling water circulation through the heat exchanger and close the inletand outlet valves.2. Then the condensate purnp is stopped and the fresh rvater discharge valve closed.3. The ejector pump is stopped and the vacuum breaker valve opened.4. Finally the heat exchanger is emptied of sea water by opening the drain valve at thebottom ofthe heat exchanger.5. Then the inlet and outlet valves ofthe sea coolinq rvater to condenser are closed.

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10. BMBRGENCY

I. WHAT ACTION WILL YOU TAKE TO REVERSE ENGINE FROM "FULLAHEAD' ' TO "FULL ASTERN'FROM CRASH STOP.Preliminary conditions1. Main engine is operating at full speed aheao.2. Star t ing a i r avai lable at engine.

A. Full astern orderl . Movei. fuel lever to STOP position.i i. reversing lever (telegraph) to ASTERN position.i i i . fuel lever to START position for a few seconds to break the engine speed.iv. fuel lever to STOP position.2. Checki. Engine rpm is reduced.3. Move fuel lever 1o START position.4. Checki. Carrshaft is in ASTERN position.i i. Engine is lotating ASTERN on air.5. Move fuel lever to MAX. position.6. Check engine speed in ASTERN increasing.7. Find best fuel notch position to avoid propeller cavitation. Reduce fuel supply

slowly.B. If engine fails to start

l . Movei. Reversing lever to AHEAD position.i i . Fuel lever to START posi t ion.2. Check engine is rnoving AHEAD on air.3 . Movei. fuel lever to STOP position.i i. Reversing lever to ASTERN position.

C. When Engine is operating at full astern,l . Star ti. Standby diesel generator.i i . Main a i r co lnpressors.2. Init iate change ovel to Diesel fuel supply.3. Adjust M/E jacket cooling water and lub. oil ternpel'atures.

2. WHAT ACTION WILL YOU TAKE IF THE ENGINE ROOM ISFLOODING?I. Stage

L In case of failure of water systems in the Engine rooln, correct action mayenable the rvater intake to be contained.Il. Stage

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1. lf the bilge rvater level is slowly rising for no apparent reasor.t, operateEngineers' alarm to call assistanca and start additional pumps to discharge the bilgewater directly overboard.III. Stage

A. If the bilge water level is rising rapidly,L Stan standby diesel generator.2. Take main engine controls from bridge to machinery space and reduce speed.3. Divert all available pumps to bilge main duty including Emergency bilge

injection.4. Attempts must be made using all available staff to locate the source of the

flooding and carry out emergency repairs.IV. Stage

A. If the flooding is such that low level auxiliary machinery may be subrnerged orlow level diesel generators may be partly immersed, then;

l. Close all nonessential sea suctions and related pumps.2. Open circuit breakers at the main switch board to all low level nonessential

auxil iary machinery.3. If the water level falls, selective opening of sea suctions may indicate the

defective service or l ine.4. lf not the main engine must be stopped, turning gear engaged and used while

the ILrbricating oil punrp kept in service.V. Stage

A. If the flooding cannot be contained before the pumps on bilge duty aresubmerged, the boilers must be secured and all machinery should be shut down.

3. WHAT SERVTCES AND EQUTpMENT ARE SUppLtED POWER FROMTHE EMERGENCY SWITCH BOARD?The emergency generator must be rated to provide power for the driving rnotors ofl. The emergency bilge pump.2. F i re punrps.3. Steering gear.4. Water tight doors.5. Fire fighting equipment.Servicesl. Emergency l ighting for occupied areas.2. Navigation l ights.3. Communicationsystems.4. Alarm systems.5. Electrical control devices in the operation of main machinery.

4. WHAT ACTION WILL YOU WILL TAKE IN CASE OF ENGINE ROOM.BLACK OUT 'AT SEA.l . Move main engine contro ls to 'STOP' .

2" Operate Engineers' alarm to call assistance.3. Start standby diesel generators nranually.4. Check required voltage and frequency available, synchronise and close dieselgenerator circuit breaker.5. Mains l ighting restored, emergency l ights off.

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6. Sequential starting of motors.i . Main F.W. cool ing pumP.i i . Main S.W. cool i r rg pumP.ii i . Steering gear and navigation equipment'iv. Main L.O. pumP.v. Camshaft L.O. pumP.vi. Turbocharger L.O. pumP.vii. Stern tube L.O. PumP.vii i . Governor amplif ier L.O. pump.ix. Boiler water circulating pump.

x. Boiler feed water Punrp.xi. Fuel valve cooling oil PumP.xii. Fuel oil primary punP.

xii i . Engine room suPPlY fans.xiv. Main air / control air compressors.

7. Check control consoles and ensure no unsafe conditions exist. Accept alarms.

8. Inform bridge that power is available.g. Reset main engine SLOW DOWN / SHUT DOWN controls.

10. Inform bridge that Main engine is ready for normal operation.

I l. Restart main engine and increase speed to normal'

12. Starl F.O. purif ier and reset automatic controls.

I 3. Start domestic fresh water purnp and restore ship and galley power supply'

14. Identify and make good any plant def'ects.

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11. FUEL OIL

I. WHAT DO YOU UNDERSTAND BY THE TERM 'SPECIFIC GRAVITY'?Specific gravily is the ratio of the weight of a given volume of a substance with theweight of an equal volurne of water at the same temperature and pressure.

2. STATE THE DESIRABLE PROPERTIES OF A FUEL OIL.1. High calorif ic value.2. A minimum of water, sediment, sulphur, sand and other impurit ies.3. A fluidity such that it can be pumped without lreating it too much.4. The oil should not be too slow burning so as to cause delayed ignition in the enginecylinder.5. The oil should burn completely without leaving any carbon residue in the form ofash or soot.

LIST THE SAFETY DEVICES FITTED ON FUEL OIL SERVICE TANKS.Fuel outlet valvesAir p ipesThermometersOverflow pipesHigh level, lorv level and high temperature alarms.

4. WHY DO SOME SHIPS MANEUVER ON A DIESEL OIL?Maneuvering on diesel oill . Ensures that the fuel l ines wil l not get clogged.2. Gives more positive starl ing and reversing.As inadequate heavy oil temperature causesl. Poor atomisation and combustion.2. Increased wear of cylinder liners and rings.3. Deterioration ofexhaust valve seat.

5. WHY FUEL IS PREHEATED TO l0 - l5 cSt BEI-ORE INJECTION?Aim:l. To ensure correct atornisation and combustion.Inadequate preheating, that is too high viscosity causes,l. Poor atomisation and cornbustion.2. Increased wear of cy'l inder l iners and rings.3. Deterioration of exhaust valve seat.4. Results in too lrigh injection pressures leading to excessive rnechanical stresses infuel oil system.

6. WHY IS IT NECESSARY TO ATOMISE TI IE FUEL IN A DIESEL ENGINECYLINDER?In order to enable a fuel charge to go through the various stages ofcombustion in a verysrnall t inre interval, it is absolutely essential for it to be broken down to minutely smalldroplets.

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7. EXPLAIN THE TERM CETANE NUMBER.The cetane number of a fuel is defined as the percent by volume of cetane in a mixtureof cetane and alpha methyl naphthalene that produces the same ignition lag as the fuelbeing tested, in the same engine and under the same operating conditions.

8. WHY HIGH INJECTION PRESSURES ARE REQUIRED?To| . overcome lhe contpression pressure.2. atomise the fuel and distribute it in a desired manner.

9. WHAT TYPE OF FUEL OILS WERE IN USE ON YOUR SHIP?l . Mar ined iese lo i l (MDO)

i. Viscosify : l3 cSt at 40 deg. Cii. Separating temperature = 40 deg. Cii i. Specific gravity : 0.84

2. Hearry Fuel oil ( lFO 180)i. Viscosiry : 180 cSt at 50 deg. Cii. Separating temperature : 90 to 98 deg. Cii i. Specific gravity : 0.98

Note:l . I cSt : I mrn2/sec2. I stokes : 0.001 nr2lsec3. mu : N-sec/m2

IO. DISTINGUISH BETWEEN HIGH GRADE AND LOW GRADE FUEL.High grade fuel.l. Reduced ignition delay2. Rapid rise in pressure3. High peak pressures early in cycles4. Reduced exhaust temperaturesLow grade fuel.l. Extended ignition delay2" Slow rise in pressure3. Low and retarded peak pressures4. Elevated exhaust temperatures leading to T/C surging

1I . WHAT DO YOU UNDERSTAND BY THE TERM VARIABLE INJECTIONTIMING?Variable injection timing is a form of fuel pump control enabling an engine to operatewith the designed maximum cylinder fir ing or combustion pressure from approxirnately75 0zo power oulput to rnaximrrm power.Advantages:l. The strength designed into the crankshaft and other important parts is better utilised.2. Improves thermal efficiency.3. Lowers specific fuel consumption.Methods:l. By lowering the pump barrel.2. Early closing of suction valve.

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12. EXPLAIN IGNITION DELAY.l. The fuel does not ignite immediately upon injection into the engine cylinder.2. There is a definite period of apparent inactivity between the time when the firstdroplet of fuel hits the hot air in the combustion chamber, and the time when it startsthrough the actual burning phase. This period is known as ignition delay or ignition lag.3. During this period there is no rise in pressure within the cylinder due to combustion.4. lgnition delay

i. Mixing period.i i. Interactionperiod.

I3. EXPLAIN DIESEL KNOCK.If the ignition delay is very long so much fuel can accumulate that the rate of pressurerise is almost instantaneous. Such a situation produces extreme pressure differentials andviolent gas vibration known as "Detonation".Remedy by"I. lncrease in compression pressure.2. Retter atomization.3. Cood turbulence.

I4. STATE IMPORTANT PROPERTIES OF FUEL OILS AND THEIRSIGNIFICANCE.L Viscosity2. Density3. Pour point: Demand for heating steam.4. Carbon residue: Deposits, fouling.5. Asphalt content: Fouling, slow burning.6. Sulphur: Corrosive wear in cylinder l iners.7 . Sil ica and alumina: Wear, abrasive wear of fuel injection eqnipment.8. Sodium and vanadium: High temperature corosion of exh. valves and seats.9. Ash content: Abrasive wear.10. Fuel cornpatibil i ty: Incompatibil i ty of blended fuels.

15. DEFINE, FLASH POINT, POUR POINT, AND ULLAGE.Flash point: The lowest temperature at which a tiquid gives off sufficient gas to fornr aflammable gas mixture near the surface of the l iquid.Pour point: The lowest temperature at which a petroleum oil wil l remain fluid.Ullage: The depth of the space above the l iquid in a tank.

I6. STATE PRECAUTIONS TO BE OBSERVED WHEN BUNKERING.L All scuppers should be plugged.2. Tank air pipes should be clear.3. Drip trays must be kept under the ship-shore connection.4. Ensure blank at opposite end ofcrossover pipe is securely in place.5. Be fully conversant with the layout of pipes, tanks, and valves etc.6. Know how much oil is needed in each tank.'7.

Every effort nrust be made to segregate bunkers frorn different sources in differenttanks.

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8. Post No Smoking signs.9. Fire fighting appliances should be in good order.10. Have a slack tank ready for any overflow condition.I l. Good communication between ship and shore must be established.12. Moorings and hose length should at all t irnes be such that there is no possibil i ty ofstretching or crushing ofthe hose.1 3. Know discharge rate of pump supplying you.14. Soundings should be taken at frequent intervals.15. Have pump slowed down when topping off.

NOTE:L The bunker sample should be retained for at least 90 days.2. Maintain the bunker tank temperature at 35 deg. C to avoid possibility of waxformation, settling tank temperature at 45 deg. C, service tank temperature at 85 deg. C.3. The max. density of fuel is 0.991 at l5 deg. C.4. When machines are working in series, the first maclrine should be set as a purif ierand the other as clarif ier.

I7 . WHAT CHECKS WILL YOU MAKE FOR F.O. TANKS?l. Drain water from tank.2. Check;

i. F.O. temperatureii. Oil level in tankii i. The free movement of f loat

3. Tank air pipes should be clear.

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12. LUBE OIL

I. GIVE REASONS FOR DETERIORATION IN LUBRICATING OIL.Reasonsl. Far advanced oxidation ofthe oil i tself.2. Presence of inorganic acid.3. Presence of water, especially in influx of sea water, as the chloride ions also act asan inorganic acid.Signs of deteriorationl. Sludge precipitation in purif ier multiplies.2. Smell of oil becomes acrid or pungent.3. Color of oil becomes dark in sight glasses.4. Machined steel in crankcase becomes coffee brown by thin layer of lacquer.5. Paint in crankcase peels offor blisters.6. Excessive carbon is fbrmed in piston cooling chamber.

2. HOW WILL YOU DETECT PRESENCE OF WATER IN OIL?l. By derv formation on the sight glasses.2. Milky appearance.3. By immersing a body (glass or metal) heated to 200 - 300 deg. C in an oil sample, ifhissing, water is present.Removal of waterl. By continuous purif ication.

3. EXPLATN ANALYSTS OF LUBE. OrL. (WFL)l. Specific gravity2. Flash point: Gives an idea of contamination with fuel oil.3 . Viscosi ty ;

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Rises by,Oxidation.Contamination with heavy fuel oil or water.

B. Decreases by,i . Di lu t ion wi th fuelo i l (d iesel ) .4. Total acid number (TAN): This is the total content of organic and inorganic acids inthe o i l .5. Strong acid number (SAN): This is the total content of inorganic acids in the oil(sulphuric acid).6. Alkalinity (Total base number) TBN: Gives remaining alkalinity in oils.7 . Water: Permissible up to 0.2 V:o.8. Conardson carbon:i. Residue from incomplete cornbustion of fuel.i i . Cracked lubricating oil.9. Precipitation number: Amount of insoluble ingredients in the oil.10. Ash content: Consists of wear narticles. sand and rust.

4. WHAT ARE THE PROPERTIES OF TELEMOTOR FLUID?l. Good lubricating properlies.

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2. Low pour point.3. Low viscosity.4. High flash point.5. Non sludge fornring.6. Non corrosive.

5. WHAT ARE THE PROPERTTES OF L.O. FOR REFRIGERATIONCOMPRESSORS?L Good chemical stabil ity.2. Good thermal stabilitv.3. Los viscosity.4. Low wax content.5. Low pourpoint,6. Moisture free.

6. HOW WILL YOU DETERMINE OIL/WATER LEAKAGE INTOCRANKCASE?Fuel contaminationl. Increase in oil level in the tank.2. Srnel lo f the o i l .3. Increase in oil viscosiry in case of H.F.O. contamination.4. Decrease in flash point.Water contanrination (CKL, WFL)L Increase in oil level in the tank.2. Sudden increase ofpressure differential across the by-pass filter.

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13. STEERING GEAR

1. EXPLAIN THE ACTION OF STEERING CEAR PUMP?1. During nonnal operation, one pump will be running. If a faster response is requiredfor instance in confined waters, both pumps may be in use.2. The pumps will be in the no-delivery state until a rudder movement is required by asignal from the bridge telemotor transmitter.3. The telemotor receiver cylinder wil l then nove, this wil l result in a movement of thefloating lever which wil l move the floating ring or slipper pad of the pump, causing apumping action.4. A return l inkage or hunting gear mounted on the ti l ler wil l reposition the floatinglever so that no pumping occurs when the required rudder angle is reached.

2. WRITE A NOTE ON RUDDER.Use: To steer the ship

Area: Length X Depth of ship Aspect ratio: Depth:260 or 70 width

l. A rudder with all of its area aft of the turning axis is known as unbalanced rudder.2. A rudder with a srnall part of its area forward of the turning axis is knorvn as semibalanced rudder.3. When more than 25 % of the rudder area is forward of the turning axis, there is notorque on the rudder stock at ceftain angles and such an arrangement is known as abalanced rudder.

3. WHAT CHECKS YOU WILL CARRY OUT ON THE STEERING GEARBEFORE LEAVTNG PORT. (WFL)A. Within 12 hrs. before depafture, the ship's steering gear shall be checked and tested.The test procedure shall include the operation ofl .2 .3 .4 .

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The rnain steering gear.The auxil iary steering gear.The renrote steering gear control systems.The steering positions located on the navigating bridge.The emergency power supply.The rudder angle irrdicators in relation to the actual position of the rudder.The steering gear power unit failure alarms.The rernote steering gear control system power failure alarms.Automatic isolating arrangements and other autonratic equiprnent.

B. The checks and tests shall includel. The full movement of the rudder according to the required capabil it ies of thesteering gear.2. A visual inspection ofthe steering gear and its connecting l inkage.3. The operatiorr of the means of communication between the navigating bridgeand steering gear compartmentC. Emergency steering dril ls shall take place at least once in 3 months. These dril lsshall includel. Direct control frorrr within the steering gear compartment.2. The cornmunication procedure rvith the navisatins bridee.

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3. The operation of alternative power supplies.

4. DESCRIBE ROTARY VANE TYPE STEERING GEAR.l .i. ln this type ofsteering gear, a vaned rotor is securely fastened on to the rudderstock.i i. The rotor is able to move in a housing which is solidly aftached to the ship'ss l ructure.2 .i. Chambers are formed between the vanes on the rotor and the vanes in thehousing.ii. These chambers will vary in size as the rotor moves and can be pressurised,since sealing strips are fitted on the moving faces.

i. Thus by supplying hydraulic fluid to all the chambers to the left of the movingvane and drawing fluid from all the chambers on the right, the rudder stock can be madeto turn anti-clockwise.i i. Clockwise movement wil l occur if pressure and suction supplies are reversed.4 .i. Three vanes are usual and permit an angular movement of 70 deg.ii. The vanes also acts as stops l imiting rudder movement.5. The hydraulic f luid is supplied by a variable delivery pump and control rvil l beelectrical.6. A reliefvalve is fitted in the system to prevent over-pressure.

5. HOW WOULD YOU OPERATE THE STEERING GEAR LOCALLY ONYOUR LAST SHrP.(WFL)1. The bridge should be innrediately notif ied in the event of imminent steering failure.2. Change over of control method should be done in the zero position of rudder angle.3. The connecting pin should be inserted into position for control ofthe steering gearby Trick Wheel from within the steering gear compartment.4. Check the operation of the means of cornmunication between the navigating bridgeand the steering gear compartment.5. The direct control from within the steering gear compartment.6. The full movement of the rudder according to the required capabil it ies of therudder.1. The steering gear power unit failure alarms.8. The rudder should be moved hard over to hard over using each power unit ir.r turnbefore cutting off the power to test the audible and visual alarrns on the bridge.9. At the same time check the rudder angle indicators in relation to the actual positionof the rudder using the communication system provided.10. Veri[ ' that the l ight provided on the bridge to indicate the running motor of thepower unit is working.I 1. Check the steering positions located on the navigating bridge.

6. WHAT SHOULD BE THE ACTION OF THE NAVIGATING STAFFDURING STEERING GEAR EMERGENCY? (WFL)l. During emergency, the navigating staff wil l not know which power unit is defective.

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2. To quickly remedy the situation,i. Both units should be switched off and,ii. Then each one statted in turn to establish which one is defective.3. Steering can then continue on the good unit.

7. HOW DO YOU TEST THE OPERATION OF ALTERNATIVE POWERSUPPLIES?

i. Isolate the direct supply l ine orOpen the breaker between the main and emergency switch boards.

2. Check the automatic starting of the emergency generator and power supply to thesteering gear.

8. WHAT ARE THE RESULTS OF AtR lN STEERING GEAR? (WFL)1. Air being compressible causes,

lncorrect balance between units.i i . Time lags and irregular operation.2. Indication,i. Dcfeclive steering.i i. Jerky operation and,ii i . Jumping at the pressure gauges.3. Should air get into the systenr, it may be removed by purging at the air releasevalves.4. Should a large quantity of air gain access giving faulty steering then totally emptyand recharge.5. Follow safety procedure.6. Inform CIE and bridee.

8. HOW DO YOU CHARGE ROTARY VANE ACTUATOR? (WFL)

l. Charging should be done in the zero position of the rudder angle.2. Ensure that the position of all valves in the system are in accordance with the nameplate on the steering gear.3. The steering gear should be changed over from telemotor to local control by handwheel within the steering gear compartment to control movements of the steering gear.4. Check the oil level in the replenishing tank.5.

'Ihe rotaty vane actuator should be charged through the stop valves on the unit with

i. the by-pass valve open, andii. air vented througlt the air release valves on the actuator and on the purnps.

L The replenishing tank must be kept topped up during the operation.2. When its level ceases to fall and only air-free fluid is escaping,i. tlre air release valves and the by-pass valve should be closed andii. all valves returned to their normal running positions.3. Under local control, the steering gear should be run slowly from hard over to hardover several t imesi. using one pump and then with the other,i i . whilst the air release valves are periodically opened to ensure that all air hasbeen released.

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WHAT ATTENTION WILL YOU GIVE TO STEERTNG GEAR SYSTEM?Maintainingthe cleanliness of hydraulic systems.the condition of l inkases.

Periodic sampling of the rv=orkine fluid.By carrying out.

steering gear checks and tests, andemergency steering dril ls.

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14. MlE OPERATIONAL DISTURBANCES

I. EXPLAIN THE CAUSES, DETECTION AND PREVENTION OFSCAVENGE FIRES.Csuses:lgnition of the dry carbon deposit settling in the upper part of the scavenge box may becaused by.l . Pro longed b low-by.2. Slow burning in the cylinder.3. Blorv-back through the scavenging pofts due to too large resistance in the exhaustsystem.Indicaliotts:I " Decrease in engine speed.2. Irregular running of the engine.3. Surging ofturbochargers.4. Increase in exhaust temperatures ofcorresponding units.5. High local temperature in scavenge trunks.6. AIarrn by temperature sensitive probes fitted to scavenge systems.1. Sparks and smoke emitted from scavenge drains.8. Smoke irr exhaust gas.Prevenliorr:l. I(eep piston rings in good order to prevent blow-past.2" Clean scavenging belts as often as possible.3" Keep the exhaust ports clear ofcarbon deposit.4. Do not let one cylinder unit be appreciably overloaded as compared with the others.frIeosures:l. Set t lte cylirrder lubricator to maximum delivery. Close the scavenge drails. Cutout the fuelpump by l ift ing and locking the roller guide. Intbrm chief Engineer.2. Slo,w dorvn irnrnediately, ask bridge forpermission to stop. Stop if permitted.3. When engine is stopped, stop pulxps for fuel oil and nozzle cooling.4' Apply fire extinguishing equipmentto the scavenging box. Close butterl ly valves inthe air duct after blowers.,5. Do not open scavenging box befbre flre is extinct and site of f ire cooled downbelow 100 deg. C. Whi le opening up, keep c lear of possib le f lanres.6. Clean all scavenging boxes ofdry deposit and sludge.1. Clean and inspect ,

A. Piston rods and cylindcr Iiners concerned fori. Surface conditionii. straightnessi i i . a l ignurent . I f good coat rv i th lube o i l .B. Stuffing box and bottorn of scavengin,q box for cracks. If good, repeat

tnspect ions dur ing turn ing.8. Ifthe piston having caused the fire cannot be overhauled at once, porver o1 theaffected cylinder rrray have to be reduced or shut offrvhen the engine is restarted.9. lf the heating of the box walls has been considerable. the nearest t ie bolts should bere-tightened and the alignnrent ofthe camshaft bearinss should then be clrecked.

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2. EXPLAIN CRANK CASE EXPLOSION.Factors:1. A source ofheat to cause the lubricating oil to vaporise.2. Correct quantity of air mixed in with the small oil particles to make the oil-airmixture explosive.3. A source of heat at a temperature high enough to init iate combustion in the oil-airmixture.Couses: Hol spots tlue to,1 . Overheating of bearings, piston rod gland (stuffing box).2. Sparks from piston blow past.3. Fires in spaces adjacent to the crankcase.4. Lowering of f lash point of lubricating oil by contamination with fuel oil.Delectiort: Deteclion of hot spot by,l. Engine noise.2. Increase in terrrperatures.3. Smell and appearance of dense white oil mist.4. Temperature sensitive probes fitted near the bearing oil returns.5. Crankcase oil mist detector.Elintinutiort: By,l. Proper maintenance, lubrication and oil condition.2. Maintaining high flash point of lubricating oil.3. When starting up after repairs, "FEEL OVER" moving parts at suitable intervals.4. Discover oil nrist in t ime and avoid hot spots.Note:L Crankcase explosion doors l ift at 5 kN/m2 or 0.05 Kglcm2.2. Temperature of hot spot, min. 360 deg. C.fuIessures:l. Slorv dorvn iurmediately, ask bridge for permission to stop. Stop if permitted.2. When engine is stopped, stop pumps for fuel oil and nozzle cooling.3. Open skylight and prepare fire fighting equipment.4. Do not open crankcase unti l 20 minutes after stopping the engine.5 .

i . Stop lubr icat ing o i l pump.ii. Cut offstarting air, engage turning gear.i i i . Take off all lowerrnost doors on one side of the crankcase.

6. Locate the hot spot.i. Feel over all sl iding surfaces.i i. Look for squeezed out bearing metal and heat discoloration.i i i . Feel over also ceil ing ofcrankcase.iv. Make similar search in thrust bearing.

1. Prevent further heating by,i . Making a perr t tanent repai r .i i . Proper lubr icat ing o i lsupply.i i i . Satisfactory condition of the frictional surfaces involved.

8. Start lublicating oil punrp and check oil f low fi 'om all sl iding surfaces, while turningthe engine one revolution with the turning gear.9. Stop and feel over, especially the frictional component that caused the heatingshould be felt over.

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3. EXPLAIN AFTER BURNING.After burning is said to occur when the third phase of combustion extends over a longperiod.Cuuses:l. Incorrect fuel grade.2. Improper atomisation, rnisplaced fuel sprays.3. Poor or excess penetration.4. Incorrect fuel tenrperature.5. Incorrect injection timing.6. Insufficient air supply.Il crcoles:l. High exhaust temperatures.2. Danrage to exhaust valves.3. Scavenge fires.4. Overheating of the Engine.5. Drop in maximurn f i r ing pressure.6. Loss of thermal efficiencv.

4. WHAT WILL YOU DO IN THE EVENT OF EXHAUST VALVE LEAK?Detectiott:l. Rise of exhaust temperature.2. Fall ing of the compression and maximum combustion pressure of the respectivecylinder.Actiort:L Exhaust valve should be changed immediately to l imit the damage.2. Fuel pump roller guide should be l ifter.

5. WHAT WILL YOU DO IN THE EVENT OF GOVERNOR FAILURE?1. The governor will reduce the fuel pump delivery to zero in case of failure ofgovernor oil pump or of the oil supply to the amplif ier cylinder.2. To permit starling and running with the governor cut out, change over toEMERGENCY.3. Whenthegovernor iscutout ,noprotect ionagainstrac ingisathand. Maneuver ingshould therefore be performed with special care particularly when sailing in hardweather.

6. WHAT WILL YOU DO IN CASE OF PISTON RING BLOW PAST?Indicatiott:l. Rise of exhaust temperature.2. Fall ing of the compression and maximum combustion pressure of the respectivecylinder.3. Sparks and smoke emitted from scavenge drains.4. Inspection of the piston ring condition through the scavenging ports.Ctuses:1. Due to collapse of otherwise intact piston rings.Acliott:

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l. There is a fair chance of bringing it to settle down temporarily by reducing the fuelpump index for few minutes and increasing the cylinder oil dosage for the respectivecylinder.2. Fuel pump roller guide should be l ifted.3. Overhaul piston and change piston rings.

7. WHAT ACTION WILL YOU TAKE IN THE EVENT OF TURBOCHARGERL.O. PUMP FAILURE?Aclion:1. The main engine should be stopped.2. lt takes l0 minutes before the T/C L.O. gravity tank is empty which is sufficient forlubrication ofthe turbochargers until these are stopped.

8. WHAT ARE THE CAUSES OF TURBOCHARGER SURGING?Turbocharger will surge due to abnormal change in either air or exhaust gas flow to orfrom the turbocharger.l .

i. A sudden reduction in engine speed with the corresponding drop in demand forair.

ii. If an engine is operated with one or more units not producing power.i i i . Malfunction in the fuel system.iv. Rapid variations in engine load.

2. Foul ingA. On the air sidei. Intake fi l teri i . Impel leri i i . Diffuseriv. Charge air coolerv. Choked scavenge poftsB. On the exh. gas sidei. Choked gridsii. Nozzle ringi i i . Moving b ladesiv. Exh. gas boiler

3. Scavenge fire or bearing damage.Actiott:l. Reduce engine speed and power.2. Water wash the turbocharger and remove fouling.

9. WHAT ARE THE CAUSES OF KNOCKING AND WHAT ACTION WILLYOU TAKE?Causes:1. Faulty fuel injection (too early injection).2. Pis ton cool ing o i l fa i lure.3. Cylinder lubrication inadequate or excessive.4. Bear ing c learances excessive.Acliott:l. Ifsound clearly emanates from a cylinder, shut offfuel from cylinder and check,

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i. Piston cooling oil outlet temperature and flow.ii. Operation of cylinder lubricators.

2. If sound clearly emanates from crankcase, STOP engine immediately and examinecrankcase.

IO. WHAT ARE THE CAUSES OF PISTON OR CYLINDER LINEROVERHEATING?Csuses:l. Inadequate piston orjacket cooling.2. Inadequate cylinder lubrication.3. Cylinderoverloaded.4. Badly worn rings or liner.5. Misalignrnent.Actiort: Check.l. Piston cooling oil outlet temperature and flow.2. Cylinder lubrication, jacket cooling water outlet temperature.3. Check power by indicator card and balance cylinder power.4. Reduce load on cylinder unti l i t is overhauled to check component alignment.5. Engage turning gear soon after stopping.6. Check fuel valves for proper action and spray direction.

I I . WHAT ARE THE CAUSES OF EXCESSIVE WEAR OF CYLINDERLINERS?Causes:l . Inadequatecyl inder lubr icat ion.2. Use of incorect cylinder lube oil.3. Improper jacket cooling water telnperature.4. Improper fuel oil purif ication.5. Faulty fuel injection.6. Over loading of the engine.Actiort: Check,L Cyl inder lubr icat ion.2. Alkalinity of cylinder lubricant used is compatible with the sulphur content of fuelin use.3. Jacket cooling temperature.4. F.O. purif ication.5. Fuel injector operation.6. Porver by indicator card and balance cylinder power.

I2. WHAT ARE THE CAUSES OF PISTON RING BREAKAGE?Cuuses:l . Rings

i. Faulty fitt ing.i i. Excessive wear of rings or ring grooves.i i i . Use of incorrect rinss.

2. Badly worn l iner.3. lnadequate cylinder lubrication.Aclion:

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l. Overhaul pistons at first opportunity.2. Reduce load on cylinders.3. Check cylinder lubrication.

13. WHAT ACTION WILL YOU TAKE IN CASE OF LOW L.O. PRESSURE?Csuses:l . Fai lure of lube o i l pump.2. Insufficient oil in the L.O. drain tank.3. Oil temperature too high.4. Excessive bearing clearances.5. Oil f i l ter choked.6. Failure of lube oil pipe or coupling.Action:l. Sfow down immediately, if oil pressure falls below 1.2Kglcm2, STOP engine.2. Check oil temperature and L.O. sump tank level.3. Examine crankcase, check all bearing fastening and piping.

14. WHAT ACTION WILL YOU TAKE IN CASE OF BEARINGS RUNNINGHOT?Csuses:l. Lube oil pressure too low.2. Obstruction in lube oil supply.3. Fai lure of lube o i lp ipe or coupl ing.4. Bearing clearances too srnall.5. Bearing danraged.6. Dirt or metall ic particles in bearing.Actiott:l. Cut offfuel from affected cylinder and observe temperature trend to ensurecontinued operation is safe.2. Avoid overloading other units.3. Stop engine irnrnediately and examine crankcase.

I5. EXPLAIN EMERCENCY RUNNING WITH CYLINDERS OUT OFACTION.Case: Pistott, crossheud, connecling rod, utrd lelescope pipes ore out.Procedure:l. Cut out the fuel punrp by l ift ing and locking the roller guide.2. Put the exhaust valve out of action so that the valve remains closed.3. Dismantle the starting air pipe and blank off the main pipe and the control air pipe.4. Dismantle piston with piston rod and stuffing box, cross head, connecting rod andcrankpin bearing.5. Blank off the stuffing box opening with 2 plates.6. Blank off the oil inlet fronr the telescopic pipe.7. Set the cylinder lubricator to'Zero' delivery.Staning after putting cylinders out of action.Before starting check,1. Oil f low through the bearings.2. The tightness of blanked off openings.

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After l0 minutes running and again after one hour, the crankcase rnust be opened forcheckingl. The bearings.2. The oil flow through the bearings.3. The temporarily secured parts.4. The tightness ofblanked offopenings.

I6. WHAT ARE CAUSES AND INDICATIONS OF OVERHEATED PISTON?Ceuses:1. Piston cooling oil failure.2. Inadequate cylinder lubrication.3. Cylindersoverloaded.4. Badly worn ring or liner.5. Increased internal friction in engine.6. Faulty fuel injection.1. Occurrence ofafterburnins.Ittdicutions:l . Engine noise.2. Decrease in engine speed.3. Rise of exhaust and piston cooling oil temperatures.4. Rise ofjacket cooling water outlet temperature.5. Smoke in exhaust gas.Mertsures:1. Slow down immediately without stopping.2. Set the cylinder lubricators to maximum position.3. Cut out the fuel pump by l ift ing and locking the roller guide.4. After the engine is sufficiently cooled it can be stopped.5. Engage turning gear soon after stopping.6. Check fuel valves for proper action and spray condition.

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15. M/B REPAIR STARTING

I. WHAT CHECKS WILL YOU CARRY OUT WHEN M/E IS RUNNING?l. Rotation: Direction corresponds to telegraph order.2. Turbochargers: Al l are running.3. Circulating oil: Pressure and oil f low is in order.4. Cylinders: Allf ire.5. Fuel valves: All are working.6. Air starting valves: If leaking, they are hot.7 . Pressures and temperatures: All are normal for the engine speed.8. Lubricators for cylinders and rocker arms: All are working, delivering correctdosage.9. Crank case oil mist detector.

2. WHY IS IT IMPORTANT TO KEEP THE F.W. OUTLET TEMPERATUREFROM THE M/E AT ABOUT 8l deg. C.?l. A lowertelnperature due to sulphur content in the fuel, may cause condensation ofsulphuric acid on the cylinder walls.2. A higher tenrperature impedes the formation of an adequate lubricating oil film onthe cylinder wall.Both results in high cylinder wear.

3. WHAT MAINTENANCE WORK IS INVOLVED IN KEEPING M/E INGOOD ORDER?A. Combustionnraintenance, involves

l . P is ton r ing replacement .2. Air irrlet, exhaust and fuel valve changes and overhaul.3. Cleaningi. Turbocharger air inlet f i l ters and blading.i i . Scavenge a i r cooler .i i i . Scavenge por1s.iv. Attending to instrumentation associated with cornbustion.

B. Bearing adjustment and nraintenance of corlect alignment in all running parts.l. Bearing examination and adjustments2. Attending to lubrication and cooling services.3. Examination of bed plates, frames, cover safety devices etc.

4. WHAT FACTORS WOULD YOU CONSIDER IN DECIDING WHETHER TOOPEN UP A CYL INDER UNIT FOR OVERHAUL AND REUSE?Overhaul:l. If the engine is operated under a planned maintenance program, cylinder unitsshould not be opened up unti l the required number ofoperating hours has been achieved.2.. If after taking indicator cards or checking cylinder pressures with a maximumpressure indicator, it is established that the compression pressure is low due to leakingpiston rings. overhaul ofthe unit should be arranged at the earliest opportunity.Reuse of piston rings:l. In deciding rvhether to reuse piston rings removed from a piston, t lre wear rate ofthe piston ring must be known.2. It is then compared to the rnaximum wear allowed in the piston ring to establish theexpected l ife remaining.3. If the expected remaining l ife is found to be less than the programned hoursbetrveen overhaul of the cylinder units, the rings must be scrapped.

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5. HOW WILL YOU CARRY OUT COOLING WATER TREATMENT IN ADIESEL ENGINE?This is done in order to reduce the risk of service diff lculties originating from thecooling water such as1. Corrosion.2. Corrosion fatigue.3. Cavitation.4. Scale formation.Procedure:l. Clean the cooling water system.2. Use de-ionized or disti l led water.3. Add the corrosion inhibitor (only nitrate / borate based).4. Carry out regular checks of the cooling water system and the condition of thecooling water.Nante of irthibilors:l. DEWT NC - Drerv ameroid U.S.A.2. CWT DIESEL QC2 - Vecom Holland.

6. EXPLAIN RUNNING IN OF LINERS AND RINGS.A.

1. The engine speel / Ioad sltonld be increased graclually,i. For a new engine or afteri i. Renetval or renovation oflarge bearings.i i i . Renewal or renovation of cylinder l iners or piston rings.2. Sequence:i. Increase the engine rpm to 80 Yo in the course ofthe first 2 to 4 hours and

rnaintain this speed for 6 hours.i i. Afterthis 8 to l0 hours running, the increase to full rpm is effected stepwise

during the follorving 12 to 14 hours, giving a total running in period of 20 to 24 hours.B.

l. If only one or two cylinders / bearings ltuve been reneteed or renoviled.i. The fuel pump index for the cylinder(s) in question is decreased by 25 %o and

the engine run up nornrally.i i . The indices concerned increased gradually during an interval of20 to 24 hours.i i i . Throughout the whole running in period of 20 to 24 hours, the cylinder oil

dosage should be at the maximum level.

7. EXPLAIN FEEL OVER SEQUENCE OF MAIN ENGINE.lf the condition of the nrachinery is uncertain (i.e., after repairs or alterations) the feelover sequence should always be follorved.L After l5 to 30 minutes running on SLOW.2. Again af ter I hour running.3. At sea after I hour running at service speed.The engine is stopped, the crankcase is opened and moving parts are felt over on slidingsurfaces.Feel:1. Main, crankpin and crosshead bearings.2. Piston rods and stuffins boxes.3. Cross head shoes.4. Telescopic p ipes.5. Chains and bearings in the chain casing.6. Canrshaf t bear ing housings.1. Thrust bearinqs.

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20. COMBUSTION CONTROL IN M/E

I. WHAT ARE THE CAUSES OF EXHAUST TEMPERATURE RISE?A. In all cylinders

1. Increased scavenging air temperature. 1 deg. rise of scavenging air temperaturecauses 2 to 2.5 deg. rise ofexhaust gas temperature.

2. Ineffective air coolers.3. Fouling ofair and gas passages.4. Improper F.O. purif ication.5. Wrong position of camshaft. (check chain tension)

B. In single cylindersl. Defective fuel valves.2. Leaky exhaust valve.3. Blow-by, leaky combustion chamber.4. Wrong position of fuel cam.

2. WHAT ARE THE CAUSES OF EXHAUST TEMPERATURE DECREASE?l. Decreased scavenging air temperature.2. Air in fuel pumps and fuel valves.3. Spindle in fuelvalve sticking.4. Fuel pump plunger sticking or leaking.5. Suction valve in fuel pump defective.

3. WHAT ARE THE CAUSES OF ENGINE RPM DECREASB?l. Pressure before fuel pump too low.2. Fuel valve or fuel purnp defective.3. Water in the fuel.4. Fire in scavenging box.5. Increased internal friction in Engine (seizure ofa piston).6. Slow down or shut down.7. Fuel oil characteristics.8. Fouling of hull or darnaged propeller.

4. GIVE AN APPROXIMATE

I . B H P2. Loss in exhaust gas3. Loss through J.C.W.4. Loss through system oil

HEAT BALANCE?o/o

4 13 520

4.0

EXPLAIN INFORMATION FROM DRAW DIAGRAM.Maxintum pressure too low, compression pressure correcl.1. Checki. Fuel valves for proper action and spray direction.i i. Fuel is injected too late.i i i . The fuel carn should be advanced.Moxinum pressure too Itigh, contpressiort pressure correct.

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l. Checki. Fuel is injected too early.ii. The fuel cam should be retarded.

C. tr'[aximum pressure too low, compressiort pressure loo low.l . Checki. Leaky piston ringsii. Leaky exhaust valve.i i i . Scavenge air supply too low.iv. Fouling of exhaust system and / or air intake system.

6. EXPLAIN PERMISSIBLE DEVIATIONS.I . Mean indicated pressure: When these deviates more than 0.5 KglCm2 from thenrean value, adjustment of fuel pump index should be made.2. Maximum pressures and compression pressures: When these deviates more than 2KglCm2 from the mean value, the cause should be found and corrected.3. Compression pressure divided by scavenging air pressure ratio:

Comoression pressure + Barometric pressure (L02 Kg/Cm2)Scavenge pressure f Barometric pressureGives valuable information about,

i. Tightness and alteration of the compression space of the individual cylinder.i i . Ratio is between 28 to 35.

4. Cooling oil: The temperature rise across the piston should not exceed 20 deg. C.5. Cooling water: The temperature rise across the engine should not exceed 15 deg. C.6. Pressure drop across F.O. & L.O. fi l ter: When this exceeds 0.5 KglCm2 the fi l tershould be c leaned.1. Temperature difference between S.W. inlet and scavenge air outlet of air cooler toolarge (Limit 20 deg. C)

i. Air cooler fouled.8. Pressure drop across T/C air f i l ter increasing (l imit 50 %)

i. Air f i l ter fouled.9. Pressure drop across air side of air cooler increasing (l imit 50 %)

i. Air side of cooler fbuled.10. S.W. temperature difference across air cooler too large (l imit 8 deg. C)

i. Water flow too small.

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16. M/E SAFETY

1. GIVE A LIST OF M/E PROTECTION SYSTEM.M/E shut dowrt:l. Main L.O. low pressure - 0.8 Kg/cm2.2. Camshaft L.O. low pressure - 0.4 Kglcm2.3. T/C L.O. gravity tank low level.4. Overspeed - 120 rprn.M/E sltut down (Additional)l. Thrust bearing segment high tenrperature, 85 deg. C.

M/E slow down:l. Main L.O. low pressure - 1.2 Kglcm2.2. Camshaft L.O. Iow pressure - 0.6 Kg/cm2.3. Cyl. cooling F.W. outlet high tenrp. - 80 deg. C.4. T/C cooling F.W. outlet high tenrp. - 80 deg. C.5. Piston cooling oil outlet high temp. - 75 deg. C.6. Crosshead bearing L.O. high temp. - 70 deg. C.hf/E slor tlown (Additional)l. Scavenge air boxes high temp. - 150 deg. C.2. Thrust bearing segment - 85 deg. C.3. Fresh rvater across M/E - 0.5 bar.4. Piston cooling oil outlet - Non flow.5. Main bearings - 70 deg. C.6. Crank shaft bealings - 70 des. C.

2. LIST THE SAFETYNAXIE

l . Rel ie f va lves2. Rel ie f va lves3. Relief valves4 . Relief valves5. Rel ie fvalves6. Interlocks1 . Shut dor'vn8. Shut down9. Shut down10. Overspeed tripI l. Oil mist detector12. Temperature probe13. Temperature probe

DEVICES FITTED TO M/E.LOCATION

Combustion clramberCrank caseScavenge spacesFuel pumps & systemsStarting air systemTurning gearLub/Cooling systemsVarious systemsBridgeEnginecrank caseBearing oil returnsScavenge space (90)

PROTECTIONExcessive pressureExplosionHigh pressureHigh pressureExcessive pressurePrevent startingLow pressureHigh/Low temp.Communication failureGovernor failureHot running partsExcessive temp.Scavenge fir'e

3. LIST SAFETY DEVICES IN THE STARTING AIR SYSTEM OF M/E.l. Non return valve.2. Spring loaded safety valve.3. Burst ing d iscs.4. Flame trap.

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4. WHAT DO YOU UNDERSTAND BY THE TERMA. Crit ical speed: The speed of an engine in rpm at which the resonant conditionoccurs is referred to as the critical speed.B. Barred speed range: The barred speed range ofan engine is the range ofspeed fromthe beginning of build up of unsafe flank stresses to the dying away of these stresses atsome higher speed.

5. WHAT DETECTORS ARE FITTED TO THE CRANKCASE? (WFL)1. Crankcase oil rnist detector.2. Temperature probes fitted to bearing oil returns.3. Piston cooling oil outlet temperature probes.4. Infra red or ultra violet flame detectors to detect hot soots. Fire releases radiantenergy in the form of

i. infra red radiation,i i . v is ib le l ight ,i i i . ultraviolet radiation.

5. Temperature probes fitted to thrust bearing.i. Main, alarm at 70 deg. Cii. crankpin, andii i. crosshead bearing L.O. outlets.

6. Crank case pressure reliefvalves.

6. WHAT DETECTORS ARE FITTED TO COMBUSTION CHAMBER?l. Cylinder safety valve.

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17. TROUBLESHOOTING IN M/E

I. WHY ENGINE DOES NOT TURN WHEN REGULATING HANDLE IS SETIN *START' POSITIONl. Air pressure in air bottle too low.2. Main valve at air bottle closed.3. Stop piston valve is sticking in closed position.4. Valve to distributor closed.5. No air pressure to pneumatic starting system.6. Master pilot valve not actuated at all.

2. WHY ENGINE TURNS TOO SLOWLY OR IRREGULARLY ONSTARTING AIR?1. Low air pressure in air bottle.2. Piston valves in starting air distributor sticking.3. Air starting valve in cylinder covers defective.4. Faulty timing of distributor.

3. WHY ENGINE TURNS ON STARTING AIR BUT NO FUEL OIL ISINJECTED DUE TO TOO LOW FUEL PUMP INDEX?l. Sluggish movement of maneuvering gear.2. Incorrect adjustntent ofmaneuvering gear.3. Failures in governor arnplif ier.4. Regulating air pressure to governor too low.5. Due to uncalled shut down functions.

4. WHY ENGINE TURNS ON STARTING AIR BUT NO FUEL IS INJECTEDDUE TO FAILURES IN FUEL SYSTEM? (F 'UEL PUMP INDEX OK)l. Air in fuel pumps and valves.2. Pressure before fuel pump too low.3. Suction valve in fuel pumps defective.4. Worn out fuel pumps.

5. WHY WHEN FUEL IS INJECTED, BUT IGNITION FAILS?1. Water in fuel o i l .2. Fuel valves or atomizers defective.3. Compression pressure during starting less than 22 Kglcm2.4. Too late injection of fuel.5. Viscosity of fuel is too high.

6. WHY FIRST IGNITIONS ARE TOO VIOLENT. SAFETY VALVES AREOPENING?l. Engine cylinders not scavenged sufficiently.2. Oi l has col lected on p is ton crown.3. Sluggish movement of re_s:,ulating gear.4. Fuel pump index raised too high.

7. WHY ENGINE STARTS BUT STOPS AFTER FEW REVOLUTIONS?l. Regulating air pressr.rre fails.

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18. M/E INSPBCTION

I. IYHAT WILL YOU LOOK FOR DURING SCAVENGE PORT INSPECTION?l. The condition of all cylinder l iners, rings, and piston rods.2. Lubricatingconditions.3. Whether piston rings are intact, not worn too much and free in their grooves.4. During the inspection, the cooling water should be circulating so that possibleintemal leakage nay be discovered.

2. WHAT CHECKS WILL YOU CARRY OAT ON CRIINKSHAFTS?Look for,l. Surface damage ofjournals.2. Cracks at f i l let radii, oil holes or other areas where stress concentrations occur.3. Slipped shrink fit by reference marks.4. Ovality.

3. HOW WILL YOU CARRY OUT CRANK CASE EXAMINATION?A. Oilflow

l. While the purnp is sti l l running and the oil is warm, see that oil is f lowing freelyfrom all

i . crosshead p i r r bear ings.i i. crankpin and main bearings.i i i . camshaft drive train bearings.iv. chain drive spray pipes.2. The oil jets should be of unifornr thickness and direction. Deviations may be a

sign ofsqueezed metal or clogged up oil grooves.3. Observe sight glasses ati. Piston cooling oil outlets,i i . the thrust b lock,i i i . the highest point of the chain drive. Ensure that an adequate amount of oil is

flowing.B. Oil pan

L After the pump is stopped, the bottom of the oil pan should be searched forfragurents of bearing metal.C. Bauring cleoronccs.

l. Check all bearing clearances with feeler gauges.D. Ruttttittg gear fastenings.

1. Check chain tension and adjust ifnecessary.2. Exarnine locking devices, all bolts and nuts in the crankcase and re-tighten if

necessary.

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19. M/E ALIGNMNNT

1. WHAT ARE THE CAUSES OF CRANKSHAFT DEFLECTION?

l. Wear of Main bearing.2. Displacement of bed Plate.3. Displacement of engine alignment and / or shafting alignment'

2. WHAT OBSERVATIONS WILL YOU MAKE WHILE TAKING

CRANKSHAFT DEFLECTION?l. whenever possible, use a gauge that shows negative readings under compression

and positive on expansion (0.15 to 0'68).

2. Watch amperage as the engine is turning to get an idea of resistance to turning' Any

sudden changes in reading should be investigated immediately'

3. HOW WILL YOU TAKE CRANKSHAFT DEFLECTION?

Crank Position1. Near bottom (Port) : X

2. Port : P

3 . T o p : T

4. Starboard5. Near bottom (starboard)

6. Bot tom (X+Y)12

Deflection from vertical rnisalignmentT - B : V

Deflection from horizontal misalignment P - S : H

To check,I . Ovality and clearances under the journal,

i . C : T + Bi i . D : P + S

C and D should be nearlY the same.

: S: Y: B

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2I. AN SAFETY

1. WHEN WILL YOU STOP AN A/E IMMEDIATELY?A/E is stopped immediately in case ofl. Abnormal sound.2. Smoke is observed at the bearing.3. Breakage of F.O., L.O., and C.W. piping.4. Detection of water leakage into L.O. surrrp.5. Sudden drop in L.O. pressure.6. Sudden rise in L.O. tentperature.1. Sudden rise in engine rpnr.8. Abnormal rise in C.W. temperature.9. Stoppage of C.W. supply.10. Abnormal rise in exhaust gas temperature.1 l. Sudden drop in T/C rpm.12. Detection of damage to working parts.

2. HOW WILL YOU PARALLEL AN A/C GENERATOR WITH OTHER SETSALREADY ON LOAD.L The speed of the incoming machine must be adjusted unti l i ts frequency isapproximately equal to that ofthe generators already connected to the busbars.2. The voltage must be adjusted to correspond with that of the busbars.3. The paralleling switch must be closed as nearly as possible at the moment when thetwo instantaneous voltages are in phase and equal in magnitude.4. The governor settings ofthe generators are adjusted to achieve kW load sharing.

3. WHAT IS THE FUNCTION OF GOVERNORS?L A governor is used to maintain Engine speed within certain prescribed limitsthroughout the operating power range.2. In addition to speed control, modern governors also provide other control functionssuch as load control and fuel l inritations which wil l protect an engine from adverseoperating conditions.

4. EXPLAIN SYNCHRONISATION.A. Using Synchroscope

L When the voltages are in phase, the pointer remains at l2 o clock.2. The dial is marked FAST and SLOW with appropriate arrows to indicate

whether the inconring rnachine is running too fast or too slow.3. lt is good practice to lrave the pointer rotating not faster than one revolution in

5 sec. in the FAST direction and to init iate closing when the pointer is at about I I o'clock.

4. In this way with the machine slightly fast it wil l immediately assume load,whereas if switched wlren running slow it rvould take a motoring load tvhich nrightpossibly operate the reverse power relay.B. Synchronising by the sequence method

l. The mornent to synchronize is when the key lamp (at the top of the triangle) isdark and the other two larnps are equally bright.

2. Switch off the synchroscope immediately after synchrorrisation.

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5. GIVE LIST OF A/E PROTECTION SYSTBM.A. Sltut tlown al

1. Cool. F.W. high temp. (80 deg. C)2. L.O. low pressure (0.6 Kg/Cm2)3. Overspeed trip (828 rpm)

B. Alsrm at1. Cool F.W. high temp., low pressure (1.6 Kg/Cm2)2. L.O. low pressure (1.2 Kg/Cm2)3. Cool. S.W. low pressure (0.5 Kg/Cm2)4. Rocker arm L.O. low pressure (0.3 KgiCm2)

C. Auto slurt, syttchro, load chonge at,1. L.O. low pressure (1.2 KglCm2)2. Cool. F.W. high temp. (70 deg. C)3. Preferential trio.

6. NAME A/C GENERATOR PROTECTION SYSTEMS.l . Preferencetr ipping.2. Reverse power protection3. Under voltage protection4. Over voltage protection5. Over current protection6. Instantaneous over current protection7. Loss of excitation8. Di l lerent ia lprotcct ion9. Earth fault protectionI 0. Distribution network orotection

7. HOW WILL YOU START AN AUX. ENGINE?L Check oil level in

i. crankcaseii. R/A L.O. tankii i. Turbocharger bearings L.O.iv. Governor L.O.v. Fuel valve cooling oil tank

2. Check F.W. expansion tank level3. The linkage betrveen the governor and the fuel pumps should be checked forfreedom of movement and the whole system lubricated.4. Start L.O. priming pump, when L.O. is circulating, turn the engine manually through2 revolutions to make sure that nothing is fouling.5. Ensure c i rcu lat ion of S.W and cool ing F.W., F.V. cool ing o i l .6. Ensure starling air reservoir is fully charged and drain water liom starting airsystem.7. Turn the engine slowly one revolution on starting air with open indicator cocks.8. The engine is then started and run on NO LOAD for 2 minutes.9. Check, L.O. temperature / pressure. C.W. temperature / pressure, Rocker arm L.O.pressure.

8. WHAT WOULD HAPPEN IF YOU ATTEMPTED TO CONNECT AN'OUTOF PHASE'ALTERNATOR TO THE MAIN BUSBARS?l. The large circulating current may trip each generator circuit breaker.2. The large forces may physically damage the generators and their prime movers.3. Result is blackout.

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22. AIE REPAIR / STARTING

I. WHAT DO YOU UNDERSTAND BY THE TERM'SYNCHRONISATION'Before an incoming generator can be connected to the live system 3 conditions must bemet to ensure synchronisation.l. The frequency ofthe incoming generator and the busbars.2. The incomer and the bus bar voltages.3. The phase difference betweerr the incomer voltage and the bus bar voltage must bewi th in acceptable l imi ts .

2. HOW WILL YOU COMMISSION AUXILIARY ENGINE AFTERDECARBONISATION?L Open D.O. valves on the engine and vent each element of the fuel f i l ter.

i. Prirne each pump, injection pipe and injector.2. The linkage between the govemor and the fuel pumps should be checked forfreedom of movement and the whole system lubricated.3. Check the L.O. sump level and start L.O. priming pump. When L.O. is circulating,turn the engine manually through 2 revolutions to make sure that nothing is fouling.4. Open appropriate valves in the sea water and fresh water circulatirrg system. EnsureS.W. and cool ing F.W. is c i rcu lat ing.5. Ensure starting air receiver is fully charged and open the starting air inlet valve.6. Turn the engine slowly one revolution on starting air with open indicator cocks.7. The engine is then stafted and run on no load for 3 - 5 minutes. After which theengine is stopped, crankcase is opened and moving pafts are felt over on sliding surface.8. The same procedure is repeated after I hour running.9. If major components such as piston rings and liners have been renewed during theoverhaul, increase the engine (speed) load gradually to 80 ohinthe course of the first 2 -4 hours and maintain this load for 6 hours.10 . A f te r th i sS - l 0hou rs runn ing , the inc rease to l i r l l r pm( load ) i se f f ec ted ins tepsduring the following 12 - 14 hours, giving a total nrnning in period of 20 - 24 hours.I l. On steady full load, check;

i. rraxinrum firing pressure,i i. exhausttemperature.i i i . Any discrepancy should be rectif ied by adjustment to the tirring or rack setting

of the fuel pumps.12. When the engine is stopped L.O. priming pump should be starled up and run for l5- 20 minutes in order to allow the pistons to cool slorvly and evenly.

3. NAME THE 3-PHASE ALTERNATOR INSTRUMENTATION-l. Ammeter2. Voltmeter3. Watt meter4. Frequency rneter5. Synchronis ingdevice

4. WHY A.V.R. IS REQUTRED?l. The alternating current generator supplying a load has a considerable voltage dropresulting frorn the load having a lagging power factor'.2. Therelbre tlre exciter in nraintaining the alternator voltage, tnust vary with the loadcurrent and also the oower tactor.

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3. Hand control of excitation is diff icult, so use is made of an automatic voltaseregulator (A.V.R.)

5. EXPLAIN POWER FACTOR.l. The power factor is a measure of the phase difference between voltage and currentand is expressed as the cosine ofthe phase current.2. with a purely resistive load, voltage and current are in phase, giving a power factorof one. So power consumed: voltage X current.3. Inductive or capacitive loads combined with resistive loads produce lagging orleading power factor which have values less than one. so power consumed - voltage Xcurrent X power factor.4. The ratio between true and apparent power is termed as the power factor

Power factor: True power / apparent power: kW / kVAThe current wave form lags behind the voltage.P : 1.732 X V I Cos(phi) Watts

6. EXPLAIN A/E 5OO HOURS INSPECTION ROUTINE.l . Clean

i. T/C air filters,i i. L.O., F.O. andiii. rocker arm L.O. filters.

2. Drain and renewi. R/A L.O.,i i . T/C bearing L.O.,i i i . Governor L.O.

3. Inspection and lapping ofi. Inlet and exhaust valves,i i . a i r s tar t ing valves.

4. Inspection ofi. fuel injectors,i i. valve gear and crankcase.

5. Check, valve tappet clearance.

7. EXPLAIN A/E 6000 HOURS INSPECTION ROUTINE.1. Clean

i . L .O. cooler ,i i . air cooler.

2. Renewal of fuel atomizers.3. Inspection of

i. Piston,i i. piston rings,i i i . big end bearing,iv. one main bearine.

4. Checki. fuel pump timing,i i. crankshaft deflection.

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23. MANOEUVERING

I. EXPLAIN PREPARATION OF TTIE MAIN ENGINE PLANT FOR SEAGOING CONDITIONS.l. Disengage turning gear, check that it is locked in 'out' position.2. Drain off

i. starting air system,ii. pneumatic starting system for water.

3. Lubricate bearings and rod connections for maneuvering gear.4. Staft L.O. pumps for

i. Main engineii. Carnshaftiii. Turbochargersiv. Govemor amplifier, and check pressures

5. Reset Main engine SLOW DOWN / SHUT DOWN controls.6. Check that lubricators for cylinders and rocker arms are filled with oil and that theyrespond to hand pumping.7. Lubricate all cylinders while turning the engine with the turning gear.8. Start Main S.W. and F.W. pumps and check pressures.9. Switch on Electric equipment for maneuvering system.| 0. Start

i. F.O. primary pump.ii. Fuel valve cooling oil pump and check pressures.

I l . Vent a l l fue l va lves12. Set stop piston valve in "SERVICE" position and open air supply to prreumaticstarting system.13. Turn engine very slowly one revolution on starting air with open indicator cocks asa safeguard against darnage from liquid which might have collected in one of thecylinders. Watch if l iquid is emitted from indicator cocks during slow turning.14. Close indicator cocks or valves.15. Inform bridge that engine is ready for starting.

2. HOW WILL YOU PREPARE THE MACHINERY FOR SEA?Deparlure porll. D.O. settl ing and service tanks to be kept full.2. Keep both air bottles fully pressed.3. Try out all 3 generators well in advance.4. H.O. service tank temperature to be brought to normal and tank to be drained offwater.5. Controls to be tested and clock to be synchronised at least 2 Hrs. prior sail ing.6. Main engine to be blown through and tried out both from Engine control room andbridge at least I Hr. before sail ing.7. At least one hour before sail ing, put standby generator on load.8. At standby record following readings.

i. M.E. counter.i i . M.8., and A/E F.O. flow meterii i . Boiler F.O. flow meter

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iv. M.E. Cylinder oil f low meter9. Staft boiler water circulating pump and open steam dumping controller valve inlet.10. Change over calorif ier heating to "STEAM".I l. At full away record following readings

i. M.E" counter.i i . M.E., and A/E F.O. florv meterii i . Boiler F.O. flow meteriv. M.E. Cylinder oil f low meter

12. Open steam to M.E. fuel oil heaters and bring up temperature gradually.13. When the temperature reaches to 85 deg. C. change over Main engine to H.O. andrecord F.O. flow meter reading on change over.14. Bring up M.E. speed gradually to normal.15. Change over sea suction to LOW.

Arrivsl Portl. D.O. settl ing and service tanks to be kept full.2. Keep both air bottles fully pressed.3. Try out all 3 generators well in advance.4. H.O. service tank temperature to be brought to normal and tank to be drained offwater.5. On receiving 2 hrs. notice from bridge,

i. Shut offboth fi'esh water generators and drain offthe heat exchangers.i i. Put standby generator on load.ii i . Change over sea suction to HIGH.

6. At I Hr. notice from bridge,i. Conrmence reducing the F.O. temperature gradually so that F.O. temperature

drops to 85 deg. C within half an hours tirne.i i. At the same time commence reducing M.E. r.p.m. gradually so that the r.p.m. is

brought to maneuvering speed 80 r.p.m. in half an hours time.ii i . Change over to D.O. exactly at half an hours time after receiving 1 Hr. notice

so that the engine is run sufficiently on D.O. before the commencement of maneuvering.Record M.E. fuel oil f low meter on change over.7. At standby record the folloling readings.

i . M.E. counter .i i . M.E., and A/E F.O. flow meteri i i . Boi ler F.O. f low meteriv. M.E. Cylinder oil f low meter

8. Set the cylinder lubricators to Maximum position.9. After f inished with engine is given, carry out the following;

i. Record M.E,. counter, M.E., and A/E F.O. flow meter, Boiler F.O. flow meter.M.E. Cylinder oil f low meter.

i i . Stop boiler water circulating pump and shut off all valves.i i i . Change over calorif ier heating to ELECTRIC.iv. Shut off steam dumping controller inlet valve.v. Open M.E,. indicator cocks.vi. Change over jacket cooling water system to warming up l ine with auxil iary

system.

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3. HOW DO YOU START M.E. FROM MANEUVERING STAND?l. Answer the telegraph and move the regulating handle from STOP to STARTposition. Now the engine rotates on air.2. Then the handle is advanced furlher cutting off adnrittance of starting air andintroducing fuel oil.3. This further movement of the handle is made when the furbocharger tachometershows that the speed is sufficient.4. Experience will show the time required for rotation on starting air for each plant.5. Check that the desired direction of rotation is obtained.

4. HOW DO YOU PREPARE M.E. FOR VOYAGE?l. D.O. settling and service tanks to be kept full.2. Keep both air bottles fully pressed.3. Try out all 3 generators well in advance.4. H.O. service tank temperature to be brought to normal and tank to be drained offwater.5. Disengage turning gear, check that it is locked in 'out' position.6. Crack open

i. Scavenge drains andii. Stuffing box drains.

1. Drain offi. starting air system,ii. pneumatic starting system for water.

8. Lubricate bearings and rod connections for maneuvering gear.9. Start L.O. pumps for

i. Main engineii. Carnshafti i i . Turbochargersiv. Governor amplifier, and check pressures

10. Reset Main engine SLOW DOWN / SHUT DOWN conrrols.I l. Observe sight glasses at

i. Piston cooling oil outleti i . T/C bearing L.O. outleti i i . The thrust bearingiv. the highest point of the chain drive.

12. Check that lubricators for cylinders and rocker arms are fi l led with oil and that theyrespond to hand pumping.13. Lubricate all cylinders while turning the engine with the turning gear.14. Start Main S.W. and F.W. punps and check pressures.15. The temperature of the cooling F.W. outlet from the M.E. shoutd be brought up to60 deg. C.16. Srvitch on Electric equipment for ntaneuvering system.17. Set stop piston valve in "SERVICE" position and open air supply to pneunraticstarting system .18. Stan

i. F.O. primary pump.ii. Fuel valve cooling oil pump and check pressures.

19 . Ven t a l l f ue l va l ves .

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20. Check F.O. viscosity and temperature to M.E. and adjust if necessary.2l . Back wash L.O. fi l ter and F.O. secondary fi l ters.22. Check F.O., L.O., cooling water and F.V. cooling oil supplies and tank levels.23. Check the telephones to the bridge and chiefEngineer's office.24. Controls to be tested and clock to be synclrronised at least 2 Hrs. prior sailing.25. Inform the bridge and turn the engine very slowly one revolution on stafting air withopen indicator cocks.26. Close indicator cocks or valves.2l . M.E . should be tried out both from engine control room and from bridge at least onehour before sail ing.28. At least one hour before sailing, put standby generator on load.29. Inform bridge that engine is ready for starting.

5. HOW DO YOU SHUT DOWN M.E. IN PORT?l. Ensure that

i. the telegraph is at 'Finished with Engines' andii. the fuel lever is at'Stop' position.

2. Close the starting air valves and isolate the control air to the engine.3. Stop F.O. primary pump and shut off steam to

i. F.O. heater andii. Fuel pipe heater tracer l ines.

4. Engage the turning gear and open the indicator cocks.5. Change over

i. Jacket cooling water system to warming up l ine rvith auxil iary system.ii. Main S.W. and main F.W. cooling pumps to auxil iary S.W. and auxil iary F.W.

cooling pumps.6. Open all drain cocks of

i. Scavenge air receiverii. Scavenge spacesii i. Diaphragm glandsiv. Starting air manifold andv. Exhaust sas svstem.By-pass Main L.O. and Main F.W. coolers.Stopi . Main L.O.ii. Canrshaft L.O. andii i. Governor arnplif ier L.O. pumps.

9. Continue L.O. purif ication for at least 12 hrs. after the M.E. has stopped.10. Check consumption of all L.O., F.O., and other consumable (Feed water, J.C.water).I l. Any adjustments needed to improve efficiency must be carried out.12. Clean

i. Scavenge air coolers andii. T/C air f i l ters.

13. At regular intervals M.E. should be turned over by the turning gear, whilst operatingthe cylinder lubricators by hand, with L.O. punlps in operation.

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24. M.E. CONSTRUCTION

I. WHAT IS THE DIFFERENCE BETWEEN 2 STROKE & 4 STROKEENGINES?l. ln a 4 stroke cycle engine, the cycle of events is accomplished in 4 strokes of thepiston travel or in trvo engine revolutions.

i. In a 2 stroke cycle engine, the cycle of events is accomplished in 2 strokes ofthe piston travel or in one engine revolution.2. Particularly at high speeds the exhaust valve of the 2 stroke cycle engine must openrelatively earlier than that ofthe 4 stroke cycle engine, ifreasonable scavenging ofthecylinder is to be obtained. This results in

i. Lower utilisation of the energy in the burned gases.ii. Poor fuel economy.

3. The separate exhaust and intake strokes ofthe 4 stroke cycle provide greateropportunity for the dissipation of heat fi'om critical parts such as the piston andessentially pernrit the 4 stroke cycle engine to run at higher speeds than the 2 strokecycle engine.4. In general the large capacity low speed diesels are predominantly of the 2 strokecycle rype, while the high speed, lower capacity engines tend toward the 4 stroke cycle.

2. WHAT ARE THE ADVANTAGES OF TURBOCHARGING?l. Turbochar_eing is the term used to indicate that the weight of air supplied to theengine has been considerably increased.2. This allows more fuel to be used per stroke with a consequent increase in engineoutput power.3. Turbocharging has had the effect of lowering the specific rveight of diesel enginesLe., more power is obtained per ton of engine weight.

3. WHAT IS THE CONSEQUBNCE OF THE TAPPET CLEARANCE BEINGTOO SMALL AND TOO LARGE?A. Too much clearance causes

l. Late valve opening.2. Early closing.3. Noisy operation.

B. Too litt le clearance causesl. Early opening.2. Late closing.3. May prevent complete closure.

4. HOW DO YOU COMPARE CROSSHEAD AND TRUNK PISTONENGINES?A. Trunk piston engines

l. Requires less head room.2. Their rvorking pafts are fewer.3. Much less costlv to Droduce.

B. Crosshead ensines

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l. The space available for the crosshead bearings is greater than the space withinthe piston for the gudgeon pin bearing assembly.

2. Lower quality fuels may be used in crosshead engines.3. The total cost for lubricants is less with crosshead engines than with trunk

piston engines of equivalemt power.

5. EXPLAIN ADVANTAGES OF UNIFLOW SCAVENGE OVER CROSS-SCAVENGED ENGINE?l. The cross scavenged engine cannot take the advantage ofan increase in thermalefficiency by increasing the stroke / bore ratio.2. Reduces the specific fuel consumption.

6. WHAT IS THE PURPOSE OF PISTON RINGS IN A COMPRESSIONIGNITION ENGINE?I. For sealing the gases above the piston.2. For spreading oil evenly around the circumference of a cylinder.3. For controll ir lg the alnount of lubricating oil passing up or down the cyli lder wall.

7. WHY DO YOU TAKE PISTON RING CLEARANCE?Ifthe ring gap is inadequate;L The ring may break due to a restriction on its free expansion.2. It may scuff the liner due to very heavy wall pressures.3. It may cause a large increase in l iner wear.Ifthe vertical clearance is insufficient;I . It may break or jam in the groove on one side and eventually allow blow past.2. Piston seizure.3. Scavenge fires.

8. WHAT IS A STERN TUBE AND WHAT IS ITS PURPOSE?l. The stern-tube bearings suppofi the overhanging weight ofthe propeller and screwshaft.2. The load on these bearings is transfered on to the stern-tube which is suppofted bythe stern-frame and the internal parts ofthe ship's structure around the aft peak.3. The forrvard end of the stern tube houses the stern gland which prevents sea waterpassing through the stern tube and into ship, and also oil leakage from the stern tubes.4. The stern tube bearings are fitted j ust behind the stern gland neck bush and at the aftend ofstern tube.

9, WHAT IS A THRUST BEARING AND WHAT IS tTS PURPOSE?l. The thrust frorn the propeller is taken up by the main thrust bearing which transmitsthe thrust to the ship's hull and causes the ship to be propelled in the direction ofthethrust.2. Tlre main thrust bearing is always fitted at the main engine crankslraft.3. The thrust bearing is most commonly of the ti l t ing pad type.4. This type of bearing builds up an oilpressure between the white metal face of thethrust pad and the thrust collar when the shaft revolves.

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IO. HOW IS A DIESEL ENGINE BED PLATE SECURED TO THE TANK TOP?The engine bed-plate is secured to the tank top by means ofl. holding down bolts2. side and end chock bolts.The transverse play is absorbed by the side-chock bolts and the fore and aft play by theend-chock bolts.

I1. WHAT ARE THE TIE BOLTS?1 . Bed plate, A-frames, scavenging air box, cooling jackets are tightened together bymeans of t ie bolts.2. Its lower nuts bear against the bed plate cross girders. The upper nuts are tightenedagainst the upper side ofthe coolingjackets by nreans ofhydraulic tools.

I2. EXPLAIN CHAIN TRANSMISSION ARRANGEMENT?A chain transmission is arranged to drive;l. Camshaft for valve actuating gear and fuel pumps.2. Governor3. Starting air distributor4. Cylinder lubricators.

I3. WHY A-FRAMBS ARE PROVIDED?1. To support the cylinder units.2. They are positioned on the upper side ofthe bed plate.3. It carries scavenging air box and coolingjacket.

I4 . DESCRIBE CYLINDER LUBRICATTON OF A DIESEL ENGINE?In cylinder lubrication, the oil is fed through from 8 - 10 smallopenings in the cylinderwall, usually located about the level of the second ring from the top of piston when atB.D.C. This oit is supplied by a small purnp to each line which measures the amount ofoil used (70 TBN oil).

I5 . HOW IS CROSSHEAD AND GUDGEON PIN BEARINGS ARELUBRICATED?L The rnain Iubricating systen supplies oil to crosshead directly by telescopic pipes orsr.vinging l ink connections. Excess oil then passes to

i. Bottom end bearirrss.i i . Guides.i i i . P is ton cool ing.

2. For gudgeon pin bearings, the oil supply is made by way of oil holes in the crankshaft to the bottom end and then through the connecting rod.

I6. WHAT ARE SCAVENGE SYSTEMS?l. Loop scavenge.2. Cross scavenge.3. Uniflow scavenge.

I7. EXPLAIN OIL COOLING AND WATER COOLING OF PISTON.Oi l cool ing

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I' The main lubricating system supplies oil to crosshead directlybytelescopic pipes orswinging I ink connections.2. From the crosshead, it passes through holes bored in the piston rod to the coolingspaces in the piston.3. lt returns via the crosshead to a collector where its flow and temperature aremonitored before it drains to the bottom of the crankcase for re-circulation.WATER COOLINGl. Telescopic glands are used to convey the water directly to and from the piston.2. The sealing glands and stand pipes for these pass through the diaphragm to a casingwhich completely isolates them ffom the crankcase.3. A separate piston cooling water system including pumps and heat exchanger will benecessary.

I7. WHAT ARE THE METHODS OF TURBOCHARGING?l. Pulse system

i. AIlows rapid acceleration2. Constant pressure system.

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25. SHIP GENERAL / BILGE PUMPING

1. WHAT IS THE PURPOSE OF THB BALLAST SYSTEM?1. To provide satisfactory stabil iry conditions.2. To assist in better weight distribution, thereby reducing hull stresses.3. To leduce slip and possible propeller-excited vibration.4. To give better rudder action.5. To give the ship better sea keeping qualities in rough weather.6. To trim the vessel so the depth of water forward is such that the possibility ofpounding damage is reduced to a minimum.

2. WHY PROPULSION OF SHIPS DONE BY LOW SPEED ENGINES?Cavitation, the forming and bursting of vapour filled cavities or bubbles, can occur as aresult ofpressure variations on the back ofa propeller blade. The results are,l. Loss ofthrust.2. Erosion of the blade surface.3. Vibrat ion and noise.

3. WHAT IS A BTLGE INJECTION VALVE? IIOW IS IT USED?l. A bilge injection valve is f itted to the end of a branch line connecting with the mainsea water suction l ine.2. Screw down non-return type.3. This valve enables the large main sea water cooling pump to be used as a bilgepunp in an emergency.

4. WHAT ARE THE PROBLEMS WITH BILGE PUMPING SYSTEMS?I. Choked suct ion st ra iner .2. Leaks in the bilge pipirrg due to internal and external corrosion.3. Seal failure at strainer casins or mud box covers.

WHAT ROUTINE IS NECESSARY FOR EFFICIENT BILGE PUMPING?Regular cleaning of rlud boxes and suction strainers.

6. WHAT IS THE PURPOSE OF THE BILGE SYSTEM?To remove loose rvater fronr machinery, boiler and cargo spaces. Pumps are;1. Bal last pumps,2. Main S.W. pumps,3. F i re and G.S. purnps,4. Bi lge pump.

7. WHAT PRECAUTIONS WILL YOU OBSERVE DURING BALLASTING?L Carefully observe trirn, stabil ity etc.2. Avoid hull damage due to tank pressurisation (D.B. tanks).3. Tank air pipes should be clear.4. Use only minimal amounts of estuary and river water for ballast purposes.5. Ballasting or deballasting operations must be started only after receipt of writteninstructions to the Chief Engineer from the Master.6. Double bottorn tanks must be fi l led up by gravity f low.

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8. HOW DO YOU RECTIFY PROBLEMS WITH BILGE PUMPINGSYSTEMS?l. when loss of vacuum occurs, the main suction valve of the bilge pump should beclosed and the vacuum on the suction side ofthe pump noted.2. If the vacuum registered shows an increase and returns to normal, the pump is inorder.3. It then becomes necessary to find the point of air ingress.PROBLEMSI ' Seal failure at strainer casing or mud box covers: When the covers are removed forcleaning, they must be carefully replaced with a new joint or gasket.2. Leaks in the bilge piping due to intemal or external corrosion

i. To locate the leak, each pipe is then back flooded by filling with water underpressure from the sea.

ii. The leak is rhen repaired with a soft rubber patch and a pipe clip to blank offthe hole and prevent air ingress.

i i i . Choked suction strainer: Regular cleaning of mud boxes and suction strainer.

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26. REFRIGERATION

I. LIST COMMON FAULTS WITH REFRIGERATION.A. Undercharge / Leakage of refi-igerant (CKL)

l. Low evaporation and condenser pressures.2. Lengthy running times.3. Lack offrost on suction pipe.4. Higher level ofsuperheat in the refrigerant vapour leaving the evaporator and

the compressor.5. High and / low pressure cutouts operate.

B. Over chargel. High evaporation and condenser pressures.2. Very sensitive expansion valve working.3. Excess frost on suction pipe.

C. Air in systeml. High discharge ternp. and pressure.2. Incorrect condenser and evaporator temp. differentials.3. Inetticient working /. iumping ofgauge pointers.

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l . High discharge pressure / H.p. cutout.2. Incorrcct condenser temperature differentials.

E. Oi l in cool ing coi lsl. Incorrect condenser and evaporator temp. differentials.2. Excess fi 'ost on suction pipe.

F. Choked expansion valveI. l l igh condenser pressure.2. Low evaporator pressure / L.p. cutout.3. Inefficient working.

G' Moistul 'e in the system: Moisture tends to freeze on the expansion valve causing;l. High condenser pressure.2. Lorv evaporator pressure.3. Excess frost on expansion valve.

2. HOW WILL YOU OVERCOME FAULTS IN REFRIGERATION SYSTEM?A. Undercltarge: The additional refi igerant should be adnritted as a l iquid at a poilt inthe low pressure part ofthe system before the evaporator when the systenr is running,unti l the desired operational conditions are obtained.B. Overcltarge: The excess ref igerant should be discharged into an empty refrigerantbottle.c. Air in the refrigerant: The air wil l tend to accunrulate in the condenser.

1. Stop the machine.2' Isolate the condenser, but maintain the florv of cooling water for I or-2 hours.3. After prolonged cooling. the conderrsed refi ' igerant should be at the sea water

temperatufe.4. If the corlesponding temperature to the pressure gauge reading is higher than

the sea water temperature then air is present.5. open the purge valve on 1he top ofthe condenser to discharse the air.

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D. Moisture in the system: Renew the chemical (activated alumina or sil ica gel) in thedrier and staft the compressor after the ice has melted.E. Leakage of refrigerant: Check all glands and shafts with

l. Soapy water2. Halide torch (Blue flame f fieon --> Green flame): When undercharge is

suspected, a leak test is necessary to confirm and locate the fault.F. Oil in the system

l. Confirm that the required specification for the oil is corect.2^ Check oil separation unit for correct functioning.3. The charge in the system should be pumped into the receiver and the surfaces in

contact with the refrigerant,i. Chemicallydegreased,ii. Flushed and dried with compressed air.4. Before recharging, the system should be purged with refrigerant to remove air

and moisture.C. Partial Blockage at the regulator

l. The fi l ters should be checked to ascertairr anv contamination.2. The regulator valve should bei. isolated,i i. dismantled,i i i . cleaned,iv. reassembled, andv. purged with refrigerant before running.

3. EXPLAIN THE FUNCTION OF THERMO-EXPANSION VALVB.1. To control the quantity of I iquid refrigerant that passes into the evaporator coils.2. To maintain a constant degree of superheat of the gas leaving the coils.

4. GIVE EVAPORATOR AND CONDENSER PRESSURES OF R-I2, AND R-22.

Evaporating temp. at atmospheric press.(deg. C)Absolute evaporator press" at -30 / -15 (deg. C)3 .0Absolute condenser press. at 30 deg. C

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5. HOW WILL YOU START AIR CONDITIONING PLANT?Cooling water circuit1 . Open

i. Cooling water pump suction and discharge valves.i i. Condenser inlet and outlet valves.i i i . Overboard discharge valve.

2. Start cooling water pump and check discharge pressure3. Vent condenser water side.Air circuitl. Check acconrmodation fans are running.2. Change a i r in let f lap to 'CONDITIONED AIR' .Gas c i rcu i tl . Check

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i. Oil level in crank case.ii. Suction valve is closed and discharge valve is open.

2. Ensure all gas circuit valves are open.i. Condenser inlet and outlet valves.i i. Receiver inlet and outlet valves.i i i . Drier inlet and outlet valves.iv. Hot gas discharges to defrosting circuits are closed.

3. Start compressor.4. Slowly open suction valve and check compressor operating conditions.Stoppingl. Close l iquid receiver outlet valve.2. Check operation of compressor low pressure cutout and that will stop compressor.3. Close conpressor suction and discharge valves.4. Change air inlet flap to "Natural supply".

6. WHAT TEMPERATURES WOULD YOU EXPECT TO FIND ANDMAINTAIN IN THE FOLLOWING REFRIGERATED ROOMS?l. Meat, Fish: -20 deg. C2. Vegetable, dairy: 0 deg. C3. Canned goods: +5 deg. C4. Lobby, potato: +4 deg. C

7. WHAT ARE THE ADVANTAGES OF R.22 OVER R-12?R-22I . It is more suitable for a low temperature range than R- 12.2. The pressure on the evaporator side of the system is higher than atmospheric at lowtemperatures, thus reducing the risk of drawing air into the system.3. Evaporating tenperature at atmospheric pressure is lower than that of R- | 2.4. Its performance is better approaching that of ammonia.5. It is not miscible with oil over the full temperature range.6. Ozone depletion potential and global warming potential are lower than that of R-12R-121 . C.O.P. of R- 12 is hisher than that of R-22.

8. WHAT PARAMETERS WILL YOU CHECK FOR REFRIGERATIONSYSTEM?1. The temperature ofthe refrigerated space:-30 / -15 deg. C2. Suction pressure: 3 bar3. Discharge pressure: l2 bar4. Suct ion p ipe ternperature: -10 to-5 deg. C I l .32or3 bar5. Discharge pipe temperature: 90 deg. C / 12 bar6. Liquid l ine temperature: 25 deg. C / 12 bar7. Compressor lunning time: rnoderate9, HOW DO YOU ENSURE THAT THE EXPANSION VALVE IS OPERATINGCORRECTLY?A correctly operating expansion valve wil l have frosting on the outlet side, but not onthe in let s ide.

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27. FIRE PRECAUTIONS

1. WHAT PRECAUTIONS ARE REQUIRED BEFORE ACTIVATING THEFIXED CO2 INSTALLATION?l. All personnel must be evacuated.2. Ventilator fans should be stopped.3. Dampers and skylights closed.4. The main engine should be stopped.5. Quick closing valves operated.6. Pumps stopped and machinery space doors closed.7. The emergency generator should be run to supply essential services.8. The emergency fire pump stafted to provide boundary cooling.9. The isolating valve on the fire main outside the machinery space must be closed.10. Checks should be made on adjacent holds and the accommodation.

2. WHAT EQUTPMENT WrLL yOU FrND tN FrRE LOCKER?l . Protect ivec loth ing.2. Boots and gloves of rubber"3. Rig id helmet .4. An electric safety lamp.5. An axe.6. Self contained compressed air breathing apparatus.7. Fire proof l i fe l ine.8. A smoke helmet or smoke mask with an air pump and an air hose.9. In lcrnat ional shoreconnect ion.

3. WHAT PRECAUTIONS WILL YOU TAKE AGAINST FIRE?l. Prevent oil leakage.2. Remove all combustible materials from vr,rlnerable positions.3. Suitable metal containers should be provided for the storage of cotton waste,cleaning rags etc., after use.

i. Such containers should be emptied at fiequent intervals and the contents safelydisposed off.4. Wood, paint, spirits, and tins of oil should not be kept in machinery spaces.5. All electric rviring should be well nraintained and kept clean and dry.

i. The rated load capacity ofthe wires and fuses should never be exceeded.

4. HOW SHOULD PAINTS, OILS AND CHEMICALS BE STORED ONBOARD SHIP?l. They should be kept in paint lockers or chemical lockers, clean and dry.

i. Strict vigilance,ii. Careful stowage,ii i . Suitable ventilation are necessary.

2. They should not be stowed in close proximity to oil or paints or near to steam pipes.

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5. STATE THE PRINCIPLE OF OPERATION OF PORTABLE FIREEXTTNGUISHERS.1. Water type

i. Cooling of the burning material.ii. Water evaporation and consequent formation of a local atmosphere which

isolates the burning products from the surrounding air.2. Foarn type

i. Fonnation of a foam layer rvhich isolates the burning products from thesurrounding air.3. Powder type

i. Inhibit ion of the combustion.ii. Interrupting the chemical chain reaction.iii. Separation of burning materials frorn the surrounding air.

4 . CO2i. Formation of a local inert atmosphere which isolates the burning materials from

the surrounding air.

5, HOW DO YOU START AND STOP EMERGENCY FIRE PUMP?l . Open

i. One fire hydrant valve on fire line.ii. Emergency fire pump suction and discharge valves.

2. Checki. F.O., L.O., and cooling water supplies and tank levels.i i. Hydraulic oil pressure setting valve for open position.

3. Staningi. Turn the battery stafting switch to "START" position and

engine picks up speed.ii. Throttle the hydraulic oil pressure setting valve to 80 Kg /iii. Check the l-ree flow of water through the fire hydrant.

release once the

Cm2.

STOPPINGl. Open hydraulic oil pressure setting valve fully.2. Gradually press the fuel lever handle downwards3. Close

i. Fire hydrant valve.i i. Ernergency fire pump suction and discharge

6. WHAT ARE THE ADVANTAGES ANDEXTINGUISHERS?A. ll/oter

I. Advantagesi. Readily available.i i. Cood cooling effect.i i i . Smothering action of steam.2. Disadvarttages: It can caase;i. Damage toa. Cargo,b. Machinery, andc. Electrical systems.

ti l l the engine stops.

valves.

DISADVANTAGES OF FIRE

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B.ii. Considerable loss of stabil ity.FountI. Advantagesi. Most suitable medium for extinguishing flamrnable l iquid.ii. lt forms a radiant heat barrier and covers the surface of the burning liquid.2. Disadvantagesi. lt leaves residue.ii. Litt le cooling effect.i i i . Not suitable for electrical f ires.Dry chentical powderI. Atlvontugesi. Most suitable nrediunr for extinguishinga. gaseous,b. chemical,c. electrical, andd. metall ic f iresii. Non toxic and non conductor of electricity.2. Disodvontogesi. Leaves residueii. Negligible cooling effect.co2I. Advanlogesi. Non toxic and non conductor of electricity.i i . Leaves no residue.ii i . It is not subject to deterioration in quality rvith age.2. Disodvantogesi. Highly asphyxiatingii. Litt le cooling effecti i i . Solid particles of CO2 generates static electricityIIalonl. Advuttagesi. Extinguishment of f ire is incredibly rapid.i i. Leaves no residue.2. Disodvantugesi. It is not effective againsta. Deep seated solid material f ires.b. Combustible chemical f ires.i i. Litt le cooling effecti i i . S l ight ly tox iciv. Damage the ozone layer.

7. HOW WILL YOU TRAIN SEAFARERS IN FIRE FIGHTING?l. Location and use of

i. Portable and mobile fire extinguishers.i i. Fixed fire extinguishing appliances.i i i . F i rc man's out f i t .

2. Startingi. Emergency generatorii. Emergency fire pump

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i i i . Emergency bilge pumpOperating appropriate valves fori. providing water for fire fightingii. pumping out bilge.Identifying emergency controls and their functionsi. Quick closing valves.Significance of various alarm signals.Locat ion o l l i fe boat s tat ion

8. HOW FIRES CANCktss

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BE EXTINGUISHED?S u ituble Extittgu islter1. Water - CO22. Soda - acidPrinciple: cooling1. Foam2. Dry powder3. CO2Principle: smothering1. Dry powder2. CO2Principle: Smothering with nonconductive material

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9. WHAT MAINTENANCE IS REQUIRED FOR F.F.A.?l. Discharge, clean, and recharge yearly.2. Weigh gas cartridge and renew if l0 % less.

10. WHAT CHECKS WILL YOU CARRY OUT ON BREATHINGAPPARATUS? (CKL)l. Pressure gauge and capacity ofair supply.

i. Open cylinder valve fully and read offpressure gauge (200 bars).2. High pressure leak test

i. Close cylinder valve and observe pressure gauge.ii. The pressure indicated should not drop more than l0 bar in one minute.

3. Low pressure audible alann (between 35 - 70 bar)i. Open and close cylinder valve.ii. Vent apparatus carefully by switching on the +ve pressure faciliry of demand

valve by hand.iii. Whistle must sound at a pressure appropriate to the cylinder fitted.iv. Deactivate the demand valve by depressing the red button.

4. Face mask air supply and tightness.i. Close cylinder valve, breathe normally unti l the air in the system is exhausted.i i. The mask should pull on to the face.i i i . If i t does nota. Open cylinder valve,b. Adjust head harness,c. Repeat test.

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28. MATBRIALS

I. WHAT MATERIALS ARE USED IN HEAT EXCHANGERS?L Plate type heat exchangers: Titaniurn2. Oil heater tubes: 70/30 cupro-nickel: 70 - copper

30 - nickel3. Lub. oil cooler tubes: Alurninium brass: 76 - copper

22 - zinc2 - aluminium

2. WHAT MATERIALS ARE USED IN HEAT EXCHANGERS?l. Pump casing; Gun metal: 88 - copper

l0 - t in2 - zinc

2. Pump impeller: Aluminium bronze: 80 - copperl0 - a luminium5 - F e5 - Nickel

3. Propeller: Aluminium bronze: 70 - copperl0 - aluminiuml0 - rnanganese5 - F e5 - Nickel

4. Pump shaft: Stainless steel: 18 - chromiuml0 - n ickel3 - molybdenum0. I2 - carbon

5. Pump bearings: Phosphor bronze6. Joints:

i. Compressed asbestosii. Rubber - cotton reinforced - for water

7. 'O' rings: Sil icone8. Valve seats: Stell i te cobalt - chromium allov

3. WHAT ARE BEARING MATERIALS?White metal: 88 - Tirr

8 - antimony4 - copperTrace - cadmium

4. WHAT MATERIALS ARE USED IN1. Cylinder Iiner: Perlit ic cast iron2. Cylinder cover: Heat resistant cast steel3. Pis ton:

i. Upper part - heat resistant cast steeli i. Lower part - Perlit ic cast iron

DIESEL ENGINES?

(0.25 % Carbon)

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4. Piston rings: Nickel chromium cast iron5. Bed plates, A-frames, scavenge box: Plates (0.23 % carbon)6. Crank shaft, Cam shaft: Fine grain Cr-Mo-Va steel forging (0.3 - 0.5 %o carbon)

5. WHAT MATERIALS ARE USED IN VALVES?1. Monel metal - 70 - nickel

30 - copper + Fe, Mn2. Diaphragm for pneumatically controlled valve: Neoprene

6. WHAT ARE TRI-METALLTC BEARINGS?A/E con. rod big end bearingsLead - t in - ' 7 5 %Tin - aluminium - 20 YoNickel - 5 Y o

EXPLAIN DIESEL ENGINE CRANK SHAFT MATERIAL?Plain carbon steels (0.2 - 0.4 % carbon) of cast throw, semi built construction.Typesi. Fully built,i i . Senribui l t ,i i i. One piece forged.

8. EXPLAIN THE EFFECT OF CARBON CONTENT IN IRON.0 - 0.3 - Mild steel0.3 - 0.5 - Medium carbon steel0 .87 -100%pear l i t e

0.5 - 1.7 - High carbon steel1.1 - 4.2 - Cast i rons

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29. ADVANCED BOILERS

I. EXPLAIN PROCEDURE FOR BLOWING THROUGH A BOILER GAUGEGLASS.A. To test a hollow colunrn water gauge installation thoroughly,

l. First prove the bottom connections are in order byi. closing terminal and gauge glass steam cocks andii. leaving terminal and gauge glass water cocks and drain pipe open.If water blows freely out of the drain, the bottom connections are in order.2. Then prove the top connections are in order byi. closing terminal and gauge glass water cocks andii. leaving terminal and gauge glass steam cocks and drain pipe open

If steam blows freely out of the drain, the top connections are in orderB. In the event of either end not blorving freely, a blowing procedure referred to as cross-blowing is adopted.

l . wi thi. Terminal stearn cock andii. Gauge glass water cock closed,2. openi. Terminal water cock,ii. Gauge glass steam cock and drainto check that the terminal water cock connection to the boiler is clear (then these cocks

and passages to the boiler is clear).3. Witlri. Tenninal water cock andii. Gauge glass steam cock closed,4. openi. Terrninal steam cock,i i. Gauge glass water cock and drainto check that the terminal steam cock connection to the boiler is clear (then these cocks

and passages to the boiler is clear).

2. WHY IS IT NECESSARY TO KEEP OXYGEN OUT OF THE BOILER?l. Dissolved oxygen can cause serious pitt ing of the metal surface.2. For corrosion to take place, oxygen ntr.rst be present to accomplish the forntation ofmetal oxides. hence de-aeration of the feed water is essential.

3 . WHAT IS pH?l. pH: Logarithm ofthe reciprocal ofthe hydrogen ion concentration in the solution.2. The pH value increases as the hydrogen ion concentration decreases.3. By maintaining the pH value of the boiler between | 0.5 to I 1.0, corrosion is kept to arninimum.4. The pH value of the feed water should be between 8.5 - 9.2.5. If the pH is too high, it can lead to,

i. Foaming in the steam drum.ii. Possibil i ty of caustic attack upon the boiler metal.i i i . pH - logl0( | / [H+] ) ; H+, the concentration of hydrogen ions in grams per l i ter.

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4. WHAT IS YOUR ACTION IF OIL ENTERS A STEAMING BOILER?l. Immediately reduce the boiler load as much as possible.2. The boiler should be scummed frequently.3. Increase the chemical dosage rate to keep the alkalinity and phosphate reserves neartheir recomnrended maximum levels.4. The alkali acts as a detergent causing the oil to form an emulsion.5. The phosphate and sludge conditioners then serve to keep these emulsified particlessuspended in the water.6. Ifavailable additional sludge conditioners should be added, especially those to reducefoaming.7 . Bottom blow down at intervals of l5 seconds to remove the oily sludge formed by thechemical treatment.8. Trace the source of oil contamination and rectify immediately.9. If the contamination is heavy, shut the boiler down and subject it to an alkali boil out.

5. WHAT DOES ALKALINITY TEST INDICATE?l. Because of the diff iculty of measuring the pH value accurately it is normal practice touse aphenolphthalein testwhich measures the amounts of hydroxides and carbonates in thesample.2. If the alkalinity level is too low then corosion can occur.3. If the alkalinity level is too high, it can lead to foaming in the steam drum.4. If the alkalinity is due to hydroxides, the resulting caustic alkalinity can lead to causticattack.

6. WHAT DOES CHLORIDE TEST INDICATE?1. This is to measure the amount of chloride in the sample.2. Under normal boiler conditions these remain in solution and are not affected by thetreatment chemicals.3. If the chloride level is too high it indicates

i. Condenser leakage into steam space.ii. Undue amounts of dissolved salts are present in the boiler water.i i i . Possibil i ty of foaming and deposits.

7. WHAT DOES HARDNESS TEST INDICATE?l. This is to measure the amount of hardness salts in the sanple.2. If the hardness level is too high, it indicates

i. Contamination.i i. Phosphate reserve being too lorv.i i i . Possibil i ty of scale formation.

8. WHAT DOES SODIUM SULPHITE OR HYDRAZINE TEST INDICATE?L To ensure that an adequate reserve of the chemical is being maintained.2. If the sulphite or hydrazine reserve is too low.

i. then corrosion can occur.3. If the sulphite reserve is too high,

i. It increases tlre dissolved solids content.4. If the hydrazine reserve is too high,

i. An excessive amount of ammonia can be formed which nray lead to attack uponcopper alloys in the feed systent.

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5. Hydrazine is normally used for boilers working at pressure above 32 Kg/Cm2.

9. WHAT DOES TOTAL DISSOLVED SOLIDS TEST INDICATE?l. This is to measure the amount of all the dissolved solids in the water includine thetreatment chemicals.2. lf the total dissolved solids is too high,

i. it can lead to foamins and deposits.

10. WHAT DOES PHOSPHATE TEST INDICATE?l. This is to measure the amount of phosphate in the sample.2. Phosphate reserve should be maintained in the boiler water ready to neutralise anyhardness salts which may enter.3. If the phosphate reserve is too low, it allows possibil i ty of

i. Scale formation,ii. Excessive amounts of hydroxide forming in the boiler water.

4. Ifthe phosphate reserve is too high, it can lead toi. Foaming in the steam drum.ii. Undue amounts of sludge deposits on the heating surfaces.

I I . DESCRIBE HOW WOULD YOU MAKE ALKALINITY TEST.l. Take 100 ml sample of Boiler water.2. Add I n l (10 drops) of phenolphthale in.

i. If the sarrple has a pH value greater than 8.4 it will turn PINK.3. Add 0.02 N sulphuric acid unti l the pink colour just disappears.4. I mlof 0.02 N sulphur ic ac id wi l lprec ip i ta te l0 ppm of CaCO3.5" Thus ml of 0.02 N sulphur ic ac id used X l0:

Alkalinity to phenolphthalein in terms of ppm CaCO3 : 150 - 300

I2. EXPLAIN THB THEORY BEHIND THE ALKALINITY TEST.1. Phenolphthalein is less alkaline than hydroxides or carbonates.2. When phenolphthalein is added to a sample containing hydroxides and or carbonates, i lwil l turn pink in colour.3. The acid used after this colouration wil l f irst neutralise tlre hydroxides, forming salts.4. lt wil l then react with the carbonate molecules present fbrming bicarbonate molecules.5. Bicarbonate molecules are less alkaline than phenolphthalein.6. Hence pink colouration wil l disappear once all the hydroxides and carbonates havebeen dealt by the acid.

EXPLAIN METHYL ORANGE TEST FOR TOTAL ALKALINITY.Take alkalinity to phenolphthalein sample.Add I ml of methyl orange.i. If i t turns yellow, it indicates the presence of bicarbonates.i i. If the sample irrtmediately turns pink it indicates no bicarbonates are present.Add 0.02 N sulphuric acid unti l pink.I mlof 0.02 N sulphur ic ac id wi l lprec ip i ta te l0 ppm of CaCO3.Total ml of 0.02 N sulphuric used in both the phenolphthalein and methyl orange tests

X l0: Tota l a lka l in i ty in terms of ppm CaCO3 :200 - 300.

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14. EXPLAIN THE THEORY BEHIND METHYL ORANGE TEST.l. Bicarbonates do not show up in the phenolphthalein test as they have a pH value lessthan 8.4 and so do not cause phenolphthalein to turn pink.2. If no bicarbonates are present, the alkalinity as deterrnined in the alkalinity tophenolphthalein test has been due to hydroxides alone.

I5. EXPLAIN BARIUM CHLORIDE TEST FOR CAUSTIC ALKALINITY.I . Take 100 ml sample of boiler water.2. Add l0 ml of barium chloride.3. Add I ml of phenolphthalein, result pink colouration.4. Add 0.02 N sulphuric acid unti l the pink colour just disappears.5. I mlof 0.02 N sulphuric acid wil lprecipitate l0 ppm of CaCO3.6. Thus ml of 0.02 N sulphuric acid used X l0:

Caustic alkalinity in terms of ppm CaCO3 : 'l

5 - 200

16. EXPLAIN THEORY BEHIND BARIUM C}ILORIDE TEST.l. Barium chloride wil l precipitate all the carbonates which are present.2" Thus any pink colouration taking place when I ml of phenolphthalein indicator is addedto the solution is due to hydroxides (caustic) only.

r7. EXPLAIN CHLORIDE TEST (STLVER NTTRATE TEST).A. In boiler water where sulphite is absent

L Take alkalinity to phenolphthalein sample.2. Add 2 mlof su lphur ic ac id.3. Add 2 ml of potassium chromate indicator.i. Result Yellorv colouration if chlorides are present.4. Add 0.02 N silver nitrate solution until a brown colouration results.5. I ml of 0.02 N silver nitrate wil l precipitate l0 ppm of CaCO36. Thus ml of 0.02 N silver nitrate solution used X l0 : ppm of CaCO3 : 150 - 300.

B. ln boiler water where sulphite is present and if the sample from the phenolphthalein testis not available

L Take 100 ml sample of boiler water.2. Add I gm of potassium persulphate and stir well unti l dissolved.3. Add I ml of phenolphthalein, result pink colouration.4. Add 0.02 N sulphuric acid unti l the pink colour just disappears.5. Follow steps 2, 3, 4, 5 as above in A.

I8. EXPLAIN THE THEORY BEHIND CHLORIDE TEST.l. The alkalinity to phenolphthalein sanrple taken has had the hydroxides and carbonatesdealt with and they wil l play no further part in the test now conducted for chlorides.2. The sample is made now slightly acidic to speed up the chemical reactions which are totake place.3. Silver nitrate has an affinity for potassium chromate and chlorides, its principalpreference however is for the chlorides.4. When it has neutralised the chlorides present in the sample, it is then free to react withthe potassium chromate, in doing so, it produces a reddish brown colouration.5. It is therefore apparent that the amount ofsilver nitrate solution used is a direct nleasureof the chloride content of the boiler water samDle.

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19. EXPLAIN E.D.T.A. TEST FOR HARDNESS.1 . Take 100 ml of filtered boiler water sample.2. Add 2 ml of Ammonia buffer solution.3. Add I ml Mordant Black 1 I solution and stir rvell until dissolved.

i. l fhardness salts are present, the solution turns wine red.4. Titrate with E.D.T.A. solution until the colour changes to purple and then blue.5. I ml of 0.02 N E.D.T.A. solution wil l precipitate 10 ppm of CaCO3.6. Thus nr lof 0.02 N E.D.T.A. so lut ion used X l0:

Hardness in terms of ppm CaCO3. :5

Note: E.D.T.A. : Ethl'\sr. Diamine Tetra Acetic Acid

20. EXPLAIN POTASSIUM IODIDE.IODATE TEST FOR SULPHITE?l . Take I 00 ml of boiler water sample.2. Add 2 ml of sulphuric acid.3. Add I mlof starch solution.4. Add potassium iodide-iodate solution unti l sample is blue in colour.5. Mlof iod ide- iodate solut ion used X 12.5 : ppm of Na2SO3 :50 - 100.

2I . EXPLAIN THE THEORY BEHIND SULPHITE TEST.l. The boiler water sample is made slightly acidic to speed up the chemical reactionswhich are to take place.2. Potassium iodide-iodate produces a blue colouration through reaction with starch. Butits principal preference however is for sulphite if it is present in the sample.3. Hence when the potassiurn iodide-iodate solution has dealt with all the sulphite present,it is then fi'ee to react with the starch present in the sample, producing a blue colouration.4. lt is therefore apparent that the amount of potassium iodide-iodate solution used is adirect measure of the sulphite content of the boiler water sample.Note:In high pressure boilers, the sulphite can break down to give hydrogen sulphide andpossibly sulphur dioxide which can attack steel.

22. EXPLAIN TOTAL DISSOLVED SOLIDS TEST?Electrical conductivity meter test;l. Take 250 ml sample of boiler water at 20 deg. C.2. Add 4 drops of phenolphthalein indicator.3. Add Acetic acid unti l the pink colour just disappears.4. Use this neutralised sample to wash out and fi l l the conductivity cell.5. A range switch is set to approximate range of reading expected.6. A central control is operated unti l NULL balance of the electrical circuit is achieved.1. Position of the central control indicates either directly interms of ppm of dissolvedsolids or as electrical conductivity.8. Conduct iv i ty in Micro s iemen I mX 70: d issolved sol ids in ppm : 500 - 1000 ppm.

Note:l. When the water is alkaline or contains hydrazine, it causes different levels ofconductivity to be produced as compared to those of the usual solids thus leading toinaccurate results. The sample should therefore be neutralised.2. Max. dissolved solids cottductivity at 25 deg. C. :2250 misro siemen / nr

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23. EXPLAIN VANADO-MOLYBDATE TEST FOR PHOSPHATE?l. Take 25 ml of filtered boiler water sample.2. Add 25 ml vanado-molybdate reagent.3. Fill comparator tube with this solution and place it in right hand compartment of thecomparator.4. In left hand compartment place a blank prepared by mixing equal volumes of vanado-molybdate reagent and de-ionised water.5. Allow colour to develop for at least 3 minutes.6. Match sarnple against disc colours.7 . Phosphate reserve in ppm (mg/l) from the disc reading: 30 - 70 ppm PO4.

24. EXPLAIN 4-DIMETHYL AMINO BENZALDEHYDE TEST.In presence of hydrazine this regent produces a YELLOW colour. The intensity of thecolour depending upon the amount of hydrazine present in the sample.l. Take 250 ml of boiler water sample, exclude air and cool to about 25 deg. C.2. Add l5 ml of 0.5 N hydrochloric acid to each of 2 Nessler cylinders.3. Add25 ml of boiler water sample and l0 ml of 4-dimethyl amino benzaldehyde to onecylinder.--( 1)4. Add 35 ml of boiler water sample to other cylinder.---(2)5. Place sample (l) in right hand compartment of the nessleriser.6. Place sample (2) in left hand comparlntent of the nessleriser.7. Match samples against disc colours.8. Disc reading / 25 : ppm hydrazine : 0.1 to 0,25Note:l. Great care must be taken to avoid the sample coming into contact with the air duringthe test, otherwise any hydrazine in the sample can react with oxygen.2. The hydrazine reserve in the boiler water should be between 0.1 to 0.3 ppm.

2s. EXPLAIN pH TEST BY COLOURIMETRIC METHOD.l. Take 100 ml sarnple of boiler water.2. Place 0.2 ml or I thymol blue tablet in a glass stoppered 50 ml Nessler cylinder.3. Add 50 ml of sample into the Nessler cylinder and ensure tablet is dissolved.---(l)4. Put 50 ml of sample into the other Nessler cylinder.---(2)5. Place sample ( l) in right hand compartment of the Nessleriser.6. Place sample (2) in left hand compartment of the Nessleriser.7. Match samples against disc colours.8. Read pH of the nearest matching colour.Note:l. Great care must be taken to avoid the sample coming into contact with the air duringthe test otherwise some of tlre carbonates may form bicarbonates so changing the alkalinitylevel of the sample.2. The nessler cylinder without the colour indicator is placed beneath the disc in-order tooffset the effect ofany discolouration of the boiler water itselfupon the observed result.

26. HOW DO YOU DETECT CONDENSER LBAKAGE?l. Increase in salinonreter reading.2. Various changes in the results of the routine tests carried out on samples of feed andboiler water.3. Rise of water level in the reserve feed tank.Actiott:

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1. lf the chloride level in the boiler water cannot be controlled, inform the bridge and shutdown.2. A temporary repair to any leaking tubes can be made by driving brass plug into the tubeends.

27. WHAT IS YOUR ACTION IF CHLORIDE LEVEL IS VERY HIGH?1. If the chloride test shows sudden increase in chloride level then,

i. Increase the boiler blowdown frequency until the chloride levels are below theadvised maximum.2. lf the chloride level is well above the advised maximum,

i. The quantify and the frequency of blowdown must be increased to bring the levelbelow the advised maximum.3. lf the chloride level is excessive, for example 3 times the maximum advised figure,then,

i. Either the boiler be shut down or at the very least,ii. The steam offtake from the affected boiler minimesed whilst keeping its pressure

normal, thereby lessening the possibil i ty ofexcessive carry over.4. Trace the source of contamination and rectif l i immediatelv.

28. WHAT IS PPM?I PPM : I gm dissolved solids i l 000 000 gm pure water: mg / Liter of pure water

29. WHY DO YOU ADD PHOSPHATES?I . Phosphates react with the sulphates of calcium and magnesium, precipitating them astheir corresponding phosphates, which can be blown out ofthe boiler before any scaleforms. or2. Converting them to highly soluble sodium salts which remain in solution.3. The imponant types are

i. Di-sodium phosphateii. Tri-sodium plrosphate

30. WHAT WILL HAPPEN IF EITHER OF THE STEAM OR WATER COCKSARE CHOKED IN GAUGE GLASS? (UK)Then water wil l gradually f i l l the gauge glass due to the steam above the water condensing.

31. WHAT IS THE POSITION OF COCKS? (CKL, WFL)l. When any gauge glass fitt ing is in operation the cock handles should be vertical.2. If they were arranged horizontally and the gauge is in operation, vibration effects maycause the cock handle to gradually tend to take up a vertical position thereby

i. closing the cock, in the case ofsteam and water cocks, andii. opening, in the case of the drain.

EXPLAIN BOILER WATER TREATMENT. (CKL, WFL)A standard boiler compound consists ofi. Sodium carbonate,i i. Di-sodiurn phosphate andii i. Starch, or a sludge conditioner in the proportions of 3,4, and I by mass

respectively.2. The sodium carbonate is used

i. to provide alkalinity and

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ii. to deal effectively with any magnesium chloride.3. The phosphate is used to precipitate any hardness salts like calcium sulphate.

i. ln presence of caustic alkalinity the disodium phosphate combines with excesssodium hydroxide to form tri-sodium phosphate thus preventing undue levels ofcausticalkaliniry forming in the boiler water.

ii. Sodium sulphate may be added to reduce the risk of caustic cracking.

33. EXPLAIN THE TYPES OF CORROSION IN BOILERS. (WFL)Types arel. Pitt ing corrosion.2. Corrosion fatigue.3. Electrochemical corrosiou.4. Galvanic action.5. Caustic cracking or caustic ernbrittlement.

Pitting corrosion:l. Pitting corosion is caused when there is relatively a large cathodic area and a smallanodic area, due to corrosion deposits.2. If the deposit is then disturbed, further corrosion will take place at that point resultingin pitting and eventually in tube failure.3. This is often found in the boiler shell in wav of the water level.

34. EXPLAIN CORROSION FATIGUE.l. Corrosion fatigue wil l be found when a metal in a corrosion medium is subjected tofluctuating or alternating stresses.2. It is often found as a series of fine cracks in the wall.

35. WHAT IS ELECTROC}TEMICAL CORROSION?l. When iron is in contact with water which contains hydrogen ions, corrosion may result.2. The hydrogen ions in contact with the metal surface become hydrogen atoms by takingan electron from the metal.3. The resultant metal ion cornbines with hydroxyl ions in contact with the metal surfaceand so form a metall ic hydroxide, which is soluble in water, hence the metal is corroded.4. So the boiler water should be

i. alkaline with,i i. very l itt le or no dissolved oxygen content.

36. EXPLAIN GALVANIC ACTION.l. When 2 dissimilar metals are present in a saline solution, galvanic action may occur,resulting in the corrosion of the more base metal (zinc, iron).2. Corrosion of nonferrous metals in steam and condensate systems may result in depositsofcopper on boiler tube surfaces which due to galvanic action can lead to boiler corrosion.

37. WHAT IS CAUSTIC CRACKING OR CAUSTIC EMBRITTLEMENT?l. This is a fornt of inter crystall ine cracking caused by water with high level of causticalkalinity coming into contact with steel which has not been stress relieved.2. It is often found in way of

i. leaking riveted joints orii. bolted fittings.

3. So ensure an adequate reserve ofsodium sulphate or sodium nitrate.

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38. HOW DO YOU FILL A BOILER FROM EMPTY?Prior to filling the boiler a thorough examination should be made both internally andexternally.Internally:L Make sure no tools and rags are left in the boiler.2. Internal surfaces should be secure and free from scale and oil.Extemally:1. All refractory should be in good order.2. All valves and cocks should be in good operable condition.3. Manhole and handhole door joints should be in good condition and properly tightened4 . Superheat control valves should be correctly set to ensure that all initially generatedsteam flows through the superheaters.5. Then close,

i. Main and auxiliary steam stop valves.i i. Gauge glass drain cocks.i i i . Feed controller and level alarms cutout isolatins valves.iv. Running down and blowdown valves.

6. Then open,i" Steam drum and superheater air vents.i i. superheater drain valves.i i i . Water level gauge glass isolating valves and cocks.iv. Pressure gauge isolating valve.v. Feed check valves.

7. The boiler can then be fi l led with disti l led de-aerated water to a level in between thelowest and normal water level.

39. HOW DO YOU FLASH UP A BOILER?L Check the f'uel oil system.

i. Start fuel oil service pump and check for leaks.ii. Heat the fuel oil to the required temperature.

2. Star-t the forced draught fan and purge the boiler.3. Carry out a final check to make sure,

i. Gauge glass isolating valves and cocks are open.ii. Water is showing in the gauge glass, and,iii. that steam drum and superheater air vents are open.

4. Flash up the burner by means of ignition equipment.5. Use the lowest possible fir ing rate.

i. Adjust the air supply so as to obtain the best combustion conditions and,ii. Check that as the boiler heats up, the water level in the gauge glass begins to rise.

40. HOW DO YOU RAISE STEAM IN BOILER?l. After about one hour, steam should show at the steam drum and superheater air ventsand, when issuing strongly,

i. Open the superheater circulating valve andii. Close the air vents.

2. When the steam pressure has reached a value of about 3 KglCm2, blow through thewater level gauges to ensure they are working correctly.

i. The feed controller and level alarms cut out isolating valves can now be openedand

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ii. the feed controller placed in service.3. At a pressure of about 14 KglCm2,

i. Open the auxiliary steam line drains, crack open the auxiliary steam stop valve andwarm through the auxiliary stearn line.

i i. Then close the drains and fully open the auxil iary steam stop valve.4. Various auxiliary equipment such as fuel oil heaters, turbo feed pumps, etc. can now beput into service.5" Ensure a florv ofsteam through the superheater and,

i. close the superheater circulating and drain valves.6. Bring the boiler up to rvorking pressure, keeping the firing rate as steady as possible.7. Adjust the safety valves to their conect blow offpressures, and test

i. The water level alarms andii. Remote operated fuel oil cut off gear.

8. Open the main steam line drains, crack open the rnain steam stop valve and wannthrough the main steam line.

i. Then close the drains and fully open the main steam stop valve.9. The procedure from flashing up to coupling up at full rvorking pressure should takeabou t4 -6hou rs .

4I. WHAT IS YOUR ACTION IF THERE IS LOW WATER LEVEL?l. After blowing through the gauge glass, when water cock has been opened. the waterflows to the top of the gauge glass, and when the steam cock is opened, the water flowsdown and out ofthe gauge glass.2. Then the water level is between the water cock connection to the boiler and the bottomofthe gauge glass.Action;L Reduce

i. Boiler load andii. rate of f ir ing.

2. lncrease the feed supply and ifnecessary puti. Standby feed pump andii. Auxil iary feed check into operation.

If level not known, checkl. The other gauge glass if provided.2. Boiler drum remote level indicator.

42. WHAT IS YOUR ACTION IF THERE IS TOO LOW WATER LEVEL?l. After blowing through the gauge glass, when water cock is opened and water does notflow up the gauge glass.2. Then the water level is below the water cock connection to the boiler.Action;I . Take the boiler out of operation.2. Shut offthe fuel and

i. close the steam stop valve.3. If it is suspected that overheating has occurred,

i. Operate the easing gear on the safety valves to release the boiler pressure.4. When the boiler has cooled dorvn it should be examined and,

i. Only retumed to service when considered to be in a safe condition.

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30. ELECTRTCAL (ADVANCED)

I. WHAT IS SINGLE PHASING IN 3 PHASE MOTORS?l. Single phasing is the term used to denote the condition arising in a 3-phase circuit,when one phase becomes open circuited.2. The open circuit in a phase will prevent a motor from starting but a running motormay continue to operate rvith the fault.Csuses:1. Blowing of one of the 3 fuses protecting the circuit.2. Faulfy contactor or broken wire.Detection:1. By overload protective devices in the supply lines (over current relay. OCR).2. Overheating, humming sound.Results:l. A motor ruming with a single phase fault will carry excess current in the remainingsupply cables.2. Motor windings wil l have unequal distribution of current.3. Overheating rvil l cause burnout of the overloaded coil.Prevention:l. By use of filled cartridge fuses and not re-wirable fuses.2, By setting the overload protective devices fairly low.3. Placing thermisters in windings to nreasure the thermal effects.Action:l. Immediately change over the running purnp.2. The cause of the fault must be located and repaired.3. In the event of a fuse blowing,i. Replace all 3 fuses in a 3 phase supply even if only one is found blown after afault.ii. The replacernent fuse link rnust be ofthe correct current rating, grade and type.4. The insulation resistance of the motor should then be checked.

2. HOW DO YOU RESTORE THE INSULATION RESISTANCE OF AMOTOR?1. Restoring the insulation value of the stator winding to a high value is achieved in 3stages.i . Cleaning.i i. Drying.i i i . Re-varnishing.2. Salt contamination can be removed by washing with clean fresh water.3. Any grease or oil in the windings has to be removed using a detergent liquid such asArmaclean.4. Dry the stator windings with low power electric heaters or lamps with plenty ofventilation to allow the danrpness to escape.5. With the windings clean and dry and if the insulation resistance (IR) remains highover a few hours, apply a couple ofcoats ofgood quality air-drying insulating varnish.

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3. WHAT IS THE MOST COMMON CAUSE OF INDUCTION MOTORFATLURE?Failure of stator insulation due tol. Dampness.2. Contamination by oil and grease from motor bearings.

4. WHAT PROTECTIVE DEVICES ARE PROVIDED FOR MOTOR?l. Short circuit protection, by fuses.2. Overload protection, byi. Bi-metallic thennal overload relays.ii. Magnetic overload relays.i i i . Built in protective devices, I ike thermistors.iv. Electronic motor orotection relavs.

5. WHAT ARE THE DIFFERENT WAYS OF STARTING A/C MOTORS?l. Direct online starting.2. Star-delta stafter.3. Auto transformer starter.4. Electronic starters.

HOW IS THE MOTOR DIRECTION REVERSED.Simply by interchanging any 2 supply line connections at the stator terminal box.This reverses the direction of the rotating magnetic field.

7. WHAT IS YOUR ACTION IF THE VOLTAGE IS VERY LOW?l. An A.V.R. rvil l control the generator's voltage to + or - 2.5 % of its set value overthe load range. This is its steady state voltage regulation.2. The A.V.R. senses the generator output voltage and acts to alter the field current tomaintain the voltage at its set value.3. A hand 'trimmer' regulator fitted on the generator control panel provides the setvoltage level.Note:1. The governor settings ofthe generators are adjusted to achieve kW load sharing.2. The excitation is adjusted to achieve kVAr load sharing. This is achievedautomatically by the A.V.R. unit.

8 . WHY DO YOU SWITCH OFF SYNCHROSCOPE?The synchroscope should not be left in circuit for more than 20 min. as it is notcontinuously rated.

9. HOW DO YOU SYNCHRONISE GENERATOR IF THE SYNCHROSCOPEGOES OUT OF ORDER?l. The SEQUENCE, nethod is preferred as it displays a rotation of lamp brightnesswhich indicates whether the inconring machine is running too fast (clockwise) or tooslow (anti clockwise).2. As with the synchroscope, the lamp sequence must appear to rotate slowly

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3. The moment to synchronise is when the key lamp at the top of the triangle is darkand the other two lamps are equally bright.4. Switch off the lamps irnrnediately after synchronisation.

10. EXPLAIN PREFERENCE TRIPPING. (110 7o of normal full load)l. lfa generator overload develops, the preference trip relay sets an alarm and acts totrip selected nonessential loads. Time interval : 5 sec.2. This reduces the generator load so that it may continue to supply essential feeders.

l l. EXPLAIN UNDER VOLTAGE PROTECTION. (70 7o or below)l. Its main function is to trip the breaker when a severe voltage dip occurs (around 50%).2. It also prevents the circuit breaker from being closed when the generator voltage isvery low or absent.3. The under voltage relay also provides back-up protection to short circuit protection.

12. EXPLAIN REVERSE POWER PROTECTION. (10 o OF FULL POWER -

LOSS)l. A reverse power relay monitors the direction of power flowing between thegenerator and the switchboard (bus bars).2. If a prime mover failure occurs, the generator would act as a motor. The reversepower relay detects this fault and acts to trip the generator circuit breaker.

13. HOW DO YOU DETECT EARTH FAULT?l. The earth fault indicators can be either

a set of lamps oran instrument calibrated in kOhm to show the system insulation resistance value

to earth on the 440 Y and220 V sections.2. Each lamp is connected between one phase and the common neutral point.3. Closing of the test switch connects the neutral point to earth.4. If the system is healthy, then the lamps wil l glow with equal brightness.

lf an earth fault occurs on one line. the lamo connected in that line show a dulllight or extinguished and the other lamps will glow brighter.

EARTH FAULTl. Tracing the earth fault must be coordinated with the operational requirements of theship 's e lect r ica l serv ices.2. Open the circuit breakers feeding loads A, B, C etc. one at a time and by watchingthe earth fhult indicator, note which circuit breaker, when tripped, clears the earth fault.The earth fault must then be on that particular circuit.3. The rnethod of tracing the fault is continually breaking down the circuit into smallerparts containing the earth fault until it is finally located.4. Where there is no earth fault indicator, an insulation resistance tester must be used.5. Causes are,

Dampness in insulation.Damaged insulation.Surface dirt.Single phasing

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I5. WHY DO YOU TEST INSULATION RESISTANCE OF MOTORS?1. A measurement of the insulation resistance gives one of the best guides to the stateof health of electrical equipment.2. The resistance should be measured between

3. The test voltage is 500 V D/C. (I:0.0005 Amp)4. The test voltage is produced either byi. an internal hand driven senerator orl l . by abattery and electronic voltage changer.

I6. HOW DO YOU TEST INSULATION RESISTANCE?l. Prove the correct operation of the instrument.

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Phase to phase andPhase to earth.

Switch the instrument to 'Mega C)'Short the probes together.

i i i . Press the test button or turn the handle ( 160 revs/min.)iv.

' l 'he pointer should indicate '0 f) ' resistance.2. Isolate and lock off the equipment to be tested.

Disconnect the supply leads and remove the links between the terminals whichare used to star or delta connect the motor.3. Prove the equipment to be dead.i. Switch the instrument to 'Mega f) 'i i . Connect the probes to pairs of equipment tenninals (U1-U2, Vl-V2, Wl-W2).

Do not press the button or turn the handle.lf the pointer deflects, the circuit is alive.

4. Measure the phase to phase insulation resistance values. Uz-V l, V2-W1, W2-Ul5. Confirm that a reliable earth connection is obtained by connecting the probes to 2separate earth points on the equipment frame while testing for continuity.6. Measure the phase (+ve pole) to earth insulation resistance values. Ul-E, Vl - E,w l -E7. If the insulation resistance is verv low. it must be restored aeain.

I7. HOW DO YOU TEST CONTINUITY BY MEGGER?l. Switch the instrument to 'f) ' or 'continuity'.

2. Connect the probes to the circuit. Ul-U2, Vl-V2, Wl-W23. All readings should be identical.4. lf one reading is significantly lowerthan the others, this could indicate thepossibil i ty of short circuited turns in the winding being measured.5. A high continuity resistance value indicates a high resistance fault or an opencircuit.6. Check the indication on the 'C2' scale (0.3 - 0.4 Q).

I8. DRAW THE WIRING OF MOTOR PHASES FOR CLOCKWISE AND ANTICLOCKWISE ROTATION.

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I9. WHAT MAINTENANCE DO YOU CARRY OUT ON BATTERIES?Battery maintenance includes,l. Keepingi. the cell tops clean and dry.ii. the cell connections clean and tight.2. Applying a smear of petroleum jelly to all cable terminals to prevent corrosion.3. Keeping the gas vents in the cell plugs free from blockage by dirt.4. Use only pure distilled lvater fbr topping up to the correct level above the plates.5. Specific gravity should be checked using syringe type Hydrometer.

6. A fully charged lead acid battery will have a specific gravity of 1.21 to 1.28 at 15deg. C. and this wil l fall to something in the region of I . l l0 when it is fully discharged.7. Voltages

Fully chargedLead acid 2.0 VLead alkaline 1.2 V

8. Sp. GravityFully charged

Lead acid 1.28Lead a lkal ine 1.19

Fully discharged1 . 7 3 Vl . 1 4 v

Fully dischargedL l l1 . 1 4 5

20. WHAT ARE THE RESULTS OF INSULATION FAILURE?Insulation failure usually result in1. An earth fault.2. Short - circuited turns in a phase.3. Phase to phase faults.

2I. HOW DO YOU TAKE SHORE ELECTRICAL SUPPLY?l. After the terminal connections are made, belbre closing the breaker,i. Phase sequence is checked with the phase sequence indicator to ensure thatmotors will not run in the wrong direction.ii. The indicator lamp shows availability of shore power at the switch board.2. The shore supply breaker is closed after the ship's alternators are disconnected.

22. HOW DO YOU MAKE SURE THAT THE PHASE CONNECTIONS ARECORRBCT AFTER AN OVERHAUL?Star-delta started motors:I . Identifu the 3 pairs of ends of stator windings by continuity testing.i. Switch tlre instrument to 'f) ' or 'continuity'

i i . Connect one end ofconnection to earth.iii. Determine the other end of connection usins IR tester. with one probe

connected to earth.iv. Press the button or turn the handle. check the indication on the 'f) ' scale (0.3 -

0.4 o).2. Identify the 6 pairs of ends of connections between

Delta contactors and motor terminals and.

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ii. Main contactors and motor terminals via safetv trios.

using insulation resistance tester.3. Then make the connections as per the star-delta starter circuit diagram.4. With the driven machine isolated. check the rotation of motor

It should turn anti clockwise when seen from the coupling end.ii. lf the rotor direction is clockwise, interchange any 2 supply line connections atthe main contactors (not at the isolating switch).

23. HOW DO YOU SYNCHRONISE A/C GENERATORS USING LAMPS?l. Lamps 'Dark' method using 2 lamps2. Lamps 'Bright' method using 2 lamps.3. Sequence method using 3 lampsIn each case, the lamps are connected between the incoming generator and the busbars.

24. EXPLAIN OVER VOLTAGE PROTECTION.The over voltage relay causes the generator circuit breaker to be tripped,l. Only if both over-excitation and an over-voltage are present simultaneously at aparticular generator with an A.V.R. fault.

25. EXPLAIN OVER CURRENT PROTECTION (150 7o of full load current for20 sec.)The over crrrrent relay causes the generator circuit breaker to be tripped,l. Only in the event ofhigh over current such as that associated rvith short circuit.

26. EXPLAIN INSTANTANEOUS OVER CURRENT PROTECTION.The instantaneous over current relay causes rapid tripping ofa generator,l. with an internal fault, and2. with currents in excess of the maximum senerator fault current.

27. EXPLAIN LOSS OF EXCITATION?The loss of excitation relay ensures thatl. Only the generator experiencing loss of excitation wil l be tripped,2. rather than healthy machines tripping on over current.

28. WHAT WOULD HAPPEN IF YOU ATTEMPTED TO CONNECT AN OUTOF PHASE ALTERNATOR TO THE MAIN BUS BARS?l. Atthe instant of closingthe breaker, the voltage phase difference causes a largecirculating currelrt between the machines which produces a large magnetic force to pullthe generators in to synchronism.2. This means rapid acceleration of one rotor and de-acceleration of the other.3. The large circulating current rnay trip each generator circnit breaker'.4. The large forces may physically damage the generators and their prime movers.5. Result is total black out of the shin.

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29. HOW DO YOU SYNCHRONISE USING T VOLTMETER?I . Connect a pair of 500 V voltmeter probes across one phase of the incomingmachine circuit breaker.2. Adjust the generator speed until the voltmeter slowly fluctuates ffom zero tomaximum.3. Close the breaker when the voltmeter passes through zero.

30. HOW DO YOU BRING UP THE VOLTAGE OF A GENERATOR BEFORESYNCTIRONISATION?l. The speed of the incoming generator must be adjusted until its frequency isapproximately equal to that ofthe generators already connected to the bus bars.2. The D/C excitation field current should be regulated to produce the requiredgenerator A/C output voltage.3. The voltage must be trimmed with a hand trimmer regulator fitted on the generatorcontrol panel, to correspond with that ofthe bus bars.4. The A.V.R. wil l then control the generator output voltage to + or -2.5% of its setvalue over the load range.

3I. HOW DO YOU CHARGE A BATTERY?L The cell is disconnected fi 'om the load andi. connected to a D/C charging supply ofthe correct voltage.2. The positive of the charging supply is connected to the positive side of the cell andi. the negative ofthe charging supply to the negative ofthe cell.

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31. M/E PERFORMANCE

I. WHY DO YOU TAKE INDICATOR DIAGRAMS? (CKL)

l. An indicator diagram records the variation of pressure in the engine cylinder with

respect to piston displacement.2. The area enclosed in the diagram represents the work done.

3. The work diagram is measured to derive mean pressure and multiplying by engine

speed and cylinder constant, the power in a cylinder is calculated.

2. WHY DO YOU TAKE DRAW DIAGRAM? (CKL)

l. At dead centres when tlre piston momentarily comes to a stop, the indicator

instrument fails to record any'thing of what is happening in the engine cylinder in a p-v

diagram.2. Important processes having a profound influence on the perfonnance ofa diesel

engine do take place at or near the dead centres.3. A draw diagram is a pressure-time diagram which is obtained by moving the drum

at constant velocity during the period covering a few degrees before and after the T.D.C.

4. The vital information obtained are;i. Contpression and maximum combustion pressure.

i i. The nature ofthe expansion curve.i i i . Loss of compression.iv. Incorrect injection timing.v. Occurrence of after burning.

3. WHY DO YOU TAKE LIGHT SPRING DIAGRAM?l. This diagram is taken rvith a l ight spring.2. The variation of pressure in the cylinder during exhaustittg and scavenging is

nagnified in liglrt spring diagram.3. The drop in pressure is a trreasure of clearness of exhaust passages.

4. This diagram also shows the pressure of scavenge air at cylinder intake.

4. WHAT ARE THE CAUSES FOR BLACK SMOKE? (CKL)

A. If all units are producing smoke.1. lmproper F.O. temperature and viscosity.2. lmproper F.O. purif ication.3. Fouling ofair and gas Passages.4. Wrong position of carnshaft.

B. If smoke is from one unit onlYl. Defective fuel valves.2. Leaky exhaust valve.3. Blow-by or leaky combustion chamber.4. Wrong position of fuel cam.5. Scavenge air suPPlY too low.

Actiou:1. Replace defective valves.2. Rectifu F.O. purif ication and timing.

3. Check F.O. tenlperature and viscosity.

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5. WHAT ARE THE REASONS FOR WHITE SMOKE AND BLUE SMOKE?(CKL)A. White smoke:

l. Water leakage into engine cylinder.2. The water may be in the fuel or leaking into the cylinder through cracked

cylinder liner, cylinder cover or turbocharger casing.B. Blue sntoke:

l. Excessivecylinderlubrication.2. Failure ofscraper rings, causing excessive lubricating oil to be burnt in the

cylinder.

6. WHAT ARE THE REASONS FOR THE OIL LEVEL TO RISE IN ENGINEL.O. SUMP?Ressons: (WFL, CKL)1. Water leaks in the cooling system, such as glands or seal rings, allowingcontamination of the crankcase from cylinder jackets, water cooled pistons etc.2. There may be a leak at the oil cooler.Action:l. Put stand-by generator on load.2. Immediately stop defective generator or main engine.3. Inform chief Engineer, and Bridge.

7. WHAT ARE THE REASONS FOR THE OIL LEVEL TO FALL IN ENGINEL.O. SUMP?Reusons: (WFL)1. There may be an oil leak in the system and this must be searched for at all L.O.

i. Pumpsii. Coolersii i . Pressure relief valvesiv. Crank case and drain tank, and void tank.

2. Water seal in the L.O. purif ier together with the purif ier pump should be checked.3. Choking of oil drain grids within the crankcase wil l cause the oil levelto build upthere and not return to the drain tank.4. Failure of scraper rings causing excessive lubricating oil to be burnt in the cylinder.

i. Stuffing box leakages.5. Piston cooling oil leakage to scavenge drain tank.Actiort:l. A check must be carried out to ascertain that no valves have been incorrectlvopened or closed, allowing oil to enter or leave the system.

8. WHAT IS CRANKCASE OIL MIST DETECTOR AND WHY IT IS THERE?(wFL)l. The crankcase oil mist detector will detect the presence of oil mist at concentrationswef l below the level at which explosions may occur (2 - 5 % of LEL).

i. Giving a warning in time to allow avoiding action to slowdown the engine andii. Prevent either a serious damase or an exolosion.

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2. If a concentration of oil mist is present in the sample, light will be obscured beforereaching the cell of the measuring tube; electrical balance between the 2 cells wil l bedisturbed and an alarm will be operated.3. In the event of oil mist being detected, the rotating arm stops to indicate whichsampling point is concerned.4. The instrument must be reset before the alarm ceases and sampling willrecommence its sequence.lllaintenance:l. The detector should be tested daily.2. The lenses and mirrors should be cleaned periodically.Types:l. Comparator ffpe2. Levle type

9. WHY CYLINDER LUBRICANT SHOULD HAVE HIGH ALKALINITY?(CKL)l. In cylinder lubrication, the alkaline oil is l ikely to protect the l iner surface againstcorrosive attack by neutralising weak sulphuric and sulphurous acids.2. So the cylinder lubricant should have a TotalBase No. of 70 to 80 rng KOH/gm.

Viscosity: 130 cSt at 50 deg. C.

IO. WHY T.B.N. OF TRUNK PISTON ENGINES IS GREATBR THAN THAToF cRossHEAD ENGTNE LUB. OrL? (CKL)1. The trunk piston engines use a dual purpose lubricating oil.2. The same oil is used for lubrication of bearings in the crankcase and also thecylinders.3. The L.O. in use in trunk trunk piston engines burning blended or selected fuel oilcontaining sulphur should possess a T.B.N. of 24 - 30 mg KOH / gm.

r l . WHAT ARE THE CRTTERIA FOR TRUNK PTSTON ENGTNE L.O.? (CKL)l. A high degree of stability without oxidation at high temperatures.2. High flash point.3. Oil iness for both bearing and liner surface lubrication.4. Non sludge forming.5. Detergency and dispersancy properties.6. Viscosity : 60 cSt at 50 deg. C.7. T.B.N. :20 mg KOH / gm.8. F lash point :215 deg. C.

12. WHAT ARE THE CRTTERIA FOR M/E L.O. SELECTION.? (CKL)l . High chemical s tabi l i ty .2. Oi l iness.3. A degree of detergency and alkalinity for mild cleaning and neutralising effect.4. A mild dispersancy propefty.5. Viscosi ty6 . T .B .N .7. Flash pointNote:

:63 cSt at 50 deg. C.: l0 mg KOH / gm.: 2 1 5 d e g . C .

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T.B.N.: The atnount of alkali required to neutralise the acid content of a standardsample.

13. WHAT ARE THE CRITBRIA FOR SELECTION OF CYLINDER L.O.?(cKL)l. lt should retain good viscosity at rvorking temperatures, 130 cSt. at 50 deg. C.2. A high degree of stabiliry without oxidation at high temperatures.3. A degree of oil iness, and4. Alkalinity (70 T.B.N. oil).

,

14. HOW DO YOU TAKE TNDICATOR DIAGRAM?A. Before taking indicator diagram ensure,

l. Indicator piston, cylinder and the writing mechanism are cleaned andlubricated.

2. Indicator cock is free fronr accumulation of soot and oil.3. The indicator is fastened to the cock in such a position that the indicator cord

becomes parallel with the movement of the drive to which the hook is fastened.4. The length ofthe indicator cord is so adjusted that,i. the diagram is positioned in the center ofthe paper.i i. the cord is t ight in all positions.

B. Operationi. With the indicator cock closed, trace an atmospheric l ine.2. Open the indicator cock and trace the work diagram by pressing the writing

pointer against the paper while the paper drum turns one tinre.3. Close the indicator cock.

C. Draw diagraml. Release the cord from drive on engine.2. Watch the movement of the writing pointer and press it against the paper at the

moment when the writing pointer moves upwards.3. Pull simultaneously the indicator cord so quickly that the writ ing pointer traces

the compression and ignition part of the cycle, the draw diagram.

I4. EXPLAIN COMPARATOR TYPE OIL MIST DETECTOR?l. The measuring tube receives a sample of oil mist from each crank position in turnand compares the density of that with the reference tube, which receives the average oilmist sarnple from all the remaining crank chambers.2. In addition, once during each scanning cycle the rotary valve passes the averagesample to the reference tube and compares with a sample of clean air drarvn through themeasuring tube.

15. HOW DO YOU TEST OrL MIST DETECTOR? (WFL)I . Oil rnist detector rneter is graduated from 0 to I 8 at right hand of the scale.2. Press the check button, the meter should move to | 8 and audible and visr.tal alarmcircuit wil l operate.3. Operate selector button and rotate sampling valve knob to position zero for zerocheck in the rneter, alarm stops.

i. At position zero, clean air is admitted to both reference and measuring tubes forzero calibration.

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32. POLLUTION CONTROL

1. EXPLAIN THE WORKING OF OIL CONTENT MONITORING SYSTEM?l '

. When the bilge pump is started, the oil content monitoring unit is also brought intoaction.2. This unit will function automaticallv.

i. Once the alarm level has been iet at either l5 or 100 ppm.jl And the sampling point selected (i.e., either after the oily water separator or aft

the filter).3. The monitoring unit will then first flush itself with fresh water to clear all pipelinesand the measuring chamber.4. change S.w valve to bilge valve so that the bilge water may be fed into theseparator.5. Sampling of the bilge water then takes place from the selected sampling point.

i. The amount of oil present is displayed on the monito r.6. where the level is acceptable, the overboard discharge valve is now opened and thebilge water is pumped overboard.7. If the monitored oil level rises to an excessive level, the monitor wii l

i . simultaneously init iate audible and visual alarms and stop the bilge pump. oril, divert the bilge water discharge to a settling or slop tank and,ii i . continue to monitor the recirculated birge water.

8 The bilge pump must then be stopped manually.

? when the bilge pump is stopped, the monitoring unit closes down after f lushingitself with clean fresh water.10 . The

i. discharge / recirculating valve,i i. Sampling valve and,iii. the clean water flushing valve are pneumatically operated.

Itlote:To test the oil content meter, introduce a drop of oit through the measttring chcrmber.

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33. M.E. POWER CALCULATIONS

I. HOW DO YOU CALCULATE INDICATED AND EFFECTIVE ENGINEPOWER?A, mm2 : Area of tbe indicator diagram as found by planimetering.L, mm : Length of the indicator diagram or atmospheric line.Cs, mm / bar : Spring constant.pi, bar = Mean indicated pressure

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The indicated engine power Pi for one cylinder measured in kW or B.H.P.: Kl X RPM X pi, where,: Engine speed: cylinder constant- cylinder diameter= piston stroke

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Kl : 1.30900 X D2 X S for porver in kW:1 .77968 X D2 X S fo r power i n B .H .P . ( l B .H .P . :0 .7355 kW)

pe : Mean effective pressure: (pi - K2) bar: (p i - l ) bar

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l. The mean friction loss, K2, forming a small part of the pi has proved to bepractically independent ofthe engine load and engine type.2. By experience, K2 has been found to be approximately I bar

Pe = Effective engine power for one cylinder measured in kW or B.H.P.: K l X R .P .M. X pe: K l X R .P .M. X (p i - l )

l. Due to friction in the bearing, the shaft power is approximately I % less than theeffective engine power.

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A.

ENGINEBRING KNOWLBDGE

Generall. Routine associated with taking over and accepting a watch2. Compilation of machinery space log book and understanding significance of

readings taken.3. Routine duties undertaken during a watch.4. Routine associated with handing over to the following watch.5. Safety precautions to be observed during a watch and immediate actions in the

event ofa fire or accident.6. Routine pumping operations of ballast, bilge and fresh water.7. Use ofoily water separator and precautions to be observed to prevent

envi ronnrenta l pol lu t ion.8. Operation of auxil iary boiler including combustion system.9. Methods of checking water level in boilers and action necessary if water level

is abnorrnal.10. Preparing, starting, coupling and changing over alternators or generators.I l. Imrnediate action necesSary in cases of electric shock.12. Location and rectif ication of contmon f-aults in pumps and purnping systems.13. Location and rectif lcation of common faults in machinery and plant in engine

and boiler rooms.(Compressors, Refrigeration, F.W.G, Steering gear, Purifiers)14. Recognition of boiler water contamination.15. Boiler rvater, tests and treatment.16. Communicat ion abi l i tv in Encl ish.

MotorL Construction, working principles o1, and watch-keeping routines associated

witlr, main diesel propulsion machinery, auxil iary boilers and auxil iarymachinery.

2. Fuel and lubricating oil systems for the marine diesel plant. Properties andtreatment of oils.

3. Preparation, maneuvering and shut down of main propulsion rnachinery undernormal and emergency conditions. Testing plant and equipment.

4. Main and auxil iary ntachinery morritoring and protection devices.5. Scavenge fire and crankcase explosion.

B.

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FUEL OIL, LUB. OIL TRANSFBR PROCEDURE

fuel oil descriptions:1. name2. quantity3. viscosity4. densiry5. f lash point6. pour point7. remarks

lub. oil descriptions:l . name2. quantity3. viscosity4. density5. flash point6. pour point7. remarks

key wordsa. management of fire extinguishing and anti-pollution applianceb. control ofthe valvesc. transferringd. mooringse. operation for topping offf. emergency shutdowng. emergency measures for oil spillageh. reporting procedures in emergencyi. communication means

officer in-charge: chief engineerl. fully responsible for the transfer of fuel oil and lub. oil.2. responsible for making applications and other repofts to oil company or harbouradministration authority through the captain.3. discuss the oil transfer plan and procedures involving the emergency shutdown andother details with the oil transfening vessel.4. responsible for making oil samples on the spot of the oil transfer operation and ifnecessary asking forthe characteristics ofthe oil supplied from the oil transferringvessel and keeping them.5. in command of treating and handling of accident of oit spil lage and other emergencysituations.

responsib le engineer

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a. ensure that the fire extinguisher, fire hose, oil container and oil dispersants areprepared in the place where the loading arrns are connected and the scuppers are allplugged.b. ensure that the valves of the tank for replenishment are fully opened and the blindflange for connection at the other side ofthe ship are tightly blanked or shut off.c. responsible for the oil transfer operation and safefy during the whole transferring.check constantly the state ofthe tanks in replenishing and control the transfer rate.d. direct the operations of topping off and the motorman in charge to make soundingoften, and keep a close watch on the changes ofullage.e. during the oil transfer operation, be prepared for an emergency shutdown at anytime. in case of something abnormal, ask the oil transferring vessel immediately to stoppumping.f. when an accident of oil spil lage occurs report to chief engineer immediately,organize all crew to remove the spilled oil at once to minimize the pollution.g. in case ofemergency, report to chiefengineer and captain at once the oiltransferring vessel to take appropriate measures quickly and do everything possible toavoid an accident.h. for safety of the oil transfer operation, the communication means and the signalsshould be confirmed with the oil transferring vessel, and the portable radiotelephonesused by the two sides should be set in the same channel.

oilera. responsible for reporling the oil levelb. when the changes of ullage are found abnormal, noti0/ the responsible engineerimmediately and the oil transferring vessel to stop pumping.c. in case of emergency, report to responsible engineer immediately and takecorresponding measures.d. maintain effective communications with the ensineers.

6th engr. / fittera. place the fire extinguishing and oil pollution prevention appliances at the position ofthe connection of the loading arms and the ship's manifolds.b. assist 3rd engineer to open and close the relevant valves and shut offall the valvesused upon the completion of the oil transfer operation.c. obey the orders of the engineer during the oil transfer operation and fulf i l l the workassigned, watch the working condition of the connection to the loading arms and thevalves.d. when the operation oftopping offapproaches, keep a close watch on the changes ofullage and assist the engineer to change the tanks for replenishing correctly, i.e. open thevalves ofthe next tank for replenishment first and then close the valves ofthe tank beingnearly fi l led up.e. in case of emergency repoft to the oil transferring vessel immediately to stoppumping and close the valves concerned.f. when an accident ofoil spil lage happens, obey the orders ofthe engineer and takeeffective measures to pt'event the spil led oil from spreading, clean and remove thespi l led o i l to rn in inr ize the pol lu t ion.g. in case ofemergency, report to responsible engineer or chiefengineer at once and

the oil transf'erring vessel to take appropriate measures quickly.

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rvatch sailor on dufya. responsible for the mooring and unmooring of the transferring vessel and watch theconditions of the moorings of the oil transferring vessel and that of its own during the oiltransfer operations.b. when an accident of oil spil lage happens, clean up and remove the spil led oilimmediately together with the members of the engine department.c. in case ofsonrething abnonnal, repoft to the duty officer or responsible engineerinimediately and the oil transferrir,g vessel to take corresponding measures.d. responsible for displaying danger signals such as red l ight or f lag during the oiltransfer operation.

instruction for lvorkiug out fuel oil / lub. oil transferring planl. fuel oil means heavy oil or diesel oil fbr shipboard use, r 'vhile lub. oil means systen)oil for main engine or auxil iary engine, cylinder oil, hydraulic oil and any other lub. oils.transfer operation tneans transferring existing fuel oil ol lub. oils onboard among their'respective storage tanks, or replenishing of fuel oils / lub. oils in their respective storagetanks, or pumping out of oil for cleaning purpose. oil transfe.:":.ng plan is compiled bythe responsible engineer, taking the conditions and real situation ofhis vessel intoaccount, tbr ensuring safe operation and prevention ofoil spil lage. the plan shouldinclude time of operation, tanks fiom or into which oil to be transferred, capacity oftanks and their existing contents, quantity of oil to be transferred. kind of oil, pipingsystem / valves i pumps to be uscd, responsible oftlcer orr the scene, locations rvhere firefighting and oil spil l prevention appliances pleced, safety prccaLrtions and applicablelocal regrrlations.2. fuel / lLrb. oils transt-erring plan is to be cornpiled by the third engineer, dulyrevierved and approved b1,the chief engineer, and then inrplemented by tlre thirdengineer.3. if the transl'er operation involves lalge quantily of oil, the third enginee r shouldconsult lvith the chiefofficer to select the appropriate tanks for the desired purpose.rvlren the chief olf icer is working out the stowage plan which requires transfelring of oilsto achieve the end, lre has to consult rvit lr the chiefengiueer so that he can advise thethird engineer to prepare his transferring plan accordingly.4. the oil transferring plan should be concise, practicable and feasible. it should beduly signed by the third engineer and chiefengineer, and then posted at the section "flel/ lub. oils transferrirrg plan" of this "shipboard fuel i lub. oil transf-er procedule".

I te l o i l t ransfer p ip ing d iagrarn.

lub. o i l t ransfcr p ip ing d iagram.