NAME:ABHIJITH

SREEVALSAN PILLAI
HK ID :53362

Third Engineer to Second Engineer

Mentoring Program
PART:I

0
Date:06/01/2020

TASK NAME: OVERHAUL A LARGE PUMP (MAIN SEA WATER PUMP)

Task Description: Overhaul a large pump viz. Ballast, MSW, M/E L.O., Fire and G.S. or
equivalent with crew assistance. Write a report on the procedures and precautions to be followed.
Make a table of the impeller and bush clearances that you have maintained.

Precautions:
• Tool box meeting is to be organized. Everybody should be briefed about the job and
should be attired in proper PPE before commencing the job.
• Switch off the breaker of the pump. Use lock out tag out system. Put “DO NOT START.
MEN AT WORK “notice over the starter panel. Put local switch in lock position.
• Complete electrical isolation checklist and isolate electrical connections to the motor as
per checklist.
• Complete a cold work permit paying attention to the points as applicable to the current
job.
• Shut all the necessary valves and drain the sea water inside pump.

Dismantling:
In order to replace impeller, shaft, mechanical seal, etc., dismantling of pump is carried out as
follows:
• Remove the coupling bolts between motor flange and pump flange.
• Remove the bolts fastening the motor to the pump frame.
• Separate the motor frame from the pump by using two jack bolts.
• Lift the motor and the dismantling part.
• Remove the pump shaft with impeller, bearing and mechanical seal.
• Draw out the shaft coupling with puller.
• Remove the lock plate of impeller nut and remove the nut.
• Draw the impeller out.
• Loosen the allen keys securing mechanical seal rotating part on shaft and draw out the
complete seal.
• Draw out the bearing.
Overhauling:
• Clean each part properly.
• Inspect impellers for cracks, damage, blockage, excessive wear, cavitation.
• Inspect shaft sleeve for corrosion, grooving, cracks etc. Replace if unsatisfactory.
• Measure wear ring clearances. Replace wear rings if necessary.
• Measure interstage bush clearance.
• Check shaft trueness.
• Replace all o-rings and gaskets.
• Check bearing condition. Should move freely by hand and no play should be there
between outer and inner race. If bearing running hour is over replace it irrespective of
condition.
• Inspect inside of pump casing for corrosion, pitting, erosion, cavitaion, cracks etc.

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 • Check bottom bearing bush condition. Replace if worn.

Assembling:
Assembling can be carried out by reversing order of dismantling and attention must be paid to
the following:
• Cleanse each part thoroughly to remove rust and scale, and be sure there is no damage
and burr in fitting parts.
• Assemble fitting parts according to match marks if any.
• Turn nuts for rotating parts securely and fix anti-rotation device without fail.
• Assembly of mechanical seal:
• Sliding face, O-ring and O-ring groove must be cleansed with leadless gasoline
and wiped with soft cloth taking care to keep off dust and other foreign matter.
• Take care not to damage sliding face and O-ring by hitting or scoring.
• When fitting be sure to apply lubricating oil to O-ring.
• Floating seat (carbon) must be inserted by hand until it touches bottom firmly
taking care not to damage sliding face.
• Burrs on the shaft sleeve must be removed beforehand.
• After fitting rotating elements, push seal ring by hand confirm if they can move
freely on sleeve by spring load. If this action is bad, seal will be imperfect and
leakage will result.
• Assemble parts in reverse order of dissembly.
• Bearing should be heated to 80deg in oil bath before fitting. While fitting only push by
inner race.
• Wear rings interstage bush are locked inside the casing by dowels. Be sure to check there
movement.
• After tightening the impeller locking nut be sure to put the lock plate over it to prevent its
inadvertent loosening.

Clearances taken:

Impeller and casing wear ring 0.9mm (limit <1.4)

2
Date:10/02/2020
TASK NAME DECARBONISATION OF AN AUXILIARY ENGINE

Task Description: Carry out complete decarbonisation of an auxiliary engine with crew
assistance and write out a report giving all essential calibrations and clearances.

Decarbonisation report:

D'carb preparation:

• Make sure the all stand by auxiliary engines are ready

• Keep all the special tools and other tools ready
• Go through the previous records/manual for clearance and adjustments
• Put the display card "MEN AT WORK", "DON'T START"
• Close air bottle valve to auxiliary engine and engine start and stop valve
• See that the turning bar is not in the flywheel and should be in place
• Open the indicator cocks
• If the main bearing is to be removed, check crank shaft deflections
• Close lube oil, fuel oil, fresh water inlet/outlet valve, drain the cooling water line
and remove connections
Removal of cylinder head:

• Rocker arm, lube oil drain connection from rocker arm, rocker arm tank and cover
connection to be removed
• Fuel oil high pressure connection from fuel pump to the injector, fuel valve cooling
connections in and out (either diesel or water) to be removed(optional)
• Remove the rocker arm assembly and the push rod. Remove all the mountings such as
indicator cock
• Remove the rocker cover and check any marking on cylinder head nuts and studs. If no
torque spanner is available, note down the markings.
• Open the cylinder head nut with box spanner and extension rod. Never use the torque
spanner. With box spanner available note down the marking .
• Put the cylinder head lifting tool and before lifting make sure all the connections are
removed. Also ensure that the liner is not removed along with the cylinder head
• Take out the metal joint between the head and the liner

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Removal of piston and connecting rod:

• After lifting the head, check the liner surface for score marks, blow past etc.
Crack remove the ridges or deposits if any on the top surface to avoid the lifting of liner
along with the piston and breakage of piston rings while lifting piston
• Fire ring has to remove by an oild piston ring by moving the piston to tdc
• Open the crank case door and remove the bottom end bearing bolts after removing the
lock arrangement and theremove the bolts
• Remove the bottom half of the bottom end bearing
• Bring the piston to TDC. Make sure the bolt holes on the piston top, lifting tool holes must
be cleared from carbon deposits. Threads should also be checked and cleared

4
•
• Put the piston lifting tools and tighten the bolts
• Lift the piston and remove top shell of bottom end bearing.
• While removing the liner holding tool has to be fit to avoid accidental lifting of liner with the
piston
• Place the piston on the piston stand and cover the crankcase pin to avoid the foreign material
damaging the crank-pin.

Cleaning the carbon content on all the parts of engine:

• Clean the piston rings, measure dimensions and keep them in order

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• Clean the piston ring grooves thoroughly and measure the groove thickness at 3 different
points
• Check for the deposits on piston crown (Sulphur, carbon or thick vanadium deposits) and
measure the dimensions
• Remove the gudgeon pin and clean the gudgeon lube oil holes as well as the bush or small
end bearing
• Check the bolts of connection rod for any cracks
• Every 20,000 hrs engine connecting rod bolt must be replaced
• New piston rings are going to be replaced, so there is no need for measurement.
• Calibrate the liner thickness by using template

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Assembly of the engine parts:

• First put the piston rings one by one and measure the butt clearance for all the rings
• Then measure the axial clearance between piston rings & grooves
• Place the piston guide on top of the liner and bring the particular crank shaft to TDC.
Apply sufficient lube oil and start lowering the piston. Make sure that butt gap should not
be in line it may cause blow past
• Before engaging check the crankpin for any cracks or scratch
• Check the bottom end bearing clearance and if needed measure the main bearing
clearance as well
• Tappet clearance is checked
• Check for any cracks in the water jacket and in the cylinder head
• Replace all rubber joints and copper gasket to be put on the cylinder cover
• Put the cylinder head gasket in the top of the cylinder
• Anti-seizure coating or powder like molycote, copper slip should be used. It is applied to
avoid any seizure mainly on the threads or joints and it will be easier while removal
• Tighten the cylinder mounting according to torque specified as in manual and make all
connection like lube oil, fuel, jacket cooling water connections etc
• Fit the rocker arm back

After D’carb:

• Crank shaft deflection is taken and recorded.

• Crank case oil should be removed and sump cleaned.
• Crank case inspection should be done so that nothing is left inside.
• Make sure all the parts are fitted and tightened as per the manual.
• All the isolated systems are put back into operation one by one, starting from the fresh
water system. Leaks should be checked thoroughly.
• Fresh oil is taken and lube oil system is put back in use followed by fuel oil system.
• Turning gear is rotated to ensure free movement of crank shaft.
• Lubrication of the moving parts is checked by trying out priming pump.

DATE : 11/02/2020

Task Name: Job Responsibility

Task Description: Write brief notes on the 2nd Engineer’s responsibility regarding:

• Maintenance routines of engine machinery

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The Second Engineer is responsible for carrying out all routine, long term, preventive
maintenance in engine room in accordance with the Chief Engineers requirements. He shall
allocate duties to other engine room personnel for daily maintenance, overhaul, etc
He will supervise work in progress and on completion, ensure that manpower is utilized to the
fullest extent, that work is safely and properly performed in accordance with the acceptable
standards and that no wastage of material takes place.
• Preparation of running Repair list
The Second Engineer should maintain a register in the engine room on which all defects found in
the machineries, pipelines, etc. are logged and deleted as and when remedial actions are taken.
The other engineers should be encouraged in making necessary entries and keeping the register
up-to-date.
• ER Fire fighting equipments and LSA
The Second Engineer is responsible for the condition and maintenance of fire-fighting and
lifesaving equipment assigned to the Engine Department. Equipment must be regularly tested in
accordance with PMS to ensure it is in good operating condition and proficient in its use. Testing
of the engine room lifesaving and fire-fighting equipment during certification periods shall be
done in conjunction with the Deck Department's testing of lifesaving and firefighting equipment.
• Requisition of spares and stores
The Second Engineer shall assist in the preparation of requisitions for Engine Department stores
and spare parts and submit them to the Chief Engineer for approval. He will maintain an
inventory of materials on hand and on order. He will receive and sign for materials delivered and
see they are properly labeled, preserved, stowed and secured to avoid loss from damage or
deterioration. He will maintain control over issuance and usage of tools and materials to prevent
waste.
• Directions to ER Fitter and crew
The Second Engineer must direct unlicensed personnel on his watch in the proper and efficient
execution of their duties. He must ensure that due diligence and adequate care to prevent waste
and improper use of material and supplies is observed and unsafe working habits or conditions
are corrected. He must see that areas and equipment are maintained in a clean condition and that
positive action is taken in all cases to ensure that operations conform to Company and other
authoritative regulations. He must take measures necessary in time of emergency for the safety
and preservation of personnel
• Daily reporting to Chief Engineer
The correct and prompt supply of information to the Chief Engineer on the matter occurring
which is not covered by a standing order from the Chief Engineer or is not a generally accepted
routine. The Second Engineer will, as far as practicable, report to the Chief Engineer at about
0800 and 2000 hours daily

DATE : 11/02/2020
Task Name: Record Keeping
Task Description: List out the records and files to be maintained by the 2nd Engineer as per
C/E filing system.
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MONTH END PAPERS

1. Monthly Technical report

2. AE Performance report
3. Monthly Machinery update
4. Running hour's status
5. ME Performance report
6. Machinery Running HRS
7. Machinery Maintenance Status
8. Butt Clearance report
9. M/E Scavenge Inspection Report
10. V-Belt Status
11. Bearing Status
12. Megger Routine / Motor Overhaul Status
13. MGPS/Shaft Voltmeter Status
14. Boiler / Cooling Water records
15. Battery Performance with updated battery expiry list
16. ME Fuel Injector Running Hrs.
17. ME Module.
18. Owner’s maintenance report .
19. Critical spare list.

REGISTERS TO BE MAINTAINED

• MINUTES OF DAILY MEETING, QMS-100

• DEFECT LIST (E/R)E-32

• TANK SOUNDING BOOK E-12

• SATURDAY ROUTINE BOOK

• UMS ALARM LOG

• EMS LOG

DATE : 13/02/2020
Task Name: Code of Safe Working Practices
Task Description: What are the 8 elements of Risk Assessment enumerated in Sec 1.9 of
Code of Safe Working Practices?

• Classify work activities

• Identify hazards and personnel at risk
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 • Identify risk controls
• Estimate the risks
• Decide the tolerability of the risks
• Prepare risk control action plan (if necessary)
• Review adequacy of action plan
• Ensure risk assessment and controls are effective and up to date

Task Description: What are the 9 main Hazards in the Work place as identified in Sec. 2.2
of the above code?

• Mechanical
• Electrical
• Physical
• Radiation
• Substances
• Fire & Explosion
• Chemical
• Biological
• Psychological

DATE : 13/02/2020
Task Name: Standing Instruction
Task Description: Read and sign on board standing instruction and keep the copy of the
same

M.T.STRAUM

CHIEF ENGINEER’S STANDING INSTRUCTION

The following instructions are formulated and put forth to ensure safe and efficient engine room
operations. There is no alternative to individual initiative and common sense when faced with a critical
situation on board. Any doubt or suggestions regarding these orders may be discussed with Chief
Engineer at any time.

Due consideration to be given to human senses like noise, smell, vibration apart from machinery
parameters and any leakages / abnormalities to be rectified / reported.

Safety Equipment:
All engine room personnel should be familiar with the location and operation of all safety
equipments on board and same to be operational and kept ready to use at all times. Tests and checks to be
carried out on all equipments as per safety register and record. If any defect is observed in the safety
equipment it should be attended to on a priority basis.

10
Personnel Safety / Protective Gear:
All engine room personnel should have a sound knowledge of all escape routes and should be
able to distinguish various alarms.

All engine room personnel are to be in proper working clothes (i.e. boiler suit, safety shoes,
helmet, earmuff and working gloves) while at work. Proper protective gear should be used while handling
gas cutting, welding, grinding, chipping, chemicals, checking batteries and working in boiler furnace.

All loose gears to be lashed and secured especially during heavy weather. All passages and exits
are to be kept clear always. While working on elevated places, all safety precautions should be observed.

Always isolate and check circuits prior any work on switch gears and motors and electrical
isolation checklist to be filled up before commencing the work.

Never try to lift heavy objects on your own. Use lifting equipment or get assistance. Use spanners
of the right size to avoid injury to user and damage to fastenings. All engine room entrances must be kept
closed and securely dogged down when not in use.

Hot Work:
No hot work to be carried out anywhere on board without permission from Chief Engineer /
Master. Hot work checklist is to be completed prior commencement of hot work. Portable fire
extinguisher and a charged hose or bucket of water should be kept ready while hot work is being carried
out. Continuous supervision and checks are to be maintained throughout the period of hot work. For all
hot work Company guide lines to be strictly followed.

Entering confined spaces:

Enclosed space entry permit / checklist is to be completed prior entering confined spaces and
completion of job. Second Engineer will be responsible for inspection, gas freeing and ventilation of the
space. A responsible person to remain at the entrance to the confined space and should have proper
communication with the party entering. Entry permits should be displayed at the entrance while SCBA to
be kept standby at the entrance. Master / Chief Engineer is to be informed prior entry and after
completion of work.

COMPLIANCE WITH MARPOL ANNEX VI

Ozone Depleting Substances

Any deliberate emission of Ozone Depleting Substances is prohibited. Regular leak test of A/C and
Refer system is to be carried out without fail. All maintenance carried out for A/C and Refer system
including charging of gas to be recorded. In case of any leak in the system should be informed
immediately.

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Nitrogenous Oxides
Main engine and Diesel Generator engine all parameter to be checked carefully. All maintenance for
fuel injectors and exhaust valve is to be carried out according to PMS. Engine performance is to be
monitored and checked on regular basis.

Sulphur Oxides
Maximum content of sulphur % allowed for heavy fuel oil and diesel oil will depend upon the
operation area and should be maintained as per regulation under guidance from Chief Engineer.

Shipboard Incineration
Incineration of sludge is to be carried out only when the ship is not inside ports, harbors or
estuaries or even at anchor. The guidance and limitation to be read from the maker’s manual before
starting incineration. Any maintenance carried out to be recorded separately.

Following materials should not incinerated as per Annex requirement.

• Annex, I, II, III cargo residues and related contaminated packing material.
• Polychlorinated biphenyl’s (PCBs).
• Garbage containing more than traces of heavy metals.
• Refined petroleum products containing halogen compounds.
Monitoring of combustion flue gas temperature should be required at all times. The oily rags should be
fed, for burning, only when the temperature is minimum allowed of 850 deg C.
SEWAGE TREATEMENT PLANT
Sewage treatment plant should be in operation all the time. Plant should not be bypassed without
permission. Proper chlorination of final discharge is to be carried out with addition of chlorine tablets. Air
filter should be cleaned and vinyl hose to be cleaned. The temp of sewage plant should not be increased
above 60 deg C. Cleaning must be carried out 7 days prior to the restricted areas.

Engineer’s call:
In case of urgent assistance is required due to malfunction of any machinery or emergency caused
in the engine room, all engineers to be called immediately using the Engineers call alarm.

UMS Operation:
Confirm that no one enters the Engine room casing alone. During UMS round, confirm that at
least two persons enter E/R for round. During attending any alarm at UMS mode, confirm that dead man
alarm is activated.

Chemical handling:
All chemicals must be stowed in chemical room. Read material safety data sheet and be aware of
hazard involved. Use proper protective gear, apron and vinyl gloves. Use proper equipment to transfer
chemicals. Avoid spillage. Never attempt to transfer chemicals using a tube and siphoning by mouth.

12
Lifting gear:
Prior using any lifting equipment, make sure to check the weight of the item to be lifted and
confirm that the equipment is designed to handle that load safely. Never stand and move across near
suspended load while it is being lifted / moved. Do not suspend lifting tackles from pipelines or weak
support as they may cause severe damage to personnel and machinery. Check all wire slings, eyebolts,
shackles etc. are in good condition and suitable for lifting load.

Arrival / Departure port:

Inform Chief Engineer when notice is given. All tests and checks should be carried out as per
appropriate checklist, logged and filed. Positively ensure that manoeuvring equipment, steering gear, aux
engines, air compressors are in good order. Air bottles as well as starting air manifold to be drained every
manoeuvring. All timings and flow meters are to be recorded in movement book. Main air starting valve
to be kept shut at all times in port.

Ballast and stripping operations is to be monitored & logged.

Maintenance:
Chief Engineer to be informed prior isolating any equipment for maintenance. All checks to be
carried out on machinery prior restarting after maintenance. Immediately after overhaul, do not leave the
machinery unattended. PMS routines for all equipment are to be followed.

Clean engine room reflects on the observance of good seamanship practice. A dirty work
place with oily surface is not only unfavorable to safe working practice but also constitutes a fire hazard.
Any oil spillage is to be cleaned forthwith without any delay. Engineer on watch to ensure that duty
Motorman cleans his platform delegated to him for cleaning regularly.

Watch keeping:
All Engineers must be vigilant during watch and check all machinery including boilers for safe
operation. Watch handover & takeover should be proper. An engine room round to be taken by taking
over watch keeper before taking over watch. Any irregularity is to be brought to Chief Engineer’s notice
immediately. Always recheck with local parameters and avoid relying on remote readings. Various
parameters to be checked regularly and any irregularities noted and brought to the attention of Chief /
Second Engineer.

Lube oil consumption to be logged down and soundings monitored especially when purifier in
operation. Leaky pumps and glands are to be nipped up. Watch keeping routines like draining of air
bottles, fuel oil tanks, scavenge drains etc. to be done regularly.

13
Inventory:
Promptly update spares / stores receipts / consumption to maintain an accurate inventory. Store
all spares safely and take possible precautions to avoid corrosion and damage. All spares to be checked
periodically to check for any sign of deterioration and damage and rectify. Ensure critical components are
supplied with Class certificates. All used spares to be tagged and kept separately.

IOPP:
The vessel to strictly comply with Marpol laws regarding the oil pollution and garbage
disposal. The engine room / machinery space water, collected in bilge tank, is to be pumped out via 15-
ppm equipment after confirming with C/E & bridge that the national and international laws are not
violated. All relevant entries are to be made legibly in the Oil Record Book. Plastics and Oily Rags are to
be segregated from other waste and stored separately. All Engineers must be familiar with the oil transfer
procedures and spill contingency plan.

After use of OWS to pump out bilge water, make sure that bilge separator overboard valve is
locked in closed position immediately. Under no circumstances should this valve be opened and no
transfer of bilge oil to take place without Chief Engineer’s knowledge.

Bunker procedures / checklists to be strictly followed for fuel / diesel oil and lube oil bunkering
and sludge transfer to shore facilities.

Logbook:
All entries in logbook are to be legible and accurate. Kindly note logbook is a legal document. Do
not overwrite any incorrect entries. Any correction is to be cancelled and signed. All important operations
and checks are to be logged down. Please ensure no pages are torn from logbook.

General:
• All Engineers to be familiar with operation of all the machineries in engine room in
normal as well as emergency mode.
• All Engineers should read, understand and sign the safety and quality manual.
• All records / registers to be updated and kept ready for inspection at any time.
• Air bottles and fuel oil tanks are to be drained off water regularly without fail.
• Night order book to be checked regularly and signed for read & understood.
• All duty engineers to read & comply with the watch keeping schedule put up in the
engine control room.
• When on full away, one air bottle should always remain pressed full with outlet valves
closed, besides the one in use to ensure adequate supply of air at all times.
• Test for cooling water system of ME, AE & boiler water is to be carried out on regular
basis. Chemicals are to be added as per recommendations and any abnormal values
should be brought to notice of Chief Engineer immediately.
• Engine Room filters & greasing routines are to be carried out on regular basis.
• Any increase or decrease of ME RPM is to be done with Chief Engineer’s consultation.

14
 • During port duty engineer to check for Boiler or AE smoke. Any emission of black
smoke should be immediately informed to Chief Engineer & all precautions to be taken
to minimize the smoke after taking into account safety of the operations going on vessel.
• Maintenance schedule should be adhered to, as per PARIS, as far as possible taking into
account the safety aspect.
• Electrical officer is to take leak test on refer & air con plant every week without fail.
Monthly alarms & trips testing should be done & record maintained.
• All the running pumps are to be changed on monthly basis. All the pumps which are not
running should be on standby.
• Aux. Boiler gauge glasses are to be blown through on regular basis. Flame appearance is
to be seen regularly when boiler is in use.
• Should it be necessary to stop or slow down the main engine for any reason, as much
warning as possible is to be given to bridge watch keeper considering navigational safety
of vessel.
• Ensure no fire zone is isolated from Fire station and hypermist system is in auto mode.
• No alarm is in repose condition in the engine control panel.
• No Soot Blow or Boiler Blow Down to be carried out after EOSP.
• Refer to the Line Diagram and Procedure for daily bunker transfer and
bunker/settling/service tank change over.

ABOVE INSTRUCTIONS HAVE BEEN READ AND WELL UNDERSTOOD

SIGNATURE DATE OF JOIN

• CHIEF ENGINEER ------------------ ------------------

• SECOND ENGINEER ------------------ -------------------

15
 • THIRD ENGINEER ------------------ ------------------

• FOURTH ENGINEER ------------------ -------------------

• ELECTRICAL OFFICER ------------------ -------------------

• FITTER ------------------ -------------------

• OILER 1 ------------------ -------------------

• OILER 2 ------------------ -------------------

Date:13/02/2020

TASK NAME: LIST OF TECHNICAL MANUALS

Task Description: Print out a complete list of ships technical manuals and their location.

LOCATION: ENGINE CONTROL ROOM

RACK 1:

• Pump Manual

• MAN Service News

• 2E Tech. File

• MAN Service Letters

• Safety Register

• QMS-100

• Nox Technical File

• Emergency Towing Booklet

RACK 2:

• MAN B&W vol.1

16
 • MAN B&W vol.2

• MAN B&W vol.3

• MAN B&Wworking drawings.

RACK 3:

• Framo Drawings

• Framo Vol 1

• Framo Vol 2

• Lifting Appliances Log

• EMS-02

• Viscosity Control.

• Float Type Level Gauge.

• Calorifier Unit

• MAC

• LO/HFO Purifier Parts Name.

• Generator Test Records

• Installations

• AE Governor Manual.

• AUX Boiler Manual

• Sewage Treatment Plant

• Fresh Water Generator

• Incinerator

• Pumps

• Emergency Generator

• Emergency Fire Pump

• CO2 System

17
 • Deck Machinery

• Arrangement Of Vent Ducts

• Sea Trial

• Hull Parts Arrangements.

RACK 4:

• Deck air compressor

• AE operational manual

• Energy conservation

• Boiler manual

• ISSA

• Spare parts.

• Defect list

• Bow thruster

• Boll filter

• Steering gear manual

Spare parts.

DATE : 17/02/2020
Task Name: PMS
Task Description: Take the print out of the job due of the machineries from PMS for the
machineries under the responsibility of 2nd engineer.

How will you deal with items that have fallen overdue?

Discuss the details of overdue items with chief engineer, check the reason for the overdue and
will plan to do the item in the next convenient occasion

DATE : 25/02/2020
Task Name: Code of Safe Working Practices
Task Description: Read chapter 20 and take 4 photographs which confirms the safe
working practices on board related to this chapter

18
 Chapter 20 USE OF WORK EQUIPMENT

20.2.6 20.7.4

20.5.4 20.6.11

DATE : 25/02/2020
Task Name: Code of Safe Working Practices
Task Description: What are the 11 steps that are recommended in Sec 6.4 of the above
Code to reduce/eliminate risk in the work place?

Section 6.4 Safe Movement

• Merchant shipping regulation place and obligation on both the Master of a ship and
employer of the master to ensure that a safe means of access is provided and maintained
to any place on the ship to which a person may be expected to go.
• Places on the ship where people may be expected to be include accommodation area as
well as normal places of work. Persons in this context include passengers, dock workers

19
 and other visitors to the ship on business but exclude persons who have no right to be on
the ship.
• All deck surfaces used for transit about the ship and all passes ways, walk ways and stairs
must be properly maintained and kept free from substances liable to cause a person to slip
or fall.
• Areas used for the loading and unloading of the cargo or for the other work processes or
for transit should be adequately and appropriately illuminated.
• For areas used for loading or unloading of cargo or other work processes a lighting level
of atleast 20lux should be provided and for transit area a level of at least 8 lux should be
provided ( measured at a height of 1m above the surface level) unless:
• A higher level is required by other regulations, eg. the crew accommodation
regulations or.
• Provision of such levels of lighting would contravene other regulations, eg. the
Collision regulation and the distress signals order.
• The employer and Master are also responsible for ensuring that any permanent safety
signs displayed onboard the ship comply with the regulations and merchant shipping
notice.
• Any opening, open hatch way or dangerous edge into, through are over which a person
may fall shall be fitted with secure guards or fencing of adequate design and construction.
These requirements do not apply where the opening is a permanent access way, or where
work is in progress which should not be carried out with the guards in place.
• All ships ladders must be good construction and sound material, strong enough for the
purpose for which they are used, free from patent defect and properly maintained.
Ladders providing access to the hold must comply with standards in Annex 6.1
• Suitable hand holds should be provided at the top and at any intermediate landing place
of all fix ladders.
• The regulations also require the employer and master to ensure that ship powered
vehicles (which includes mobile lifting plant) are only driven by a competent person who
is authorized to do so, and to ensure that they are used safely. Such vehicles must be
properly maintained.

Date:27/02/2020
TASK NAME: ME FUEL PUMP TIMINGS

Task Description: Check and adjust ME fuel pump timings of your engine and compare same
with shop trial data.

Safeties:
• Shut main air start valve.
• Isolate fuel oil system to ME.
• Engage turning gear.
• Open all indicator cock

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Checking ME Fuel Pump Timinging by fuel pump cam lead checking

21
 .

Adjustment of Fuel Pump Timing:

• The timing can be altered by inserting or removing semi-circular shims between top cover
and fuel pump housing. These shims change the vertical position of the barrel in relation to
the plunger thus altering the timing of injection and Pmax accordingly.

• Another method is to force lubricating oil between the cam and the camshaft for individual
adjustment of timing by turning the cam. Also same method can be applied to turn the chain
wheel in relation to camshaft for all units’ simultaneous timing changes.

Date:29/02/2020

TASK NAME: OPERATION OF CRITICAL EQUIPMENT

Task Description: Demonstrate and write down the procedure of operating emergency fire
pump and emergency air compressor. How do you ensure that the emergency fire pump is
operating at the right capacity?

EMERGENCY FIRE PUMP OPERATING PROCEDURE:

• Ensure Discharge Valve is Open.
• Check Lubricating Oil Level of Priming Pump (Above 50%).
• Open Quick Opening Suction Valve.
• Start the Emergency Fire Pump.
• Check the Motor Amps And Discharge Pressure.

EMERGENCY FIRE PUMP PERFORMANCE TESTING:

• Rig two fire hoses one in forward of the ship and other on bridge deck aft.

• Check priming tank water level.

• Start the emergency fire pump and check if priming device engaging and disengaging
well without trouble.

22
 • Check pressure developed at the pump pressure gauge and record same. Acceptable
criteria for performance are that pressure developed by pump should to be at least 7
bar.

• Check amperage of the motor and record same.

• Check for abnormal vibration if any.

EMERGENCY AIR COMPRESSOR (MAIN AIR COMPRESSOR #1) OPERATING

PROCEDURE:
• Check Sump Oil Level.
• Partially Drain the Emergency Air Bottle up to 20 Bar.
• Start The Emergency Compressor
• Press. Up The Air Reservoir from 20 to 26 Bar.
• Record the Time Taken to Press up (Normal Time 8 Min for 20 to 26 Bar).
• Stop The Compressor.

Date:29/02/2020

TASK NAME: OPERATION OF ALL CRITICAL EQUIPMENTS

Task Description: Write down the procedure for flooding CO2 in the engine room. What
precautions are to be taken prior commencement of flooding?

PROCEDURE FOR CO2 FLOODING:

CO2 Flooding system for E/R is provided to extinguish fire in the engine room when all other
extinguishing methods like portable extinguishers, fire hoses fail to suppress the fire. CO2 is to
be used as a last resort for controlling and extinguishing the fire. CO2 extinguishes the fire by
cutting of oxygen to the seat of fire as it is heavier than air and also gives smothering effect.
Before releasing CO2 in E/R following points should be checked.

PRECAUTIONS BEFORE RELEASING CO2:

• All ship crew mustered and head count taken. All personnel should be accounted for
otherwise there may be a chance that the missing person may be trapped in the E/R and if
CO2 is released he will die of asphyxiation.

• If any crew member is missing he should be searched for.

• All the ventilation fans for E/R should be stopped and dampers shut. This will help in
reducing the supply of fresh air to the fire and also chances of CO2 escaping via them are
greatly reduced.

• All the doors leading out of E/R should be shut.

• Funnel flaps to be shut.

• Boundary cooling should be continued.

23
 • Quick closing valves to be closed.

• Emergency stops for lube oil pumps, fuel oil pumps to be operated.

PROCEDURE FOR RELEASING CO2:

• CO2 must be released by chief engineer in consultation with master.
• Break the glass and take out key for CO2 release cabinet from key box. Using local CO2
release cabinet is preferred.
• Open the release cabinet. Audio visual alarms will sound and ventilation blower trips will
activate.
• In the CO2 release cabinet, open pilot cylinder valve first. Now open valve 1 for master
valve first. Then open valve 2 for CO2 releasing mechanism. CO2 will be released after 60-
90 seconds of time delay.
• Now the system pressure can be checked from the pressure gauge on the manifold.
• If CO2 is not released, then follow emergency releasing procedure. Open master valve
manually and open each CO2 main bottle by manual actuation lever.

DATE : 29/02/2020
Task Name: Vessel Garbage Management plan
Task Description: Take a photograph of garbage drums which complies with company’s
garbage management plan.
Describe how you would dispose off OWS coalescer filters and oily soot water.

A . GARBAGE STATION – ENGINE ROOM

24
B. MAIN GARBAGE STATION - DECK

C. GARBAGE DRUMS - ACCOMODATION

OWS COALESCER DISPOSAL PROCEDURE:

Used OWS coalescer filters to be dried and keep in engine workshop, and land to the shore
reception facility in the next convenient port.

SOOT COLLECTION TANK DISPOSAL PROCEDURE:

On vessels where the Soot Collection Tank is retro fitted ensure that the same is used only
once certified.
• Wherever practicable, the water component of Economizer / Boiler wash water collected
in the Soot Collection Tank should be evaporated or transferred to a sludge tank and the
soot component collected and landed ashore. Disposal of wash water directly overboard
carries the risk of pollution from oil traces that may be present.
• The Soot Collection Tank overboard valve(s) shall be kept shut and locked at all times.
The keys shall be in the custody of the Chief Engineer.

25
 • Disposal of the contents of the Soot Collection Tank should be recorded in the Chief
Engineer’s Log book (BE 11), Oil Record Book Part 1 or Garbage Disposal Record
Book (QMS 34) as appropriate.

Date:12/03/2020

TASK NAME: FRAMO CARGO PUMP

Task Description: Assist in overhaul of a Framo Cargo Pump and prepare notes on the
procedures and precautions.

26
Dismantling Wear ring and impeller

27
Dismantle wear ring Support and wear ring, Dismantle impeller by loosening bolts two turns.
Press down or knocking bolts removes bolts. When impeller becomes loose remove all bolts.
Now Two bolts are to be replaced Between volute casing and pump unit with lifting bolts.
(M12*90)

Remove remaining bolts between Volute casing and pump cover.

LOwer volute casing pumo cover and impeller in one peice.

Slide lift Volute casing together with impeller and suction cover out of well.To avoid damage on
suction well coating,volute casing must be placed upon slides.Wear rings can now be
replaced.Suction cover and impeller can now be dismantled from casing. Loosen lock nut and
remover impeller hub nut.Impeller can now be pulled out by extractor for impeller.Precaution
have to taken to not damage the ceramic sleeve and o rings.Ceramic sleeve can break if
drooped ,since its very brittle.

REMOVAL OF SEALS

Install assembling cylinder fot protection of seals. Remove seal ring housing,dismantle now the
support ring and double lip seal.check and clean ceramic sleeve and change seal set.

DISMANTLING MECHANICAL SEAL

We have to drain the pump in order to replace mechanical seal.Hydarulic pressure inlet valve and
valve on pilot line have to be closed.Release all pressure chambers by using the bleed plugs in
STC valve and non return valve.Reove blind falnge at drain connection located under pump
cover.Use drain tool to unscrew plug, and connect the hose with snap on coupling or the air
operated pump on the female snap on coupling.Pump the oil to a drum located on deck.Pump
unit must be disconnected from pipe stack and volute casing and impeller must be removed
before removing pump unit from pipe stack.

Install bracket on the flange on top of the cover .Turn the pump head upside down.use protection
on tank top to avoid damage the coating.

Lifting of bearing housing

Installation of tool

Remove bolts between falnge of bearing housing and pump cover.Install 4 pcs of "support bolts"
through clearance hole in flange for bearing housing and into M12 holes in pump cover.Install

28
plate and secure to Support bolts by nuts.Install two pcs lifting bolt through holes in plate and
into M12 hole in flange for bearing housing.

Lifting

Turning the lifting nuts can now lift motor and bearing housing assembly. Remove 4 out of 8
bolts between bearing housing and flange for bearing housing.

SECURING

Lift up seal rings to flange for bearing housing.Place support brackets in correct position.Secure
to pump cover by 4 M12 bolts.Lower bearing bracket to support brackets.Remove plate,lifting
the bolts and support bolts.Remove remaining 4 bolts between bearing housing and flange for
bearing housing and remove upper seal house.

Remove flange for bearing housing.Dismantle stationary part of mechanical seal.Remove

rotating part of mechanical seal.Before removing rotating part of mechanical seal,loosen the 3
locking screws.Precaution to be taken before removing rotating part of mechanical seal that
locking screws are not in contact with shaft.

DISMANTLE BEARING HOUSING

Remove hydraulic motor from bearing housing. Remove circlips and pull out shaft,ball bearing,
rotating part of backstop unit,roller bearing as one unit.

ASSEMBLING

Check all seal elements,back up rings,seal element grooves and seal faces.Teflon rings to be
checked for no deformation or radial grooves.change seals if damaged.check seal faces on pump
for corrosion or cracks,dirts.

Date14/03/2020

TASK NAME EXPLOSION LEVELS (FOR TANKERS)

Task Description Write down the meaning of the terms LEL, LFL, UFL

Lower explosive limit (LEL):

The lowest concentration (percentage) of a gas or a vapor in air capable of producing a flash of
fire in presence of an ignition source (arc, flame, heat).The term is considered by many safety
professionals to be the same as the lower flammable limit (LFL). At a concentration in air lower
than the LEL, gas mixtures are "too lean" to burn. Methane gas has an LEL of 4.4%. If the

29
atmosphere has less than 4.4% methane, an explosion cannot occur even if a source of ignition is
present.
Percentage reading on combustible air monitors should not be confused with the LEL
concentrations. Explosimeters designed and calibrated to a specific gas may show the relative
concentration of the atmosphere to the LEL—the LEL being 100%. A 5% displayed LEL
reading for methane, for example, would be equivalent to 5% multiplied by 4.4%, or
approximately 0.22% methane by volume at 20 degrees C. Control of the explosion hazard is
usually achieved by sufficient natural or mechanical ventilation, to limit the concentration of
flammable gases or vapors to a maximum level of 25% of their lower explosive or flammable
limit.

Upper explosive limit (UEL):

Highest concentration (percentage) of a gas or a vapour in air capable of producing a flash of fire
in presence of an ignition source (arc, flame, heat). Concentrations higher than UFL or UEL are
"too rich" to burn

DATE : 14/03/2020
Task Name: Code of Safe Working Practices
Task Description: Read chapter 22 and take 4 photographs which confirms the safe
working practices on board

Chapter 22 MAINTANANCE

22.2.3 22.6.1

30
 22.7.2 22.11.2

Date:20/03/2020

TASK NAME ME UNIT OVERHAUL

Task Description Complete a ME Unit Overhaul Report, complete with all readings and
calibrations. Compare with the last Report for the same M/E unit and compute the liner wear
rate / 1000 running hrs.

A routine maintenance has to be performed on Piston and cylinder head overhaul as per maker’s
instruction. Following procedure is to be followed when carrying out Unit overhaul of a MAN
6S42MC engine:

1)       Inform company and take permission.

2)       Take immobilization certificate from port.(If in port)

3)       Read the manual and have a tool box meeting with everyone involved in the job. Discuss
the procedure.

4)       Prepare important tools and spares to be used in this operation

5)       A risk assessment of all personnel doing the operation to be prepared and documented

6)       Shut main engine starting air

7)       Engage turning gear to the main engine crankshaft

31
8)       Open indicator cocks of all cylinders

9)        Stop main engine lube oil pump after cooling down of engine

10)    Open crank case doors of fore and aft unit

11)    Open crank case doors of that unit in which maintenance is to be carried out.

12)    Put blower and ventilate the crankcase thoroughly as it is an enclosed space.

13)    Prepare enclosed space entry checklist.

14)    After sufficient ventilation wearing proper PPE you can enter the C/C.

15) Close cooling water inlet valve and Outlet Valve, Drain Cooling water of the respective
Unit.

16) Close fuel oil inlet valve.

17) Shut Control air and safety air and drain air and vent maneuvering system through the ball
valve.

Remove cooling water connections from exhaust valves and cylinder head. Remove drain pipe
from intermediate pipe between cylinder cover and exhaust valve. Remove fuel HP pipe
connections. Dismount control air pipe from air starting valve. Remove starting air pipe. Remove
Exhaust v/v high pressure pipe and Drain oil pipe. Remove protective jacket enclosing the
intermediate pipe between the exhaust receiver and exhaust v/v. Place eight spacer rings, one
around each nut, and screw the eight hydraulic jacks onto the studs. Connect the high-pressure
pump to the jacks by means of the distributor block and the high-pressure hoses. Using the vent
screws of the hydraulic jacks, vent the system and increase the pressure. Loosen the nuts by
applying the Tommy bar through the slots in the spacer rings. Relieve the system of pressure.
Disconnect the high-pressure hoses from the jacks. Remove the hydraulic jacks and spacer rings,
and unscrew the nuts.. Hook the engine room crane on to the lifting attachment on top of the
exhaust valve. Lift away the cylinder cover complete, and land it on a couple of wooden planks..
Remove and discard the sealing ring between cylinder cover and cylinder liner

Dismount all valves and pipes on the cylinder cover. Dismount all studs on top of the cylinder
cover. Remove the four screws which secure the cooling jacket to the cylinder cover. Lift the
cylinder cover free of the cooling jacket and land it on a couple of planks. If the cooling jacket
32
sticks, use Rubber hammer to force the jacket/cover apart. Remove and discard the O-rings from
the cover, and carefully clean the cooling jacket and the cylinder cover. Provide the cylinder
cover with new O- rings, well lubricated with oil. Lift the cylinder cover and guide the jacket
cover into position. Mount and tighten the screws for the cooling jacket. Fuel v/v, exhaust v/v
and starting air v/v to be replaced with new o/h ones and their respective bore to be
reconditioned before installation.

Lubricate the threads with system c/case oil and mount the valve studs. Tighten up the studs in
accordance with the screwing-in torque stated on the data sheet. Fill up the grooves between the
valve studs and the bores for the valve studs with permatex to prevent water or oil from entering
the bores during operation of the engine. Provide the water connection flanges with new gaskets,
and keep the cylinder cover ready for replacement.

Piston removal:

Turn the crosshead down far enough to give access to the piston rod stuffing box and the screws
for the piston rod. Release the stuffing box by removing the innermost screws from the stuffing
box flange. Do NOT remove the outermost screws from the flange. Remove the screws from the
piston rod. Mount the two distance pieces on the piston. Carefully smooth out any wear ridges at
the top of the cylinder liner. Make a scratch mark in liner and piston cleaning ring to ensure the
correct mounting.

Remove the piston cleaning ring. Carefully remove any wear ridges at the top of the cylinder
liner. Turn the crosshead towards TDC, while checking that the stuffing box lands correctly on
the distance pieces. Turn to TDC and to guide the stuffing box. The top of the piston is now free
of the cylinder liner. Clean the lifting groove of the piston crown and mount the lifting tool in
such a manner that the two ‘fixed’ claws of the tool fit into the lifting groove of the piston. Fit
the third, adjustable, claw of the tool to the lifting groove and tighten it up against the stop of the
tool. Lift the piston out of the cylinder liner. Lower the piston rod foot and stuffing box through
the opening in the platform. Place the two halves of the support around the piston rod and secure
the two halves with screws. Place a cover over the opening for the piston rod stuffing box in the
bottom of the cylinder unit. Clean, measure and recondition the cylinder liner.

Piston overhaul:

Ease the piston down so that the stuffing box is below the floor. Assemble the two halves of the
piston support around the piston rod and land the piston on the support. Dismount the locking
wire and the innermost screws between the rod and the piston crown. Dismount the locking wire
and screw up the support screws of the piston support to a position just below the piston skirt.
Remove the piston skirt screws. Screw the four screws of the support down- wards until the skirt
rests on the support. It the skirt will not budge, free it by means of two dismantling screws. Lift
away the piston crown. Remove and discard the sealing rings on the piston rod and on the skirt.
Dismount the bolts of the cooling oil pipe flange. Mount the eye bolts and lift out the cooling oil

33
pipe.After inspection of the cooling oil pipe, re-mount the pipe. Thoroughly clean and inspect all
parts of the piston. Replace all sealing rings of the piston. All the new sealing rings must be
coated with lubricating oil before the piston is assembled. Coat all screws with Molybdenum
Disulphide (M082). Assemble the piston in the reverse order to disassembly. Use the guide
screw to ensure the correct positioning ol the piston rod in relation to the piston crown. Tighten
all the screws diagonally to the torque 80Nm. Lock all the screws with locking wire. Mount the
locking wire in such a way that the wire is tightened if one of the screws works loose.

Fill the piston and piston rod with lubricating oil. Mount the pressure-testing tool around the base
of the piston rod. Pressure-test the piston at the pressure 7 bar. Check the contact surfaces of the
piston and the sealing rings for tightness. Check that there are no cracks in the piston crown.

Piston rings:

Ring grooves:

Measure the total clearance between the piston rings and the ring grooves. The total clearance
must not exceed the value

Measurements are to be taken at the top(E) and bottom (F) between the piston ringand piston
ring groove.

Total clearance = E + F.

Uppermost piston ring:

If possible, measure the depth of the pressure relief grooves with a caliper. The piston rings must
be replaced if the radial depth of the grooves has worn down to less than

It is recommended to change piston rings whenever a piston is removed from the engine. Before
dismantling the piston rings, measure the free ring gap of all the piston rings. Take off the piston
rings by means of the ring expander. Clean and inspect the rings. Measure the radial width of the
rings. Note down the results.

Liner calibration:

Clean the cylinder liner and scavenge air ports. Position the cylinder liner measuring tool.
Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring
tool. See Data. Take measurements in the fore-and-aft and athwart ship directions. Carefully
scratch over any scores or marks on the cylinder liner running surface, and grind away the wear
ridges. Check the lubricating points of the cylinder by pumping cylinder oil to each individual
lubricating point. Clean any blocked lubricating duct.

34
Piston cleaning ring:

Measure the PC ring radial width B, and find the most worn place. Compare with data and
calculate the wear of the PC ring. Multiply the wear by 2 to get the PC ring diameter wear.
Measure the liner in the fore-and-alt and athwart ship directions at piston skirt TDC position,
corresponding to measuring point No. 5 on the liner measuring tool. Compare the measurements
with the diameter of a new liner as stated in data. Calculate the wear of the liner. Compare the
PC ring diameter wear with the wear of the liner. lf wear of the two components does not deviate
more than 0.5mm, then reinstall the PC ring. If the deviation between PC ring wear and liner
wear is more than 0.5, or if the PC ring is broken or cracked, replace the ring with a new PC ring.
When a new liner is installed, also a new PC ring must be installed. When a new liner is ordered,
also a new PC ring must be ordered.

Stuffing box:

Normally, overhaul of the piston rod stuffingbox is carried out by routine methods in connection with
the dismantling (pulling) of the pistons.During such overhauls, the piston rests on a support placed over
one of the cut-outs in the top platform.Work on the stuffing box is then carried out from the platform
below.

Overhaul inside the engine is carried out in the same way as outside the engine .

1. Mount two eye bolts in the stuffing boxflange, and hook on two tackles.Lift the stuffing box a little up
the pistonrod, and mount the worktable round the piston rod at a suitable working height.Land the
stuffing box on the worktable,and remove the tackles and eye bolts.

2. Remove the 0-ring of the stuffing box. If the 0-ring is intact and is to be used again,

move it up the piston rod and secure it inthis position, for example with tape. Remove the nuts from the
stuffing box assembling bolts.

3. Take out the six bolts, and pull away onestuffing box half. 3.Mount two eye bolts on the stuffing box
half and remove it from the worktable. 002-45

4. Using a feeler gauge, measure the vertical clearance of the rings.

5. Remove the remaining stuffing box half and press all sealing rings and scraper rings

down against the worktable.

6. Measure the clearance between the ring segments to determine whether replacement

is necessary.

Dismantle and stack the rings in the same order as when fitted in the stuffing box.

Carefully clean all the ring segments.Inspect and assess the surface quality of the sealing rings. If their
sliding surfaces have scratches or marks, replace the rings.

7. Check the lengths of the springs..

35
8. Inspect the surface of the piston rod. If small longitudinal scratches have occurred (caused by poorly
adapted stuffing box rings), smooth the _piston rod surface carefully

with a fine grained carborundum stone. In the case of coarse scratches, it may prove necessary to
machine-grind the surface in a workshop.

9. Clean the halves of the stuffing box housing

1 0. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned)
with molybdenum disulphide (MoS2). For correct mounting of the sealing and scraper rings see the
sketch. The scraper ring in groove no. 4 must be without relief

grooves on the underside

Date:22/03/2020

TASK NAME MAIN ENGINE BEARINGS AND PIN

Task Description: Assess the condition of any main engine bearings and pin (at least 2),
which are opened up for survey. State in detail your comments on its condition. Propose
any action to rectify the defects noticed. Give reasons if bearing is to be discarded.

BOTTOM END BEARING

36
MAIN BEARINGS:
Condition of the bearing Opened up for class Surveyor inspection were found to be
satisfactory.

37
Date:24/03/2020
TASK NAME: FAMILIAR WITH CORRECT WAY OF USING ALL PRECISION
INSTRUMENTS

PRECISION EQUIPMENT INVENTORY:

SR. NO. DESCRIPTION LOCATION

1 M/E LINER CALIBRATION TOOL - A/4 (1/2) C/E STORE

2 M/E LINER CALIBRATION TOOL - A/4 (2/2) C/E STORE

3 M/E DEFLECTION GAUGE ECR

4 MEAS TOOL FOR M. BEARING CLEARANCE - A/1 C/E STORE

5 M/E INDICATOR CARD INSTRUMENT ECR

6 A/E DEFLECTION GAUGE ECR

7 A/E CONROD OVALITY C/E STORE

8 A/E LINER CALIBRATION TOOL C/E STORE

9 A/E PEAK PRESSURE INSTRUMENT ECR

10 A/E PISTON PIN MICROMETER C/E STORE

11 TEMPRERATURE CALIBRATION TOOL ECR

12 FILLER GAUGE - 3 NOS. ECR/ C/E STORE

13 VERNIER CALIPER ECR

14 INFRARED THERMOMETER ECR

15 MICROMETER C/E STORE

16 PRESSURE CALIBRATOR C/E STORE

CALIBRATION OF ME CYL LINER INTERNAL DIAMETER:

• Clean the inside of liner especially at top and near scavenge ports.

38
 • The measuring tool and liner should be at same temperature. If temperature differs then
corrections should be applied accordingly.

• Do the Zero Setting of the measuring tool.

• Place the standard template which has pre-positioned holes according to the measuring
points of the liner of that particular make of engine.

• Place one end of the measuring into the hole of the template touching the liner surface
and other end on the opposite side.

• Move the tool in little horizontal and vertical motion and check the reading for correct
diameter of the liner at that point.

• Note down the readings.

• Liner should be renewed if wear is more than 0.4~0.8% of new liner dia.

Date:26/03/2020
TASK NAME TIME MANAGEMENT PLAN

Task Description: Complete a time management plan for a large maintenance task as main
engine unit decarbonisation. Reassess completion times as work progresses and keep relevant
Senior Officers updated.

A planned approach to repair and maintenance, essentially, is the single most important factor.
Without careful planning there can be no identification of workload which could lead to
improper work allocation, inefficient manpower utilization, oversights and negligence.

Main engine decarbonisation time management plan:

ACTION ESTIMATED TIME ACTUAL TIME OF REMARKS

FOR COMPLETION COMPLETION
Debriefing of the 30 MINS 45 MINS Oil level was low in
task and arrangement hydraulic pump. One
of spares and tools of the hose was
missing from place.
Unit isolation and 1 HOUR 1.5 HOUR Exhaust manifold
disassembly of connection bolts
cylinder head stuck.
connection
Removal of cylinder 1 HOUR 2.5 HOURS Cylinder head bolts
head and piston were stuck and
opened only after
repeated tries.
Cleaning cylinder 2 HOURS 2 HOURS Completed in

39
 head, liner estimated time.
calibration, lowering
overhauled piston
Installing piston and 1.5 HOUR 1HOUR Completed in
cylinder head estimated time.

All connection 1 HOUR 1 HOUR Completed in

assembly estimated time.
Try out ,safety 30 MINS 45 MINS Leakage from
checks and securing exhaust valve
of tools and spares cooling connection.

ESTIMATED TIME OF COMPLETION: 7.5 HOURS

ACTUAL TIME TAKEN: 9.5HOURS

DATE : 30/03/2020
Task Name: Structural Condition Report for an ER Double Bottom Tank.
Task Description: Complete a Structural Condition Report for an ER Double Bottom Tank
or void space.
The report should be complete with frame nbrs,steel plate material and its thickness.

Bilge water tank cleaned and inspected.

Percentage of wastage on steel structure-Almost Nil
No deformation on shell plate and signs of structural damage found.
No signs of corrosion found.
Paint coating is intact and in good condition.
Suction bell mouth and Sounding pipe inspected for wastage of material and found intact and
clear no pitting noticed.
Conditions of piping and associated valves are in very good condition.
Negligible mud accumulation in bottom section of tank

40
41