REFERENCE OF MARINE ENGINEERING KNOWLEDGE FOR

M.O.T 2nd Class Part B (Oral)

Table of Contents
Compiled by Min Zar Tar
01) Indicator Diagram 1
02) Lubricating Oil 9
03) Bearing 19
04) Boiler 31
05) Compressor and Air Bottle 43
06) Purifier 49
07) Refrigeration and Air condition 53
08) Heat Exchanger 61
09) Steering Gear 63
10) Governor 67
11) Fire and Safety 69
12) Pump 80
13) Explosion 81
14) Electro-Technology 90
15) Naval Architecture 111
16) Scavenging and Supercharging 129
17) Fuel Pump 139
18) Cylinder Liners 141
19) Marine Pollution Prevention 147
20) Piston 155
21) Piston Ring 161
22) Crosshead 165
23) Stuffing Box 166
24) Thrust Block 167
25) Fuel Valve 169
26) Exhaust Valve 175
27) Foundation Chock 179
28) Cylinder Head 181
29) Cylinder Relief Valve 182
30) Crankshafts 183
31) Stern Tube 187
32) Engine Operational Faults 195
33) Fuel oil 205
34) Shaft Generator 210
35) Survey and Inspection 211
 1 2 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

I.P = MEP x Length of stroke x cylinder bore area x rps (Watts)

IP = P L A N x No. of Cyls (KW)
What is the indicator diagram?
2
The diagrams indicating, simultaneously, the pressures and the relative position of the piston in P = MEP (KN/m ) = (Area of diagram / Length of diagram ) x Spring scale
the engine cylinder are known as indicator diagrams. L = Stroke Length ( m )
A = Cylinder bore area ( m2 )
PURPOSE (WHY) OF TAKING INDICATOR DIAGRAMS N = N for 2/S single acting (rps)
a) Determining the indicated engine output = N/2 for 4/S single acting
b) Determining combustion (Pmax) and compression pressures (Pcomp) = 2N for 2/S double acting
c) Evaluation of the combustion process and its peculiarities
d) Evaluation of the exhausting and scavenging conditions Purpose of Each indicator diagram
Power diagram - To calculate indicate power. It also shows peak pressure.
HOW TO TAKE INDICATOR DIAGRAM? (SQUENCE) In phase with piston movement, with fuel on.
a) Check whether the spring fitted on the indicator instrument will meet the peak pressure to be
expected (max. pressure of Engine). Out-of-phase diagram - An out-of–phase diagram (draw card) is required to be taken if the
b) Stretch diagram paper firmly over the drum. compression pressure is to be accurately determined.
c) Before taking diagram, open indicator cock, two or three firing strokes, to blow out soot and It shows Pmax (more accurately), P compression and ignition delay period (Nature of
combustion residues in the cock. expansion curve). It also shows combustion process (early or late combustion)
d) After drawing atmospheric pressure line, hook the cord to indicator drive, open indicator cock, and To evaluate injection, ignition delay, fuel quality, combustion, loss of compression, expansion
take power diagram and shut the cock. process, fuel pup timing, and after-burning.
e) Remove hook, turn the drum by hand to a place clear from the power diagram, took compression
90° out of phase with piston movement, with fuel on, to determine Pmax
pressure line with fuel cut-off.
f) Having taken indicator diagrams from all cylinders, open the indicator instrument and clean all
Compression diagram - To know compression pressure of the cylinder and cylinder tightness.
parts especially the piston, thoroughly. After cleaning, apply high temperature grease into the
In phase and fuel cut-off.
surface of all parts.
Note: Do not allow the indicator instrument to become overheated by too many firing strokes, as it
Light spring diagram - This diagram are taken for determining the pressure variation in the cylinder
will affect the instrument accuracy. during the exhaust and scavenging periods
The diagram shows-
Types of Indicator diagram? Choke exhaust ports or valves
Power card Loss of scavenge air
Draw card In phase, using light spring, with fuel on, to determine
Compression card
Light spring card When taken?
Taken at every month and after every major O/H on the way.
What is indicated power? How to calculate power? By according to the engine condition.
It is the power developed in the cylinder.
Firstly, take the power diagram for each cylinder PRECAUTION NECESSARY TO AVOID INDICATOR MALFUNCTION
The area of the diagram can be measured by means of a planimeter. To reduce the effect of friction the indicator piston is removed, the piston and the cylinder cleaned
Measures the length of diagram; check spring scale. and lubricated with a few drop of cylinder oil
Calculate the mean effective pressure The tightness of the indicator piston in the cylinder should be checked. This can be done by
dismantling the piston and allowing it to drop slowly through the cylinder by its own weight.
Diagram area The drum should not hit the stop at end positions. Play in the pencil mechanism will distort the
diagram
M.E.P = ---------------------------- x Spring scale
The cock should be free from accumulation of soot and oil
Mean Length of diagram
The stylus should be adjusted to a light writing pressure
Before taking indicator diagrams, open indicator cock two or three firing stroke to blow out soots
Record the engine revolution(RPM)
and carbon residues in the cock.
Calculate the power for each unit
Check whether the spring fitted on the indicator instrument will meet peak Pr: to be expected.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 3 4 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Stretch diagram paper firmly over the drum 3) Fuel injection pump plunger has been set too high (Incorrect fuel pump timing or wrong V.I.T
After drawing atmospheric line, hook the cock to the indicator drive, open indicator cock and take setting)
power diagram, shut the cock 4) Incorrect adjustment of the fuel cam on the camshaft
Remove hook, turn the drum by hand to a place clear from power diagram, took compression 5) Incorrect adjustment of fuel valve spring pressure (low)
pressure line with fuel cut-off
Do not allow the indicator instrument to become overheated by too many firing strokes, as it will LATE IGNITION
affect the instrument accuracy Effects:
Having taken indicator diagrams, from all cylinders, open indicator instrument and clear all parts, 1) Lower peak pressure
especially the piston thoroughly. 2) Higher Exhaust temperature with black smoke
After cleaning, apply high temperature grease into surfaces of all parts 3) Loss of power
4) Reduced Thermal efficiency
How to maintain good Performance 5) Reduced Scavenge efficiency
01) Maintain good power output per cylinder 6) Higher Exhaust gas pressure at blow down period and increasing pulsation in the exhaust
02) Take power Card, to check power output/cylinder manifold
03) Take Compression Card, to check for cylinder tightness 7) Higher expansion line
04) Check ratio of Absolute compression pressure to absolute scavenging pressure. 8) Ignition occurs after TDC
05) If the ratio is same as that during sea trial, piston rings and exhaust valves are sufficiently tight. 9) Increase S.F.O.C
(With B&W engine, this ratio is about 30)
06) If absolute pressure ratio is less, check for cylinder tightness, charge air cooler, scavenge air Causes
ports, scavenge valves, piston rings, exhaust valves, TC, etc. 1) Incorrect fuel pump timing and wrong V.I.T setting
07) Light spring diagram is taken if necessary 2) Faulty fuel valve (Excessive injector spring setting)
08) Check exhausts temperatures, exhaust smoke, load indicator and engine running parameters. 3) Injection viscosity too low
09) Check fuel, CLO & LO consumption 4) Lack of scavenge air or cold air
10) Regular maintenance works and repairs. 5) Bad atomization
6) Slack chain drive
Absolute Pressure = Gauge Pressure (of Manometer) + Atmosphere Pressure (15 psi or 30 Mercuy)
7) Lower cetane number of fuel
8) Worn out fuel pump, cam and roller
In compression pressure is low: 9) Low compression
Carry out unit O/H and renew liner, piston and rings. 10) Under cooling of parts within the cylider
TC checked, clean and overhauled, to have efficient operation 11) Leaky fuel pump delivery valve or spill valve
Check Scavenge air line, charge air cooler, for insufficient scavenge air condition It may cause:
Check Inlet and Exhaust valves may be leaking. a) Exhaust valve burning
Clean Scavenge Ports, Scavenge Valves, if 2/S engine. b) Turbocharger surging
c) Fouling of exhaust system
Early Combustion d) Uptake fires
Effects: e) High cylinder temperature resulting in liner lubrication difficult.
1) Very high peak pressure Pmax at about TDC
2) Lower Exhaust temperature After Burning
3) Increase Power Symptoms & Effects
4) Increase Thermal efficiency 1) Rise in expansion line during latter part of the load
5) Heavy shock load to bearings 2) Exhaust temperature and Exhaust pressure will be high, with burning fuel and carbon passing to
6) Engine knocking exhaust.
7) Lower expansion line 3) This may burn exhaust valves and foul the exhaust system, with risk of T/C surging or uptake
8) Ignition occurs before TDC fires.
9) Less S.F.O.C 4) High temperatures within the cylinder cause deterioration in lubrication and possible damage to
liner surface & piston rings. This may be the cause of piston crown burning.
Causes 5) Smoky exhaust
1) Overheated piston
2) cetane number of fuel than normal

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 5 6 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Causes Causes
1) Incorrect fuel pump timing (Slow or late combustion of fuel) 4) The contamination in the fuel in which debris may choke the small atomizer holes in the injector
2) Faulty fuel injector (leaky fuel valve) 5) A leaky injector allowing hot gas to blow back into the injector causing carbon to form and choke
3) Heavy fuel oil temperature too low and high viscosity the injector.
4) Lack of scavenge air 6) Overheating of injector nozzle may also cause build-up of carbon.
5) Poor compression
6) Poor quality fuel Remedies
Change the fuel valve
EXHAUST VALVE OPENING Clean the whole fuel system
Exhaust valve opening in a slow speed engine can be checked by means of light spring Ensure correct centrifuging and filtering of fuel
indicator diagram. Maintain correct cooling temperature of fuel valve
Early opening
1) Indicates high exhaust temperature with the risk of overheating and contamination LEAKY FUEL INJECTORS
2) Causes a loss of power since pressure is released too soon. Symptoms
01. Loss in power
Late opening
02. High Exhaust temperature with smoke
1) Reduces the scavenge efficiency by reducing blow down
03. Knock or pressure wave in fuel injection system
2) Affects the supply of energy to the turbocharger.
It can be detected by taking both Power card and Draw card, which shows fluctuation of
pressure during the expansion process due to secondary burning of fuel leaking from the valve.
CHOKE EXHAUST PORTS OR VALVES It may cause:
Symptoms a. Afterburning
1) Higher exhaust pressure with sooty smoke b. Hot gas from combustion chamber blow past into the injector and forming carbon
2) Higher mean temperature of working parts Earlier Exhaust trumpets choking the injector
3) Higher Exhaust temperature with heavy smoke Sufficient time for Cyl: c. Fouling and loss efficiency of turbocharger due to afterburning
4) Lower Pmax , Lower Pcomp d. Coking of exhaust ports and grids.
Press: to fall below
5) Loss in power
6) Surging of Turbocharger
charge air press . When
the scav Ports uncovered.
Causes Increased pulse energy
1) Faulty fuel injection system available from the
2) Lack of scavenge air exhaust gas which can be
3) Excessive cylinder lubrication used to improve pulse
4) Fouling of exhaust system
T/C performance.
By advancing exht Diagram showing leaking injector
Remedies
Timing, Gain in T/C
Correct fuel timing and fuel injection system
Maintain scavenging system in good order output is greater than loss Remedies
Correct cylinder lubrication feed of expansion stroke. The fuel valve should be renewed and tested for faults and rectified.
Clean exhaust grid and Turbocharger Fuel purification and separation system should be kept in good order
Fuel system temperature and Nozzle cooling temperature must be maintained in correct levels.
CHOKED FUEL VALVE
Symptoms LEAKY PISTON RINGS OR WORN LINER
1) Loss in engine power Symptoms
2) Hammering in the fuel pipes between fuel pump and injector (This may lead to rupture of fuel 1) Loss in engine power
pipe) 2) Lower compression (Pcom) and combustion (Pmax)
3) Reduce exhaust temperature 3) High exhaust temperature with smoke
a. It can be confirmed by indicator diagram power and draw cards. The diagrams show Causes
b. irregularities at the peak of the diagram. 1) Excessive cylinder liner wear

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 7 8 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

2) Lack of cylinder lubrication High Cetane Number Effects

3) Worn, broken, stuck or poorly maintained piston rings 1. Shorter delay period
4) Worn piston ring groove landings allowing rings to cant and jam 2. Early combustion
5) Carbon jamming rings in grooves 3. Increased power
6) Turbocharger failure due to fouling 4. Knocking
7) Blockages in the exhaust gas system. Low Cetane Number Effects
It can be detected by taking Draw card which shows higher dip in compression line. It may 1. Longer delay period
cause: 2. Late combustion
(1) Blow past of combustion gas 3. Decreased power
(2) High rate of cylinder liner wear due to poor cylinder lubrication 4. After burning
(3) Scavenge fire 5. High exhaust temperature and smoke
(4) Piston seizure due to local overheating
Diesel Knock
Remedies Violent knocks produced by high rate of pressure rise, RPR, during combustion, as delay
period is longer then normal
Renew cylinder liner if necessary
Overhaul piston
Causes
Clean ring grooves and gauge
1. Too low working temperature
Machine or fit new groove inserts as necessary
2. Cold start
Renew piston rings with correct clearances
3. Too early fuel injection
Maintain cylinder lubrication and avoid overload

Calculate the indicted power diagram by Mid ordinate Method

Sum of mid ordinates

Calculate mean height of diagram =
Number of parts in diagram

Calculate MEP = Mean height of diagram x Spring scale

Leaking piston rings

Cetane Number
A measure of ignition quality of fuel
The higher the Cetane Number the shorter the time between fuel injection and rapid combustion
The higher the Cetane No. the better the ignition quality
Considered as poor fuel, if C< 37 Usual range is 30-45

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 9 10 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

(7) What is the flash point ? ***

It is the lowest temperature at which the oil will give off a sufficient inflammable vapour to
produce a flash when a small flame is brought into the surface of the oil.
(1) Function of a lubricant ? *****
01) Separate entirely the working surfaces, thus reducing static and dynamic friction to a Close flash point for crankcase LO is around 220 °C.
minimum and preventing wear.
02) Remove heat, generated either within the bearing or from an out side source.
Why flash point is important ?
03) Protect against corrosion
04) Flush away contaminants. FO It is important, fuel oil flash point is to be fairly high because of they were low, there
05) Dampen noise. would be a possibility of fire in storage.
06) In some case; act as a sealant. LO Engine crankcase oil flash point should be as high as possible to prevent crankcase
explosion.
(2) Types of Lubrication
Hydrodynamic - Full fluid film lubrication. (For safe storage) to limit the oil storage tank heating temperature at least 14 °C lower than its
Boundary - Thin film lubrication F.P prevent fire.
Hydrostatic - Thick film lubrication
Elasto-hydrodynamic - Thin film or square film lubrication. Average Closed Flash Points
Petrol = -20 °C 70cSt Fuel Oil = 71 °C
(3) Properties of crankcase lube oil ? Paraffin = 40 °C Lube Oil = 220 °C
(a) Viscosity (Suitable) (b) Viscosity index (Hight)
Diesel Oil = 65 °C
(c) Pour Point (low) (d) Flash point (high)
(e) Oxidation stability (f) Carbon residues (low)
(8) What is TAN and TBN ?
(g) Total acid number (TAN) + Total basic number (TBN)
It is the neutralization value of used engine lube oil.
(h) Detergency (i) Dispersancy
The ability of an oil to react with a base reagent which indicates the acidity expressed as TAN.
The ability of an oil to react with acidic reagent which indicate the alkalinity expressed as TBN.
(4) What is viscosity
The results are expressed intern of milligrams of potassium hydroxide (KOH) required to
A measure of its internal resistance to flow. neutralise one gram of sample oil for both TAN and TBN.
Viscosity of oil changes with temperature, falling when temperature rises and vice versa. TBN for an oil used for
Crankcase L.O – 130 to 240 seconds, Redwood No-1 at 60°C.
For cylinder oil, viscosity is 12.5 – 22 Cst Crosshead type diesel engine crankcase is 8mg KOH/gram of oil.
For trunk type engine using heavy oil is 30mg KOH/gram of oil.
(5) What is viscosity index ? (VI)
(1) The rate of change of viscosity of an oil in relation to change of temperature. (9) What type of engine are using high TBN and why ?
(2) Low viscosity index has greater change of viscosity with change in temperature than the oil of At trunk type engine using heavy fuel oil if blow pass occur incomplete combustion products
high VI. reach directly into the crankcase and may cause the contamination with acid easily. Thus in this type of
Good crankcase oil = VI scale is 75 to 85. engine to neutralize the acid contamination must be used high TBN oil.
For cylinder Oil, VI is 85
(3) Highest VI of mineral oils is about 115 and with special additives, this may be raised to about (10) What are detergency / dispersancy ?
160 It is a chemical compound called detergent which has property of preventing the deposition of
(4) Hydraulic oils, used in remote control hydraulic circuits must have very high VI; otherwise carbonaceous deposit and wash away with the lube oil.
erratic response to the controls can be troublesome (Telemotor hydraulic system oil has VI of Dispersant additive addition is made to divide the larger size deposits into tiny particles to be
110) carried in a colloidal suspension evenly throughout the bulk of oil.

(6) What is a pour point ? (11) Explain the L O sampling procedure to send for LO test ?
(1) It’s the lowest temperature at which an oil will barely flow. The sample should be drawn with oil circulation with the system such as a test cock on the
(2) Pour point indicates that oil is suitable for cold weather or not. discharge side of the LO oil pump.
(3) Pour point of engine crankcase should be -18 °C Before taking the sample oil sufficient amount of oil should be drain out to clear the line.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 11 12 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

The sample is filled into the chemically cleaned container after it is rinsed with the sample oil and (13) Where do locate ME LO sump and its fitting ?
immediately closed. It is located under the engine in the ship double bottom and surrounded by cofferdams.
The container should be attached 1) engine type 2) engine running hours 3) LO running hours 4) It consist of 1) level gauge 2) man holes 3) air vent pipe 4) sounding pipes 5) heating steam coils
fuel used 5) draw off point and 6) date. 6) suction pipe and 7) valves for LO p/p and purifier.

Sampling Procedure (14) Why magnetic fitter is fitted on LO system ? Where fitted ?
Draw samples from a connection that comes directly out of the main oil supply line to the
engine. Always sample for the same point. Sample only when the oil is up to its operating temperature To prevent pump damage due to ferrous metal particles.
with the engine running. Screw p/p used in LO oil system is working in very fine clearance thus to prevent entering the
small ferrous particles into the p/p.
Magnetic fitter is fitted prior to the main circulation LO p/p.

(15) Contaminants in the lube oil ?

a) Contamination of fresh Water (JW leaking)
b) Contamination of SW (Cooler leakage)
c) Contamination of fuel (Poor Atomisation, Unburned Fuel)
c) Oxidation products (High Exhaust Temperature, Burned Cyl Oil, Carbon from
incomplete combustion)
d) Products of fuel combustion
e) Foreign mineral matters (Scale formation, Wear and tear)
f) Bio logical contamination.

(16) Water contamination in lube oil ?

Depending upon the draw off point, sufficient amount of oil should be drained out of the line
prior to drawing the sample. The sample should be filled into a chemically cleaned container after it is Causes 1) condensation of water vapour within the crankcase
rinsed with sample oil and immediately closed. The container should be attached with a label as follows: 2) Leakage from the cooling water system for cylinder or piston
3) Leakage from the sump tank heating steam coils.
Records for Sample
(1) Date of sample drawn
Effects - Reduce cooling efficiency.
(2) Point of sample drawn - Increase the acid formation in trunk type piston engine.
(3) Type of oil - Can cause corrosion on m/c parts.
(4) Type of machinery use - Microbial degradation, [Reduce centrifuging efficiency; promote local pitting and
(5) Temperature of sample drawn corrosion]
(6) The period of time since the last renewal of oils.
- Reduce load carrying capacity
Avoid - Reduce L.O properties, and TBN of oil
Sampling form places where the oil may be stagnant or have little or no flow, such as: - Form sludge due to emulsification
Sumps Remedies - Proper purification with minimum throughput
Auxiliary smaller pipelines - Batch purification if heavy contamination
Purifier suction or discharge lines.
Drain cocks of filters, coolers etc.
Sampling while engine is stopped Maximum Allowable % of water in LO
For crosshead engine, < 0.2 % is satisfactory
(12) Essential factor effecting the establishment of hydrodynamic lubrication ? If water content exceed 0.5 ~ 1.0 %, immediate action should be taken
If > 1%, engine can be damaged
*****
01) Viscosity of oil For trunk type engine, < 0.1% is satisfactory
02) Load acting on the bearing If > 0.5 %, immediate action should be taken and
03) Surface smoothness of moving parts It is maximum permissible content
04) Speed of rotating
05) Continuous LO supply
(17) Fuel dilution in lube oil ?
06) Bearing clearance, bearing length and pin diameter.
07) There must be convergence between fixed end and moving surface. Causes Poor atomization of a fuel injector and back leak through the fuel injector
p/p plunger and barrel.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 13 14 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Effects Fuel dilution usually diesel oil.

Lower viscosity and low fresh point (26) What will be happen temp: is lower than pour point ?
The oil can not freely flow thus effect the pumping system (lubrication system)
Lower viscosity LO reduces this properties ( e.g load carrying capacity )
Lower fresh point will case crankcase explosion. (27) Why viscosity is important ?
FO Low viscosity is required for fuel in order to obtain good atomization at fuel valve.
How to move contaminants
LO LO must be chosen which has a suitable viscosity for the working temperature for
Filtering - Removed large oil insoluble matter
efficient lubrication.
Gravity separation - Heavy matters, sludge and water
Adding special additives - Reduce acids, sludge, finer oil insoluble matter
(28) How to maintain L.O on board ? ******
Centrifuging - Sludge, foreign matter and water
Water washing - Only for straight mineral oil or oil without additives, can (1) L.O onboard test is carried out regularly.
remove acids. (2) Regular cleaned L.O line filter.
(3) L.O purifier should be run during ship is in sea
What will you do if LO is contaminated with FW or SW ? (4) Maintain L.O purifier performance
(5) Periodic batch purification must be carried out & cleaned L.O sump tank once a year
(1) Batch Purification must be done
(6) Maintain L.O temperature within receptacle limit
(2) Renovating Tank heating and regular draining
(7) Maintain good L.O cooler efficiency
(3) For SW contamination, Water Washing is required
(8) Keep good fuel combustion system
(4) Sump to be opened and thoroughly wipe out.

(29) Why cooler is installed after filter ?

(18) How do you make batch purification ?
It is more effective to filter the hot oil, as pressure drop through the filter is less and filter is
Firstly take the immobilization permit from the port authority.
more complete.
The entire oil charge should be pumped by the purifier or by main circulation p/p into
renovating tank.
(30) Action of L.O temperature abnormally high (What will you do as 2/E, if M/E L.O
It should be allowed to settle for at least for 24 hours with heating about 60°C (60°C).
Water and sludge should be drained out periodically. temperature abnormally high) ********
Cleaned the interior of the sump tank and carefully examined. (01) Inform bridge & reduce engine speed Quick response
The oil should be passed through the purifier at its optimum efficiency and than pump back (02) Check engine overload or not (Exhaust temp:, fuel rack,..)
into the sump tank. (03) Check L.O sump & L.O cooler & L.O purifier temperature (set value)
When sump tank empty, its interior should be cleaned and exaimed. (04) Check L.O sump tank heating valve.
(05) Shut L.O cooler by-pass totally after stopping (or) too high temperature not fall
(19) When periodic batch purification make ? (06) Clean L.O cooler
If the oil is suspected from containing strong acids, (07) Check sump tank heating coil leakage
High insoluble contents due to poor combustion or water due to leak cooling system. (08) Make L.O onboard test (esp Viscosity)
It is also made at least once a year when cleaned and examined for sump tank. (09) Check L.O piping system leakage or blockage
(10) Make (inspection & check bearing clearance & loosing attachment
(20) What is grease ? (11) Check ampere (or) load when turn the turning gear
It is a semisolid lubricant consisting of high viscosity mineral oil and metallic soap with filler.
Metallic soaps are compound of Ca, Na, Al. (31) Action when increase L.O level
Filler are lead, zinc, graphite and molybdenum. (01) Check piston cooling system (water)
(02) Check L.O purifier (gravity disc is correct or not) [L.O purifier water outlet sight galss]
(21) What is solid lubrication ? (03) Check filling valve from storage tank
Grease lubrication (04) Check L.O cooler/although oil pressure is greater than S.W pressure.

(22) At what point will feed to the piston ? (32) Action when decrease L.O level
The cylinder oil is feed to the piston at the time when the top two piston rings pass the (1) Check rate of decreasing if slowly decrease, fill up L.O and find the leakage without stopping
lubrication holes in the cylinder during the piston stoke. engine
It is a limited lubrication.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 15 16 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

(2) If rapidly decrease, inform to bridge and stop the engine. Find the leakage and repair. Possible 5) Purified oil sent to laboratory and tested
leakage points: 6) During this time, new oil should be used
(2a) Bed plate crack (check engine room bilge) 7) Oil should be reused, if lab results recommended that it is fit for further use. (Straight mineral oil
(2b) Piston cooling L.O system (check scavenge space & under piston space {entablature}) 3% water washed. Additive oil1% water washed)
(2c) L.O cooler & L.O purifier
(2d) All pipes and connection Difference in Cylinder oil and System oil
(3) Check L.O return valve from crankcase to sump tank close or not Cylinder oil is detergent / dispersant oil
(4) Check oil scraper rings & stuffing box System oil is straight mineral oil

(33) Action when decrease L.O pressure L.O on board test

1. Start stand by pump Viscosity Determination
2. Change & clean L.O filter The simplest method is three tube rolling ball viscometer
3. After engine stopping, check bearing clearance and L.O pipe connection Assuming the oil in the engine to be SAE 30 grade, one tube is filled with minimum safety
4. Check L.O pump discharge & suction pressure viscosity (about SAE 20) and another one filled with maximum safety viscosity (about SAE 40). The last
5. Check L.O temperature tube is to be filled with test sample.
All tubes are placed in a bucket of warm water until the oils are at the same temperature. The
three tubes then mounted on a tilted board and inverted. An internal hollow ball in each tube then rises
Hydrodynamic lubrication (full fluid film) to the surface.
(1) Moving surfaces are separated completely by the pressure of a continuous unbroken film or a If the time taken in the test sample is between that of the lower and upper limit oils, the oil is fit
for further use. If not, it must be replaced.
layer of lubricant, generated by the movement of the two surfaces relative to each other.
(2) Essential requirement is formation of a wedge of lubricants between surfaces. Insoluble Content
(3) Thickness of film 0.025 – 0.10 mm. A drop of sample oil is released from a given height onto a special filter paper. Compare the
(4) Lubrication for Journal Bearing, Bottom End Bearing, Tilting Pad Thrust Bearing result with the known varying insoluble content. The upper limit for straight mineral oil is 1% to 1.5 %
and for detergent dispersant oil is 5%.
Boundary lubrication Water and other Contaminants
(1) It exists when a full-fluid film lubrication is not possible. A known amount of sample oil in the test tube is heated and must be shaken the while doing so
(2) The sliding surfaces are separated by only a thin film of lubricant. 1) If there is no cracking, the oil is dry
(3) High friction between the surfaces and some degree of metal to metal contact occurs 2) If there is slightly cracking, the oil having a trace of water
3) If there is a heavily crackling, the oil is heavily diluted with water
(4) Lubricant oil film decreases, until asperities of mating surfaces touch
Acidity / Alkalinity Determination
Hydrostatic lubrication Acidity is tested by extracting the acids from the sample by means of shaking with a known
(1) A form of thick film lubrication, but instead of being self- generated, it is supplied from an amount of distilled water. The acidic extract is then placed on a watch glass with an indicator solution of
known strength. The mixture is then drawn up into a glass tube and its colour compared with a series of
external source by oil under pressure from a pump. colour standards, each representing a known PH value, from which the sample can be determined quite
(2) Lubrication for Crosshead Bearings, with attached pump. accurately.

Elasto-hydrodynamic lubrication Another method is:

A drop of indicator solution is placed on to blotting paper and this is followed by a drop of
(1) Applies to line contact or nominal point between rolling or sliding surfaces, such as rolling sample oil placed at the centre of the drop of previous absorbed indicator.
contact bearings and meshing gear teeth. If the change of colour is Red, it is acid
(2) Thin film or squeeze film lubrication limits metal to metal contact. If blue/green, it is alkaline.
(3) Elastic deformation of the metals occurs, and there is effect of high pressure on the lubricant. If yellow/green, it is neutral.

Foreign Particles Test

I f LO is c ont a m ina t e d w it h SW This can be done by either Spectrochemical analysis or Ferrographic analysis or Ferrographic
1) When sump oil is contaminated with SW, find sources of leakage (may be from LO cooler during analysis, each giving particle size less than 10 uM to 100 uM range depending on the tests applied.
ME stopped) stoppage and rectified The most powerful technique is Inductively coupled plasma atomic emission spectrometry (ICP
OR PES), which uses a direct spray technique to determine the wear and contaminant elements
2) In port or while ME is stopped, transfer contaminated oil through purifier or transfer pump into
present in the oil. This technique will in the main only detect the particles below 10 uM size.
Renovating Tank, settled for at least 24 hours at about 60°C, and water and sludge drained out In ferrographic test, the sample is thinned first with some solvents and allowed to pass slowly
periodically down a slide surrounded by powerful magnetic field.
Then it is examined by special microscope with red and green filters under lights. The shape of
3) Oil passed through purifier at 78°C with optimum efficiency, and pump back to Renovating Tank the particles is used to identify the source of the wear debris.
4) When sump tank is empty, interior cleaned and examined

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 17 18 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

The advance ferrography method was added to the PFA (Progressive Fast Analysis) How do you do lubricator quill overhaul ?
programme where all samples pass through the combination of two machines, a particle quantifier (PQ) 01) Remove nut on lubricator quill (L.O connector)
and a rotary particle depositor (RPD). These test measures the induced magnetic moment of debris as 02) Take out lubricator quill fitted directly to the cylinder without passing through the jacket cooling
deposited on a substrate or contained within a specific volume of liquid.
These machines provide accurate test by rotating the metal particles and then separating into space.
three different sizes, Theses three bands of particles are examined by very powerful microscope to 03) Remove lubricator quill (L.O outlet side)
determine the type of materials and shape. 04) Take out spring and non return ball valve.
If more detailed examination is necessary, the debris may be subjected to a scanning electron 05) Clean all parts in diesel oil.
microscope. 06) Check non return valve for occur.
07) Check spring tension.
08) Place the non return valve and spring into the lubricator quill then tighten out.
09) Fit the lubricator quill to the cylinder tighten the nut.
10) After fitting the lubricator quill, It is operated by hand at the same time check the cylinder liner wall
for sufficient oil come out.

Lubricator
The lubricators are driven by a common drive from the engine it supply cylinder oil to the REQUIREMENTS OF CYLINDER LUB OIL *****
cylinder. They are synchronized with the engine to provide timed lubrication. (01) It must reduce sliding friction between piston rings and cylinder liner to a minimum.
How to arrange to supply oil to cylinder (or) when they supply L.O to engine (02) It must process adequate viscosity at high working temperature and still be sufficiently fluid
Lube oil be fed to the piston at the time when the top two piston rings pass the lubricating holes to spread rapidly over the entire working surfaces to form a good adsorbed oil film.
in the cylinder during the pistons upstroke. (03) It must form an effective seal in conjunction with the piston rings, preventing gas blow by,
burning away of the oil film and lack of compression.
Timed lubrication (04) It must burn cleanly, leaving as little and as soft a deposit as possible.
(05) It must effectively prevent the build up of deposits in the piston ring zones and exhaust ports.
1) Lubricators of each cylinder are synchronised with engine to provide timed lubrication
(06) It must effectively neutralize the corrosive effects on the mineral acids formed during
2) Cylinder oil is fed; at the time when top two piston rings pass the oil feed points, in the cylinder
combustion of the fuel.
during piston upstroke [4/S and 2/S Uniflow engines]
3) Loop scavenge Sulzer RND engine use accumulator system of timed lubrication
Effects of excess lubrication:
4) Accumulator provides constant oil pressure, which is greater than scavenge air pressure, with
1). Fouling of ring grooves and resulting ring zone deposits.
uniform supply at every period around TDC and BDC positions.
2). Consequently, loss of gas sealing effect and blow by follows.
5) In this way, oil is delivered to quill, only when low pressure and temperature prevails on running
3). Fouling of scavenge space and scavenge fire follows.
surface of cylinder liner.
4). Also affecting combustion process.
6) 8 supply points at top, and 1 point for scavenge and 1 point for exhaust ports at bottom
5). Leading to breakage of piston rings
6). Fouling of exhaust system and turbocharger.
Timed lubrication has little merits, because
7). Increase consumption.
1) It requires very rapid injection of oil at correct time, with correct amount, and pressure
2) It is discharging through very small bore; with long pipes to various oil feed points Effects of reduce lubrication:
3) Having a non-return valve at the top of lubricator, hence it complicates the timed injection 1). Promote wear of liner and rings
4) The hot combustion gases tend to carbonise the oil, and block the orifices. 2). Overheating of local area resulting micro seizure due to lack of boundary lubrication.
3). Consequently major damage to piston and cylinder liner.
Lubricator Quill
Lubricator quills are arranged around the periphery of the cylinder liners and connect cylinder How to check correct amount of lubricator feeding ?
lubricators with oil feed points in the cylinder liners. Checking by open scavenging drain (little coming out O.K) at sea.
In port: Check the liner is wet or not (thin layer wet O.K)
Requirement of lubricator ***** Oil has to not collect at the scavenge space.
a. Must be capable of delivering regularly every stroke a quantity of oil against moderate pressure
b. Must have a wide range of adjustment
c. The quantity of discharged oil per strike should be clearly visible
d. Can be operated by hand

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 19 20 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

a Soft metal flows locally without damaging the harder steel called conformability
a Allows abrasive particles to embed to prevent damage to journal
Corrosion resistance – to withstand corrosive attack from lub oil
Compatibility between bearing & journal under boundary condition
Classification a Anti-weld & anti-score property between shaft & journal during start up & stop and by using
1) Main bearing turning gear.
2) Top end bearing = Cross Head / Gudgeon Pin bearing Antifriction & wear properties –depends upon type of oxide film that material forms on reaction
3) Bottom End Bearing / Crank pin bearing without lube additives.
4) Thrust Pad bearing
5) Pedestal bearing (generator alternator side insulated bearing)
Bearing Material
White Metal = Tin (Sn) +_ Antimony (Sb) + Copper (Cu)
1. MAIN BEARINGS
a Thin walled bearings, stiff cross head assembly 88% Sn + 8% Sb + 4% Cu
Function : Support crankshaft and keep it aligned.
To remove heat produced by friction a Thick walled bearing, flexible crosshead & Bottom end bearing 87% Sn + 9% Sb + 4% Cu
a Tin forms soft matrix to accommodate misalignment
2. TOP END BEARINGS a Antimony forms hard cubes to withstand load of journal. Tends to float and segregate during
Cross head Engines: Transmit load from cross head pin to connecting rod casting
Allows relative movement of con rod & cross head pin a Copper holds antimony in evenly dispersed pattern, solidifies first.
Trunk Piston Engines: Transmit load from gudgeon pin to connecting rod
Allows relative movement of con rod & gudgeon pin Copper Lead & Lead Bronze = Brass (Cu + Zn) & Bronze (Cu + Sn)
a Can withstand 3 times higher load than white metal
3. BOTTOM END / CRANKPIN BEARINGS a Copper / Bronze matrix supplies the strength
Function: Transmit load from con rod to crankshaft a Lead remains in free state, provides bearing properties and Steel strips provides backing
Allows relative movement of con rod & journal a Overlay of 0.024 -0.04 mm thickness of lead –tin, lead –tin –copper.
a Running in prevents acid attack against lead but poor embeddability & conformability
Bearing Operation: Depends on
` Operating temperature of bearing Aluminum Tin = Al Matrix + Si (minor) + Overlay7 (Pb+Sn) + Steel Backing
` Working temperature of bearing a Soft Aluminum forms the matrix and provides embedability & conformability
` Minimum oil film thickness a Tin held in suspension provides bearing properties
` Rate of oil flow a Lead Tin Overlay of 0.02 mm for initial running in
` Rate of heat production a 3 times load carrying capacity than white metal but requires hardened journal
` Power loss of bearing. a Resistant to acid attack and fatigue strength same as Cu & Pb

Bearing Loads: Combustion forces, Inertia forces & Centrifugal force of rotating masses Bearing – Lubricant – Shaft – Interaction
Varying resultant load from gas forces & inertia forces
Two stroke engine No load reversal Bearing Lubricant Shaft
Four stroke engine Load reversals at the end of exhaust stroke hence, wear uniform & Composition Dimensional
lubrication better. Viscosity
Strength Surface Finish
Fluctuating gas force results fatigue failure in bearing Stability Composition Dimensional
Ductility Bore Profile
Compatibility Strength Surface Finish
Fatigue Strength Features
Bearing Material Properties Adhesion Hardness Features
Conformability
Oiliness Compatibility
Mechanical Strength Compatibility
Additives Corrosion Resistance
a Fatigue & compressive strength to carry load – depends upon thickness Embeddability
Bulk Modulus
a 0.3 mm white metal can withstand 141 bar pressure and 0.08 mm white metal can withstand 211 Corrosion Resistance
bar pressure
a Thin lining has poor conformability and too soft material tends to flatten under heavy loads Bearing Material – Shaft Material – Lubricant
a Too hard material withstands high loads, posses high frictional characteristics & may be brittle High local pressure at the point of contact
with poor fatigue characteristics. Localized welding at these points
Alloy formed at welds
Soft & low melting point material Shear strength at welds.
a Softness & modulus of elasticity of bearing alloy should be as low as possible but hard enough to Shear strength (alloy) > Shear strength (metal)
withstand heaviest continuous loading or chock loading without plastic deformation

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 21 22 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

THIN SHELL BEARING Cause of thin shell bearing shifting ?

Wall thickness to diameter ratio varies 0.05 mm for 40 mm shaft diameter and 0.02 mm for 400 (01) Defective tag
mm shaft diameter. (02) Insufficient nip clearance
Interference fit or bearing crush (03) Suddenly applied extreme load.( pounding)
Fretting – Interference fit resists relative movement, prevents fretting. (04) Improper fitting
Locating Tags - For correct axial location of shell but not intended to resist motion (05) Incorrect size of bearing use
- Recessed below bearing joint face. (06) Due to over tightening bolts
Free spread - Bearing shell in snapped into bearing housing (07) Frictional force from the back of the shell and keep.
- Bearing can be held in place when inverted during assembling.
Crosshead Bearing Construction Features.
What is nip ? Thin shell bearings are used and bearing on either end of crosshead pin.
The external circumference of a pair of bearing shell is slightly larger than the bore of housing. No shim used with thin shell bearing
The difference is called nip. Oil grooves or gutter used on bottom half to distribute oil.
Grooves do not extend to end and grooves are small because of loaded half.
Advantages of Thin Shell Bearings Grooves to be limited otherwise reduce bearing surface.
High load carrying capacity; approximately 5 time > conventional bearing Lubricating oil is directly supplied to crosshead bearing
Uniform wall thickness permits better metallurgical control of white metal casting process. Bearing material usually Sn-Al with Pb-Sn overlay.
High Bond Strength and ultrasonic method of bond testing between layers is accurate.
Reduced thickness & absence of keying grooves results in higher fatigue strength Crosshead Bearing Working Condition
Blistering on bearing surface due to H2 emission form is less. High sudden load – Effect of combustion is directly on bearing
High bearing pressure – Bearing is placed high in engine. - Space limitations. – Assembly
Oil Grooves on Bearing Shell reciprocating.
Oil Grooves to avoid at pressure areas as oil tend to escape high to low pressure zones Diameter & length – Diameter & length of bearing are low. – Bearing area limitations. –High
Circumferential grooves to compensate with increase length of the shell specific loading
Longitudinal groove is not extended to ends to avoid excessive side leakage. Possibility of bearing distortion – Bending moment & deflection are maximum at center. Pin
bored at center (earlier model engines). Less stiffness & high stress concentration. – Bearing
Main Bearing Groove surface deflection. – Alignment difficulty.
Circumferential groove most effective and satisfactory Lubrication – Unsatisfactory or difficult oscillating moment. – Con rod swings over 25° -30°.
Oil supply at all angle and wide variation of load angle. Oil supply disturbed – Difficult smooth & uninterrupted oil flow.
2 stroke engine – Unidirectional load.
Different between conventional and thin shell bearing ?
a) Conventional bearing Modification of Crosshead Bearings Over Last Few Decades:
(a1) It is made of forged steel and running face is lined with white metal. Conjugate Deflection – Sulzer Engines (crosshead pin bored at center)
(a2) Vertical clearance is adjusted by shims. Crosshead mounted mechanical lub oil pump – MAN Engines (oil supplied when load is lowest & oil
(a3) Not easy to replace and must be done remodeling. film is not broken at highest pressure)
(a4) Not easy to handle, transport and store. Continuous full length bottoms half of crosshead bearing – MAN B & W, Sulzer Engines.
(a5) Suitable oil grooves design is required. Eccentric bored bearing & machining shell – Fiat Engines
(a6) Lower load carrying capacity. Large diameter stiff crosshead pins L/D ratio less (small con rod and crank throw ratio. Sliding
(a7) More cost in manufacturing. velocity high & lub oil film improved)
Hardened cross head pin high degree of surface finish < 0.1µ
b) Thin shell bearing Thin shell bearing & improved material.
(b1) It is made of tri-metal, they are steel shell, copper or lead alloy and thin layer of soft
metal surface.
Bearing Housing Design Feature
(b2) Easy replacement incase of bearing worn out. ( Re-metalling method no longer required)
☯ Bearing shells are in place by interference fit
(b3) No need to adjust by shim ( can not be adjusted by shims.)
☯ There is no relative movement of housing & shell
(b4) Easy handling, transport and storage as spare.
☯ Effective heat transfer between shell & housing is essential
(b5) Higher bearing load carrying capacity.
☯ Cap holding bolts are to be closely pitched to prevent distortion
(b6) More economy in manufacturing.
☯ Housing is robust to prevent excessive strains on shell.
(b7) No need to take lead reading.
☯ Housing is not too stiff to prevent localized load concentration on bearing.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 23 24 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

No fretting marks at the back of bearing shell and crush at bearing shell ends within limits Bearing Clearance: Depends on ---

Medium & High speed engine's Con Rod bottom end bearing housing tendency to distort.
J Desired operating temperature – extremely critical J Engine speed
J Oil flow ∝ (clearance) 3 J Oil film thickness
BEARING CAPS J Working viscosity of lubricant J Load carrying capacity
Load is always on down wards & construction is light J Operating temperature J Engine ambient temperature.
Load rotates but bearing cap is rigid
Bolts centers are kept close together.
Bearing Clearance Methods:
Two halves of bearing housing is kept concentric by fitted bolts, stepped cap & serrate cap
It is important that regular checking of bearing clearance is carried out, as the clearance
BEARING BOLTS determines the effectiveness of lubrication.
Adequate tensile strength
High resilience, capacity to absorb maximum strain before yielding Lead wire > Traditional method, but requires that bearing are tightened just to obtain
Reducing diameter to bottom of thread over the length of the bolt reduces localized stress except clearance. Accurate as long as load is not over squeezed. Lead is not to squeeze blow 1/3rd of
at fitted. original diameter.
Turn the crank shaft and set the crank at TDC position.
Remove locking arrangements, mark the nut position.
INSPECTION OF BEARING & JOURNAL FOR DEFECTS Slacken the nut and lower the bottom half with bolts.
Bearing should be inspected at the overhaul / survey for the following defects Then three lengths of lead wires would be laid circumferentially in the bottom half at three
places.
BEARING Place the bottom half into position and tighten the nut to its tightening torque.
1) Abrasive damage: Fine scratches caused by particles in the lub oil. Very common on HFO Lower down the bottom half again.
burning engines Remove the lead wires and take the measurement.
2) Erosion damage: Removal of the overlay in strips caused when the oil supply pressure is low or It must have within the limit, if out of limit, the bearing shell must be replaced with new ones or
rapid journal movements occur. More usual on medium speed engines. readjust the clearance by adjusting shims.
3) Fatigue damage: The overlay becomes detached from the lining when the bearing load becomes
too high. The bearing surface loads cracked paving. Feeler gauge > Quick method, but more difficult to be accurate when using the long feelers
4) Corrosion: Discoloration and roughening of the bearing surface indicate4s that the oil has as measuring point may not be the minimum point.
become acidic. Turn the crank shaft and set the crank at BDC.
5) Wiping: This is overlay removal by melting Wiping can be re-alignment of the bearing to journal, Insert the feeler gauge between lower half and crank pin.
but if too much metal has been removed then clear4aqnces may be affected. Take the measurement readings.

JOURNAL Plastigauge > Relies on the width of a plastic strip after compression. More accurate than
1) Cracks: These will appear at the high stress points of the fillet radii and oil holes. These cracks
leads.
may be removed by light grinding, but engine derating would be required if deep / numerous cracks
are found. Bridge gauge > Depends on bedplate condition and crankshaft rigidity
2) Scoring: Similar problem to the abrasive bearing
Bridge gauge is an instrument for main bearing wears down measuring.
3) Overheating: As the bearing is weaker than the shaft, the bearing should fail first. However if the
Remove the lube oil supply pipe.
engine is run on a failed bearing then shaft overheating will occur. This 'bluing' of the shaft
Remove upper bearing half and fit the bridge gauge.
increases the hardness of shaft and hence the shaft is less able to resist crack growth.
Then take the measurement by inserting feeler gauge.
Classification states a maximum hardness for crankshaft journal.
Micrometer > More accurate
Bearing checking
1) Edge wear
2) Score & scratch (striation wear) Effect of excessive bearing clearance ?
3) Overheating surface (blur/violent colour show heating cracks) Low LO pressure
4) Cavitations & erosion (10% bearing surface) Reduce load carrying capacity
5) Corrosion Pounding will case and bearing will damage.
6) Crack in galvanic layer High impact load on crankshaft.
7) Pitting & fretting

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 25 26 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

C /E's Procedure for Complete Inspection of a Crosshead Emphasizing Areas of Types or Crosshead Bearing failure:
Significant Interest (extract form B & W manual) Various types of failure occur in cross head bearing lining. If it is found early, can be rectified
and continue in service. Failure of the white metal in less- severe forms usually progress so that the
The cross head bearings consists of steel shells with 1.0 to 1.5 µmm of white metal (WM) having a bearing must be remetalled.
25 µm lead based overlay for running in. Cracking of white metal
Complete inspection may be carried out on a time basis i.e. after 8000 operating hours, for a 4 Fatigue failure of white metal
years survey of following inspection carried out without opening up. Squeezing of white metal so that oil grooves are partially blocked; oil holes may be partially
blocked or wholly blocked in extreme cases.
1. Check without opening up Failure of white metal when the bearing surface of the white metal becomes plastic or even melts.
Just after stopping feel over bearing, check that uniform oil jets appear form all the oil outlet Corrosion depends on the nature of the contamination of the lubricating oil.
grooves in the lower shell.
Check clearance (on top) with feeler gauge and compare with records.' Causes of Crosshead Bearing failure:
Bearing failures may result from any one or combination of the following causes.
Visually inspect sides of bearing for signs of white metal squeezed / missing
Deterioration of surface finish or cross head pins.
Dismantle & inspect if oil jets are oblique / twisted / reduced / missing / if white metal gives cause
Poor quality of white metal
for concern or if clearances have increased.
Insufficient supply of lubricant
Impure lubricant or water contamination
2. Inspection & Overhaul
Excessive firing pressure in cylinder
Crosshead opened up, condition of white metal and journal surfaces noted and entered in engine
room log. White metal should be checked for wear / wiping / cracking / discoloration due to
How to check the bearing ? (Bearing overhaul) ******
corrosion / bonding defects.
Before removal
It is quite normal for the overlay to be disturbed at the most highly loaded areas.
a. Check locking device and nuts tightness.
Overlay or WH squeezed into the oil wedges and oil grooves or small spots, which have loosened,
b. Check for wiped out of loose white metal at bearing end.
can be removed with a scraper. c. Check bearing clearance ( roughly ) by tongue gauge.
If wiping is less than hand size scrape to blue marking cracks formation which will eventually
cause WM to become loosened and dislodged may be due to lack of bonding strength or geometric After removing
irregularities causing local overloading. a. Check pin or key or tag.
Areas of small local crack formation discovered at an early stage should be relieved by scraping. b. Check holding down bearing surface.
The back side of the shell should be inspected for even contact fretting or cavitation. c. Check white metal bearing surface (crack and damage)
Journals to be inspected for roughness and ovality; slight ovality is acceptable. d. If over 30 % of wear or crack in the contact area it should be renewed.
Change journal if _ e. Check oil grooves and passage holes.
a Loaded part is heavily worn f. Check pin diameter & pin ovality
a More than 1/3 of the contact area is scratched.
a Roughness has caused a large area of the WM to be wiped What points to be check after removing main bearing ?
a Manual polishing with hemp rope will not then be satisfactory. (01) Check bearing thoroughly ( tag, oil grooves and holes, bearing surface)
Coin test for roughness, No vibration heard or felt when lightly held coin is passed over the surface (02) Journal ovality-take measurement at least 3 spaces.
Surface roughness New 0.05 µm, Run in 0.1 µm, Trouble possible 0.125 µm. (03) Checking bearing clearance-0.4 to 0.6 mm for 550mm shaft diameter.
Roughness will most likely be due to abrasive or corrosive (acid or SW) contamination of the lube
oil. What points to be checked after removing big end bearing ?
Note that 1% SW contamination of the lub oil can promote galvanic attack of the WM formation of (01) After cleaning, inspect the bearing thoroughly at crank pin ovility two halves of bearing
very hard black tin oxide (Sno) which will roughen journal surfaces. together with oil holes and grooves.
(02) Thoroughly, examined the bolts ( no cracks, no extension and no twisting )
What point to be check after removing X head bearing ? (03) Check sign of movement of the joint point such as two halve of bearing joint and between top
(01) Check bearing thoroughly. halve and connecting rod foot.
(04) Bearing clearance.
(02) Check X head pin ovality.
(03) Check bearing clearance.
(04) Lubrication system and oil holes. What points do you check after removing upper half bearing ? ****
(05) Check Guide shoe wear down. (1) Check upper half bearing & bearing keep
(2) Check the bearing wear down by using bridge gauge & feeler gauge ovality of journal pin
(3) Check crack pin condition, oil holes
(4) Check upper bearing clearance by lead wire method

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 27 28 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

(5) Visual check to edge of lower bearing half, bearing pocket (11) Cavitation Erosion

What points do you check after removing crank pin bearing ? Wiping of Bearings Surface
Wiping is a slight transient phenomenon & is undetected until the machinery is opened up for
(1) Check pin ovality & oil holes
survey.
(2) Check two bearing halves with oil holes and grooves (tag, crack, wear,)
In serious cases, complete bearing failure occurs due to over heating of bearing metal which occur
(3) Check the bolt (crack & stretching)
owing to -
(4) Check the movement at the joining point such as two halves of bearing joint and between the
top half and connecting rod foot Temporary lack of oil ` Very slow start up of engine
Too small bearing clearance Misalignment of pin and bearing
What points do you check on thin shell bearing during overhaul ? Fabricated cross girder of bedplate Tin oxide corrosion
1. Visual inspection of any wiping & squeezing
2. Check axial play Nitride surfaces
3. Check of local temperature after test run Surface to be machined at least by 0.025 mm to prevent bearing damage.
Stainless steel shafts & white metal bearing surface – wiping, pick up & seizure
For new thin shell Failures – Due to lack of compatibility and the problem is worst at high specific load.
1. Fit into housing and check the contact area after thorough cleaning Ni or Cr Plating: on journals / pins must be voided which results in scuffing seizure.
2. After clean, check bearing running surface (any crack, grooves, tap)
3. After renew test run for 30 minute and again, after 5 hours operation, manual checking bearing Fretting
temperature. In dynamic loaded bearings / pivoted pad bearing i.e. thrust pads of thrust bearing
Fretting occurs on the back of support surface where the interference fit / nip is insufficient for
Check new bearing before fitted dynamic forces involved.
Bearing thickness, length, crack, surface smoothness, edge, oil hole, groove, tap Caused by the housing, which is insufficiently rigid for the load cycle involved.
Casing & keep surface
Pin ovality, Fatigue
Bearings carrying high dynamic loads are liable to fatigue damage
How to decide that shell to be replaced ? Caused by a concentration of load due to mechanical imperfection i.e. poor geometric form,
1. Shell with galvanic layer worn down over 30% of developed working surface to be replaced (X misalignment and distortion.
head 5% ) White metal bearings are particularly prone to fatigue since any high loading not only increases the
2. Running hour excess of 40, 000 to be replaced in any case (O/H or not) stress in the lining, but the associated temperature rise reduces the strength.
3. Running hour excess of 30, 000 to be replaced when engine overhaul Causes of fatigue cracking is due to poor bonding of white metal to its steel shell.

How to check bearing wear down (Main bearing) without bearing removal ? Tin Oxide Corrosion
(1) Remove LO pipe connection from keep a bore has in the keep Tin oxide is extremely hard & brittle and corrosion takes place at tin phase of white metal
(2) Hole also be provided in upper bearing half This breaks off rapidly, causing wear of the surfaces & breakdown of oil film
(3) Clean holes & insert the depth gauge & take reading Appearance – Grey at initial stage, becomes darker as its thickness increases & particle become
The different of present reading & previous reading give lower bearing wear down detached.
With high loads when the oxide layer becomes thick, the bearing temperature may rise sufficiently
to melt the underlying metal & failure occurs by wiping.
Bearing Problems & Diagnostics Cause - Water mixes with LO promoting electro chemical reaction.
Types of bearing defects ? Prevention – Regular & continuous removal of water from lubricating oil prevent tin oxide
(01) Crack formation.
(02) Fatigue failure of white metal
(03) Squeezing of white metal, so oil grooves are partially blocked. Acid Corrosion
(04) wiping Takes place in high temperature condition
(05) Faulty casting and faulty machining. Bearing alloy is attacked by acid (condensation of SO2) form high 'S' content fuel.
(06) Tin oxide Corrosion Steel working parts corrode more than bearing alloy
(07) Acid Corrosion Solution – Add rust & corrosion inhibitor in lub oil and select proper material.
(08) Thermal Ratcheting
(09) Electrical Potential Thermal Ratcheting
(10) Fretting Caused by alternate cooling & heating of bearing

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 29 30 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Results in bearing deformation By removing the cooling outlet pipe

Indication of high bearing temperature By filling the L.O into the sump at the same time open the drain valve and drain out the hot oil
Place mainly in thrust pad bearing surface By reducing the engine speed to the suitable speed.

How to check plumber block at sea ?

Electrical Potential Check L.O level and L.O temperature
This type of damage occurs frequently in electrical machinery due to stray currents. Cooling water outlet temperature
The damage consists of uniformly distributed pitting, the pits being generally hemispherical with Noise and vibration
the intensity increasing to a maximum in the zone of thinnest oil film. Overheating of casing by hand touch feeling
Caused by incorrect earthlings system which cause spark erosion damage.
Prevention – Insulate the non-drying end bearing (pedestal bearing) of electrical machines and Main bearing removing procedure.
sometimes in both bearings.
Measure bearing clearance.
Turn crank shaft to efficient position.
Cavitation Erosion
Remove lube oil pipe, locking arrangement and nuts.
Severe damage to complete bearing area. Took out bearing keep with thrust nut by means of wire sling and chain block or special tool. Took out
Cavities are usually around at low pressure areas i.e. oil groove or oil holes. upper bearing shell.
Caused by an implosion of gas or air bubbles released from a lubricating oil film under particular Took out lower bearing shell.
conditions 1. By fitting lower bearing taking out tool fitted at oil hole at crankshaft or adjacent crank web and
The pressure set up locally during theses implosions are very high , possibly 220 bar & may cause turn the crank shaft (the direction is according to the maker instruction, usually opposite to the ahead
a pitting / cavitation running direction.)
Prevention – May be reduced by viscous oil because of damping effect high viscous oil & 2. By use of hydraulic jack to lift the crankshaft just clear, about 0.1 to 0.3mm and turn the
viscosity must be in limit. bearing shell without rotating the crank shaft.
Eye bolt fitted to the back of the shell and lift it out of the engine.
Cause of white metal squeezing is when bearing metal is pressed out into the oil groove due to
load on bearing exceed its compressive strength. Big end bearing removing and fitting procedure.
1) Measure bearing clearance.
Cause of faulty casting and machining is due to premature failure even under normal running 2) Turn TDC position.
conditions. 3) Remove locking arrangement and slackened the nuts. The bottom half lower a few and took out bearing
clearance adjusting shim, each set being tied separately and note taken of the side to which each set
Causes of bearing overheat belongs.
4) Chain blocks connected to eye bolts, screw into each bolt. After removing two nuts, bottom half lowered
Improper viscosity of oil (lower)
into the sump. If necessary it can be taken out from crankcase.
Insufficient lubrication
5) Putting hanging bar in position, connect chain blocks to crankcase door frame and eye bolts which is
Improper oil clearance
screwed into each side of the top half. Then turn the crankshaft to the position where the top half can be
Foreign matters in oil
taken out.
Misalignment of shaft and bearing 6) Inspection on crank pin, bearings, oil holes, grooves, bolts cracks, sign of movement and elongation.
Scored journal
Poorly fitted bearing

Big end/crank pin bearing bolts failure

1. Over stressed on bolts (due to piston seizure, over tightening, propeller strike some
obstruction)
2. Too long in service (renew after 10 years)
3. Wear of bolts & enlarge of holes can cause the easing of nuts.
4. Too much clearance of bearings, shock resulting fatigue in bolts

What do you do if intermediate bearing or tunnel bearing or plumber block bearing temperature
is increase ?
Overheating of plumber block bearing can be reduce by following ways
By applying maximum lubrication
By applying maximum cooling
By reducing to suitable engine speed.
By applying the air

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 31 32 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

9) Open the steam cock, the water in the glass should fall to the level of the water in the boiler.
# Working position – all cocks handle are in downward position.

What is the meaning of boiler ? 6. Why need to blow down the boiler water ?
It is a pressure vessel in which the water is heated to evaporate and generate the steam and Boiler blow down is made to reduce the density of salt and to remove the dissolved and
the unit is so arranged that the generated steam accumulated in it. The two main types are water tube suspended solids, also the floating solid impurities in the boiler system.
and fire tube. If there are not removed from the boiler water system, foaming, priming, corrosion will occur in
the boiler steam space and feed water system.
1. What is the boiler mounting ?
7. Why do scum blow down and bottom blow down ?
It is directly fitted to the boiler shell. They are 1. Safety valve 2. Main steam stop valve 3.
Air vent cock 4. Two gauge glass level indicators 5. Feed check valve 6. Scum blow down valve Scum blow down ( surface blow down )
7. Bottom blow down valve 8. Salinity cock or test cock 9. Man hole doors. To remove accumulated, suspended and floating solids, impurities and also remove dissolved
solid concentration, they hinder the formation of steam.
2. Where are air vent cock located and its purpose ?
Bottom blow down
The air vent cock is fitted at the top of the steam space of the boiler.
To remove suspended solids and residual sludge that have settled at the bottom.
Its purpose are-
If these contaminants are not removed regularly they will build up until they hinder the
1. To release air from the boiler either filling the boiler water or raising the steam.
circulation patterns.
2. To allow air to enter in the event of boiler cooling down or blowing down .( to prevent
vacuum effect)
8. Purpose of boiler water test ?
To ensure that proper chemical treatment are maintained at all time.
3. Boiler safety devices ?
To detect the present of contaminants in the water that may be injurious to boiler and system.
1) Safety valve
2) Low / high water level alarm
9. Enumerate the boiler water test
3) Too low water level alarm and shut down
4) Water level indicators 1) Alkalinity test
5) Pressure gauge a. Phenolphthalein ( p) alkalinity test
6) Low fuel oil pressure alarm b. Total ( T ) alkalinity test (2 x P)
7) Low / high fuel oil temperature alarm 2) Chloride test
8) Flame failure alarm 3) Condensate PH test
9) Smoke density alarm 4) Amerzine test ( Hydrazine test )
10) Easy gear arrangement 5) Excess phosphate test
11) Air vent 6) Conductivity test (Total dissolve solids test)
12) Force draught fan stop alarm 7) Hardness test
13) Low / high steam pressure alarm
10. Purpose of Boiler water test ?
4. Why need to blow down the gauge glass ? 1) Alkalinity test
Gauge glass blow down is made to know the boiler and gauge glass connection is clear or not This is to ensure that the boiler water prevent corrosion by neutralisation of acidic gases
and to give the exact water level in the boiler.
(a) Phenolphthalein ( p ) alkalinity
This test is carried out to prevent acidic corrosion
5. Boiler gauge glass blow down procedure ?
To test for presence of all of the hydroxide, one half of the carbonate and one
1) Shut steam and water cocks than open the drain cock.
third of phosphate present in a water sample. ***
2) After draining water from the sight glass, there is nothing come out, both steam and water
cocks are good in order.
(b) Total ( T ) alkalinity test
3) Open the steam cock side, blow out the steam.
To determine the amount all of hydroxide, all of the carbonate, and two thirds of
4) Close the steam cock side, the steam connection is clear.
the phosphates
5) Open the water cock side, blow out the water.
6) Close the water cock side, the water connection is clear.
Note: Hydroxides and carbonates can co-exist together in a solution but hydroxides
7) Close the drain cock.
and bi-carbonates cannot.
8) Open the water cock, water should then gradually come rise up to the top of the gauge glass.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 33 34 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

2) Chloride test 13. What is boiler priming and how to prevent it ? ****
To know the amount of salt in boiler water. *** It is condition in which large amount of water are carried along with the steam into the steam
To minimize chloride level and to adjust the blow down. line.
It is caused by 1. Excessive foaming 2. Improper amount of steam space 3. By a sudden
3) Condensate PH test rush of steam such as is produced when steam stop valve is suddenly opened.
To control condensate PH value within a limit. **** To prevent priming, never keep the water level too high.
To minimize corrosion in steam and condensate system. Open steam stop valve slowly.

4) Amerzine test ( Hydrazine test ) What action do you made take in case of foaming and priming ?
To test for dissolved Oxygen content ****
1. Scum blow down
To know reserve hydrazine (N2H4) ppm and to prevent corrosion and aeration.
2. Reduce boiler fire rate
To minimize oxygen pitting and corrosion in boiler, steam and condensate
3. Check whether boiler chemical added are in excess
system.
4. Detect the source of contamination
5. In case of bad priming the boiler may have to be taken out of service, shut down.
5) Phosphate test
For contamination due to oil have to be chemically cleaned.
To control the scale formation due to hardness (presence of Phosphate in
sample means no hardness salts) ***
14. Boiler blow down procedure ( cool down )
A reserve of phosphate should be maintained in the boiler water ready to
neutralize any hardness salts which may enter. 1) Change the fuel oil burning system from HO to DO and then shut down the burning system.
2) Stop feed p/p close feed check valve.
3) Drain down the boiler after allowing it to cool down.
6) Conductivity test 4) If no sufficient time to do this, lower the boiler pressure to 3 to 4 bar.
Measure of the total amount of dissolved solids (T.D.S) including the treatment 5) Shut the main steam stop valve.
chemicals. (Excessive density leads to priming and or deposits) ** 6) Open the ship side valve then open the blow down valve.
To remove dissolved and suspended solid by blowing down. 7) Banging noise will appear when boiler is empty.
8) Close the boiler blow down valve and ship side valve.
7) Hardness test 9) Then release the steam pressure through safety v/v by means of easing gear.
10) When pressure is off, open the air vent and the boiler to cool down.
To check for salt causing “hardness”
Note
Opening up and Inspection Procedure
Hardness test of boiler water are not necessary when the phosphate is above the lower limit of
Follow as procedure above, After making sure no vacuum in it, first---
the control range.
1. To remove top man hole door, slacken the dog holding nuts but do not remove them until first
broken the joint
11. Purpose of boiler water treatment 2. Remove nuts and dogs and take out the door.
1) To prevent the scale formation in the boiler and feed system 3. The bottom door can be removed after warning personnel to keep clear of the top door.
2) To prevent corrosion in boiler and feed system. 4. Make ventilation before entering. Do not allow naked light near the boiler.
3) To control the sludge formation and prevention of carry over with the steam. 5. Preliminary internal inspection carried out before cleaning, to check scale deposits and any special
4) To maintain the boiler water in alkaline condition and free from dissolved gases. points.
5) To prevent of entry into the boiler of foreign matter such as oil, waste, mill scale, FeO, Cu , 6. Plug orifice to blow down valve to prevent choke, place guards over the manholes landings to
Sand etc. prevent damage.
7. Carried out cleaning and internal works.
12. What is foaming in boiler and how to prevent it ?
It is the formation of thick layer of steam bubbles on the top of the water surface inside the When all works completed, a full internal examination must be carried out
boiler due to: Cleanliness, all openings are clear, water level gauge connection clears from deposits,
High concentration of impurities. All internal pipes and fittings have been replaced correctly and securely attached,
By the animal or vegetable fats in feed water carry over from the oil heaters. Remove plug from the blow down valve orifice,
Increase in level of dissolved & suspended solid TDS level. The face of manhole doors and landings inspect to clean and undamaged).
Increase in water level. Replace manhole doors by using new joints.
Operate all boiler mountings. Open air vent cock and fill the boiler with water to sufficient level.
To prevent foaming, surface or scum blow down should done frequently to expel any floating
impurities for the boiler and no lube oil should be allowed to enter the boiler.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 35 36 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

15. Describe the boiler fresh up procedure from cool condition ? Erosion
The boiler is carried out firing from cold condition to normal working pressure condition to avoid It is a mechanical attack on the metal surface which may be due to a disturbance in the flow of
thermal stress. the fluid over the metal surfaces, resulting in a loss of metal. Suspended abrasive matters in the fluid
1) Check the boiler blow down valve in close position. can increase the rate of metal losses.
2) Shut the main steam stop v/v.
3) Open the air vent cocks. Corrosion
4) Open the feed check valve and pumping up to ¼ of gauge glass level. It is the deterioration of metals due to oxidation. The present of water in an acidic condition
5) Start the force draft fan with dampers, open correctly to purge the furnace and combustion provides the electrolyte required for corrosion action.
space of any foul gas.
6) Light the burner after closing the recirculating valve. Two forms of corrosion
7) Normally allow the fire to burn for 5-minutes and stop for 30 mins. This step continues until Direct chemical attack
steam come out. It occurs when metal at high temperature comes into contact with air or other gases, resulting in
8) When steam coming out from the air vent close the air vent. oxidation or sulphidation of the metal.
9) Rise up the working pressure step by step slowly. (Allow the fire to burn for 30 mins and stop
the fire for 10 min.) Electro-chemical action.
10) When the steam pressure reached Is working pressure drain the steam line. (to avoid water Galvanic action, this being set up when two dissimilar metals are placed in an electrolyte. The
hammer) noble of the two metals form a cathode to the base metal which, forming the anode, is wasted away.
11) Main steam stop valve open slowly (crack opening)
Caustic embrittlement.
Caustic embattlement is a form of inter crystalline cracking, which results from a solution of
16. How do take action if gauge glass showing low water level ? sodium hydroxide or caustic soda, becoming more and more concentrated at the bottom of a crack or
If water level has not yet dropped completely out the sight glass, water may be put into the fissure (narrow opening) which may be the result of fatigue, in the boiler plate or furnace.
boiler. The plate must be stressed intention (]yi f:]yi f: x efx efo u fa7m
u fo n f), so that wastage take place
If water drops completely out of sight glass, check another sight glass, if both disappear water; at the bottom of crack, the plate weakens, the crack extends to expose new metal to the caustic action
do not add water until the boiler is cool enough to prevent any possible damage due to rapid cooling of and thus it proceed.
Caustic embattlement will only occur when there is a high caustic alkalinity that is when the
over heated plate. ratio of NaOH to the alkalinity is high. To keep this ratio at the safe level the sodium sulfate to sodium
1. The fire must be immediately stopped. hydroxide should be maintained above 2:5. The sodium sulfate comes out of solution in high sodium
2. The main steam stop valve must be closed. hydroxide concentration and by doing forms a protective layer on the surface of the plate.
3. Blow down and cool down the boiler. Also keep the lowest T.D.S level. (Total dissolved suspended & solid)
4. Check leakage, drum outside, Located the cause of trouble and make necessary repair.
pH value
5. Enter the boiler after it has cooled and examined any possible damage. Logarithm of reciprocal of hydrogen iron concentration.
6. After repair, water fill up slowly and restore to normal operation.
7. If no damage occurred, inject the water slowly into the boiler and restore it to operation. 17. What do you do for preventing of oxygen ?
The oxygen-scavenging chemical which is used for deaeration the water are usually sodium
Possible causes:
sulphate or hydrazine.
One gauge glass defective
Boiler tube crack and leaking
2Na2So3 + O2 = 2Na2So4
Feed regulator jammed
N2H4 + O2 = 2H2O +N2
Fail feed pump (Air in feed water line or pump)
Level controller malfunction
Excessive dosage of hydrazine could lead to steam and condensate line corrosion due to
Steam consumption is too much
ammonia being produced as the excess hydrazine decomposed.
In high pr boiler, by using the sodium sulphite, the sulphite can break down to give hydrogen
16. What is caustic embrittlement? How to prevent it ? sulphide which can attack steel brass and copper.
It is inter crystalline fracture. It is cause by high concentration of caustic soda and the material
under stress. The stress corrosion cracks follow the grain or crystal boundaries of the material and
18. If chloride is found too much in your boiler water what will you do ?
failure.
Blow down frequently
Sodium sulphate or sodium nitrate is used for the prevention of caustic embrittlement.
Reduce the boiler load to minimum.
It can be found in highly stress area in boiler. Such as tube and tube plate connection, riveted
If highly contaminant shut down completely and wash out.
head, seam and boiler mountings.
Trace and find out the fault and remedies.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 37 38 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

19. What do you understand composite, alternative, and economizer boiler ? c. Measure gap between compression nut and spring casing.
Composite boiler d. Make a compression ring equal to this gap, and insert under compression nut.
e. Gag the spindle of this safety valve, to prevent opening, while remaining valve is being
If exhaust gas and oil fired can be used the same time, it is termed the composite boiler.
set.
In this type a separate nest of tube for exhaust gas is provided, situated above the return tubes
8) Remaining valve is again set and insert compression ring.
from the fire furnace. Uptake from the tube nest are separated.
9) Remove gag and retest both valve to lift and close together.
10) Cap, cotter and easing gear to be refitted
Alternative boiler
11) Caps and cotter pins padlocked to prevent accidentally altering the setting.
If the exhaust gas and the oil fire are arranged to be used only at a time, the exhaust gas boiler 12) When the surveyor satisfied the setting pressure, easing gear should be tested.
term as the alternative boiler. 13) All safety valves set to lift at not greater than 3% above approved working pressure (design
This unit can be oil fire heated by the exhaust gases alternatively. pressure).
It required only one uptake.

24. How do you take action if one of the passages of gauge glass is chocked ?
Economizer
Steam and water cocks and passages in the gauge can be cleared while the boiler is still
In this system a separate exhaust gas economizer is connected to an oil fired auxiliary boiler or
steaming.
an accumulator by means of piping and a set of circulation pump. Exhaust gas is used as heating
To do this, shut the steam and water cocks and open the drain cock. Remove the check plug
medium and it has no steam space.
opposite the obstruction. Insert the cleaning plug. Screw in the plug with small hole about 5 mm
diameter, drilled through it in place of the cleaning plug. Insert into this hole a rod of such a size that
20. What is meant of accumulation pressure ? held by a gloved hand, it can be easily moved without being stack.
Accumulation pressure is the rise in boiler pressure which take place when the spring loaded Then open the chocked and push the rod through to clear the blockage. When clear, open
safety valve lift due to the increase loading caused by further compression of the spring. drain to prevent a build up of pressure and only a small amount of steam will blow past the rod, the
glove protecting the operator from injury.
21. Purpose of accumulation pressure test ? Then close the cock and replace the normal cleaning plug. The gauge glass can be tested now
To detect the safety valve is suitable for this boiler or not. To limit the rise in boiler pressure and if satisfactory return to service.
under full fire condition. *Do not carry out this operation on a plate type glass on a high pressure boiler.

22. Procedure of accumulation pressure test ? 25. Causes of furnace blow back ?
This test is carried out a new boiler or new safety valve. Insufficient purging time,
1) Shut off feed water Accumulation of oil in furnace from the leaky burners,
2) Closed main steam stop valve. Boiler tubes and uptake have full of soots.
3) Arrange the boiler fire rate to a maximum. Air registers control not operating for the high flame mode.
4) Safety valve will be lift during the test. Too little air
5) The test is carried out as long as the water permits in the boiler. During of the test is 15 mins Insufficient oil temperature
for a tank boiler and 7 mins for water tube boiler
6) Accumulation pressure should not exceed 10% of working pressure. 26. How to keep boiler not in service ?
For fire tube boiler out of service for short period, the boiler must be completely filled with
23. Safety valve setting under steam pressure ? alkaline water.
Setting of safety valves: The boiler must be topped up periodically and any air in the system must be got rid off.
1) Take standard pressure gauge (approved by surveyor) for accuracy. Regularly test the boiler water and keep the alkalinity and phenolphthalein in the range of
2) Fill up water up to ¼ of gauge glass level, and shut main steam stop valve, feed check valve. recommended value.
3) Without compression rings, hoods and easing gears, reassembled the safety valves with If the boiler is to be taken out of service for long periods.
spring compression less than previous setting. It should be drained completely and open up.
4) Raise the boiler pressure to desired blow off pressure. Dried out by means of heater units.
5) Screw-down spring compression nuts of any lifting valves, until all are quite. Then the trays of quick line should be place internally in suitable positions.
6) Arrange to have the desired steam pressure Blanks should be fitted to the pipe connections in the event of steam being maintained in other
7) Adjust each valve in turn: boiler and blow down line.
a. Slacken compression nut until the valve lifts. The quick line should be renewed at least once every two months.
b. Screw-down compression nut sufficiently enough, so that when the valve spindle is
lightly tapped, valve return to its seat and remain seated. 27. The purposes of boiler water treatment ?

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 39 40 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

To prevent scale formation ( Trisodium phosphates is used) It can be check by opening of ship side blow down valve. Banging noise will appear, scum blow
To remove trace of oxygen (sodium sulphide or hydrazine is used ) down valve is in open position.
To give alkalinity and minimize corrosion.(sodium hydroxide or sodium carbonate is used ) It can also detect, over heating of scum blow down pipe.
To reduce risk of caustic cracking ( sodium sulphate or sodium nitrate is used. 35. Where is manhole doors fitted ?
They are fitted at one at steam side and other one for steam side.
28. Difference between safety valve and relief valve ?
Safety valve 36. Effect of foaming and priming ?
1) Directly open the design lift at set pressure. a) can occur water hummer
2) Can open manually by easing gear. b) can cause contamination and scaling.
3) Setting pressure is just above the working and not more than 3% above the approved c) Can cause fluctuation of working water level.
working pressure.
Relief valve 37. What is blowback ?
1) Setting pressure is 10% above working pressure . It occurs when lighting up with explosive gas and oil droplet (Oil residue) inside the furnace
2) Opening is proportion to the increase in pressure. without pre-purging sufficiently.
3) Can not be open manually. The ignition results in a large flue gas inside the furnace and these gases blow out with
increase high pressure through the furnace opening.
29. Marking on safety valve ?
Manufacturer’s name 38. Procedure for hydraulic pressure test ?
Serial number Hydraulic pressure test is 1.25 times working pressure, ( 10 minutes maintain ) Close all opening.
Inlet diameter
1) Open air vent cock.
Operating pressure
2) Fill up boiler water fully
Discharge capacity
3) Close the air vent cock
Safe working pressure
4) Place hydraulic jack to feed water line.
Blow off pressure
5) Fit standard pressure gauge.
6) Applied hydraulic pressure 1.25 times of working pressure and maintain 10minutes.
30. Types of boiler by pressure ?
Low pressure boiler - up to 10Kg / Cm2
39. What is liquid coagulant ?
Medium pressure boiler - 10-25 Kg /Cm2
It is more molecular wt colorless solution, such sodium aluminates, starch, terming, and resin.
High pressure boiler - Over 25 Kg / Cm2
Once being dose into the boiler water floating solid particles and suspended solid are settled to
the bottom of the boiler and easily remove by blowing down.
31. What is water hummer / how will you prevent it ?
The impact of moving water in steam line when the steam is allowed to enter a line with
40. How to renew the boiler gauge glass ?
condensed water. The steam will condenses and partial vacuum occurred and move back the water the
Shut steam and water cocks and open drain cock.
along the pipe with very high velocity, and the water will strike at the vent or valves.
To prevent the water hummer – Check any leakage from the respective cock.
a) Install steam trap in the line Slacken the gland nuts.
b) Open the drain first before allowing the steam into the line. Open the cap and remove gauge glass.
c) Crack open of steam valve at first. Fit new gauge glass, correct size and length into its space.
Give the expansion allowance 1/8 in vertical clearance.
32. How to make boiler water test on your ship ? Use new packing.
The boiler test is carried out as follows. Close the cap.
Firstly take the boiler water sample from the salinometer cock or test cock and cool down. After fitting, warm the glass by steam.
The test is carried out by the using maker’s supply test kit, chemicals, instruments and Tighten the gland nut.
instructions. Then steam and water pressure should be tested whether they are fair and clear.
Close the drain and open the water and steam side cocks.
33. How do you take boiler water sample ? Check the leakage; all are satisfactory put back into operation.
Slowly open the salinometer cock until clean hot water coming out.
Then collect the boiler sample with copper jar. 41. Boiler maintenance:
Clean the rotating cup.
34. How to know scum valve open or not ? Check and adjust the belt tension between motor and rotating shaft.
Clear the pilot burner nozzle and fitter.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 41 42 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Clean carbon deposit on electrodes ( igniter ) and adjust the gap. Boiler safety valve closed examination and attention during overhauling
Check the fuel valve and air register linkages and joints. Checked its valve and valve seat for wear, cavity corrosion and any fault. They should be
Check and clean the flame eye cover glass. grounded properly but maker’s limit must be maintained such as width of seating, clearance between
Check and clean inspection peep hole glass cover. valve lip and seat.
Adjust the fuel air ratio. Valve chest must be cleaned condition and drain line clear.
Clean fuel oil fitter. The spring should be hammer tested for any fracture and check for corrosion. Free length is
Check the fuel oil pressure. limited to 0.5 % of original free length.
The spindle should be hammer tested for any crack and its straightness.
42. When boiler safety valve setting made ? The guide plates and bushes are checked for uneven wear and have sufficient clearance to allow
free movement of spindle.
Every boiler survey.
The compression nut and cover bush’s threads are carefully checked it for any sign of wear and
After safety valve overhaul.
tear.
The easing gear should be checked in good order including bearings, cable pulley, and
43. Why ship side blow down valve is open first and close last ? connecting links.
To prevent pressure build up in blow down line. k:) and pin should not bent or pinhole gone out of
Connecting pin should be a free fit in the lid (t z H
In pipe burst, it may injurious to watch keeper.
shape.
All safety valves are to be set to operate under steam a little above working pressure not greater
44. If no test and treatments is done to boiler, the following may rise.
than 3% above the approve working pressure of the boiler.
(01) Reduction in boiler efficiency due to poor heat transfer
(02) Reduction in tensile strength
(03) Reduction in factor of safety Why safety valve is fitted in two numbers ?
(04) Overheating of metal resulting distortion and eventual failure To make sure that the positive discharging of higher steam pressure from boiler efficiency.
(05) Increase in fuel consumption Why fitted in one valve chest ?
To reduce stress by hole on pressure vessel (boiler)
(06) Excess concentration of NaOH (caustic soda) may cause caustic embrittlement on boiler metal
To minimize the numbers of cutting hole on boiler to save it's strength.
and tend to failure of boiler metal
(07) Corrosion
(08) Scale formation
(09) Foaming, Priming, carried over (due to increase T.D.S level, foaming is present and tend to
carried over and priming)

45. Control of Evaporation (How to control / reduce excess EGE pressure)

01) By regulating the amount of gas flowing over the extended surface, i.e. by damper regulation.
02) By dividing the unit into sections so that each section is controlled by an inlet valve.
03) By passing steam through an automatic pressure controlled surplus valve to a dump condenser.
04) By a system designed for a higher pressure than that it is to operate.

Soot Blow
Purpose To remove soot, to prevent EGE fire
To get steam generating efficiency good
To increase heat transfer efficiency

Time Day time at sea 2 -3 times/day

Procedure Inform to bridge
Check wind direction, good it transverse direction
Raise boiler pressure
Open drain cock until drain clear
Open soot blower valve
Open steam valve & carried out by turning wheel 20 -30 sec
Then close steam valve, soot blower valve
Open drain valve

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 43 44 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Fusible plug
When the temperature high (above 105 °C) Pressure is released by melting (fusing) the
metal.
It cannot be used next time. ( permanently damage)
1. What is emergency air compressor ? Release all content or pressure to empty.
It is a small compressor independently driven by diesel engine or hand operated.
It must be fitted to press up the emergency air bottle and to start auxiliary engine of a dead ship. It has 7. Why multistage compressors are mostly used than single stage compressor ?
no connection between the main air bottle. More stages are needed to increase the required final pressure.
Easier to control the air temperature.
2. Air compressor safety devices ? ****** Reducing in air compressor size.
Bursting discs are fitted on the cooler shells (At water side). Lubrication problem does not exit.
Relief valves are fitted to discharge side for every stages. Reduced the thermal stress.
Moisture drain valve (unloader) are fitted at each cooler side Lower work done to compressing air.
Cooling water failure alarm. Improve compressor efficiency
Low L. O pressure alarm.
Delivery air high temperature alarm on after cooler outlet (Max 93°C) 8. Advantages of inter cooling of air compressor ?
To avoid excessive temperature rise associated with higher compression ratios, and to
LP discharge pressure 4 bars : HP discharge pressure 30 bars. approach isothermal compression.
Intercooler inlet air 130°C : Intercooler outlet air 35 °C Saving in power.
After cooler inlet air 130°C : After cooler outlet air 35°C Volumetric efficiency is increased.
Intercooler is single pass type : After cooler, double pass U-tube type Reduced the volume of air delivered and also reduced the compressor size.
It can reduce the air temperature.
3. Purpose of unloder valve (moisture drain valve) ? Due to less temperature suction & delivery valves remain cleaner without being fouled with
At starting this valve must be opened, this reduced the starting torque for the machine and carbonized oil.
clear out any accumulated moisture and oil in the system. It can avoid a danger of an explosion takes place in compressor cylinder.
It allows good lubrication of the compressor piston.
4. What would be affect of suction valves of an air compressor having too much lift ? Moisture separation is easier through inter cooler drains.
The valve will be late in closing and this would reduce the volumetric efficiency of the It also enables to deal with a greater wt of air for the same energy expended.
machine .The valve too much lift reach at the end of their travel will grater force and therefore are more
liable to break.
Why intercooler will fitted in Main air compressor?
5. Affects of reduced volumetric efficiency of air compressor ? 1. Reduced air temperature, volume and increased air density for next stage
Grater bumping clearance. 2. So increased Volumetric efficiency and compressor efficiency.
Sluggish opening and closing of suction and delivery valves. 3. Due to reduced temperature give better lubrication for cylinder and piston rings
4. Drain are fitted from which water and excessive oil can be drained out, to prevent air bottle
Insufficient cooling water that effect of high air temperature. corrosion and starting air explosion and fouling of inter coolers and pipe.
Dirty or partially chocked suction air fitter. 5. Save the work done.

6. Different between relief valve and bursting disc ? Advantages of after cooler purpose
Pressure relief valve To reduce final discharge air temperature thus air bottle seize can be reduce.
Excess pressure is released by opening the valve. To reduce air volume after it has been compressed to the final pressure.
It opens at 10% over working pressure. So greater amount of air could be stored in air bottle.
Valve lift is proportional to excess pressure build up. Increase volumetric efficiency
Valve setting pressure can be altered by spring tension.
9. How to start the air compressor manually ?
Bursting disc
Change the switch to manual position on the switch board.
Pressure is released by bursting the disc.
Check the L.O sump level and condition.
It permanently damaged.
Open the moisture drain valve.
It burst at setting pressure.
Open the compressor discharge valve & charging valve of air bottle.
Setting pressure cannot be altered in place.
Open cooling water system valves.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 45 46 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Turn the compressor flywheel by hand (one turn). FACTORS AFFECTING VOLUMETRIC EFFICIENCY
Start the motor, after draining the moisture shut the drain valve. 1) The bumping clearance (the larger the bumping clearance the less air is discharged per stroke)
Check the motor ampere consumed. 2) Sluggish opening and closing of suction and delivery valves
Check the pressure gauge readings. 3) Leakage past compressor piston rings.
Frequently drain the moisture. 4) L.P inlet air temperature too high
When charging full, open drain valve and stop the compressor 5) L.P inlet filter dirty and choked
6) Inlet cooling water temperature too high
10. How do you check compressor efficiency @ running ? 7) Insufficient cooling water owing to fouling of coolers

a Checked by filling time with the previous record and also check the first stage discharge pressure. If
compressor efficiency is lower, compressor will run longer and compressor temperature will rise. 15. Difference between intercooler and after cooler ?
a First stage and second stage pressure gauge must be correct and stabled Intercooler
a No escape air from suction filter Fitted intermediate stages.
a Intercooler and after cooler outlet air temperature should not be high Saving in power.
a If open drain valve nothing can found Increase volumetric efficiency.
a Low L.O consumption Reduce temperature for next stage and it can avoid a danger of explosion in
a Oily air mixture must not blow out from breather pipe. compressor cylinder.
Can provide good lubrication of the compressor piston.
11. Safety devices on main air bottle ? No carbonized material form of discharge valve.
Moisture separation is easier through intercooler drain.
Pressure relief valve.
Fusible plug.(if safety valve is not directly fitted on the bottle)
After cooler
Pressure gauge.
Fitted at the final stage discharge side.
Low air pressure alarm.
Reduce final discharge air temperature to room temperature.
Moisture drains valve.
Increase volumetric efficiency.
Air bottle size is smaller.
12. Where is the fusible plug fitted ? Purpose ?
Moisture separation is easier through after cooler drain.
Fusible plug is fitted under side of the pipe between relief valve and air bottle.
It is fitted to release the compressed air in the event of abnormally high compressed air
16. Why need bumping clearance ?
temperature. Fusible plug melt at 105 °C and release all content of air. It is made by 50% Bismut, 30%
This is a clearance must be provided between the piston top and the cylinder head when the
tin, 20% lead.
piston is top dead centre. it must be kept as small as possible for achieving the best compressor
A fusible plug is fitted after the second stage cooler to limit the delivered air temperature and
efficiency.
thus protect the compressed air reservoirs and pipe work.
To prevent mechanical damage to the compressor.
To provide for thermal expansion and
13. Can you fit the relief valve at the space of bursting disc and why ? ***** To provide necessary space for valve operation.
At the compressor, relief valve can not be fitted at the bursting disc, because of their difference
operation. 17. How to adjust the bumping clearance ?
Bursting disc is fitted for totally release and stop operation circuit.
It can be adjusted by two ways.
Release valve opens excess pressure at compressor running and reseat at when pressure
By altering the head gaskets (cover joint ) thickness,
reduce or when the compressor is stopped. Thus cooling water can enter to compressed air space; it
By adding and subtracting shims between the connecting rod food and bottom and bearing.
can cause water hammer when the next start of compressor.

18. Main air compressor bumping clearance taking procedure ?

14. What is volumetric efficiency ?
Stop the compressor and (lock off) take out fuse.
It is the ratio of the actual volume of air drawn in each suction stroke to the stoke volume.
Drain the cooling water.
Remove the cylinder cover.
Clean the cylinder head face and piston crown.
Actual volume of air drawn in suction stoke Place the lead wire ball on the top face of the piston. That is larger size than expected by
Volumetric efficiency =
Volume of air for stoke volume clearance.
Cylinder cover is placed on the cylinder with correct joint thickness and tightens the head
bolts.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 47 48 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Turn the compressor slowly by hand over top centre so that lead wire ball is pressed. First stage delivery
Then remove cylinder cover again. 1) Reduce delivery
Remove the compressed lead wire ball. 2) Increase discharge temperature
3) Less air drawn in due to high pressure air leaking back into the cylinder
Take the measurement of lead wire thickness by using micrometer. Second stage suction
1) High pressure in suction line of 2 nd stage
19. At what condition fusible plug is fitted main air bottle ? 2) High temperature in suction line of 2 nd stage
3) Reduce delivery
Fusible plug is fitted at main air bottle, when relief valve is fitted indirectly to the air bottle. It can 4) Increase running time
cause any obstruction by human error. Second stage delivery
1) Increase suction pressure in2nd stage
2) Reduce delivery in 2nd stage
20. Purpose of bursting disc? Where is fitted ? 3) Increase delivery pressure from 1st stage
It is fitted on each cooler shell of air compressor, to give ample relief of pressure when cooler
tubes burst. 26. FALLS OF COMPRESSOR PERFORMANCE
(Causes of poor performance)
(01) Choked air suction strainer
21. Why bursting disc need to be annealed ? (02) Leaky or sticky valves
Due to heating and time expanded bursting disc is harden so to get back the normal relief (03) Too much L.P bumping clearance
pressure . It must be annealed. (04) Leaky piston rings
(05) Leaky cover and gaskets
(06) Leaky drains
22. First start arrangement ? (07) Leaky relief valves
Firstly start the emergency air compressor to fill up the air to the emergency air bottle up to (08) Leaky coolers
(09) Worn crankpin or bearings
desired pressure obtained.
(10) Faulty capacity controller
Drain out oil and water.
Open emergency air bottle outlet valve and pressed up desired pressure. How to maintenance air compressor efficiency ?
Then start the generator with correct procedure. 1. Cleaning of suction air filter
Close the breaker and switch on the lighting. 2. Adjusting bumping clearance
Start the required machinery ( especially G/E FO booster pump, S, W cooling pump, E/ R 3. Regular overhaul the suction and delivery valve and checking bearing
4. Check the piston rings and liner
blower).
5. Clear the cooler drain free from deposits
Start the main air compressor and press up to main air bottle. 6. Clean the cooler
After that, made M/E warming by using generator jacket water and start the L.O pump.
Air bottle pressure test
23. Why provide air compressor on board ? 01) Gag the relief valve
(1) Starting Diesel engines, 02) Close all openings
(2) Instrumentation and control systems, 03) Fit test pressure gauge
(3) Various pneumatic tools and cleaning equipments, 04) Remove filling valve and fill F.W completely
(4) Boiler soot blowing and 05) Air purge and connect hydraulic pump at filling line.
(5) Ship's whistle. 06) Apply pressure 1.5 times of working pressure and maintain at least 30 min
07) Check leaking points.
24. Why need minimum lubrication ?
To prevent carbonizing of the valves Purpose of drain valve (Compressor and Air bottle)
To avoid loss of compressor efficiency due to sluggish action of valve It is process to remove the accumulation of oil water and sludge from the air bottle, scavenge
To avoid loss of cooler efficiency due to deposition of oil on the cooling surface space, compressor intercooler and settle and service tank.
To prevent air line explosion, to prevent air bottle corrosion 01) To drain the water and surplus oil in the air bottle.
02) To avoid air bottle corrosion
25. VALVES LEAKING 03) To prevent staring air line explosion and sluggish & corrosions system valve.
Valves can leak and finally fail. Valves may fail owing to wear and fatigue, insufficient
of over-lubrication, presence of foreign particles, oil decomposition and excess valve lift.

EFFECTS OF VALVES LEAKING

First stage suction
1) Reduce air delivery
2) Reduce second stage suction pressure
3) Increase running time
4) Unload the compressor

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 49 50 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

9. How to change purifier from H.O to D.O ?

Replace the gravity disc, which is smaller than the heavy oil
Open heater by pass vale.
Closed the F. O heater steam in/out valves.
Open heater drains v/v.
1. What is gravity disc ?
The gravity disc is important part of purifier, which set the location of the oil, and water interface
Remarks. Pure D.O purifier cannot change to H.O, it has no heater.
line, which is variable according to the maker’s design.
Pure clarifier cannot change to purifier, it has no water outlet.

2. How to choose the correct size of gravity disc ?

10. Why multidisc provided ?
1 can choose it. Separation temperature 2. density of oil at this temperature 3. desired through
To separate the liquid into thin layer & create shallow settling distance between discs.
put of oil and by using of nomogram .
Improving separation of oil from heaver liquids & solids particle

3. What is paring disc ?

11. Cause of excessive vibration on purifier
It is a stationary impeller mounted in a chamber at the neck of the bow.
Sludge too much
It function is convert the rotating energy into a pressure head.
Foundation damper & spring failure
Bearing failure
4. What about water washing ? Worn gear
Water washing is widely used techniques to remove acids, salts, and other impurities from the Uneven wear of frictional clutch
oil. Motor speed too high or too low
The oil must be straight mineral oils or without dispersant additive oils.
Water should be injected into the oil before purifying at a rate of between 3 to 5% of the oil flow 12. Explain purifier over flow
that is continuously renews the water seal in the purifier bowl.
1. Incorrect purifier disc size (inside diameter too large)
The oil temperature should be around 75 °C and water temperature about 5 °C higher than 2. Too low fuel oil temperature
oil .It can be done continuously or intermittently. 3. Too much rate of throughput
4. Too much sludge inside the bowl
5. Low speed (rpm) of bowl rotation
5. What is steam jetting ? 6. Sealing water failure
By blowing steam into the engine lube oil just pair to its purification. 7. Operating water failure
Coagulation of colloidal carbon will occur. 8. Worn out main sealing ring
Purifier will remove this carbon more effectively.
Why have not get enough rpm when purifier is running ?
6. Compare purifier and clarifier ? 1. Improper touching with friction clutch (worn out frictional clutch)
Purifier Clarifier 2. Touching with break
3. Excessive sludge in the bowl
a. Remove water and suspended a. Remove finer and lighter particles 4. Bearing failure
Solids particles from oils from oil 5. Motor running at overload
b. Two outlets water and clean oil b. one outlet for clean oil 6. One phase power failure (Single phasing)
c. Gravity disc on top c. No gravity disc only sealing ring 7. Sump oil level too high
d. Blind disc on the top of disc stack d. Blind disc at bottom. 8. Vertical shaft and horizontal shaft are out of alignment
e. Sealing water required e. Sealing water not required
How to adjust bowl high ?
By turning vertical shaft adjust screw
7. How do you change purifier to clarifier ? By shim by bowl body
Open up the purifier and set the blind disc at the bottom of the disc stack.
The water outlet is blocked by a seal on the gravity disc. Reduce purifier bowl high Oil goes through the water outlet.
Blank off the sealing water inlet line.

Why need sealing water ?

8. What is purifier, clarifier ?
To seal the water outlet & to prevent the overflow of oil from the water outlet.
Purifier is a centrifuge, which is arranged to separate water and solid impurities from oil.
Clarifier is a centrifuge, which is arranged to separate finer solid impurities from the oil.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 51 52 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Adjusting the Bowl height

Checking the play above and below the centripetal pump

WESTFALIA SEPARATOR

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 53 54 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

6. What is the function of thermostatic expansion valve ?

1) To control the flow amount of liquid refrigerant to the evaporator in such a way as to keep
practically the entire coils filled with the evaporating refrigerant.
1. Safety devices on refrigeration system 2) To keep constant super heat on the refrigerant vapour leaving the evaporator.
1) L. P cut-out on compressor suction side: Set at a pressure corresponding to 5°C below the lowest 3) It sudden drop in pressure and temperature
expected evaporating gauge reading
Automatic and prompt responds of refrigerant flow to match the Evaporator Load.
2) H.P cut-out on compressor discharge side: Set at a pressure corresponding to 5°C above the
Prevention of Liquid Refrigerant being entered into the Compressor.
highest expected evaporating gauge reading
Maintaining appropriate amounts of Refrigerant in the High pressure side and Low pressure
3) Lube oil low pressure cut-out: Oil pressure usually set at 2 bar above crankcase pressure
side of the system.
4) Cooling water L .P cut-out in condenser side
5) Safety spring loaded liquid shock valve on compressor cylinder head
6) Bursting disc on cylinder head, between inlet and discharge manifold 7. What is relative humidity ?
7) Bursting disc on Condenser, [if fitted] Ratio of amount of water vapour in given volume of air, to maximum amount of water vapour
8) Relief valve on Condenser; air purging valve on condenser that can be present before precipitation occurs.
9) Master solenoid valve: to prevent liquid being entered into Compressor, when the plant is It is the mass of water vapour per unit volume of air compared to the mass of water vapour per
standstill, especially in Large Plant unit volume of saturated air at the same temperature.

2. What is critical temperature ? 8. What is saturated air ?

Critical temperature above which it is impossible to liquefy the refrigerant regardless of The air contains maximum wt of water vapour at the particular temperature.
pressure.
It should be as high as possible and certainly above the maximum expected condenser 9. What is super heating ?
temperature. Temperature above which the saturated temp:

3. What is the primary refrigerant ? 10. UNDER CHARGE

It is a medium which is used in a vapour compression cycle to remove heat from a low Symptoms
temperature region and convey it to a high temp: region .It undergoes change of physical state during Low discharge pressure
its working cycles. Large bubbles in the liquid sight glass
Compressor delivery temp: high.
1) Mostly volatile liquid and employed inside direct expansion closed system. The machine runs for longer periods between cut out.
2) Evaporate at low temperature and at reasonable pressure
3) Condense at SW temperature at reasonable pressure Remedies
To charge the refrigerant until the bubbles disappears in the liquid sight glass and
4. What is secondary refrigerant ? charging will correct the pressure gauge reading.
To find out the leaky points by halide torch or soap solution or electronic leak detector.
It is a substance which is transferred heat by conduction and convection. Brine is a secondary
refrigerant .Its density 1250 kg /m2
11. OVER CHARGE
1) It is a non volatile liquid during it working cycle and employed at large, complex installation, to Symptoms
avoid circulation of expansive Primary Refrigerant in large quantities. It is indicated by high compressor discharge pressure.
2) Cooled inside Refrigeration Machinery Room and pumped around the ship to batteries in each Compressor runs cold.
cargo space Excess frost on compressor suction line after evaporator.
Full of sight glass.
5. What is solenoid valve? How to operate? Why fitted ?
Remedies
Solenoid valve is a liquid stop valve.
The excess refrigerant is released to atmosphere through the purging valve fitted on the
The valve is fully open and close.
condenser until discharge pressure return to normal.
To control the cool room temp: within set limit
It is a electro magnetic cut in cut out devices when the cool room temp reaches the desire point,
12. AIR IN THE SYSTEM
the pressure switch which is connected to the thermo bulb in the cool room shut the solenoid
. Symptoms
valve which stop the refrigerant flow into the evaporator.
High condenser and compressor temp:

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 55 56 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Abnormally high discharge pressure 4) High suction pressure

Jerky pointer gauge
Very small bubbles in liquid sight glass. Defective Discharge valve
Indication
Remedies 1) Continuous running of compressor
To remove the air from the system – 2) Insufficient cooling effects
Change the compressor to manual position 3) Noisy operation
Closed the liquid stop valve after the condenser 4) High suction pressure during running
Pumping down the entire charge into the condenser 5) Low discharge pressure during running
Until the suction pressure just above zero. 6) Suction pressure faster after compressor is shut down
Stop the compressor and closed the consider inlet valve 7) Warm cylinder head
Then allowed to cool the consider contents.
Air is expelled through the purging valve until the refrigerant gas appears at the valve. 16. How do take in action high pressure cut out and low pressure cut out ?
H. P pressure cut out
13. MOISTURE IN THE SYSTEM Occurs due to condenser coolant failure, low coolant pressure and malfunction of consider
Symptoms cooler valve operation.
Starving of evaporator and rapid condenser pressure rise cause compressor short cycling.
Also can cause dirty or chocked condenser tubes.
Frost at expansion valve inlet.
The refrigerant can not liquefy rapidly .The discharge pressure will abnormally raise and high
pressure cut out will take in action.
Remedy
Clean expansion valve filter.
Low pressure cut out
Renew drying agents of dehydrator.
Operate the solenoid valve is closed when the cool room temp: reach its desired temp:
(setting temp:)
14. Cause of expansion valve chocking Can cause when expansion valve is chocked by dirt or freeze up by water present in the
When a valve is functioning correctly frost forms on the outlet side of the valve, and if the inlet system.
side does show frosting then this is a sign of blockage. Starving of evaporator and rapid condenser pressure rise.
It is caused by dirt or freeze up by water present in the system. Compressor may stop by low pressure cut out.
Starving of evaporator and rapid consider pressure rise cause compressor short cycling.
17. Leakage Test for Refrigerant
Remedy CO2 – Soap and water solution
Clean the expansion valve filter
NH3 –Wet litmus paper (Red ~ Green); Sulphur candles, which gives off white dense smokes
Renew the drying agent of dehydrator. (activated alumina or silica gel )
when contact with Ammonia
Freon – Soap and water solution / Halide torch /Electronic leak detector (buzzer sound)
15. OIL IN THE SYSTEM
By halide torch, How to indicate the flame ?
Symptoms Content is methylated spirits type. Butane can also be used.
Incorrect condenser and evaporator temperature differential.
When the leak is detected the flame will change from blue to green depending on the concentration of
The system running longer than normal.
gas.
Difficult to cold down room temperature.
Remedy 18. What is refrigeration ?
Pumping down the entire charge to condenser.
It is a process in which the temperature of a space or its contents is reduced to below that of
Along the system must be blown out with compress air by stripping individual unit component.
their surrounding.
Repair the oil separator.
Renew the compressor piston rings.
19. What is air conditioning ?
It is the control of temperature and humidity in a space together with the circulation, filtering and
Defective Suction valve
refreshing of the air.
Indication
1) Continuous running of compressor
20. What is ventilation ?
2) Insufficient cooling effects
3) Noisy operation It is the circulation and refreshing of the air in the space without necessarily a change of
temperature.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 57 58 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

21. Comfort zone ? 26. Why fitted high pressure cut out ?
It is between the 40 to 70 % relative humidity at the temperature of 20 to 29C dry bulb temp:, It is fitted to shut down the compressor in the event of high pressure .After remedy the fault,
air motion is 100mm per sec. have to run necessary to reset.

22. Advantages of secondary refrigerant ? 27. Why fitted master solenoid valve for large plant ?
Low initial cost If compressor stops due to a fault, the master solenoid valve will close to prevent flooding by
Low maintenance cost liquid refrigerant and possible compressor damage.
Suitable for large refrigeration plant
Easily produce onboard by mixing Ca Cl2 and distilled water. 28. Explain about one method of refrigerant charging ?
Easily store as a salt onboard Normally charging is made through the liquid charging valve at the high pressure side.
01). Firstly, weighting the gas bottle.
Defrosting 02). Connect the gas bottle and charging valve with the connection pipe.
A method of removal of frost, built-up on Evaporator coils. Defrosting should be done before 03). Before tightening the cap on charging pipe, open bottle valve to remove air in the pipe.
snow thickness exceeds ¼”. 04). Then tighten the cap and open bottle valve fully, charging valve is still closed.
05). Change compressor to manual running and start it.
Reasons for defrosting 06). Close the condenser outlet valve.
Affecting heat transfer properties 07). Pumping down the entire charge to the condenser.
Affecting air flow and circulation 08). Open the charging valve slowly when suction pressure just above zero.
Liquid back to compressor 09). Control the valve opening slowly that no frost formed on the compressor suction
pipe.
23. Defrosting methods ? 10). Check the level in the condenser sight glass.
By stopping the system 11). Close the charging valve and pumping down the entire charge until suction
By washing with warm water pressure just above zero.
By means of electric heater coil fitted at the evaporator 12). Stop the compressor and close the discharge valve.
By hot gas defrosting method 13). Cooling water kept running for some hour.
14). Then air is purged out through purging valve on condenser until the refrigerant
Defrost brine System gas appear at the valve.
Hot brine thawing : Best and fastest method, used powerful brine heater with separate 15). Calculate the amount of refrigerant (charging) and enter the engine log book.
thawing system. Watertight trays under the pipes, collected the dripping water
Hot air from atmosphere : It is important that isolating doors in air trunks are perfectly tight, so 29. Why super heat is required at evaporator outlet ?
as to prevent hot air going into cargo spaces. To prevent the liquid refrigerant entering into the compressor.
If no super heat, hammering may happen and the valve will suffer damage and breakage.
By shutting off brine : Allow the snows to be melted by the heat of the heat of the air in
circulation .Very slow operation and tends to throw back great deal of moisture into cargo space. 30. How to fill fridge plant compressor oil ?
01) Change the compressor to manual running.
Notes: 02) Pumping down the entire charge to condenser.
Direct expansion grid system : Hot gas defrosting 03) Connect the L.O hand pump to L. O filling valve after air is purged out.
Battery cooling system : Water spray, electrical or steam heater 04) When compressor suction pressure just above zero, open the oil filling valve, inject the L.O
Brine cooling : Hot brine thawing into crank case.
05) Then stop the compressor and close compressor discharge valve. Then cool down the
24. Purpose of ventilation for cargo hold ? refrigerant.
To remove surplus heat and humidity 06) Then purged out the air through the purging valve until refrigerant appears at purging valve.
To prevent the condensing of moisture on cargo or hull
To remove gases produced in ripening process of some fruits and vegetables cargos. 31. Types of expansion valve.
Thermostatic control
25. What is short cycling ? Electronic control
It is a condition of a compressor unit repeatedly running for a few second and then cutting Manual control
out .This is the result of L.P controller.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 59 60 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

32. Prevention of Liquid Flow Back More green house gas ~ Warmer & more humid climate ~ more desert, less forest, agri: problem,
higher sea level, sea ecology system destroy. (When the concentration of CO2 & other gases
2) Liquid shock valve (on cylinder head0
3) TEV increases)
4) Master solenoid valve (when the plant is standstill, especially in Large plant) Refrigerant effected to Ozone layer. ~ R11 (CClF3), R12 (CCl2F2), R22 ( CHClF2)
5) Defrosting
Refrigerant not effected to Ozone layer. ~ NH3, R134A
6) Bursting disc (on cylinder head, between inlet and discharge manifold)

Back pressure valve at the outlet of vegetable room to prevent under cooling of coargo.

Objectives
(01) To extract excess heat
(02) To raise air temperature when required
(03) To add moisture as required
(04) To reduce too great a moisture content as required
(05) To maintain sufficient Oxygen and air flow
(06) To remove dust

Control of Temperature

Comfortable temperature range is about 22 °C and RH about 60% (usually 40 ~ 70%)

All zone temperature
1) Controlled by compressor suction pressure, via solenoid valve as step controlling.
2) Thermostat, placed at some accommodation space actuates the Master Solenoid Valve of the
plant, which will stop the Compressor, when pre-set temperature is reached
3) Capacity Unloader of compressor units, does last step controlling, as required

Particular zone temperature

1) Controlled by flap valve fitted in each zone loop
2) Local cabin temperature can be adjusted by volume control at delivery point of air duct controller.

Ozone depletion.
Ozone is gas; between 15 & 30 kilometer above the surface of earth.
This layer controls our climate & protects us from radiation. The release of industrial waste and
other process are now increasing the ozone breakdown to disturb the natural balance.
How ozone is destroyed.
Pollutant (e.g. - CFC) gas from ground level travel to atmosphere.
In the upper atmosphere Ultra Violet Ray breaks off Chlorine atom from the CFC molecule.
The free chlorine atom attack the one ozone molecule. Breaking it form to chloromonoxide. The
remainder of the ozone molecule formed into regular oxygen molecule.
A free oxygen atom now steels the oxygen from chloromonoxide molecule form an oxygen
molecule. Chlorine atom is again free, attack and break up an ozone molecule. In this way single
chlorine atom destroy 1 million of ozone molecule.

Ozone depletion ~ More ultra violet radiation ~ Global warming, Increasing skin cancer, immune
system affected, reduced forest production and crops & sea ecology disturb.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 61 62 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Purpose of baffle plate

01) To prevent the tube
02) To guide the flow of fluid
What is Charge Air Cooler purpose ? 03) To increase cooling surface area
04) To minimize the tube vibration
To reduce air temperature & increase density of charge air.
All more fuel can be burnt more power can be obtain Cause of loss of vacuum effect in F.W.G
Reduce exhaust temperature and engine thermal load.
(01) Failure of ejector pump
Increase scavenging efficiency, safe working temperature.
(02) Failure of ejector nozzle (fouling, erosion)
(03) Malfunction of check valve (at ejector nozzle)
Cooler maintenance for optimum efficiency (04) Defective vacuum breaker
1. Cooler should be checked any deposit of line, scale or oil sludge may be present in cooler it should (05) Any air leakage into the system (At joint)
be cleaned.
2. Cooler of water side can be done with soft tube brush and oil side with carbon tetra chloride solution
in reverse direction to normal flow with hand pump for about 4 hours. What will happen while vacuum reach 100%
3. After cleaning the cooler are hydraulically pressure tested normally 1.5 times the working pressure. 1) Increase the salinity because of agitation. AT that time boiling rate is very high.
4. It 10% of the tubes have been leaked retubing in necessary. Normal leaking tubes may be stopped
by plugging. 2) To control this condition: I open the vacuum breaker to maintain 93% vacuum.
5. Corrosion can be protected by means of preservative coating (Anti corrosive paints) inside the shell
and water boxes and by means of anodes such as zinc fitting inside water boxes. Why F.W.G is fitted onboard ship ?
6. Essential cooler for optimum efficiency can be maintained by controlling of temperature of fluid or
1) To produce the high purity distilled water from sea water
sea water.
2) To provide make up water fro boiler and portable water for drinking and domestic used. So can
Purpose of division plate save cost.
1. To providing to increase numbers of pass
2. This increase the cooling efficiency. Treatments for drinking purposes.
Sterilizing methods.
What do you know L.O cooler leakage ? How to do L.O cooler leakage occur ?
Chlorination.
When engine run,
01) Oil comes out at the cooling water overboard. Ultra violet light.
02) Sump tank oil level will fall down. Libration of silver ions from the consumable.
03) L.O pressure will drop Improving the platability.
04) If L.O cooler leaks the engine should be stopped with permission from bridge. The leakage can be
detected by carrying out a hydraulic pressure test to the oil side. Osmosis.
05) After cooling down the engine stop main circulating L.O pump and main S.W cooling pump. Different concentration solutions are separated by a semi-permeable membrane. Water from less
06) Close necessary valve of them
concentrated solution pass through the membrane to equalize the concentration of the two solution. It
07) Open water box covers cooler both side.
08) Blank off discharge pipe of cooler oil side. create hydraulic pressure gradient across the membrane as the volume and level of weaker solution fall
09) Connect hydraulic pump to inlet of cooler. and those of the stronger solution rise.
10) Apply oil pressure normally 1.5 times the working pressure. Then check the leakage at cooler both Reverse osmosis.
sides The pressure greater than the osmotic is applied to the side of higher concentration, the process is
11) Normally leaking tubes may be stopped by plugging reversed. Water from the stronger solution is forced back through the semi-permeable membrane to
12) If 10% of the tubes have been leaked retubing is necessary. dilute the initially weak solution on the other side and further increase the concentration of the strong
13) Then the engine is put back normal running.
solution.
How do you know air cooler leakage ? The total pressure required for this process consists of the osmotic pressure(between 4 bar for brackish
01) Check water level insight glass fitted at cooler drain pipe. water up to 28 bar for sea water) plus the system pressure losses and net driving pressures (around 25
02) Drain the cooler / taste the water bar).
03) If the water continuous comes out, the cooler is leakage. Also in the funnel white & dense smoke.
04) Thus the engine should be stopped with permission from bridge. Membranes
05) Normal leaking tubes can be stopped by plugging. 1. Hollow fine fiber (aromatic polyamide or cellulose acetate spurn to form hollow fiber)
06) Then the engine is put back normal running.
2. Spirally wound (cellulose acetate for backish water and polymide or polysulphonate for sea
How to check cooler efficiency ? water.)
01) Check sea water in/out temperature difference. Less amount poor efficiency of cooler (must be high)
02) Check coolant medium in / out temperature (Difference temperature: should be low)
03) Feel over cooler shell, upper hot, middle warm, down cool is normal.
04) Check pump and by pass valve.

Compiled by Min Zar Tar 2/14/2005 10:31 AM

 nd
63 64 REFERENCE FOR M.O.T 2 Class Part B (Oral)

The emergency Rudder angel indicator and communication system to Bridge being provided
at the Emergency station.

In case of electrical telemotor failure

Put bridge control to manual
Type of Telemotor System
Emergency steering gear system is operated by (solenoid button) whether port or starboard.
1) Hydraulic system
Rudder angle indicator and communication system between steering room and bridge must be
2) Electric system
provided.

Type of Steering system Emergency steering gear operation.

1) Elector hydraulic system 1. Disconnect auto pilot system.
a) Ram type system (2 ram or 4 ram) 2. Took out change over pin from attachment with telemotor receiver & fit to the hand gear.
b) Vane type system 3. Communication system with telephone from steering gear room to bridge.
2) All electric system
a) Ward Leonard system Steering gear test & maintenance.
b) Single motor system Control test - Just prior to 1hour before departure of vessel.
12 hour before departure.
Operation of main & auxiliary steering gear.
Non follow up system. Operation of remote control system.
When steering gear set to required position, rudder is moved & when rudder reach the required Operation of emergency power supply.
position, steering gear must be set to off position. This system uses the three solenoid valve. Alarm test.
Actual rudder angle & indicator.
Follow up system. Communication system.(Bridge, Engine room & Steering gear room)
When steering gear set to required position, rudder is moved & when rudder reaches the set
position, steering gear still remains at that position. This system uses the hunting gear arrangement. Every 3 months interval.
Emergency steering gear drill at steering gear room to bridge with sound communication system.
2. What is hunting gear ?
7. Types of pump used in hydraulic steering system ?
It is feed back mechanism of steering gear which repositions the floating lever of hydraulic
pump as the tiller moves to the desire position. Motor driven constant speed variable stroke delivery pumps. There are two types.
Radial piston type ( hele- shaw pump )
Axial piston type ( swash plate pump )
3. Safety devices for steering system ?
Hunting gear
Buffer spring 8. Advantages of rotary vane type over ram type ?
Angle adjusting stop (Hand over position limit switch) Smaller space required
Double shock valve Law installation cost
Relief valve Low in weight
Tank level alarm (oil) Smaller power required, for the same load, because it can transmit pure torque to the
Over load alarm rudder stock.

4. Indication of air in the system

9. Disadvantages
Jumping pressure gauges
Synthetic rubber backed steel sealing strips at vane tops are not strong enough for large
Jerky operation
Defective steering ship gear.
Can be used for rudder stock ratings of about 1700 KNm and less torque generated by two
5. Effect of air in the system ? ram is 120 to 160 KNm and for four ram 250 to 10,000KNm.
Air being compressible gives incorrect balance between units, time lags and irregular
operation. ( which can be dangerous ) 10. Test required before departure ?
Steering gear should be checked at least one hour prior to departure.
6. Emergency steering gear operation? Telemotor transmitter oil level to be checked
Oil level of actuating system tank should be checked and replenished if necessary.
In the case of Telemotor failure, by switching the change over pin, Emergency steering can
be carried out by isolating the Receiver Cylinder and directly controlling the connecting rod of the Rudder carrier bearing and bottom sea gland checked and greased.
Main Steering Power Unit's pump lever. Start pump and check response of the gear

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
65 66 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Check abnormal noise and heat a. Absorb the difference between the steering order speeds and follow up speed.
Check load carrying and running of the gear b. Absorbed the movement of steering wheel if it is mishandled when the hydraulic pump
( swing from port 35 to STB 30 within 28 sec ) stop in.
c. Absorb the movement of the control lever when rudder drift
11. Properties of telemotor hydraulic fluid ? d. Absorb the vibration and shocks from the rudder.
Good quality mineral lubricating oil is used.
Its properties are- When carry out emergency steering system ?
Low pour point (-50°C) Every voyage (UHA)
Low viscosity ( to reduced fractional drag, but not too thin to mate gland sealing, 30 Once at least within 3 Months (SOLAS)
@ Survey
Redwood Secs at 60°C)
High viscosity index (110)
High flash point (150°C closed) Daily check in steering gear room
Non sludge forming Pressure gauge of steering pump.
Non corrosive Motor ampere on the steering switch board & motor hand touch feeling
Good lubricating properties Noise and vibration.
Specific gravity 0.88 at 15.5°C Oil level in tank
Oil leakage in system
Grease in rudder carrier bearing
12. Purpose of buffer spring ?
Check the bottom seal gland whether good or not.
To prevent the damages of the control system.

Steering system regulation.

13. Requirements for steering gear ? Every ship shall be provided with a main steering gear and an auxiliary steering gear. The failure of
To move the rudder in either direction instantly when required one of them will not render the other one inoperative.
Relief valves shall be fitted to any part of the hydraulic system.
Should come to reset immediately in the position corresponding to that shown on indicator The main steering gear and rudder stock shall be:
on the bridge. A of adequate strength and capable of steering the ship at maximum ahead service speed.
Provision must be made to protect the steering gear from damage should a heavy sea A capable of putting the rudder over from 35' on one side to 35' on the other side with the ship at its
strike the rudder. deepest sea going draught and running ahead at maximum ahead service speed and, under the
same conditions, from 35' on either side to 30' on the other side in not more than 28 seconds.
The design should be sample, the construction robust and its performance reliable at all A So that they will not be damaged at maximum astern speed.
times. The auxiliary steering gear shall be:
A of adequate strength and capable of steering the ship at navigable speed and of being brought
speedily into action in an emergency.
14. Purpose of swivel block ? A capable of putting the redder over from 15' on one side to 15' on the other side in not more than 60
To control linear movement of the rams to the rotary movement to the tiller arms and rudder seconds with the ship at its deepest seagoing draught and running ahead at one half of the maximum
stocks. ahead service speed or 7 knots, whichever is the greater.
In every tanker, chemical tanker or gas carrier of 10,000 gross ton and upwards and in every ships of
70,000 gross ton and upwards, the main steering gear shall comprise two or more identical power
15. Explain ward Leonard system ? units.
It is the one types of electrical steering gear system. Which control the speed of DC motor Essential requirement for steering gear.
from zero to maximum in either directions. a To move the rudder in either direction instantly, when required.
a Should come to rest immediately in the position corresponding to that shown on indicator.
a Provisions must be made to protect the steering gear from damage should a heavy sea strike the
16. In four rums type steering gear system, what unit you make in service rudder.
when one cylinder damage ? a The design should be simple, the construction robust and its performance reliable at all times.
If one cylinder damage, four rams steering gear can be used as two rams type steering Tests required before departure.
gear. a Steering gear should be checked at least one hour prior to departure.
First place the rudder at mid position. Isolate the circuit valves of two cylinder inlet. a Telemotor transmitter oil level to be checked.
a Oil level of the actuating system tank should be checked and replenished if necessary.
One cylinder is defective and another one, but they are not in diagonal position. Open the vent at a Rudder carrier bearing and bottom sea gland checked and greased.
that cylinder. a Start pumps and check response of the gear.
a Check load carrying and running of the gear.

17. Purpose of buffer spring ?

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
67 68 REFERENCE FOR M.O.T 2 Class Part B (Oral)

10. Cause of engine hunting ?

It is unavoidable time lag between the movement of the governor act and the movement of
engine response.
1. What is governor ?
11. What is isochronous governor ?
Governor is a device which controls the speed of engine automatically in the prescribed
It is a constant speed governor .It is able to maintain exactly constant speed without hunting.
limits.
This type of governor that has proportional and reset is called isochronous governor.
The governor does its job in two steps.
a. measuring the speed and
b. control the a amount of fuel supply to the engine. 12. What will happen when over speed occurred ?
Engine revolving and reciprocating parts may damage due to inertia effects.
2. Function of governor ?
To adjust the rate of fuel supply in such a way as to keep the engine running at a steady 13. Why will you test G/E over speed trip ?
speed regardless of the load . It can be tested by increasing the engine speed by speed adjuster at no load condition. Over
To control the engine running at a steady speed under all conditions of load. speed trip will cut-out the fuel supply at 115% of normal speed.

3. What is governor droop? 14. Why speed droop governor is used at G/E ?
When considering the engine and governor combination, the difference between the no load It is fitted to get load sharing ability isochronous governor gives constant speed, thus can
speed and full load speed is called governor droop. not sharing the load.
Small droop rapid swing AVR is fitted at alternator.
Large drop slower response to change in speed.
15. Why over speed trip provided although governor fitted ? ******
4. Types of governors. Governor only control the engine speed in prescribed limits. When accidental sudden load
a. Mechanical governor. change that from full load to no load, engine speed become too high above 15% of rated speed.
b. Hydraulic governor Due to time delay of governor control, engine parts may become damage. Thus to prevent
c. Inertia governor [fitted on older slow speed engine] this effect over speed trip must be provided to shut down the engine by cutting fuel.
d. Electronic governor Note : it need to reset before restart the engine.

5. What is compensation ? 16. How to operate/act Isochronous governor ? *****

The use of temporary speed droop to prevent over correction of the fuel supply is called It maintains constant speed without hunting. Speed droop for it is temporary
compensation. It acts 2 actions
It required two actions- 1. Droop application (as fuel supply is changed)
a. Droop application - as the fuel supply is changed 2. Droop removal (as engine responses to fuel change and returns to original speed)
b. Droop removal - as the engine response to the fuel change and returns to original
speed . Sensitivity : Ability to control the engine speed, within narrow limits
Stability : Governor is stable, when there is only one radius of rotation of flywheel
6. What types of governor used in G/E and M/E ? for each speed, at which governor operates within the sped range.
G/E governor is a droop speed governor with over speed trip. 17) Why Inertia type Governor is not used nowadays ?
M/E governor is a constant speed governor with over speed trip. 1) Although very simple type, it requires an engine speed increase of 5% or more to make it
operate
7. Why fitted over speed trip in main engine ? ***** 2) In some cases, increase of engine speed will bring into or near to critical speed that can cause
severe vibration.
It is fitted to control the sudden load change and sudden increase in speed. e.g severe load
change when loss of propeller in heavy sea .Thus, to prevent engine parts damage, over speed trip
Governor Maintenance
is provided.
Periodically check oil level
Set the speed 15% more than MCR. It is attached at camshaft through gearing.
Change the governor oil
If engine speed rise more than 10 to 15% above the rated speed, It shut of fuel & stops the
Grease the linkage and joint
engine. The mechanism has to be manually reset before engine start again.
OVER SPEED TRIP Speed rise more than 10 to 15% above the full load speed, shut down the
8. Why hydraulic servo governor is widely used ? engine. Reset the engine before starting the engine.
Hydraulic governor is widely used because of their
a. sensitivity OVER SPEED GOVERNOR Not effective certain limit up to 110% of normal speed. 10% above
b. isochronous and normal speed shut off fuel supply to engine and 5% below normal speed automatically recut in fuel
c. having grater power to move the fuel control mechanism of the engine . supply to engine.

9. What is hunting ?
It is a fluctuation of engine speed due to the over correction of the fuel supply. (too much increase or
decrease fuel supply)

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
69 70 REFERENCE FOR M.O.T 2 Class Part B (Oral)

5. Where emergency fire pump in your ship ?

It is fitted at steering flat, shaft tunnel, forward part of the ship.
The pump to be located remote from machinery space.
Class of fire.
A - Ordinary combustible material. 6. Requirements for emergency fire pump ?
B - Flammable liquid & gases.
C - Electrical fire. Passenger ships of 1000 grt and upwards and in cargo ships of 2000 grt and upwards must
D - Metal fire. have fixed emergency fire pump independently driven by a self cooled compression ignition engine
or an electric motor driven by electric power from emergency generator.
Detector. It must be located outside the E/R room, in the steering flat, shaft tunnel or in forward part
1. Combustible gas. (Galley, ER fwd bulkhead adjacent to p/p room under floor plate) of the ship.
2. Heat (Galley, Boiler room, Laundry, control room) It must have own suction, total suction head should not exceed 4.5 meters under all
3. Smoke (Machinery space, Cargo space, Laundry, at stairways, corridor, escape route
within Accommodation space) conditions of list or trim.
4. Flame (Engine room, near fuel handling equipment) Pump capacity must not less than 25m3/hr and must be able to deliver two ½ inches bore
jet of water having a horizontal throw not less than 40 ft.
Fire tetra hedron. Fuel tank for engine shall contain sufficient to run on full load for at least 3 hrs and reverse
Heat, oxygen, fuel, chain reaction. fuel for 15hrs, store outside the machinery space.
The prime mover engine at that unit must be hand started and able to start by one man.
Various medium used for fire fighting
If the pump is fitted above the water level, priming arrangement must be fitted.
If diesel engine driven:
1. Water : This is extinguishing mainly by cooling the material at fire. Steam generation is
useful for smothering. Water is more suitable against fire in wood, paper and textiles.  Easily started in cold condition (0C by hand cranking
 Fuel tank for engine shall contain sufficient to run on full load for at least 3 hrs and
2. Foam: The extinguishing effect of the foam is a combination of smothering and cooling.  Sufficient reverse fuel for 15 hrs, store outside the machinery space
Foam is used against fire in oil surfaces. If motor driven: emergency power supply heating arrangement

3. Dry powder:The extinguishing effect of the powder is mainly by inhibition (change breaking) and
effective mainly against fires in flammable liquid, gases and electrical equipment. No. of Fire Pump
a Passenger ship of 4000 GRT and upward at least 3 pumps
4. Carbondioxide: The extinguishing effect is smothering and inhibiting. CO2 is heavier than a Passenger ship of < 4000 GRT and Cargo ship of 1000 GRR & above at least 2.
air, the best condition for extinguishing is in closed spaces. CO2 give no secondary damage. It is a Cargo ship of < 1000 GRT according to administration
electrically non-conductor and therefore suitable against electrical equipment fire.

5. Halon: Extinguishing effect is nearly exclusively inhibition. Halons are suitable against fires 7. What are the portable fire extinguisher used for? Where are they located ?
in liquid and electrical equipment. All Halons are consider to be toxic to some degree because with Portable fire extinguishers are the first line of defence.
hot surfaces and flame causes them to break down yielding toxic substances. It can be deal with an emergency as prompt action
All extinguishers should be:
1. How many kinds of extinguishers in E/R ? 01) Locate in an easily accessible Position
There are 3-kinds of extinguishers in E/R. There are foam, CO2, and dry power types. 02) The correct type to deal with the class of fire expected in that area
03) Painted in the appropriate color code.
2. How do operate chemical foam extinguisher ?
04) Regularly inspected and tested.
It can be operated by releasing the cap by means of operating handle and turning it up side
Water-signal red, CO2 –black, foam- pale cream, dry power- franch blue.
down. Aim to near the fire (base or wall). Shake the bottle foam coming out.

3. How to operate and extinguish the CO2 extinguisher ? 8. Why do you make CO2 room ventilation ? Where ?
Remove the safety pin and then the valve-operating lever is squeezed to pierce the disc. To remove the leakage CO2 from the CO2 room .CO2 gas is heavier than air and does not
The liquid CO2 leaves into the discharge horn and emerge as a cloud of CO2. support to human life (Suffocate). (CO2 room must be well ventilated before entry) Outside the
machinery space usually at main deck and it must be separated compartment.
4. What is emergency fire pump ?
It is a fixed emergency fire pump independently driven by self cooled compression ignition 9. How to make it ?
engine or an electric motor which power is supply from emergency generator. All the fire pumps out
It is made by motor driven exhaust blower or fan, which suction is drown from CO2 room
of action either by disabling the pumps or their source of power, it can be used.
floor, because CO2 is heavier than air and leakage CO2 can accumulate on the CO2 room floor.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
71 72 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Fan control switch is fitted outside the CO2 room entrance. The entire system is initially charged with fresh water at a pressure of about 8 bar by a tank,
maintained under pressure by compressed air. It is also connected to an independent sea water
pump with its own sea water suction.
10. How to extinguish control room small electrical fire ? Each sprinkler head has a quartzoid bulb which retains a diaphragm seal in the outlet of the
When E/R control room electrical fire breaks out, we must use CO2 portable fire water pipe. This bulb is partially filled with a special fluid so arranged that a rise in temperature in the
extinguisher, because CO2 is electrical nonconductor. compartment concerned will cause the liquid to expand and entirely filled the space, the bulb burst,
the water pressure forces the diaphragm out and water flow out from the sprinkler.
01) First give the fire alarm signal. Under the specific pressure of 5 to 8 bar, maintained in the tank by air pressure, the water
02) Check the condition of fire and cut out the power if is possible. from the sprinkler is deflected upwards and outwards and broken into a fine spray by the serrated
03) Shut off E/R ventilator and close the E/R entrance door but one exit door must be opened edge of the sprinkler base and will adequately cover a floor area of about 16 square meters.
behind me. The resultant pressure drop at the release of the water causes an alarm to sound on the
bridge and indicates on the board, the zone in which the ruptured sprinkler heads are situated.
04) Take CO2 portable extinguisher and fight the fire by staying up steam of air and the When the system pressure dropped to 5 bar, the sea water pump will start automatically and
distance about 3-4 ft from fire. continue supply with sea water.
05) Move back to the exit door. Each head must deliver 100 litters per minute. The number of heads in one section is limited
not more than 200. They are spaced not more than 4 meters apart and 2 meter from any bulkhead
06) Leave the extinguisher and close the exit door.
or part of the ship's side which forms a boundary of the protected space.
Section alarms can be tested individually by test cocks on each section. At least two
Carbon dioxide flooding system. sources of power must be provided to operate the sea water pump and automatic alarms. The
1) Steel cylinder, 67 liters capacity, each charged with 45 kg liquid CO2 under pressure of 55 bar. component should be tested weekly.
Provided with safety disc, bursts at a pressure of 175 to 195 bar.
2) Quick release or total flooding cylinders are arranged that 85% of the capacity can be released 12. Sprinklers system requirements ?
within 2 minutes. Can be discharged individually. 01) Each sprinkler head must be capable of 100 lit/min.
3) Manual release cylinders for individual release.
4) Both groups are manifolds together. 02) Each sprinkler head is sufficient to cover the area of about 16 square meters.
5) The liquid when released produces about 450 times its original liquid volume in the gas form. 03) One section is permitted to contain 150 to 200 heads.
One kg of liquid CO2 can produce 0.56 cubic meter gas. 04) Sprinkler heads are spaced not more than 4 meter apart and 2 meter from the vertical wall.
6) To be effective in smothering a fire the total carbon dioxide gas to be obtained at least 30% of 05) There must be at least two powers source for the sea water pump, alarm system and FW
the gross volume of the largest room of the ship and the total flooding system must release to
obtain 40% of the gross volume of the machinery space and held until the fire is out. pump.
7) The visual and audible smoke detecting cabinet is located in the wheel house and two exhaust 06) This system consists of independent S.W p/p with its own sea water suction.
fans are installed in the water tight galvanized steel box on top of it. The three way valves, under 07) Section alarm can be tested individually by test cock on each section.
the smoke detecting cabinet, are normally closed to CO2 line and the blower sucks air from the
holds through smoke detector will be closed and CO2 can be discharged to the required cargo
Mechanical foam.
hold.
1) Foam is smothering agent. The production of this foam is mainly a process of agitation of a
mixture of water, air and single foam compound, resulting in which is a vast and continuous
11. How to release the CO2 gas from fixed instillation to machinery space ? bubble formation.
01) CO2 flooding to machinery space must be done by master’s order. 2) Foam compound is an aqueous solution of partially hydrolyzed keratin, stabilized with iron salts.
3) With modern foam making nozzles, the mechanical foam constituency can be varied from sloppy
02) CO2 must be released by competent engineer, CE or 2/E. to stiff. Stiff foam has only blanketing quality. Sloppy foam has speed of smothering and
03) When cabinet door is opened alarm will sound and all E/R fans will be stopped. additional cooling properties.
04) Before releasing CO2, all ER crew to be counted (No absence). 4) The expansion ratio is 30:1 water to foam compound, producing 200:1 foam to compound.
05) All openings must be shut (ventilator flaps, fire dampers). 5) Quantity of the foam to give about six inches depth over the areas to be protected. The duration
for the whole capacity discharge should be less than 5 minutes. The foam should not be
06) All fuel pumps and quick closing valves of fuel tanks and fuel transfer line must be shut disturbed too early and reignition may occur from the residual heat.
from remote control position.
07) After opening the cabinet door, master valve must be opened first. 13. Differentiate between explosimeter and Davy’s safety lamp ?
08) Pull the operating handle of pilot cylinders. Explosimeter
09) CO2 released from pilot cylinders, operate the gang release bar so that all CO2 from quick To measure the consideration of inflammable gas and vapour in the atmosphere
release or total flooding cylinders will be released to machinery space. Quickly and accurately.
10) By regulation, 85% of the capacity must be able to be released within 2 minutes. It can measure remote from required tank.
It is necessary to skill full for operation.
Sprinkler or pressure water Based on Wheatstone bridge principle.
The system consists of several sections comprising a number of sprinkler heads mounted No need to handle with care.
on the pipes, each section being connected through a section control valve to a sprinkler main which Davy’s safety lamp
in turn is connected to a pressure tank and a pump.
To detect the tank atmospheres, whether it is explosive gas or fatal gas.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
73 74 REFERENCE FOR M.O.T 2 Class Part B (Oral)

It can get verify roughly the tank is gas free or not. 05) After through ventilation, tank atmosphere tested for any toxic or explosive gases, by invited
It is required to apply directly into the required tank. chemist or with Davy’s safety lamp before entering.
Based on the ordinary fire process. 06) When the tank is gas free, the following LSA to be carried or kept ready, when entering,
No need to highly skill. a. Lifeline or harness to be put on.
But it required careful handling. b. Spark proof hand torch to be brought in.
c. BA set to be kept ready.
Davy's safety lamp. d. Resuscitation equipment to be kept ready.
Employed for detection of the tank atmosphere whether explosive or containing fatal gases. e. Have rescue team, readily available and properly led.
1) If the flame in the lamp burn clearly, the tank atmosphere is free from any fatal or explosive
f. Competent person, stand by at entrance.
gases.
2) If it is develops a faint blue cap above, it is the sign of an explosive gas present. g. Agree a communication system, before entry.
3) If the lamp burns black or goes out, foul gas such as carbon dioxide is present. The lamp will not h. Have adequate illumination.
burn in an atmosphere containing less than 16% of oxygen.

18. What precaution to be taken before enter the tank ?

14. What are LFL and HFL ?
1) Gas free certificate
Lower flammable limit (LFL) 2) Tank entry permit
The concentration of hydrocarbon gas,1% by volume in air below which there is insufficient 3) Davy safety lamp to be brought into and test tank air
hydrocarbon gas to support and propagate combustion is Lower Flammable Limit. 4) Breathing apparatus, resuscitation equipment to be kept ready at entrance.
Higher flammable limit (HFL) 5) Life line to be put on
The concentration of hydrocarbon gas inn air 10% by volume, above which there is 6) A spark proof hand torch light to be brought in
insufficient air to support and propagate combustion. 7) competent person to be kept on watch
It is a highest concentration of hydrocarbon gas in air for explosion. 8) Smoking and naked light not allowed in vicinity

19. Is there any device onboard to detect any foul gas ?

15. Advantages of inert gas purging system ?
Davy’s safety lamp is employed for detection of tank atmosphere it is explosive gas or any
No explosive mixture can form in the tank.
foul gas such as CO2.
Reduce corrosion.
Reduce pumping time because of the positive pressure in the tank at all the time.
20. How to extinguish E/R bilge fire ?
Reduce the fire risk in the event of cargo loading, transporting and discharging.
First check the condition of fire; it is small oil fire in the bilge well.
Then raise the fire alarm signal.
16. FO setting tank (service) gas free procedure ? Remove the combustible material near vicinity
Drain down the entire charge into the double bottom tank through the dumping valve. It is a small fire, extinguish by foam portable extinguisher. It is operated by releasing the
When the tank is empty, open the manhole door which located one on top and other on cap the cap by means of operating handle and turning it up side down. Foam will emit from
side. nozzle.
Make force ventilation by blower fan through the manhole door at least 24 hrs. Release the foam direct to the fire by deflecting it from another surface.
Foam is lower specific gravity than oil or water that it will flows across the surface of oil and
Then check the tank atmosphere by Davy’s safety lamp.
cover.
If the flame burns clearly, the tank atmosphere is free from explosive or fatal gas.
The fire will stop by blanking with foam.
Enter into the tank and clear the sludge and wipe out with cotton rags. During entering the
tank ventilation must be provided continuously.
21. What are the effects of chemical form ?
One competent person must stand near the entrance to keep on watch.
The extinguishing effect of the form is a combination of smothering and cooling.
Use spark proof torch and lamp. Naked light and smoking not allowed in the vicinity. When burning surface is covered with foam, it will insulate the flame from the liquid surface,
there by the heat radiation against the liquid is decreased and the gas generation decreased. So
Gas free procedure that the fire stops.
Foam is used against fires in oil surface.
01) Gas freeing is essential before entering empty. (Gas free certificate, Tank entry permit
02) Manhole doors to be opened for at least 24 hrs before entry.
What is chemical foam safety device ? It function ?
03) Forced ventilation with air duct, to be done with electric blower for at least 24 hrs.
1. Small radial hole at cap
04) With forced exhausting system, minimum of 2 air changes should be completed during that
2. Atmosphere valve
time.
The cap has small holes in the threads or also has in the middle of bottle thread so that any
internal pressure must be released before the cap is fully removed.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
75 76 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Firstly, unscrew slowly foam will emit, so it cannot injure. Check bolts and bracket of heating coils and their tightness.
Check magnesium anode.
22. What is fixed installation ? Check float ball indicator.
It is a fixed fire extinguishing equipment fitted for engine room and C/H to extinguish the Check numerator tank gauge.
immerse fire controlled by remote station, (Eg. usually mechanical foam or CO2.) Check striker plate wear down.

23. How do take action for cabin fire ? 27. How will you test smoke detector ?
When I found the fire in cabin give the alarm signal. Smoke test- by applying smoke to the detector head, alarm will activate and light up the
Check the condition of fire and remove the combustible material near vicinity. indicator lamp.
Isolate electrical supply to that cabin. Check the line cleanliness between cargo hold and smoke detector by checking nylon
Take the soda acid or CO2 or foam portable extinguisher from the alley way. propellers. It must rotate when are clear.
If use soda acid type, remove the safety guard and strike the knob smartly. Any blockage can be clear by using compressed air. (Open the 3-ways valve fully, it will
Then release the water to the fire spaces. contact the CO2 main and cargo hold line and blow with compressed air.)
Give the boundary cooling to it adjacent spaces, if the fire is great.
The fire will stop by cooling effect. 28. What is the fire control plan ?
It is a general arrangement plan which shall be permanently exhibited onboard for the
23. Safety devices on CO2 fixed installation system ? guidance of ship personal and also exhibited outside the deck house with water tight enclosure for
Master valve with alarm switch for cargo hold. the guidance of shore fire brigade.
Relief valves at each brunch line It consists of –
Stop valve and pull handle are in lock cabinet and alarm switch. 1) fire control stations
Safety bursting disc at each CO2 bottle. 2) Location of various portable fir extinguisher & FFA.
3) Fire detecting and alarming system.
Maintenance of CO2 flooding System 4) Means of escape.
1. Before entry CO2 room must be well ventilated 5) Ventilation system.
2. Weekly inspection for alarm system 6) Fixed fire fighting instillation system.
3. Bottle should be weighted yearly, level checked by ultrasonic or radio active isotope detection.
Level reference mark should be provided. If 10% loss of weight, recharge them. 29. Principle of fire fighting ?
4. All the pulley, wire, rope and toggle must be free from dirt, scales and well lubricated.
Cooling to reduce the temperature.
5. CO2 branch pipe and nozzle should be cleared with compress air at two year interval
Smothering to reduce emission of vapour.
6. Bottle should not be exposed to temperature of 60°C Cutting off combustion material.
Cutting off O2.
24. How will you do for cargo hold fire ? Interrupting chain reaction by chemical.
Remote detector fitted at the bridge can detect concerned cargo space.
This operation must be done by master’s order. 30. What is international shore connection ?
After ensuring no person left in cargo space, seal off the cargo space (closing of ventilation It is a standard size flange, together with bolts, nuts and washers which has a couplings
fan, fire damper, and hatch cover). fitted which is suitable for the ship’s hoses. It is used to connect up the shore water main in any port
to the ship's fire main and equipment. (w.pr –10.5 bar )
25. Where do you use CO2 A fire extinguisher ? Material Ý Steel at 1.0 N/mm2 designed
CO2 fire extinguisher is used in electrical equipment fires. Dimension Ý OD = 178 mm, Ý Flange thickness = 14.5 mm
It is electrically nonconductor. Ý ID = 64 mm, Ý Slots in flange: 4 holes, 19 mm Φ, equal spacing
CO2 is heavier than air but it can be carried away by combustion gases and flame, if it is Ý PCD = 132 mm, Ý Bolts & nuts: 4, 16 mmΦ , 50 mm length, 8 washers
used out door.
The best condition for extinguishing is in enclosed space.
31. Why fitted emergency fire pump on board ship ?
CO2 is a clean medium and give no residue, therefore it has no secondary damages.
It is fitted and alternative means of providing water for fire fighting if a fire in any one
compartment could put all the fire pumps out of action either by disabling the pumps of their source
26. What point to be checked after cleaning the FO service tank ? of power.
Check heating coils that is no deformation and burst.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
77 78 REFERENCE FOR M.O.T 2 Class Part B (Oral)

32. E/R fire fighting / detecting equipments.

1) Check emergency light and all other lights 1) Check weight every 2 years
2 no of fire hydrants at each floor. 2) Check exhaust fan / ventilation 2) Testing of cylinder at 228 bars
3 types of portable extinguisher.(CO2, foam, Dry powder) Located in easily accessible 3) Check all bottles overall condition, clamps, 3) Blow through the lines
valves etc.
position (2 nos. of within 10 m) and correct type to deal with expected class of fire in that 4) General Instructions
4) Check operating wire condition
area 5) Check CO2 alarms Key
Non-portable fire extinguisher (136 Litres ( 50 gallons) foam extinguisher for boiler space.) 6) Key should be in position Emergency lights
Sand box with shovel. 7) Check the operating instructions Ventilation
8) Inspection to be removed in log book and
Smoke detector and alarm system. Alarms etc.
Saturday safety routine book.
Fixed instillation system.

CO2 Room Safety Arrangement

Mechanical foam Chemical foam
Exhaust fan, and suction duct
Bubble filled with air Bubble filled with CO2 Provide at the bottom of the room. Any accumulated CO2 from leakage at the bottom can be
Foam produced by mechanically mixing of foam Foam produced chemical reaction of exhausted to atmosphere.
Cable operated safety valve
concentrate , water & air (Special nozzle require) Al2(SO4)3,NaHCO3, & foam stabilizer Fitted on the pilot cylinder discharge line. It prevents accidental discharge of CO2 from quick release
Expansion ratio is higher 30:1, 200:1 Lower expansion ratio cylinder due to action of leakage gas from pilot cylinder.
Relief valves
Mostly used fixed installation & non portable
Mostly Used as PFE Fitted on each discharge line from cylinders so that leakage gas can safely dispose to atmosphere
extinguisher Check valve
Fitted on connection pipe between each cylinder discharge valve and manifold, so that leakage of
one cylinder cannot effect other cylinder.
Bursting disc
CO2 SYSTEM REQUIREMENTS
Each bottle has a combined bursting disc, which will rupture spontaneously at a pressure of 177 bar
1) Engine room 40% of gross volume, (for < 2000 GRT cargo ship 35%)
at 63°C
2) Safeguard against unauthorized usage
Pressure gauge and pressure alarm in the mainfold
3) Machinery sector valve fitted with alarm and blower trip
4) Operation triggers alarms
5) Permanent piping (up to bilge and tank top) Precaution before CO2 operation
6) Distribution piping mover than 19 mm diameter 1) All personnel to be evacuated and head counted
7) Distribution manifold and piping tested 122 bar 2) All remote valves to be closed (FO, DO and LO tanks valve)
8) Copper pipes and high pressure flexible pipes allowed between cylinder outlet valve and 3) Stop all fuel and lub oil pumps from remote operation
manifold 4) Stop all ventilation fans from remote operation
9) Pipes to cargo space not to pass through E/R unless all pipes tested to 122 bar 5) All openings, skylights, funnel flaps etc to be closed
6) Open control box to activate CO2 alarm (warning to personal for CO2 release)

Precaution after CO2 operation

Requirements of CO2 Bottle CO2 Properties Limitation
For a room where CO2 has been released, take the following cautions without fail.
1) All bottles stamped at 52 bar 1) In CO2 atmosphere, you are in danger of suffocation due to oxygen lack. Never attempt to enter
01) CO2 is heavier than air into a room filled with CO2 without putting on breathing apparatus. Before entering into the room
2) Bursting disc 177~ 193 bar at 63°C 02) Less cooling effect full of CO2 never fails to put on hose type or oxygen type breathing apparatus. But don't use
3) Store in temperature less than 55°C 03) Static electricity induced activated carbon type mask.
4) Recharge if 5 % loss 04) Heavily asphyxiating (suffocating) 2) The room should be ventilated after fire in the room has been extinguished completely, Enter
5) Clamped against movement and vibration(by 05) Ineffective if > 10 ~ 12 minutes into the room when it becomes full of fresh air.
wooden plank) 06) "One off" no reserve 3) Even after fire has been extinguished completely, never bring bare flame such as candle light
6) Remote and manual operation 07) Total evacuation required or lighted cigarette into the burnt room, other wise fire may break out again due to explosion of
7) Hydraulically tested to 228 bar 08) Possibility of thermal shock combustible gases, if any.
8) Level tested (by radio active level indication) 09) No protection of personal 4) In order to allow persons to get away quickly and safely in case of fire, entrances and exits shall
9) (if > 10 years internal and external examination 10) Expands 450 times its volume in liquid to be always kept clear in particular carefully at around CO2 injecting sports.
required produce gas. 5) Should a person be suffocated with CO2, bring him into a place of fresh air without delay and
practice artificial respiration. Some of the symptoms of suffocation are as follows:
CO2 Room Inspection CO2 Survey a) Accelerated respiration
b) Accelerated pulsation
c) Debility
6) When extinguishing fire from electrical equipment, turn off power as soon as possible for
checking spread of fire and safety.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
79 80 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Safety device on life boat

Mechanical brake (to prevent accident falling)
Centrifugal brake (to control life boat falling speed between 20 to 40 m/min)
Limit switch (to prevent over tightening of rope) (it is fitted arm of davit just before in limit) Cavitations
Cavitation can be occurred when the pump suction contains air or when the pump is running
Harbour safety pin (for davit)
faster than the designed speed.
Low pressure regions occur in the flow at points where high local velocities exist. If
Windless safety device vaporisation occurs due to these low pressure areas then bubbles occur, these expand as they
move with the flow and collapse when they reach a high pressure region.
Cable stopper (chain stopper, bow stopper)
Such formation and collapse of bubbles is very rapid and collapse near a surface can
Overload trip generate very high pressure hammer blows which results in pitting, noise, vibration, and fall off in
Hand brake the pump efficiency.
Slipping clutch for overload prevents any undesirable damage such hull damage due to anchor and So the pump should be run at designed speed and throttling of the suction valve
should be avoided.
rope broke out.
How to no water come from ballast Pump ?
How will you do for cargo hold fire ? 1) Incomplete priming
01) If cargo hold (C/H) fire broken out. While the ship is at sea. 2) Too high suction lift
02) Smoke detector will give alarm and signal on the bridge. Duty officer will check which cargo 3) Low net positive head
holds is broken out of fire. 4) Air leaks in suction line
03) Give the fire alarm 5) Gas or air lock
04) To extinguish the fire. Following procedure must be done 6) Suction filter choke
05) Check any person left in the cargo hold (Head count all crew). Totally isolate the cargo hold.
(Shut cargo hold ventilation, blower and damper) hatch cover, man hold.
06) Fully open the three way valve to that cargo hold, the line to smoke detector is closed and Screw pump overhaul
connect the CO2 main line and cargo hold. 1) Remove fuse from motor starter box
2) Close suction and discharge valve
07) Then I go to CO2 room and open master valve for cargo hold. 3) Remove suction and discharge pipe flange bolt & nut, coupling bolt of motor coupling
08) CO2 alarm will sound in the cargo hold 4) Remove pump foundation bolts & take out pump from motor
09) Check the required amount of CO2 bottle to use for that cargo hold. 5) Remove gland nut, take out gland & gland packing and neck bush
10) Then release required CO2 t cargo hold by pulling the wire connected to CO2 to cargo hold by 6) Remove cover both side & remove driver screw & driven screw with bearing.
7) Clean all parts.
pulling the wire connected to CO2 bottles or open one by one by manually
11) Fire will stop because room atmosphere is smothering by CO2 gas. Screw pump check point
Neck bush surface condition
Inert gas generator. Bearing
Driver screw and driven screw wear & tear
1. Special air cooled diesel generator. Pump casing internal surface
2. Washing & cooling boiler flue gas. Clearance between driver and driven
Gas ~ N2 85%, CO2 14%, O2 1% Clearance between driven and casing
Maintain 75 milli bar above the cargo. Clearance between driver and casing.

Sprinkler (quartzoid bulb) Centrifugal pump overhaul

1) Remove fuse from motor starter box
Red - 68' C 2) Close suction and discharge valve
Yellow - 79'C 3) Remove suction and discharge pipe flange bolt & nut, coupling bolt of motor coupling
Green - 93'C 4) Remove pump foundation bolts & take out pump from motor
Blue - 141'C 5) Remove impeller lock & nut & take out the impeller
Violet - 182' C 6) Remove gland nut and take out gland, packing neck bush
7) Remove bearing cover from other side & take out shaft with ball bearing
8) Clean all parts.

Check point
Impeller Wear ring Neck bush Ball bearing shaft.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
81 82 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Safety Cap maintenance

a By instruction, renewed or reusable.
a For renewable type, renew after complete running hours.
1. How will airline explosion occurred ? a For reusable type, annealing must be done.
The main cause of starting airline explosion is the leaking starting air valve or jamming at
open position of the valve. 5. What notice if scavenge fire occur ?
Initially, the oil which is discharged from the air compressor to starting air line system it will When fire has been broken out-
deposit as a thin moist film on the internal surface of the pipes but not ready to combustion. The scavenge air and the exhaust gas temperature of particular cylinder will increase.
If starting air valve leaked or jammed at open position, hot gas or flame may enter the In some causes turbocharger start may surging.
starting air manifold, vaporize the oil and set the fire to oil mist and greasy matters, which generally The engine will slow down immediately because the cylinder will not be receiving their normal
charge of fresh air at the end of the firing stoke.
deposit on the surface.
Heavy smoke will emit at exhaust funnel.
At that condition, mostly arrival first start for manoeuvring time, high pressure compressed
Discharge of sparks, flame or smoke through drain cocks from scavenge air box.
air coming into contact with the fire and may cause explosion. Cooling outlet temperature of the affected cylinder increases.
Visible outlet temperature of the affected cylinder increases.
2. How to prevent the air line explosion ?
Made regular overhaul and maintenance of starting air valve. 6. What is scavenge space fire ?
Before departure, test the air starting valve leakage. In scavenge air space there is normal accumulation of carbonized cylinder oil, unburnt fuel
Regular drain off the air bottle drain valve. and carbon from the residual products of combustion. They will ignite under certain faulty operating
Regular drain off air starting system. condition (such as flame blow by) indicating afire in the enclosed scavenge air box. This is a
Regular cleaning of the compressor suction air fitter and used oil wetted suction fitter scavenge fire.
Feed minimum absolute cylinder lubrication to compressor.
7. How to prevent scavenge fire ?
Keep piston rings in good working order.
3. Safety devices on starting air line ? Find the adequate amount of cylinder oil
Spring loaded safety valve or bursting cap.(if bursting cap fitted, no need relief valve) Drain the scavenge space at every watch.
Flame trap.(At Joint where manifold to each cylinder starting line) Clean the scavenge space and exhaust port regularly
Keep the fuel injector tight.
Starting air line drain valve (Inlet of automatic valve)
Cylinder liner wear must be within admissible limit.
Turning gear interlock Prolong engine or any cylinder over loading must be avoided.
Reversing interlock Piston rod stuffing box must be maintained to prevent oil ingress in the scavenge space.
In case of times lubrication, the time has to be checked as per PMS.
4. How to test starting air valve leakage ?
8. Causes of scavenge space fire ?
By hand touch feeling to adjacent pipe to the valve while in engine is operating. The main causes of fouling of the scavenging air space are blow by of the products of
If leak hotter than others incomplete combustion.
By means of pressure testing prior to the sailing. (In port) Factors contribute to the scavenge fire:
1) Blow past of combustion products caused by –
Shutting the isolating valve to air pilot distributor 1a) Leaky sticky or broken piston rings
All indicator cocks must be opened 1b) Bodily worn out liner, scoring or scuffing at the liner surface.
Disengage the turning gear 1c) Faulty cylinder lubrication (i.e. quantity, quality or timing)
Open the main air bottle stop valve 1d) Insufficient axial clearance of piston rings.
Set the control lever to starting position 2) Overheated piston dissipates heat to the under piston area caused by -
Check all the indicator cocks 2a) Faulty atomization and injection pressure
Escape of air through indicator cock will show a leaking starting valve 2b) Faulty fuel pump timing
It should be replaced immediately. 2c) Lack of scavenge air
2d) Engine operation in overload condition
2e) Failure of coolant circulation or insufficient cooling due to formation of scale.
Safety cap
When explosion occurs burst out of safety tube, the outer hood can be moved round just far 3) Blow back of exhaust gasses by caused by –
enough to blank off the holes in the inner hood, thus preventing air leaks when the engine continue 3a) Fouling of grid before turbine inlet
using air. It is only use for emergency and the safety tube should be renewed as soon as possible. 3b) Fouling of turbine blades
The detector fixed to the safety cap will by bent out at the explosion and it tells at a glance 3c) Choking of EGE or economizer gas outlet
which tube has busted. 3d) Partly chocked exhaust ports

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
83 84 REFERENCE FOR M.O.T 2 Class Part B (Oral)

4) Sometimes contain fuel oil due to- 10. Cleaning and inspection after extinguishing the fire ?
4a) Defective fuel injector
After extinguishing the fire the engine should be cooled down at least 15 minutes.
4b) Incorrect pressure of injectors
4c) Fuel particles landing on the cylinder liner. All the scavenge air space should be opened
5) Excessive cylinder lubrication which is drained to the scavenge spaces Then thoroughly cleaned and all debris removed
6) Oxygen plentiful during engine operation After cleaning the piston rods and cylinder liner should be examined for surface blemishes
7) Fouled scavenge manifold.
and straightness.
The accumulation of fuel residues mixed with excessive cylinder oil in the scavenge air Examine the diaphragm glands to ensure that they are operational and not damage.
space.
Accumulation of such mixtures can be set alight by the sparks or flame blow by scavenge Inspection After Scavenge Fire
fire occur.
1) Intense fire can cause distortion and may upset alignment.
Ca use s of sc a ve nge spa c e fire ? 2) Check by turning engine and watch movement of piston in liner, check for any occurrence of
The main causes of fouling of the scavenging air space are blow by of the products of binding at part of stroke (Binding indicates misalignment of piston)
incomplete combustion. Due to – 3) Check spring on scavenge space relief device, if the device was near the set of fire.
Defective fuel injector 4) Piston rod packing spring also should be checked, which may have become weakened by
Faulty fuel pump timing
overheating
Lack of scavenge air
Partly chocked exhaust ports 5) Check piston rings and liner for any distortion or burning (reddish) mark
Engine operation in overload condition 6) Check diaphragm and frame near affected part.
Defective piston rings or 7) Check guides and guide shoes
Badly worn out cylinder liner.
8) Check tie bolts pretension.
The accumulation of fuel residues mixed with excessive cylinder oil in the scavenge air
space.
Accumulation of such mixtures can be set alight by the sparks or flame blow by scavenge Scavenge Space Protection Devices
fire occur.
1) Electrical temperature sensing device fitted within the trunking, which will automatically
9. Dealing to scavenge space fire ? Action sound an alarm the event of an excessive rise in local temperature (above 200°C)
a) If the fire is not too great 2) Pressure relief valves consisting of self-closing spring loaded valves are fitted and should be
Inform to the bridge to reduce the engine speed. examined and tested periodically.
Reduce the engine speed
3) Fixed fire extinguishing system may be CO2, Dry Powder or Steam.
Cut off the fuel to concern cylinder
Increase the cylinder lubrication to that cylinder
Shut the scavenge drain valve. 11. What is crankcase explosion ?
Coolant flow through jacket and piston is maintained.
An explosion occurs in the crankcase. For an explosion to occur there must be in the
Keep clear of scavenge space relief door to prevent human injury.
crankcase a mixture of oil mist and air in the ratio that is within the range of flammability.
b) If the fire is too great In addition there must be a source of high temperature energy sufficient to initiate
It necessary to stop the main engine, inform to the bridge and take the permission combustion. Explosion occurred. This source is called hot spot.
to stop.
The turning gear should be engaged as soon as engine stopped and turn the
engine. (To prevent overheat, distortion and seizer of the engine parts. 12. How to cause crankcase explosion ?
If the fire fighting equipments is fitted, it should be brought into operation. The normal content of crankcase is air. In this air there are oil globules (droplets) formed by
If no equipment is available the fire will generally subside in about 5 to 15 minutes.
the mechanical atomization of the oil as it s sprayed from the edge of the bearing and other places
Person should avoid standing close to the relief valve.
and as it is thrown about and churned by the quickly moving parts.
Fire should be extinguished after sometimes, If the fire spreads in the other scavenge spaces along If a hot spot occurs the oil particles in the neighborhood will evaporate. This evaporation
with the scavenge manifold, then- may cause the formation of a quantity of white condense oil mist in the cooler regions. The continual
1) Inform bridge and stop engine generation of heat at hot spot vaporization may proceed a space until the ratio of vapour to air lies
2) Stop fuel oil booster pump within the range of flammability.
3) Open indicator cocks, engage turning gear and turn engine to prevent engine seizure If hot spot can provide the necessary heat for ignition of vapour, a primary explosion may
4) Normal engine cooling and bearing lubrication are maintained occur.
5) Scavenge air duct flap valve before engine is to be shut
6) Release the smothering gas (CO2or steam) to extinguish fire 13. What is hot spot, and why occur ?
7) Before opening scavenge door ventilate the space thoroughly if CO2 is released. It is an overheated part, sufficient to initiate combustion.
A hot spot occur due to –

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
85 86 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Failure of lube oil to bearing, sprockets and similar parts. 06. After about 30 minutes or more when the engine is sufficiently cooled down , stop lub oil
Hot gas blowing past the pistons may provide spark sufficient to cause an explosion in pumps and open crankcase door.
the trunk type pistons engine. 07. Try to locate the hot spot by hand feeling over and by observation
(Hot spot temp: 280-400 °C Above the L.O flash point) 08. If the hot spot is located, prevent reoccurrence by making permanent repair
09. Make through inspection of crankcase.
How will you know whether hot spot or not ? 10. Pay particular attention to hot bearings, piston, bottom end bolts, guides and piston rod around
1. By hand feel to crankcase door stuffing box.
2. Abnormal noise in crankcase. Irregular running engine 11. Start lube oil pumps and check for proper flow of oil from every lubrication point.
3. Bearing L.O temperature increase 12. If everything is found normal, inform bridge, start the engine and gradually increase speed.
4. Alarm will operate when it reach at oil mist concentration 2.5 – 5% LEL Outside feel over sequence to be carried out for satisfactory operation.
5. Smelling & appearance of the dense oil mist when open breather pipe, drain cock.
15. Crankcase safety devices ?
1) Breather pipe with flame trip 2) Exhaust fan 3) Oil mist detector 4) Crankcase relief
14. How to prevent the crankcase explosion ?
doors. 5) Bearing temperature sensor 6) L.O return temperature sensor 7) Routine test on used
To minimize the formation of explosive mixture.
L.O for viscosity, flash point and contamination.
Breather pipe or exhaust fan fitted on crankcase.
To prevent the formation of hot spot in the crankcase.
16. Why is breather pipe fitted in the crankcase ?
a. The bearing should be in correct running clearance.
b. Lubricating oil should be adequately supplied to bearing , chain with sprocket wheels It is fitted to prevent crankcase explosion and to reduce pressure build up in it.
and other running parts It maintains the pressure level in the crankcase about 25mm of water below the atmospheric
c. The piston with rings and cylinders should be in safe working limits. pressure.
d. Good fitting and efficient locking of working parts.
Why crank case relief valve is fitted ?
Preventive measure of crankcase explosion It is fitted to release any sudden rise of internal pressure with large free escape area thus to
01. Engine cooling should be continued for sometime to ensure adequate cooling of the engine. prevent secondary explosion
02. Engine proper purification and analysis of lub oil.
03. Lub oil filter to be changed over & cleaned as per schedule 17. Requirements of crankcase relief valves ?
04. Ensure proper cylinder lubrication by checking the condition of piston, piston rings and liner The internal combustion engine of a cylinder diameter of 200 mm or a crankcase volume of
through scavenge or exhaust ports 0.6 m3 and above shall be provide with crankcase relief vale of a suitable type with sufficient relief
05. Clean scavenge space as per schedule & drain scavenges space regularly. area.
06. Maintain the stuffing box gland sealing in good condition In small engine cyl: dia; does not more than 300mm, crankcase door of which are usually
07. All running gears maintenance & checks to be carried out as per PMS very strong. It may have relief valve or valves at its end.
08. Be alert & rectify for any abnormal noise in crankcase In large engine, cyl: dia; over 30cm, It required one relief valve to be placed on each
09. All safety trips & alarms fitted on M/E to be tried out for satisfactory crankcase door.
10. Proper watch on al running gears temperature & pressure to be maintained Its free area should not smaller than 45cm2and there shall be minimum of 115cm2/m3of the
11. Blow through all sampling tubes of OMD regularly gross crankcase volume.
12. Zero adjustment & sensitivity of OMD to be checked regularly Spring setting for opening pressure is 0.07 bar at an internal pressure and will close when
13. Check for oil leakage at crankcase explosion relief doors & check for the operation by hand the pressure has been relieved.
14. Check flame trap for cleanliness and intact condition. The valves open smartly and close positively and rapidly.

Action after detecting hot spot 18. How would you test crankcase relief valve ?
01. Inform C/E & Bridge
When engine is stopping, after removing the flame trap and press up the valve disc and
02. Reduce the engine speed to reduce the heat generation
check the action of opening and closing.
03. Increase lubrication to the running surfaces
The valve must be opened smartly and closed positively and rapidly. The valve must be oil
04. Keep clear off crankcase relief door to prevent personnel injury, keep fire extinguisher ready 7
and gas tight.
open skylight.
When the engine is running we must only check the oil leakage that the v/v is seal or not.
05. Inform bridge, stop engine, open indicator cocks, engage turning gear and turn engine with lub
oil circulation continuing to prevent engine seizure.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
87 88 REFERENCE FOR M.O.T 2 Class Part B (Oral)

19. Causes of bearing high temperature ? 24. Dealing to economizer fire ?

Improper viscosity of oil Inform to the bridge and CE. Take the permission to stop.
Insufficient lubrication Gradually slowdown the ME and then stop.
Misalignment of shaft or bearings If fire fighting equipment is fitted, it should be brought into operation.
Foreign matters in oil Cool down the economizer by means of boundary cooling
Score journal Circulation pump must be run but large amount of water lost it must be stopped.
Poorly fitted bearing There is no heat source and fire is out.
Improper oil clearance When economizer fire occurs never made soot blow to economizer.
Whenever the bearing begins to heat up, check the lubrication whether it is clear, correct It can cause hydrogen fire and melt down the coils stack. It can cause deformation and
temp: and flow sufficient or not. tube bulking because intensive heat and high thermal stress formed at economizer coils.
After fire is out
20. What is the blow pass /blow by ? Cool down to ambient temperature.
Blow pass and blow by is the same. Hot gas or flame passed through the piston rings and Open the economizer cover.
cylinder liner from the combustion space. Clean inside parts of the economizer.
Check the any defective coil and repair for temporary used by welding or plugging the
21. What are EGE fire/ Why EGE fire occur? tubes.

A flame is appear at the economizer coil during running of main engine at sea while the
EGE is put into service with circulation water passing through the coils it is called Fighting the fire
1) Slow down the engine.
economizer fire. 2) Shut off oil burners, draught fans, dampers & air register.
It is actually cause by soot fire at the economizer coils. 3) Raise water level full and blow down continuously so as to maintain good flow of water.
For the economizer coils fire, heat is already presented due to passing the gases of ME . 4) Reduce boiler pressure by easing gear.
Air due to excess supply of scavenging air into the unit combustion chamber. 5) Spray water on the external casing of the uptake to cool the affected area.
6) A few times starting and stopping of M/E should be done to blow out collected soots at the
Fuel is thick deposit ,unburnt fuel, carbon residue (soots) sticking at the economizer coils . uptake.
Soots are formed from incomplete combustion and use of low great fuel and high carbon
content fuel. Big considerable soot fire
At the manoeuvring time, the more incomplete combustion may occur and at that time 1) Shut down the engine.
2) Shut down the boiler.
leaving flue gas velocity is very low, thus unburnt fuel can be adhering on the economizer
3) Follow all of the above steps.
coils. 4) After the self perpetuating fire died down, open up & clean the smoke side with pressure
A flame is produced when air and fuel are proportionally mixed in the sufficient heating jetting, check damage.
temperature.
Self-perpetuating Fire (or) Hydrogen Fire.
When the fire causes the metal itself burning at about 700(C, if steam smothering soot
22. Indication of EGE fire ? blowing system or water jetting system have been attempted, the big hydrogen fire may result.
Smoke smell will get from the economizer. The applied steam dissociates into Hydrogen and oxygen and accelerating the fire.
Once such a fire has started, resulting two kind of fires may take place simultaneously, one
Over heat at economizer body ( external casing of uptake.)
kind, iron burning in steam, and the other, the hydrogen burning in an air exothermic way.
Heavy smoke and sparks will emit from the funnel.
This combined fire being self supporting and lasting until the supply of steam is exhausted.
Sudden unexpected increase in uptake gas temperature ( Abnormally high stack pyrometer The primary object of dealing the fire is to cool the surface and burning material as quickly
reading) as possible.
Flame visible in the smoke indicator.
Sparks emitted from funnel. 25. Source of oil coming into air bottle ?
It is due to
23. How to prevent it ? Excessive oil level of compressor
To get complete combustion. Maintain the M.E optimum combustion condition..( governor, fuel Excessive cylinder lubrication
injection pump, fuel injection valve, fuel injection timing, fuel condition, air cooler, turbocharger, Defective oil scraper rings
do not run too long M.E with slow speed) Oil vapours inhaled from the engine room atmosphere.
Regular open up & cleaning smoke side depending upon soot accumulation.
Regular soot blowing operation. Check & maintain soot blowing equipment. 26. What point to be checked when crankcase inspection ?
Regular overhaul boiler burner, correct air fuel ratio & damper.
-To check

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
89 90 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Appearance of all parts inside the crankcase

Hot spot, Corrosion, Wear and tear
Locking arrangement
Loosing attachment
Bolts tightness
Chain inspection
Lube oil system
Metal chip in the crankcase What is emergency generator ?
Bearing axial play It is a small separate generator which supplies the electric power for emergency load in the
Crankcase relief valves, flame trap event of main power supply failure.
Crankcase door joints. It is located outside the main and auxiliary machinery space and not forward of the collusion
Crankshaft deflection bulkhead.
It has own switchboard near vicinity.
27. Why fitted oil mist detector ? It is provided with independent means of automatically starting,( by air or battery) to ensure
It is fitted to detect the oil mist concentration in the crankcase and to give early warning. immediate run up following a main power failure and repeated starts of at least 3 times, and
To prevent the primary explosion. further attempt can be made within the 30 minutes temporary battery life
Alarm setting 2.5% of the lower flammable limit. Adequate and independent supply of fuel with a flash point of not less than 43°C (109.4°F)
Must be able to be started in cold condition up to 0°C (32°F)
For cold weather, JCW system must be treated with anti-freeze agent, and heating
28. Oil mist detector maintenance ?
arrangement provided.
Daily check zero adjusting (r ) ( Send
a jy me J
h to shore)
Daily check alarm system Emergency generator Maintenance
Clean measuring tube & reference tube 01) Every Saturday, emergency generator must be tested run
Clean / wash mirror, lens and photo electric cells 02) Air bottle pressed up or starter battery fully charged, at all-time
Adjust the mirror 03) Changeover the selector switch to local position before starting
Check the lamp 04) Make sure breaker switch at ‘off’ position before starting (an interlock between ER Main
Check the blower fan efficiency switchboard breaker and emergency switchboard breaker is provided to prevent simultaneous
Check rotating selector v/v performance closure of both breaker)
Clean sampling pipes. 05) During testing, check frequency, voltage and ampere
06) Fuel tank, always checked to ensure adequate level
29. How will you take action when OMD alarm is on ? 07) Air filter of generator, regularly cleaned
Inform to C/E 08) Required tools and spares kept in a container
Inform to bridge, take the permission to stop the engine 09) Emergency light for this room should be always checked
Gradually reduce the engine and then stop.
Cool down the engine. What is emergency switch board ?
Check the inside parts of the crankcase inspection. It is a switchboard which distributes to emergency load that power is supply from emergency
Made necessary repaired. generator when the main power source failure.
Reset O.M.D and start engine It has two sections- one for 440V and another is 220V.

Actions after receiving alarm from OMD Emergency switch board distribution
Note the position of the crankcase chamber having hot spot pointed by the sampling knob. 1) There are 2 sections: 440 V and 220 V
Operate the selector button; turn the sampling valve knob to zero position or zero check, alarm 2) Under normal condition, 440 V supply is taken from ER Main Switchboard, through a Circuit
should stop. Breaker
Operate the check button the meter should swing on the scale and alarm should sound / operate 3) When main power is lost, this Circuit breaker is tripped (opened)
Release the selector button, if the alarm comes from the same crankcase channel then it is 4) Emergency generator comes into action, and supplies power through another circuit breaker
confirmed that the alarm is not false. 5) An interlock is provided, to prevent simultaneous closing of both breaker (both main and
emergency generator may be running, simultaneously)
6) From 440 V section

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
91 92 REFERENCE FOR M.O.T 2 Class Part B (Oral)

a. Emergency Bilge pump 1) Emergency lightening (at alley way, stairways and exits, muster and embarkation stations,
b. Sprinkler system machinery space, control room, main and emergency switchboard, firemen’s outfits storage
c. One of tow steering gears positions, steering ger room,)
7) From 220 V section 2) Fire detecting and alarming system
a. Navigation Equipment 3) Internal communication equipments
b. Radio Communication 4) Daylight signaling lamp and ship’s whistle
c. Transformed and rectified supply to Battery systems. 5) Navigation equipment
6) Navigation lights
Transitional Emergency Power Battery (Emergency lights for 30 minutes) 7) Radio installations, (VHF, MF, MF/HF)
Low power DC system Battery (Alarms and control system) 8) Watertight doors
9) One of the fire pumps, emergency bilge pump
Various load supply from emergency generator ? (Essential Services from Emergency
A set of automatically connected Emergency batteries must be capable of carrying certain
Power Source)
essential services for the period of 30 min.
It is called emergency load
1) Emergency lighting
Emergency lightening to alley way /boat deck / engine room.
2) Navigation lights
Navigation system
3) Fire detecting and alarming system
Steering gear
4) Internal communication equipments
Emergency fire pump
5) Daylight signaling lamp and ship’s whistle
Emergency air compressor
Battery charging
Cargo Ship
Fire detecting and alarming system
Emergency power source, Emergency generator must be sufficient to operate certain
Radio equipments (Communication equipment)
essential services at least for the period of 18 hours.
Daylight signaling lamp and ship’s whistle
1) Emergency lightening (at alley way, stairways and exits, muster and embarkation stations,
Navigation Aids
machinery space, control room, main and emergency switchboard, firemen’s outfits storage
General Alarm
positions, steering ger room,)
Manual fire alarm
2) Fire detecting and alarming system
Watertight doors
3) Internal communication equipments
4) Daylight signaling lamp and ship’s whistle
Emergency Power Sources
5) Navigation equipment
All passenger and cargo vessels shall be provided with emergency sources of electrical
6) Navigation lights
power, for essential services under emergency conditions.
7) Radio installations, (VHF, MF, MF/HF)
Emergency source may be generator or batteries, but must be complied with the rules
8) One of the fire pumps, emergency bilge pump
Emergency sources must be installed in position such that they are unlikely to be damaged or
affected by any incident, which has caused to main power.
Where emergency source of electrical power is an accumulator battery, it shall be capable of
Emergency source of power should be capable of operating with a list or up to 22 ½ ° and a
carrying loads without recharging and battery voltage throughout discharge period must be
trim of up to 10 °.
maintained within 12% above or below its nominal voltage
Emergency generator with its switchboard, is located n a compartment which is
Battery system is automatically connected upon loss of main power
Outside and away from main and auxiliary machinery space
Batteries are required as transitional power source for 30 min for following items
Above the uppermost continuous deck, and
1) Fire detecting and fire alarm
Not forward of collision bulkhead
2) Emergency lightening
Batteries: the above same rules applied, nut must not be fitted in the same place as
3) Navigation lights
emergency switchboard
4) Internal communication equipments

Rules for Emergency Power Sources

Passenger ship Emergency generator Starting when black out
Emergency generator shall be automatically started and connected within 45 sec 1) Normally cut in automatically when main power fails
Capable of supplying simultaneously at least the following services for the period of 36 hours 2) Starting is initiated by start up relay

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
93 94 REFERENCE FOR M.O.T 2 Class Part B (Oral)

3) Falling of frequency or voltage of Main power, cause the start up relay to operate generator Increase load on main engine
starting equipment More complicated mechanism.
4) If this system fails, after switching the MODE selector to Manual (Local) position, generator
can be started manually by means of Back up starting equipment within 30 minutes of What is earthling device ?
transitional emergency power battery lighting It is a propeller shaft grounding device. Its function is to ground the static electricity to the
ship hull caused by propeller rotation.
Emergency light Maintenance
Every Saturday, routine testing of emergency lights, carried out by E/E What is earth lamp ? How will you know when earth fault occur and how to trace it ?
Ensure that batteries are fully charged and ready for use A set of lamps, which show the presence of earth fault in distribution system. Each lamp is
Burnt out bulbs replaced at once connected between one phase and common neutral point.
If earth fault occurs the lamp will show dim light or goes out because potential is zero.
Emergency lighting The location of fault can be traced by switching off the individual branch circuit breaker and
checked the condition of earth lamp. When the branch circuit with the fault is switched off, the earth
1) Engine room lighting
lamp will return to normal brightness.
2) Bridge lighting
3) Passage way lighting
Earth lamps of 3 phase, 3 wire system, AC
4) Embarkation light
Each lamp is connected to secondary connections of each single phase step-down
transformer, and primary connections are common to star point, which is earthed to ship
Requirements for Navigation Light panel structure.
Navigation light should be connected to a distribution board, which does not supply other Normally 3 earth lamps burn with equal brightness if there is not fault
services If phase A is earth fault, lamp A becomes dark while the other two lamps burn with extra
There should be a changeover switch, so that it can be transferred to another source or brightness
power supply Location of fault can be traced, by switching off the branch circuit, one at a time
Visual and audible alarms required for individual Navigation Light failure (duel bulb system for When branch circuit with fault is switched off, dark lamp will become normal glow and all 3
change over) lamps burn with equal brightness.
Fuse protection provided

Why earth lamp is fitted ?

Navigation Lights
Earth lamp is fitted to give visual signal when there is an earth fault occurs in the system.
1) Fore Mast (No. 1 & 2 or Up, Down)
2) Main or Aft Mast (No. 1 & 2 or Up, Down)
What is megger insulation test ?
3) Stern light (No. 1 & 2 or Up, Down)
The instrument used for measuring high resistance in million of ohms. It is used for
4) Part light (No. 1 & 2 or Up, Down)
measuring the insulation resistance of cables, electrical equipments wiring insulation.
5) Starboard light (No. 1 & 2 or Up, Down)

Why Megger Reading is taken ?

What is shaft generator ? Advantages and Disadvantages ?
To verify insulation resistance
It is an alternator driven by main propulsion unit through clutch and gearing to produce
To detect insulation fault
electricity.
It can be used while vessel at sea running with a sea speed.
It must be able to supply normal sea load. Megger testing
Megger tester [generally a 500V set] is used for measuring high resistance, like insulation
Advantages resistance of cable, electrical equipment and wire installation in million ohms
Slightly reduce total fuel consumption. The test voltage is produce either by an internal hand driven generator or by a battery and
Reduced running hours of auxiliary generator. electronic voltage changer.
Reduced noise in E/R. A measurement of the insulation resistance gives one of the best guides to the state of health
Can made overhauling the aux: G/E at sea. of electrical equipment.
The resistance should be measured between insulated conductors and earth, and between
Disadvantages conductors.
Can not be used at rough sea.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
95 96 REFERENCE FOR M.O.T 2 Class Part B (Oral)

To get more accurate results, using the large instrument, it is important that the terminal Switch board survey.
marked earth, which is the + ve pole, shall be connected to the earth 1. Performed during dry-docking. (G.E black out)
2. Check volt meter, ammeter, watt meter all calibrators and accuracy.
3. Check all trips over current trip, reverse power trip, preferential trip.
AC DC
4. Synchronizing test. (load sharing test)
Phase to phase Pole to pole 5. Switch inside each terminal to be checked for insulation resistance min: 1M , all contact must
Phase to earth Each pole to earth be clean.
Rotor winding to earth Field to earth 6. Tightness of loose joint and connection, bus bar support, fuse holder.
7. Check automatic circuit breaker A.C.V and automatic voltage regulator A.V.R.
Armature to earth
8. Earth detecting lamp and alarm system.
How insulation Resistance of a motor is tested ?
1) Switch off at Main switchboard Meters fitted on main switchboard ?
2) Take out the fuse Ammeter, Voltmeter, Wattmeter, Frequency meter, Ohm meter, Synchroscope.
3) Tag the label on the S/B Don’t start
4) Disconnect the connection from starter
What is essential load ?
5) Test with megger
Essential services those are required for the safety of personal and for the safe navigation
6) Insulation Resistance is tested while at hot condition because it is minimum at that time
and propulsion of the ship. They include certain supplies to navigation aids, machinery spaces,
control stations and steering gear.
Difference between earthed and short circuit ?
Earthed
What is non-essential load ?
A fault in an electric circuit where a conductor come into contact with the ship hull or
It is a load that has no effects on the safe navigation and main propulsion unit when they are
a met enclosure. ( leakage of conductor due to insulation failure to ground.)
cut off. They are
Short circuit
Air condition, some blower fan except E/R blowers, galley (1st trip 5 sec)
A fault condition where a low resistance connection occurs between two points in a
Refrigerated cargo plant (2nd trip 10 sec)
circuit, a large current flow will usually occurs. (contact to each other or leakage of line conductor or
Deck equipment, purifier, air compressor, cabin power source except lighting (3rd trip 15 sec)
leakage of line to neutral.)

What is dash pot, where fitted ?

Switchboard safety devices ?
It is a mechanical device which makes time leg of trip with different viscosity of oil.
Overload trip
It is fitted –a overload trip
Preferential trip
Preferential trip
Under voltage trip
Under voltage release / trip
Over voltage trip
Dash pot
Reverse power relay (No voltage trip)
Dashpots are fitted for overload trip to get time delay action, so that breaker will not be
Reverse current trip
opened, due to momentary current surge
Fuse
When load current is in excess, it attracts plunger of the solenoid
A .C .B( Air circuit breaker )
Plunger or piston moves up against the displacement of viscose oil or silicone fluid, through a
Earth lamps.
small hole on the piston
Low frequency trip
Time lag depends upon hole size, and viscosity of oil
Meters
Load current setting for trip is about 25% above maximum, but should not exceed 50%
Synchroscope
Emergency synchronizing lamp
What is preferential trip ?
Ebonite handrail and Rubber footstep
It is a generator protection device which is designed to disconnect nonessential load from
the main switchboard in the event of generator over load or partial failure of the supply.
Precaution on Switch board Preferential trip
An insulation rubber or plastic mat is placed in front of the S.B 1. Operate after a fixed time delay, causing non-essential loads to be shed
All metal parts of the S.B are connected to the earth 2. Usual setting for overload trip is 150% load (50% overload)
The operator is to put on the electrician hand gloves to operate the switches 3. When generator load reaches 110%, preferential Trip comes into operation as follows
First tripping at 5 sec

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
97 98 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Shut down non-essential loads (air-condition, entertainment, accommodation fans, cargo It is a chemical cell (accumulator) which store up electric energy converting chemical
hold fans, amplifiers, etc.) to reduce the generator load substance into another form while charging. The store electric charge in chemical form transforms
back electrical energy.
Second tripping at 10 sec It has two types [lead acid and alkaline (Nickel Cadmium battery) type]. It has low internal
Shut down essential loads (service required for running the ship properly, leaving the loads resistance. Capacity and voltage per cell is high.
of top priority services to maintain propulsion and Navigation) if generator load is still high Nickel Cadmium battery [alkaline battery]
+ ve plate Nickel hydroxide + graphite
Third tripping at 15 sec - ve plate Cadmium + Iron
Shut down the main generator as last action, if the load is still too high, it may be due to ElectrolytePotasssium hydroxide solution (strong alkaline)
short circuit or insulation breaking. Normal Sp.Gr [1.21] does not change with charging or recharging
Purpose of reverse power relay ? But Sp.Gr of Electrolyte gradually decrease, and Electrolyte should be renewed
If prime mover failure occurred, the generator would act as a motor; the reverse power relay when Sp.Gr. becomes [1.160]
detects this fault and acts to trip the generator circuit breaker. It is a sealed battery, thus no gassing during charging
Very low open circuit losses, but requires 67% more cells than Lead Acid battery [1.2 V per
What is fuse ? cell when fully charged 1.7 V per cell]
Fuse is a protecting device it the circuit against damage from excessive current. Not harmful when overcharged
It is fitted in a circuit to protect the circuit from short circuit and over load. Left for long period, either fully charged or fully discharged, without deterioration
Difference between Circuit Breaker and Fuse Better mechanical strength and durability than lead acid battery
High initial cost but longer life
Circuit breaker
1) Has switching actions to close the circuit or to open the circuit, and has a trip circuit if load
Lead Acid Battery
current exceeds the set value
+ ve plate Lead Peroxide [chocolate brown]
2) After tripping, circuit breaker can be reused without replacing any part
ve plate Spongy Lead [slate gray colour]
Electrolyte fully charged H2SO4, SG 1.8, Renew when SG is 1.110. [1.8 V per cell
Fuse
when fully charged 2 V per cell] when undercharge, + ve plates are pale brown or yellowish,
1) Have only breaking function, and fitted in the circuit to protect the circuit from damaging effect
instead of deep chocolate and very difficult to convert back to normal form
of high current flow
Efficiency (watt hour efficiency) is higher than Alkaline Cells
2) It breaks the circuit by melting the fuse metal itself
3) After breaking, the blown fuse must be renewed
Battery room inspection and maintenance
Intrinsically Safe 1) Battery installation and its charging rectifier checked
1) An electrical circuit or part of a circuit is intrinsically safe, if any spark or thermal effect 2) Battery room environment must be dry and well ventilated
produced normally (e.g. by breaking or closing the circuit) or accidentally (e.g. by short circuit 3) Battery tops shall be clean and dry, and terminal nuts must be tight and a smear of petroleum
or earth fault), is incapable of igniting a prescribed gas mixture, under prescribed test jelly applied to prevent corrosion
condition 4) Electrolyte at proper level, and shall have correct value of specific gravity by checking with a
2) An equipment, which cannot released sufficient electrical or thermal energy, under any hydrometer
condition to ignite a particular flammable vapour in its vicinity. 5) Rubber gloves and goggles used when handling electrolyte
6) Charging equipment checked for dirt, overheating, loose connection and correct functioning of
indicators
What is primary cells ?
7) Ventilation arrangement for battery locker checked. Battery installation f both lead acid and
It is a chemical cell in which it is possible to transform chemical energy into electrical energy alkaline needs good ventilation
.It can not recharge.
8) Since both type generates hydrogen gas during charging, no smoking and naked light allowed
The internal resistance of a primary cell is usually high capacity of cell low and voltage per
9) Steel works and decks adjacent to lead acid battery, should be painted with acid proof paint
cell is also low. Simple cell consists of cu plate (positive plate) and zinc plate ( negative electrode)
[For Cad-Ni cell, alkaline resistance paints]
and dilute H2 SO4 acid contained in.

Battery room safety arrangement

What is secondary cell ? Safety is provided by
1) Proper ventilation
2) Prevention of heat source for ignition

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
99 100 REFERENCE FOR M.O.T 2 Class Part B (Oral)

1) Switch off the main switch

Ventilation 2) Out mechanical lock on
Independent exhaust fan provided 3) Take out fuse
Inlet duct should be below battery level, and outlet at top of the compartment 4) Put a signboard “Man Working on Line”

Prevention of heat source for ignition A.V.R Automatic Voltage Regulators are used in conjunction with generator for controlling the
No naked light and no smoking terminal voltage to give a steady voltage under varying load
Uses of externally fitted light or flameproof light
Cables of adequate size and they are well connected Types of A.V. R ?
Never placed Emergency Switchboard in this room Carbon pile regulator
Use insulated spanner and plastic jug for distilled water, to prevent short circuit Vibrating contact regulator
Room temperature, maintained at 15 ~ 25°C Static A.V. R.
Rotating sector
How do you know when the battery is full charge ? Multi contact
It can be known by measuring the electrolyte specific gravity by using hydrometer. Magnetic amplifier
If fully charge it has an specific S.G of about (1.27 – 1.285) Hydrometer scale 1270 to 1285 Electronic amplifier
If fully discharge which fall to S.G of 1.1 (1100) @ fully charged battery will warm up
Automatic voltage regulator ?
How can you know battery is over charge ? Effect of overcharge ? Which senses and controls an A.C generator’s output voltage within (+ or -) 1 to 2%.
For battery is overcharged bubbles will form at the surface, the current flowing into the cell
causes breakdown or electrolysis of water in the electrolyte. Carbon Pile Regulator (AVR)
Both hydrogen and oxygen are evolved and released through cell vent caps into the battery 1) A resistance from a carbon pile (stack), which is varied by pressure changes, controls the
compartment. There is an explosion risk if H2 is allowed to accumulate. (4% of H2 in air). current flow through exciter shunt field
2) Pressure is applied by springs and relieved by magnetic field strength of electromagnetic coil
When Battery is overcharged (Lead Acid battery) Same as above 3) Current for electromagnetic coil is supplied from Alternator output to switchboard
Overheating cause buckling of plates 4) AVR is designed such that variations in Alternator Voltage, due to load change will effect
Internal short circuit strength of electromagnetic coil and hence alters carbon pile resistance
Sludge formed at the bottom of cells (lead peroxide) 5) When Alternator voltage is low, spring exerts greater pressure and carbon pile resistance
Battery may be ruined becomes low, so more currents flow through exciter shunt field and then increase the output
Lower the capacity voltage
6) When Alternator voltage is high electromagnetic coil relieves pressure on carbon pile and
When Battery is undercharged (Lead Acid battery) resistance becomes high. Less current flows through exciter shunt field and decreases the
Over discharging voltage
+ ve plates are pale brown or yellowish, instead of deep chocolate Ú (Strength of Electromagnetic coil relieves spring pressure on carbon pile)
- ve plates, almost white colour
Falling of voltage 1.8 V / cell, and SG of H2SO4 1.15 What is rectifier ?
It is an electric device or circuit capable to allow an A.C current to be converted to D.C
Depolarisation current.
Liberation of H+ at – ve electrode (cathode) and that will decrease the current flow
What is excitation ?
Why AC is popular onboard ship ? To supply and control the correct D.C current for the rotor pole winding to produce the
1) Smaller, lighter and compact machine size, for a given kW required generator A.C output voltages.
2) High power and high voltage AC generator can be easily manufactured Production of an electromagnetic field of a generator by supplying exciting current for
3) Voltage can be raised or lowered by transformer magnetizing the field magnet
4) AC can be easily converted to DC For excitation, DC is sued because DC produces constant rate of magnetic flux

Electrical repair job hazard Electric shock prevention

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
101 102 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Continually regulated to maintain the generator output voltages as the load demand An instrument, which indicates that, voltages, frequencies and phase angle of two electrical
fluctuates. supplies of running machine and incoming machine, are in synchronism and can be
paralleled.
Exciters The source, which generates the field current for excitation of field magnets. Synchroscope should not be left in circuit for more than 20 minutes as it cannot continuously
rotate.
Equalizing bar
Equaliser is a low resistance circuit, connected across armature ends of series coils of Synchroscope is a small motor with coils on the two poles connected across red and yellow
parallel compound generators, via a special bar in switchboard phase of the incoming machine and the armature winding supplied from the red and yellow
Equaliser is fitted to stabilize parallel operation of compound Dc generators. switchboard bus bars.

Rotary converter What is the synchronizing ?

1) A rotating diode to convert AC to DC current for alternator excitation The process of bring the voltage, frequency and phase angle of electrical supplies into line
2) Synchronous motor and generator combined unit in order to be paralleled and share the loads.
3) Filed and armature coils are similar to DC generator, except that slip rings are located on the Synchronising method
end of the shaft opposite to commutator Synchroscope is the main method
4) AC turns the converter (as synchronous motor) and DC is taken from commutator brush Back-up methods are
Lamp dark method
Procedure for alternator overhaul ? Lamp bright method
Shut down the generator prime mover and lock off the starting system. Rotating lamp method or Sequence methods (preferable)
Lock off the circuit breaker and isolated the alternator electric heater. Tag the label on the
switchboard. Sequence method
Inspect the tightness of terminal connection and insulation. 1) One of the lamps known as key lamp is connected in one phase
Check the bearing oil level and condition. 2) Other two lamps are cross-connected
Clean the cooling air intake filter and exhaust opening. 3) If two frequencies differ, lamps will bright up in rotation. Clockwise indicates incoming
Clean the rotor and stator windings by means of vacuum cleaner with rubber hose and nozzle. machine is fast, and counter-clockwise indicates it is slow
If the oil is deposited on the surface of winding, open the drain plug and then removed by 4) Synchronising moment is when key lamp is dark and other two lamps equally bright
special degresant liquids. (Electro cleaner) 5) If phase rotation is wrong, all lamps will become bright and dark together. Remedy is to
Measure the air gap clearance between rotor and stator. (Carefully at lower part) interchange any two phase connections
Baking the alternator with lamp. Keep a temp not more than 43 °C.
Disconnect the neutral point from the terminal box. How to parallel the two generator with the aid of synchroscope ?
Measure between – rotor to earth All meters and indicators must have in good working order.
phase to earth Start the incoming generator with the correct staring procedure.
stator to earth Check the working condition by readings pressure gauges, thermometer and audible and
phase to phase visual.
It is must at least one mega-ohm, if mega reading has reasonable value, the windings are to Watch for a minutes until prime mover come to stable.
be covered with high quality air drying insulation varnish. Check the voltage of existing and incoming generator on the switchboard, check trip if have
reset.
After maintenance work- Move the selector switch to incoming generator. At that time, synchroscope pointer will rotate
Reassemble all necessary parts. clockwise or counter clockwise direction.
Check no load running, the synchronizing and loading. Check the frequency and voltage of existing and incoming.
On load, practically check for excessive temperature rises and load sharing stability Carry out the adjustment by means of speed adjuster of prime mover to obtain the condition
when running in parallel. such that synchroscope pointer rotate in the clockwise direction at a speed of about 4sec/rev.
Close the circuit breaker of incoming generator when the pointer reaches just before 12’ O
What is synchroscope ? clock position.
An instrument fitted at the main switchboard which indicates when two electrical supplies are Made off the selector switch.
in synchronism and can be parallel (or) Made load shearing the two generators by the speed adjuster of generator.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
103 104 REFERENCE FOR M.O.T 2 Class Part B (Oral)

How do you parallel the two generators if synchroscope is out of order ? Slip ring induction motor.
If synchroscope is out of order, the two generators can be paralleled by emergency
synchronizing lamps with sequence method. Squirrel cage induction
The lamps are fitted as triangle forms, one on top and two on bottom. 1) Most widely used of all types of AC motors, due to simplicity, strength of construction and
To make parallel ease of maintenance
Reset if any trip 2) Made up of two main parts, rotor and stator and no direct electrical connection between them.
Move the selector switch to incoming generator. At that time, synchronizing lamps will give No wire winding or slip rings.
bright and dark sequence rotate clockwise or counter clockwise direction. 3) Rotor has a series of plain bars (copper or Al) running in slots the length of the iron core
Check the frequency and voltage of existing and incoming. 4) Each end of the bar is brazed into 2 heavy copper rings, one at each end. Those bars form a
Carry out the adjustment by means of speed adjuster of prime mover to obtain the required cage, that looks like squirrel cage
frequency and voltage. 5) Stator has 3 separate windings supplied from a 3 phase AC supply
Adjust the speed to meet the slow clockwise direction. 6) Phase difference 120 and umber of poles 2, 4, 6 or more, depending on speed required
Incoming machine breaker is closed by hand when the top lamp (key lamp) dark and the both
bottom lamps are equal brightness.
Off the selector switch and make load sharing the two generators by speed adjusting.
Difference between Synchronous Motor and Induction Motor
Synchronous motor is almost exactly the same as an alternator
How do you monitor the correct instant for synchronizing without the aid of
Induction motor cannot run normally at synchronous speed. It has slip
synchroscope or synchronizing lamps ?
It can be synchronized with 500V voltmeter as follow. AC motor overloads protections
Connect a pair of 500V voltmeter probes across the one phase of the incoming machine circuit 1) Magnetic overload relay
breaker. 2) Thermal overload relay
Adjust the generator speed until the voltmeter slowly fluctuates from zero to maximum. 3) Built-in protective device
Close the breaker when the voltmeter passes through zero.

Causes of motor overheat ?

Can you parallel the load of main G/E with emergency G/E and shore supply ?
Motor running @ overload
It can not parallel, circuit breaker interlocks are arranged in this system?
One phase failure (single phasing)
Defective cooling fan blades
Generator safety devices ?
Bearing failure
1) Over sped rip Poor ventilation
2) L.O low pressure trip @ alarm Misalignment
3) F.O low pressure alarm
4) Jacket water high temperature alarm
When phase failure occur, A.C motor run or not ?
5) Thermometer
When motor is running, the motor keep on running but over load and over heat will occur.
6) Pressure gauge
When motor is starting, the motor can not run.
7) L.O high temperature alarm
8) Dip stick
What is moving iron instruments ?
9) Crankcase relief valve
It is an instrument suitable for measuring A.C voltage or current as well as D.C voltage or
current.
Methods of armature reaction compensation ?
By fitting inter poles between the main poles
What is potentiometer ?
By fitting carbon brush rocker
It is an instrument which is used to measure or adjust the potential different in the circuit.
by fitting neutralizing winding

What is induction motor ? What is moving coil instruments ?

It is a motor which run at a speed below that of the rotating magnetic field. It is an instrument used for D.C only and as voltmeter or ammeter.
Squirrel cage induction motor

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
105 106 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Static Electricity 1) Slipping clutch is commonly fitted between prime mover and gearing
Electricity at rest instead of in motion 2) It is incorporated with motor, magnetic brake and drive shaft
Electric charges may be induced by friction or atmosphere effect 3) Set to slip at approximately 133% of full load torque
4) Letting go or dropping speed is controlled by friction brake
Static Electricity in oil tank, Prevention 5) Hauling speed is 0.15 m/sec

1) Earthing device, earth bond across flanges on pipeline

2) Inert gas Why fitted ?
1) In windlass, undue stresses must not be applied to chain cable and machinery
Single phasing 2) Without slipping cultch, excessive stresses could be applied to cable, by armature
momentum, by sudden obstruction when heaving, or when bringing the anchor into
1) Single phasing occurs when one of the 3 phase circuits is opened, hence the remaining
hawsehole
circuits carry excess current
3) Fitted also to avoid inertia of prime mover being transmitted to windlass machinery in the
2) One phase of the circuits becomes open, due to blown fuse, faulty contactor, or broken wire
event of shock loading on cable, when anchor is being housed
3) It prevents a motor from starting, but a running motor may continue to run with this fault
4) When ship is riding at anchor, bow stopper prevents the strain for windlass
4) For a running motor, it can be detected by overloaded device in supply line, or overheating
5) For an idle motor, it cannot be started
6) Due to single phasing, overheating in a stalled or running motor will cause, burnt out Electric breaking system
overloaded coil 1) When electric deck motor is used for lowering or lifting load, electric brake system is used. All
brakes are failsafe types
Residual magnetism 2) In the event of power failure, brake automatically applied, thus preventing the load running
back. A number of brake pads [free to move] are located in carrier, which is keyed to motor
1) Magnetism remaining in the fields of a generator, after exciting current is cut off
shaft
2) Residual magnetism is essential for initial generation of current, necessary for further
3) Armature plate applies pressure to brake pads, by means of a number of springs, to force
3) Build up shunt field strength
against friction surface of back plate, so that it prevents the motor shaft from turning
4) Generator may fail to excite, if there is loss or reversal of residual magnetism of the pole
4) When energized, armature plate is attached to magnet, thus releasing the thrust pressure and
allowing the shaft to rotate
Remedy, when generator fails to excite
Winch brake adjustment : Adjust the distance between pressure plate and friction plate
1) Pass a current through shunt field coil in correct direction
2) Correct direction means the current will re-magnetise the iron core in the right way Drying out of Electrical Machine
3) Current for restoration can be obtained from another DC generator or from a battery. If battery It is essential, when machine has been exposed to weather, or when accidentally immersed
is used fro re-magnetising: A 12 V battery is connected [exclusively]
Across shunt field coil with the machine stopped
When Electrical Machine is flooded with SW
Current flow in right direction, for a few seconds, only will establish the field
1) Machine is disconnected from power sources and dismantled
4) During this time faulty generator must be in stopped position
2) All salt deposits washed out with FW
3) If deposited with oily bilge water, wash out with Electro Cleaner
Excitation Loss 4) Should be heated with lamp, and enclosed or covered up to retain the heat
4) Energize with Battery 5) Moisture should be escaped, by lifting the cover continuously or periodically
5) Tap with hammer to field coil core of Excitation Motor 6) Hottest part of the machine shall not exceed 90 °C, while heating
7) IR readings and temperatures taken regularly, until constant value reach about 1 m Ω
Winless safety devices ? 8) Then spray the machine with insulation vanish
Emergency stop 9) Assemble and out in service with low load, if possible
Overload trip
Over speed trip
Mechanical break Short, open and grounded circuits
Slipping clutch for over load, to prevent any undesirable damage such as hull damage due to Short circuit : A low resistance path that actually shorten the intended path for the flow of
anchor and rope brake out. current
Open circuit : The path for the flow of current is broken. A switch s one method of
Slipping Clutch creating an “open” intentionally
Grounded circuit : A circuit that has come in contact with the earth, by coming in contact

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
107 108 REFERENCE FOR M.O.T 2 Class Part B (Oral)

somewhere in itself, or by a conductor which is connected with the earth 3) Can be sued for motors of electric steering gears of ships with DC power
4) Used today on ships with AC power for deck machinery such as windlass, mooring winch etc.
Shore connection 5) Working motor, which powers the steering gear, windlass or other equipment is a DC
Shore connection box is provided at convenient position, to receive shore power supply, so machine, because speed control of these is easy
that ship’s generators can be shut down, in port or Dry Docking Method
Lloyd’s requirement 1) A DC generator is driven by AC squirrel cage induction motor (AC powered ship) Output
1) Connection box contains a circuit breaker or isolating switch with fuses voltage of DC generator is applied as power supply to armature of working motor.
2) Provided full information of supply system, normal ship voltage and frequency for AC current 2) Speed and direction of working motor varies with magnitude and direction of applied voltage
3) Main Switch board must be provided with a link switch or a circuit breaker, voltmeter, 3) Output voltage of DC generator is increased or decreased by Potentiometer, as magnetic
ammeter, and an indicator to show that the cable is energized field strength is altered by changing the field current to field windings of the generator
4) For 3-phase supply with earth neutral and earthing terminal must be provided, for connecting 4) As output voltage of the generator varies, speed of the working motor also varies
the hull to shore side. 5) Change of current flow direction, also by Potentiometer, through the field poles of the
5) A phase sequence indicator is necessary to ensure correct connections generator will cause the change in direction of generated current, supplied to the working
6) Means shall be provided for checking polarity, and terminals should be labeled motor and thereby also the running direction of the motor
How will you check the frequency of shore power supply ? How to change speed ?
Shore power supply connection box shows phase sequence of shore power generator with Through Potentiometer by changing the strength of field current to field winding of DC
bright and dark lights generator out put voltage of DC generator changed working motor speed is also
Frequency can be check at Main Switchboard, after shore supply is ‘on’ through link switch or changed (Adjusting field current by means of rheostat)
circuit breaker.
Control A.C motor
Common faults in DC Generator and Motors Adjusting nos. of poles by means of selector switch.
1) Sparking at brushes
2) Overheating
How to change direction ?
3) Failure to excite
Through control handle movement of Potentiometer by changing the direction of field current
through field poles of DC generator Direction of generated current is changed running
Sparking at Brushes
direction of working motor is changed
1) Wrong brush position
2) Dirty commutators Motor earthing symptom
3) Brushes not properly bedded 440V, low insulation alarm
4) Incorrect spring pressure on brushes Earth lamp signal
5) Wrong grade of brush
6) Overloading Effect of motor earthing
Over heat
Overheating Burn out
1) Overloading Get the smell
2) Blocking up of ventilation passages with dirt Noisy

Test for over current trip Fuse to Order

By increasing current injectors ;( e.g. by using Welding Machine) 1) Amperage of the circuit (AC/DC)
2) Type of fuse wire (Tin or lead wire0
3) Standard Wire Gauge (SWG)
Test for Reverse Power Trip
12 (0.104” dia) 14, 16, 18 or 20
By reducing frequency
Battery Order
Ward Leonard System 1) Voltage
1) Used for fine control of shunt motor speed from zero to full in either direction 2) Ampere/hour
2) Able to give the motor a robust torque characteristic 3) Size

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
109 110 REFERENCE FOR M.O.T 2 Class Part B (Oral)

4) Type (Lead Acid or Alkaline) Inert gas maintains above cargo in the tanks.
3
C.O.W operation must be start after pumping out 1M because of to make sure no water remain in the
tank.
Switch board Survey, what documents to give to Surveyor ?
1) Voltmeter, Wattmeter, Ammeter Calibration test result Open loop
The loop is open, there is no feedback and the action of the controller has no reference to the
2) ACB test result (Survey result) result it produces.
3) Control Circuit Safeguard test results (Safety trips and Alarm test results) Manual control gives satisfactory results. In certain cases boredom, carelessness of the
4) Maintenance reports operator may lead to an end product of result that fails to meet the requirements. The arrangement
5) IR test results of each terminal; all 440 V and 220 V main circuit may then decide to install automatic control. The controller must replace the human brain.

Survey approved IR (mΩ) 1 mΩ =106 Ω The close loop automatic control system.
In practical automatic control systems, the controlled variable must first be measured. This may
Date to be given Surveyor for electrical survey require both a detecting (sensing) element and a measuring element, or two may be combined in a
single unit; the measured value is then compared with the desired value in the comparison element.
1) Voltmeter, Wattmeter, Ammeter calibration test result The output from the comparator, commonly called the error, causes the amplifier to vary its
2) ACB test result (Survey result) output in such a way as to reduce the error.
3) Control Circuit Safeguard test results (Safety trips and Alarm test results)
4) Maintenance reports Closed loop
In an automatic process the closed loop is formed by the sensor, which feeds back
5) IR test results of each terminal : all 440 V and 220 V main circuits information of the final process. This feedback or closed loop, return into a mixing point or
6) IR test results of all motors & their safety factors comparison point where it compares itself against reference or set point signal. Any deviation
a. Test date, time, place between these two signals will alter or adjust the control mechanism.
b. Voyage No.
Open loop
c. Ambient temperature An open loop is a manual process where by information is not feed back to the control
d. Weather condition, hot or humid system. A man is required to sight visually or read display information and then make an adjustment.
e. Machine is hot or cold
Data logger
That section of a computer in which is mounted a typewriter whose keys are controlled
Difference between DC and AC generators electronically. The data logger is capable of producing a printer record of off limit conditions. It can
DC generator has commutator and AC generator has slip ring also produce a printed log of plant sensors at predetermined intervals or on demand.

What is drop test ? (Volt drop test) Automation

It s a kind of test for exploring the open circuit fault, short-circuit fault of an armature winding
or a set of field windings it is more reliable check than the growler test. Any or all of the combined processes used aboard ship that have the ability to control work, notify
the operator of its status and warn of malfunctions. This allows less people to control more
machinery in a more accurate and efficient manner.
Testing
1) Insulation test (Megga test)
2) Continuity test
3) Voltage test
4) Current test

How many types of motor starter

1) Direct on line starter
2) Star delta
3) Auto transformer
4) Rheostat
2 & 3 is to reduce the starting current

Static electricity.
Electricity produced on dissimilar materials through physical contact & separation.
Out going material negative, remaining material positive. After having high potential spark occur.
This is occurs in thin oil. Explosion occurs when tank cleaning operation and gas freeing operation.

Protection
In bunker pipes are electrically bonded and from ship earthing arrangement to shore.

Compiled by Min Zar Tar 2/14/2005 10:49 AM

 nd
111 112 REFERENCE FOR M.O.T 2 Class Part B (Oral)

The chalk must have continuously around the watertight sealing, it has water
tightness.
Hose method –
Close the watertight door or watertight hatch cover tightly.
1. Bow thruster Hosting with water jet with a pressure of 2 bar and directed to the sealing edges
Bow thruster are maneuvering devices which is fitted in an athwartship tunnel near to the away from 1.5 m.
bow and aft of the collision bulkhead. It gives additional maneuvering ability. There must be no water leak through the other side.
That door or hatch are good in order for watertight.
2. Bulwark
A barrier fitted at the deck edge to protect passenger and crew to avoid the loss of items 10. Dead weight and light weight ?
overboard while the ship rolls excessively. Dead weight is the weight of cargo, fuel, water, store etc. that a ship can carry.
Light weight is ready to sea going but no fuel, no crew, no cargo.
3. Why fitted D.B tank ? Displacement = Dead weight +Light weight
It is fitted to prevent foundering (flooding) in the event of hull damage.
To control the stability by ballasting 11. What is windless?
To provide buoyancy It is a machine used for hosting or lowering anchor.
To store F.W and F.O
12. What is stern tube ?
4. Why fitted wing tanks ? It is a watertight tube enclosing and supporting the propeller shaft. It consists of a cast iron
To control the ship stability (healing) or cast steel cylinder fitted with bearing surface up on which the propeller shaft (enclose in a sleeve)
To carry cargo rotates.
To store F.W and F.O
13. What is hatch coaming ?
5. What is half beams ? The vertical plating bounding a hatch for the purpose of stiffening the edges of the opening
Transverse beams which are cut at hatch side coamings are termed half beams. and resisting entry of water to ship hull.

6. Water tight bulkhead ? 14. What is girders?

Water tight bulkheads are important element of transverse strength, particularly against The continuous stiffening member which run fore and aft in a ship to support the deck.
racking stress.
They divide the ship into longitudinal subdivision. 15. Stealer strake, stringer, stringer plate ?
They also give protection against fire and founder
Stealer strake A single wide plate which replace two narrow plates in adjacent strake of
They are Collision bulkhead or fore peak bulkhead
a ship.
After peak bulkhead
Stringer A horizontal stiffener fitted along the ships’ side or a longitudinal
One bulkhead at each end of the machinery space
bulkhead, in order to provide strength and rigidity.
Stringer plate The outboard strake of plating on any deck.
7. Collision bulkhead ?
Collision bulkhead is a forepeak watertight bulkhead to protect foundering and against Duct Keel
racking stress.
An internal passage of water tight construction (two longitudinal girders spaced not more
It is fitted not less than 5% or not more than 7% of the ship length aft and stern at load water
than 2.0 m apart) running same distance along the length of the ship, often from the forepeak to the
line.
forward machinery space bulkhead.
It must extend to upper deck.
To carry the pipe work, and an entrance is at forward machinery space via a watertight
Stiffness may be spaced 600 mm apart.
manhole.
Its water tightness can be tested by filling the fore peak tank to the level of water line or
hose test along the boundary. No water leak through other sides.
Bulbous bow A bulb shaped under water bow which is designed to reduce wave making
8. After peak bulkhead ? resistance and any pitching motion of the ship.
To enclose the stern tube in a watertight compartment. Camber Curvature given to a deck transversely. It is measured by the difference between
This bulkhead need only extend to first deck above load water line, if it forms a watertight the heights of the deck at side and centre. The camber amidships is frequently one fiftieth of the
flat. breadth of the ship.
Plating in after peak bulkhead must be doubled or thickened around the stern tube to resist Carving note Form completed by the owner of the ship under construction. Gives details of
vibration. tonnage, name, port of registry, etc.
Cofferdam Narrow void space between two bulkheads or floors that prevents leakage
9. How do you check water tight door’s tightness ?
between the adjoining compartment.
Watertight hatch cover and watertight doors’ tightness can be check by chalk method or
hose methods. Coffin plates They are used to connect stern frames to the flat plate keel. The stern frame is
Chalk method-apply chalk to watertight flat sealing continuously. extended forward far enough, two or three frame spaces, to provide a good connection with a flat
Close the door tightly, then open plate keel. The aft most plate of the keel, coffin plate is dished around the extension.
Check the watertight door sealing.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
113 114 REFERENCE FOR M.O.T 2 Class Part B (Oral)

CRP Contra - rotating propeller. A propulsion arrangement with two propellers rotating The forward perpendicular is a vertical line at the intersection of the fore side of
in opposite direction on the same shaft. the stem and the summer load waterline.
Freeboard Vertical distance from the load water line to the top of the freeboard deck. The after perpendicular is a vertical line at the intersection of the summer load
Freeboard has considerable influence on sea worthness of the ship. The greater the freeboard waterline and the after side of the rudder post or stern post, or the centreline of the rudder stock if
larger is the above water volume of ship. This provided reserve buoyancy assisting the ship to there is no rudder post or stern post.
remain afloat in the event of damage.
Types of keel Bar keel, Duct keel, Flat plate keel. Lightening holes, Large apertures cut in floor plates, side girders, and tank bracket plates. In
Freeing port an opening in the lower portion of a bulwark, which allows deck water to drain double bottom vessels they provide an access to the different cells for inspection and upkeep,
overboard. Some freeing ports have hinged gates that allow water to drain overboard but that swing besides taking weight off the structure, which is their principal object. In a general sense any hole
shut to prevent seawater flowing in board. cut in reduce weight without impairing strength.
Dead light A hinged steel cover, which is part of a port or scuttle. It is used to cover the Margin line. An imaginary line drawn 75mm below the bulkhead deck at the ship's side. It is
glass in heavy weather. the highest permissible location on the side of the ship of any damage water plane in the final
Dead rise Athwartship rise of the bottom from the keel to the bilge. Also known as ' Rise of condition of sinkage, trim & heel.
floor '. Margin plate The outboard strake of the inner bottom. When the margin plate is turned down
Deep tanks Tanks extending from the bottom or inner bottom up to or higher than the lowest at the bilge it forms the outboard boundary of the double bottom, connecting the inner bottom in the
deck. They are often fitted with hatches so that they also may be used for dry cargo in lieu of fuel oil, shell plating at the bilge.
ballast water of liquid cargo. Oxter plates. They are peculiarly curved plates, fitted where the stern frame meets the
Devil's claw A stretching screw with two heavy hooks or claws. It is used to secure the anchor overhang of the stern.
in the hawse pipe. Panting. The pulsation in and out of the bow and stern plating as the ship alternately rises
Displacement A ship floating freely displaces a mass of water equal to its own mass and this and plunges deep into the water.
mass is known as the ship's displacement. Permeability The ratio of water which can enter with the volume of the empty compartment.
Light displacement is the displacement of the ship complete & ready for sea but no crew, Permissible length The length between bulkheads on a ship in order to ensure that it will
passengers, baggage, stores, fuel, water, cargo on board. Boilers, if any, are filled with water to remain afloat if one, or more, compartments are flooded. The permissible length is some fraction of
working level. the floodable length. The fraction is called the factor of subdivision.
Load displacement is at the maximum permissible draught and is made up of the light Pintles. The pins of bolt that hinge the rudder to the gudgeons on the rudderpost.
displacement and the dead weight. Pleuger rudder An active rudder in which a small motor driven propeller is incorporated in a
Docking plug A brass screw fitted in the garboard strake of the shell plating at the bottom of streamlined casing. Ship steering at very low speeds is thus possible and the rudder angle can be
each compartment to drain the water, which remains in the ballast tanks while the vessel is in dry greater than 35degrees.
dock. Pounding. The impact of the water surface against the side or bottom of a ship hull, whether
Flare. The spreading out of the hull form from the centre vertical plane usually in the caused by ship velocity, water velocity, or both.
fore body above waterline. Rising tanks. Double bottom spaces in which the inner bottom is higher at centre line than at
Floodable length The length of the ship that may be flooded without sinking below her safety or sides. This arrangement has the advantage of allowing moisture from the cargo drain into the bilge
margin line. pockets on each side.
Floors. They are transverse vertical plates those run across the bottom of the ship from Scantlings. The dimension and the thickness of rolled sections and the breadth and
the centre girder to the bilge. Watertight or oil tight floors are used to divide the double bottom space thickness of plates, which together compose the ship's structure or part of same.
into suitable tanks. Schottle rudder A Z or double right-angled drive mechanism in which the propeller operates
Flush deck ship A ship constructed with an upper deck extending through out her entire length within a duct. The propeller and the duct can be rotated in order to steer the driven vessel.
without a break or a super structure such as forecastle, bridge or poop. Sheer. The curvature of the deck in a longitudinal direction. It is measured between the
Free surface Liquid in a partially filled tank that tends to remain horizontal as the vessel heels deck height at amidships and the particular point on the deck. The forward shear is twice of the aft
or rolls shear.
Garboard strake. The strake of the bottom shell plating adjacent to the keel plate. Sheer strake. The course of the shell plating at strength deck level.
Intercostals. These are plates, angles, etc., fitted down between others or cut to allow other Shoe plates. They used to connect the stem to the flat plate keel. The forward end of the shoe
parts to pass through them. Side girders, parallel to the centre girder & fitted between the floors, are plate is dished around the stem, whilst the after end is flattened to connect with the keel plate.
intercostals. Vessels of up to 20 meters in breadth must have one intercostal side girder on each Sole piece. The fore-and aft piece, forming the lower part of the stern frame in single-screw
side. Vessels of greater are to have two such girders on each side. vessels extending from the propeller post to the rudderpost.
Kort nozzle A shroud or duct fitted around a propeller in order to increase thrust at low Standard fire test The exposure of a material of a specimen, in a test furnace to a particular
speeds. It is often fitted to tugs and trawlers. temperature for a certain period of time.
Length, overall The extreme length of a ship measured from the foremost point of the stem to Stealer plate. At the ends of a vessel, particularly at the bow, the width of the strake decreases
the aftermost part of the stern. and it is often desirable to merge two strakes into one, this being done by a stealer plate.
Length between perpendiculars The length of a ship between the forward and after Stern -Cruiser stern - A spoon-shaped stern used on most merchant ships, designed to give
perpendiculars. maximum immersed length. Transom stern - A square-ended stern used to provide additional hull
volume and deck space ships.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
115 116 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Stiff A vessel is said to be stiff if she has an abnormally large metacentric height. 4. Gallery, washing & sanitary.
Such a ship may have a short period of roll and therefore will roll uncomfortably. 5. Sky lights, domes & trunks.
Storm valve. A check valve placed at the end of soil or scupper pipes discharging through the
ship' Deducted space
side near the waterline. It allows the water to discharge overboard but prevents seawater from The tonnage of these spaces must be measured first and may then be deducted
backing up the pipe. from the gross tonnage of the ship to give the net tonnage.
Streamline A line in a fluid such that its tangent at any point is parallel to the instantaneous 1. Master & crew accommodation, provision store.
velocity of the fluid at that point. 2. Chain locker, steering gear space, anchor gear and capstan space.
Stringer A fore-and-aft girder running along the side of a ship at the shell and also to the 3. Workshop, storerooms.
outboard strake of plating on any deck. 4. Donkey engine & donkey boiler space, pump room. (Outside the machinery space)
SWATH Small water plane area, twin-hull vessel. Twin torredo shaped hulls are fully 5. Water ballast tanks. (maximum limit of 19 % of the gross tonnage is imposed)
submerged with streamlined fins or struts supporting the upper platform or deck. It is used for 6. Propelling power allowance.
passenger carrying and research vessels because it provides a stable platform.
Tender A vessel is said to be tender if she has an abnormally small metacentric height. Propelling power allowance (PPA)
Such a ship may have a long period of roll but may list excessively in a strong wind and may be This is the largest deduction and is determined according to certain criteria, as
dangerous if a hold is flooded following a collision. follows:
Tumblehome The slant inward from the vertical of a transverse section of a hull about the If the machinery space tonnage is
designed waterline. 1. Between 13% to 20% of gross tonnage PPA = 32% of gross tonnage.
Turbulence flow Fluid flow where the particle motion at any point is rapidly changing both in 2. Less than 13% of gross tonnage PPA = proportion of 32% of gross tonnage.
direction and magnitude. 3. More than 20% of gross tonnage PPA = 1.75 times the machinery space tonnage.
Maximum limit of 55% of the gross tonnage for the PPA.
Turning circle A circle moved through by a ship when the rudder is placed in its extreme
Net tonnage.
position. It is a manoeuvred carried out on sea trial.
This is the tonnage value obtained by deducting from the gross tonnage the total
value of the deducted spaces. The net tonnage is considered to represent the earning capacity of
Buoyancy. When a substance is immersed in the water it will appear to suffer a loss in
the ship.
weight. Since the actual mass of the substance is not changed, there must be force acting vertically
upwards to create the apparent loss of weight. This force is called the force of buoyancy, and is
CORROSION AND PREVENTION
considered to act vertically upwards through a point called centre of buoyancy.
The prevention of corrosion deals with the provision of (1) protective coating for the ship
Reserve buoyancy. The watertight volume of a ship above the water line is called the reserve structure steel and its continued maintenance. Also a means of preventing electrochemical wastage
buoyancy. It can be defined as the buoyancy a ship can call upon to meet losses of buoyancy due to is required, which is known as (2) Cathodic protection.
damage of the main hull. Its use in the general working of the ship is to provide a sufficiency of There are two types of cathodic protection method, Sacrificial anode system and Impressed
freeboard to make the vessel seaworthy. current system.

Ships vibration 1. Synchronous or resonance vibration.

SACRIFICIAL ANODE SYSTEM
Sacrificial anodes are metal or alloy attached to the hull, which have a more anodic potential
2. Local vibration. than steel when immersed in seawater. These anode supply the cathodic protection current, but will
3. Vibration due to external forces. be consumed in doing so and therefore required replacement for the protection to be maintained.
Sacrificial anode may be fitted within the hull, and are often fitted in ballast tank. Magnesium
Gross tonnage. anodes are not used in the cargo tank of oil tankers owing to the spark hazard. Should any part of
This is the total of the under deck tonnage and the tonnage of the following the anode for and strike the tank structure when gaseous condition exist an explosion could result.
spaces. Zinc anode may be safely employed.
1. Any tween deck space between the second and upper decks.
IMPRESS CURRENT SYSTEM
2. Any enclosed spaces above the upper deck.
3. Any excess of hatchways over 0.5 % of the gross tonnage. The impress current system consist of a (1) source of direct current, (2) anodes, apparatus for (3)
4. At the ship owner's option and with the surveyor's approval, any engine light and air space on or measuring and controlling the current and a (4) high quality inert protective coating around the area of
above the upper deck. the hull nearest to the anode.
Continuous control of the impress current required for adequate protection varies with the (1)
Exempted space immersed area, the (2) ship speed, the (3) salinity of the water and (4) condition of the hull paint work.
This control is usually obtained by the used of reference anode positioned some distance from
These are spaces, which are not measured for the gross tonnage calculation.
the operating anode. If too great a current well to flow it could destroy paint coatings on the ship hull.
1. Wheel house, chart room, radio room, navigation aid room. Around the anode a protective coating is epoxy resin is applied directly to hull for a radius of
2. Spaces for machinery & condenser, stability tanks one meter or more, since highly alkaline condition arise near the anode. A propeller bonding
3. Safety equipment and battery spaces. arrangement must be fitted with impress current system to ensure propeller protection.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
117 118 REFERENCE FOR M.O.T 2 Class Part B (Oral)

PREVENTION OF MARINE GROWTH AND FOULING UNDER CUT

This is a cutting away of the base metal surfaces at the edge of the weld. It decreases the
Anti fouling paint are used for this purpose. They consist of a vehicle with pigments thickness of the metal at that point.
(ta7mifxGuf), which give body and colour together with materials poisonous to marine vegetable and Any material reduction in the metal thickness also reduces the metal strength, thus causing
animal growth. joint failure since the designed load of the joint is based on the original metal thickness.
Mercury and copper are the best-known poisons used in anti fouling paint. The possibilities of failure at this point are increased when under cutting occurs at the toe of
To prolong the useful life of the paint the poisonous compound dissolve slowly in seawater. the weld; a point there is high stress concentration. This defect is caused by:
Once the release rate falls below a level necessary to prevent settlement of marine organism the 1. Improper arc manipulation.
anti fouling composition is no longer effective. 2. Slow travel
A recently developed anti fouling paint is non-toxic in operation it is based on a metallised 3. Excessive welding current.
acrylic polymer and psychically influences the film which form on immersed hull. Adherence by
marine organism is made almost impossible by the paint altering the critical surface of the film. POROSITY
It is the presence of pockets containing gas, in the welds. Excessive porosity in metal arc
ATTACHEMENT OF ZINC BLOCK TO HULL welds has a serious effect on the mechanical properties of the joint.
Avoiding best prevents porosity:
1. Overheating and under heating of the weld metal,
O2 O2 2. Too high a current
3. Too long in arc.

SLAG INCLUSION
Slag inclusions are elongated or globular (tvHk;) pocket of metal oxides and other solid
IRON COPPER (CATHODE) compounds. It may be caused by concentration of the weld metal by foreign bodies.
ANODE - In multi layer welding process, failures to remove the slag between the layer cause slag
+ SEAWATER inclusion. Preparing the groove and weld properly before each beat is deposited can prevent most
slag inclusion, making sure that all slag has been removed and cleaned from the surface of the
IRON OXIDE previous bead.

LACK OF PENERATION
Many ship corrosion problems are associated with the coupling of metallic parts of differential, This is the failure of the filler in base metal to fuse together at the root of the joint. Lack of
which consequently form corrosion cells under service condition. The corrosive rate of metal and penetration will cause weld failure if the weld is subjected to tension or bending stresses.
alloy and seawater has been extensively investigated and as a result galvanic series of metal and This may be due to:
alloys in seawater have been obtained. 1. Incorrect joint design,
Zinc block attached to the hull, in way of bronze propeller and other immersed fitting, have a 2. Fast travel
more anodic potential than steel when immerse in seawater. These anodes supply the cathodic 3. Electrodes too large
protection current, but will be consumed and doing so and therefore required replacement for the 4. Current setting too low.
protection to be maintained.
LACK OF FUSION
Lack of fusion is the failure of a welding process to (1) fuse together layers of weld metal or (2)
DEFECTS ASSOCIATED WITH WELDING weld metal and base metal.
This is generally referred to as overlap. Lack of fusion is caused by failure to raise the
temperature of the base metal or the previously deposited weld metal to the melting point.
UNDER CUT OVER LAP
Reason for this failure include:
SLAG INCLUSION 1. Too small electrode
2. Too fast travel
POROSITY LACK OF FUSION 3. Too close and arc gap
4. Too low welding current.

LACK OF ROOT PENETRATION DISTORTION

It is caused by uneven heating and cooling, which involve the expansion and contraction of
the base metal. The heat can be controlled by back-step welding sequences, by clamping the parts
OVER LAP into their original position in a special fixture, and by single beat welding, which means that instead
This is overflow of weld metal over the base metal without fusion (t7nfaysmfIpyf_cif;). Failure of of making two or three passes with small diameter electrodes, one parts is made with a large
the joint is certain when the overlap is located at the toe (ta_c) of the weld. electrode.
This is the serious defect and should be avoided. It may be caused by: Distortion can be eliminated by increasing the welding speed and by closing the distance
1. Low welding current between the parts to be welded.
2. Fast travel
3. Improper electrode manipulation.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
119 120 REFERENCE FOR M.O.T 2 Class Part B (Oral)

CENTER LINE CRACKING WHEN FIRE BREAK OUT

It is caused by the inability of base metal to move when the weld solidify and contracts, by a) IF THE FIRE IS SMALL
using incorrect electrodes, by using in balance of base metal masses or in too high carbon content Find the origin of fire, inform to C.E and all engine room member, restrict is not to spread out if
in the base metal.
possible and extinct it on the spot with potable extinguisher or by another means. (In practice, as
This can be eliminated by
1. Design the joint correctly, soon as, noticing of the break out of fire, the fire alarm or emergency alarm must be activated before
2. Preheating the parts to be welded prior to welding, taking any action.)
3. Maintaining the preheat temperature in the base metal during process,
4. Allowing the base metal to move freely as the welding process takes places b) IF THE FIRE IS IMMEMSE (tvGef}uD;aom)
5. Stress relieving the welded parts as soon as the operation completed. I. Sound fire alarm system.
II. Evacuate all ship crew, count them and assign as per muster list.
III. Remote stopping of all fuel pump to be done.
FIRE FIGHTING ARRANGEMENT IV. Remote closing of all quick closing to be done.
Since fire on board is very dangerous and Shore Professional Fire Brigade can not be call at V. Remote closing of skylight door and engine all watertight door to be done.
sea thus fire prevention is vital. Fire prevention included regular fire drills on board with proper
training. VI. Remote closing of all engine room ventilation damper to be done.
VII. Prime mover and all machinery to be stop.
PREVENTION VIII. All engine room entry and exit door to be closed perfectly.
(1) CLEANLINESS: IX. All ventilation fan in engine room to be stopped manually.
X. Fire fighting fixed installation system to be operated by C/E or 2/E in a very proper manner.
a) No oils, oily rags and wastes should be allow in the vicinity of the heat source such as the
places of (Boiler, Heaters and M/E exhaust system). They are liable to ignite spontaneously.
b) No oil leak should be tolerated (wif;cHonf) such as from oil tank’s trays and drip pan, fuel and SPACE MINIMUM REQURIEMENT IN MACHINARY
lube oil separator’s trays, fuel and lube oil valves, oil burners and piping connection. I. Two numbers of fire hydrants with hoses, which can extinguish when any place of fire occurs
c) Tank top and bilges should be cleaned and hose down frequently. Cleaning could be done with in engine room. (Minimum)
some chemical such as oil spill dispersant if oil accumulated considerably. II. Ten feet tube of sandboxes and with scoop.
d) Tank tops and bilges should be painted white and these place illuminations (rD;xGe;f xm;_cif;) to be III. One fixed installation of CO2 or foam or Halon.
provided. IV. Portable extinguisher of at least two numbers of 2 ½ gal of foam or CO2 (Numbers of portable
extinguishers depends on the BHP of engine).
(2) HEAT SOURCES V. Semi portable extinguisher of 45 kg of CO2.
Should be preventive and minimize. VI. Dip pans and trays for every F.O and Lube oil tank.
VII. Monitoring detection and alarm system.
a) No naked lights and smoking should be allowed inside the engine room and near the bunker. VIII. Emergency fire pump.
b) Paint should be stored in special well ventilated stored away from machinery space or heat IX. Two numbers of main fires pumps.
source and automatic water sprinkler system to be provided as per latest regulation. X. International shore connection.
c) Welding practice should be done only in workshop and away from combustible material storing XI. Inert gas system.
spaces carefully, then all the protective cloths to be put on and earthing should be ensured.
(3) FIRE FIGHTING APPLIANCES
Should be kept in working order: RUDDER
Types of rudder.
a) All portable extinguishers and semi portable one to be ensured in good working order and 1. Unbalanced rudder ~ A rudder with all of its area aft of the turning axis.
properly placed inside the machinery space and always made handy. 2. Semi-balanced rudder ~ A rudder with a small part of its area, less than 20%, forward of the
b) Fixed fire fighting installation should be test once a week and it’s maintenance to be done turning axis.
periodically such as compress air blowing of lines and discharge nozzle and alarm testing and 3. Balanced rudder ~ When 25% to 30% of the area is forward of the turning axis there is no
function testing. The contents inside the unit to be weight or checked periodically. torque on the rudder stock at certain angles.
c) Emergency fire pump should be kept in good working order and test run to be done weekly It is usual to limit the rudder angle to 35 degrees on each side of the centreline,
without any failure. since, if this angle is exceeded, the diameter of the turning circle is increased.
d) Fire detection, monitoring alarm system to be tested to weekly without any failure. The rudder is used to steer the ship. The turning action is largely dependent on the area of
e) All fire hydrants and their connection should be kept in very good order also to the sandboxes the rudder. The required area of the rudder varies with different type of vessels since (1) desire
and scoop. maneuvering ability differs considerably and the general (2) ship design may imposed restriction.
f) Fire men outfits two numbers should be also kept in good order and handy at all time. In practice the rudder area is usually relative to the area of the immersed metal plane.
g) International should be placed at proper location and to be in good order. The ratio of the depth to width of a rudder is known as the aspect ratio and is usually region
h) All engine room members should be properly educated about fire fighting appliances and their two.
operation. When a rudder is turn from the centerline plane to any angle, the water flows round the
i) Fire drill should be carried out at least once a month. rudder and creates an additional resistance on that side of the centerline, the force that acts on the
rudder parallel to, the centerline to the two components.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
121 122 REFERENCE FOR M.O.T 2 Class Part B (Oral)

1. The force created by formation of streamline around the rudder that is due to change in RUDDER BEARING
direction of the water. The rudder is supported by pintles, which fits into the gudgeons. The upper parts of each
2. The suction on the after side of the rudder caused by eddying (a7_yef0*
J 7uf). pintle are taper and fit into a similar taper and in the rudder gudgeons. The pintle is pulled hard
against the taper by means of a nut with some suitable locking device.
The force on the rudder depend on A brass liner if fitted around the lower part of the pintle. The lignum vitae or synthetic
1. Area of the rudder materials like Tufnol are used for bearing.
2. The form of rudder Bottom pintle is known as bearing pintle. It rest on harden steel disc. A hole is drilled in the
3. The speed of the ship gudgion, with a smaller hole in the bearing pads to allow for the free circulation of water which act as
4. The angle of helm (yJhxdef;vufudkif) the lubricant for bearing, an along the bearing disc to be punched out when worm.
Rudder may be (1) hinged on the pintles and gudgeons, or the may turn about and (2) axle The weight of the rudder may be carried partly by the lower pintle and partly by a rudder
which passes down through the rudder. carrier within the hull.
The weight rudder may be taken by (1) bearing pintles, or by a (2) bearing at the rudder head In some rudder type, for example, the spate types which only supported within the hull. The
(carrier), or by a (3) combination of both. carrier carries the full weight.
A rudder carrier may incorporate the watertight gland fitted at upper end of the rudder trunk.
A rudder with all of it area aft of the turning axis is known as unbalanced rudder.
Most of the rudder’s weight may come onto the carrier bearing if excessive wear down of the lower
A rudder with a small part of its area, less than 20%, forward of the turning axis is semi-
pintle occur, and the bearings have cast iron cone which limit the wear down.
balance rudder.
When 25%~30% of the area is forward of the turning axis there is no torque on the rudder
Inclining experiment
stock at certain angles and such an arrangement is therefore known as a balanced rudder.
It is usual to limit the rudder angle to 35’ on each side of the centerline, since, if this angle is Results are used for “High of the transverse metacentre above the keel may be found from the
exceeded, the diameter of the turning circle is increased. metacentric diagram and hence the high of the center of gravity of the ship may be determined”.

RUDDER STOCK • All ship rope must be slackened

• All tank must be full or empty
• All moving parts are securely tighten
• Ship must be upright

UNBALANCE BALANCE A small mass ‘m’ is moved across the ship through a distance ‘d’.
RUDDER RUDDER m xd
If ∆ is the displacement of the ship, GG1 = ----------
∆

But GG1 = GM tan θ

m xd
GM tan θ = -----------
∆
CONSTRUCTION mxd
Modern rudders are of stream lined form and are fabricated from steel plate, the plate size GM = --------------------
∆ tan θ
being stiffen by internal webs. Where the rudder is fully fabricated, one side plate is prepared and
a
the vertical and horizontal stiffening webs are welded to this plate. L = length of the pendulum, so tan θ= --------
The other plate often called the closing plate is then welded to the internal webs from the L
exterior only. This may be achieved by welding, flap bars to the webs prior to fitting the closing plate,
and then slot welding the plate. mxd x L
The upper face is formed into a usually horizontal flat palm (vufz0g;), which acts as the GM = --------------------
∆x a
coupling point for the rudderstock.
A lifting hole is provided in the rudder to enable a vertical inline lift of a rudder when it is
being fitted or removed. This lifting hole takes the form of a short piece of tube welded through the Slip
rudder with doubling at the side and closing plate.
A drain hole is provided at the bottom of the rudder to check for water entry when the ship is Apparent slip
examined in dry dock.
To prevent internal corrosion the interior surfaces are suitably coated, and in some cases Since the propeller work in water, the ship speed Velocity will normally be less than the
theoretical speed. The difference between the two speeds is known as Apparent slip and is usually
the rudder may be filled with inert plastic foam.
express as a ratio or percentage of the theoretical speed.
The rudder is tested when complete under a head of water 2.45 M above the top of the
rudder.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
123 124 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Theoretical speed {VT} - ship speed {VS} Hogging. If the (1) buoyancy amidships exceed the weight due to loading or when (2) the wave crest
Apparent slip = ------------------------------------------------------------ x 100 % (vdkSif; xdyf) is amidships, the ship will Hog, as a beam supported at mid length and loaded at the end.
Theoretical speed {VT}

Real slip or true slip

This is the difference between the theoretical speed and the speed of advance, express as a ratio or
percentage of the theoretical speed.
The real slip is always positive and it dependant of current.

Theoretical speed {VT} – speed of advance {VA} HOGGING

Real slip = ----------------------------------------------------------------- x 100%
Theoretical speed {VT}
Sagging If the (1) weight amidships exceed the buoyancy or when (2) the wave trough (vdSkif;cGuf) is
amidships the ship will sag, as a beam supported at a ends and loaded at mid length.
SPEED LENGTH RATIO USED FOR FROUDE’S LAW OF COMPARISON

If Rr α L3 , then V α √L V V1 V2
--------- = Constant ----- = -----

√L √L1 √L2
SAGGING
Above expression is known as speed length ratio.
Where Rr = residual resistance
L = linear dimension of vessel TRANSERVES STRESS
V = speed of vessel A transverse section of amidships is subjected to static pressure due to the (1) surrounding
1. At corresponding speeds the wave-making characteristic are the same. water as well as (2) internal loading due to the weight of the structure, cargo, etc.
2. At high speed the speed length ratio is high and the wave making resistance is large. The parts of the structure, which resist transverses, are
3. A ship is therefore consider slow or fast in relation to it’s speed length ratio. 1. Transverse bulkhead
If ratio is below 1.0 the ship is said to be slow. If ratio is above 1.5 the ship is said to be fast. 2. Floor in the double bottom
Thus a speed of 15 knot would be regarded as slow for a ship 225M long, but fast for a ship 100M 3. Bracket between deck beam and side frame, together with bracket between side frame and tank
long. top plating, or margin plate
4. the pillars in hole and tween deck. DECK BEAM

STRESS
The modern ship is made up steel plating, section and builds up girders so connected as to
LOCAL STRESS
provide adequate strength in all parts to withstand the forces acting on the ship under all condition of
SIDE FRAME PILLER
service.
These are created by such item:
The forces acting on a ship may be static or dynamic.
a: Heavy concentrated load like boiler, engine etc.
The static forces are due to the difference in the weight and buoyancy, which occur through
b: Dead cargo such as timber BRACKET
out the ship.
c: Hull vibration
The dynamic forces are cause by (1) the motion of the ship at sea and (2) the action of the wind
d: Ship resting on block on a dry dock. TANK TOP MARGIN PLATE
and (3) wave.
These forces create:
1. Longitudinal stress
2. Transverse stress DYNAMIC FORCES
3. Local stress. The dynamic effects arise from the motion of the ship itself. A ship among waves as three linear
The greatest stress set in the ship as wholes are due to the distribution of load along the motions.
ship, causing longitudinal bending. 1. Vertical moment (Heaving)
2. Transverse moment (Swaying)
3. Fore and aft moment (Surging) and three rotational motion.
a. Rolling about longitudinal axis
LONGITUDINAL STRESS b. Pitching about a transverse axis
The forces are two in number, the (1) weight of the ship and all that it carries acting down c. Yawing about a vertical axis
wards and the vertical component of the (2) hydrostatic pressure. When the ship motions are large particularly in pitching and heaving, considerable dynamic
Depending upon the direction in which the bending moment acts the ship will Hog or Sag. forces can be created in the structure.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
125 126 REFERENCE FOR M.O.T 2 Class Part B (Oral)

PANTING Dissolve in slowly in seawater. Release rate falls below a level necessary to
As wave passes along the ship they cause fluctuation in water pressure which tends to create in prevent settlement of marine organisms the anti-fouling composition is no longer effective.
and out movement of the shell plating. This is particularly the case at the fore end. Developed anti fouling paint - non-toxic in operation. It is based on metalised
The rules of the classification societies required extra stiffening, at the end of the ship, in the acrylic polymer and physically influences the film, which forms on immersed hull. Adhere by marine
form growth is made almost impossible by the paint altering the critical surface tension of the film.
of beams, brackets, stringer plate, etc: in order to reduce the possibility of damage. This in and out
movement is called panting.
Pilgrim nut

SLAMMING OR POUNDING 1. The pilgrim nut provides a predetermined grip between the propeller and its shaft.
In heavy weather when the ship is heaving and pitching, the fore end emerges from the water 2. The propeller boss is fitted with a S.G cast iron internally tapered sleeve, which is secured (fixed
and reenters with a slamming (7dkufonf) effect which is called pounding. firmly in position) into the boss. This sleeve is bedded to the shaft cone before mounting in the
Extra stiffening require at the fore end to reduce the possibility of damage. boss so that better fit is achieved which, combined with the pilgrim nut push up, ensure a good
friction grip. No key is required.
3. The pilgrim nut is a threaded hydraulic jack, which screwed on to the tailshaft. A steel ring
Load line. The load line is a term given to a mark located amidships on both sides of a ship receives thrust from a hydraulically pressurised nitrile rubber tyre. This thrust is applied to the
to show the limiting draught to which the vessel may be loaded. This limiting draught is obtained by propeller to force it onto the taper sleeve.
measuring from the uppermost continuous weather tight deck (normally the freeboard deck) down to 4. Propeller removal is achieved by reversing the pilgrim nut and using a withdrawal plate, which is
the load line mark amidships. This distance is called the freeboard of the ship. fastened to the propeller boss by studs. When the tyre is pressurised the propeller is drawn off
the taper.
Deck line
Advantages
1. The sleeve has a similar thermal expansion to the steel shaft, thus reducing the risk of
slackness in hot water.
Minimum summer freeboard 2. An extension to 5 years survey period is allowed by classification societies.
3. The boss stress are reduced.
4. The cast iron/ steel contact has a higher friction coefficient than bronze/ steel.

TF
Stern tube The water tight tube enclosing and supporting tail end shaft. It consists of a cast
F
iron or cast steel cylinder fitted with bearing surface within which the tail shaft, enclosed in a sleeve,
T
rotate.
S

Stern tube (water lubricated)

W
The forward end is flanged and studs are used to secure the flange to the after bulkhead, a
WNA
make up liner of lead or wood being inserted between the two. The forward end is supplied with a
stuffing box packing and gland to keep water out of the tunnel and aft with a bearing, four times the
Corrosion prevention
shaft diameter in length, composed of lignum vitae, the wood strips being fitted dovetail (wedge-
1. Protective coating.
shaped joint) fashion into the brass bush.
2. Cathodic protection.
Waterways are left between lignum vitae strips to allow access of water to the shaft after
(a) Sacrificial anode system, (zinc anode)
bearing. The wood strips are kept in place forward by a lip on the bush and aft by a check ring. The
(b) Impressed current system.
bearing cannot attain a fully hydraulic film, mainly due to low viscosity of water and there is
1. Direct current 2. Anodes 3.Appratus for measuring and controlling the current and 4.High
considerable rubbing contact with consequent (direct result of something) wear.
quality inert protective coating around the area of the hull nearest to the anodes (epoxy resin,
Normal clearance is 0.003 to 0.004 of diameter of the shaft.
around the anode radius one meter or more.
Continuous control of the impressed current required for adequate protection varies with the
Stern tube (oil lubricated)
1.Immersed area 2. Ship speed 3. Salinity of the water and 4. Hull paints work.
Two bushes are pressed into a stern tube which itself pressed into the ship's
1. Reference anode, 2. Operating anode.
stern frame. Mechanical seals are provided at both ends of the stern tube, which is filed with oil,
Too great a current ~ destroy paint coating.
maintained at slightly above sea water level pressure by means of a static pressure header tank
Fitted propeller shaft bonding arrangement.
providing at a considerable height.
Running in oil bath, the shaft is not required sleeve for protection. The
Prevention of marine growth and fouling.
classification will generally accept the continuous length of bearing metal at 1.5 to 2.0 of the shaft
Antifouling paint (Give body & colour together with materials poisonous to marine vegetable and
diameter at the after end with calculation that the specific load does not exceed 0.8 N/mm2 and at
animal growth.)(Eg ~ Mercury, copper)

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
127 128 REFERENCE FOR M.O.T 2 Class Part B (Oral)

0.6 to 1.25 of the shaft diameter at forward end. The bush is gray or nodular cast iron which are Hogging: the condition of a ship when distribution of weight and buoyancy along its length is such
lined centrifugally with white metal. that the buoyancy amidships exceeds the weight
Oil clearance usually provides is 0.0015 to 0.002 of the shaft diameter. Sagging: The condition of a floating ship when distribution of weight and buoyancy along its length
is such that the weight amidships exceeds the buoyancy.

Pounding / Slamming: The effect resulting from the rise and fall of the forward end of a ship when
Advantages of Oil lubricated heaving and pitching.
1. Oil is better lubricant the water Dynamic Stress : The transverse distortion of ship's structure due to acceleration and
2. Oil is Lower frictional coefficient than water. So less wear and score etc.. deceleration during rolling.
3. White metal oil film lubrication can carry more load. : It is greatest when the ship is in light or ballast condition. It is prevented by
4. Bearing surface reduced. beam knee and bracket.
Static Stress: In dry dock if the vessel is not properly placed on keel block, the static
5. No sleeve required in tail shaft.
stress may set up.
6. No abrasive particle like seawater causes wear and corrosion.
7. Oil act to improve vibration damping. Difference between Stiff on ship and Tender ship

Stern tube seals Stiff Ship Tender Ship

1. Simple stuffing box.
Greater GM due to high density cargo on Small GM (but not negative ) due to loading
2. Lip seal. bottom on top
3. Radial face seal. Ship rolls very fast Ship rolls very slowly
Very uncomfortable Uncomfortable but better than stiff ship
Pressure test of cargo tanks.
1. A structural test by testing with water to a height of 2.45 meters above the tank crown, or What are tunnel water tight door requirement ?
2. A leak test consisting of a soapy solution test while the tank is subjected to an air pressure of
0.14 bar. It is recommended that the air pressure is initially raised to 0.21 bar and then lowered 1) The door may be either vertical or horizontal sliding
to the above test pressure before inspection is carried out. 2) The means of closing the door must be positive ie. They must not rely on gravity or a dropping
weight
Water tight doors
Watertight bulkheads are constructed to ensure their water tightness. Where 3) They capable for operating with a list of 15 degree and to be capable of being quickly closed
openings are necessary in these bulkheads special watertight doors must be fitted. form an accessible position above the bulkhead deck
4) It must be operated from the vicinity of the door in addition to a point above the bulk head deck
SHIP MOTION
5) If no power is available in hydraulically operated system,
Linear / Translation Motion along x Surging, along y Heaving, along z Swaying
6) The door may be closed and opened by manual operated pump
7) Must have an index at the operating position showing whether the door is opened or closed.

1) Surging The forward and aft liner motion (along x) of a ship is called surging
2) Heaving The vertical up and down linear motion (along y) of a ship is called heaving
3) Swaying The side to side linear motion (along z) of a ship is called swaying
4) Rolling The rotational motion of a ship about longitudinal axis is called rolling
5) Yawing The rotational motion of a ship about vertical axis is called yawing
6) Pitching The rotational motion of a ship about transverse axis is called pitching

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
129 130 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Disadvantages of cross and loop scavenging ?

The air inlet and exhaust ports are arranged at the same end of the cylinder.
The air and exhaust gas change in direction in passing through the cylinder.
Purpose of compressed air onboard.
Short circuiting or excessive mixing may occur.
1) Starting of engine.
2) Instrumentation control air. Thus reduce the scavenging efficiency.
3) General purpose air. It require long piston skirt or exhaust timing v/v is necessary to prevent scavenge air leak
4) Whistle air. into the exhaust while the piston is at top of its stoke.
It has thermal stress between scavenge and exhaust ports.
What is scavenging ?
Scavenging is the process of removing the burnt gas in the engine cylinder by means of What is super charging ?
incoming charged air. It is the process of the increasing of the wt of the charged air by increasing the density of the
charged.
Scavenging efficiency ?
Wt of air enter into the cylinder What is turbocharging ?
Scavenging efficiency =
Wt of air for stroke volume It is one kind of supercharging by using exhaust gas turbocharger. In which the energy in
the exhaust gas expelled from the engine cylinder is utilized in driven in gas turbine, which is
connected to a centrifugal air blower and air is supplied to scavenge air trunk.
How many types of scavenging? Which one is the best and why ?
There are three types of scavenging
What do understand constant pressure and pulse system ?
1. Cross scavenging
2. Loop scavenging Constant pressure system
3. Uniflow scavenging Exhaust gas from all cylinders into a common large manifold where pulse energy is largely
dissipated.
Uniflow scavenging is the best because of high scavenging efficiency. The air inlet and The gas flow will steady rather than intermitted and at a constant pressure at turbine inlet.
exhaust do not change in direction in passing through the cylinder. The possibility of short circuiting
or excessive mixing is therefore reduced. TC arrangement
No exhaust grouping
Exhaust gases enter into large common manifold and then to turbine
How do you understand the 3 kinds of scavenging ?
Firing order not considered
Cross scavenging
The air inlet and exhaust ports are arranged at the same end of the cylinder liner and they
Advantages and disadvantages for constant pressure system?
are placed opposite to each other. Scavenging efficiency is 0.75 to 0.8.
Loop scavenging Advantages
The air inlet and exhaust ports are arranged at he same end of the cylinder liner but the Good performance in high load (Efficient when Bmep is above 8 bar)
exhaust ports are on the top of the inlet ports. Scavenging efficiency is (0.8 to 0.9). More suitable for high output engine.
Uniflow scavenging There is no need to group the cylinders exhaust into multiple of three. (Simple piping system)
The air inlet ports and exhaust ports or valves are arranged the opposite ends of the No exhaust grouping
cylinder liner. Scavenging efficiency is more than 0.9. High turbine efficiency due to steady flow.
The work transfer at the turbine wheel is smooth.
Reduction in SFOC of 5% - 7%
Advantages of loop scavenging ?
It has no exhaust valve and its driving mechanism .It saves the energy losses to drive the
Disadvantages
exhaust valves.
When running at reduced speed and starting up low available energy at turbine. Thus it
supplies inadequately air quantity of the scavenge pressure necessary for efficient
Major requirement for the loop system ?
scavenging and combustion. It required scavenge assistant.
The inlet air ports are angled to give rotary swirling effect to the incoming air. Poor response in changing load.
It also required long piston skirt or exhaust timing v/v to prevent scavenging air leak into
exhaust while the piston is at top of it’s stoke.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
131 132 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Pulse system Cause of turbocharger surging ?

Makes full use of the higher pressure and temperature of the exhaust gas during the blow It is caused by –
down period and rapidly opening the exhaust valves Scavenge space fire / Exhaust trunking fire
exhaust gas leave the cylinder at high velocity as pressure energy is converted into kinetic Poor power balance
energy to create the pressure wave or pulse in exhaust, lead to the turbocharger. Dirty nozzle and blades
Exhaust pipe, so constructed in small diameter, is quickly pressurized and boosted up to form Individual cylinder misfire
pressure pulse or wave Chocked scavenge /exhaust ports
Pressure waves reach to turbine nozzles and further expansion takes place. Suddenly load change by heavy sea
Incorrect matching of turbocharger to engine.
TC arrangement Poor scavenging or leaky exhaust valve
Interference exists between exhausting and scavenging among cylinders
To prevent this, cylinder are grouped relatively with connections to two or more exhaust pipes What is exhaust tunning ?
Pipes are arranged, in small diameter to boost up pressure pulse and in short, straight length
Exhaust tunning means by arranging the exhaust pipes with suitable length and suitable
to prevent energy loss
valve timing to exhaust into the same pipe without disturbance.
Number of exhaust branch depends upon firing order, no: of cylinders and TC design
When the exhaust valve of a diesel engine opens, the cylinder rapidly expands, and gain
velocity and kinetic energy as they pass into the exhaust pipe.
Advantages and disadvantages of pulse system ? The kinetic energy of the mass of exhaust gas carries it along the exhaust pipe, and causes
a pressure build up ahead of the mass of gas and a partial vacuum behind it. This principle is
Advantages
used in a tuned exhaust system. The partial vacuum created by exhaust from one cylinder is used to
At low load and low speed it is more efficient (Still efficient when Bmep is < 8 bar) help exhaust expulsion from the following cylinder.
No need assistant of scavenge pump and blower at any load change. Grouping of exhaust pipes depends upon the firing order, length & diameter of exhaust pipe.
It is highly response to change engine condition giving good performance of all speed of
engines. High available energy at turbine Effect of inter cooling the charged air ?
Good TC acceleration . Advantages
The effect of cooling reduces the scavenge air temp and increase the density of air
Disadvantages delivered to the cylinders, thus increasing the power out put delivered by the engine. It can increase
The exhaust grouping is complicated. the output by about 10%.
Different sizes of exhaust pipes are needed for spare. Cooled scavenge air reduces cylinder and exhaust gas temperature at a given power level
High pressure exhaust from one cylinder would pass back into another cylinder during the and these temperatures thus remain within the acceptable limits.
low pressure scavenging period thus adversely effecting the combustion efficiency.
Types of turbocharger L.O system ?
Under piston pressure
(a)Own sump and
1) It is a type of constant pressure charging system (b) External L.O supply system
2) Air charged by T/C is passed through CAC into first stage manifold, and then through non- Ball type bearing (rolling type ) are used in turbocharger – lube oil from the sumps on
return valves into second stage and under piston space both air and exhaust sides is sprayed onto the bearing by means of attached rotor driven
3) In down stroke, piston under side compress further the scavenge air
gear type pumps.
4) Differential pressure shuts the inlet non-return valves as scavenge ports are uncovered, and a
pulse effect is given to cylinder
For sleeve type bearings are lubricated by external L.O supply system.
By gravity from independent header tank situated about six meters above the
Advantages
bearings. The tank capacity must supply for about 15 minutes after engine is stopped.
Assist tangential swirl and ensure complete evacuation of remaining exhaust gas
From a main L.O pump lead to the bearings with a separate L.O pipe line. It has also
No auxiliary blower may be required, during manoeuvring
gravity tank incase of failure of L.O supply. (Under main engine L.O system)

What is the turbocharger surging ?

Function of labyrinth seals ?
When the discharge volute pressure exceed the pressure built up in the diffuser and the
The bearings are separated from the blower and turbine by labyrinth seals. These seals are
impeller. It produces a back flow of air from discharge to suction and it is characterized by noise and
sealed by air supply from the discharge of blower to prevent oil entering the blower and to prevent
vibration of turbocharger.
contamination of the oil by the exhaust gas.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
133 134 REFERENCE FOR M.O.T 2 Class Part B (Oral)

If be defect of labyrinth seals ? What is K value ?

At the blower side It is a distance between the rotor shaft end and the flange of bearing cover measured by
Oil is leaked into the air system the cooling surfaces are covered with oil which are blower side.
insulators and the cooling efficiency will be reduced. Purpose of K value ?
Also there will be deposits on the blower and the blower efficiency will be reduced. To ensure that rotating impeller does not to touch the stationary blower casing cover in case
of thrust bearing worn out.
At turbine side
If the oil is leaked into the exhaust side there will be carbon deposits on the nozzle and What will you do in case of TC failure ?
turbine blades. 1) Rotor to be block
Reduce blower efficiency and fire in the exhaust piping. It will cause turbocharger surging. 2) Exhaust gas to be by-passed the TC
Oil will contaminate with exhaust gas. 3) Run engine with reduced speed with remaining TC
4) Use Auxiliary Blower
How will you know T/C air fitter chocked ? 5) Maintain all temperature and pressure fuel, cooling water and lubrication within limit
It can be known by comparing the manometer difference. If manometer difference is greater 6) Discuss with Captain for manoeuvring difficulties
than normal, T/C air fitter may choke.
It can cause - reduce engine power Procedure for cutting of turbocharger ?
- Black smoke will emit from the funnel When it is necessary to cut-off T/C due to heavy vibration, bearing failure, etc. cutting
-scavenge pressure will reduce procedure should be done as per engine maker’s instruction
Cutting-off operation depends on number of T/C installed and number of T/C damaged
Function of nozzle ring ? 1. Remove the nozzle ring
To change pressure energy to velocity (kinetic energy) 2. Lock of the rotor shaft
3. Blank off the blower discharge
Pulse system ?
This system makes full uses of higher pressure and temperature of the exhaust gas during Following procedures are in accordance with Sulzer RT engine practice
blow down and rapidly opening of exhaust valve or ports the gas leaves from the cylinder at high Case I: Failure of one T/C, with Exhaust by-pass piping
velocity as pressure energy is effectively converted into kinetic energy to create a pressure wave or 1) Lock rotor as per T/C manual
pulse in the exhaust pipe. 2) Remove blank flange in by-pass exhaust piping
This pipe is so constructed in small diameter is quickly pressured and boosted up to form a 3) Open covers of scavenge air trunk
pressure pulse. 4) Auxiliary blowers must be running during operation
The pulsating pressure waves reached up to the turbine and further expansion take place. 5) If casing is cracked, stop T/C cooling
Buchi system –one type of pulse system used in 4 stroke engine. 6) If T/C is supplied with external lubrication, shut L.O supply

What is labyrinth seal ? Case II: Failure of one T/C, of two T/C engine
1) Lock rotor of damaged T/C
It is a sealing ring which is sealed by air supply from the discharge of blower.
2) Remove expansion joints of both exhaust inlet and air outlet of damaged T/C and ppt
Functions
blank flanges
To prevent oil entering the blower
3) If casing is cracked, stop T/C cooling
To prevent the contamination of the oil by the exhaust gas.
4) If T/C is supplied with external lubrication shut L.O supply
Output 15% RPM 50%
Purpose of inducer ?
To feed the shock less air flow to the impeller. (To guide the Air smoothly into the eye of Case III: Failure of all T/C of an engine, without Exhaust by-pass piping
Impeller) 1) Lock rotors of all T/Cs
2) Open all covers of scavenge air trunk
Function of Diffuser 3) Auxiliary blowers must be running during operation
To direct the air smoothly into Volute Casing 4) If casing is cracked, stop T/C cooling
Convert KE to PE of Inlet Air 5) If T/C is supplied with external lubrication shut L.O supply
Output 15% RPM 50%

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
135 136 REFERENCE FOR M.O.T 2 Class Part B (Oral)

T/C out of order. The various parts should be warped in waxed paper to protect them against dirt and
(One of two) moisture.
1. Rotor lock by locking device.
2. Insert orifice plate in compressor air outlet & inlet. (Small air flow to cool the impeller.( small gas
T/C overhauling checking.
flow to prevent condensation.)
Blade condition.
3. Engine running with reduce speed & load with auxiliary blower running depending upon the
Labyrinth seal.
engine running condition.
Bearing clearance. (a) 0.2 ~ 0.3 mm axial
0.15 ~ 0.2 mm radial
Only one T/C.
Nozzle ring.
1. Rotor & nozzle ring remove.
After reassemble, check for balance & deflection.
2. Blanking plate are inserted.
Check impeller & casing clearance. (K value)
3. Remove compensator, between compressor outlet & scavenge air duct.
4. Engine running with reduce speed & load with auxiliary blower running depending upon the
engine running condition. What parts will you check when G/E T/C overhauled ?
Check the deflection of divergent nozzle.
T/C out of order.(UHA discussion) Measure the K value at blower side.
• Rotor lock by locking device. Change the bearing on both sides with the new one (because bearing service life is same as
• Insert orifice plate in compressor air outlet & inlet. (Small air flow to cool the impeller, T/C overhauling time).
small gas flow to prevent condensation.) Clean blower and turbine side with chemical and inspect carefully.
• Engine running with reduces speed & load with auxiliary blower running depending Check the labyrinth seal.
upon the engine running condition. Made clear the labyrinth seal air line
Check the casing for crack & wear
• Rotor & nozzle ring remove. Blade condition
• Blanking plate are inserted. After reassembled
• Remove compensator, between compressor outlet & scavenge air duct. Check Static Balance
• Engine running with reduces speed & load with auxiliary blower running depending Check Impeller and Casing clearance
upon the engine running condition.
When will you change TC Bearing ?
• If exhaust gas by pass system to turbocharger is available. As per Running Hour
• Rotor lock by locking device. As per clearance
• Blanking plates are inserted inlet and outlet of turbocharger. Use the exhaust gas by pass When damaged
system. When vibration is heavy
• Engine running with reduces speed & load with auxiliary blower running depending
upon the engine running condition. How to check deflection of divergent nozzle ?
By using (1) Pick tester &
Procedure for T/C O/H ? (2) Magnet stand
Lock off the engine staring mechanism.
Remove the T/C air fitter. What is the main purpose of T/C water washing ?
Drain off the oil from both drain plugs. To ensure efficient functioning of turbocharger.
Remove the bearing covers from both sides. To protect the compressor and turbine from contamination (Deposits).
Remove the locking wires.
Unscrew the hexagon screws and remove oil suction pipes.
Disadvantages of T/C water washing to turbine side ?
Tighten again the hexagon screws of the bearing boxes.
Engine speed has to lower.
Check the deflection of the divergent nozzle by using pick tester and magnet stand.
Thermal stress and corrosion usually occurred.
Remove the divergent nozzle by screw driver.
Longer cleaning time.
Measure the K value at the blower side by using depth micrometer or caliper and straight
Very fine hard deposits and residues can not be removed easily with water washing.
edge.
Lock the rotor with special tool.
Extract the lubricating disc. Advantages of solid (crystal) cleaning ?
Extract the both bearings by bearing extractor. Not required to reduce engine rpm, thus not effect on scheduled voyage
No used of water, so no corrosion and thermal stress.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
137 138 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Cleaning time is short. Why T/C exhaust outlet lower than inlet temperature ?
Not wear turbine blade. Some exhaust gas heat & pressure energy is transferred to mechanical rotating energy,
Effectively removed combustion residues and hard particle. thus pressure become decrease and temperature lower.

How will you carry out T/C turbine and blower side water washing ? What will occur is oil leak in T/C system ?
Blower side water washing If oil is leaked into the air system the cooling surface are covered with oil which are insulated
It can be done when M/E on full load. & cooling efficiency will be reduce (ie. Scavenge temp: drop ; Exht: temp: high)
Fill up the warm fresh water to hopper and closed the cover. Also there will be deposits on the blow and blower efficiency will be reduced
Open the valve and water will flow into the blower casing and mechanically attack the If oil leaked into exhaust side, Carbon deposits on the nozzle & turbine blade. It cause
blower blades and clean the deposit.
surging, reduces blowers efficiency and fire in the exhaust piping (uptake fire)
Closed the valve, open the cover and check the cleaning water must be empty.

Turbine side water washing procedure TC over run

Turbine side water washing can be made with hot fresh water. Causes:
Inform to the bridge Happened in constant pressure turbo-charged engine
Reduce the M/E rpm to recommended speed and T/C rpm.
Caused due to fire and /or detonation of scavenge space
Check the water washing injection nozzle if fitted. (directly aim to the exhaust grips before
Exhaust trunk fire due to accumulation of leaked or excess LO and unburned fuel
entering to the T/C )
Open T/C drain valve.
Open the water supply about 1 bar to turbine side. Effects:
Water washing must be made until the clean water coming out. TC bearings, casing damaged
Closed the water supply and remove the nozzle. ER fire
Exhaust side drain can be closed after all water is drained out and dried.
Inform to the bridge and increase the M/E rpm gradually to sea speed. Prevention:
The turbine side water washing is usually at departure after manoeuvring time. Scavenge space regular cleaning
For usual practice cleaning is done at every 500 hr, running hour depending on the Exhaust gas pipe regular cleaning
cleanliness of the T/C. Maintain complete combustion of fuel
Liner, piston and rings, fuel vales, cylinder lubrication, maintained in good order
Cereal Grains or Activated Charcoal particles cleaning of Turbine (Dry Cleaning)
Avoid operating ME under reduced load for long term
1) Turbine side cleaning is superseded by coconut Charcoal particles, with grain size of 12 to 34
mesh
2) No speed reduction required and cleaning can be done at full speed, once every 240 hours TC Vibration
3) Compressed air of (3 -5 bar) us used to help the grains strike the deposited Turbine Blades
Unbalanced
and Nozzles, giving effective cleaning of hard particles
4) Air supply pipe is fitted to solid grain container, and grains are injected into exhaust system by Bearing defects
air pressure, at the same point (as in water washing ) just after exhaust grids Deposits in nozzle ring
5) Turbine casing drain kept open during cleaning time of (about 2 minutes only) until drains Impingement
become clear Surging, Scavenge Fire, Overloading

When G/E T/C overhaul, what measurements do you taken ? TC Balancing

K value, it is a distance between the rotor shaft end and the flange of bearing cover Static balance
measure at blower side (axial clearance). Dynamic balance
Check radial clearance (at plane bearing), by placing clock gauge on the shaft from the top
and clamp by screw driver from bottom, record the clearance.
Rotor and Casing clearance (for new casing or new rotor) (L & M values)

How to measure TC axial and radial clearance ?

Axial Clearance : Push the shaft by screw jack and measure by Depth Gauge (0.2 – 0.3
mm)
Radial Clearance : Lift the shaft radially and measure by Dial Gauge (0.15 - .02 mm)

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
139 140 REFERENCE FOR M.O.T 2 Class Part B (Oral)

By adding or reduction shims on the pump base, or

By turning the plunger up and down adjustment screw on the pump roller guide, or
By shifting the coupling flange between the pump and the drive side of the engine in case of
Function of fuel injection pump combined unit system, (for small engine)
To supply accurate metering amount of fuel with sufficient pressure to open fuel injector in Large engine
correct timing. The timing can be altered by shifting the camshaft to the position relative to the crankshaft
(after removing the idler gear between the crankshaft and the camshaft.) For large engine
How to fuel cut out (Individually) For adjustable cam type engines timing can be altered by individual cams of the fuel pumps.

Reduce the engine speed

Remark
By lifting the pump roller form cam peak and securing the pump roller guide
Individual unit timing checking up & adjustment required for movable cam type engine
By making pump rack to zero position
For solid camshaft type, it is only required for checking on No. 1 unit.

How to notice the incorrect timing ?

If no TDC mark on flywheel, How will you check pump timing?
Difficult to start the engine
IN M/E
Abnormal exhaust temperature reading
1) Make a marking between cross head and guide Shoe while they are before TDC and also mark
Black smoke coming out
at the flywheel.
Irregular running of engine.
2) Turn the crank shaft in the same direction until the crosshead and guide shoe are at the
previous mark (coincide)
How to check the fuel injection pump timing ?
3) Make the second marking on the fly wheel. We got two marks on the flywheel mid point between
Lock off the starring mechanism
the two points is TDC.
Start L.O pump
4) I will divide 360C around the flywheel.
Open all indicator cock
By hair line method-
IN G/E
Turn the engine so that the unit to be check is toward the TDC of compression stroke (plunger
1) Remove the fuel valve
upstroke) so that hair line on plunger & pump body are coincided.
2) Insert the rod onto the piston (mark on rod and flywheel)
When hair lines are coincided, stopped turning and check the mark on the fly wheel whether timing
3) Turn crank until the rod previous mark
is correct or not.
4) Make the second marking on the fly wheel
In hair line not given-
5) Mid point between the two points is TDC
Take out fuel in/out pipe on pump (by removing binjo bolt)
By using hand torch & mirror on each side
What points do you check on fuel pump when overhaul or how will you decide ?
Turn the engine so that the unit to be check is toward the TDC of compression (at plunger upstroke)
Check plunger guide wear & tear
so that the light on mirror is disappearing ( ie torch light has gone on mirror )
Check spring (length & stiffness, crack)
AT this time, stopped engine turning & check the mark on flywheel.
Plunger & barrel wear & tear, check clearance (5 micro for DO, 15 micro for HO) by dropping
By Goose net method
the plunger into the barrel it fall down slowly is OK
Turn the engine so that No.1 piston is at the top dead centre position at the beginning of the firing
Check control sleeve and rack for crack
stroke
Check the Delivery valve face
Turn the engine backwards to a point which is a little earlier than the fuel injection point.
Check ‘O’ ring of fitted.
Shut fuel oil supply and remove delivery valve assembly with delivery pipe to fuel valve of No. 1 unit
and put on a bent pipe in place of the delivery pipe on the pump discharge.
METERING OF FUEL
Fuel supply valve to the engine is to be opened and put the fuel lever to running position. Fuel oil will
Controlling the fuel amount in two ways, by means of a helix groove on the plunger or by
flow out from the bent pipe. means of control valves. for effective stroke.
Turn the engine towards the TDC in its running direction slowly until fuel cease to flow and check the The quantity of fuel delivered is regulated by the vertical length of the helix where it is in line
marks on the flywheel whether the timing position is correct or not; with the suction port. This setting may be altered by rotating the plunger. In stop position, the
vertical slot of the plunger is in lined with the spill port where then ports are opened and thus
no injection occurred.
Adjustment
Small engine
Slightly different variation can be adjusted-

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
141 142 REFERENCE FOR M.O.T 2 Class Part B (Oral)

VIT system.

The VIT mechanism automatically change the injection timing according to the load to
maximum combustion pressure at the engine load between 85 ~ 100%.
Advantage - Fuel save about 1.5 gm/kw-hr @ 85% load.
- Maximum combustion at its normal maximum value.

AP MOOLER GEK QUESTION

1) EMERGENCY
BLACK OUT –How do you make the procedure to restore if going to black out in your ship?
E/R FLOOD – How do you take action when ER flooded? ( in sequences )
2) –Preparations for before arrival manoeuvring
_Preparations for before departure
3) GENERATOR
What are these do you check on main switch board when G/ E is running?
Is your G/E capacity is sufficient with the incoming load?
If not in sufficient how do make in action ?
How many G/E do you run when to be recovery required load?
4) ELECTRICAL
-How do you check the condition of the motor?
-Besides the insulation test for meter reading how can check the motor if it is not in running?
-Besides the physical damage what is wrong the insulation shorted in winding?
-What points do you check in running motor?
PSYCHO TEST - Chosen wards, you are expected by others and expected by your self. ( Time –
unlimited)
I.Q TEST -50-Questions ( Time- 15 minutes)

(INYA LAKE HOTEL 26-11-02)

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
143 144 REFERENCE FOR M.O.T 2 Class Part B (Oral)

9) Scavenge air temperature too low.

10) Insufficient combustion.
11) Use of low sulphur fuel oil in conjunction with high alkalinity lube oil.
Function
The compression of air and the combustion of fuel/air mixture take place inside the cylinder Types of wear
liner, so it forms part of the combustion chamber. Scratching: Small Scratch may develop in the region of ring travel due to small particles entrapped
between the bore and rings. Those particles originated from the machined surfaces of the mating
Cylinder liner wear pair.
Normal frictional wear : Due to metal-to-metal contact with very high surface asperities under
Scoring:
marginal lubrication condition.
Score confined to the region of ring travel and may extend to the region swept by the piston.
Abrasive wear : Due to presence of hard foreign particles from Air, fuel and lub oil
Scoring being developed from Scratching and the origins is similar to Scratching.
Corrosive wear : Due to H2SO4acid attack owing to products of combustion. Sulphur within
Scuffing:
a fuel. Only about 0.1% of the Sulphur in the fuel causes corrosive wear,
Scuffing is a condition develops in the ring travel on the thrust side of the liner and depends
like hot and cold corrosion, and the remainder escapes with exhaust
on the efficiency of the Lubrication, speed and Loading.
gases.
Due to Hydrochloric acid attack because of salts in air, charge air cooler
leakage, sea water in fuels and lube oils. Clover leaf pattern:
Some liners wears irregular ovality patterns but some gives "Clover-Leafing" pattern of
Causes of liner wear longitudinal corrosive wear at several points around the liner concentrated between the lubrication
orifices.
(A). Improper running-in-during first few hours, 10 to 20 hours, the piston rings have to form an
The cause is owing to combined effects of incorrect feed rate of cylinder oils (inadequate)
effective seal against the passage of destructive blow by gases. Surfaces of rings and liner
and acidic effect of combustion products (or low TBN lube oil). The wear concentrated between the
slide freely against one another without the asperities welding together when engine is
points of lube oil quills.
under load. Metallurgical changes take place on the metal surfaces during the initial
running- in that a thick work hardened layer is formed, which has good anti-wear
In actual practice, wear never takes place concentrically, and it depends on heel and trim of
properties in subsequent operation.
the ship in service, and effective guide clearance
(B). Misalignment of piston, or distortion of liner, preventing bedding-in of piston and liner.
In tankers and bulk carriers, where long ballast passage are made with the trim aft,
(C). Inadequate oil supply or unsatisfactory arrangement of cylinder lubrication.
Maximum wear will be in the fore and aft plane, and especially on aft side of the liner.
(D). Lube oil is too low in viscosity or too low in alkalinity (Grade of cylinder oils).
(E). Incorrect piston rings clearances.
(F). Unsuitable liner material (quality). WEAR RATE
(G). Unsuitable piston and ring materials. Liner wear rate is high during the running in period after which it will come to a uniform wear
(H). Contamination of lube oil by abrasive materials. rate within most of its service life.
(I). Cylinder wall temperature too high or too low. Finality the wear rate increases as wear becomes excessive and rapidly due to difficulties in
(J). Engine overload. maintaining the rings gas tight.
(K). Scavenging air temperature too low, resulting in excessive quantities of condensed water Wear rate can be high about 0.75mm/1000 has in large slow speed engines using residual
entering the cylinder (leading to dew point corrosion). fuel oils which contain in excess of 1.5% of Sulphur
(L). Inefficient combustion, promoting deposits formation and degradation of the lube oil. Wear rate being lower about 0.02 mm/1000 hrs in medium speed engines, due to burning
(M). Use of low Sulphur fuel oil in conjunction with high (TBN) alkalinity lubes oil. low Sulphur fuel oils.
When the Vanadium is added during manufacturing, the wear rate could be significantly
reduced to 0.025mm-0.50mm/1000 hrs.
Causes of cylinder liner wear.
1) Improper running in.( 10 to 20 hours) Maximum wear allowance of liner = 0.7% to 1% of original bore for large output engines
2) Misalignment of piston or distorted liner.
3) Inadequate oil supply or unsatisfactory arrangement of cylinder lubrication. WEAR PATTERN
4) Cyl oil is too low in viscosity or too low in alkalinity. Maximum liner wear is at the upper limit of the travel of the top compression rings at the top
5) Incorrect piston ring clearance. of the stroke
6) Unsuitable liner material. This reduces towards the lower end of the stroke but will increase in way of exhaust and
7) Contamination of cyl oil by abrasive materials.
scavenge ports.
8) Engine over load.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
145 146 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Reasons for maximum wear at top of the stroke being: Cause of cylinder liner crack.
(01) The gas load behind the ring is maximum
1. Excessive thermal & mechanical load.
(02) It is the hottest region 2. Poor material & design.
(03) Viscosity of oil film is low and liable to breakdown under heavy load and high temperature 3. Piston seizure.
(04) Abrupt Change in direction of piston rings, at dead ends of reciprocating motion. 4. Localized scavenge fire.
6. Over or Uneven tightening of cylinder cover nut.
(05) Corrosive wear
7. In loop & cross scavenging, high temperature gradient.
(06) More liable to be attacked by acids. 8. Water side corrosion reduce liner strength.

Reason of maximum wear around the ports.

PREVENTION
Due to leakage of hot gases past the top ring into the ports and these hot gases will tend to burn off
(01) Use torque spanner
the oil film.
(02) Maintain C.W temp: at a level within a limit
(03) Close watch on temp: and press: of gases, Fuel oils and C.W ETC…
How to maintain minimum liner wear ? (04) Renew cylinder liner when worn down beyond limit about 0.7% more than original bore.
(01) By use of good quality cylinder oils with detergent additives of proper TBN valve.
(02) By use of corrosion resistant liner materials with some proper percentage of Vanadium, Consequence of excessive liner & piston ring wear
Titanium, Chromium and chrome plated liners.
1) Blow pass occur & scavenge fire can occur
(03) By maintaining good Fuel injection condition (efficient cleaning of F.O, Correct F.O temp:,
2) Blow pass occur & crankcase explosion can occur
Correct F.O grade)
3) Over heat on liner & liner crack & piston seizure & piston breakage may occur
(04) By maintaining Jacket, water temperature as high as practical to avoid dew point
4) Engine become unbalance & power loss
condensation of acid products.
5) Turbocharger surging may occur
(05) By maintaining proper feed rate of cylinder oils.

Removing and refitting the liner

Points to remember:
Before removing
(1) Lubricator timing
1) Immobilisation permit taken from port authority
(2) Position of quills
2) Vessel in upright position
(3) Oil feed rate
3) Lifting gears and tools in good working order
(4) Oil refreshing rates
4) All spares are ready.
(5) Oil film thickness
5) Persons grouped for assigned jobs.
(6) Engine load
Removing the liner
Sign of liner crack 1) Drain CW from cylinder jacket
(01) Fluctuation of pressure and temperature of jacket C.W system 2) All lubricator quills removed
(02) F.W coming out from the scavenge drains 3) Cylinder cover, piston and stuffing box removed in usual way
(03) Overload at that particular unit (high in exht: temp: and Jacket temp) 4) Cover the piston rod stuffing box seating with special cover
(04) Expansion tank foaming 5) If liner is to be reused, liner wear should be measured and recorded
6) Position of liner, relative to cylinder jacket, properly marked
CAUSES 7) CW outlet pieces to cylinder cover removed
(01) Due to rapid contraction of metal 8) Attach the liner withdrawing tool as per instruction, and tighten the upper nut until liner
(02) High difference in Jacket water (working) temperature comes in contact with upper supporting bar [strong back bar]
(03) Insufficient cooling 9) With overhead crane and sling arrangement, liner is drawn out
(04) Over tightening of cylinder head bolts
(05) Design failure Before refitting
(06) After effect of immense Scavenge fire 01) If old liner is to be reused, clean thoroughly
(07) Due to loosened out foundation chocks resulting tie bolt slackening and Hoop Stresses on 02) Landing surface of quills checked for damage and carbon deposits on oil holes cleaned.
Cylinder liner increases 03) Rubber sealing ring groves, cleaned with old round file until to bare metal
(08) Due to very high injection viscosity 04) Surface inside jacket, coated with anti-corrosive paint, and sitting surfaces cleaned.
05) Sharp edges inside jacket, chamfered slightly to prevent cutting rubber sealing rings.
06) If new liner is to be fitted, gauged before fitting

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
147 148 REFERENCE FOR M.O.T 2 Class Part B (Oral)

07) New liner is to be lowered down into position, without sealing rings fitted, to ensure it is
correct size. Liner should not only drop freely by its own weight, but there should be slight
radial clearance between liner and jacket to allow for expansion.
08) Radial clearance at lower end, < 0.2 mm for 750 bore liner
09) Radial clearance at top, < 0.001 mm/mm of liner bore.
10) Rubber sealing rings should grip firmly around liner, and a 10% stretch would be adequate
11) If there is no original reference mark on liner, quills should be fitted and mark the correct
position of liner relative to cylinder jacket.
12) Remove the liner again and sealing rings fitted.

Refitting liner
1) Soft soap or similar lubricant to be applied to rubber sealing rings for easy fitting
2) Fit in correct position as per instruction
3) New liner re-gauged after final landing to check any distortion and recorded
4) Refit quills and test lubrication. All parts refitted in usual way
5) Fill cylinder jacket and check water-tightness under pressure.

Running in During the first 10~20 hours

1) Cylinder oil feed rate at maximum
2) Engine load reduced
3) Reduce oil feed rate to normal and increase the load stepwise
4) Liner checked from inspection door and scavenge space, at first opportunity

Fitting cylinder liner

1) Clean close fitting parts, L.O fittings, rubber sealing ring grooves.
2) Clean inside the jacket and coated with anti corrosive paint.
3) Chamfered slightly sharp edges inside the jacket.
4) Soft soap or similar lubricant apply to rubber ring and fitting surfaces.
5) For new liner first lowered into position without fitting rubber ring to check the fitting clearance
and fitting of cylinder lubricator.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
149 150 REFERENCE FOR M.O.T 2 Class Part B (Oral)

How will you discharge bilge ? *****

Take C/E permission to discharge Oily Bilge through O.W.S
If ship is outside special area, Vessel must be enroute , oily bilge are discharged through
Why fitted the O.W.S ?
O.W.S with ODM system , oil particle less than 15 ppm.
Oil/water separator are used to ensure that ships do not discharge oil when pumping out If ship is within special area , vessel must be enroute, oily bilge are discharge d through il
bilges, oil tanks or any oil contaminated space, according to the regulation on marine oil pollution filtering equipment with automatic stopping device, oil particle less than 15 ppm
prevention 73/78. After operation, discharge quantity, time and location to be put in oil record book.

Requirement of O.W.S What is the bilge injection ?

01. Oily water separators for bilge and ballast applications should be capable of giving an affluent It is emergency bilge suction lead to main sea water pump suction line, commonly called the
containing less than 100 ppm of oil irrespective of the oil content of the feed supplied to the bilge injection. This valve is of screw lift screw down type. No mud box or strainer this line.
equipment. It can be used in case of E/R flood & in case of emergency
02. Filtering system are further required to provide and effluent of not more than 15 ppm under all
inlet conditions.
Action of bilge flooded

Safety device on O.W.S At Sea : Use direct bilge, Bilge injection valve only flooded with dangerous condition
In port : Put into bilge tank if not capable sends to the shore
Pressure relief valve on discharge pipe
O.D.M system with high ppm alarm and automatic pump stopping device.
Test cock (level), drain valve Bilge system requirement
1) Bilge system to be entirely separate from other system
What do you when alarm is on ? 2) Main bilge is connected two bilge pumps, direct bilge suction are fitted on each side of
machinery space (P & S)
Open the oil drain cocks and check the oil control level
3) Emergency bilge suction lead to main cooling S.W pump suction line. Fitting mud box or strum
Stop the pump
box should be avoided.
4) Direct bilge suctions in the machinery space and tunnel, mud boxes fitted at platform level,
How will you pump out oily bilge overboard O.W.S discharge regulation ?
easily accessible cleaning.
Regulations controlling the Pollution by Operational Discharge 5) The bilge pump are self priming or capable of being quickly primed
Oily bilges are prohibited from discharge into the sea except the following conditions. 6) Each suction is fitted a screw down non return valve in order to prevent inter communication
7) is fitted to the discharge side of the bilge pump (to prevent the discharge oil overboard)
Machinery space / Ballast tanks Discharge
Cargo slops Attachment of O.W.S
Outside Special Area Within Special Areas Photo copy of MARPOL certificate
Outside S.A Vessel enroute Vessel en route Original oil disposal to shore certificate
More than 50 NM from Has in operation oil Has in operation oil Dirty oil and sludge piping diagram
land discharge monitoring filtering equipment with USCG warning

Vessel en-route system, oily water automatic stopping device

How do you operate the O.W.S ? *******
Instantaneous rate less separator Oil particles less than 15
Take the permission form C/E
than 30 litres per NM Oil particle less than 15 ppm
Close the drain valve; open up all necessary valves on the system.
Total 1/30000 of cargo ppm Run pump, first taking suction from sea chest to fill up the separator with sea water keeping an
Operating oil separator, eye on the shell pressure
slop tank ODM. Open all vents and cocks to release air from separator.
Switch on the ODM and alarm system
Special Area Open steam heater valves and maintain the temperature about 60 °C
1) Black Sea, 2) Red Sea, 3) Mediterranean Sea, 4) Persian Gulf Area ,5) Gulf of Aden, 6) Antarctic Flush the oil content meter with fresh water for at least 5 minutes before putting the monitor
Sea, 7) North Sea, 8) Wider Caribbean Sea, 9) Baltic Sea, operation. Then change over from fresh water to sampling line.
Change over pump suction to draw from bilge tank.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
151 152 REFERENCE FOR M.O.T 2 Class Part B (Oral)

During operation, regular checking of water oil interface through test cocks. Outside special area Within special area
If lower test cock comes out oil, open the drain valve until upper test cock come out water & 1. Vessel enroute. 1. Vessel enroute.
shut oil valve 2. Oil particle less than 15 ppm. 2. Oil particle less than 15 ppm.
After operation, flush the system with sea water & flush oil content meter with Fresh water then 3. Has an operational oil discharge 3. Has an operational oil discharge monitoring
bilge discharge amount & time & ship location to be put in O.R.B. monitoring system and alarm system and alarm system and 15 ppm stopping
system. device.

Why O.D.M is fitted at O.W.S ?

To monitor the oil content in the discharge water from O.W.S and to give warning. Bilge overboard discharge valve must be tight close and kept under chain and lock and bilge
connection must be blanked by Blind Flange. This connection must be absolutely free from oil
and sludge.
How to test ODM ? Bilge tank must be make ready and transfer to the bilge tank.
Disconnect the sample pipe Minimize the oil leakage control the increasing of machinery space bilge water.
Switch on the ODM system
Inject the oil into sample line by opening sample line valve
Alarm will operate

What is the coalescer ? Its function ?

Coalescer is the fitter element fitted at the oily water separator system made of steel wire
mesh or Nylon fibres.
Its function is to coalesce tiny remaining oil particles to from a large drop (size) of oil.

ODM operation
A sample of the effluent is passed through a vertical cylinder, and receives energy emitted
from an ultra violet lamp at the top of the cylinder. The energy emitted due to any fluorescence is
monitored by a photoelectric cell, which produces a signal dependent on the amount of oil, present
in the sample.
In the event of excess oil contents, this signal operates the diverting valve and the separator
discharge is diverted to the slop tank instead of discharging overboard.

Maintenance to O.W.S
1) Routine attention is needed to obtain satisfactory performance
2) Obey the maker instructions.
3) Removed of internal contaminant
4) The prevention of corrosion by removal of sludge
5) Check for places where anti corrosion coating had deteriorated & apply anti-corrosive painting
6) Preservation of bilge pump
7) If coalescer is disposal checked & renewed
8) If coalescer is renewable checked and cleaned
9) Checked & test the ODM
10) Oil sensor probe must be cleaned
11) Cleaned & coated to catch plate
12) All test cock line clear

Instruction for oily water separator. (As a C/E)

1. Inform to C/E. C/E select the position after taking the ship position from the bridge.
2. Operation.
3. Regulation.
In port not allow.
Regulation

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
153 154 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Coliform Count
1) Coliform is the name given to bacteria group, found in intestine
2) Not normally harmful, but can cause Dysentery, Typhoid, and Gastro-enteritis.
3) Coliform Count checks effectiveness of disinfection
What is sewage ?
4) Carried-out on effluent sample and incubating it for 24 – 48 hours at 35 °C
Drainage and wastes from toilets, but not including wash water form basins, and wash tubs. 5) Colliform Bacteria count: 200 / 100 mlt. [Maximum]
All drainage from medical premises, including wash water from basins and wash tubs.
Drainage from spaces containing living animals.
Regulation controlling Sewage Discharge

Emission of Black Smoke

Black smoke from ship may lead to pollution of air space, and many countries have their Distance in NM from nearest land
Type of sewage
own regulations that are not to be violated. Smoke from ship is checked for blackness; by comparing 0 4 12
with Ringelman Scale Chart. On this scale, white card is numbered ‘0’ and totally black card is ‘5’.
There is specific time limit, during which black smoke emission is not penalised. Sewage treated by approved
No visible floating solids or discoloration
Sewage treatment plant
The allowable black smoke emissions are:
Sewage comminuted and
1) Continuous emission must not be longer than 4 minutes
disinfected with approved Prohibited
2) Short emission in every 20 minutes period, must be limited to 3 minutes.
equipment
3) Another part of ruling limits, emission must be not more than10 minutes in any 2 hour periods.
Untreated sewage Prohibited
BIOLOGICAL (AEROBIC) SEWAGE TREATMENT PLANT Moderate rate, ship
1) The unit is divided into three compartments, the aeration Chamber, Settling Chamber and Sewage held in holding tanks Prohibited en-route at not less
Chlorinator. than 4 knots.
2) Sewage enters Aeration tank, through soil inlet retained for about 24 hours being thoroughly
mixed and aerated by the aerators located at the bottom of the tank.
Annex V
3) The aerobic bacteria and micro organisms break down the organic wastes and produce new
bacteria cells and organisms.
Garbage type Outside special Areas In special area
4) Air, which provides the oxygen for bacteria and micro organisms, is supplied by a rotary
blower to the aerators Plastic – includes synthetic ropes, fishing nets
Disposal prohibited Disposal prohibited
5) The mixture is replaced by incoming sewage into Settling Tank, after passing through coarse and plastic garbage bags
screen
Floating dunnage, lining and packing materials > 25 miles of shore Disposal prohibited
6) All solids are precipitated in Settling Tank as activated sludge which is then returned by air lift
back to the aeration tank where it is mixed with the incoming raw sewage. Paper, rags, glass, metal bottles, crockery and
> 12 miles Disposal prohibited
7) Clean liquid is displaced into the chlorinator, where remaining bacteria are killed. similar refuse
8) Discharge of harmless effluent is controlled by float switch connected to the discharge pump. All other garbage including paper, rags, glass
> 3 miles Disposal prohibited
comminuted or ground
Important Equipment
Food waste not comminuted or ground > 12 miles >12 miles
1) Two Rotary Blowers
2) Two Discharge Pumps
Comminuted or ground garbage must be able to pass through a screen with mesh size no
3) Safety Valve at Aeration Blower
larger than 25 mm. Garbage disposal regulations for special areas shall take effect in accordance
4) High water level activating switch
with regulation 5 (4)(b) Annex V
5) Low water level activating switch
6) High water level alarm

Biochemical Oxygen Demand, BOD

Amount of Oxygen taken up by Bacteria Incubation Process, in PPM

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 nd
155 156 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Sludge tank requirements

1) Capacity must be minimum 1 % of used HFO for 30 days (or)
½% of used DO for 30 days
2) Sufficient manholes to reach all parts of tank
What is incinerator ? 3) Adequate heating arrangement
It is a waste disposal burning until which will burn solid material and all types of waste oil. It 4) No direct connection between sludge tank discharge piping and overboard discharge piping
is fitted to prevent pollution of sea. 5) Fitted with designated pump, having suitable capacity and discharge head
6) Fitted with standard discharge connection ( International Discharge Connection)
Safety System 7) Fitted with high level alarm
1) The safety devices shut down the unit and give out alarms:
a. When the pilot and main burner fail to operate Sludge Tank Capacity
b. When the flue gas temperature reaches above 400’C For ship, which does not carry ballast water in oil fuel tank, minimum sludge tank capacity
c. When the cooling fan fails to operate should be calculated as:
2) Emergency fuel shutdown valve
3) Micro switch, fitted to hinged furnace door (Interlock) 3
V = KCD m

Burning capacity of incinerator

It is mentioned at the supplementary of IOPP Certificate, and the incinerator should burn: Where K = 0.01 for ship, where HO is purified for ME (i.e. 1%)
1) Waste oil K = 0.005 for ships using DO or HO which does not require purification before use ( i.e. ½%
2) Oil and water mixture up to 25% of water content C = Daily fuel oil consumption
3) Rag and galley waste D = Maximum period of voyage between posts (in days)
4) Solid matters from sewage plant In absence of precise data, a figure of 30 days should be used.
Note: Sludge Tank Capacity (min) = 1 % of used HFO for 30 days (or)
Function of cooling fan ½% of used DO for 30 days
1) To cool and protect incinerator shell from overheating
2) To keep the combustion chamber at a negative pressure
3) To keep the flue gas temperature below a safety limit

Action when sludge too much ***** How will you control the sludge on board ?
At sea : incinerated by waste oil incinerator after getting C/E permission and put the incinerated
amount in oil record book after incinerated them
In port : Send to shore; get the received letter form shore authority

How to incinerate the waste oil ?

01) Get C/E permission
02) Give heating to waste oil service tank about 60C
03) During heating drain out the water at drain valve
04) After heating start the agitator to agitate the sludge mix some D.O if necessary
05) Start the fan to purge the furnace at least 1 min
06) Open the D.O tank valve
07) Adjust the fuel air ratio of burner
08) Light up the pilot burner with aids of spark igniter
09) Flame burns at pilot burner – start the main burner and check flame
10) When the flame is stable – open the waste oil valve, close the D.O valve
(D.O valve crack open if necessary)
11) Enter to the engine log book and oil record book amount of incinerated oil, position and time.

Compiled by Min Zar Tar 2/14/2005 11:01 AM

 157 158 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

If when the wear deeper than (6.0 mm/ 11.0 mm/ 12.0 mm) or 30% to 50% of the crown
thickness, Build-up welding of special alloy steel (INCONEL) to the flame side of the crown
can be introduced along with proper heat treatments.
Function In case where only light burnt off positions are ingrained, grinding or filing them down and
Piston forms the lower part of the combustion chamber. It seals the cylinder and transmits smoothing out the sharp edge zones with emery cloth will be sufficient.
the gas pressure to the crankshaft through connecting rod. The piston absorbs heat of combustion
and this heat must be conducted away if the metal temperature is to be kept in safe limits. Caused of Piston Overheated
It may be due either to:
Causes of Cracks of Piston Crown (01) Inadequate or failure of coolant supply and excessive deposit in cooling gallery.
Cranks, in star pattern on the crown, mainly happen owing to thermal and mechanical (02) Continued overload operation
stresses may be either of the following faults: (03) Unbalanced cylinder load
(01) Unsuitable material or inadequate matching for a rating of engine. (04) Incomplete combustion owing to loss of compression, faulty fuel timing, unstable fuel and
(02) Excessive scales on cooling gallery insufficient charge air.
(03) Cavitations erosion (05) High friction on liner owing to failure of lubrication, faulty rings conditions, long skirt touching
(04) High coolant temperature the liner due Misalignment of piston and distorted liner
(05) Local impingement (06) Late ignition faulty fuel timing
(06) High water content in fuel (07) Excessive water content in fuel.
(07) Poor atomization, High penetration of fuel (08) Faulty rings conditions causing blow-by
(09) Long skirt touching the liner due Misalignment of piston and distorted liner
Causes of piston crown burning (10) Excessive deposit in cooling gallary
a) Heavy deposits inside cooling gallery causing overheating of piston.
b) Faulty fuel valves allowing fuel impingement on the crown owing to incorrect spray angle. Piston crown wear, burn
c) Too high injection viscosity causing over penetration and impingement on the crown then Clean the piston crown
surface ignition will occur. Check the crown wear by means of template (maker supply wear down gauge[template]) &
d) Fuel containing excessive amount of water also may cause impingement attack on crown. feeler
e) High coolant temperature The permissible burn away is shown on maker supply wear down gauge.
f) Late and incomplete combustion
Measurement at unit overhaul unit survey
Remedial actions against burning away Liner calibration (maximum wear 0.75 % to 1.0 %of bore dia)
When the piston crown burns down the following checks to be made: Piston crown wear & ring groove
Fuel system : heating temperature, kinds of fuel, pureness of fuel, Piston ring gap clearance (0.2 % to 0.5 % of bore diameter, maximum allowance is 3 times the
standard of maintenance of fuel pump and fuel valve. original
Reduce water contents in F.O (be sure purification), Piston ring vertical clearance (0.2 to 0.25 mm)
fuel injection timing must actuate Piston ring radial thickness (1/30 of bore diameter)
High load :overload or over-torque during adverse weather Stuffing box sealing & scraper ring gap clearance (6 mm at each gap)
Lowering of cooling effect : abnormality in cooling passage, degree of pureness
of cooling medium, deposits on under crown area and Trunk engine piston seizure
preventive control for corrosion.(regular test and 1) Blocked coolant supply to piston
treatment of C.F.W must carried out) 2) Overheating of the unit
Lack of air :dirty scavenge air and exhaust gas system 3) Exhaust valve damaged
4) Rings damaged
The additional countermeasures to be taken are:
Proper selection of material How to pressure test when piston overhaul ?
Higher rate of cooling
• After cleaning the piston, externally and internally reassemble the piston will new two synthetic
Proper surface treatment
rubbers ‘O’ ring.
Installation of jet cooling system to the cooling side of the crown
• Invert the piston crown on the platform
• Fill L.O into the oil outlet pipe of the piston rod until oil is fully to outlet and inlet pipe.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 159 160 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

• Fit the piston rod with special test flange which consist of the connection pipe Crown Cooling Passage Design
• Connect the hydraulic pump to the connection pipe of the flange after air is purged out Boring of cooling passage closer to combustion chamber surface
Cooling passage to cover optimum surface are to maintain piston temperature within safe limit.
• Apply the pressure 1.5 times the working pressure for more than 10 minutes
Cooling passage design should be such to prevent formation of vapour pockets, sludge &
• Check L.O leakage between piston crown and piston skirt, piston skirt and piston rod. choking.
To maintain designed flow rate of coolant.
The piston seizure may due to:
01) Blocked coolant supply to piston Piston Cooling Design
02) Over fuelling of the unit It should be capable of lub oil splash by a jet from top of connecting rod.
03) Valve damage Should have chambers & passages in the crown through which coolant is conducted
04) Ring damage In some design ducts run full, and passages are of small sectional area to obtain high coolant
05) Faulty timing velocity
06) Cylinder lubrication failure Other designs use large chambers to operate coolant partially full and to promote violent
splashing due to piston motion termed as cocktail shaker design.
Piston
Cooling of Piston
Function of Piston
Heat transfer takes place following means-
Piston forms part of combustion chamber. To liner jacket cooling through piston rings
Piston converts gas force to mechanical power by reciprocating motion Oil sprayed on the inner surface from c/c by rotating cranks & bearing
Shape of piston is governed by combustion chamber Coolant is circulated through cooling passages in the piston
In Trunk Type engine: Piston skirts take up the side thrust due to connecting rod angularity
and guide the whole piston in the liner. Cooling & Coolant : Oil Specific Heat 2 temperature 10°C
In Cross Head Type Engine: The side thrust due to connecting rod angularity is not on the : Water Specific Heat 4 temperature 14°C
liner. The side thrust is taken up by the guide and guide shoe For same cooling effect, the amount of cooling oil circulation is 2.8 Times the amount of water
Modern Large Engines use Oil Cooled Piston
Constructional Feature of Piston
Composite pistons are made in two parts and used in highly rated slow and medium speed engines. Cooling Flow Pattern
Crown : Top part of piston Coolant enters at the lowest part of the cooling space & leaves from the upper most part.
Skirt : Bottom part of piston Upward movement of the coolant is uniform on opposite sides of the piston to prevent distortion.
The flow direction is in such a manner that the piston is always full of coolant and the underside
Crown of the crown is always in contact with coolant.
Concave or convex shape external contour Piston is partially filled with coolant at slow running of the slow speed engine
Concave crown is suitable for proper combustion Cocktail Shaker (splash method) cooling effect
Convex crown is suitable for high mechanical stress due to thick material Modern engine is bore cooling and equipped with jets for slow running
Thin crown is for low thermal stress.
Tapered on top of piston ring to allow for thermal expansion. Capacity of Coolant Pump
Subjected to high mechanical and thermal stresses. To maintain designed coolant flow rate
Carries compression rings in the grooves Low flow rate will cause overheating of piston and consequences
Heat resistance material e.g. Cr-Mo Steel / Alloy Steel used for highly rated engines High flow rate will cause under cooling of piston and consequences i.e. poor combustion; cold
Extensive cooling is essential for piston crown corrosion and effect scavenge temperature
Modern engines are made of thick crown with ‘Bore’ cooling & lub oil cooled.
Stress on Piston
Skirt Piston is subjected to compressive and tensile stresses caused by bending action due to gas
Takes up side thrust due to connecting rod angularity (trunk type engine) pressure, inertia forces and thermal stresses.
Guides piston in the liner and prevents rocking The top surface of the crown will be subjected to compressive loading & bottom surface to
Accommodates oil scraper ring in the groves tensile loading in fluctuating nature.
Provided with wearing ring in some design The thermal stress set up in a piston is caused by the difference in temperatures; this stress Is
Made of wear resistant & low co-efficient of expansion material e.g. Cast Iron greatest where the difference in temperature of the material across any section is greatest.

Crown Thickness Considerations When the crown of a piston is subjected to gas pressures the top surface of the piston is under
Higher strength & heat resistance properties of material compressive loading and the lower surface is under tensile loading.
Rigidity to withstand thermal & mechanical loading without distortion At the end of the stroke when retardation occurs, the inertia effect tends to cause the piston to
Mass to be controlled to limit inertia forces and should have heat dissipation capacity how upwards so that the top surface of the piston, together with the sides, is under tensile
loading and the lower surface of the crown is under compressive loading.
When the piston is retarded on its approach downwards to BDC, the piston crown tends to how
Properties of Crown Material
downwards, and its upper surface & the piston walls are in compression and the lower surface
Higher mechanical strength and higher fatigue strength
of the crown is then in tension.
High thermal conductivity and high creep resistance property
High surface property i.e. hardness, anti-corrosive
Low co-efficient of expansion

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 161 162 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Diametrical Clearances of Piston Gudgeon Pin Boss Failure

Piston diametrical clearance in liner is necessary to take up thermal expansion & distortions Above boss circumferentially
in admissible range. The body of the piston must be reasonably good fit in the cylinder in order that Longitudinally top of boss
the piston rings have a minimum overhang. Lower ring groove closely above pinhole
In 2 stroke engine piston diametrical clearance is 0.2% of cylinder bore
In 4 stroke engine piston diametrical clearance is 0.1% of cylinder bore. Piston Repair
These figures may be increased when wear rings are fitted but excessive clearance between piston
Gauge piston crown and ascertain shape & wear down beyond recommended limit
& liner can be extremely detrimental due to
Examine for fractures or cracks, piston rings grooves & general condition
Defective piston ring action
The crown will be welded up with proper weld metal to correct shape & height above datum
High lubricating oil consumption
Piston rings to be welded up and examine after welding is completed
Blow past of gases (may lead to c/c explosion in trunk type engine & scavenge fire in cross
If it is in order it will be heated up
head type engine)
Piston crown & grooves to be machined
Scuffing and excessive wear of piston rings
Seizure of piston in the liner in extreme cases.

Difference between Water Cooled and Oil Cooled Piston Piston Related Problems

Oil Cooled Piston Water Cooled Piston Faults in Piston Cause of Piston Running Hot
Cracking: Piston crown and upper piston wall Inadequate circulation of coolant
No risk of contamination Chance of water contamination in oil mainly Excessive deposits in cooling passage
No extra pump or pipes required Extra pump and pipes required Burning : Piston crown top surface Poor cylinder lubrication
Sealing : Piston cooling chamber and Faulty piston rings
Costly, excess oil required No cost of water passage Cylinder liner distortion
Low specific heat capacity (2) High specific heat capacity (4) Stepping: Edge of piston ring grooves Piston misalignment
Wear : Wear ring, piston skirt and side wall Engine/Unit overloading
Low temp difference with piston crown High temperature gradient with crown Corrosion: Hot corrosion on piston crown and Excessive water in fuel
No chance of deposit is if cooling water is acidic corrosion under crown Insufficient combustion air
Carbon deposits at high temperature Late fuel injection
treated
Main Reasons: Poor combustion
Oil oxidized at high temperature Can operate at high temperature Sever thermal & mechanical stresses
No hardness scale formation May form hardness scale Fluctuating gas load Piston Crown Burning
Excessive scaling Poor combustion conditions
Cavitation erosion Closely directed fuel sprays
Inspection of Piston High coolant temperature Fuel valve characteristics
Piston crown Burning at top part and wear at side wall of crown & ring grooves Local impingement from fuel Alterations of air swirls – directing flame front
Poor atomization & high penetration fuel Towards crown
Cracking at top (thermal & mechanical due to high temperature
High water content in fuel (slow down Heavy local cocking on crowns
corrosion)
combustion)
Hot corrosion at top surface and acidic corrosion at lower part
Actions in case of Piston Running Hot
Piston ring & groove Free movement of piston rings
In case a piston is running hot during operation, following immediate steps are essential:
Ring clearance / groove clearance Inform bridge & reduce engine speed, Sudden stopped can result in seizure of piston
Wear stepping and scuffing Cut out fuel to the affected cylinder to prevent further addition of heat to the piston
If possible, do not stop engine & allow piston to cool down before stopping
Piston skirt & side wall Any rubbing marks In case the engine has to be stopped, turn engine by Turning Gear until piston cools down to
normal.
Wear down of wear ring
Causes of piston seizer
Cooling passage Scaling due to poor water treatment 1. Heat of combustion.
Cocking due to high temperature 2. Heat of piston ring rubbing against liner.
These heat must be conducted away by piston cooling system, jacket cooling system and scavenge
Locking bolts & wires, studs and O’ ring condition air system, and supply sufficient cylinder oil.
The piston would become so hot due to cooling not sufficient, excessive deposits in cooling
Inspection & Maintenance spaces, insufficient lube oil, low temperature of cylinder cooling water, misalignment of piston rod,
Periodical inspection through scavenge ports distorted liner, excessive slackness of crosshead guide or insufficient air from turbocharger.
Overhauling accordingly or as per PMS Then the lubricating oil on the cylinder wall would be vaporized and the friction of the piston rings
Conditions monitoring through process analysis becomes so great that the metal would fuse and seizure occurs.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 163 164 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

2) By taking compressing card

3) By checking its spring action form peed holes (during stopping engine)

Piston rings
FUNCTIONS Materials : Cast Iron Alloy /Ordinary Grey Cast Iron
(01) To provide an efficient reciprocating gas seal with proper radial wall pressure (blow by
Piston ring Material Properties
control) without scuffing.
High mechanical strength and good tension properties
(02) To prevent excessive build up of pressure in the crankcase which will cause crankcase
Elasticity and wear resistance with low friction
explosion in the case of dry sump engine.
Must be corrosion resistance and resistance against high temperature
(03) To act as a scraper and oil control avoiding excessive oil consumption which could result if
Self lubricating properties and compatible with cylinder material
lubricant is allowed to leak past into the combustion chamber. Compatible with piston for thermal expansion to maintain ring groove clearance
(04) To conduct heat away from the piston into the liner wall.

Piston Ring Design Factors

Requirement of piston ring
Piston ring surface temperature, liner surface temperature and ring groove temperature
1) Have spring action Piston ring surface finish and cylinder liner surface finish
2) Have low coefficient of linear expansion Engine design feature to ensure adequate cooling
3) Can resist high temperature & pressure
4) Good wear resistance Optimum Sealing of Piston Rings
Piston ring should be well lubricated and must work with minimum lubrication
CAUSES OF PISTON RING FAILURE (Breakage) Piston ring should move freely in the groove
Piston ring & groove and cylinder wall should be proper shape
Must seal under condition of high temperature & pressure
1) Insufficient piston ring and groove clearance:(vertical clearance 0.4 mm for top ring 0.2 mm
Must be extremely compatible with the bore / surface of the cylinder
for lower rings)
Must have sufficient strength to withstand high shock loads owing to firing impulse
2) Insufficient lubrication
Must be of free shape to conform cylinder bore at operating temperature of minimal high
3) Insufficient Ring gap (butt clearance 0.5 % of cylinder bore, for moderate rating and 1.0 % pointing around its periphery.
for higher rating. Over 500 mm bore)
4) Large amounts of wear in cylinder liners
Piston Ring Clearances
5) Excessive wear on piston ring leading face in the piston ring groove
Butt / Gap clearance
6) Excessive diametrical clearance between the piston and cylinder
Butt clearance 0.4 ~ 0.5 % of cylinder bore and it is measured by placing ring squarely in ring
7) Excessive relieving at ring edge (Oil wedge action cannot be attained) gauge
8) Excessive lubrication (Excessive ring zone deposits and fouling of grooves and micro Should be as small as possible (as per maker’s instruction) but should never close completely
seizure may occur) If the ring gap is inadequate the ring may break due to a restriction on its free expansion when
9) Ring sticking in ring grooves coming up to working temperature. Whether a ring breaks or not, it may scuff the liner due to
10) Improper ring material heavy wall pressures causing the oil film to break down or at least causing large increase in
11) Improper fitting liner wear
12) Misalignment of piston Axial clearance
13) After burning It is essential for free movement during operation
Insufficient vertical clearance will stick or break in the groove when they come up to working
temperature
Causes of piston ring sticking
To be kept minimum to avoid ring hammering / ring groove wear
1) Continued overload running Back clearance
2) Defective oil filtration Must be as small as possible
3) Excess sulphur & ash content in fuel Large clearance is conducive to oil pumping
4) Faulty fuel combustion
5) High rate of cylinder lubrication Ring Joint Ends may be:
But (Vertical Cut) – Gives a robust joint for top rings
Scarped (Diagonal / Angle Cut) – Better gas seal but less robust
How will you check piston ring breakage?
Lap / Bayonet Joint – Good gas seal, vulnerable to breakage & used in lower rings
1) By listening by stethoscope (running)

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 165 166 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Piston Rings Inspection Wear Ring

Material Bronze Alloy
In good condition Sticking Wear rings are fitted into circumferential –machined grooves
Running surfaces will be bright Thick and hard deposits of carbon They are usually fitted in two pieces with good clearance at the butts to allow for thermal
Move freely on grooves Cannot move freely in grooves expansion.
Not unduly worn, and it should be well oiled Due to lack of sealing i.e. gas blow by They provide rubbing surface with low frictional characteristics and they prevent the hot upper
Edges will be sharp without burns side wall of the piston making contact with the working surface of the liner.
Breakage / collapse Working clearance is maintained by wear ring.
Micro-seizure / Scuff Blackish appearance In trunk piston engines the use of wear rings allows the detrimental effects of trunk distortion,
Scuffed and hardened Lack of ‘Elastic tension’ caused by the interference fit of gudgeon pins in the piston trunk. They are fitted above and
Good ‘mirror surface’ deteriorated below the gudgeon pin location.
Appearance of vertical strips / sharp burrs if Piston ring blow-by
extensive seizure occurs Black dry areas on rings Top Piston Ring Position and Working Condition
Black dry zones on upper part of liner wall Piston rings give the best result when their working temperature is the lowest practicable.
Piston rings scratched So, it is necessary for the top piston ring, which has the severest duty to perform, should be
Due to hard abrasive particles or catalytic fins Deposits on Piston well clear of the hottest part of the piston.
Enters cylinder via fuel On the side of piston crown This is then imposes a limit to the minimum distance from the top of the piston to the upper
Can have serious consequences On the ring lands most grooves.
Lack of gas sealing is cause blow by The space formed between the side of the piston crown and the cylinder liner above the top
Lubrication condition piston rings is an area where carbon and ash from lubricating oil may encrust and build up
Working temperature should be as low as possible but too low temperature form carbon and
Reasons for Rings Replacement ash deposits.
If piston rings wear rate is such that it will be unsafe up to the next maintenance schedule. If carbon and ash flake away cause rapid abrasive wear on landing face of piston rings as well
If a piston rings is found stuck in the ring groove and if it wears more on one side than another. as liner.
If the axial height of the rings is reduced so that a large clearance is found Chromium plated piston rings is fitted only in the top piston ring groove.
If performed piston rings having pressure variations around their circumference are fitted in any
groove and micrometer measurements show variation in the radial thickness of the ring Which material is harder between Piston ring and Liner ? Why ?
If the chrome layer on chromium plated piston ring is worn through or worn very thin. Piston rings material are made harder than the material of cylinder liner in which they work
This has the advantage of giving the piston ring a long working life by reducing the redial wear
Reasons for piston Rings failure rate.
Insufficient piston rings and grooves clearances, which cause the ring to jam in the groove at
working. How can the life of a Piston ring and Cylinder liner be increased ?
Insufficient cylinder lubrication. Piston ring life can be increased with an increase in cylinder liner life, by fitting the top piston
Large amount of wear in cylinder liner. ring groove with chromium plated piston ring. This increases the hardness of the surface that makes
Excessive diametrical clearance between the piston and cylinder liner contact with the working surface of the cylinder. Thus improve anti-friction conditions and
Excessive wears on piston rings landing face in the piston ring groove consequently increasing piston ring and liner life.
Ring gap too small. This usually leads to ring breakage, but could ultimately lead to disastrous
consequences. Scuffing
Incorrect preparation of ends of piston ring adjacent to gap. Defined as a form of damage occurring between two sliding surfaces, when there is a
Radius at top and bottom of exhaust and scavenge ports in cylinder liner inadequate, the ring breakdown of lubricating oil film separating the surfaces.
then receiving a shock when sliding past the port edges. When scuffing occurs, the breakdown of lubrication in way of the high points or surface
Wear on the port bars relative to cylinder liner working surface is such that surface of the bar is asperity is caused by very high-localized pressure on the high points. The heat generated by the
below the surface of the liner. friction between the high points on the cylinder liner and the piston rings causes the high points to
weld together.
Piston Ring Treatment The movement of the piston and piston rings causes the weld to break away as soon as it is
Chromium Plating created and a roughened surface then results.
On the running surfaces of compression rings and the sharp edges of scraper rings.
Indicating of Scuffing
Used in 4 stroke engines but not used in chromium plated liner. Appearance of
Plasma Coating: Spraying method at Plasma State (4th state of matter) Slight roughening of the surfaces with light score marks
Gas mixture N2 & H2 or Argon gas at temperature 10,000 – 15,000°C most materials Brownish to very dark brownish – Gray colour
& mixture melt Increased hardness value of piston ring rubbing surface by hardness test
Molybdenum High resistance against scuffing but poor heat resistance, Copper
Suitable for running in. Factors Causing Scuffing
Compound of Cr, Ni, Mo & Cr Carbide high resistance to corrosion, wear, abrasion and Scuffing may occur at any time, but it is more likely when cylinder liners, piston rings etc are new.
scuffing Any factor, which cause or allows the lubricating oil film between the working surfaces to become
Copper Plating disturbed, is likely a cause of scuffing. Some of the common factors are as follows:
Ferox Coating & Phosphating Materials for liner & piston rings are not compatible.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 167 168 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Surface finish of liner is too smooth, and thus has inadequate oil retention properties. [The 5) Two stroke engine : No load reversal, which does not help the oil flow into the loaded
surface of the liner must be smooth, but the honing marks at 45° to its axis should be deep part of the bearing.
enough to retain some lubricant and allows it to spread.]
Unsuitable cylinder lubricant i.e. viscosity too high or too low. (Too high viscosity with too low Different approaches adopted to overcome crosshead bearing problems
cooling water temperature or too low viscosity with too high cooling water temperature)
Defective cylinder lubricator or defective lub oil pipe to cylinder from lubricator 1) Conjugate deflection : Bearing deflection follows that of crosshead pin. Natural deflections of
Improper cylinder cooling water temperature pin and bearing remain inline, resulting in lower specific load
Defective piston rings or high localized wall pressure on liner during running in period 2) Crosshead mounted LO pump : Attached high-pressure pump, operated by connecting rod
Improper scavenge air temperature or malfunction of scavenge air water separator
movement, press oil into bearing gap when bearing load is lowest
Poor combustion or may be engine over loading.
3) Large diameter stiff crosshead pin : Reduced Length / Diameter ratio, but pin deflection is
minimum for uniform distribution of oil films over the whole bearing width
Piston Rod Gland 4) Continuous full length bearing face under pin : Low specific load on bearing. Load is
Piston rod gland consists of transmitted directly downwards
Upper gland group Lower gland group
5) Large diameter pin and smaller Connecting rod : Crank throw ratio: Obtained higher
Scraper ring Oil scraper ring
Seal ring Scraper ring sliding velocity of the bearing, with better LO oil film, to carry high loads.
Guide ring Coiled garter spring 6) Hardened crosshead pin with high degree of surface finish : Surface finish is preferably
Coil garter spring better than 0.1 µm
Upper section rings act as scavenge air sealing and scrape of dirty oil from piston rod on its
downward stroke 7) Eccentric bored bearing : One of the finest designs for crosshead, which gives the same
Lower section rings act as oil control rings and scrape of excess crankcase oil from piston rod effect of load reversal (GMT engines)
during upper stroke. 8) Thin shell bearing : Bearing is renewable and pin is detachable. Produces high load carrying
capacity, and better resistance against fatigue failure. Thin shall gives true circular shape,
which improves lubrication characteristics.

Function Crosshead.
The crosshead bearing is a particularly highly stressed element and the lube oil film in it is extremely
To minimize the force imposed upon the cylinder liner by the piston thin, because of oscillation motion only and because of no load reversal for the entry of the lube oil.
To provide long stroke of piston & get more engine output These problems are solved by following methods
Causing the piston move centrally in liner 1) Pumps mounted on crosshead.
2) Increasing the lube oil pressure.
3) Use of conjugate bearing.
4) Use of large diameter stiff short pin.
Crosshead problem
Load -High specific load & uneven load acting downward on lower bearing half.
L.O problems -
a). No chance for LO entering due to unidirectional load
b). Boundary lubrication due to oscillation movement (no relative movement)

Crosshead bearing is prone to failure, because of

1) High sudden load : Full effect of combustion, directly to the bearing
2) High bearing pressure : Bearing is placed high and the whole assembly reciprocates full Function
length of stroke. So, limited bearing area results in high specific To prevent the piston rod taking up oil from the crankcase and to counter act the leaking out
load of scavenge air.
3) Distortion : Bending moment and deflection are maximum at centre, where pin
is often bored to carry piston rod. Where fitted : At the bottom of the scavenge air boxes.
4) Poor lubrication : Due to following factures:
a). Slow oscillating movement where connecting rod swings through 25 ~ 30°, hence it is How to check it during engine running ?
difficult to build up full fluid film By watching the outlet from test cock on manoeuvring platform.
b). Reciprocating movement where oil supply is disturbed by vertical movement of pin and Leakage of air indicates that sealing rings are defected
bearing. Excessive oil outlet means that the scraper ring need overhaul

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 169 170 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Check point when overhaul The radial clearance of the journal bearing can be measured by taking lead
o Check clearance of rings (vertical, gap) reading or roughly by means of a feeler gauge after removing oil seal on the end
o Check spiral spring tension cover.
o All drain holes cleaned Axial clearance = 1 to 2 mm
o Check the fitting bolt. Renew locking washer, Renew ‘O’ ring. Radial clearance = 0.5 to 0.8 mm for 440 mm diameter

Advantages of Tilting Pad Bearing

Have ability to absorb, change in direction of load, more readily
Have greater flexibility to absorb shaft deflection or misalignment
Tilting of pads, allow oil to form wedge shaped film, between faces of collar and pads.
Wedge shaped oil film prevents metallic friction and enables the thrust pads to carry loads.
Where
Between flywheel & engine end rest on tank top & is connected solidly with the engine
Disadvantages
bedplate.
Each pad in a set must be exactly the same thickness and even a ‘thou’ difference might
result in a single pad carrying the entire load, thus increasing the risks of failure.
Purpose
To prevent axial movement of the crankshaft which would result from the thrusting effort of the
screw propeller.
It is designed that the total thrust is conveyed to the hull of the ship by the lower half casting.

What consist in ?
Thrust shaft
Collar
Bearing pad (forward & aft)
Pad carriers
Adjusting liner (or) distance piece

Why pivot line on pads provided ?

For to tilt & to form wedge shaped film between the faces of collar and the pad.

How will you check clearance ?

1) Remove top covered
2) Insert a feeler gauge between face of collar and the pad (both ahead & astern) take the
reading
3) Force the shaft aft by means of a screw jack placed between casing and the back of the
coupling until the collar is hard up on the pads.
4) Check position of the shaft is truly central in the journal bearings.
5) Test also that both liners are bearing equally on the casing.
6) Take a micrometer (a dial gauge) reading of the shaft position.
7) Repeat this operation, moving the shaft forward, and take a second micrometer reading.
8) The difference in the two readings is the total clearance. (about 1 mm being typical)
9) If clearance is excessive or less, it can be adjusted by subtracting or adding shims to the
distance pieces on the back of the pad carriers.
Feelers can be used as an alternative between thrust ring and casing. Use of
feelers in the thrust pad/collar gap is likely to cause damage and may give a false
reading.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 171 172 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

High Penetration
1) Fuel particles travel further into the combustion chamber and some may rest on the cylinder
liner and piston crown
FUNCTIONS 2) Lower rate of combustion and after burning
Fuel valve is one of the vital parts of the Diesel Engine due to their high precision
in manufacturing and the intricate duties it has to perform, to atomiser, penetrate and distribute as
swirling action achieved.

Atomisation
Atomisation is the splitting up of the fuel into very small droplets by the fuel injector, forcing
fuel at high pressure through small atomiser holes.
The droplet size will depend upon the size of holes and the pressure difference between fuel
pump discharge and that of the compressed air in the combustion chamber, and consequently the
size of droplets may vary.
Atomised droplets have a high surface area to mass ratio, giving good heat transfer and
causing efficient combustion with minimum of unburnt fuel.

Atomization – to ensure that each minute particle of fuel is surrounded by particle of oxygen with
which it can combine.

Atomization. Is the break up of the fuel charge into very small particles it is injected into the cylinder.

Penetration refers to the distance that the fuel particles travel or penetrate into the combustion
chamber.

Why fuel is required to atomise ?

To get complete (fully) combustion of charge fuel within a short time.
To ensure that each minute particle of fuel is surrounded by particle of oxygen

Turbulence
Excessive Atomisation
It is the movement of compressed air and fuel within the combustion space before
1) Smaller oil particles have insufficient KE, to go through combustion chamber
combustion occurs. This may have several causes. Swirl is imparted to the air during its entry at
2) Dense compressed air has high resistance to the motion of oil particles
scavenge ports. It may be further agitated by the furl spray pattern and the shape and movement of
3) Smaller particles tend to cluster around injector tip, and oxygen-starved during combustion
the piston crown.
4) Can cause after-burning
Turbulence will improve the mixing of fuel and air for effective and rapid combustion. It is
particularly desirable for rapid combustion of heavy fuels in medium or higher speed engines.
Insufficient Atomisation
1) Oil particles become larger and will have more KE and travel further into combustion
chamber, and some may rest on cylinder liner and piston crown. Propose of cooling to nozzle tip
2) Carbon built-up around the top of cylinder and piston crown To prevent carbon trumpet (or) formation & needle valve seizure
3) Lower rate of combustion and after burning To maintain the tip region temperature within acceptable limit
To avoid the malfunction of operation mechanism
Penetration
It refers to the distance the oil droplets travel into the combustion space before mixing with How to check the fuel valve is OK or Not ?
the air and igniting.
Set pressure (on pressure gauge)
This will depend upon droplet size (atomisation), velocity leaving the injector and the
Atomization (visual check & listening jarring noise)
conditions within the combustion chamber. It is desirable that fuel should penetrate into the whole of
the combustion space for efficient space utilisation and good mixing, but droplets should not impinge Spray pattern (by maker supply spray pattern plate, holes on it must not touch the oil or paper
on the internal surfaces before burning. The number of atomiser holes and their position will decide method @ right angle to valve)
the spray pattern. Dribble (sensing hand feel after correct pressure test)

Low Penetration Effect of trumpet formation ?

1) Less intimate mixing of air and fuel particles in combustion chamber 1) Interfere the spray pattern
2) Fuel cluster around injector tip causing after burning
2) Increase fuel consumption

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 173 174 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

3) Poor combustion resulting in black smoke In other words, weeping and dribbling has been prevented by cutting the needle angle about
4) High exhaust temperature 2 ° larger than the seat angle of about 60 °. This arrangement ensures sharp opening and closing of
the fuel valve.
Fuel valve overhaul ?
1) Test & check the old valve Worn nozzle hole
2) Slacken the lock nut & adjusting screw to release spring pressure It is due to erosion of fuel oil which contains abrasive particles. That is due to insufficient
3) Make upside down & remove retaining cap nut, take out nozzle & dowel pin fitting filtration and purification or the fuel valve does not close snappily after injection.
4) Make upright, remove lock nut, adjusting screw, spring, spindle and spring retainer It affects the spray pattern and atomization. It cause burning away of piston crown due to
5) Clean all parts with kerosene especially on nozzle holes check all parts thoroughly & renew if the fuel impingement and secondary burning and seriously effects engine performance.
necessary
Check point: How to decide nozzle is suitable for further used ?
Nozzle hole diameter with pin gauge (Maker supply)
By titling the nozzle body & needle valve assemble 30 ° from horizontal position.
Needle valve surface
If the needle valve falls from the nozzle body at only a slightly tilting angle the whole sprayer
Valve lift
must be renewed.
Spindle for straightness
Spring tension
Nozzle leakage
Lock nut & pressure adjusting screw wear & tear
It is due to defective needle valve of partial opening of needle valve. It is due to defective
Body especially oil passage
delivery valve of fuel pump that causes dribbling of needle valve.
It may causes secondary burning, reduced combustion efficiency and high exhaust
6) Reassemble correct sequence and set the pressure on test pump and check the following
temperature. It may cause trumpet formation of carbon on the nozzle tip.
a. Set pressure (some holding pressure)
b. Atomisation
How to detect leaking fuel valve ?
c. Spray pattern
Loss in power in affected cylinder (Power card)
d. Dribble
Smoke at exhaust
Exhaust high temperature
What point do you check when overhaul fuel valve ?
There may be a knock or pressure wave in the injection system
Needle valve lift
Draw card show fluctuations of pressure during expansion process due to secondary burning
Seat clearance (tilted 30 ° from horizontal position needle must not fall down) of fuel leaking, higher expansion line.
Nozzle atomisation hole
Spindle & spring Affect of leaking fuel valve
Fuel line & Cooling Water line to be clear, dowel pin fitting)
Increase fuel consumption
Contact surface of nozzle and body
Engine over loading
Knocking
Excessive needle valve lift High exhaust temperature
1) Spring failure Lifting of cylinder relief valve.
2) Impact damage between needle shoulder and thrust face & impact damage at the seat
3) Combustion gas may blow back into nozzle due to prolonging opening period FULE VALVE TESTING
To pressure-test a fuel valve:
Too low/small needle valve lift The valve is connected to a test pump with pressure gauge.
1) Restrict the flow The passages are primed by pumping oil freely and all air forced through the valve air vent
2) May overload the pump when the spring tension is low.
The correct lifting pressure is stated on the adjustment sheet for the engine.
Anti-dribbling arrangement The adjusting screw for the spring is now set so that the spindle lifts at this pressure: the screw
The angles of the needle valve and its seat are cut difference about 1 ° or 2 ° to achieve is then locked in position and the lift pressure rechecked. If everything is in order, the needle
point contact thus preventing dribbling and sharp closing. valve will open suddenly when the correct pressure is reached.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 175 176 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Next, the nozzle is wiped thoroughly clean and pressure reapplied, this time to 10 kgf/cm2 How to know fuel valve spring is broken ?
below the injection working pressure. If the pressure remains steady for a few minutes, the Over fuelling
valve is tight. A trace of oil at the nozzle holes is of no importance, as the valve will normally be Engine knocking
worked-in completely after a few minutes of running. However, should the nozzle become wet Black smoke from funnel
or should drops appear, then replacement or regrinding of the valve is necessary. Exhaust temperature high.
Condition of the spray holes can be checked by placing a piece of cardboard just below the Tip
(not held by hand) and depressing the tester handle briskly once. Chocked nozzle cooling space
The pattern (for a symmetrical nozzle) should be symmetrical.
It is due to insufficient pressure of cooling liquid (if in separate system). It is due to choked
Observe whether the nozzle 'chatters' whilst the fuel is discharged.
cooling line due to internal corrosion that is resulted from failure of anti-corrosive liquid to be added
Injectors should be tested when removed, as a diagnostic check on their condition, and after
into cooling water system.
recondition. It may be due to incorrect alignment of nozzle holder and nozzle. The choked nozzle cooling
Opening pressures set too high can result in spring failure. If the opening carbonization of nozzle tips and clogging of nozzle holes.
pressure is adjusted low, combustion gas can blow back into the injector and build * scale formation, sticking of nozzle needle*
up lacquer and carbonaceous deposits.

Atomization test
Test handle is to be pushed hard two or three times.
To see fuel spray pattern is uniformly
Not dripping
Listing jarring noise.

Pressure drop test (Set pressure test)

300 kg/cm2 200 kg/cm2 (30 to 90 sec)

Dribbling test
Maintain oil pressure of 10 kg/cm2 below opening pressure
Check nozzle tip

Spray pattern test

Original test bench has hole plate (same number with nozzle hole) when the spray can enter into the
hole without touching the plate.
Paper method fuel valve and paper right angle position.

Incorrect spring pressure setting

It is due to
1) Broken spring
2) Loose pressure adjusting nut and loose lock nut
3) Incorrect initial pressure setting
4) Sticking of spring
5) Worn out spring
It may cause
Early injection (low pressure setting)
Late injection (high pressure setting)
Early injection may causes knocking the engine unit. Shock heavy load on bearings.
Late injection may causes high exhaust temperature with reduced engine output and fouling
of exhaust system.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 177 178 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Insufficient cooling
Incorrect hardening down of exhaust valve on cylinder head leading to valve seat distortion
Incorrect valve seat material
RESULTS
Disturbance to Voyage
Burning of exhaust valve and seat by high velocity hot gas
Function Surging of turbocharger
It is used for expelling the burnt gases from the engine cylinder it seals gases on Fouling of exhaust system
compression and combustion periods. Uptake fire

PREVENTION
Why need to rotate the exhaust valve ? Avoid excessive power and combustion efficiency
To distribute evenly wear on valve & seat Regular and proper Overhaul
To loosen the seat deposited Regular check of Tappet clearance
Proper hard facing material for valve and valve seat so as to avoid hot corrosion leading to
To extend the valve operation life leaking exhaust valve
To reduce wear of valve seat Proper Bore cooling arrangement
Proper Valve rotation during service
Why exhaust valve burn ? Correct valve and seat angle
1) Incorrect valve closing (or) incorrect tappet clearance Proper Design (Inner contact or any late coming practice)
2) Insufficient cooling
3) Incorrect fuel valve spray angle Excessive tappet: Late open, close early
4) Overload running
5) Poor combustion Cause Noise; reduce maximum lift of the valve, damage from impact on working surface
6) Vanadium attack due to use of bad fuel
7) Valve spindle not rotate Insufficient tappet: open early, close lately
8) Unsuitable material
Cause Increase maximum lift prevent valve closing completely, hot gases to blow pass valve
Cause of Exhaust valve burning faces & burn the valve
Continuous overloading of engine or particular unit
Poor combustion (or after burning) of fuel due to dirty fuel injectors, incorrect fuel injection
Purpose of tappet
pressure, incorrect fuel temperature , late fuel injection timing , air starvation, water or
impurities in fuel. To allow for thermal expansion of valve spindle
Valve not closing properly due to incorrect tappet clearance or starvation of closing air. To ensure that positive closing of the valve.
Insufficient cooling water supply may cause the valve to overheat
Hot corrosion due to bad quality fuel, which contains high vanadium, sodium etc.
Why two spring fitted ?
Unsuitable material used.
To prevent falling exhaust valve if one spring damage
To prevent bouncing effect when it close
Indication of Exhaust leaking
Indicates high exhaust temperature in that unit
Indicates low compression pressure and low peak pressure in the indicator diagram
To long the exhaust valve life
Low compression pressure and low peak pressure can be a cause of shortage of air supply,
but in that case scavenge air or supercharging air pressure will increase abnormally. Rotator or vane fitted
Sufficient cooling provided
Indication of exhaust valve leaking ? Satellite coating at valve seat
SYMPTOMS
High exhaust temperature
EXHAUST VALVE KNOCKING (For two stroke)
Noise
Exhaust valve knocking is caused by insufficient cushioning in the hydraulic system.
Smoky operation
This is due to three different reasons. Basically,
Low Pmax
01. Deficiencies in the oil supply
Low Pcomp
02. Errors in the air spring
Abnormal light spring diagram showing pressure dropping down
03. Excessive leak in the high pressure oil system

CAUSES
Cylinder power in excess of design rating 01. Deficiencies in the oil supply can, for instance, be:
Poor combustion of fuel (after burning) 1a). Air in the oil (foaming), most possibly caused by air being drawn-in at the pump via suction
Valve not closing properly due to incorrect tappet clearance
side

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 179 180 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

1b). Too low supply pressure Crack at the flame face

1c). Too high oil temperature, giving low viscosity
02. Errors in the air spring system can be:
2a) Incorrect supply air pressure (too high)
2b) Defective safety drain valve

Supply air pressure Safety Valve opening pressure

5.5 bar 17.5 bar
7.0 bar 21.0 bar

03. Excessive abnormal leakage in the high-pressure oil system can, for instance, be:
3a) A maladjusted or defective throttle screw
3b) The oil cylinder piston rings, on either cams or exhaust valve sides
3c) The oil cylinder safety valve, on the cam side
3d) The punctured or leaked non-return valve
3e) High-pressure pipe joints
3f) The venting valve at the top of the exhaust valve
Exhaust Valve Problem
Exhaust Valve Burning due to high temperature : Use bore cooling
Exhaust Valve Material : Use valve rotational mechanism
Valve seat satellite material : Use Nimonic material
Valve Lid Nitride/Nimonic Seat trumping and wear
Valve bouncing : Use air spring &hydraulic actuator
Valve Spindle Nimonic material
: Or increase number of spring with improved material
Valve Cage Pearlitic cast iron Hot corrosion and erosion at the valve seat & its underside
Valve guide Pearlitic cast iron Possibility of scaling due to poor water treatment
Valve Bush Bronze Thermal stress due to heating and cooling
Cracks at the seat and centre of the flame face
Material Properties Braking at the valve neck
High tensile strength & creep resistance properties
Resistance at high temperature properties Cause of high exhaust gas temperature read at engine operational faults
Resistance to high temperature corrosion.
Explain exhaust valve burning process.
Exhaust Valve Improved Design A small leakage results in local overheating of the leakage area, which builds up relatively
slowly. The increased temperature, combined with the flow through the leakage, gives a higher
Bore cooling for efficient cooling system (as low as 327 °C at full load)
corrosion/ erosion rate, gradually expanding the leakage and starting the vicious circle1 that the
Valve rotational mechanism
valve spindle being sometimes burned beyond repair.
Heat and corrosion resistant material used
Hydraulic push rod with controlled valve landing speed
Air spring (or increase number of spring with improved material ) to reduce valve bouncing When engine is smoking, detect one unit fault or all units ?
Guide bush is sealed by pressurized air Particular unit smoke may be detected by shutting fuel off from each cylinder by open each
For less obstruction of gases, use valve seat angle 30 ° instead of 45 °.
unit indicator cock and allow to blow on wet rag a deposit will show, it cause to smoke. (smoking unit
Exhaust valve Stress or all unit fault)
Thermal stress 3 times greater than mechanical stress
Thermal stress in radial direction greater than axial direction What point to be check when engine is smoking ?
Largest mechanical stress at the flame face centre (A)
Check Fuel pump
Highest thermal hoop stress (B)
Largest mechanical stress in the radial direction along the blend radius circumferentially (C) Charge air temperature and pressure (check by light spring)
Maximum combined stress at the valve neck points. (C& D) T/C suction air filter
Fuel Valve
Stress Failure Draw card to be taken
Circumferential and radial cracks around head radius
Breaking at the neck
Radial crack at the seat
Dishing in the head 1
A situation in which one problem cause another problem which then makes the first problem worse.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 181 182 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

How to do rotocap overhaul of cages exhaust valve ? How to check Foundation Chock ?
01) Take out rotocap from valve spindle after removing cotters. 1. Check according to running hour
02) Remove circlips of rotocap 2. Regular retightening done or not
03) Remove spring cover, Belleville washer (spring plate) springs and balls 3. Check for crack, fretting, piece or rust, scale etc
04) Clean all parts in diesel oil 4. Check for slackness by hammer testing.
05) Check Belleville washer and balls for no wear
06) Check springs tension Fitting of chocks.
07) Place balls and spring into the rotocap body, by means of fitting direction mark Record crank shaft deflection.
08) Then place Belleville washer and spring cover
For metal chocks.
09) Then fit circlips, check rotate or not Machined slightly over size and then hand filed and scraped to fit. Surface contact 70%.
10) Fit the rotocap to valve spindle with cotters. Record crank shaft deflection.

For Epoxy Resin chocks.

Cleaned surfaces.
Apply thin film of zinc to machine base and foundation for corrosion resistant.
Prepare dam in chock area. Greased up holding down bolts, inserted and hand torqued prior to
pouring.
Chocking area is maintained at not less than 16°C by hot air blowers.
Function.
1) Any variation in the surface of the tank top does not cause misalignment. Resin is mixed and poured into position. Care that heating does not cause local hot spot.
2) Individual adjustment of chocks can be carried out. When chock fast hardens, bring chock and adjacent plate to 16(C or higher for 48 hours.
3) Any distortion can be corrected. Ensure chocks are below 38(C before tightening bolts.
4) End chocks absorbs collision loads. In case of integral thrust block, it absorbs propeller thrust
and propeller excited vibration. Bed plates
5) Side chocks absorb side loads due to components of unbalanced reciprocating forces. It helps
holding down bolts to resist the lateral forces when the vessel is rolling.
Forces
Materials 1. Forces of gas pressure in the cylinder.
Metal chocks Cast iron 2. Inertia forces of the moving parts.
Steel 3. Side thrust from guide faces.
Epoxy Resin chocks.
4. Weight of all engine parts located above bed plate.
5. Torque reaction from propeller.
Purpose 6. Hull deflection.
01) To avoid misalignment on tank top surface 7. Vibration forces due to torque fluctuations, shock load.
02) To carry out adjustments on individual chock 8. Thermal stresses.
03) To correct any distortion 9. Forces due to ship movement in heavy sea.
04) To absorb collision load by end chocks
05) To absorb side load, due to unbalanced reciprocating forces, by side chocks Material
1. Prefabricated steel.
Advantages Of Chockfast System [Eposy Chock] 2. Cast iron.
01) Reliable and permanent alignment without machining foundation, bedplates or chocks.
3. Hybrid arrangement of cast steel and prefabricated steel. (Fabricated mild steel for
longitudinal girders and cast steel for transverse girders.)
02) Provides uniform precise mounting for superior retention of critical alignment.
03) Resists degradation by fuels, lubricants, eliminates corrosion in chock area.
Machined surfaces
04) Non-fretting condition permanently.
1. Top of frame attachment.
05) Reduces noise levels, maintaining alignment and hold down bolt tension.
2. Side for side chocks and entablature cover plates.
06) The modulus of resin helps to maintain crankshaft deflection and machinery alignment during
3. End for thrust block housing, turning gear and end chocks.
hull distortion. 4. Bottom for chocks, tie bolts, oil sump pan.
07) Can be used on all sizes and types of engines
08) Installation time is measured in hours, not in days Faults in bed plate.
09) Withstands the temperature up to 80°C 1. Crack.
10) Gives chock thickness of up to 40 mm. 2. Oil leaks.
3. Loose chocks.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 183 184 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

4. Loose frames.
What DEFECT on cylinder cover ? Preblem
Cracks usually occurs at following spaces. Burning: a due to flame impingement.
1. Fabricated transverse girders often show cracks in welds around the bearing pockets. Cracking: a hairline crack between fuel valve and exhaust valve apertures. They are cause
2. At the junction welds between fabricated cross girder and side girders. by over heating and casting strain.
3. Radially tie bolt and frame bolt holes. Distortion: a Due to improper uneven tightening down of holding down studs, overheating,
4. Around lightening holes. unrelieved casting strain the cylinder head can be distorted.
5. At the base of main bearing keeps. Corrosion and deposit: a cooling water is not suitably treated or maintained. (excessive
scaling)
Cause of bed plate failure.
1. Excessive vibration.
2. Slack tie bolts. Check point when overhaul
3. Overloading because of excessive bearing wear. 1) Taken to make a thorough examination to the underside of the cylinder head. (Crack,
4. Poor welding. burning )
5. Not properly stress relieved. 2) Check Cooling space of fouling due to corrosion, scaling and sludges and cleaned inside
6. Stress risers on welds. 3) Check gasket landing surface
4) Check cooling water ‘O’ ring & replace
Repairs 5) Check abnormal distortion
Mild steel and cast steel - Crack should be chipped out and welded. Care not to distort the
6) Defects must be searched thoroughly by using Dye penetrant and hydraulic test about 7 bar.
part. Use ductile electrodes which give deposit close to base metal.
7) All the pockets and apertures must be cleaned and properly ground in.
Cast iron - Small crack - Arrested by drilling.
Serious crack - Metal locked.
How to maintain cylinder head ?
Evenly tighten down cylinder head bolts

Make regular cooling water treatment
Check & Clean cooling passage @ every overhaul
Function All the parts have to be thoroughly cleaned until exposure of bare metal.
Coolant treatment must be regularly carried out as per regular and accurate test.
Cylinder heads form the top part of the combustion space. The primary function of the
cylinder cover is to close the end of the cylinder and to seal the gases involving extreme pressures
Hot corrosion
and temperatures. The cover is exposed to high mechanical and thermal stresses.
m Vanadium Penta-oxide (V2O5) melting point 690°C and is a corrosive liquid
Material : Pearlitic or Nodular Graphite Cast Iron / Cast Iron m Complex of Sodium (Na), & Vanadium (V) salts melting point 550°C and is a corrosive liquid
m At high temperature slug deposits on the valve seat, neck, casing and on cylinder head
Properties
m When temperature reaches at this melting point, slug melts and creates hole at this place.
Must be of sufficient strength to withstand the gas load at maximum pressure
Resist bending and be symmetrical in shape m This type of burning of exhaust valve and cylinder head is called hot corrosion.
Have a rate of thermal expansion compatible with adjacent parts and transfer heat readily.

Design Feature
m The cylinder head /cover forms the top part of the combustion space
m The head is of intricate design
m The cover lands on the top of the cylinder liner flange and is secured to the cylinder block by a
number of cover studs and nuts. These are tightened hydraulically to maintain a gas tight seal
Function
under fluctuating pressure and temperature conditions.
m The cover must also locate and support all the valves required to operate the engine together To protect the cylinder against excessive pressure. The blow-off pressure should be
with their securing. adjusted 20 to 30% above the normal working load.
m Large two stroke engine covers are machined from solid steel forging drilled to give bore cooling.
m They are circulated with fresh water from the jacket cooling system which maintains moderate
temperatures and allows intensive cooling of exhaust valve seating while making separated fuel Causes of Relief valve Opening while Starting
valve cooling unnecessary.
m Four stroke engine covers are usually formed from a casting, which may be of pearlitic or
1) Manoeuvring handle being moved too far causing fuel injection excessive.
nodular graphite cast iron, or in some cases cast iron.
2) Incorrect fuels pump timing causing over-fuelling.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 185 186 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

3) Incorrect adjustment of fuel valve opening pressure (low). Cannot repair in section
4) Incorrect governor setting causing over-fuelling. Cost expensive
5) Fuel oils remain on top of the piston owing to:
Used in small high speed engine
A. Improper priming operation
B. Fuel valve renewal period
(02) Fully Built QAll components of the crankshaft (pin, webs and journal) are made
C. Fuel oil injected in previous fail-start operation still remaining on piston top.
separately and then assembled into a complete crankshaft by means of
shrink fit.
Causes of lifting in service
Incorrect fuel pump timing, Properties Easy to manufacture
Air start valve stuck open or wrongly timed.
Can be repaired in section
Incorrect camshaft timing, chain breakage or Governor Fault especially in heavy seas.
Used for large marine engine
Action if relief valve leaking
(03) Semi Built Q Crank throws and journals are made separately and then assembled into
Inform bridge & reduced engine speed a complete crankshaft by means of shin fit only at the journal.
Cut out fuel to concerned cylinder
Rotate the spindle on its seat until leakage stops Properties Lighter than fully built, so web size become less
If it remained out of action
Can be repaired in section
The engine stopped at 1st movement opportunity for replacing it with spare valve.
Continuous grain flow between pin & webs (popular design)

Why immediate action need ? **** Used slow speed engine

If leakage occur (04) Welded Q A number of parts (A crankpin and two webs, with a half length of journal
Hot & abrasive gases come out, the valve & seat may be burnt on each web) are forged or cast separately and then welded together to
Minor leak may proceed to major leak and fire risk may occur form a complete shaft.

Why M/E cylinder relief valve are sometimes explored during the period of maneuvering. Properties Easy to manufacture
Accumulated fuel oil due to
1. Incomplete combustion. (Remaining fuel in combustion chamber.) Can be repair in section
2. Fuel valve dribbling. Has resistant to fatigue failure
3. Incorrect timing of fuel pump.
Remaining fuel combustion ~ excess pressure than normal.
Blow off pressure should be adjusted 20% to 30% above the normal working pressure. Why welded on Mid of journal ?
There is a low load area on mid of journal, where it is welded.

In large marine engine which type is used and why ?

Usually Semi-built is used because
Only on shrink-fit between web and journal [less chance of slippage]
Can get grain flow in way of web and pin
Webs are smaller [no shrink-fit]
Can be repaired section by section when damage occurred
Function
Device for converting the reciprocating motion of the piston, driven by expansion of the gases, Why crankshaft deflection taken (or) purpose ?
to rotating motion. To detect the axis of crankshaft journal deviate from the theoretical shaft axis
Power produced by the engine is taken off the crankshaft by a transmission. Interpretation of crankshaft deflection gives an indicate of high or low bearing

Types of crankshaft WHEN TO TAKE CRANKSHAFT DEFLECTION ?

(01) Solid Forged (02) Fully Built (03) Semi Built (04) Welded (01) At initial installation and after 1000 R / H
(02) At subsequent annual intervals if normal (6000-8000hrs)
(01) Solid Forged Q The whole crankshaft is forged from a single piece steel billet. (03) At foundation chock repair or renewal
(04) At the time of major structure has been disturbed, such as:
a. Propeller bending or impounding with something
Properties More resistance to fatigue failure due to continuous grain flow
b. Ship grounding

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 187 188 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

c. Docking (before and after) (08) Ensure that flywheel and end coupling arrangement is true.
d. After fire breakout (09) Loading condition
(05) At the time of main bearing overhaul or renewal or removal for survey. (10) Sea water temperature
(06) Damage on bearing bracket, holding down bolt, chock
Crankshaft Alignment Method
CAUSES OF MISALIGNMENT b Bridge Gauge This method is satisfactory if
(01) Main bearing damaged Hull deflection is not excessive
(02) Main bearing pocket cracked Bedplate is not distorted
(03) Wear of main bearing lower shell Bearing housing is not excessively worn
(04) Wear and ovality of main journal pin b Measurement of Main bearing bottom shell
(05) Bedplate deformed – transverse girder damaged b Crankshaft Deflection Combination of
(06) Slack or broken tie bolts Bridge Gauge & Deflection reading is satisfactory.
(07) Foundation chocks _ broken, cracked, or fretted
(08) Foundation bolts loose or fracture
Where to put dial gauge, if no punch mark ?
(09) Defective propeller shaft bearing
Fitted between adjacent webs (at a point in line with the outside of the journal furthest from
(10) Weakening of structure due to corrosion
the crank pin) opposite the crank pin at the half diameter from the shaft centre
(11) Distortion of supporting ship’s structure
(12) Lifting of flywheel side
(13) Hull deformation due to: How to take crankshaft deflection ?
a. Excessive bending moment caused by carried cargo. Stop L.O pump, open crankcase doors both side, clean the oil @ entrance & on the webs
b. Grounding, and Check dial gauge error &response
c. Fire Place the gauge at the punch mark on the webs
Turned engine toward BDC with dial gauge close to connecting rod and set dial gauge zero
RESULTS OF MISALIGNMENT reading with slight pretension
(01) Bending of crankshaft Turn crankshaft ahead by turning gear, read & record values on dial gauge at both horizontal
(02) Fatigue failure owing to cyclic stresses crankpin positions and at TDC.
(03) Undue Vibrations within the engine Turn crankshaft until clock gauge is close to the connecting rod on the other side. Record
(04) Damage to main bearings value at this position.
Similarly other unit’s reading taken and recorded, for the unit near flywheel before taking
reading a little reverse turn must be made.
How to know the amount ?
All reading are tabulated & calculate for BDC reading
Difference between the values at TDC and BDC indicates the amount of crankshaft deflection,
The difference between values at BDC & TDC indicates the amount of crankshaft deflection
during one revolution
during one revolution
Interpretation of crankshaft deflections gives and indication of high and low bearings
Interpretation of crankshaft gives an indication of high and low bearing

What will happen if a bearing is high or low ? Crankshaft inspection procedure

When a bearing between two cranks is higher than those on either side of it, both sets of 1) Stop L.O pump, open crankcase door both side, engine turning gear
crank webs will tends to open out, when the cranks are on BDC, and close in when on TDC. 2) To check appearance of all parts inside the crankcase
Vice versa, if there is a low bearing between two cranks 3) To check bearing axial play & wipe out
Requirements when taking crankshaft deflection 4) To check bolt tightness
Hull deflection not excessive 5) Make chain inspection
Bed plate not distorted or bearing pockets not worn 6) To check loosening attachment
7) To check locking arrangement
What will you do/record before taking crankshaft deflection ? To check L.O system by running L.O pump
(01) Ship's draught and trim must be checked and recorded 8) To check metal chip in crankcase & on the perforated sheet
(02) Engine room and engine temperature (must be taken in warn condition.) 9) To check crankcase relief valve (flame trap, spring) After inspection, check thoroughly any
(03) The ship must always be afloat instrument & rags left in crankcase, closed the doors.
(04) Ensure that at all main journal pins are true without excess ovality.
(05) Ensure that the main journal pins are resting on the lower halves of main bearings. The
bottom clearance must be almost zero.
(06) Ensure that foundation chock and bedplate alignment is true.
(07) Ensure that all foundation bolts are not loosening and the engine is firmly bolted down.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 189 190 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Oil Lubricated Type

1) Two bushes of white metal lined, grey or nodular cast iron are pressed into stern tube.
2) Mechanical seals are provided at both ends and stern tube space is filled with oil
Water Lubricated Type 3) Oil pressure is maintained slightly above seawater pressure by means of static header tank,
This design is now superseded by oil lubricated type keeping the static head pressure, 0.30 bar higher than seawater pressure
01) SW is used for cooling and lubricating this bearing. Open aft end allows SW to flow in with
supplementary SW connection, piped into stern tube from ship’s main. Advantages
02) A soft packing gland fitted at forward end and slight leakage is allowed to ensure cooling of Less wear is experienced
packing Very less power loss at bearing
03) Tail shaft is protected by corrosion resistance bronze liner, shrunk or pressed on tail shaft, Less heat is generated
extending from propeller hub to forward of forward gland seal (continuous or single piece) Hydrodynamic lubrication can be established
04) Liner may be continuous or in two pieces No bronze liner required in way of bearing
05) Liner thickness, dictated by Classification rules, is 23 mm for 500 mm shaft No abrasives enter the bearing
Advantages Oil is superior lubricant and good vibration damper
1) Very hard and wear resistant Low clearance reduces shaft movement and vibration
2) Natural lubrication assisted by SW
3) Low swelling due to SW absorption Disadvantages
4) Predictable wear rate allows scheduling of docking in advance White metal debris may choke and restrict oil supply, speeding up failure
5) No sophisticated ford/aft seal required Contaminated oil supply, causes abrasive wear
Prolonged low sped operation may allow only boundary lubrication
Disadvantages
Poor bonding of white metal to bush may exist
1) Higher wear rate due to large clearance and sue of SW as lubricant
Bearing metal failure due to fatigue
2) Less load carrying capacity due to staved surface
Lack of oil supply, due to low level in header tank, obstructed flow, damaged pipe work.
3) Shaft needs extra liner for SW corrosion protection
4) Fatigue crack generating form corrosion pits could be the outcome, as galvanic action
Continuous length of bearing metal = 1.5 to 2.0 x shaft diameter, for aft end bearing
between shaft and sleeve (liner) is possible
= 0.6 to 1.25 x shaft diameter, for forward bearing
5) More shaft movement and vibration due to larger clearance
6) Packing grips at forward end wears out liner unevenly
Thickness of bearing bush : Varies according to Classification Society : 3.8 mm
7) Oil is better vibration damper than water
thickness for 300 mm diameter shaft and 7.4 mm thickness for 900 mm shaft.
8) Abrasives enter the bearing
Oil clearance : Depends upon Class and LR recommends 0.0015 – 0.002 of shaft
Normal clearance : 0.003 to 0.004 of shaft diameter
diameter
Maximum clearance : Varies between 6 -10 mm.
Maximum clearance : 2 times original clearance

Checking clearance (or) Wear Measurement is by inserting small wooden wedge or feeler gauge, Stern Bearing Wear Measurement
between the shaft liner and lignum vitae, once the rope guard has been removed when ship is in dry
01) Measurement at every dry dock and always should be measured at the same radial position
dock
with usually 4 reading taken at 90 ° intervals
02) ‘0’ marks are stamped on the periphery of aft chrome steel liner flange. (Ideally chisel or
Wear rate
similar marks should be left on the propeller boss. Alternatively the readings can coincide with
Cargo ship with engine amidships = 0.5 mm to 4 mm / year
the propeller blades.)
Tanker or ship with engine aft = 1 mm to 13 mm / year
03) Measurement is taken at plugged oiling hole (top Check Plug) and drain hole (bottom Check
Lignum vitae size : typical length 9” x 2” width x ¾” thick
Plug) of aft seal intermediate ring, through the seal housing. (To give max. accuracy it is
Clearance at which re-wooding required varies between 6 -10 mm.
recommended that readings be taken at top and bottom if possible, so that any eccentricity of
the shaft is taken into account)
Survey interval of tail end shaft
04) Mating marks are curved at top and bottom Check Plugs
Single liner tail shaft to be exposed for examination every 3 years
05) In measuring, bring the ‘0’ mark on chrome steel liner to fixed position at all times
Double liner tail shaft to be exposed for examination every 2 years
06) Screws down the wear down depth gauge into the hole tightly and align the mating mark
and ’0’mark

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 191 192 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

07) Measurement is recorded in record sheet Procedure to minimise leakage

1) Tip the vessel to allowable trim
Survey interval of tail end shaft : Special Survey at 4 years interval 2) Use more viscous oil
Anot he r Answ e r 3) Place a temporary header tank of about 200 litre drum with flexible hose, at lower head.
Position the drum in such a vertical height, that only a slight head pressure is exerted
1) Use Poker Gauge or Wear down Gauge or Vernier Calliper
4) Use lower header tank if provided
2) Remove rope guard
3) Take out Check plug and Drain plug Stern tube oil : Oil is a compound type with sp. Gr. 0.95 and viscosity 300 RW No. 1 at 60 °C
4) Turn the tail shaft until coincide the '0' marking on tail shaft (periphery of aft chrome steel liner
flange) and stern tube [Sometimes measurement had been taken when No. 1 Unit was at TDC,
Safety devices
and important thing is that it should b eat same radial position as last docking]
Temperature sensor and pressure gauges are usually fitted
5) Measure at top hole and drain plug (bottom) through 180° at same redial position as previous Oil pressure fluctuation with respect to ship draught, means leaking of oil seal
docking.
6) Compare with previous readings. How to check Stern tube wear down ? (Lignum Vitae)
3 Types of sealing arrangement 1) Measurement can be taken by Wedge Gauge or Feeler
2) If Wedge Gauge is used, the side of the Wedge contacting the bearing is chalked and inserted
01) Simple stuffing box
into the clearance space between top of the screw shaft and bearing
02) Lip seal type 3) Gauge is pressed move and withdrawn
03) Radial face seals 4) Clearance Is measured on the Wedge at the point where the chalk marking is scrapped of by
bearing
Lip seal type
01) Aft seal consist of three portions, 3 pieces of sealing rings, a metal housing holding the rings For Oil Lubrication Bearing
inside, and a liner which rotates along with propeller shaft 1) 2 mm clearance
02) Lip type seals of ‘viton’ or ‘nitrile’ rubber seal rings, supported by garter springs and bear on 2) When the ship is on Dry Dock, release system oil and remove plug on the end of the stern
stainless steel or bronze liner, which rotates along with propeller shaft tube, and insert Poker gauge to measure the distance from the datum to the top the shaft.
03) Typical aft seal uses 3 pieces of seal rings, outboard ring keep out dirt and SW, inner ring to 3) The difference between new reading and original measurement is bearing wear down value
retain bearing LO, while central ring provides oil space
04) Check plugs are fitted on top and bottom of aft seal intermediate ring, to check wear down of All types of Stern Bearing
stern tube. 1) Fit a Dial Gauge on the Rope Guard or Stern tube Nut so that the Gauge spindle is vertical
05) Forward seal consists of four portions, 2 pieces of rubber sealing rings, a metal housing and touching the Propeller Boss
holding the rings inside, and a liner which rotates along with propeller shaft, and a clamp ring 2) A hydraulic jack is placed on the Stern Frame Skeg at same point over a Keel Block so that
holding the liner. the Skeg is supported
3) A wood shoe is placed between the jack and the Propeller boss
06) Sealing rings can withstand both tearing and maximum oil temperature of 110 °C
4) The jack is then used to lift the Propeller until the screw Shaft contact the upper parts of its
Prevention of oil leakage outboard in port Stern Bearing
Shut down stern tube LO system 5) The lift recorded in Dial Gauge gives the bearing clearance
Close header tank valve
SW pressure become greater than head pressure Skeg : An arm extending to the rear of the Keel to support Ruder and protect Propeller.
SW comes into the system
Tail end shaft taper : ¾” to 1” per foot length
Notice : Prior to staring ME
Stern tube bearing length
Open stern tube LO system drain valve
Aft bearing 4D Forward Bearing 1 – 2D (Water-cooled)
Drain out any water present
Aft bearing 1.5 – 3D Forward 0.6 – 1.25D (Oil cooled)
Fill the stern tube space with oil completely
How will you check Stern tube Sealing in Dry dock ?
Minimising the amount of leakage at sea
LO header tank is topped-up and checked for leakage for 24 hours
Rate of leakage depends upon
Relative pressure head between header tank oil level and SW level above aft oil seal
What action to be taken when SW leaks into stern tube oil system ?
Effective area of leakage
Viscosity of oil Higher up the Stern tube oil tank level to counteract SW force

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 193 194 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Stern tube Leakage Test The steering gear Cross-head top clearance must be substantially greater then the ‘Jumping’
1) Oil to be used must not attack sealing Rings. Generally oil sued for main propulsion unit is clearance, so as to prevent any bending moment from damaging the steering gear, in the event
of running aground.
SAE 30.
The Steering gear Cross-head bottom clearance should be sufficient to cater for wear in the
2) Fill up stern tube header tank & record the level
Rudder Carrier bearing, which could otherwise affect the movement of the rams. This bottom
3) Remove screw plug. Oil pressure must amount to only 0.2 -.0.3 Kg/cm2 more than SW clearance should be substantially greater than the Riding washer clearance.
pressure Confirm that the bottom Clearance is reducing, to verify downward displacement, over a period
4) Preheated to 60 – 70 °C when viscose oil is used or low temperature prevails of time.
5) Remain in this condition for several hours (says overnight) and turn engine by Turning Gear to The Steering gear Cross-head top and bottom clearances are of the order of 20 – 25 mm for
change the shaft position 3 - 4 times small to medium size vessels.
6) Check oil leakage from Drain Plug, harder tank and if it is all right, fit back Drain Plug and fill oil Insufficient Riding washer clearance would lead to wear of the carrier bearing. There should be
no keel blocks in way of the Skeg.
from venting and filing plug and close
7) Forward seal is fitted
Stern tube seal leakage

Cause
The stern tube seal leakage can be caused by
1. Misalignment of bushes.
RUDDER CLEARANCES 2. Poor seal material and design.
The sketch below shows the principle clearance checked during Docking. 3. Liner material weakness.
4. Fishing line or similar material entering into the seal.
5. Electro static pitting due to an unsatisfactory shafting earthing device.
6. Operating at a reduced R.P.M for prolong time, at which a hydrodynamic oil film would not be
established.
7. Contaminated oil supply with grit, dirt welding slag etc:. this scores the liner and rips the rubber
seal.
8. Wear of the seals or loss of tension in greater spring.
9. Rubber seal damage at high temperature, cracking and hardening.
10. Distortion and rupture due to excessive pressure difference.

Remedy
This defect can be remedy by
1. Made sure alignment for of bushes.
2. Used superior material and an improve lip profile for seal.
3. Ceramic coating applied to the stern tube liner at lip running surface.
4. The design of rope guard should as far as practicable to prevent this happening.
5. Keep always-good condition in earthing device.
6. Avoid operating at the reduced R.P.M for prolong time.

Rate of leakage is depend on

1. It is a function of the relative pressure head between header tank oil level and sea water level.
2. Depend on the effective area of the leakage.
3. Viscosity of a oil.

To continued the voyage

(a) Loss of oil

The serious oil leakage from aft seal can be minimize and to continued the voyage by
1. Tip the vessel to certain allowable trim.
2. Use more viscous oil (e.g. cylinder oil).
3. Reduced the oil pressure head by introducing a temporary header tank, normally in the form of a
200 Lit oil drum connected to the system by a flexible hose. The drum can be arranged in such
a vertical position. That only a slight pressure head is exerted.
Rudder clearances 4. In large vessel, lower header tank can be used instead.
5. Reduced R.P.M if required to avoid boundary lubrication.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 195 196 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

(b) Ingress of sea water

Indicated by emulsification of lubricant.

1. Use higher oil header tank.
2. Slow down the shaft revolution

To repair at port
Following repair can be done in port if no dry dock facilities will available, also stern tube
seal capable of being split in a longitudinal direction having in news, enable all the sealing ring to be
renew. When the vessel is sufficient tip to raise the astern out of the water.
If due for a scheduled for dry-docking or dry dock facilities will available, arrange a dry dock
and renew the all seal.

To claim for insurance

When leakage was occur, arrive to port inform the master of the vessel negotiate with the
chatterer, arrange both classification surveyor and under writer surveyor will invite on board to
survey and to witness the damage through agent.
After surveying found that, stern tube liner was misaligning due to the last recent dry dock’s
labours error. So we have to arrange the claim for insurance.
In the mean time, contact shore repair firm and ask them to submit the quotation for repair
under the classification surveyor instruction, the method of repair as per G.L rules and requirement.
When calculating for insurance claim cost, including the repair labor charge, spare parts
cost, port stay charge, ship labor cost, cargo delay cost, etc. but not including the transportation
cost.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 197 198 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

2) Charge air temperature & pressure check (by light spring card)
3) Suction air filter is dirty or choke
4) Check fuel valve
Causes of High exhaust temperature at all unit
Factor contributing to increase exhaust temperature are What should be carried out ?
High Scavenge air temperature (Air cooler fouling, Ambient climate condition) To be taken draw card & evaluated the combustion pressure.
Fouling of air and gas passages
Fouling of T/C Engine overload indication
Wrong camshaft position (faulting timing of fuel pump & exhaust valve) [incomplete
Speed drop
combustion, after burning]
High exhaust temperature at same rpm
Wear of Fuel Cam and Exhaust Cam
More fuel consumption
Bad fuel quality
Inadequate FO purification
Causes of engine overload
Overloading (such as hull fouling, propeller blade bending)
Hull fouling (caused by marine growth)
Propeller damaged
High exhaust temperature for one cylinder
Shallow water
Faulty fuel valve & fuel pump (poor atomization, late injection, after burning, or incorrect timing
Heavy weather
of this unit)
Leaky exhaust valve
Cause of excessive noise from crankcase
Scavenge fire in this unit
1) Slack chain (or) worn gear
Blow pass Wrong adjustment and damaged cam
2) Knocking from slack bearing
Insufficient cooling water to this unit
3) Slacken or break bolts, studs
4) Engine overload
Cause of decrease exhaust temperature on one unit
5) Lubrication fault (insufficient oil pressure, poor quality, chock oil passage, failure of oil pipe)
Air in fuel valve
6) Piston ring blow pass
Faulty fuel valve (ie. Needle valve lifts too low)
Defective suction valve in fuel pump
Cause of M/E speed reduce on the way (Ship’s speed slowdown)
Fuel pump plunger sticking or leaking
Cause Improper combustion of ME
Smoky Exhaust
1) Seized or leaky fuel pump plunger
Overload Defective fuel valve
2) Sticking fuel valve spindle
Scavenge fire
3) Burst fuel delivery pipe
After burning
4) Choked fuel line filter
Unstable fuel
5) Choked air inlet filter
Insufficient air supply
6) Water in fuel oil
TC rpm not corresponding with engine rpm
7) Overloading of engine
a. Fouling of propeller
Colour of Exhaust b. Increased propeller slip due to heavy weather
Blue Excess cylinder oil, leak of oil cooled piston 8) In case of scavenge fire
White Excess water and air, one unit misfire
Black More fuel, fuel valve leak, ignition too late Remedies
Yellow High Sulphur content (Normal 1 – 1.5%) 1) Take all Indicator cards
Colourless Good 2) To consider the developed power
3) Evaluate combustion and expansion process, Pmax and Pcamp from out of phase diagram
What point do you check when engine is smoky ? 4) Check cylinder tightness
To check 5) Evaluate exhausting and scavenging process from light spring diagram
1) Fuel temp 6) Defects found should be rectified as soon as possible

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 199 200 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Why causes that engine start with air but no turn ? 01. Increase in the resistance of ship's hull
1. Air pressure low 02. Propeller damaged.
2. Faulty open of valve / stop valve/ bottle isolating valve to distributor 03. Sailing in shallow water
3. Turning engage (Turning gear inter lock) 04. Change in the centerline of the shafting increased resistance.
05. Air / gas / steam remains in the fuel injection pump or in the fuel line. In the case, open the
4. L.O pump not starting.
air vent valve, which is used for priming, and remove the air from the fuel oil lines
06. Fuel oil includes water; Wastewater should be removed form the service tank at regular
Why causes that engine not ignite but engine turn ? intervals, or to be separated by means of the purifier.
1. Governor tip (over speed trip) 07. Improper fuel quality.
2. Fuel system fault (Settling & service tank no Oil / F.O pump not start) 08. Defective fuel valves(s) or fuel pump(s)
3. Air pressure low & so compression pressure low 8a) Unsatisfactory functioning of the fuel injection valve.
4. Air in fuel pump, pipe line or Fuel valve 8b) Insufficient pressure of the fuel injection pumps suction
5. Incorrect air staring timing. 8c) Abnormality of the fuel adjusting links device.
09. Oil pressure before fuel pumps too low.
How would you investigate and find the cause of an engine cannot start ? 9a) The fuel oil strainer is clogged or damaged.
9b) Insufficient supply of fuel oil due to unsatisfactory functioning of the fuel oil flow meter
If air line is Ok or not,
10. The governor is sticking at the position of low engine speed.
1. Insufficient air pressure 11. Overheating of the moving parts .The engine should be stopped immediately
2. Air staring valve sticking 12. Unsatisfactory functioning of the exhaust valve and the dirty scavenge ports
3. System air lock 13. A fire occurs in the scavenge chamber and air is insufficient. The engine must be stopped
4. Defective distributor immediately
5. Water in fuel 14. The turbocharger of the air cooler is dirty or damaged.
6. Fuel line air lock 15. Slow down or shut down. Check pressure and temperature levels. If these are in order,
7. Defective nozzle check for faults in the slow down equipment.
8. Too late fuel timing (faulty fuel pump)
9. Poor compression Re m e die s
10. Lack of scavenge air 7) Take all Indicator cards
11. L.O low temperature 8) To consider the developed power
9) Evaluate combustion and expansion process, Pmax and Pcamp from out of phase diagram
12. Safety interlock.
10) Check cylinder tightness
11) Evaluate exhausting and scavenging process from light spring diagram
Action when engine cannot start 12) Defects found should be rectified as soon as possible
1. Inform to bridge
2. Check the air bottle Sudden Stopping of Engine:
3. Check inter lock system (Turning gear, L.O, JKT FW, F.O pressure) and telegraph position. Causes for unexpected stop of the engine are as follows:
4. If no rotation of flywheel when starting check starting air system (automatic air staring valve, 01. Drop of the system lubricating oil pressure and the turbocharger lub oil pressure actuates
air distributor, air staring valve, linkage of air staring mechanism) the emergency stop device.
5. If rotation of flywheel when starting, check fuel system. 02. The fuel oil supply to the fuel injection pump is shut of f by the causes of the stop of fuel
6. Due to poor combustion, lack of scavenge air, too late fuel pump timing, fuel line air lack circulating pump or fuel oil service tank is empty.
defective nozzle. 03. The fuel injection pump rack was pulled back suddenly to "0" position due to governor
trouble.
Special care during reduce speed 04. When continuous fuel injection failed due to damage of the fuel oil line.
05. When the exhaust valve driving parts or the exhaust gas passages were damaged and gas
01) Increase cylinder oil.
02) If necessary change H.O to DO. discharge from the cylinder was troubled
03) If necessary, run auxiliary blower. 06. Turbocharger is damaged.
04) Check temperature & pressure of L.O, F.W & scavenge air.
05) Check exhaust smoke & temperature.
Impossible of Reversing
If the camshaft does not move to the reversing position even the operation is made for
Reversing causes for such impossible of reversing are considered as follows:
Drop of Engine Speed 01. The start / stop lever is not in the stop position
Causes for the trouble that the engine speed, in some cases, drops during operation in spite 02. The main engine speed is not under the speed enabling for reversing.
of the correct position. 03. The valve on the starting air reservoir or air line is closed.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 201 202 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

04. The valves on the control system control air line are sticked. 10) Engine overload
05. The pressure of the control system control air line is too low 11) Lubrication fault (insufficient oil pressure, poor quality, chock oil passage, failure of oil pipe)
06. The starting air pressure is too low 12) Piston ring blow pass
UEC 50 LSH
07. The stopper of the safety device for camshaft shifting gear is slicked.
Rise in Exhaust Gas Temperature
08. Oil amount in the reversing oil bottles of the camshaft shifting gear is insufficient
The exhaust gas temperature rise has a great effect on the life on the exhaust valve and
09. The reversing pilot valve is not operational because of poor adjustment of the reverse handle.
also on the wear of the piston ring and cylinder liner. The causes for exhaust gas temperature rise
are considered as follow.
Abnormal Explosion on Starting
Since cause for the abnormal firing on the engine staring are considered as follows, take
All cylinders
care sufficiently at inspection before the starting, and at inspection and maintenance for the parts in
1. Increased in engine load.
question.
1a) The fouling and deformation of the ship's hull increases resistance to a fairly great extent,
01. The manoeuvring handle position is too much increased and fuel is injected excessively.
liable to increase engine load.
02. Oil is remaining on the top of the piston head from the beginning.
1b) Bending of propeller blades due to drifting woods and going ground subjects the engine to an
03. Incorrect adjustment of the fuel injection n valve namely, insufficient opening pressure.
increased load.
04. Insufficient facing up of the fuel injection valve nozzle and needle valve.
05. Incorrect setting of the fuel injection pumps rack and fuel injection timing. 2. Fouling of scavenge air passage
06. Incorrect setting of the linkage between handle and governor 2a) Fouling of airside due to oil mist on suction casing and diffuser of the turbocharger
07. Incorrect setting of the governor 2b) Clogging of cylinder liner scavenge port by combustion products.
08. Due to sticking of the fuel injection pump delivery valve, the presence of foreign matters and 3. Fouling of exhaust gas passage.
incorrect facing up of the valve, fuel oil flows into the fuel injection valve too early and too 3a) Combustion products stick to the turbocharger nozzles and the surface of turbine blades, thus
long clogging the exhaust gas passage and reducing the turbocharger efficiency.
In the following case, open the indicator valves of all cylinders and the engine should be 3b) Failure of nozzles and blades of turbocharger caused by foreign materials results the
operated by means of starting air only slightly longer and blow off the fuel. reduction in the turbine efficiency.
a) In priming operation of the fuel oil injection line, the fuel oil entered on the piston head. 4. Leakage of scavenging air
b) When the fuel injection valve is dismantled, fuel oil entered on the piston head. 5. Insufficient suction air
c) Due to failure and repetition of starting operation, fuel oil injection in previous operation still 6. Increased scavenge air temperature owing to in adequate air cooler function.
remained on the piston head. 7. Inadequate fuel oil cleaning, or altered combustion characteristics of fuel.
8. Wrong position of camshaft (maladjusted or defective chain drive)
Knocking in Engine 9. Wear of Fuel Cam and Exhaust Cam
The knocking and noise, during the engine operations caused by the engine trouble. The
noise due to the knocking in the engine is, in many cases, produced by the loosened moving parts, Single Cylinder
early ignition and uneven load distribution among carried by the cylinders. It is very difficult to detect 1. Defective fuel valves, or fuel nozzles.
the noise by hearing. a) Due to the enlarged nozzle hole of the fuel injection valve, which was used for a long period
If the noise is due to early ignition or due to uneven load distribution among the cylinders, of time?
fuel oil of the cylinder in question can be cut as an emergency measure. It can be early detected 1. Blow by in combustion chamber (A fire occurs in the scavenging chamber and air is insufficient)
through the indicator diagram of the cylinder in question where the noise comes from ignition timing 2. The scavenging valve in the scavenging air trunk is damaged or opening and closing function of
and uneven load distribution among the cylinder. scavenging valve is not good.
3. Leaking exhaust valve.
1. In case of early ignition, the following things are considered.
4. Wrongly adjusted, or slipped, fuel cam (Check the fuel pump lead) (B&W)
a) Leakage in the fuel injection valve or poor its spring pressure.
5. Abnormal exhaust gas temperature or pressure in cylinder.
b) Incorrect adjusting of the fuel injection pump.
a) Exhaust valve closing timing is deviated due to clogging of orifice off exhaust valve driving
c) A large amount of low viscosity oil mixed in fuel oil.
gear, usually accompanying with a slight water-hammering of exhaust valve driving oil and
2. In case of uneven load distribution among the cylinders, the following things are considered.
causes deviation of exhaust gas temperature and pressure in the cylinder. (UEC)
a) Incorrect adjustment of the fuel injection pump
b) Incorrect adjustment of the fuel adjusting links.
Blow by of Exhaust Valve
Diesel knock ~ Due to rapid burning of the charge of fuel oil accumulated during the delay period If the following phenomena are observed during operation, damage of exhaust valve shall
between the time of injection & ignition. be doubted. Quickly stop the engine, dismantle the susceptible exhaust valve, make inspection and
repair it or replace parts with spare ones if necessary.
Cause of excessive noise from crankcase 1) Rise in exhaust gas temperature
7) Slack chain (or) worn gear 2) Abnormality of compression pressure
8) Knocking from slack bearing 3) Noise
4) Abnormal Pressure of cooling water pump.
9) Slacken or break bolts, studs

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 203 204 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Blow-Past Ä Adjustments are limited to ensure units are not overloaded, exhaust temperatures are not
a Blow- past is the term used when combustion gases at high temperature leak past the piston excessive and that pump control still cut of f when brought to stop.
between the piston rings and cylinder liner. Ä Fuel pump rack positions and exhaust & cooling outlet temperatures from each cylinder should
a Blow-past causes rapid local overheating, removing the lub oil film and causing further damage be noted.
to the surfaces and possible piston seizure. Ä Equal exhaust temperatures on their do not necessarily show an accurate balance.
a In tow stroke engines, burning gases will enter scavenge spaces causing fouling, overheating Ä Power balance can be checked by measurement from indicator diagrams by calculating the area
and even scavenge fires. or mean height form each cylinder.
a In four stroke engines, these gases will enter the crankcase with sever risk of a crankcase Ä If an engines operates in an unbalanced conditions, some bearings and running gear may
explosion become overloaded; this may cause overheating and bearing failure.
Causes of blow-past: Ä Overloaded in cylinder may cause piston blow past, with the corresponding dangers of
Excessive cylinder liner wears. overheated / seized piston.
Lack of cylinder lubrication Ä Unbalance will also set up vibrations which, if maintained for prolonged periods, will cause
Worn, broken, stuck or poorly maintained piston rings. fatigue from the fluctuating stress induced. This may in turn lead to fatigue cracking of metal in
Worn piston ring groove landings allowing rings to cant and jam bearings , fracture in bearings studs or bolts, cracks in crankshaft and bedplate, and slackening
Carbon jamming rings in grooves. or failure of holding down bolts.
Remedy of blow-past Ä For proper power balance, engine running condition should be normal by observation of the
Gauge the cylinder liner and renew if necessary relevant temperature & pressure, particularly exhaust and cooling outlet temperatures, lubricating
Overhaul piston oil and turbocharger pressures. The exhaust should be clear of smoke and there should be no
Clean piston ring grooves and gauge them unusual noise or vibration.
Machine or fit new groove inserts as necessary
Renew piston rings with correct clearances
Maintain cylinder lubrication and avoid overload.
'
When all unit scavenge fire broken out.
Engine power balance.
Timing checking.
Took indicator diagram.

Surging in Turbocharger
In case surging occurs in the turbocharger while the engine is in service, generally the
following causes may be considered as reasons for such surging:
1) Rapid change in load Sudden fluctuation in rough weather or at the time of crash
astern running.
2) Insufficient supply of fuel Due to clogging of strainers and incorrect adjustment of the
circulating pump pressure
3) Abnormally of fuel system Due to sticking of fuel injection pump, damaged high-pressure
pipe or the failure of plunger barrel.
4) Narrowed scavenging air passage Due to pronounced fouling on the top surface of the air
cooler.
5) Narrowed exhaust gas passage Increase in the resistance of the exhaust gas discharging
passages
6) Engine operation at overload Due to fouling of ship's hull or damage of propeller.
7) Failure of turbine blade, nozzle or diffuser Turbine blade, nozzles or diffuser is remarkably
fouled or damaged unexpectedly when they are opened for repair.
8) Increased air resistance The turbocharger suction filter is extremely dirty, or there is a great
air resistance due to a small piece of cloth and vinyl etc. adhering to the filter surface.

Power Balancing of Engine

Ä For economy and efficient running of an engine equal power should be produced from each
cylinder. This is then said to be power balanced and it may be necessary to make some minor
adjustments to achieve this.
Ä Power produced is related to the quantity of fuel injected and balancing is carried out by small
adjustment to individual fuel pump controls.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 205 206 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

4) Reverse gear and clutch.

Couples.
It can be defined as a pair of forces of equal magnitude acting in parallel but opposite in
direction.

Ship vibration.
1. Synchronous or resonance vibration due to main & auxiliary machinery.( critical speed)
2. Local vibration ( small portion of hull structure such as bulkhead, brackets)
3. Vibration due to external source.
(a) Propeller unbalance
(b) Environment of ship.

To reduce vibration.
Detuner ( forward flexible flywheel) Vibration damper. (e.g. magnetic slip, coupling spring &
centrifugal friction coupling.)
Aft side no need because of thrust block, it can absorb vibration.

Causes of propeller vibration.

1. Excessive clearance of stern tube.

2. Misalignment of propeller shaft.
3. Due to shallow water effect.
4. Propeller blade unbalance.
MAINTAING GOOD ENGINE PERFORMANCE. Barred speed range
Engine running with critical speed condition with severe vibration at barred speed range.
1. Check exhausts smoke & sound. Working stroke of various pistons synchronized with one of the natural frequencies of the crank
2. Check exhaust temperature & engine running parameters. shaft.
3. Perform regular maintenance works & damage repair. Produce resonance condition & severe vibration.
4. Engine can be run with rated speed. Sound rough, at mid-stroke the torsional oscillation of the cranks with biggest amplitude,
5. Took indicator diagram & perform power balancing. longitudinal vibration of connecting rod, lateral vibration of piston & entablature.
Difficult to control the possible critical and where vibration is too dangerous for continuous
Balancing of engine. operation.
Reducing, eliminating and minimizing of the vibration. How will you notice your engine overload?
The forces which causes vibration are - Fuel rack, T/C rpm, exhausts temperature.
1. Inertia force.
2. Gas force. Cause of excessive load - Sea condition, Wind condition, Hull fouling, Shallow water, Propeller
3. Spring force. unbalance.
4. Damping force.
Balancing is a way of controlling vibration by arranging that the overall summation of the out of Increase fuel consumption (suddenly)
balance forces and couples cancels out or is reduced to a more acceptable amount. Loading condition, Trim & list, Wind & sea condition, Hull fouling, Propeller unbalance, Check dry docking
interval, Leakage of fuel oil system.
Engine balancing.
Engine balance can only be achieved by correcting values in the following order.
Engine performance curve.
Compression pressure; Crank angle at Pmax point; Pmax; Expansion pressure; Fuel pump index;
Engine maker usually provided Performance curve which contain compression pressure, max: efficiency
Exhaust gas temperature.
peak pressure, T/C rpm, exhaust temperature, scavenge air pressure, engine rpm, S.F.O.C etc: in
relation to engine load.
Static Balance.
When C.G of the shaft coincide on the polar axis of its journal, it is said that the system in a static
balance.

Dynamic Balance.
With the static balance condition in the presence, additionally when the shaft is revolved, the
load on each bearing must remain constant trough out 360' rotation.

Methods of reversing.
1) Direct reversal of the engine.
(a) cam shift axially (b) cam shift angularly
2) Controllable pitch propeller.
3) Diesel electric system. - Engine and electric generator run in a constant direction, supplying power
to a reversible electric motor.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 207 208 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

BUNKER SPECIFICATION Estimate Trim & Heel condition.

F.O SPECIFICATION Environmental condition such as weather, current.
+ 3 days reserve.
Atypical fuel specification for main propulsion marine engine: Check R.O.B.
Amount, Type of fuel, Viscosity are gave for bunker requisition.
SG at 15C calculation, choice of gravity disc.
Density - 991 Kg/m3 (max), usually measured at 15 °C As a C/E when bunkering.
Viscosity - 700 Cst at 50 °C (max) Correct heating temperature for end (10 ~ 14 Cst)
heater, handling, preheating and centrifuging 1. Safety 2. Pollution 3. Stability & 4. Calculation.
Flash Point - 60 °C (min) for maximum storage tank heating temperature, fire risk factor If possible, the bunker oil does not mix with other fuel oil.
Pour point - solidification in tanks and pipelines
Carbon content residue - fouling of gas ways and piston rings After taking bad fuel oil
(CCR) a Protest through head office.
Conradson carbon - 22% by weight (max) a Check engine performance.
a Check purifier.
Asphalt - 14% by weight (max)
Sulphur - 5% by weight (max)
S & D Daily Fuel Oil Settling and Service Tanks Requirements
Water - 1% by weight or volume (max) sodium content of salt water
For fuel oil settling tank low/high level alarm and service tank low level alarm
Cetane number - for distillate fuels: measure of ignition quality
- F.O low temperature alarm and heater on
Ash - 0.2% by weight (max), abrasion
- F.O high temperature alarm and heater off
Aluminium - 30 mg/Kg (max)
- F.O transfer pump cut on / cut out device
Vanadium - 600 mg/Kg (max), undesirable by itself, but when present with sodium,
(01) Filling line with a valve of Gate or Sluice type.
leads to exhaust valve corrosion, cylinder and turbocharger despots, which
(02) Supply lines to the engines and boilers with quick closing valves.
can cause overheating and failure. A mass ratio of 1:3 of Na:Va can be
(03) Sounding pipe is with a gas tight cap. A striker plate of a quarter inch per a half inch thick is
troublesome, especially with high vanadium content.
welded under this pipe to prevent wear of the tank bottom by sounding sticks.
Sodium - 30% of the Vanadium content
(04) A remote reading gauge, pneumercator gauge or a gauge glass, fit to give a visual reading. If
gauge glass is fitted, the bottom gauge cock should be of self-closing type to prevent escape
Name of vessel
of oil should the glass break.
Port of delivery
(05) Vent pipe, 25% more area than the filling pipe, with a flame trap of copper wire gauze, 28
Date of Bunker
squares per square inch.
Bunker operation time (Duration)
(06) An overflow pipe with a sight glass, leading to overflow tank, to prevent spreading out of oil
Temperature of product
from the vent when the tank is overfilled.
(07) Steam heating coils heating surface area 0.5 square feet per ton of oil, is fitted by means of
which the temperature of the oil will be raised to at least 50 C, to reduce its viscosity, and to
As a C/E checking for bunker receipt facilitate the process of separation.
(08) A thermometer pocket to insert thermometer to record the temperature of the tank contact.
1. Viscosity {Engine inlet temperature setting}
(09) A drain valve of self-closing type at the tank bottom to draw off sludges and water.
2. Quantity
3. Specific gravity {Calculation and purifier gravity disk and temperature selection}
(10) A dumping valve of self-closing type to drain down the whole capacity into the double bottom
4. Bunker barge temperature {calculation for bunker receipt} tanks in case of fire in the vicinity.
5. Pour point {Maintain temperature at D.B tank and transferring} (11) Two manhole doors, one on the top other on the side, about two feet from the tank bottom.
6. Flash point {Maintain temperature at settling and service tank}
7. Water, sulphur and other impurities check.
One unit of main engine blanking up procedure.
Calculation of bunker receipt. (01) Check the damage condition of the engine.
The specific gravity of fuel oil change in relation with temperature change. So the bunker barge (02) Cut off fuel supply to effected cylinder by lifting the plunger with roller of fuel injection pump.
temperature must be considered to correct the actual specific gravity to calculate the correct amount of (03) Blank up starting air pipe, nozzle-cooling pipe.
fuel. (04) When piston is took out or hang up by hanging bar, exhaust valve is locked at closed position
SGT = SG15 - 0.00064 (T - 15)'C by taking out push rod and lift up the rocker arm.
(05) Piston with piston rod and crosshead is took out or hang up by hanging bar.
Bunker sample taking method. (06) If piston with piston rod is took out blank off the stuffing box opening with two plates. (towards
1. Continuous dripping. scavenging air box and crankcase). Minimum plate thickness 5mm.
2. Spot check. (a) Random check from bunker barge tank (07) Took out connecting rod and crank bearing.
(b) Random check from bunker pipe. (08) Blank off the oil inlet from telescopic pipe.
(09) Put cylinder out of operation.
How to order bunker at next port as C/E. (10) Run the engine with minimum vibration condition.
Took the essential data from Master.
Fuel oil treatment.
Distance & average speed estimated.
To estimate steaming time, river passage, pilotage, anchorage, port staying time. 1. Fuel oil sample sent to laboratory.
To estimate HO & DO consumption. (Running hours of M/E, G/E & Boiler.) 2. DB tank Dose Fuel Oil Treatment.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 209 210 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Maintain temperature 10'C above poor point to prevent formation of sludge & 04. Upsetting centrifuge’s operation
pumping. Dosage sludge conditioner.
3. Frequent cleaning of transfer pump suction filter.
4. Settling tank Maintain temperature at least 14'C below flash point. c) Asphaltenes
Drain out water & sludge. 01. Blockage of filters and pipe lines.
5. Purifier clean suction strainer 02. Upsetting centrifuge’s operation
Temperature & gravity disc selection. (S.G) 03. Fouling of combustion chamber and scavenge space
6. Service tank Maintain temperature at least 14'C below flash point. 04. Black smoke emission
Drain out water & sludge. 05. Trumpets or Petal formation of nozzle
Chemical dose. (For improve combustion) Proper treatment with a special asphaltenes dispersant.
7. Engine inlet temperature setting depending upon required viscosity.
8. Check engine performance. d) Conradson carbon residue [C.C.R]
It may cause unburned carbon deposits and smoke emission has been increased with high
Waste Heat Recovery System. C.C.R value.
Turbocharger, Exhaust gas economizer, Fresh water generator, Jacket heating system, boiler feed C.C.R value over 10% will cause fouling of combustion chamber and scavenge space.
water heating system & Turbo compounding system. Further more resulting smoky emission and trumpet formation at nozzle.
Modern 2 stroke cycle, slow speed, long stroke engine
• Shaft propelling 52% e) Sulphur
• Heat loss to cooling service 19% It may cause low temperature corrosion or acid corrosion or acid corrosion.
• Heat loss to exhaust To combat the acid effect when burning high Sulphur fuels.
Recovered by E.G.E 14% In combustion, sulphur tends to decrease calorific value of fuel, each 1% of sulphur causing
Loss with gas 14%
0.7% of C.V to be lost.
• Radiation loss 1%

Closed pressurized mixing tube. f) Ash {Vanadium, Sodium, Aluminum, Nickel, Silicon, Sand}
1. Expel vapor. May cause hot corrosion during combustion these contaminants are chemically combined with
2. Prevent foaming. the fuel and can not be removed by centrifuging alone they are highly abrasive particles and
3. Sludge & water can be drain out. abrasion occur between liner and piston, fuel pump, fuel valve.
4. Temperature maintain.
Hot corrosion, especially by vanadium and sodium highly corrosive in liquid state. These
motten compounds at temperature (480~560), adhere especially to the exhaust valve surface and
Marine Machineries
dissolve the protecting coating.
Marine machineries are designed to operate when the ship is upright and when inclined at
any angle of list up to and including 15° either way under static conditions and 22.5° under dynamic The corrosive flux of sodium vanadal will also attack turbine blades and leading to unbalance
conditions (rolling) either way and simultaneously inclined dynamically (pitching) 7.5° by bow or system and blockage of the nozzle rings.
stern. The also attack high-pressure boiler and super heaters especially at the fireside.
(SOLAS 74/78)

With reference to main engine using poor H.O g) Catfins

1. How the impurities attack the machinery parts.
Having highly abrasive characteristic which cause serious wears and scratching an fine
running engine’s components, cylinder liner and piston, fuel pump plungers and fuel valves.
a) Water
More than 1% may cause The small particles being the most trouble some since they are settle out less easily and
01. Corrosion passed through filters.
02. Poor atomization and poor combustion
03. Emulsification of fuel leading to sludge formation
04. Seizure of fuel pump and fuel valve h) Microbial degradation of distillate fuel
05. Misfiring of engine Degradation of micro organisms show themselves by smell, clogging of filters frequently
06. Surging of turbocharger creation of sludge and development of slimy build up in tank’s surface.
07. Stopping of engine in extreme case
08. Natural L.O film can be removed Factor govern the ignition
09. Promotion of microbial degradation Water: poor combustion, poor atomization, injection viscosity increase. It cause late
10. Difficulty in separation of fuel injection and combustion
11. Foaming of fuel in mixing tube.
Sulphur: lost of calorific value, thermal efficiency reduce, late injection and combustion
b) Sludge Asphaltene: trumpet or petal formation at nozzle the smaller the size the greater their readiness
Sludge may cause to burn in a short time, extant passage choking. Late combustion.
01. Instability of fuels
02. Incompatibility of fuel C.C.R: Unburned carbon deposits ring zone and trumpet formation, lost of compression
03. Blockage of filters and pipe lines duet to damage gas sealing, it cause late combustion.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 211 212 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

Cetane No: high cetain number, shorter time between fuel injection and rapid combustion, better Spare gears
ignition quality, early combustion. 1. If 3 G.E 1 complete set of generator.
2. 1 unit set of M.E.
Viscosity: injection viscosity at nozzle, low viscosity cause early injection and combustion.
1. M.E one cylinder cover complete, one additional seat of valves for one cylinder,
2. Exhaust valve - 1/2 no: of cylinder.
Bad fuel oil. 3. Fuel valve - complete set with spring & fitting of 1/2 of cylinder.
Action after taking. 4. Cylinder liner - 1 complete set.
01. Invite bunker surveyor. 5. One set of cylinder liner joints for engine.
02. Frequent cleaning of F.O filters. 6. One piston.
03. Fuel oil sample sent to laboratory.
04. DB tank - Dose Fuel Oil Treatment.
05. Maintain temperature 10'C above poor point to prevent formation of sludge & pumping.
06. Frequent cleaning of transfer pump suction filter.
07. Settling tank - Maintain temperature at least 14'C below flash point.
- Drain out water & sludge. What is the shaft generator ?
08. Purifier - Run F.O purifier 2 numbers parallel with for each 50% slow through put. It is an alternator which is driven by main propulsion propeller shaft through clutch and
- Temperature & gravity disc selection. (S.G)
09. Service tank - Maintain temperature at least 14'C below flash point. gearing, especially those sailing for long period at constant ship speed.
- Drain out water & sludge. It can be used at sea when M/E is running o full speed. It is capable for load
10. Chemical dose. (For improve combustion)
11. Engine inlet temperature setting depending upon required viscosity. Lloyd’s Requirements
12. Check and record engine performance.
1) Lloyd’s register would regard a shaft generator as a service main generator, if ME is intended
Effect. to operate at constant speed (CPP)
1. Impurities attack to Machinery parts. 2) If ME does not operate at constant speed, shaft generator would be disregarded as a service
2. Hot corrosion, cold corrosion, trumpet formation. main generator, and at last 2 other independent generators would be required
3. Fuel oil filters chocking.

Automatic system control. Running condition

1. Electronic 1) Full generator capacity is available within 60 ~ 100 % of normal speed
2. Electro hydraulic
3. Electro pneumatic 2) More suitable for shaft with CPP, (constant shaft sped and variable blade pitch)
4. Pneumatic.
Advantages of shaft generator
Self closing Valve 01) Saving in fuel cost is main advantage
Where self closing type valve are fitted and why these are fitted ?
It is fitted dumping valve and drain valve of settling tank and service tank. 02) Saving in LO consumption, repair and maintenance cost due to reduced main generator’s
To prevent changing of working position (accidentally opened & human error) due to ship running hours
rolling and vibration. 03) Reduction in noise, space and weight, capital saving by reduction of numbers and ratings of
main generators
Where fitted back pressure valve ?
High temperature setting room evaporator outlet before collecting point.
Disadvantages
Quick closing Valve 01) Reduction in ship speed
Quick closing valve are fitted at outlet of settling and service tank to engine, G.E and boiler 02) Problems can rise to maintain electrical supply, during emergency manoeuvring astern
and on some L.O tank.
03) Increase in capital cost
They are also fitted on the fuel oil transfer pump suction from the double bottom tank.
It can be closed from remote position in case of fire in engine room or emergency.
ME driven generator
What are the function of feed check valve ? 01) Fuel consumption is saved
They are non return valve. They are used to allow feed the water into the boiler by feed pump and to
02) Lower running and maintenance cost
prevent back flow of water.
03) Lower noise level in ER
Safety valve 04) Simple and most compact installation
Fully open at set pressure Varying speed of ME, driving a fixed pitch propeller, can be converted by variable gear ratio, to
Close at set pressure
provide constant Generator speed.
Relieve excess pressure
Can open manually
Setting pressure not more than 3% above approve working pressure.

Compiled by Min Zar Tar 14/02/2005 11:15 AM

 SURVEY AND INSPECTION nd
213 214 REFERENCE FOR M.O.T 2 Class Part B (Oral)

(02) After blow through, shut starting air valve on air bottle
(03) Engage turning gear and turn for at least ½ hour, crank CLO 40-50 times
(04) After ½ hour, stop LO pump and stop turning but keep the turning gear engaged
How to Plan for Machinery Survey (05) Put up notices in the control room for the M/E pumps, which has been stopped and also on
a Check survey list of machinery or instruction of company for survey the engine control
a Check spares and tools for survey machinery (06) Open crankcase door and start ventilation by blowers.
a Man power and time available in port (07) Open scavenge space door and under piston door and start ventilation
a Read instruction manual and previous record. (08) Isolate JW inlet and outlet valves for the unit affected and start draining. JW pump kept
a Brief other engineers for engaging work running for keeping other units warm
a After reaching port, take permission from port authority if required and start doing work with (09) Isolate fuel inlet and return valves for the affected unit. Fuel is on re-circulation for other
necessary precaution units
(10) Shut off the control air and safety air supply. Also shut off the air supply in the reduction unit
UNIT SURVERY (MAN B & W Engine) for the hydraulic /pneumatic exhaust valve, and vent the system.
(A) Planning (11) Remove
01) Get exact date of survey and estimate immobilization period Exhaust bellow and sensor
02) Check and prepare all necessary spares and tools JW outlet pipe before the outlet valve, thermometer and temp sensor
03) Tools: Spring air connection
a) Piston and Cylinder Cover Actuator oil drain
Hydraulic pump, hoses and cylinder head jacks Hydraulic actuator HP Pipe
Lifting gears e.g. engine room crane, shackles, slings etc. Injector HP pipes
Piston lifting tool and cylinder head lifting tool Injector fuel return connection
Piston ring funnels or ring compressor Staring air valve connection
Stuffing box spacer and hole cover Staring air valve pilot connection
Feeler gauge and internal micrometer. 12) Protect all openings with clean rags
Piston ring expander
Piston stand Removal of Cylinder Head
Piston crown template , Fit hydraulic jacks on all cylinder head nuts and connect the HP hoses
Liner calibration template , Open jack vents and start to pump slowly ensuring no excessive pressure build on
Liner calibration ladder , Use Tommy bar to loosen nut, ensure all nuts are loose
Other necessary tools , Release pressure, remove jacks and remove nuts.
, Fit cylinder head lifting tool
b) Liner , Lift slowly the cylinder head using the E/R crane
Liner lifting tool and liner support beam , Care must be taken when lifting so as cylinder head does not comes in contact any other engine
Liner jack and jack support part during lifting thus causing damage
, Place the cylinder head on a couple of wooden planks.
04) Spares , Remove and discard the sealing ring between cylinder cover and cylinder liner.
Piston rings Liner O-ring
Piston O-ring Cylinder head joint Piston Removal
O-ring, rings and springs for stuffing box Other connection clearance etc. , Turn the crosshead down for enough to give access to the piston to rod stuffing box. the
tightening screws for the piston rod, and to the telescopic pipe
05) Consult manual for special instructions and data e.g. jacking pressure, clearance etc.
, Release the stuffing box by removing the innermost screws for the stuffing box flange Turn
06) Check all lifting devices and crane for SWL, corrosion and other damage
piston towards TDC but stop much before it reaches TDC
07) Test lifting gears
, Remove the screws from the piston rod.
08) Check hydraulic pump, jacks, HP hoses and connections for satisfactory operation
, Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to
09) Prepare and check previous survey records
guide the stuffing box.
10) Carry out briefing for every one involved in the work about precautions, work to be done and
, Carefully smooth out any wear ridges at the top of the cylinder liner by using a hand grinder
time available
, Put some grease on the circumferential gap between piston and liner
11) Safety gears to be worn during work
, Turn the crosshead to TDC, while checking that the guide pins of the distance pieces enter the
12) Prepare piston stand near engine
holes in the stuffing box.
, Clean the lifting groove of the piston crown and mount the lifting tool
(B) Shutting Down and Removal of Connection
, Ensure crane is straight and ship is even keel
(01) On F.W.E, get immobilization permission and propeller clearance from bridge. Inform bridge
, Using E/R crane slowly lift up the piston
of estimated immobilization period.

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
215 216 REFERENCE FOR M.O.T 2 Class Part B (Oral)

, Ensuring piston is not swinging causing piston palm coming in contact with liner surface b) Liner
, Once out, lower piston on its stand and place a cover over the opening for the piston rod stuffing Liner lifting tool and liner support beam
box in the bottom of the cylinder unit. Liner jack and jack support
, Remove the lifting tool
04) Spares
Liner Removal Piston rings Liner O-ring
01) Remove all quill connections for that unit Piston O-ring Cylinder head joint
02) Remove liner-securing bolts
O-ring, rings and springs for stuffing box Other connection clearance etc.
03) Mount the two lifting screws in the cylinder liner
05) Consult manual for special instructions and data e.g. jacking pressure, clearance etc.
04) Remove the screws of the cooling water in let pipe
06) Check all lifting devices and crane for SWL, corrosion and other damage
05) Attach the crane to the lifting tool. Hook the chains from the lifting crossbar on to the lifting
07) Test lifting gears
screws and lift the cylinder liner with the cooling jacket out of the cylinder frame
08) Check hydraulic pump, jacks, HP hoses and connections for satisfactory operation
06) Land the cylinder vertically on, for instance, a couple of planks.
09) Prepare and check previous survey records
07) Lift away the cooling jacket by means of the tackles and land it on the wooden planks
10) Carry out briefing for every one involved in the work about precautions, work to be done and
08) Check and assess the condition of the cylinder liner.
time available
09) Clean the cylinder liner and the cooling jacket both internally and externally. Pay special
11) Safety gears to be worn during work
attention to the O-ring grooves and lubricating ducts.
12) Prepare piston stand near engine

Inspection and Cleaning

(B) Shutting Down and Removal of Connection
Before commence cleaning assess piston crown, ring grooves and oil grooves (01) On F.W.E, get immobilization permission and propeller clearance from bridge. Inform bridge
After cleaning, check crown burn out using the template and measure the burn out of estimated immobilization period.
Assess for signs of wear, crack, scoring and pitting (02) After blow through, shut starting air valve on air bottle
Also check ring groove condition (03) Engage turning gear and turn for at least ½ hour, crank CLO 40-50 times
After cleaning of liner and fitting back, it is checked for wear, scoring etc (04) After ½ hour, stop LO pump and stop turning but keep the turning gear engaged
Calibration taken (05) Put up notices in the control room for the M/E pumps, which has been stopped and also on
Checking of ring clearance and piston clearance the engine control
CLO flow checked (06) Open crankcase door and start ventilation by blowers.
Piston crown and skirt opened up for survey, cleaning (07) Open scavenge space door and under piston door and start ventilation
Assemble and pressure test (08) Isolate JW inlet and outlet valves for the unit affected and start draining. JW pump kept
running for keeping other units warm
(09) Isolate fuel inlet and return valves for the affected unit. Fuel is on re-circulation for other units
(10) Spring air valve isolated
(11) Remove
UNIT SURVERY (Sulzer RTA Engine) Exhaust bellow and sensor
(A) Planning JW outlet pipe before the outlet valve, thermometer and temp sensor
01) Get exact date of survey and estimate immobilization period Spring air connection
02) Check and prepare all necessary spares and tools Actuator oil drain
03) Tools: Hydraulic actuator HP Pipe
a) Piston and Cylinder Head Injector HP pipes
Hydraulic pump, hoses and cylinder head jacks Injector fuel return connection
Lifting gears e.g. engine room crane, shackles, slings etc. Staring air valve connection
Piston lifting tool and cylinder head lifting tool Staring air valve pilot connection
Piston ring funnels or ring compressor (12) Protect all openings with clean rags
Stuffing box spacer and hole cover
Feeler gauge and internal micrometer. Removal of Cylinder Head
Piston ring expander , Fit hydraulic jacks on all cylinder head nuts and connect the HP hoses
Piston stand , Open jack vents and start to pump slowly ensuring no excessive pressure build on
Piston crown template , Use Tommy bar to loosen nut, ensure all nuts are loose
Liner calibration template , Release pressure, remove jacks and remove nuts.
Liner calibration ladder , Fit cylinder head lifting tool
Other necessary tools , Lift slowly the cylinder head using the E/R crane

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
217 218 REFERENCE FOR M.O.T 2 Class Part B (Oral)

, Care must be taken when lifting so as cylinder head does not comes in contact any other engine CLO flow checked
part during lifting thus causing damage Piston crown and skirt opened up for survey, cleaning
, Place the cylinder head on wooden blocks Assemble and pressure test

Piston Removal
, Turn piston to BDC and remove piston palm bolts and locking device
, Fit the stuffing box spacer on the piston palm Cylinder head survey
01) Take immobilization from port authority
, Remove stuffing box securing bolts and its locking device
02) Close main air stop valve and lock starting system.
, Turn piston towards TDC but stop much before it reaches TDC 03) Engage turning gear and stop L.O pump.
, Remove cylinder head metal gasket 04) Close jacket water valves (in/out & necessary valves)
, Put some grease on the circumferential gap between piston and liner 05) Drain jacket water to a certain level to prevent flow out.
, Clean liner surface of deposits so, as piston does not get stuck during extraction 06) Remove off all pipe connection on cylinder head
, Clean and re-tap the lifting holes on the crown 07) Remove all valves on cylinder head
08) Clean thread from all cylinder head studs.
, Fit piston lifting tool ensuring all bolts are secured
09) Loosen the cylinder head nuts by hydraulic tensioning device and remove
, Ensure the liner securing bolts are still in position and secured them.
, Ensure crane is straight and ship is even keel 10) Attach lifting eye bolt (special tool) on the cylinder head.
, Using E/R crane slowly lift up the piston ensuring the stuffing box spacer does not contact with 11) Lift the cylinder head by crane with suspension rope.
the diaphragm 12) Place the cylinder head on stand
, Continue to lift ensuring piston is not swinging causing piston palm coming in contact with liner 13) Clean all of the valves pockets and check crack.
14) Open water chamber inspection door and clean
surface
15) Clean under side of the cylinder head and check wear, flame
, Once out, lower piston on its stand and secure the stuffing box impingement, distortion, and crack.
, Remove the lifting tool 16) Display surveyor.

Liner Removal Cylinder liner survey

01) Remove all quill connections for that unit (1) to (7) from cylinder head survey.
08) Remove the cylinder head and press liner by using liner pressing tool.
02) Remove liner-securing bolts
09) Turn crank shaft until the piston is BDC.
03) Lower the liner support beam vertically and rest it on the diaphragm 10) Clean liner wall, exhaust and scavenge posts thoroughly.
04) Change sling position and swing it around and lift it up a little so that it can be fitted to the 11) Take measurements on liner by using micrometer, extension bar and
under side of line template.
05) Once beam properly secured, sling and crane hook is removed from inside of liner 11a) Max wear 0.75 ~ 1.0 of original
06) Turn engine till TDC 11b) Wear rate o.1 mm/1,000 hr
07) Fit the jack support on to the cross head pin 12) Check cylinder lubrication by operating
08) Put the jack on top of the support and connect it with hydraulic pump using HP hoses 13) Display liner and measurements to surveyor.
09) Purge air from jack using the vent and pump slightly
10) Once air is purged, start jacking slowly Piston survey (M/E unit survey procedure)
(1) to (7) from cylinder head survey
11) Slight pressure should be able to push the liner
8,9, 10 from cylinder liner survey
12) If too much pressure, stop pump release pressure and re-check the connection
13) Once liner is shifted out of the guide, fit the liner lifting tool on the liner flange
11) Remove 1 Stuffing box holding nuts from diaphragm
14) Attach crane and lift up liner slowly 2 Piston cooling connection
15) Lay down the liner carefully and secure it 3 Piston rod nuts.
16) After securing, remove liner support beam 12) Turn the crank shaft until piston is TDC.
13) Remove combustion deposited from the thread hole of the piston crown by
17) Release jack pressure, remove jack and jack support
using thread tab.
18) Cover the stuffing box hole using the cover provided 14) Screw down piston lifting tool at the thread hole of the piston crown
and connect it to crane.
Inspection and Cleaning 15) Pull up the piston by crane out of the liner together with stuffing
box.
Before commence cleaning assess piston crown, ring grooves and oil grooves
16) Place piston on the top platform.
After cleaning, check crown burn out using the template and measure the burn out 17) Remove piston rings and clean piston and ring grooves
Assess for signs of wear, crack, scoring and pitting 18) Overhaul the stuffing box.
Also check ring groove condition 19) Clean the liner and check times lubrication
After cleaning of liner and fitting back, it is checked for wear, scoring etc 20) After cleaning work complete measurement to be taken on the following
Calibration taken place. Then display the parts for surveyor.
a) Piston crown wear (max wear allowance shown on special template)
Checking of ring clearance and piston clearance

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
219 220 REFERENCE FOR M.O.T 2 Class Part B (Oral)

b) Piston ring gap clearance (Max allowance is 3 times of the original) 11) Inspection on crank pin, bearings, oil holes, grooves, bolts cracks, sign of movement and elongation.
c) Piston ring vertical clearance
d) (0.2 to 0.25 mm) 11) Take measurements of crank pin at least 3 place top, bottom and port, stb check ovality.
e) Radial thickness of piston rings. (Generally (1/13)one thirteenth of 12) Display surveyor, check points are
the cylinder bore diameter) 12a) Bearing clearance (0.5 to 0.7 mm for 550 mm diameter crank pin)
f) Cylinder liner bore (Calibration) (Max wear 0.75 to 1.0% of
original) 12b) Bearing surface (No crack, no damage and if wipe out 30% renew it)
g) Stuffing box sealing and scraper rings, gap and groove clearance. 12c) Check holding down bearing surface.
(Gap clearance = 6 mm for each gap)Total gap clearance = 18 mm for 3 12d) Oil hole and grooves (No damage)
segments (groove clearance = 0.07 to 0.12 mm)
12e) Crankpin ovality and its surface
Cross head Bearing survey 12f) Lubricating system (clear)
01) Take immobilization from port authority 12g) Big end bearing bolts (Good thread, no extension, no cracking and no twisting)
02) Close main air stop valve and lack staring system. 12h) heck sign of movement of the joint point such as two halve of bearing joint and between top
03) Engage turning gear and stop L.O pump
04) Open crankcase doors / Stop M/E warming. halve and connecting rod foot.
05) Turn crankshaft until crank is horizontal position.
06) Take guide shoe clearance and side clearance by using feeler gauge. Main bearing survey (Sulzer, RL)
07) Turn crank shaft until crank is BDC. 01) Take immobilization from port authority
08) Take bearing clearance by inserting feeler gauge between bearing upper 02) Close main air stop valve and lock starting system.
half and X head pin. 03) Engage turning gear and stop L.O pump
09) Remove bearing cap nuts of both sides. 04) Open crankcase door.
10) Fit eye bolts on the bearing upper half and remove them outside from 05) Turn crankshaft until crankshaft is convenient position
the crankcase. 06) Take bearing clearance by inserting feeler gauge between bearing upper
11) Turn crankshaft until crank is TDC. half and journal
12) Tie the connecting rod with two chain block. 07) Remove the L.O supply pipe and locking arrangement.
13) Fit the hanging bar in position according to the operations manual. 08) Remove the bearing keep nuts or bolts.
14) Turn the crankshaft until the bearing lower half clear from X head pin. 09) Fit eye bolt on the upper bearing dip and remove it outside from the
15) Take measurements of X head pin at least 3 place top, bottom and port, crankcase
stb. check ovality. 10) Also fit eye bolt on the upper bearing shall and remove it outside from
16) Display surveyor, check points are – the crankcase.
a) Bearing clearance (for X head bearing = 0.2 – 0.5 mm) 11) Use special spanning, bolted to the adjacent crank web of the concerned
b) Shoe and guide clearance (for surface 0.25 – 0.55 mm) bearing, the end of which are engaged to the collar of the lower
c) Shoe and guide clearance (for each side = 0.1 – 0.2 mm) bearing shall.
d) Bearing surface (No crack and No damage) 12) Turn the crank shaft about half revolution to the opposite of the
e) Oil holes and grooves (no damages) running direction.
f) X head pin ovality 13) Bearing half will rotate with the shaft to the top opposition.
g) X head pin surface (No crack and No damage) 14) Fit eye bolt to the back of the shell and lift it out of the engine.
h) Lubricating system (clear) Some methods use hydraulic jacks to lift the crankshaft a few distance,
about 0.1 to 0.3 mm, and turn the bearing shell without rotating the
Big end bearing removing and fitting procedure. crankshaft.
1) Take immobilization from port authority 15) Measure throughout the journal at least three places (top, bottom and
port, stb) to check the ovality.
2) Close main air stop valve and lock starting system 16) Display surveyor, check points are,
3) Engage turning gear and stop L.O pump a) Bearing clearance (0.4 to 0.6 mm for 500 mm diameter journal)
4) Open crankcase door b) Bearing surface (No crack and No damage)
5) Turn crankshaft until the crank is BDC c) Oil holes and grooves (No damage)
d) Bearing tap (No damage)
6) Measure bearing clearance by inserting feeler gauge between bearing lower half and crankpin. e) Journal ovality (25% of max: oil clearance)
7) Turn the crank shaft to TDC position. f) Journal surface (No crack and No damage)
8) Remove locking arrangement and slackened the nuts. The bottom half lower a few and took out bearing g) Lubricating system (Clear)
clearance adjusting shim, each set being tied separately and note taken of the side to which each set Main engine unit survey procedure.
belongs. (01) Works should not be disturbed the ship's sailing schedule.
9) Chain blocks connected to eye bolts, screw into each bolt. After removing two nuts, bottom half lowered into (02) Immobilization must be taken from the port authorities.
(03) Group the engine room engine room staff, each group having an engineer and assisting crew
the sump. Putting hanging bar in position, connect chain blocks to crankcase door frame and eye bolts for efficient work.
which is screwed into each side of the top half. Then turn the crankshaft to the position where the top half (04) Prepare tools and spare parts to be used.
can be taken out. (05) Engage turning gear. Stop lub oil pump, piston cooling, fuel valve cooling and close jacket
10) Also take out the bottom half with bolts outside the crankcase cooling water inlet and outlet valves.
(06) Piston to be put to TDC by turning gear.

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
221 222 REFERENCE FOR M.O.T 2 Class Part B (Oral)

(07) Exhaust valve and pipe, fuel pipes, fuel valves, fuel valve cooling pipes and air starting pipes to 3) All tank sounding to be taken and account.
be removed. 4) All portable fire extinguishers to be ready at required place.
(08) Removed cylinder head nuts and cylinder head by engine room crane, placed it on special 5) Fire fighting fixed installation to be kept ready at required by
stand or wooden bocks. shipyard’s rule.
(09) Remove piston rod nut, attach piston lifting attachment to piston crown after cleaning 6) Emergency generator, emergency fire pump, emergency air bottle,
thoroughly the bolt holes by using taps. Pressing up liner with maker supply tool. The piston emergency air compressor must be kept in good condition.
with the rod to be taken out by means of engine room crane. Care should be taken to prevent 7) Shore cooling sea water supply for refrigeration and air condition
the piston rod thrust on the stuffing box and liner wall. The piston assembly to be placed on the plant must be ready to receive.
top platform. 8) Shore electrical supply (at entry of dock) Phase, Hz, V, AC or DC.
(10) If the stuffing box required to be overhauled, it can be taken out together with piston or 9) Main engine crank shaft deflection to be taken and recorded.
separately.
(11) Clean all carbon deposits on the piston crown, rings, ring grooves, liner with exhaust and air (3) Before a few hour
inlet ports and scavenging space. 1) Boiler should be shut down and release all steam pressure by using
(12) Inspect piston rings broken or sticking in grooves, liner and piston crown burning and wearing. easing gear.
Pressure test to piston cooling system. Tested cylinder lubricators. 2) An instruction to give all engine room personnel that smoking is
Took measurements prohibited in engine room at ship is still in dock.
1) Cylinder liner bore. (max: wear 0.75 to 1% of original) 3) Main air bottle, emergency air bottle pressed up to full and close
2) Piston crown wear. (wear down gauge) tightly.
3) Piston ring gap clearance. (max: 3 times of original) 4) Ready to stop ship generator as soon as vessel enter dry dock and to be
4) Piston ring vertical clearance. (0.2 to 0.25 mm) kept an electrical officer stand by on shore connection box when shore
5) Radial thickness of piston ring. (One thirtieth of cylinder bore diameter) power is taken.
6) Stuffing box sealing and scraper rings gap clearance. (6 mm at each gap) 5) Settling and service tank top up, after topping up sounding of all
tanks must be taken and recorded.
6) Remind all engine room personnel their duty and ready for emergency
Dry Docking Preparation use.
(a) A few months before
1) Information about The dry docking (estimated time and duration) to be (4) On dock
taken from C/E 1) Repair work to be divided into two categories, one for ship staff and
2) Preliminary repair list must be collected and arranged by instruction other for dry dock.
of C/E. 2) Tool and spare must be checked and prepared for use.
3) Repair work to be divided into two categories; one for dockyard and 3) Take daily record of work done by ship staff and dry dock workers.
other for the ship’s staff. The repair list must contain the followings 4) Negotiate with in charge of dock yard about work sequence and show him
a. Nos. of sea suction chests and grids and their size location of item to be repaired.
b. Nos. of sea suction valve and their sizes. 5) At the end of every day, feed back condition of work to C/E.
c. Nos. of ship side discharge valve and their size. 6) Examine all work done by dry dock and engine crew. If unsatisfactory
d. Nos. of scupper valve and their sizes. condition was found, inform to C/E and dock yard in charge.
e. Nos. of piping to be repaired including their length, 7) All engine room personal should be instructed to use store and spare
inside/out side diameter, bends, no. of flange and their P.C.D thoroughly and without wasting.
[including detail drawing] 8) Bottom survey carried out together with class surveyor, master & C/O.
f. No. of engine room valves to be renewed or repaired and their 9) Assist class surveyor visit and his subsequent survey.
specifications. Supervise when at sea cannot overhaul works.
g. Main engine overhauling preparation (1) Spare (2) tools (3) At witness for docking survey item.
measurement (4) instruction manuals. Supervise the docking repair item.
h. Auxiliary engine, boiler, pump & other machinery preparation Measure stern tube wear down, rudder wear down and jumping
for overhauling.
clearance.
4) Exact location of items to be repaired or overhaul must be marked with
Propeller check cavitation, corrosion and any damage (Crack,
tag label according to repair code.
deformation)
5) Tools and spares, stores should be checked and prepared for use.
6) Store and spare requisition which will be repaired to use during
docking periods must be ordered. After Dry Docking
7) All tools must be marked with paints to prevent mixing with shipyard’s Price Negotiate (Man/power, material /repair list)
one. Dock charge damage claim
8) Organization of E/R staff ie. Safety purpose, assign works. Report
9) Distribute work assignments among engine room staff in group by group. Closely check sea valves
10) Maker’s instruction on manuals and all drawing must be kept ready Performance of repaired machinery
for prompt work. Took M/E crankshaft deflection.

(2) A few days before Crankcase Inspection

1) Ballasting and transferring carried out in corporation with chief
01. Consult with Chief Engineer and inform Master
officer to achieve required trim and draught.
2) Engine room bilge well and tank top to be cleaned thoroughly. 02. Safety

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
223 224 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Shut off main air starting valve and air bottle main valve Stretching is the results of pin and bushing surface wearing out.
Open indicator cocks and engage turning gear Chain length is measured in terms of number of links.
Ensure engine has been turned for at least half an hour before stopping lub oil pump & cross 01) Stretching of the chain must be measured periodically.
head oil pump 02) Check wear of the chains, teeth of sprockets, bearing of wheels.
Stop lub oil pumps & cross head oil pump and circuit breaker off. Post notice "Don't Start 03) Check any seized up of rollers.
Men at Work" 04) Check for fatigue cracks on rollers & link plate.
Inform duty officer for propeller clearance. 05) Check alignment of the wheels by examining every links for blemish, and for bright marks on
Open crankcases door and ventilate properly. side plate. (due to misalignment of wheels)
Wear safety gears e.g. helmet, boots, raincoat , gloves etc. 06) Check abnormal wear takes narrow polished strips on the inside surface of the sprockets teeth.
Use safety lamps, torches and tools 07) Check for loose bolts & pipe connection.
Pockets to be emptied of contents and tools taken inside to be accounted for. 08) Check lub: oil pipes, sprayers, oil flow & direction.
One responsible person must be standing outside. 09) Check rubber clad guide ways for cracks.
03. Inspection 10) Slackness
Firstly check oil condition for any smell, discoloration or degradation.
Turn engine to BDC and start checking from under stuffing box area for any signs of black oil, Excessive Tension - will cause high loads, possible damage and breakage of the chain system.
if so indication of stuffing box leaking.
Check piston rod surface for scoring marks and roughness. Symptom of slack chain.
Check piston palm bolts and locking device for slackness and fretting.
Check guide and guide shoe bearing general condition and area around frame where guide is 01) Excessive chain vibration and noise due to slackness.
attached for any visible cracks. 02) Loss of power in all units indicated by power card.
Check guide shoe end cover bolts in place and not slack. 03) Late injection and low Pmax revealing on out of phase card.
Check cross head bearing general condition 04) Late closing of exhaust valve in all units can be seen on light spring diagram with high exhaust
Top & Bottom end of con-rod bolt, nut and locking device for slackness, sign of fretting etc. temp: & smoke.
Check sliding of bottom end bearing (axial movement) or floating of con –rod.
Check for slip of web and journal by checking the reference mark Effect of slack chain.
Check web in the area of stress concentration and check tie bolts (bottom side) 1) Slack chain will impose heavy mechanical load and adding to cyclic stresses which could result
Check cross girder, area around main bearing and bearing keep for signs of cracks and check fatigue failure.
main bearing. 2) Slack chain damages both chain system and engine frame.
All bearings to be checked for silvery colour (indicates bearing wiping) 3) Slack chain cause retardation of timings of fuel pumps and exhaust valve resulting:
Check all surrounding of oil pan area of all units for any sludge deposits, bearing metal pieces Reduce scavenging efficiency, due to late closing of Exhaust valve
etc. Reduce engine power,
Check crank case relief door wire mesh (should be wet) spring tension, sealing ring Low Pmax, due to late injection
condition etc. High exhaust temp: with smoke, due to after burning
Check the teeth of transmission gears for signs of wear 4) Can cause hot spot.
Check chain drive for tightness.
Oil mist detector sampling pipe to be checked for clear passage. Chain slackness checking.
Clear foreign materials from the crankcase and tools accounted for.
1) Turning (astern) the engine so that slack part of the chain is on the side of tension wheel.
Start lub oil pump and cross head oil pump and check oil flow and distribution
Check crank case door sealing condition and close crank case door. 2) Pull vigorously to and fro at the middle of the free length of the chain. Under normal condition the
Inform Chief Engineer (for satisfactory checking of C/C) and Duty Officer. chain should vibrate by half to one chain link.
3) If the chain is slack it should be adjusted.
4) Measure @ the longest span.
5) By measuring the transverse displacement of the chain at its mid point between two designated
CHAIN CASING INSPECTION.
sprockets.
Before 4,000 running hrs and after lengthy voyage, chain tension is checked at mid span of
Allowance 1/2 to 1 link, more than 1 link - readjusted.
slack side, in transverse direction.
Limited transverse movements is ½ to one link pitch on slack side.
Elongation allowance.
Excessive tension may cause chain breakage.
Elongation more than 2% of original length - renew.
Excessive slackness may cause vibration and eventual failure.
Elongation more than 1.5% of original length - closely care.
Elongation (chain wear) is checked between 3,000 - 5,000 running hours
Total length of 10 links drawn tight and measured and chain stretch calculated in % by comparing
How to check chain elongation
with original length of 10 links.
Turn the engine to ahead direction, so as to set the tightness of chain.
Maximum elongation : not exceed 2% . Over 2% the whole chain must be renewed.
Due attention to be given when the elongation reaches 1.5 %.

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
225 226 REFERENCE FOR M.O.T 2 Class Part B (Oral)

Measure the length of the chain between two fix points and count the nos. of chin link pitch. Carry out Saturday routine
Then original chain length can be calculated from instruction book. Testing of emergency fire pump
Calculate original chain length = Nos. of chain link pitch x Original pitch length Emergency generator and emergency air bottle.
Then compare with the original chain length and actual chain length. Lifeboat engine
Fans and ventilation
Measure actual - Maker siven original CO2 bottles (links, secured location of key)
Testing of fire detectors.
chain length chain length Testing of engine room fire extinguishers.
Calculate elongation = x 100
Original chain length Checking of funnel flaps.
Hydrant and nozzles in engine room
Ensure operated fire doors.
Maximum elongation on the chain should not exceed 2% and due to attention to be given when
Safety harness and fireman's outfit in engine room
elongation reaches 1.5 %.
Engine room ship side valves operated
Testing of engine room lifting gears

RESPONSIBILITY OF 2ND ENGINEER

Machinery Maintenance
Duty and responsibility of 2nd Engineer is to plan, operate and carry out work in accordance
In state of readiness at all times
with established rules and procedures to Safe Guard Life at Sea, Protect Marine Environment and
Proper round checks carried out
Maintain the Seaworthiness of the vessel at all times.
Safe operation of all machinery on board
PMS jobs to be carried out
Maintain and Update Documentation
Attend to all major repair work
Documentation under 2nd Engineer responsibility which requires maintaining and updating are as Keep track of all defects and repair required
follows- Able to manage any other emergency repairs outside PMS
Daily record book. Saturday routine book Ensure handing / taking over reports cover the engineer's general duties, their performance and
Machinery maintenance record book Engine room logbook any special job as a requirement.
Defect and repair list Updating of PMS
Major spares inventory Stores and ROB (spares of Aux. Machinery) Pollution Prevention
Oil record book Lub oil and chemical inventory Ensure all Engineers know –
FFA and LSA record book (LSA – BA, Life jacket, ELSA etc) Procedure of oily water separator
Engine Room Management Procedure of incinerator
Procedure of sewage plant
Personally responsible to CE
Oil record book and E / R logbook updating
Ensure engine room is properly manned
Bunkering / transferring procedure
Proper distribution of job
Bilge overboard valves are shut and locked in port and in special areas.
Clear briefing done before a job is carried out.
Ensure all engineer and crew practice safe working procedure and wears safety gears at all
Emergency Procedures
times.
Guidance and proper training of juniors Steering gear emergency procedure
Ensure everyone understands the consequence of pollution Main Engine local control
Responsible for compilation of all work done for future records Fire and abandon ship drill
Flooding / Grounding / Collision
Power failure procedures
Engine Room House keeping
Oil spill drill
Ensure E / R is maintained in a clean, painted and sanitary condition
Ensure all tools and stores are kept safely and location recorded. TAKING OVER AS 2ND ENGINEER
Secure all heavy items at all times Report to Chief Engineer and Master
All leaks and damages are attended as soon as possible Meet to out going 2nd Engineer and go through-
Bilge garbage and sewage management as per regulation a) 2nd Engineer's work done book
b) Oil record book
Safety of Engine Room and Ship c) Machinery maintenance book
Ensure all engineers know the location of LSA and FFA. d) Spares inventory record book
All emergency escape routes are clearly marked and clear of any obstruction e) ROB of fuel oil, Lub oil and Chemicals record
Malignance of all FFA and LSA under 2nd engineer's responsibility f) LSA and FFA maintenance book
g) Saturday routine book

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
227 228 REFERENCE FOR M.O.T 2 Class Part B (Oral)

h) Engine room defect list The oil film acts as a dielectric. The puncture voltage in the bearing depends on the thickness of
i) Spare requisition (record of emergency spares) the oil film
j) Finished plans and operating manuals If load increases oil film thickness decreases.
k) Engine room logbook In early stage, the roughened area can reasonable pitting erosion, but later will roughness
Go through the handing over report with out going 2/E and ask if any doubt increases; the small craters will scrape off and pick up the white metal, hence the silvery white
Special standing instruction by chief engineer appearance.
PMA outstanding maintenance Keep shaft voltage below 50 mV.
Take rounds of engine room – familiarize High voltage means shaft is not grounded properly
Know all emergency exits Spark erosion occurs between main bearing and journal only.
Know your emergency station
Check all FFA and LSA in E/R, also the fire detectors
Know the special tools location What do you do at heavy sea as a 2/E ?
Visual inspection of M /E, Boiler, D /G, OWS and incinerator Fill settling & service tank and drain water and impurities sediment
Visual inspection of steering flat and steering gear condition Fill sump oil of all machines if necessary
Visual inspection of tank top and pipe lines condition Clean F.O strainer and place then stand by
Visual inspection of motors, lighting and electrical appliances Secure all parts which can be move in rough sea
Check bilge pumps and ships side valves Run stand by generator and place it parallel
Emergency steering procedure Reduce Main engine speed if necessary
Local manoeuvring procedure of M /E Instruct all watch keeper to call 2/E if necessary
Check emergency fire pump, emergency generator and emergency compressor Instruct on watch keeping engineer to stay in E/R and one watch keeper to check all engine
Lifeboats condition (internal & external) and test the lifeboat engine room running machines and other possible damage.
Check boiler area and if it is not being used for cargo discharge then a few safety cut outs to be
tested and check gauge glass. .Shipboard Oil Pollution Emergency Plan: SOPEP
Inspect the fix fire fighting system and know the checks to be made and check past records Every oil tanker of 150 GRT and above, and every ship of 400 GRT and above, shall carry
Know the bunker lines and valves onboard a Shipboard Oil Pollution Emergency Plan.
Fuel and LO tanks location and quantity The plan shall consist at least of:
Check a few UMS alarms 1) Procedures to be followed by Master, or other person having charged of the ship to report an
Get to know sub-ordinates and their responsibilities oil pollution incident.
Know the performance of the ship staff from outgoing 2E 2) List of authorities or persons to be contacted, in the event of oil pollution incident
3) Detailed description of actions to be taken immediately by persons onboard, to reduce or
control the discharge of oil
MAIN ENGINE SAFETY DEVICES 4) Procedures and point of contact onboard, for coordinating shipboard action with local
SAFETY DEVICES SAFETY TRIPS (Safety Devices) ME SLOW DOWN authorities in combating pollution.

1. Crankcase relief door 1. Over speed trip 1. LO high temperature Procedures, when accidental oil overflow occurs:
2. Scavenge space relief valve 2. Lo low pressure trip 2. JCW high temperature 1) Notify Harbour /Terminal Authority immediately through the Master
2) Actions immediately taken by persons onboard to stop, reduce or control the oil discharge
3. Cylinder head relief valve 3. Camshaft LO low pressure trip 3. Piston cooling high temp.
3) Coordinate shipboard actions with local Authorities
4. Staring air relief valve 4. Piston cooling low pressure trip 4. OMD alarm 4) Inform owner, agent, P & I Club, Flag State Authorities, and vessels in vicinity
5) Invite P&I (Protection and indemnity) correspondents
5. Starting airline flame trap 5. JCW low pressure trip 5. Thrust bearing LO low press
6) Record in ORB, time & place of occurrence approximate amount & type of oil, circumstances of
6. Oil Mist Detector 6. Thrust bearing high temp. trip 6. Control air low pressure discharge or escape.
7. Rotation direction interlock 7. Main bearing high temp. trip(may be) 7. Scavenge air high temp
Before arrival procedure
8. Turning gear interlock 8. OMD alarm (in case of excess oil most) 8. Exhaust gas high temp
01. When one hour notice is given from bridge
9. Spring air low-pressure trip 02. Inform to C/E
10. Manual emergency trip 03. Call the required engineer assistance
04. Stop F.W.G
05. To change H.O to D.O shut F.O heater steam valve
SHAFT GROUNDING SYSTEM 06. Slowly reduce engine speed from sea speed to harbour speed
Spark Erosion: Caused by voltage discharge between the main bearing & journal 07. Change the lubricator position and adjust air cooler temperature, put auxiliary blower (auto)
The cause of the potential is the development of a galvanic element between the ship's hull (by 08. Start the stand by generator & sharing load
seawater), and propeller shaft / crankshaft 09. Start the oil fire boiler
The voltage produced should be grounded; spark erosion occurs if not grounded 10. Pressure up main air bottle and drain out oil & water

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY AND INSPECTION nd
229 230 REFERENCE FOR M.O.T 2 Class Part B (Oral)

11. Check bilge O/B valve closed. Lock position and sewage valve 09) Try out the Main engine in ahead/astern direction; Verify that all alarms, safety devices and
12. Change fuel system H.O to D.O when temperature reach 90°C recorders are functional.
13. Record flow meter counter & time changing time 10) Test steering gear. Ascertain smooth operation and check for any leaks.
14. When S/B telegraph is received, take S/B M/E revolution counter. 11) Airs whistle and telegraph to be tried out.
12) Check operations of windlass and mooring winches.
13) Departure checklist to be filled in plant ready for to staring.

Before departure to sea Procedure after departure & full away

Before departure the port, all machineries must be kept in good working order and keep During start check the following
ready to sea. All exhaust valves are operating correctly
24 hours prior vessel’s departure Turbocharger(s) are running
Upon receipt of departure notice, the following is to be carried out, 24 hours ahead of the All cylinders are firing
event. All temperatures and pressures are normal and corresponding to the actual engine speed
01) Maintain a sufficient level of fuel in the diesel/heavy oil service tanks. Transfer oil to fill up Check for any leakage or unusual noise
settling tanks (H.O and D.O) prior to arrival in port. No oil transfer to be carried out in port, as All cylinder lubricators are working satisfactorily
far as possible. When full away is ring on telegraph
02) Drain off water from Fuel tanks, while maintaining the tank temperatures. F.O is heated and then the temperature of F.O is high enough for injection, M/E is change
03) Ensure filters in L.O and F.O pipelines are clean with D.O to heavy oil.
04) Check operation of safety equipment including emergency generator and safety devices on Note the flow meter counter reading
the starting air system must be in good order. Close valve of main air bottle and open the vents of air staring line.
05) The starting air valves also should be tested for leakage. After engine is navigation speed, check again all temperature and pressure are within their
06) Check temperature of jacket cooling water and adjust preheating, well in advance, in order to permissible limit. Checks scavenge drain, stuffing box drain.
have the engine sufficiently warmed up. The cooling water temperature is to be about 60°C. F.W.G can be start if the ship is not in 50 N miles form land.
The pipe system and cylinder jackets should be examined for leaks.
07) In cold climates, when necessary heated to main engine system oil.
08) Take soundings of al oil tanks and engine room cofferdams. Warming up of M/E necessary before sailing
09) Start the exhaust gas boiler water circulating pump well in advance. Warming up of M/E is essential before staring because
10) Within 12 hours before departure, check the operation of the steering gear, including the 1) Cold staring is very difficult
emergency steering. 2) To prevent thermal stresses on working parts.
11) Fill up both Air bottles to full pressure and drain off the condensate from the bottles 3) Circulating of jacket water effect is warming up of combustion chamber
12) Records of the above must be maintained in the log book. If it is not warming up, the heat produced by compression of air at piston stroke will not enough to
ignite the injected fuel
Two Hours before vessel’s departure Thermal stress will occurs due to high temperature difference between cylinder liner and cylinder
On receipt of Notice J.C.W
01) Start the second Generator check for normal operation and parallel onto the bus bars So, Main engine must be kept warming above 50 °C by G/E jacket cooling water or heater of
02) Start the following Main engine auxiliaries Steam/Electric
a. M/E jacket cooling water pump
b. M/E Piston cooling water pump Clean ballast tanks (C.B.T)
c. M/E LO pump As a temporary measure, older tankers have been permitted to dedicate certain tanks to be
d. M/E FO booster pump used for ballast only. Cargo piping may be used for the introduction and discharge of the ballast.
e. Any other pumps associated with running of the Main engine.
f. Ensure that the stand-by pumps are working, and all relevant valves are open while Segregated ballast tanks (S.B.T)
switching on various pumps mentioned above, ensure that the operations are New large tankers are required to be build with and adequate number of ballast (only) tanks,
smooth and trouble free and that pressures are normal. so that under normal circumstances water will not have to be carried in cargo tanks. Ballast is
03) Stop preheating, carried out for J.C.W & P.C.W, prior to the start of Min engine. handled by means of other than the cargo discharge pipe system.
04) Verify that following are adequate for safe operation
a. Main L.O sump tank Checking after ship grounded.
b. Main and auxiliary engine cooling water expansion tanks
c. Turbocharger L.O levels Open high sea suction & close low sea suction.
d. Fuel valve nozzle cooling tank Took all tank sounding every 10 minutes.
e. Stern tube L.O overhead and gravity tank Clean filters & sea strainer of sea suction.
f. F.O/D.O service tank Took M.E crank shaft deflection & crank case inspection. (After ship grounded is free)
g. Boiler Hot well tank Check propeller blade if possible.
05) Ensure that L.O Filters are clear and that the differentia pressure drop is normal. Carried out steering gear test.
06) After getting propeller clearance, the main engine is to be turn on by turning gear for a few Check load & ampere when M.E turning by turning gear.
minutes (three revolutions) and at the same time, the cylinder lubricators off all units are to be Check Tunnel & intermediate bearing for hull deformation.
manually operated.
07) Disengage and secure turning gear, and drain the air bottles and the starting air line of water.
08) Blow through engine and shut all indicator cocks. Close drains on coolers, scavenge spaces,
exhaust manifold and the economizer.

Compiled by Min Zar Tar 2/14/2005 11:26 AM

 SURVEY, CERTIFICATE 231 232 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

SOLAS CERTIFICATE 1. Life saving appliances. CARGO SHIP SAFETY RADIO 9. General condition of the hull as far as
2. Fire fighting appliances. CERTIFICATE (1 year) could be seen.
1. Passenger ship safety certificate. 3. Navigation lights & equipment. 10. Approved stability booklet.
2. Cargo ship safety construction certificate. 4. Sound signals & alarm system. Issued on satisfactory of inspection on radio 11. Position of load line mark and deck
3. Cargo ship safety equipment certificate. 5. Vessel's documentation. equipment on board and in survival craft. line.
4. Cargo ship safety radio certificate. 6. Display of fire control plan & life saving
5. Exemption certificate. appliances plan. SAFETY CERTIFICATE. I.O.P.P SURVEY
6. Nuclear passenger ship safety certificate. 7. Nautical publications.
7. Nuclear cargo ship safety certificate. 8. Training manuals. 1. Load line certificate. 5 years interval at least one intermediate
9. Drills & Test records. 2. Safety construction certificate. survey, not before six months prior to and not
CERTIFICATE ON BOARD (CARGO SHIP) 10. Pilot boarding arrangements. 3. Safety equipment certificate. later than six months after the half way date of
4. Safety radio certificate. validity of certificate. (MARPOL
1. Certificate of registry. SAFETY EQUIPMENT SURVEY. 5. MARPOL CERTIFICATE(IOPP, ISPP) REGULATION: 4 1.C)
2. Certificate of classification.(Hull & 6. Certificate of fitness for the carriage of 1. Check the validity of certificate.
Machinery) Every 2 years interval and annual inspection of dangerous chemicals in bulk 2. Check the OWS & piping system.
3. International tonnage certificate. its certificate validity + 3 months. 7. Certificate of fitness for the carriage of 3. Check alarm test and 15 ppm stopping
4. International load line certificate. liquefy cargo in bulk. device
5. International load line exemption 1. To run lifeboat engine both ahead and 4. Check every valves in good order.
certificate. astern direction, check fuel oil tank & LO LOAD LINE CERTIFICATE 5. Filter element spare on board.
6. Intact stability booklet. sump. 6. U.S.C.G Notice should be placed on
7. Minimum safe manning certificate. 2. To inspect means of illuminating power Valid for 5 years subjected to annual, O.W.S.
8. Cargo ship safety construction certificate. source for launching (lights) lifeboat and periodical load line inspection. 7. Check waste oil tank and capacity.
9. Cargo ship safety equipment certificate. life raft. 8. Check the fuel consumption.
10. Cargo ship safety radio certificate. 3. To swing out lifeboat at least 50% lowered LOAD LINE SURVEY 9. Calculate sludge formation and compared.
11. Deratting or Deratting - exemption into sea, lowering & hosting device to be 10. Check oil record book and prepared up to
certificate. kept in good order. It should be held at 5 years intervals from date.
12. International oil pollution prevention 4. To lay out and survey all life boat the date of built and if practicable whenever 11. Check incinerator capacity.
certificate. equipment. the periodical special classification survey is 12. Sludge tank low & high level alarm test.
13. Oil pollution insurance certificate. 5. Check (LSA) life jacket, life buoy, life raft, made. 13. Certificate of sludge transferred to shore
14. Certificate of financial responsibility. and immersion suit, breathing apparatus During this survey all freeboard items to be facility.
15. STCW. and fireman outfit. examined and load line marking to be verified. 14. Check the trademark of the maker and it
16. Certificate of cargo handling gear. 6. To inspect and test emergency and main The main purpose of the load line survey is must be approved by I.M.O.
17. Safety management certificate. fire pumps, keep fuel tank full. that the ship construction must meet the 15. Bilge overboard discharge valve must be
18. Oil record book. 7. To inspect & test emergency generator, requirement of the conventions and can be tight close and kept under chain and lock
19. Articles of agreements, Port clearance emergency battery & emergency lighting grouped into 4 categories. and bilge direct connection must be
system. 1. Structural strength. blanked by Blind Flange. This connection
CARGO SHIP SAFETY CONSTRUCTION 8. To inspect &test emergency air 2. Weather tight integrity. must be absolutely free from oil and
CERTIFICATE. (5 years / Annual compressor and emergency air bottle. 3. Stability and sludge.
inspection) 9. To inspect fire hoses nozzles & container 4. Crew quarter protection.
box. PORT STATE CONTROL.
This certificate will issue on satisfactory, 10. To inspect all portable extinguisher, The following item should be inspected.
inspection of the following items. nonportable extinguisher, fixed installation 1. Hatch coaming, hatchway, hatch cover A port state inspection is a particular form
1. Ship structure including structural fire system (level of gas, clearing line with and closing appliances. of statutory survey. It is carried by a surveyor
protection. compress air, operating system), and 2. Ventilators, air pipes and closing representing the authorities of the government
2. Internal examination of ship bottom, cargo alarm system. appliances, fuel oil tank air pipes and of the port in which a ship find it self. The
and bunker piping system. 11. To inspect audible and visual fire alarms, flame trap. intention of the survey is to check that the ship
3. Boilers, pressure vessel and fittings. fire detecting system, abandon ship 3. Watertight door and stop valve in the using the port meet with international minimum
4. Electrical installation. warning and ship sirens, Muster list. watertight bulkhead and closing requirements. The inspection carried out
5. Main & auxiliary machinery and steering 12. To call for fire drill, boat drills and appliances. regardless of the nationality of the visiting
gear. abandons ship drill. 4. Hand rail, catwalk, bulwarks, scuppers vessel. At every port where the ship called on,
13. To inspect means of stop switch of E/R for of freeing ports, gangway and guard the government body concerned has a right to
CARGO SHIP SAFETY EQUIPMENT fans, FO pumps, FO & LO tank valves, fire rails. access to the ship and conduct inspection on
CERTIFICATE. (2 years/ Annual inspection) dampers; sky sight door & watertight 5. Scuppers and other discharge valves the
doors. and pipes below the freeboard deck. 1. Safety equipment.
Every merchant ship over 500 grt 14. To inspect latest Nautical publication. 6. Cargo ports below the freeboard deck. 2. I.O.P.P certificate.
needs a safety equipment certificate. It is 15. To inspect navigation equipment & light. 7. Exposed engine opening and their 3. Oil record book.
issued by the government of the flag state 16. To inspect vessel documentation. closing appliances, engine room 4. Sewage treatment plant.
after a survey has shown that the vessel skylights and their closing appliances. 5. MARPOL equipment for port state control
meets the requirement of SOLAS Convention 8. Opening in the sides and ends of measured.
Given to cargo ship covers enclosed superstructures. 1. The international convention of load line.

2/14/2005 11:28 AM
 SURVEY, CERTIFICATE 233 234 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

2. The international convention for the safety IACS (International association of 3. Rudder. Date, Identity of tanks, Last contain oil,
of life at sea. (SOLAS) classification society) 4. Stern frame. Cleaning process (position of ship & time @
3. The international convention for the 5. Tail shaft, propeller shaft. the start & completion)
prevention of pollution from ship.( 1. Registro Italiano Navel (Italy) 6. Stern tube bearing, gland. 2. Discharge of dirty ballast or cleaning
MARPOL 1973/78) 2. USSR register of shipping (Moscow) 7. Sea valve, chest. water from oil fuel tank refer to under
4. The international convention on standard 3. Lloyd’s register of shipping (London) 8. Grids, scupper. section 1.
of training certification and watch keeping 4. Bureau Veritus (Antwerp) 9. Cathodic protection. Date, Identity of tanks, Position of ship
for seafarers.(S.T.C.W) 5. American Bureau of shipping (Newyork) 10. Anchor cable layout & wear down. at start & completion, Ship speed, Method of
5. International regulation preventing collision 6. Det Narske Veritas (Oslo) discharge, Quantity of discharge.
at sea.(Colag) 7. Germanischer Lloyd (Hamburg) FIRE CONTROL PLAN 3. Collection & disposal of oil
6. The merchant shipping minimum standard 8. Nippon Kaiji Kyokai (Tokyo) residues.(sludge)
convention. 1. Control station Date, Identity of tanks, Total quantity of
7. E/R cleanness & incinerator operation. What is the purpose of C.S.M? 2. The various of fire section enclosed by retention
class A & B division. Date, Method of disposal, Quantity of
(Same as ISM inspection) Instead of opening up for the survey during 3. Fire detecting and alarming system. disposal & retained.
the class renewal period, all the survey items 4. Sprinkler installation & fire extinguish 4. Non-automatic discharge overboard or
P & I CLUB. (Protection & identity club) are equally distributed within the 5 years appliance. disposal otherwise of bilge water which
period for the convenient for the owner. Owner 5. Means of escape has accumulated in machinery space.
Insurance for small damage. to be requested the classification society to 6. Ventilation system(position, damper, no: of 5. Automatic discharge overboard or
Formed by ship owners to insure certain enter the C.S.M. fan control) disposal otherwise of bilge water which
damage related to ship, which does not has accumulated in machinery space.
cover by insurance policy. What included in C.S.M survey? FLAG STATE CONTROL. Date, Quantity, time & position of ship
@ start & completion, Method of discharge.
SOLAS International convention for safety 1. Main propulsion machinery (a) steam The administrations have responsibility of 6. Condition of oil discharge monitoring
of life at sea turbine (b) diesel engine. the ship built to their flag commonly with the and control system.
S.T.C.W International convention 2. Power transmission system and main requirements of the conventions in Date,Time of system failure &
for standard of training, shafting. (reduction gear) construction and up keep after wards. Operational, Reason.
certification & watch keeping for 3. Auxiliary engine. For this intention the government body 7. Accidental or other exceptional
seafarers. 4. Air compressor. carried out surveys and issued certificates discharge of oil.
GMDSS Global maritime distress and 5. Cooling pumps. relating to the shipping industry includes. Date, Time, Place, Quantity, Reason.
safety system 6. Fuel oil pumps. 8. Bunkering of fuel (or) bulk lubricating oil.
I.S.M International safety management. 7. L.O pumps. 1. Passenger ship safety certificate. (1yr) Date, Place, Time of start & completion,
S.M.S Safety management system 8. Feed water pump, condensate pump, 2. Cargo ship safety construction Type & Quantity(added & total)
D.O.C Document of compliance drain pump. certificate.(5yr) 9. Additional operational procedures and
S.M.C Safety management certificate 9. Bilge, ballast and fire pump. 3. Cargo ship safety equipment certificate. general remarks.
I.A.C.S International association of 10. Condenser and heater. (feed water) (2yr)
Classification Society 11. Coolers & Oil heaters. 4. Cargo ship safety radio certificate. MARPOL (73/78)
MARPOL International convention for the 13. F.O tanks. (1yr)
prevention of pollution from ship 14. Air receivers. 5. Exemption certificate. Annex I Regulation for the
SOPEP Shipboard oil pollution emergency 15. Deck machinery. 6. International load line certificate. prevention of pollution by oil.
plan (5yr) Annex II Regulation for the control of
Items not cover by C.M.S. 7. MARPOL certificate pollution by Noxious Liquid substances
General check list for audit. (ISM code) IOPP, oil record book & ISPP Annex III Regulation for the prevention
1. Propeller and propeller shaft. (5yr) of pollution by Harmful substances in
1. Certificates and documents including ORB 2. Sea valve below lead water line. Packaged forms
& log book. 3. Boiler, economizer, thermal oil system. Annex IV Regulation for the prevention
2. Safety in general. 4. Cargo handling equipment. SPECIAL AREA of pollution by sewage.
3. Testing & drill. 5. Measurement of crank shaft deflection. Annex V Regulation for the prevention
4. Navigation equipment 6. Sterntube wear down measurement. 1. Mediterranean sea, Baltic sea, Red sea, of pollution by Garbage from ship.
5. L.S.A 7. Rudder bearing and pintle measurement. Black sea & North sea
6. F.F.A 8. Performance and pressure test. 2. Gulf of Aden, Persian Gulf SLUDGE AMOUNT.
7. Radio installation including GMDSS 9. Special equipment design.(proto type, etc) 3. Antertic Area, Wider Caribbean Area
8. Load lines 10. Small capacity & low operational (Other sea area & many inland water way) 1 to 2 % of fuel consumption.
9. Hull construction frequency equipment. At least 1 % of fuel consumption.
10. Machinery in engine room 11. Foundation bolt. OIL RECORD BOOK (LIST OF ITEMS TO
11. Electrical equipment BE RECORDED) TO CHECK FIRE ALARM - Tested by
12. Mooring equipment BOTTOM SURVEY smoke detector.
13. Marine pollution 1. Ballasting and cleaning of oil fuel tanks.
14. Cargo gears 1. Shell plating. TO CKECK CO2 ALARM - Tested by CO2
15. Accommodation 2. Propeller. cabinet box

2/14/2005 11:28 AM
 SURVEY, CERTIFICATE 235 236 REFERENCE FOR M.O.T 2nd Class Part B (Oral)

OIL RECORD BOOK 1. The insurers to assess the premium Fire fighting equipment for machinery Fire mans outfit
relative to the ship (hull insurance) and cargo space.
Record to be kept on board for the (cargo insurance). 1) Protective clothing.
operation of oily water, Sludges & bunkering. 2. The owner to find an insurer who accepts to 1. Portable fire extinguisher (CO2, Foam, Dry 2) Boots and gloves. (electrically
cover the risks incurred by the ship. power) nonconducting material)
ATTACH WITH OIL RECORD BOOK 3. The owner to charter his ship. - Capacity 9 liter, not more than 13.5 liter, 3) Rigid helmet.
4. The charterer to select advisedly the ship - At least two numbers at every 10 m 4) Electric safety lamp. (min: burning period 3
1. Photo copy of MARPOL certificate. whom he will entrust with his cargo. walking distance. hours)
2. Original oil disposal certificate. 5. A future owner to assess the quality of the 2. Non portable (Foam) 5) Axe
3. Dirty oil & sludge piping diagram. ship prior to the purchase. - 2 numbers (Boiler room & Machinery 6) Life line.
6. The flag authorities to trust the ship and space.) 7) Breathing apparatus.
BILGES PUMPING OUT CRITERIA. therefore to register her into their fleet. - Capacity 45 liter.
3. Fixed installation.( CO2, Foam, Pressure Underwriter.
- In port not allow Classed ships water )
4. Sand box & Scoop. A person who insures the whole or a part of a
OUTSIDE SPECIAL AREA WITHIN SPECIAL AREA Upon confirmation of their compliance ship or its cargo.
1. Vessel enroute 1. Vessel enroute with the requirements of the Rules through
2. Oil particle less than 2. Oil particle less than Personal life saving appliance.
classification surveys by the surveyors, the Underwriter surveyor.
15ppm 15ppm
3. Has an operational oil 3. Has an operational
ships are entitled to a class appropriate to their 1. Life jacket.
discharge monitoring system, filtering equipment types and to the services on which they are 2. Life buoy. A person recognized by insurance company
oily water separator. with automatic stopping engaged. For the ships entitled to a class, the 3. immersion suit. who is witness of insurance company for
device. classification societies issue a Classification insurance claiming.
Certificate which confirms that the ships have
BREATHING APPRATUS CAPACITY. both structural and mechanical fitness for their Emergency & safety drill @ sea. Damage survey
intended services.
- At least 30 mins for hardworking. - For safety of ship, crew & cargoes. Damage to hull, machinery or equipment,
45 mins for light working. Maintaining the class which effects or may effect seaworthiness of
- 1200 lit classification, is to be submitted by owners or
By owners carrying out regular Saturday routing. their representatives for examination of the
Boiler survey surveys of the hull, machinery and equipment, surveyor. All repairs found necessary by the
as well as repairs that may be required from 1. Fire drill. surveyor are to be carried out to his
• Every 2 years up to 8 years after built. time to time as a result of wear and tear or 2. Emergency fire pump operation. satisfaction.
• Every year, after 8 years. accident, all under the supervision of 3. Fire detector, alarm & sound signal.
classification of classification surveyors. The 4. Emergency generator operation. Pre-loading survey
Annual survey class is granted generally for a term of five 5. Life boat drill
years during which its validity is subject to 6. Check life boat engine & test run both Pre-loading surveys of refrigerated cargo
The annual survey requires a general compulsory periodical surveys. ahead & astern direction. installation are also conducted at the request
inspection of the whole machinery and of the owners / charterers for the loading of the
equipment. Statutory surveys LIFE SAVING APPLIANCES. refrigerating machinery in working condition
and inspection of the refrigerated cargo
Periodical survey Statutory surveys are differ from 1. Life boat, life raft, life buoy, life jacket. compartments are to be made prior to loading
classification surveys in that they are not 2. First aid kit. of intended refrigerated cargo.
The periodical survey requires a assessing or measuring something for a client. 3. Compass.
thorough inspection and include performance Statutory survey is simply inspecting 4. Line throwing appliance. Surveys relating to merchant ships in
test and inspection of electrical installation etc: something against a set standard or law. On 5. Life boat radio with 2 way V.H.F service.
completion of his survey, he issues the ship system.
Classification Societies. with a certificate which is essential to the 6. Life boat engine & food ration. Part A - Classification surveys
ship's ability to trade. It is issued on behalf of 7. Fire fighting equipment.
Classification Societies are third party the government and has a legal, international 8. Immersion suit for every crew of 1. Annual survey, special survey and
independent bodies whose function is to status. rescue boat & thermal protective aid. continuous survey (Hull and Machinery)
ensure that a ship is soundly constructed and 9. Rador responder of two numbers on 2. Boiler survey
that the standard of construction is maintained. Fire hose & nozzle required for a ship. each side of ship. 3. Dry docking survey
They also carried out the statutory surveys on 10. Muster list & emergency instruction. 4. Tail shaft survey
behalf of the Administrations according to the At least two numbers of hose & nozzle 11. Rescue boat. 5. Shipboard automatic and remote-
various international regulations and codes from fire hydrant can reach any part of the fire 12. Survival craft embarkation & launching control systems survey
relating to ship safety and prevention of hazard on board ship. equipment. 6. Refrigeration plant survey
pollution of marine environment. 13. General emergency alarm system and 7. Damage survey
Classification of the ship enables :- P.A system.

2/14/2005 11:28 AM
 SURVEY, CERTIFICATE 237

Part B - Statutory surveys Part C - Surveys requested by authorities, Big end bearing removing and fitting procedure.
charterers, owners, underwriters, etc.: 1) Take immobilization from port authority
1. Load line survey
2. Safety construction survey 1. Damage survey
2) Close main air stop valve and lock starting system
3. Safety equipment survey 2. On/off hire survey 3) Engage turning gear and stop L.O pump
4. Safety radio survey 3. Laid up ship survey 4) Open crankcase door
5. MARPOL surveys 4. Surveys according to IMO codes 5) Turn crankshaft until the crank is BDC
6. Tests, examinations and inspections 5. Pre-loading survey
of ship's cargo handling machinery and gear. 6. Draught survey 6) Measure bearing clearance by inserting feeler gauge between bearing lower half and crankpin.
7. Conditional survey 7) Turn the crank shaft to TDC position.
8) Remove locking arrangement and slackened the nuts. The bottom half lower a few and took out bearing
SAFETY EQUIPMENT SURVEY. (As a C/E)
clearance adjusting shim, each set being tied separately and note taken of the side to which each set
belongs.
Every 2 years interval and annual inspection of its certificate validity + 3 months. 9) Chain blocks connected to eye bolts, screw into each bolt. After removing two nuts, bottom half lowered into
the sump. Putting hanging bar in position, connect chain blocks to crankcase door frame and eye bolts
1. To run lifeboat engine both ahead and astern direction, check fuel oil tank & LO sump.
2. To inspect means of illuminating power source for launching (lights) lifeboat and life raft. which is screwed into each side of the top half. Then turn the crankshaft to the position where the top half
3. Lowering & hosting device to be kept in good order. can be taken out.
4. To inspect and test emergency fire pump (keep fuel tank full) and main fire pumps, 10) Also take out the bottom half with bolts outside the crankcase
5. To inspect & test emergency generator, emergency battery & emergency lighting system.
6. To inspect & test emergency air compressor and emergency air bottle. 11) Inspection on crank pin, bearings, oil holes, grooves, bolts cracks, sign of movement and elongation.
7. To inspect audible and visual fire alarms, fire detecting system. 11) Take measurements of crank pin at least 3 place top, bottom and port, stb check ovality.
8. To inspect trips, means of stop switch of E/R for fans, FO pumps, FO & LO tank valves, fire
dampers; sky sight door & watertight doors.
12) Display surveyor, check points are
12a) Bearing clearance (0.5 to 0.7 mm for 550 mm diameter crank pin)
Class survey. 12b) Bearing surface (No crack, no damage and if wipe out 30% renew it)
Class survey is to ensure that a ship is soundly constructed and that the standard of 12c) Check holding down bearing surface.
construction is maintained. (Goal is sea worthiness)
Unclass ship can enter or departure from the port but statutory survey is strict for unclass 12d) Oil hole and grooves (No damage)
ship. 12e) Crankpin ovality and its surface
12f) Lubricating system (clear)
At sea garbage disposal requirements
12g) Big end bearing bolts (Good thread, no extension, no cracking and no twisting)
Garbage type Outside special area In special area 12h) heck sign of movement of the joint point such as two halve of bearing joint and between top
halve and connecting rod foot.
Plastics - Includes synthetic ropes and Disposal prohibited Disposal prohibited
fishing nets and plastic garbage bags.

Floating dunnage, lining and packing > 25 miles off shore. Disposal prohibited What points to be checked after removing big end bearing ?
materials. After cleaning, inspect the bearing thoroughly at crank pin ovility and two halves of bearing surface (wear,
Paper, rags, glass, metal, bottles, > 12 miles Disposal crack and damage) together with oil holes and grooves. (If over 30 % of wear or crack in the contact area it
prohibited should be renewed)
crockery and similar refuse. Thoroughly, examined the bolts for cracks in the threads (no extension and no twisting )
All other garbage including paper, rags > 3 miles Disposal prohibited
Check sign of movement of the joint point such as two halve of bearing joint and between top halve and
glass, etc. comminuted or ground. connecting rod foot.
Bearing clearance.
Food waste not comminuted or ground. > 12 miles > 12 miles Check holding down bearing surface.
Food waste comminuted or ground. > 3 miles > 12 miles

Mixed refuse type *** ***

*Comminuted or ground garbage must be able to pass through a screen with mesh size no larger
than 25 mm .

2/14/2005 11:28 AM Compiled by Min Zar Tar 14/02/2005 11:29 AM

 ① ②

Fuel valve cooling 01) OSD 200 litres. ¶

All fuel valves need proper cooling to maintain the tip region temperature within acceptable zone 02) Chemical splash suit 10 nos.
to avoid malfunction of the operation mechanism. The cooling is insufficient may result: 03) Goggle 10 pairs.
Cracking of fuel oil leading to clogging of sprayer holes, sticking of needle valves and wearing 04) Boots 10 pairs.
and distortion of sprayer holes. 05) Nitrile gloves 10 pairs.
Carbon trumpets formation of or carbon petal formation on the tip around the sprayer holes. 06) Sawdust and cotton rags. ·
Over cooling may result; Low temperature corrosion, insufficient flow quantity and too high degree of 07) Oil seals 30 nos.
penetration.
08) Oil coushions 40 nos.
09) Oil scoop (non-spark) 1 no. ¸
Anti dribbling arrangement 10) Deep pan shovel (non-spark) 1 no.
As the valve closes at the end of pumping, the piston section of the pin, or unloading collar, enters the
11) Disposable bags 10 nos.
valve seat bore to extract a small amount of fuel from the high-pressure line before the valve is completely
closed. 12) 29 ft³ Container 2 nos.
This extraction causes a negative pressure wave which travels along the fuel line to the nozzle and 13) Bucket (non-spark) 1 no.
ensures that the nozzle valve closes rapidly to give a sharp cut-off to the end of the injection, to prevent dribble 14) Brooms 6 nos.
and secondary injections. 15) Scupper plugs ¹
16) Cement for plugging
17) Submersible pump (Wilden)
18) Bilge and Ballast Piping Diagram.
19) Fuel and LO system Piping Diagram.
20) HO responsible address.
21) Port Authority Address.
22) Agent Address.

Procedures, when accidental oil overflow occurs:

1. Notify Harbour/Terminal Authority immediately through the Master.
2. Actions immediately taken by persons onboard to stop, reduce or control the oil discharge.
3. Co-ordinate shipboard actions with local Authorities.
4. Inform owner, agent, P&I Club, Flag State Authorities, and vessels in vicinity.
5. Invite P&I (Protection and indemnity) correspondents.
6. Record in ORB, time & place of occurrence, approximate amount & type of oil, circumstances of
Shipboard Oil Pollution Emergency Plan: SOPEP. discharge or escape.
Every oil tanker of 150GRT and above, and every ship of 400GRT and above, shall carry onboard a Bridge gauge
Shipboard Oil Pollution Emergency Plan. A bridge gauge enables the measurement of journal bearing wear down with the crankshaft in
place.
The plan shall consist at least of: Top half of housing must be removed and the gauge place on the butt face of the bottom half
01) Procedures to be followed by Master, or other person having charged of the ship, to report an oil pollution bearings. The feeler gauge is inserted between the journal and the apex point and readings recorded and
incident. compared with the previous and the original recorded and compared with the previous and the original
02) List of authorities or persons to be contacted, in the event of oil pollution incident. results.
03) Detailed description of actions to be taken immediately by persons onboard, to reduce or control the
discharge of oil.
For journal ovality, the crankshaft turned through 30° or 45° interval for each successive
04) Procedures and point of contact onboard, for co-ordinating shipboard action with local authorities in measurement. (All results must be the same, if not journal is ovality).
combating the pollution.
Single Phasing
SOPEP Requirements: Single Phasing means that one of the three phases of the motor is disconnected. If a
Oil spill kit inside Oil spill Locker: motor is already running, and this occurs, it may lead to excessively high currents and eventual
Can be grouped into: ¶ Solvent · Absorbent ¸ Cleaning ¹ Plugging material. burn-out of the motor.
 ③ M.O.T 2nd Class Oral Question ①

Steering gear / Stern tube / Rudder a How to know air cooler leakage ?
1. How to know power of steering a Operate main air compressor by
motor ? (Power test/Swing test) manually ?
2. How will you carry out steering a Air compressor busting disc and
ger test, what are the purposes relief valve different operation
of swing test ? and can be used in the same
3. When telemotor failure what will place.
you do ? 6/63 a To get good performance of air
4. Checking of steering gear room compressor.
66 a How to know efficiency of air
5. What are the daily checks in compressor is good or not ?
steering gear room ? 66 a What is bumping clearance,
6. How to check leakage of stern effect when less and more ? Why
This situation can take place if one of the back-up fuses blows or a Contactor is open it is important ?
tube oil ?
circuited. The currents in the remaining lines increase and the torque becomes uneven, besides causing 7. How to measure rudder wear and a Why compressors used in marine
excess current through the remaining phases. The three thermal elements of an Over current relay (OCR) can when ?191 are multiple states ?
detect un-equal heating due to this situation, which trips the motor Contactors. 8. How will you measure stern tube
wear down ? 188/190 Indicator Diagrams
9. State function of hunting ?2/63 a Do you know how many kinds of
indication cards ?
Explosion a Why power diagram is taken ?
a How to prevent crank case a How will you take power
explosion ? 14/85 diagrams ? How do you calculate
a State maintenance of oil mist its ?
detector . 28/89 a Why is draw card taken ?
a How is crank case explosion a Why light spring card is taken ?
occurred? a If you don’t have Planometer how
As seen in the sketch, the contacts are normally closed (NC). If there is excess current, all the a What are the safety devices for will you calculate area of power
crank case explosion ? diagram ?
three bimetallic strips move to the right, to operate the trip due to over-current. In case of single a How to check crank case relief
phasing, the current through the remaining lines may not be sufficient to operate the trip, however, the door ? Boiler
a What are the requirements of a Are there how may kinds of
single bimetallic strip, of the line which is open-circuited, remains on the left (in the last sketch), which crank case relief door ? boiler safety valve ?
causes the upper and lower parts to shift relative to each other, and the resultant movement causes the trip a Why does air line explosion a How to set boiler safety valve
to operate. occur ? pressure ?
a Say prevent for air line a How do you understand boiler
For larger motors, a separate device called a negative phase sequence relay is used, to measure explosion. flash-up ?
the unbalance between the currents. a What are the safety devices ? a Flash-up procedure
A stationary motor will not re-start when single phasing occurs. a How can you detect leaking air a Boiler mounting.
staring valve at sea and in a What is back fire ?
port ? a If you find oil in boiler, what
MAINTENANCE a How do you carry out safety cap will you do ?
Cleaning of sea water side and oil side is at regular interval. After cleaning, the coolers are maintenance ? a If you found oil in the feed
hydraulically pressure tested about a little more than its Working pressure. If the 10% of the tubes have water tank, Why has in it ? what
Air bottle and compressor will you do ?
been leaked, retubing is necessary. Normal leaking tubes may be stopped by plugging. a What are the air bottle safety a Carry out boiler gauge glass
In surveying the L.O cooler, the following points to be checked; devices ? blow down.
a Carry out air bottle pressure a Carry out scum blow down.
(01) Test pressure and any leak points under test. test. a How can you know exact boiler
(02) Check division plate (holes) a State air compressor safety water level ?
(03) Numbers of plugged tubes device ? a Cause of boiler corrosion.
a Why 1st and 2nd state relieve a Boiler Foaming, priming and
(04) Condition of water boxes and anodes for wear valve of air compressor open ? water hammering.
(05) Condition of shell for heat transfer surfaces, Vent plug and drain plug. a Where is fusible plug fitted ? a Boiler water contamination.
(06) Condition of Safety leakage ring a Why is fusible plug fitted ? a Safety vale pressure setting
a What are the purposes of procedure.
(07) Condition of tube plate surfaces for pitting corrosion bursting disc ? a Soot blower maintenance.
(08) Total removal of tube stack and inspect inside the shell and baffles for any wastage and pitting a Why intercooler is fitted to air a There are excess chloride in
compressor ? boiler water, what will you do ?
corrosion and cleanliness of heat transfer surfaces. a State function of inter cooler ?

Compiled by Min Zar Tar 14/02/2005 11:30 AM

② M.O.T 2nd Class Oral Question M.O.T 2nd Class Oral Question ③

a Why take T-Alkalinity in boiler a regulation. State purpose of axial clearance. State difference between Duplex
water test ? a State garbage regulations. State scavenging system and filter and magnet filter.
a Explain about waste heat a What/Explain is bilge injection explain loop scavenging system. What will you do in cause of
recovery system ? valve ? Are there how many kinds of leakage of generator engine air
a What will you do steam excess in exhaust system ? State cooler ?
economizer ? Fire and Safety advantages of constant pressure. M/E chain elongation maximum
a How to control steam generation a How to enter into the fuel oil Say, three kinds of scavenging allowance and checking ?
of economizer ? empty tank ? system ? How does cross-flow How would you take crankshaft
a When is soot blowing carried out a Enclose space, F.O service tank work ? deflection ?
and why ? entering procedure . Difference constant and pulse . Why take Crank shaft deflection ?
a Cause / How to prevent scavenge Explain turbocharger surging ? What will you check during crank
Fuel Oil System fire ? Why installed the T/C header case inspection ?
a What are the settling tank a Explain Uptake fire ? tank ? How do you overhaul rotor cap of
mounting ? a How many methods of fire exhaust valve ?
a What type of drain valve is used extinguishing ? M/E Unit overhaul piston & liner
in settling tank ? Self-closing a Say, five items of fire fighting How to carry out liner check point
type media ? calibration ? How much wear down What in the tappet clearance ?
a Say, how many kinds of fuel a How do you extinguish with CO2 limit ? (1% of original dia) Why take ?
valve tests, how to carry out portable extinguisher? How to get main bearing Piston ring clearance (1) Gap –
dripping test ? a What are the fire man outfits ? clearance ? 3 times of original (2) Vertical
a How would you perform fuel valve a How to extinguish oil fire with What will you check thin shell 0.2 – 0.
test ? water ? bearing for further use ? How will you know unbalance of
a What will you check when you a What type of fire can be Say, how much normal clearance M/E ?
overhaul fuel injection pump. extinguished by Soda-Acid P.F.E ? for main bearing of diameter 500
a Fuel pump timing checking. (Carbonaceous material) mm.(550 dia – 0.8 mm max.) Pump
a How will you check leakage a How to use foam extinguisher, State survey procedure for M/E How to control discharge
delivery valve ? why deflection is carried ? main bearing & measurements to pressure of positive
a Fuel pump metering. a Where is quick closing valve be taken ? displacement pump ? By pass
a What is V.I.T ? fitted and why fitted ? Explain crank pin bearing ? relief valve
a How would you prevent a What is the international shore Overhaul Cross head Overhaul reciprocating pump ?
antidribbling ? connection ? Carry out cross head survey. What will you check in screw
a State F.O specification at a Do you understand fixed What will you do in cause of pump ?
bunker ? installation ? high temperature at intermediate Why does not ballast pump
a Explain F.O pour point ? a What is SOPEP ? State equipment bearing ? discharge ?
a How to check oil tank leakage ? of SOPEP ? If thrust bearing is high, what Why vacuum is created in bilge
a What is the flash point ? a What is emergency fire pump ? will you do ? pump ?
a How to clean duplex filter ? Capacity ? What are the cause of connecting What is cavitation ?
a How will you check once a week rod big end bearing failure ?
Refrigeration for smoke detector ? What will you check for piston Metal
a How do you check leakage of a What will cause if CO2 cabinet crown ? What is fatigue failure ?
refrigeration. door is opened ? How to carried out pressure test Stress relieving, why, how ?
a What is refrigerant ? a What do you check for CO2 fixed in piston overhauling ? Annealing explain it ?
a Sate properties of refrigerant ? installation system ? What will you check at plumber Case hardening ?
a What / Why is critical a CO2 room safety device. block ? Explain welding defects and
temperature important? a Economizer fire fighting / How What is purpose of thrust block ? explain under cut.
a What effects will occur, if air to prevent Economizer fire ? How to overhaul stuffing box ?
in the refrigeration system ? a Cargo hole fire extinguishing by Governor drop.
Purifier
a What are the operational faults CO2 Governor function.
What will you check for purifier
of overcharge ? a Foam portable fire extinguisher Function of mechanical governor.
over flow ?
a What are the effects of moisture no spray, what will you do ? Why over speed trip is fitted in
Explain purifier overflow.
in the refrigeration system ? a How many type of fire detector ? additional to the governor ?
Why purifier cannot reach its
a Explain function of back What are the cause of high
rated rpm ?
pressure valve ? Location. Turbocharger exhaust temperature ?
Purifier bowl high measuring
a Carry out air purging of What do you check during T/C How to overhaul lubricator
procedure. Why take the bowl
refrigeration system ? overhaul ? quill ?
high ?
a Refrigeration safety devices ? How to wash T/C turbine side ? State maintenance for lubricator
Carry out T/C water washing quill. After fitting how to
test ? Heat exchanger
State action to be taken for T/C
Pollution What is the critical speed ? How to check efficiency of heat
surging.
a State regulation of sewage State difference between over exchanger ?
State measurements to be taken
disposal ? speed trip and governor.
during T/C overhauling.

Compiled by Min Zar Tar 14/02/2005 11:30 AM Compiled by Min Zar Tar 14/02/2005 11:30 AM
④ M.O.T 2nd Class Oral Question

What will you check after Explain about balance rudder ?

cleaning of cooler ? Explain overall length and
How to know L.O cooler leakage length between perpendicular.
while engine running ? How to calculate propeller sip ?
How to take L.O sample ? What is camber ?
How to make batch purification ? What is the free board ?
L.O contamination test How to check water tight door is
If 100% vacuum is created in fully closed or not ?
Fresh Water Generator, what will Docking plan
cause ? How mush shell
temperature of FWG ?

As a second engineer, state

precaution to be taken at rough
sea ?
Explain duties of 2/E
How will you check plumber block
at sea ?
What are the safety devices of
life boat ?
Explain about statements written
in Oil Record Book.
Are there how many kinds of
drill ?
How to clean sea chest strainer ?

Electro technology
Explain the earth fault lamp ?
How will you detect earth
faults ?
How to control speed of AC
motor ?
How to control of DC motor ?
What will you check in failure
of motor ?
What is the AVR ?
What is the synchroscope ?
What are the safety devices for
generator engine switch board ?
What are the safety devices for
M/E switch board ?
State machineries of equipments
supplied by emergency switch
board ?
What is essential load ?
Explain about preferential trip ?
State single phase on motor.
What is dash pot ?
Explain about Megga test ?
How to run two generator in
parallel ?
Power factor

Naval Architecture
Where is load water line marked ?
What is GRT ?
What is duct keel ?

Compiled by Min Zar Tar 14/02/2005 11:30 AM