ASSINGMENT NO.

01

WORKSHOP PRACTICE AND FITTING HAND TOOLS

HAMMER:

It is a tool meant to deliver an impact to object most common uses are driving a important fitting
parts, forging metal and breaking up objects. Hammer are often designed for special purpose and
very widely in their shape and structure. The usual features are handle and hand operated but
mechanically operated hammer are also available as for steam hammering, the types of hammer
are:

 Common nails hammer with curved craw.

 Rip hammer with straight craw.
 Finishing hammer.
 Soft face hammer.
 Carpenter’s mallet.

CHISEL:

It is a tool which is characteristically shaped cutting edge of blade on its end for carving or
cutting a hard material such as stone, wood or metal. The handle and blade of some type of chisel
are made of metal or wood with a sharp edge in it. The types are:

 Butt chisel.
 Carving chisel.
 Corner chisel.
 Bevel edge chisel.
 Flooring chisel.
 Dove-tail chisel.

VICE:

It is a mechanical screw apparatus used for holding or clamping a workpiece to allow work to be
performed on it with tool. Such as saw, drills,screw drivers,mills,etc.vice usually have one fixed
jaw and another parallel jaw which is moved towards or away from the fixed jaw by the screw.
The types are:

 Wood working vice.

 Engineers vice.
 Hand vice.
 Machine vice.
CENTRE PUNCH:

It is a hard metal rod with a sharp tip at one end and a blunt butt end at the other which is usually
struck by a hammer. Punches are used to drive such as nails or to form impression on the tip on
the workpiece. The types are:

 Nail punch.
 Pin punch.
 Centre punch.
 Letter/Number stamp punch.

SCRIBER:

It is a hard tool used in metal working to mark lines on work piece prior to machining. The
process of using a scriber is called scribing and it is just part of marking out. The types are:

 Machine scriber.
 Tungsten carbide scriber.

HACK SAW:

It is a fine tooth saw with a blade, under tension in a frame used for cutting materials such as
metal or plastics. The types are:

 Hand saw.
 Rip saw.
 Back saw.
 Mechanical powered saw.
 Circular saw.

FILE:

It is a metal working and wood working tool used to cut fine amount of materials from a work
piece. It commonly refers to the hand tool style which takes the form of steel bar with a care
hardened surface and a series of sharp parallel teeth. Most files have a narrow tangle at one end
to which a handle can be fitted. The types are.

 Mill files.
 Hand files.
 Crossing files.
 Knife files.
 Round files.
SCRIBER BLOCK:

It is a instrument consisting of two principle parts. These are the movable scriber and the block
to which the scriber is attached. It is principally used to mark straight lines upon engine and are
used on plain surface called as surface plate.

CALIPER:

It is a device used to measure the distance between two opposite side of an objects a caliper can
be as simple as a compass with inward or outward facing points. The tips of the caliper are
adjusted to fit across the points to be measured. The caliper is removed and the distance between
the tip id read. The types are:

 Inside caliper.
 Outside caliper.

DIVIDER:

In metal working field dividers caliper are used in the process of marking out suitable work
piece. The points are sharpened so that they act as scriber. One leg can be placed in the dimple
created by a center or prick punch and the other leg pivoted. So that it scribes the line on the
work piece surface, forming on arc or circle.

TRISQUARE:

It is wood working or metal working tool used for marking and measure a piece of use of
measuring the accuracy of right angle. It is used to,

 Check squares.
 Check flatness.
 Check lines
STEEL RULE:

A ruler sometimes called as a rule or line gauge is an instrument used in geometry technical
drawing, printing and engineering or building to rule straight line. Ruler is essentially a straight
edge used to rules line. But typically ruler also contain calibrated lines to measure thickness.

MICROMETER:

It is sometimes called as a micrometer screw gauge is a device incorporating a calibrated of

small distance for precise engineering and machining as well as most mechanical tradesalong
with other metrological department instrument such as dial vernier and digital caliper micrometer
are often, but always not in the form of caliper. the types are:

 Outside micrometer.
 Inside micrometer.
 Depth micrometer.

REAMER:

It is a metal working tool to created an accurate size hole. They may be used as a tool or in a
machine tool, such as milling machine or drilling machine. The types are:

 Adjustable reamer.
 Straight reamer.
 Hand reamer.
 Shell reamer.

VERNIER CALIPER:

A vernier scale is an additional scale with which allows a distance or angle measurement to be
read more precisely than direct read measurement scale.

The vernier caliper provides three basic function of inner and depth gauge. In all cases the
measurement is read from the same scale. The measuring device that consists of a main scale
with a fixed jaw and a sliding jaw attached vernier.
TAPS AND DIES:

These are cutting tools used to create screw thread which is called threading. A tap is used cut
the female portion of mating pair. A dies is used to cut the male portion of mating pair. The
process of cutting threads using a tap is called tapping threading. Both tools can be to clean up
the thread which is called chasing.

Types of taps are:

 Bottom tap/ Plug tap.

 Intermediate tap.
 Taper tap.

Types of dies:

 Older split dies, without top adjusting screw

 One piece dies, with top adjusting screw
 One piece dies, with adjusting screw
 Two piece dies, with side adjusting screw

DRILL BITS:

They are cutting tools used to create cylindrical holes. Bits are held in a tool called a drill, which
rotates them and torque and axial force to create a hole. Specified holes are also available for
non-cylindrical shaped holes. The types are:

 Universal bits
 Twist drill bits
 Long series drill bits
 Gun drill bits

SCREW DRIVER:

It is a tool for driving screw and often containing rotating other elements with mating device
system. The screw drivers is made up of a head or tip which engages with a screw a mechanism
to apply torque by rotating the tip and some way to position and support the screw driver. The
types are:

 Square
 Hexagonal
 Cross
 Slot
 Line
MARKING TABLE:

Marking out or layout is the process transferring a design or pattern to a work piece as the first
step of manufacturing process surface plate or marking out table provides true surface from
which to work.

SPRING CALIPER:

These caliper have adjustable screw and nut

 Spring is hardened and tempered.

 Solid nut, washer permits fast and positive adjustment.
 Made of high grade and uniform tension and polished finish.
 All calipers are measured from joints to the point.
SHAPING MACHINE:

It is a type of machine that has liner relative motion between the work piece and a single shapers
are classified as standard draw cut, horizontal, vertical, greased. Universal, crank, hydraulic,
contour and travelling head.

Uses of shapes:

 Keyways in the bass of pulley or gear.

 Can be machined.
 Internal surface.
 Dove tail slides.
 Keyway cutting in blind holes.
 Machining horizontal.
 Machining vertical surface.
 Machining angular surface.
 Machining irregular surface.

Tools of shaping machine:

 Cylinder cutter.
 Cycle hoods.
 Milling combination.

Frequently used cylinder cutters,

 Flat miller.
 Rotating cutter.
 Grain cutter.
 Groove cutter.
 Quarter round cutter.
 Quarter chamber cutter.

Milling combination,

 Milling set for finger prongs.

 Groove cutter and spacer ring door.
 Fold milling combination.
 Milling combination for window.

GRINDING MACHINE:

It is process of removing metal by application of abrasives which are bonded to form rotating
wheel. When moving abrasive particles contact the work piece they act as tiny cutting tool, each
particle cutting a tiny chip from the work piece.
The grinding machine supports and rotates the grinding abrasive wheel and often supports and
position the work piece in proper rotation to the wheel.
 ASSIGNMENT NO. 02

ADVANCE WORKSHOP PRACTICE

Lathe (longitudinal axis tool holding equipment)

The lathe can be defined as a machine tool which holds the work between two rigid support
called center or in a Chuck or face plate while the latter revolves .The Chuck or face plate
mounted on the projected end of the machine spindle. The cutting tool is rigidly held &
supported on the tool past and feed against the revolving work, while the work revolves about its
own axis the tool is made to move either parallel to or at an inclination with this axis to cut the
desired material. In doing so it’s produce a cylinder surface if it’s is feed parallel to the axis or
will produce a tapered surface if its feed inclination

Various lathe operations:-

 Turning :-It provides straight , conical curved or grooved workpiece

 Facing:- It produce a flat surface at the end of the workpiece
 Boring:-To enlarge the hole
 Drilling :- To produce a hole
 Cutting off :-To cut of work piece
 Threading :- To produce threads on workpiece
 Chamfering:- shouldering , grooving,recessforming,internal& external parting off

TOOLS USED IN LATHE:-

 Single and multiple cutting tool

 Thread cutter bit
 Right and left hand turning cutter
 Tipped cutter bit

TOOLS USED IN MILLING

 helical cutter
 plain miller cutter
 slab miller
 side mill
 inter locking mill
 staggered tooth mill
  t slot cutter
 double end mill
 gear tooth cutter

SHAPING MACHINE:-

It is a type of machine that has liner relative motion between the work piece
and a single point cutting tool to machine a liner tooth plate sharpness as classified as standards
horizontal vertical universal cranes hydraulic and travelling head.

USES OF SHAPES:-

 Keyways in the boss of pulley on gear, can be machined.

 Can be machined
 Internal spines
 Keyboard cutting in build holes
 Machining horizontal surface
 Machining vertical surface
 Machining vertical surface
 Machining angular surface machining irregular surface

Tools of shaping machine:-

 Cylindrical cutter
 Lytle hoods
 Milling combination

Frequently used cylinder cutter:-

 Flat miller
 Rotating cutter
 Grain cutter
 Groove cutter
 Quattro chamber cutter

MILLING COBINATIONS:-

 milling set for finger prongs

 groove cutter and space ring door
 fold milling combination
 Milling combination window.
GRINDER MACHINE:-

Grinding is the process of removing metal by applications of objectives which are

bounded its form rotating wheel. When the moving abrasive particles contact the work piece they
act as tiny cutting tools, each particles cutting a tiny chip from the work piece. The grinding
machine supports and rotates the grinding abrasive wheel and often supports and position the
work piece in proper rotation to the wheel.

GENERAL GRINDING OPERATIONS:-

 Cylindrical grinding
 Surface grinding
 Tool and cutter grinding
 Tool and cutter grinding
 Offhand grinding
 Polishing
 Buffing
 Lapping

TYPES OF GRINDING WHEELS:-

 Straight
 Cylindrical
 Tapered
 Straight cap
 Flashing cap
 Dish

KNIFE EDGE TOOL:-

It is a high speed tool bit that has only one cutting action proceeding at a time .the
shank is the main body of tool unit. The node in part of tool which is sharpened to a point and
forms the corner between side cutting edge and end cutting edge. The nose radius is sounded at
edge of the tool bit.
BORING TOOLS:-

Boring tools bits are ground similar to left hand turning tool bits and thread cutting
bits but with move and clearance angle and to prevent the heel of tool bit from stuffing
against the surface of the hole. The boring tool bit is usually clammed to a locking tool holds but
it can be a one piece unit,. The locking tool bit and holder clamp into the tool part.

PARTING TOOL:-

It is also km\now as cut off tool bit .this tool bit has the principal cutting edge at the squared and
of the bit, that to advance at a right angle into work piece. Both sides should be ground slightly
narrows at the back than at cutting edge. Brides being used for parting operations, this tool bit
can be used to machine square corners and grooves.

KNURLING TOOL:-

The common knurling tool consists of a cylindrical cutter called knurls which rotates in a
specially designed tool holder. The knurls contain teeth which are called against the surface of
the work piece. The common knurling tool accepts points of knurls, each having different pattern
or the pitch.

GRINDER:-

A grinding machine often shortened to grinder in a machine tool used for grinding which
is a type of a machine tool used for grinding which is a type of machining using an abrasive
wheel with as cutting tool. Each grain of the abrasive wheel with a small chip from the work
piece via sheer, deformation .grinding is used to finish work piece which must have high
accuracy of space and dimension.
 ASSIGNMENT NO.03

FABRICATION, WELDING

WHAT IS WELDING:-

Welding is the process of joining similar metals by applications of heat with/without

application and pressure and adoption of filler metals

What are the types of welding are being done in workshop:-

1. Arc welding
2. Gas welding

ARC WELDING:

It was most extensively employed method of joining metal parts here the source of heat is
electric, the arc column is generated between an anodes which is positive pole of dc, two
conductors are brought to distance of 2-4 mm.

Gas welding:-

Gas welding is done by burning a combustible gas with air flame of high temperature.
The other welding method flame is to the filler also to fill the joint.

OXY ACTELENE WELDING

It is accomplished by matching the edge to be joined by a gas flame and allowing the
molten metal to flow together, this forming a solid continuous joint upon cooling, this process is
particularly suitable for joining metal sheets and plates having thickness 2.50mm

TUNGSTON INERT GAS WELDING:-

This welding process uses the intense heat often electric arc between non-consumable
tungsten electrode, the shielding is obtained form on inert gas shielding is obtained form on inert
gas such as helium/argon. The inert gas displace the air surrounding the arc and weld point inert
shielding some advantages.

 It produce high quality welds in nonferrous method

 The arc and the weld point are closer
 Visible to the welder

SUBMERGED ARC WELDING:-

It is an automated process developed primarily for the production of high quality butt
welds in thicker steel plate the arc is formed between the ends of continuous submerged under
the power and it is visible to operator.
 The flux maybe made up of silica metal and the components.
 The bas electrode is fed form the reel down through lathe gun of nozzle the operation can
move it slowly the arc and then set the proper feed rate on control box.

 It is often automated and this is much faster than regular arc welding

 Deep penetration with high quality weld is possible

 The operator can work and move easily without the equipment

GAS WELDING:-
The cutting of iron and steel with the aid of extensively used now a day’s in industry
.This is based on the ability of certain metals to burn in oxygen with the great deal of heat theory
melting the metals and forming oxides
Oxygen cutting is performed by means of ordinary gas welding equipment except the
welding torch is placed by a cutting torch which delivers the gas mixture of preheating and
oxygen for burning the metal. The oxygen at high pressure is supplied through a central opening
for cutting the metal. The faster the rate to the bottom logs behind the top of the cut and it is drog
evidenced by a series of curved line on the side of kerfs.

WELDING TORCH:-
This is the tool for mixing the oxygen and acetylene is correct proportion and burning the
mixture of tip .This are available is to two general’s type.

 Equal pressure
 Injective type
GAS FLAME:-

 The correct adjustment of the flame is important for reliable work.

 Then acetylene are supplied to the torch in nearby equal volume and a natural flame is
produced.

NATURAL FLAME HAS TWO DEFINITE ZONES

1. BRILLIANT SHARP ZONE

A carburizing flame ionize with excess of acetyl and this flame has three zones
Sharply defined linear zone
An intermediate zone for which color

2. The bluish outer zone

An oxididising flame is one in which excess of oxygen is present. This flame has two
zones
The smaller line zone has purple tinge
The outer zone
An oxidizing flame is one is which excess of oxygen is present, this flame has two zone.
The smaller liner zone has purple triangle
The outer zone

ELECTRODE:-

Both non consumable electrodes are used for arc welding.

NON CONSUMABLE ELECTRODE:-

 This may be made up of carbon. Granite tungsten which donned get
consumed operation.

 Consumable electrode

These may be made upon of various metal depending upon the purpose and the chemical
composition and metal to be welded.
Electrode area sub divided into two groups

 Lightly coated electrode

 Heavily coated electrode
 Coated electrodes several purpose to provide a means of alloying metal not contained, in
case of wire
Soft steel wire containing 0.1-0.18%

Carbon an 0.029-0.4% .phosphorus and Sulphur used for the electrode in welding the carbon
steel.

WELDING CURRENT:-

The current for manual operation of metal arc usually ranges from 30-500A.for automatic
operate from 150-6000A.A large current produce are bellow surface around the arc which need
to deflect the arc.

Usually current and voltage for machine used in welding.

VOTAGE (V) CURRENT (A)

15 UPTO 150
20 OVER 100-150
25 OVER 150-200
30 OVER 200-250
35 OVER250-300
40 OVER 500

WELDING GOOGLES:-

It is fitted with color glass which provides protection to the eye against harmful heat
and UV, IR rays.

GOLVES:-

They are used to provide the hand for any injury.

SAFETY PRECAUTION DURING WELDING:-

Optical radiation

The welding process produce a large quality of visible light UV and IR rays which
causes skin damages and cause hazard to health so use of goggle should be executed during the
welding.

FUMES

Welding gas rise to fumes which are oxides of metals alloying element and thus are very
harmful.

BURNS AND MECHANICAL HAZARDS:-

A welder needs to wear good quality gloves safety shoes, quality cap, apron for welding to
provide adequate production against burn and the other hazards.
 ASSIGNMENT NO.04

DIESEL ENGINE IDENTIFICATION AND FAMILIARITY WITH DIESEL

ENGINE

PARTS/COMPONENTS

PISTON:

The four stroke trunk piston is usually shorter in length. It may be casted in one piece or may be
made as composite piston with crown and skin of varying material for better piston property it is
usually splash lubricated and hence it needs oil scrappers rings it also has compression rings

CONNECTING RODS:

The connecting rod transmits the gas force from the piston to the crankshaft. A bore is drilled
through the center of connecting rod for flow o the center of connecting rod for flow of the
lubricating cooling oil. The flow is upward since it is a trunk piston engine. The connecting rod
usually has a split bottom and or small palm type with adjustment of the compression pressure

CRANK PIN:

The bottom end of the connecting rod is joined to the crankpin which form the part of the
crankshaft the connection is through a bearing to permit relative motion between connecting rod
and crank pin with this assembly ,the up and down motion of piston is converted into the rotator
movement of the crankshaft.

BOTTOM END BEARING HOUSING:

The bottom and bearing permits relative motion between crankpin and connecting rod to the
smooth and avoids friction and fatigue failure. This is of shell type bearing and mostly made of
trimetal on white metal. This is molded in place around the crank pin by connecting rod bottom
end and the bottom bearing pouring kept together by bottom end bolts.

BOTTOM END BOLTS:

They are used to hold the connecting rod and the bottom bearing housing together which houses
the crank pin surrounding by a bottom end bearing.
They must be tensioned too high, because it will made the movement loading to bearing damage.
They are subjected to tensioning forces due to centrifugal force of mass of connected rod and due
to the inertia force due to reciprocating masses
COUNTER WEIGHT:

Counter weight are added to crankshaft to make the shaft dynamically balanced. Balancing is
necessary to prevent the shaft from vibration and damages usually these counter weights are
fitted in the bottom of crank webs on may be forged with crank web.

DIP STICKS:

They are metal sticks which are provided to engine having wet sump to check the level of lube
oil in the sump. It has threaded cap which is removed from its holder while checking the web oil
sump level.

MAIN BEARING BOLTS:

They are held in place by pair of holding down bolts. These bolts are fastened to bed plate
through the bearing housing so that the bearing arc rigidly placed out the bed plates. These bolts
are subjected to heavy loads fluctuating in magnitude and direction.

CRANK CASE RELIEF DOOR:

A large number of relief door are provided for automatic relief of pressure in the event of
explosion wave reaching up to the door in the crankcase so the crank case must be self-closing
and preferably be provided with flame traps to prevent discharge of flame inside room.

CYLINDER LINER:

The bore of each cylinder in engine is formed in a liner which can be replaced when worm out
and which can be replaced when worm out and which is surrounded by a cooling water jacket.
The water is indirect contact with the liner outside surface as a result of which it is termed as
“wet lines”.

VALVE DISC:

These are steel valve disc which can resist high temperature. The valve disc in contact with valve
seat on the cylinder cover provides perfect sealing to gases. The disc moves into the cylinder
downwards to open the valve and moves up to close the valve. This is connected to valve
spindle’

VALVE SPINDLE:

This is of same material and some piece of that of valve disc. The top of the spindle is in contact
with rocker arm. This transmit the force from rocker arm against the spring load to open the
valve, helical.
PUSH ROD:

They transmits the force from crankshaft through the follow to rocker arm to open the valve

ROCKER ARM:

This is lever which transmits the force from the pushrod to valve spindle through the valve
tappet. This is hinged to the cylinder head .this is done by adjusting screws. This clearance is for
the expansion during operation.

EXHAUST MANIFOLD AND TURBOCHARGER:

Modern medium speed engines are turbocharged the exhaust gas is led to turbine entry casing by
mean of exhaust manifold. The turbine nozzle may be connected with individual lines from each
cylinder or form a group of two or four cylinders.

NAME OF THE PARTS CLEARANCES

Main bearing clearance 0.130-0.294mm
Cam shaft bearing 0.125-0.215mm
Big end bearing 0.145-0.230mm
Gudgeon pin 0.050-0.112mm
Valve tappet clearance 0.09-0.15mm

NAME OF THE PARTS MATERIAL

piston Aluminum alloy(high speed),cast iron
Connecting rod Forged steel or cast steel
Crank shaft Solid forged from single piece of steel.
Main bearing Shells are made of steel with a lining of
bearing metal which may be copper lead or
aluminum alloy.
Cylinder head Cast iron
Cylinder liner Closed grained cast iron
Inlet valve High tensile steel material
Exhaust valve High resisting chrome steel.
Cam shaft Carbon steel
Piston rings Fake graphite cast iron
 ASSIGNMENT NO. 07

PISTON AND PISTON RINGS

FUNCTION OF PISTON RINGS:

COMPRESSION RINGS:

 To provide effective rings

 To prevent excessive buildup of pressure in crankcase
OIL SEPERATOR RINGS:

 Fitted mainly in trunk piston engines

 Main function is to prevent possible oil entry into the combustion chambers
MATERIALS OF THE RING

 Piston ring are made up of cast iron

 Gray cast iron gives better wear and stuffing resistance
 Modular chromium plated malleable cast iron gives better fatigue resistance
MEAN EFFECTIVE PRESSURE

It is the theoretical constant pressure acting on the piston during its power stroke. There is
a great variation of pressure in a diesel engine during a cycle of operation, but the power is
calculated on the basis of mean pressure. It is determined from the indicator diagram. MEP is
more correctly seated as means effective pressure

PEAR PRESSURE

It is the Maximum developed pressure inside the combustion chamber when the fuel is
injected and gets injected. This pressure pushes the piston down and causes the power stroke.

COMPRESSION PRESSURE

It is the pressure in the combustion chamber when the fuel is often compression stroke
this pressure plays a vital role in effective combustion as the pressure creates temperature to burn
the fuel

MATERIAL

 The piston ring is made of cast iron

 Gray cast iron gives better and sufficient resistance
 Modular chromium plated malleable cast iron gives better fatigue resistance
 RVK with aluminum bronze as a running in coating
 ASSIGNMENT NO. 08

PISTON AND CONNECTING ROD BEARING

WRITE NOTES ON BOTTOM END BEARING WORKING CLEARENCE AND

LUBRICATION?

The connecting rod is connected to the crank pin on the crankshaft by the bottom end
bearing this is the white metal bearing are similar to the main bearing this steel of relatively this
wall section have a lining off bearing metal. white metal upper level on the aluminum and thin
flashing of cord or to provide an anti-corrosive layer, it has tags for location and oil groovier
rounds the center from its axial length which corresponds with grooves in bearing housing
through which oil is transmitted up through the rod to lubricated the small end to coat piston the
shell depends on the accuracy of the bone to hold them in a circular shape.

Usually big end bearing clearing is 0.145 0.230nm.

PROCEDURE FOR DISMANTLING THE BEARING:-

1. Remove the cylinder cover

2. Scrap-off carbon depositing around upper part of lines.
3. Remove anti-polishing ring.
4. Clean the threatened hole in the piston crown and the lifting tool.
5. Turn the crankshaft from TPC towards the operating the side of cylinder covered.
6. Lift the distance sleeve
7. Connect the house of hydraulic pump and proceed to open the connecting rod.
8. Remove the hydraulic tool and sleeve from connecting rod studs.
9. Open the nuts and remove the studs.
10. Remove the upper stud
9. Lift big end bearing together with bearing self out of engine.
10. Lift piston a lift to remove upper and bearing stud.
11. Cover crankpin oil holes with tape.
12. Lift the piston together with connecting rod out of the engine.

ASSEMBLY OF BEARING:-

 Lubricate the gudgeon pin and mount on same side where it was removed
 Mount the ring
 Take the protecting tape from the crank pin oil and lubricate the crank pin.
 Faster the piston crown with lifting tool
  Turn the crankshaft 55*from TDC
 Lift the piston and connecting rod
 Lubricate bearing surface and face of upper shell bearing
 Lower piston connecting rod carefully into cylinder lines
 Lower the piston further until the connecting rod can be placed on the crankpin
 Lubricate the bearing surface and end face after bearing shell and place the shell
in the bearing cap.
 Lift the bearing cap and mount the upper by connecting it up hand mount the
neck.
 Lift the distance slews and hydraulic tools
 Mount the side cover
 Mount the cylinder head

Safety precautions to be taken while dismantling and assembling the bearing:-

 Encage the turning gear

 Shut off all valves in control air supply.
 Shut off all starting air receiver
 Open the indicator cock
 Use proper capacity lifting tool
 Never stand under the hanging parts
 Bearing shell should be correctly mounted keeping clearance in mind.
 It is very important that bearing shell are mounted carefully
 Check the connecting rod whether it is movable axially after lighting or not
 Tighter the bottom end belts to torque.
 ASSIGNMENT N0. 09

FUEL VALVE

HOW DOES A FUELVALVE WORK?

A fuel valve has two basics parts the nozzle and the nozzle holder on the body. The high pressure
fuel enters and travels down in the passage in the body and then into the passage in the body and
then into the passage in the nozzle, ending finally in a chamber surrounding the needle valve.
The needle valve is held in the closed position on the meter seat by a intermediate spindle and as
spring in the injector body. The spring pressure and the injector body pressure are manufactured
as a matching pair and a accurately ground to give a good oil seal the two are joined by a nozzle
nut the needle valve open fuel pressure acting on it needle valve tapered face exerts a sufficient
force to overcome the spring compression the fuel then flows into the lower chamber and forced
out through the series and arranged to atomize or break in to the drop allow the fuel oil which
will the burn once the injector pump or the timing valve cut off the high pressure fuel supply the
needle valve will shut quickly all the two speed stroke engine and many medium flow stroke
engine are operated almost continuously an heavy fuel a fuel circulating system is therefore
necessary and is usually arranged within the fuel injector during injecting the high pressure fuel
will open the circulation valve for injection high pressure fuel will open the circulation valve for
the injection to take place when the engine is stopped the fuel oil booster ensures fuel supply
which the recirculation valve directs around the injector body

How do you understand by atomization?

Atomization is the process of increasing surface area of the droplets to obtain the better mixture
with the air as the fuel passes into the fuel valve it approaches the lower chamber and force act
through tiny holes the small holes are sized and arranged to atomize as leak into tiny drops all the
fuel oil which will eradically burn

What is the working pressure of the fuel valve?

Working pressure of the fuel valve is around 275 kg/cm to315 kg/cm
What precautions are to be taken while testing the fuel valve?

The precautions to be taken while testing the fuel valves are

 Use of proper testing equipment and eye protection

 Don’t allow the atomized fuel to come in contact with your body

Don’t put your hand below the fuel valve while testing as this may cause fuel to penetrate the
skin and result in blood poisoning

What is the meaning of blood poisoning?

The nozzle injects the fuel spray under very high pressure is about 250 bars while testing if
by mistake any put of body moves in contact with the spray the fuel oil enters in to the blood
stream which may land to the blood poisoning
 ASSIGNMENT NO.10

VALVE GEAR

What is there difference between inlet and exhaust valve?

There is not any constructional difference between the inlet and exhaust valves. Only
difference is in their arrangement and application. The inlet valve allows the charged air to enter
the combustion chamber whereas the exhaust valve allow the exhaust gases to leave the
combustion chamber.

Inlet valve open during intake stroke before TDC and exhaust valve open during exhaust
stroke before BDC

Exhaust valve require a cooling medium whereas inlet valve do not require any cooling
medium.

Are the material for both valve same?

The material used for inlet and exhaust valve are not same.

It is different because of different operation condition to which they are subjected.

For inlet valve, silicon chrome steel containing about 0.4% carbon, 0.5% nickel, 0.5%
magnesium, 3.5%silicon and 8% chromium is used.

For modern heavy duty engines nimonic alloys are used which consists of carbon ,magnesium
,silicon , chromium cobalt, titanium, aluminum, iron & nickel are used for exhaust valve.

What do you understand by tappet clearance?

The clearance between the spindle (edge) and the rocker arm is called tappet clearance.
The clearance is necessary to take the thermal expansion of the spindle. Excessive tappet
clearance will cause the valve to open late and close early in the cycle and will reduce its
maximum lift. It will also cause noise and eventually damage from the impact of working
surface. If the tappet clearance is less, it may result in improper closing of the valve.
 ASSIGNMENT NO.11

FUEL PUPM

What do you understand by plunger and barrel?

In the part controlled fuel pump, there is a plunger in which is closely fitted inside barrel.
He plunger and barrel are responsible for effective pumping of the fuel oil. The barrel is the is
stationary one and plunger can move upward and downward in the barrel. Also the plunger can
rotate about its longitudinal axis.

How does a fuel pump is worked?

A downward stroke of the plunger is the filling period during which the pump barrel is
filled up through a suction port is connected to a chamber surrounding the barrel. During the
upward stroke of the plunger a pressure is created immediately after the inlet port is converted.
The delivery takes place by lifting the loaded delivery valve above the pump chamber.

How is delivery of fuel terminated and quantity of fuel delivered is regulated?

The regulation of quantity of fuel is effected by grooves in the plunger. The plunger is
capable of rotation about its longitudinal axis besides vertical oscillatory motion. It has a vertical
slot and milled helix on its body. When the plunger is angular position is such that vertical slot is
held against port, the pumping of plunger creates no pressure. In pump barrel when plunger is
turned away from the position it is set for admission of fuel. A pressure is created above the
plunger as soon as suction parts are covered. An injection begins almost instantaneously and is
continued till the helix edge uncover the suction port. Pump may be set at any intermediate
position between no delivery to maximum delivery.

The top edge of the plunger controls beginning of the injection which once set
remain constant during the operation of the engine. The end of injection is controlled by the
profile of helical edge uncover the suction port, pressure in the pump chamber is quickly delayed
terminating the delivery. For fuel regulation, plunger is turned away to another angular position.
The angular position of the plunger in relation suction port determines the quantity of fuel
delivered.

What do you understand by helical grooves? Where will you find the same in fuel pump?

The milled helix on the body of plunger is called helical grooves. This helical grooves is
controlled the end of injection of the port.
 ASSIGNMENT NO.13

CAMSHAFT

What is the function of camshaft?

Camshaft is used in diesel engine to operate the mechanism connected with opening and
closing of exhaust valve, air inlet valves, air starting pilot valve, driving fuel pump etc. Which
control the engine cycle. Each valve or pump is activated by cam follower which rises or fall as
the cam rotate beneath it. Cam shaft is driven by power transmitted from engine crankshaft
through gear. Camshaft rotation must be accurately synchronized with crankshaft and timing
must be checked periodically and after any adjustment or repair is carried out.

How inlet and Exhaust Valve opened?

The inlet and exhaust valve are mechanically actuated from camshaft. The shape of cam
control the timing and lift up the valve. The rotation of cam peak rises the follower and push rod
to operate a valve spindle through a tappet and causes the valve to open.

How fuel pump is operated?

A fuel pump is operated by fuel cam which is designed to raise the plunger at rate
required to build up fuel pressure and maintain this for the corresponding period to operate the
fuel injector. Since the pump only discharge on its upstroke, the flank of fuel operate the timing.
The trailing flank of the cam causes the plunger to retract to the bottom of the stroke to allow the
chamber to refill. Timing can be controlled by the relative angular position of the cam peak with
respect to the crankshaft. It can be adjusted by moving the cam with respect to shaft.

What is the relationship between the rpm of crankshaft and camshaft?

For four stroke engine, camshaft operate or rotates at speed of half as the speed of
crankshaft whereas in case of two stroke engine the speed of camshaft is equal to the speed of
crankshaft.
 ASSIGNMENT NO.14

LUBRICATION OIL PUMP

How does lubrication in the four stroke diesel engine take place?

Lubrication in four stroke diesel engine is done by shaft driven gear pump taking drive
through the crankshaft through gear. Pump takes suction from, the main engine sump and
transmitted through bore in the crankshaft and connecting rod at required pressure and flow rate.

What is the safety features in lubrication oil pump?

As the lube pump is positive displacement pump (gear), it will continue developing
pressure even if the discharge valve get closed. Thus there will be an increase in pressure on the
discharge side pipe and holes if excess pressure build up, it may cause damage to the working
part of pipe. Thus in order to protect the rupture of various parts, pressure relief valve are
provided in lubricating oil pump. The working pressure of these relief valve are generally 10% of
the pressure of lubricating oil pump.

What are the material used for gear?

The gear are normally made up of cast hardened alloy steel. A simple gear pump has
rotate (gear) and shaft which are integrally forged of nitral steel. Close grained grey cast iron is
used for casing and bearing housing.

How is lubricating oil pump driven?

Diesel engine and gear box lubrication systems are normally supplied by gear pump
which are independently driven by large 2 stroke slow speed engine and standby duties. But for
medium and high speed engines it is usually shaft down.

Before starting diesel engine what precautions are taken regarding lube oil?

Following precautions to be taken for lube oil before starting the engine
Level of lube oil checked in sump by dip stick
Check the condition of lube oil
Check the turbo charger lube oil
Check the alternator pedestrian bearing lube oil level or flow of oil
Check the rocker arm lube oil level and condition of lube oil
Check the crank case door venting line is clear
Safety features of on the engine concerning lube oil pressure?

On the engine, there are two main safeties concerning lube oil pressure drop due to some
reasons there will be an alarm at present lube oil pressure indicating the drop in lube oil pressure.
Proper precautions are not taken even after alarm, the drop is further pressure will trip the engine
off at present low lube oil pressure. This safety is often called lube oil pressure trip.
 ASSIGNMENT NO.15

FUEL OIL PRIMARY PUMP

How is fuel supplied to fuel valve in four stroke engines?

The fuel oil is at first stored in the double bottom tank which also has a heater to maintain
the viscosity of the oil from the double bottom, the oil is transferred to the settling tank where,
due to gravity difference, the impurities settle down at the bottom of the tank, which is drained
out at continuous time interval from the settling tank with the help of centrifugal pump, the oil is
pumped to the purifier and clarifier where it is purified by the centrifugal action. After
purification oil is passed to the daily service tank, also having the heater from daily service tank.
The oil is passed through mixing column through a flow meter which indicates the fuel
consumption. With help of the booster pump the oil is pumped to the heater and then to the
viscosity regulator and then to the engine driven fuel pumps. The fuel pumps deliver high
pressure fuel to their respective injector.

What are the safety features in the fuel pump?

As the pump is positive displacement pump, it wills continuous developing pressure in

case the discharge valve closed. The building high pressure can break the weakest point of the
system. In order to prevent this pressure relief valve is provided to the pump.

What do you understand by air lock?

Air lock is the form when the air enters the fuel line and air bubble interrupts the
continuous flow of the oil.

How is fuel oil pump driven?

The fuel oil pump is driven by electric motor of the suitable capacity. It can also driven
by steam turbine or rarely a chain drive by the engine.

How will you prime the fuel pump?

The fuel pump is primed by the slackening the spill valve and priming pump is started.
The air bubble is purged out and continuous flow of oil is obtained after this spill valve is
tightened.

How is the fuel pump regulating in the diesel engine?

The fuel pump is regulate in the diesel engine by means of governor. The governor is
depending on the load control the speed by controlling the fuel supply. In the port controlled fuel
pump, the rack is connected to the governor. I order to control the fuel oil the governor may pull
or push the rack so that helical groove in the plunger rotates and control of fuel injection. In the
valves controlled fuel pump spill valve is connected to the governor. The governor is alert
eccentricity of spill valve which in turn regulates fuel oil.

What are the difference between MDO and FO?

Fuel oil is the left as residues after extracting all distillation products proceed in refinery
process while heavy diesel oil is distilled in lighter fraction compared to HFO which means they
have high capacity calorific value. This also indicates that MDO requires less heating the fuel
oil. Fuel oil required as longer time to complete its combustion. So fuel is mostly used in long
stroke engines where the piston travelling time from TDC to BDC is more and so the time
allowed for high fuel for combustion is more and it is economical for the owner to use fuel oil in
the long stroke engines.
 ASSIGNMENT NO.16

CRANKSHAFT

How reciprocating motion of the piston is transmitted to the flywheel?

A reciprocating motion of the piston is transmitted to the flywheel through connecting

rod & crankshaft assembly.

What is balance weight with respect to crankshaft?

Balance weights are additional weight fitted through crankshaft to balance the weight of
piston, stress of piston rod assembly of various unit of thee crankshaft. If it is provided to present
the loading of crankshaft a it may accelerate the wear down of the main bearing, These balance
weight can be an integral part of crankshaft or can be bolted to crankshaft, thus making is
adjustable.

How is crankshaft supported in the bedplate?

Crankshaft is supported in the bedplate of the main bearing which is usually made of
bearing material like white metal backed by steel block, bolted to the bed plates. Main bearing
transmit gas load to the engine from bed plates. The gas load is maximum, when the piston
passed the TDC after ignition take place.

What do you understand by the following?

A) Crankpin
Crank pin used to connect the connecting rod to the journal. The rubbing surface between
the crankpin & connecting end is linked with big end bearing.
B) Crank web
The crank head is supported or held by two crank web one either side, which transmit the
revolving motion of crankpin about crank shaft/ journal, axis of journal. Other end of the
journal is connected to journal.
C) Journal
The journal lies along the axis of the rotation of crankshaft. The journal rotates on the
axis and it’s supported to the main bearing. Thus journal transmit drive to flywheel and is
used to transmit gas load, to engine from bed plate through main bearing.
What is a white metal and where it is used?
White metal alloy represent majority or sliding bearing anti frictional, metal usually
known as babbits. Babbitt divides into tin based and lead based alloy. A typical
composition of white metal are:
Tin- 85.65%, Antimony-7.5%, Copper-4.5%, Lead-0.35%
White metals are used in main bearings, big end and small end.
What do you understand by tri-metal bearing?

Tri-metal bearing are made up of three different type layers of material instead f a single
white metal shell. It usually consists of a shell with a layer of brass like metal, over which a
thin film of white spray is given.
 ASSIGNMENT NO.17

STARTING VALVE

How is a diesel engine started?

Diesel engine is started pneumatically by supplying 6 bar compressed air from the air
bottle and thus opening pilot valve and 30 bar compressed air is passed inside the combustion
chamber for combustion. This compressed air is stored in air bottle which should be drained so
as all the moisture content from the bottle is removed.

What precaution are taken before starting a diesel engine?

 The lube oil pumps must be running, check the oil flow through sight glasses for piston
cooling and turbocharger
 The HT cooling water pumps must be running preheat temperature maintain minimum
600 c.
 The pressure of main air bottle and control air should be checked.
 Drain air bottle
 Turn the engine by slow turning
 Disengage the turning gear and lock it
 Lift the locking plate of main starting valve to service position, open indicator cock
 Turn the slow turning switch to the slow turning position
 Move regulating handle to start position
 Check whether any fluid flows out of an indicator cock
 Check all the corresponding fuel pump roller are shifted to the end position
 When the3 engine has moved one revolution, move the handle back to opposite direction
and turn the engine once more
 If not doing slow turning then, engage turning gear and turn the engine one full turn with
lubricator operated manually
 Disengage turning gear
 Close indicator cock
 Open the main start valve and shut off valve for starting air distributor
 Check the fuel oil supply pump and circulating pump are in operation
 Lubricate the bearing and rod connection in the regulating gear etc.
 Set the auxiliary boiler in auto mode
What are the minimum and maximum air starting pressure?

Minimum and maximum air starting pressure is 6-7 bar for opening the starting air valve
and 25-30 bar for starting the main engine.

What is the function of starting air valve?

The function of starting air valve is that as the compressed air is passed at 6-7 bar inside
the starting air valve, it should open the valve spindle so as air at 30 bar can enter and push their
piston from TDC to BDC and make engine ready for working.

Dismantle and overhaul of starting air valve?

Every 5000 hrs. Of operation the starting valve must be removed, clean and if necessary
re seated

Procedure:-

 Unscrew the banjo lug of the controlled air piping

 Release nuts and take off flange
 Remove the spring dowell which secures the castled nut, the valve head must be held
firm with screw driver
 Dismantle the valve and wash components in cleaning petrol
 Check the valve seat and correct by regrinding if necessary
 During assembly, lightly coat the control piston with molybdenum
 Before fitting the flange, check the valve for freedom of motion
 Only new copper rings should be used for reassembly

How starting air valve operate?

 When the main starting valve is open, chamber of the starting of valve is pressurized
through the starting air pipe
 The starting valve is kept closed by starting spring
 When the chamber above the piston of the starting valve is pressurized with control air
from the3 starting air distributor, the starting valve opens and starting air flows from the
starting air pipe to the cylinder
 When the starting period is finished chamber is vented through the vent pipe of the
starting air distributor and the starting valve will closed
 Venting of the starting air in chamber and the starting air pipe takes place slowly through
small holes in the starting air pipe.
 ASSIGNMENT NO.18

CYLINDER UNIT

What is a cylinder liner, how it is fitted and how cooling is carried out?

Cylinder liner is replaceable part of the engine which piston reciprocates. They are
designed to give and extensive working life with long period between overhauls. They must
maintain low wear rates and friction wear loss from the sliding motion of the piston rings under
fluctuating pressure and temperature. Materials for liner must provide adequate strength and
fatigue life radially transfer heat, resistant, abrasive and corrosion. Liners are cast in grey cast
iron to which alloying elements such as vanadium titanium are added to enhance strength, wear
and corrosive resistance.

The upper end of the liner from the flange of sufficient strength to support it. This flange
is secured between the cylinder cover and the jacket or engine entablature, leaving the lower end
of the liner free from the thermal expansion. Thickness may be reduced towards the lower end
where pressure and temperature are less, bur external flanges and boring may be added to
accommodate rings, lubrication and connection etc.

What is liner calibration?

The cylinder liner should be gauge internally at fixed interval during cylinder overhaul
(6000-8000 hrs.) to measure the increase in cylinder bore. Continuous records of gauging should
be kept free for each cylinder. Liner is gauged with an internal micrometer and extension bore
which has been calibrated against a master gauge. The gauging list taken at number of vertical
position (6-8) over area swept of piston. Reading are taken from aft tank forward direction of the
ship. To ensure the reading taken at corresponding and template must be used.

What is ovality?

After some running hours, wear occurs in liner when measure with micrometer gauge at
some parts, the internal diameter have to be in shape from cylinder to oval. This is known as
ovality of cylinder.

How cooling is carried out in the cylinder liner?

Cylinder liner cooling is often referred to as jacket cooling and is carried out by
circulating fresh water between outer surface of liner and cylinder jacket or sleeve in which it is
supported. The water space extend over upper part length of liner. Silicon rubber ring fitted into
grooves in the liner make a water tight real at lower end while still allowing freedom for thermal
expansion of liner. The upper end is sealed by landing flange. Water enters at lower end of
jacket, flowing upward and leaving at top of pass on to cool the cylinder cover.

How is sealing of cooling water obtained?

The sealing of cooling water is obtained by help of o ring. An o ring prevents the leakage
of cooling water in the cylinder liner.

Why cooling water has to be treated?

A cooling water used for engine cooling should be properly treated with an approval
cooling water in-hibitor and alkaline agent to avoid corrosion attack, sludge formation and scale
deposit. The commonly treatment used is sodium nitrate or sodium bi-carbonate. They are safe
for handling nontoxic, not dangerous if over closed and contain a pH suffer to provide protection
against acidic corrosion

What are material used for liners?

The material used for liner are cast iron with alloy of nickel, chromium, molybdenum, vanadium
copper and titanium is used.

What do you understand by liner wear and what is the maximum liner wear permitted?

There are three types of liner wear which are as follows:-

Corrosive wear:-
 It is the wear on the liner surface due to the temperature corrosion of Sulphur.
Sulphur di oxide in the gaseous state combine with water which has form due to
condensation or sweat ring when the temperature is low. Thus acid are formed
which lead to corrosion.

Abrasive wear:-

 It is due to hard particles of ash deposits and catalyst fines, which continuously
cut, scratch and plough the liner surface.

Frictional wear or adhesive wear:-

 Mechanical friction wear is due to the piston ring friction on the liner walls. This
wear takes place usually where the oil film has depleted or broken down.
 Maximum wear before removal is usually limited to 0.6-0.8% of original bore
diameter or less than manufacturer advice, wear rate may be differ for different
engine but no appropriate of 0.1mm for 1000 hrs.is acceptable for large engine.
What is an Indicator cock?

It is a valve mounted on the cylinder head to accommodate indicator for measuring

cylinder pressure and power developed. It is also used for blowing through the combustion gases,
moisture from the cylinder before starting the engine.
 ASSIGNMENT NO.19

LUBRACATING OIL COOLER

What is the function of the lubrication oil cooler in diesel engine?

Generally a tubular of heat exchanger is used for cooling the lubrication oil or the fresh
water used as coolant, in the primary closed circuit of the diesel engine. The function of
lubrication oil cooler is to maintain of temperature of the lubrication oil within optimum working
range.

What will happens if lubrication oil is not cooled?

If the lubrication oil is not cooled, oil gets heated to the temperature when it is circulated. This
lead to carbonization of the oil & result in deposits of collected carbon residues on the walls.
This act as insulating layer & causes poor heat transfer.

If proper heat transfer is not there, I will result in thermal stress of the component
because the heat as well as temperature will keep on increasing.

How is oil cooled in the cooler?

Generally a shell & tube of the heat exchanger is used to cool the lubrication oil. In this
type of heat exchanger, the coolant which is seawater, flows through tubes while the lubricating
oil outside. The tube in the shell. The continuous flow if sea water ensures that the oil is cooled
to required temperature.

In plate type heat exchanger, there are the metal plates with the grooves. The grooves are cast for
an easy flow & creating more surface area for contact. These plates are sandwich between the
cast header plates. The coolant flows through one plate while the oil flows in the adjacent plates
this way oil is cooled.

What is tube nest?

A tube nest is a tube bundle or stack inserted inside shell. Whose branches are connected
into the circulating system of the fluid. The stack comprises of the number tubes secured into a
plate at each end and series of baffles direct the hot fluid back and forth across the tube bundle.

What is tube plate?

A tube of the shell and heat exchanger are held in the plates which are called as tube
plate.
What is the material of various parts?

 Shell : Cast iron or steel fabricated

 Tube : Aluminum Brass
 Tube Plate : Naval Brass
 O-rings : Synthetic rubber
 Sacrificial End : Soft Iron or Zinc
 End Cover : Cast iron or mild steel fabrication.
 ASSIGNMENT NO.21

SPARE PARTS & GEAR

List of dismantling gear & special tool?

Following are the dismantling gear and special tool.

1. Valve sheet dismantling device.

2. Exhaust valve grinding device
3. Assembly tool of settling of camshaft.
4. Presenting jacks, tools, connecting rod bolts, cylinder head bolts, tie rod, main bearing
bolts.
5. Lifting piece in cylinder head.
6. Main bearing extrusion tools.
7. Piston removing tools.
8. Hydraulic jack join bolts.
9. V-pin extractor.
10. Special tool for dismantling purifier.
11. Special tool for dismantling & assembly turbocharger.
12. Eye bolts.
13. Chain bolt.
 ASSIGNMENT NO. 22
CRANKCASE RELIEF VALVE
Why is it necessary to provide a crankcase relief valve?
It is necessary to provide a large number of crankcase relief valves for automatic
relief of pressure in the event of an explosion wave of pressure in the event of an explosion wave
reaching up to the valves. Such valves should be self-closing and preferably be provided with
flame trap to prevent discharge of flame inside the engine room.
What do you understand by an oil mist and crankcase explosion?
OIL MIST:
Oil in the crankcase vaporizes when it comes in contact with any hot spot. This
vaporized oil being light in weight rises to cooler areas in the crankcase and condenses forming
oil mist.
CRANKCASE EXPLOSION:
Following are the conditions for crankcase explosion,
A. A source of heat or ignition which is required to vaporize the oil into a fine vapor: The
source of heat of ignition is mostly a hot spot due to a bearing running hot. This heat
cause’s lube oil in contact with the hot surface, to vaporize into a fine vapor. This oil
vapor forms an oil mist in the presence of condensation in a relatively cooler section of
crankcase.
B. The correct air to fuel ratio required for explosion: When this fine oil mist ignites in the
presence of a hot surface, pressure rise occurs which depends on the weakness or richness
of the oil particle to all ratio. An explosion occurs if this mixture is in the explosive
range.
C. Fine oil vapor with a high surface area to mass ratio: A primary explosion is relatively
slow as the crankcase atmosphere is too high with oil vapor, but may cause a rupture of
the crankcase allowing ingress of oil. This ingress of air causes a very good air to oil
particle ratio and a secondary explosion occurs.
What is a “hot spot”?
The most probable source of heat in crankcase is that arising out of friction
between two bearing surfaces. In a trunk engine where the liner is hung directly inside the
chamber leaky piston rings will cause passage of flame or hot gases from the combustion
chamber to the crankcase. Heat may also be transmitted to heat up the atmosphere inside the
crankcase through the wall separating the crankcase or heated piston rod in case of a fire in the
scavenge space adjacent to a cylinder.
What precautions are taken to avoid crankcase explosion?
A. The scaltings enclosing the crank chamber are made sufficiently strong to withstand an
explosion pressure in the event of safety door failing to open. The doors are rigidly bolted
on or screwed by such positive means that under a live pressure they are not to be pulled
out.
B. A detection system which will continuously monitor the oily water level in the
atmosphere of crankcase to a detector which will measure and display a warning if the oil
mist density is increased beyond a safe level.
C. A smothering system capable of discharging a smothering gas for inserting the crankcase
atmosphere as the indication of an explosion or fire in the crank chamber.
D. A large number of relief doors are provided for automatic relief of pressure in the event
of an explosion wave reaching up to the door.
 ASSIGNMENT NO. 23
FUEL OIL FILTER ASSEMBLY

WHY IS IT NECESSARY TO PROVIDE A FILTER ON THE FUEL OIL LINE?

The term filter describes a device designed to prevent the passage of unwanted solids into
or further along a system.
It is necessary to provide a filter on the fuel oil line due to the following reasons;
To remove3 the smallest particles of dirt from oil before the oil enters the machined
engine parts.
To remove the larger contaminating particles, prevent in oil.

HOW WILL YOU CLEAN THE FILTER?

 Open vent screw of clean filter bowl of 2-3 hours.
 Slowly turn taper plug until the contaminated filter bowl is disconnected.
 Close venting screw when fuel free of bubbles enlarges.
 First open the vent and then the sludge drain of the disconnected bowl.
 Loosen and lift off the cover by screwing off the nuts. Screw off nut and lift out filter
element.
 Clean gauge filter element in fuel and with soft fresh cleaning can be assisted by flowing
out the gauge cloth from the clean side
 Rinse out dirt at filter bottom through sludge drain opening.
 Ensure perfect sealing of cover when assembling fasten cover by uniformly tightening the
nuts.
 Close sludge drain plug with sealing ring and screw plug.
 Slowly middle position until fuel free of bubbles emerges. Clean the vent and move the
cleaned filter bowl into standby position by slowly turning the taper plug.

WHAT DO YOU UNDERSTAND BY DUPLEX FILTER?

A filtering arrangement having two filter and a three-way code is known as duplex filters.
With this arrangement, both filters can be in use at the same time. But using three-way code one
of the two filters can be shut off from service for cleaning and maintenance, without stopping
machinery as the another filter is in working condition. So this helps machinery to run non-stop
while carrying out maintenance job on filters.
WHAT IS MESH SIZE?
Perforation size in filter element is known as mesh size. For strainers the perforation size
varies from 3-12mm, but for filters it is very small as the stout wire formers are covered by
gauze cloth which can trap minute sized particles.
 ASSIGNMENT NO. 25
TECHNICL DETAILS: DIESEL PROPULSION PLANT

MAIN ENGINE:
Make : MAN B&W
Model : 6542 MC MIC.7
Number : SB6542-4332
Building year : 2006 (STR Engine -KOREA)
Cylinder bore x piston stroke : 429 x 1764 mm
Output power : 8475 BHP (or) 6232 KW
No of cylinders : Uniflow scavenging
Turbocharger system : Constant pressure type
Cross head/ Trunk piston : Crosshead engine
No of outlet valves :1
Highest RPM : 130.8 RPM
Lowest RPM : 50 RPM
Fuel type : HFO
Compression pressure : 12 bar
Max. Compression pressure : 18 bar
Specific fuel consumption : 1778 gm/KW.hr
Method of starting : Air starting system
Crank length/ connecting rod : MAN B&W thrust block with ahead & astern
Thrust pad : Separate/ built in thrust block
PROPELLER:
Make : Sila metals-KOREA
Type : Keyles propellers.
Fixed/CPP : Fixed pitch
No of blades :5
Right/Left hand : Right hand
Pitch : 3.335 m
Thrusters : Not applicable
SHAFTING:
Components : Intermediate of tail shaft
Maxm RPM : 130.8 RPM
Type of stern tube : oil cooled
Type of bearing : 2 no. bush bearing, one in forward and one in aft.
STEERING GEAR:
Manufactured type : By bendo steering gear PPSM-2
Number : 2005 LFMF 45190
Ram arrangement : Rotary vane type
Control arrangement from bridge : Electrical telemotor
Emergency arrangement : Emergency control by manual operated or
solenoid Valve
 ASSIGNMENT NO. 26
TECHNICAL DETAILS: AUXILIARY SYSTEM

SHIP NAME: SLIPPER TENANCIOUS NO-19

Prime mover of generator:
DIESEL ENGINE:
No on board :3
Manufacturer : YAUMAB Company LTD. JAPAN
Type : 6M8L-TV
Year : 2005
Power output : 755 RPM
No. of revolution : 720 RPM
Stroke : 4 Stroke
Turbocharging : Constant pressure
Type of fuel : HFO
Engine starting : Air Starting
Maxmcompression pressure : 16 bar
Minmcompression pressure : 12 bar
SFOC : 17.5% KWH + 5%
Turbine : Not applicable
EMERGENCY DIESEL GENERATOR:
Manufacturer : Standard AC generator new age international
Limited LN lolnsmire ENL and LAN TSPE TVC
OMRILET, 2005
Stroke : 4 Stroke
RPM : 1800 RPM
Power : 140 KW
TANKS:
AE LO storage tank : 9.6 m3
AE LO settling tank : 8.1 m3
ME Cylinder oil tank : 30.8 m3
ME LO settling tank : 17.7 m3
ME DO service tank : 14.7 m3
FO settling tank : 14.3 m3
FO service tank : 26.9m
ME cylinder oil daily service tank : 0.8 m2
FUEL CLEANING SYSTEM:
No. of purifier : 1 each
Make of year : Self ejectors SamgonCo.LTD AWG 2005, Model
3T loch 765
Type of purifier : 1 HFO, 1 DO, 1LO purifier
No. of clarifier : 2 NOs
Capacity of purifier : 1200 l/hr., Rev 1000RPM
Types : 1HFO clarifier, 2 LO clarifier
Fuel oil heating : Made by Dong HWR, KOREA, code LBG NO: 05
FUEL OIL HEATING:
Fuel transfer pump : Generators engine DO supply
No of Board : 2NOs
Pump make : AG German
Type : SPE 10R 3843-W20
Make : 2005
Discharge : 17.4-18 L/min
MAIN ENGINE x AE FO SUPPLY PUMP:
Pump make : 1 MOP/PST
Motor : Brooke Crompton, 60Hg 2004.
ME AND AE-FO CICULATION PUMPS 2NOs:
Boiler to pump : 2 NOs
Pumps : All wasles AG, GERMAN
Fuel : HFO and DO
REFREGERATED HOLDS:
Provision rooms : Meat room-1
Fish room-1
Vegetable room-1
Compressors : Yorh Industries/Type 580914
Displacement : 19-47.4 cm3 /hr.
Speed : 1750 RPM
Temp meat room : -20o C
Fish room : -20o C
Diary room : -5o C to -8o C
Veg room : +8o C
Lobby : +8o C
STARTING CONTROL AND SERVICE AIR SYSTEM:
Main air receiver : 2 NOs
Classification : ABS: volume -3.5m3
Design pressure : 3.3 Mpa
Test pressure : 4.95 Mpa, 2005 Make
Manufacturer : Hang RPM in V Co LTD, HONKONG CITY,
KOREA
Safety relief Valve : 2 (JOKWANG Co .LTD, model 754 FEC)
Seal diameter : 22mm, size: 250 x 404
Set pressure : 33+1 Cm2
Capacity : 6.857 m3
CONTROL AIR COMPRESSOR:
Classification : ABS, volume-1m3
Design make pressure : 0.77 Mpa
Test pressure : 1.16 Mpa
Kanguin industries Co. Ltd, KOREA
Associated air system equipment: -
Air plyer : 1(SAM KNG CENTURY MAX-8 220V, 60 HZ
Single phase)
Capacity : 80 m3 /hr.
Weight : 60 Kg
FLUID CAPACITY SHELL SIDE TUBE SIDE
Operating pressure 2.3 Mpa 82.4 kg/cm2
Inlet temperature 60oC 60-69oC
Outlet temperature 98oC 169.6oC
Test pressure 0.2 Mpa 0.7 Mpa

Weight : 97 Kg capacity
Viscosity controller : DAE HO FLOW INSTRUMENTS CO-LTD,
KOREA
Fuel blending system : Not applicable
ENGINE LUBE OIL SYSTEM:
Main lube oil system pump :2
On board type : Gear pump
Made by : Houttuin BR-Hotland
Year : 2006
Type : 211.135
Quantity : 1.55 m3 /hr.
Pressure : 5.2 bar
Viscosity : 26 mm3 /s
NPSH : 170 RPM
Power : 39 KW
LUBE OIL PURIFIER:
2 NOs onboard, self-ejector, samgong Co. ltd.
Model : 5J10LH
Speed : 10,000 RPM
Capacity : 1200 L/min
Motor : Hyindainneau industries
FRESH WATER:
Fresh water evaporator dongtiwa :1
Entoc
Make : Aug. 2009
Type : SFD 13118
S.NO : F14650A
Capacity : 1-8 tons/day.
 ASSIGNMENT NO. 27
TWO STROKE DIESEL ENGINE
What is a two stroke diesel engine? What is the difference between four stroke and two
stroke diesel engine in theory as well as construction?
A two stroke diesel engine works in two stroke, i.e., suction and compression as its first
stroke and power and exhaust as second stroke. A diesel engine is an internal combustion engine
which operates using the diesel cycle. Invented in 1892 by German engineer Rudolf Diesel, it
was based on the hot bulb engine design. All diesel engine uses compression ignition, a process
by which the fuel is injected after the air is been compressed in the combustion chamber causing
the fuel to self-ignite.
TWO STROKE VS FOUR STROKE: -
 Two stroke engines are more simple mechanically the four stroke, but more
complex in thermodynamic and aerodynamic process.
 In two stroke engine four cycles i.e., intake, compression, ignition, exhaust occurs
in one revolution, while in four stroke it occurs in two revolutions.
 All two stroke engine requires artificial aspiration to operate and will either use a
mechanically driven blower or a hybrid turbo super charger to charge the cylinder
with air, while the four stroke engine may or may not require a turbocharger for
its operation.
 In case of four stroke inlet and exhaust valves are required for suction and
discharge while in 2 stroke engine this can be done using ports that opens or
closes as the piston works.
 A two stroke engine fires every revolution while 4 stroke fires once every other
revolution. This gives 2 stroke engine a significant power boost.
 Two stroke have the potential for about twice the power in the same size because
these are twice as many power strokes per revolution than a 4 stroke.
 Two stroke engines wears out faster thus it requires a special lubrication as
compared to 4 stroke engine
 The two stroke engine completes one cycle of events for every revolution of the
crankshaft compared with the two revolutions required for four stroke engine
cycle.
 Theoretically, the two stroke engine should develop twice the power compared to
a four stroke engine of the same cylinder capacity.
 With a power stroke every revolution instead of every second revolution, the two
stroke engine will run smoother than 4 stroke power unit for the same size of the
flywheel.
 Unlike the four stroke engine, the 2 stroke engine does not have the luxury of
separate exhaust and induction strokes to cool both cylinder and the piston
strokes.
  For less maintenance is expected with the two stroke engine compared to four
stroke engine, but these can be the problem of the products of combustion
carburizing at the inlet, transfer and exhaust ports.
 With a two stroke engine, 40-50 % more air consumption is necessary for the
same power output, therefore the air pumping work done will be proportionally
greater.

What do you understand by reverse scavenging and Uni flow scavenging?

REVERSE FLOW SCAVENGING: -
In reverse flow scavenging the incoming air passes over the piston crown then rises
towards cylinder head. The exhaust gases are forced before the air passing down and out of
exhaust ports located just above the inlet ports.
UNI FLOW SCAVENGING: -
Scavenging is the process in a diesel engine in which low pressure air is utilized to blow
out the waste gases of combustion i.e. scavenging and refill the cylinder with fresh pressurized
air for the next compression stroke.
In uniflow scavenging the incoming air enters at the lower end of the cylinder and leaves
at the top. The outlet at the top of the cylinder is a large poppet valve.
What are the main differences in the components and parts of a two stroke diesel engine
with one having loop scavenging and other with uni flow scavenging?
One with uniflow scavenging will have a comparatively complex design then loop
scavenging. Main constructional changes would be in crosshead design, where the crosshead of
uniflow scavenging system has exhaust ports/valves while in case of loop scavenging the design
of crosshead will be plain and simpler without any ports.
 ASSIGNMENT NO. 28
PISTON AND PISTON ROD
What are the main difference between 2 stroke piston and 4 stroke diesel engine piston?
A 2 stroke piston consists of parts such as piston crown, piston skirt and the piston rod
while in the 4 stroke engine instead of piston rod it is connected directly to connecting rod
through a gudgeon pin, which transmits the power from the piston to the big end bearing. Since
these are no cross head guides in four stroke, the piston skirt helps in transferring the side thrust
produced from the connecting rod the line walls. Hence 4 stroke skirt length is more. In large
cross head 2 stroke diesel engine with uniflow scavenging, these skirts are short in length and act
as guide and stabilizes the piston insides the liner. But in case of cross or loop scavenging the
piston skirt is slightly larger for blanking of the ports.
In higher speed 4 stroke diesel engine the inertia forces of the piston constitute major
unbalanced forces. Thus 4 stroke engine pistons are made by aluminum alloy with small amount
of copper, nickel, magnesium and silicon. Large two stroke diesel engine pistons are divided in
parts where the major strength bearing component is the piston crown. The crown is thus made
by casting of low alloy steel alloyed with nickel chromium and molybdenum
What do you understand by piston skirt and what is the function of same?
The cylinder bottom part of the piston is known as the piston skirt. In 2 stroke engines,
the piston skirt has the function of opening and closing the scavenge and exhaust ports inside the
cylinder, while in 4 stroke piston, piston skirt helps in transferring side thrust produced from the
connection rod to the liner walls. The piston travels up and down the cylinder wall, the lack of
lubrication may result in scrubbing of piston’s skirt.
Which part of the piston requires cooling? How does it takes place in 2 stroke diesel
engine?
The combustion side of the piston needs cooling in the piston crown and this is done by
circulation of cooling water. The internal cooling space should be periodically checked against
leaks of water by a pressure test when the piston is withdrawn for examination.
The piton cooling water is conveyed to and for the moving piston by telescopic pipes.
Two identic telescopic pipes, one serving as inlet of water and the other as outlet are attached
with piston rod flange and sealed inside with rubber rings. The reciprocating members of the two
telescopic pipes are the outer pipes the inner stand pipes are stationery, being held with end of
the cool water chest.
The stand tubes are fitted with mouth piece. The inlet pipe is provided at its end with a
narrow injection nozzle and the outlet pipes with large outlet nozzle. The telescopic pipes are
entering in the cooling water chest. Drain and vent pipe are provided.
 Nozzle at the mouth of inlet stand pipe impact turbulence to the cooling water. It also
sucks air. The cooling action inside is intensified by shaker principle. The outlet id placed above
the inlet and a rub separates them to prevent short circulating.
What are the different mediums used for cooling of piston?
It is generally stated that water has the advantage of being the most efficient cooling
medium but by careful design, both the system has been made to function as efficiently.
However, both have their points of merits and demerits.
 Water compared with oil has more than twice the cooling effect and hence a large
capacity to absorb and conduct heat away. It implies therefore if the degree of
cooling is to be the some of the flow of oil in oil cooled pistons has to be more
than double. The system must accommodate pumps for higher flow capacity or
flow at a high velocity to increase the rate of heat transfer from the piston cooling
surfaces.
 The chief gain in oil cooling system is to estimate changes of crankcase oil
contamination by water and its additives with its consequent bad effect on
lubrication and the risk of corrosion. The design of the conveying mechanism for
lubricating oil to the moving piston can be made a lot simpler.
 Corrosion scale formation on piston interior surfaces remains a serious draw back
in water cooled pistons. Water for the cooling system must be carefully selected
and rendered passive by treatment with a corrosion inhibitor. The system design
must also provide means to avoid crankcase contamination by leakages through
glands etc. and also in the event of a pipe failure.
Enumerate the difference in oil cooled and water cooled pistons and indicate with which
scavenge system will they be used?
WATER COOLED PISTON: -
Water cooled pistons use water as a cooling medium, which is treated with corrosion
inhibitor. These pistons are basically utilized during cross flow or loop scavenging is present in
the system. Here a pressure ring is required to seal the piston crown against leakage of water.
The funnel is bolted inside the cooling water space which collects the return water and leads it
out. Funnel is fixed and is connected to a pipe there is free to slide inside the piston rod. The
cooling water is conveyed to the reciprocating piston by telescopic pipe. Two pipes on for entry
and other for exit of water are fitted.

OIL COOLED PISTON: -

Piston is cooled by circulating of lubricating treated with a rust and corrosion inhibitor is
forced through a telescopic pipe via the crosshead and piston rod. The flow moves along the
walls of convex contour of the crown ensuring a high velocity flow of coolant passes the surface
under the influence of high temperature.
 ASSIGNMENT NO. 29
PISTON ROD STUFFING BOX
What is a piston rod stuffing box?
A piston rod stuffing box is a seal between the scavenge space and the crankcase
in the area of the piston rod penetration. It seals the crank shaft case oil entering into the
scavenge space, and scavenge deposits or cylinder oil entering the crankcase. It is made up of
two section. Each section consists of segmented metal rings held against the piston rod by garter
ring.
How is the stuffing box secured to the engine?
Stuffing box is mounted on a flange which is bolted to the underside of the double
bottom of scavenge air box. The stuffing box is removed together with the piston rod during
piston, inspection but can also be dismantled for inspection in the crankcase while the piston
remains mounted in the engine.
Why stuffing box is required?
The stuffing box assembly is required to form a seal, to prevent the mixing of oil
from crankcase to enter in the cylinder liner.
How is the sealing of combustion product from the liner achieved?
The stuffing box housing is provided with some mechanical ring with sealing
rings grooves, the uppermost of which are fitted with sealing rings to prevent scavenging air
from passing downward along the piston rod.
What is a crankcase? How is the oil from the crankcase prevented from entering from
entering into the cylinder liner?
Crankcase is an integral part of cylinder block. The function of crankcase is to
provide support for the main journal end bearing of the cam shaft. Rigidly maintaining crankcase
is shaped like a box with no bottom root and being formed by the lower decks of the cylinder
block.
The stuffing box assembly is used to prevent the mixing of oil from crankcase to
the cylinder liner. The stuffing box consists of two rings-one ring prevent any air or oil escaping
into crankcase. The second ring is the scraper ring. Any oil clinging to the rod, while exposed in
crankcase is scraped off and returned to the crankcase by these rings
 ASSIGNMENT NO. 30
CYLINDER LINER AND COOLING JACKET

WHAT IS THE DIFFERENCE BETWEEN A FOUR STROKE AND TWO STROKE

ENGINE CYLINDER LINER?
TWO STROKE LINER FOUR STROKE LINER
1. Cylinder liner ha parts in it It has no parts. It has valves
2. It is difficult to manufacture due to Easier to manufacture as it has simpler
complex design design
3. Pads in liner cause non uniform wear Wear down of piston rings is uniform
down of piston rings
4. Large two stroke engines have separate Same lube oil is used to lubricate both
cylinder lubrication system cylinder line r and bearings

WHICH PARTS OF THE LINER OF TWO STROKE ENGINES RRQUIRES

COOLING?
Maintaining the correct surface temperature in the vicinity of combustion spaces by good
heart transfer is necessary to prevent the risk of low temperature corrosion and cranking in lower
portion of the liner. As top part of liner is close to combustion area in two stroke engine it
requires cooling.
WHAT IS CYLINDER LUBRICATION?
One of the latest type of lubrication system is the alpha lubrication system in the MAN B&W
engines. Each cylinder liner has a no of lubrication quilts which are arranged evenly at the
circumference of the top part of the liner above the exhaust port. Through these quilts oil is
introduced into the cylinder by alpha lubricators. In addition, two other feed points are provided
below the parts on the exhausts side of the liner. The lubricators deliver oil to the space below of
accumulator at a pressure. The delivery takes place through filter tube and non-return ball valve
to grooves on the cylinder surface when pressure inside the cylinder falls below accumulator
pressure. The oil is pumped into the cylinder when the piston rings pass the lubricating orifices
during the upward stroke. The lubricators are supplied with oil from a pump station to which the
oils supplied from a header tank.
HOW IS THE LUBRICATION OF LINER ACHIEVED?
The cylinder oil is forced under pressure against the gas pressure in the cylinder by a small
pump. The oil passes through a fitting which is called oil quill or cylinder quill. The quill is
usually screwed into a hole tapped into the cylinder liner. Some oil quills are fitted with NR or
CHECK V/V within the quill others have the N/R V/V fitted external to the quill.
WHAT IS AN OIL FIRM AND HOWIS ACHIEVED IN THE LINER?
Oil firm is a thin layer of oil maintained in between the moving parts. The lubrication of
cylinder liner is the thin film or hydrostatic lubrication the lube oil forms a thin layer between the
liner and piston ring. This is achieved by supplying lube oil at correct pressure through the quill.
The piston ring has a cut at a slight angle which causes a wedge shaped oil film to be maintained.
WHAT ARE THE PROPERTIES OF CYLINDER LUBRICATION OIL?
Cylinder lubrication oil must pass the following properties:
1. It should reduce sliding friction between rings and liner by forming on oil film between
them.
2. It should have proper viscosity at working temperature.
3. Oil should be able to spread evenly over working surface to form good oil film.
4. It should neutralize the combustion and acidic products especially due to Sulphur content
in the fuel.
5. It should help the piston ring for sealing with the liner.
6. It should disperse the carbon particles which tend to accumulate a piston rings.
7. It should burn without leaving any hard deposits like ash etc.
8. Cylinder oil has a TBN (Total Base Number) value of 70mg KOH per and SAE so
viscosity selection of TBN value is done with respect to the Sulphur content to ensure
low wear rates of cylinder liner.

SULPHUR CONTENT TBN VLUE

0.20% to 0.25% 10mg KOH per g
0.25% to 1% 10-20 mg KOH per g
1% to 3% 70mg KOH PERG
ABOVE 3% More than 70mg KOH per g

WHAT IS CYLINDER OIL CONSUMPTION AND HOW IT IS EXPRESSED?

The cylinder oil supplied to the liner to lubricate it will burn up due to combustion gas
temperature and reacts with it to neutralize the combustion and acidic properties products
especially due to Sulphur content in the fuel. So the cylinder oil supplied is consumed to
neutralize to acidic condition inside the combustion chamber. Cylinder oil consumption/feed rate
is increased with vessel operating at slow speed.
Specific cylinder lube oil consumption is given by,
𝑄∗ ∗𝑟
𝑞𝑎 = 4𝐿𝑐
gm per BHP-HR
Where
Qa = Actual feed rate gm. per KW hr.
Q= Measured value liter per day.
R= Corrected specific gravity of oil at measuring point temp.
Lc= Engine output in kW
Units: gm. per KW hr. or gm. per BHP hr. (according to power).
 ASSIGNMENT NO. 31
CYLINDER HEAD

WHAT ARE THE VARIOUS ITEMS FITTED ON THE CYLINDER HEADS AND
FUNTIONS OF THE SOME?
The various mountings fitted on cylinder head are:
- Fuel injector
- Air starting valve
- Indicator cock
- Relief valve
- Exhaust valve
- Inlet valve
FOLLOWING ARE THE FUNTIONS OF THESE MOUNTINGS:
FUEL INJECTOR:
It injects the highly pressurized fuel after atomization of fuel particles into the combustion
chamber to produce power.
AIR STARTING VALVE:
It is used to admit air into the cylinder and on the piston to move it when starting the engine.
Its timing for opening and closing is controlled by cams.
INDICATOR COCK:
It is an arrangement used to blow through the engine before starting and also to accumulate
the indicator instrument used for measuring peak pressure. The instrument is also used to take
the indicator cards through which operating parameters of engine are checked.
RELIEF VALVE:
It is used to prevent any high pressure build up inside the cylinder due to abnormal
conditions. They are designed reduce pressure in excess of 10% above normal. A spring keeps
the valve closed and its lifting high pressure is adjusted by the appropriate thickness. A small
amount of lift is permitted and the escaping gases are directed to a safe outlet.
EXHAUST VALVES:
It provides the passage for the combustion gases to make its way out of the cylinder into the
exhaust manifold. The valve can be operated either a rocker arm is hydraulic or pneumatic
system.
INLET VALVE:
In four strike engines inlet valve provides the passage for fresh air to flow into the cylinder
and fill it with fresh charge of air.
HOW THE COOLING IS CARRIED OUT?
A cooling jacket is mounted on lower part of cylinder cover whereby cooling water space is
formed. Another cooling water space is around exhaust valve seat where exhaust valve seat is
installed. These two spaces communicate through large number of oblique/radial cooling bares.
The water is supplied from cooling jacket surrounding cylinder cover and further through
cooling bares to space around exhaust valve seat. From here the water is discharged to main
cooling water outlet pipe.
WHAT IS THE MAIN DIFFERENCE BETWEEN CYLINDER HEAD OF UNIFLOW
AND REVERSE FLOW SCAVENGED DIESEL ENGINE?
In uni-flow scavenged diesel engines the cylinder cover has exhaust valve to drive
combustion gases out of cylinder while it is not present in reverse flow scavenged diesel engine.
In a reverse flow scavenged diesel engine there may or may not be a centrally located fuel
injector while in uni-flow scavenged engine it is not so.
HOW ARE THE COMBUSTION GASES SEALED BETWEEN THE CYLINDER HEAD
AND LINER?
A sealing ring made up of mild steel or copper or a soft metal is placed between the cylinder
head and the cylinder liner and the cylinder liner is held down on the liner by the studs. This way
the combust ion gases are sealed between head and the liner.
WHAT ARE THE VARIOUS METHODS USED FOR TIGHTRNING THE CYLINDER
HEAD NUTS?
The cylinder head is tightened against the top of the cylinder liner by means of nuts and long
studs fitted the cylinder frame.
These nuts are tightened with the help of torque wrenches in case of cylinder hydraulic jack is
used for tightening these nuts.
 ASSIGNMENT NO. 32
CONNECTING ROD AND CROSSHEAD

WHAT IS A CONNECTING ROD AND CROSSHEAD? STATE THE FUNCTION OF

THE SOME?
The main function of connecting rod is to transmit the gas load from the crosshead into crank
pin in order to convert reciprocating motion of piston to rotary motion of crankshaft. In addition,
it has an auxiliary duty to convey lubricating oil for piston cooling or crosshead and guide
lubrication. It is one of the components which is subjected to a high axial compressive force
magnitude of this force depends on mass of piston and speed of engine.
Crosshead is usually found in 2 stoke engines crosshead consists of journal steel block
secured to the fact of piston rod. It includes journal for top end bearing which acts as a hinge by
which it absorbs the side thrust and transmits it to the guide shoes.
WHAT ARE THE GUIDES AND GUIDE SHOES?
The guide is fixed on a frame or column and provides alignment to the crosshead. The guide
shoes is made up of cast steel and liner with white metal having grooves for lubrication which is
supplied from the crosshead bearing lubrication system.
WHAT IS CROSSHEAD BEARING? HOW THE LUBRICATION OF SAME IS
CARRIED OUT?
A crosshead pin is supported by two bearings which rests on crosshead bearings seats on
crosshead bearings shells linked with white metal steel. Lubrication is carried out by ‘Elasto
hydrodynamic’ lubrication in which oil supply is same as that of bearing lubrication oil whose
main pressure is boosted to 10 bar supplied via the lube oil articulated/area/arms
 ASSIGNMENT: 33
THRUST BLOCK
WHAT IS A THRUST BLOCK? WHY IT IS REQUIRED ON A MAIN PROPULSION
ENGINE SYSTEM?
A thrust block transfers the thrust from the propellers to the hull of the ship. It may have been
independent unit or integral part of the main propulsion engine. Both ahead and astern thrusts
may be catered for her construction must be strong enough to withstand normal and shock loads.
It must be solidly constructed and mounted onto a rigid seating or frame work to perform its
tasks.
The casing of the independent thrust block is in 2 halves which are joined by fitted bolts. The
thrust loading is carried by bearings pads which are arranged to pivot or tilt. The pads are
mounted in holders and faced with white metal. The thrust pad extends three quarters of the
distance around the collar and transmit all thrust to the lower half of the casing.
Other designs employ a complete ring of pads. An oil scraper deflects the oil lifted by the
thrust collar and directs it to the pads stops. From here it cascades over the thrust pads and
bearings. The thrust shaft is manufactured with internal flanges for belting to the engine or gear
box shaft and the intermediate shaft and a thrust collar for absorbing thrust.
When the thrust shaft is an integral part of the engine the casing is fabricated in a similar
manner to the engine bedplate to which it is bolted pressurized lubrication from the engine
lubricating oil system is provided. Other construction is similar to independent type of thrust
block.
WHAT IS A THRUST PAD? WHAT IS THE MEANING OF HEAD THRUST PAD AND
ASTERN THRUST PAD?
Thrust pads absorbs the thrust from the thrust shaft. In the thrust shaft bearings, a thrust collar
is forgetting integrally with the thrust shaft.
Thrust pads fitted at the forward end are called ahead thrust pads and which are fitted at the
aft of the thrust collar is called astern thrust pad.
WHAT IS A THRUST COLLAR?
When the thrust bearing is fitted forward of the main gearwheel the cast of the heavy forging
for a normal thrust shaft with integrally forged collar can be reduced to that of a plain shaft. The
forward end of the main gear wheel shaft is machined to a taper with a thread at the end. The
thrust collar is machined from a flat forged disc with a tapered hole which fits on the taper of the
shaft end and is held in place with a heavy nut capable of taking the astern thrust. A key is fitted
within the taper the thrust housing is arranged so that the thrust collar can be removed without
lifting the shaft thus allowing the thrust collar to be removed for re machining without a lot of
disturbance to other equipment
HOW IS THRUST PADS FITTED TO OBTAIN THE TAPER OIL WDGE?
In tilting pad type thrust block bearing builds up an oil pressure between the white metal face
of the thrust pad and the thrust collar when the shaft revolves. The oil pressure is due to the
formation of an oil wedge which can build up only when the thrust collar is supplied with oil is
revolving. As the pad is able to tilt it becomes self-adjusting to the shape of the wedge.
 ASSIGNMENT NO. 34
CHAIN DRIVE

What is a chain drive? Why it is required on diesel engine?

Chain drive in diesel engine is used to transmit the drive from the crankshaft to the
crankshaft intermediate wheel for fuel pump and can driven drives as a guide while an adjuster
wheel serves may be connected to a separate chain for driving motors to the lubricators,
governor, air distributors etc.
How is lubrication of gear and chain drive carried out?
Gear teeth are lubricated by means of oil spray nozzles from the main lubricating pump.
The chain lubricated by means of oil sprayer which directs a continuous flow of lubricating oil
into chain bearing. The oil will lubricate and cool the bearing and will functioning loads.
How is the tightening of the chain drive done and why is it required?
With courses of time, the chain will elongate gradually. A block chain will update
improving heavy additional mechanical loading which can result in failure of the chain can be
measured by its extension to avoid heavy vibration tightening is done.
Procedure for tightening of the chain one:-
(A) By turning engine to that all the black is taken on side of the length.
(B) Pull all the middle of the till length of the chain under normal conditions. The chain
should vibrate by half of one chain link.
(C) By opening two lochuts as the chain, tighten bolts so that bolt is free.
 ASSIGNMENT NO. 35
TURBOCHARGER SYSTEM

What is super charging/turbo charging in diesel engine and how it is achieved?

Combustion and power depends on the amount of fuel and air supplied some proper
combustion required a proper air fuel mixture ratio 14:1.The amount of fuel to be burnt is limited
by the ratio of air that can be supplied. If most of air is energized is the density and pressure fuel
can be used for burning. Hence supercharging or pressure charging of combustion air supplied
allows more power to be developed with proper combustion super charging is the pressure
charging of air supplied to the cylinder at the beginning of compression. In two stroke machine
engines in order to achieve correct combustion scavenging and effective quantity is supplied.
Why an auxiliary blower is required as turbocharging engine and under what
circumstances it is used?
Auxiliary blower which one independently driven type are used turbocharged engines.
They are used mostly in the first and second type of supercharging system only as a scavenge
assistance. They are used during the starting of the engine and when engine running at slow
speed the turbocharged is not able to supply enough air for engine process.
Pulse turbocharging:-
It uses the pressure pulse drive to expand the gas further at the turbine
nozzles and blades exhaust gas from each cylinder is directly leads to the turbine inlets. Pressure
walls are created when the exhaust value suddenly opens and exhaust is flow down in the
exhaust piping of smaller diameter thereby
 ASSIGNMENT NO. 36
EXHAUST VALVE AND GEAR

What is an exhaust valve?

Exhaust valve is a slide way which closes the exhaust pipe shortly after scavenging is
engaged until the exhaust port are closed that no air may escape during the upward piston stack.
Where it is fitted and why it is required?
The exhaust value is fitted on the cylinder head. It is required on a 2-large 2-stroke
uniform scavenging diesel engine to drive the combustion gases after expansion, out of the
engine.
What are the special features of valve and seat?
 Check resistance at high temperature
 Corrosion and oxidation resistance
 Wear resistance
 Erosion resistance
 Machinability
 Compatible with value guide materials
 Impact resistance and surface hardness
 High temperature strength

Value material are:-

 Nickel based alloy
 Precipitation hardness steel
 Austenic steel
 Si-chrome steel

How is the guiding of valve and valve seat carried out:-

 Mount and secure the guiding machine. Use helical gauge, check that spindle is
correctly controlled
 Adjust the grinding wheel head to achieve the correct guiding angle.
 ASSIGNMENT NO. 37
INDICATOR CARD

What is an indicator used?

An indicator diagram is a pressure/volume graph taken from the pressure in the cylinder of
working engine. It is plotted as the continuous line showing all pressure changes during one
complete engine cycle. The purpose of indicator card are;
 To ensure evaluation of power developed in each cylinder.
 To highlight conditions during fuel injector, combustion and after burning.
 To highlight conditions prevailing in the cylinder during the scavenge/exhaust
gas exchange process
 To show the pressure variations in the cylinder with respect to piston
displacement.

How will you take the indicator card on two stroke diesel engine? What arrangement
are provided for the same?

As 2-stroke marine diesel engine are slow speed engines, it is possible to obtain indicator
diagrams from each cylinder by using engine indicator. The indicator instrument can be
connected to take indicator card.
In many modern sophisticated engines, measuring devices may be fitted to record
cylinder pressures as an oscilloscope trace or printout.

To take the indicator diagram:-

 Fasten the instrument to cock so that instrument is out.
 Trace the atmospheric line with the cock shut.
 Open the indicator cock and lightly press the pointer (stylus) against the paper till the
cycle is described.
 Close the cock.
 Disconnect the card. Open the indicator cock and put it by hand. A compression
ignition sequence is recorded. The pull is to be timed when the pencil is upward (i-e)
the pencil is at the TDC.
What parameters can be checked by indicator cards?
 Peak pressure (power card)
 Mean indicated pressure (power card)
 Compression pressure (compression card)
 Pressure changing during fuel combustion (draw card)
 Pressure changing during exhaust and scavenge ( light spring card)
What is a draw card? What all can be checked by draw card?
It plots the pressure variations in the cylinder and can be integrated with a plain meter to
calculate the mean indicated pressure. The power can be developed in the cylinder can be
calculated by multiplication of the engine speed and the cylinder constant. It also highly after
burning.
How will you calculate IHP and BHP of the indicator cards?
 Mean indicated power pressure (pi) bar :-
Pi= A/L x Cs
Where: A= area of the indicated diagram by plain meter (mm2)
L= length of the indicated diagram (mm2)
Cs = spring constant (mm/bar).

 Mean effective pressure (Pe) bar:-

Pe= pi–k1
K1= mean functional loss ≈ 1 bar
 Indicated engine power (pi) :-
Pi= k2 x n x Pe
K2= cylinder constant = 0.78 x D2 x S
D= cylinder diagram in m.
S= piston stroke in m.
N= engine rpm.
 Brake or engine effective power (Pe):-
Pe= K2 x n x Pe
K2= cylinder constant 0.78 x D2 x S
D= cylinder diameter in m.
S= piston stroke in m.
How often the indicator cards are taken?
Indicator cards are taken for a particular engine according to the instruments of the engine
manufactured, that when the ship is en route through a calm sea.
Every time when unit decarbonisation is done.
Every time after fuel injector is overhauled or changed
Every time after some major maintenance work is done.
What are the instruments and instruments known as for taking the indicator cards and
calculating power?
Indicator instrument and plain meter are well known instruments for taking the indicator card
calculating the power respectively.
 ASSIGNMENT NO: 38
RUNNING GEAR
What do you understand by running gear of 2-stroke diesel engine and how will you
inspect the same? What will you check during inspection?
The moving parts of engine which include piston, piston rod, connecting rod, valve
gear, bearing etc., are known as running gear. These parts are carefully examined periodically
as per planned maintenance schedule, the main schedule include documentation of
observation noting deflects, wear down for each individual components for checking
following pro- parameters.
Serving, cleaning, gearing, checking clearance. Functional test to ensure operation within
periodic link such as, temperature, pressure etc. survey of government bodies.
Self-maintenance program to be carried out on machinery which include renewal,
readjustment, bedding valve grinding calibration.
How are the following items checked during inspection?
Main bearings and bolts:-
Every 2000- 3000 hrs the bearing thickness tightness of bolts etc. are
checked clearance is measured with the help of bridge gauge. The top cover is removed and
gauge is over the top surface and throw the hole on the bridge gauge. Instrument is inserted.
This indicate the top of drop at aft side or wear down of main bearing.
Top and bottom end bearing bolts:-
Bearing clearance are taken for every 2000 to 3000 hrs of running tightness of bolt,
oil flow character is checked. Every 1000 hrs bearing is dismantled for checking of surface
and bolts are checked for cracks using dye penetrant test.
Crank case:-
Every 4000 hrs foundation bolts are checked and retained 1000- 2000 hrs. The self-
release are push rod and overhauled after 3000 hrs till oil is drained from crankcase cleaned
and checked. Before filling fresh oil ensure that all pieces of rags, clothes are removed.
Lube oil flow:-
Oil flow to bearing and other parts of running gear is checked at various interval.
Pipeline are checked for leakages flow meter and other indicating instrument are checked and
calibrated. The sumo is checked for contamination.
Crank web and main journal:-
Every 2000- 3000 hrs crank web shrinkages twisting of crank pin, main bearing
journal due to transmission of variable torque is checked with sequence to fall a take mark
every 4000 hrs. Crank shaft alignment is taken using dial gauge.
Cam shaft bearing and drive:-
 Bearing gears are checked along with the sign of wear and crank of savange marks
lube oil flow to the bearings are checked. Every 4000 hrs the tooth force and oil spray nozzles
are checked in case of chain drive slacken rotor surface sprocket wheel teeth etc. are checked
and chain is retentions.
Various lock and wire lasting:-
Slackness of locking and wire lasting are checked and retightened if necessary. If it
has same defect the components are renewed with a new one and new length of wire.
Tie rods:-
Every 8000hrs, pretentioning of the rods are checked, excessive vibration of rod is
noticed and the drop is measured. if the rod has broken the clearance will get reduced.
Gear train and lubrication of same:-
The inspection is carried out for every 4000 hrs. The gears are checked for scar
marks. And peak factor. The back clash of teeth are checked and proper lubrication is
ensured.
Crankcase sump:-
Presence of any material particles in the crankcase sump indicates the strainer are not
working properly. The fittings are opened up and contamination of oil that is drained and
send for purification. Sumo is cleaned and fresh oil is filled.
Crosshead and guides:-
The cross head assembly is dismantled after 1000 hrs. The crosshead pin and bearing
shells are checked for wear and scar marks. Lube oil bolts are blow down through a
crosshead blockage deposit. The bearing clearance are taken out. The lube oil flow pipe is
checked for leaks and cracks.
 ASSIGNMENT NO. 39
SCAVANGE PORT AND SCAVANGE MANIFOLD INSPECTION

How will you carry out scavange port at scavange manifold inspection?
Scavange ports can be checked and cleaned without taking out the liner either by
entering into the scavange manifold or through crankcase.
 Scavange ports are checked for any cracks.
 Carbon build up should be cleaned.
 Edge of scavange ports are made fine using emery paper.

How will you look for during inspection and how will you check the following?
Scavange ports:-
They are inspected for deposition of carbon and any cracks developed by entering
through the scavange manifold or when the liner or piston taken out.
Condition of piston rings and piston rod:-
Piston inspection:-
 check the crown surface for any trace of fuel, water or cracks.
 This piston crown is cleaned and the burn away on the surface is checked with the
help of tern plate. For cracks, use a simple white chalk test or dye penetrant test.
 Remove the rigs with the expanded tool.
 Clean the grooves and measure the groove/ring clearance.

Piston ring clearance:-

Ring gap or butt clearance:
It is taken where the liner is least worn, usually at the lower part or in the new liner.
They used ring (ie) inserted into the liner and the ring gas are butt clearance is taken by
making an impression of the gap on paper.
Groove axial clearance:-
It is taken using a filler gauge inserted horizontally in the gap betwwen the top of the
using ring and the groove.

Ring width:-
It is taken at 3 different points around the circumference of the ring.
Carbon deposits:-
It can be checked by scrapping of surface of the scavange manifold, piston crown and
scavange port.
Cylinder lubrication and liner calibration:-
 For inspecting liner condition, the piston must be brought to BDC and it can be
inspected through scavange port. the liner should be glazing and wet lube oil.
 Cylinder lubrication should be hand checked and amount of oil coming out should be
noted down and checked for any blocks in quills.
 Check for scuffing and scoring in liner.
 Liner should be checked for carbon formation at the top most point where the piston
start downward stroke.

Scavange valve and under piston space:-

Scavange valve should be removed and cleane
d. Plate should be checked for any damage of edges.
Piston and stuffing box is inspected and rings are checked.
Under piston leaking can be checked from the amount of oil in the tank. Scavange
manifold cleaning.
Scavange manifold should be cleaned after the under piston area and liner have been
cleaned.

Scavange drain:-
It should be opened once during watch and amount of oil must be watched and noted
down.
It can be checked for any metal part or presence of water in drain must be checked. It
indicates the JCW cooling at scavange air is uncooled.
 ASSIGNMENT NO. 40

AIR COMPRESSOR
What is an air compressor? Why it is required on ship?

Air compressor is a machine used to raise the pressure of a gas with the minimum expenditure of
energy. There are four principle types of air compressors

 Reciprocating air compressor(air is compressed by positive displacement of

piston in cylinder)
 Turbo machinery ( air is driven by high speed impeller rotating in confined space)
 Ejectors ( air is moved using kinetic energy induced by high velocity jet through
nozzles)

Air is compressed by positive displacement of pistons in cylinders. Flow is controlled

by valves. Reciprocating air compressors are used in marine diesel engine plants for
starting of engines and other control systems. Air reservoirs are necessary as
reciprocating compressors provide pulsating air delivery. When the movement of air
tight piston compresses air, the pressure increases the volume decreases. When air is
compressed, a rise of pressure as well as temperature takes place.

Discharge valve closes with the aid of spring loaded valve, trapping a
small amount of high pressure air in the clearance volume space. Expansion of this air
takes place first, before suction valve is opened.

It is important that the compressor clearance volume is kept as small as

possible in order to improve volumetric efficiency for greater efficiency, air
compressor should be isothermal as this requires minimum work input. The coolers
are provided to obtain a process that is near to isothermal process since in practice,
easy to achieve.

Effect of leaky valves: Leaky discharge valve will result in air flowing back into the
cylinder on suction stroke. It results in reduced efficiency and high operating
temperature. Leaky suction valve will result in air returning to suction space during
compression. This results in reduced air delivery and increased running time.
What are the factors that affect the volume of air discharged by compressor?
 Excessive bump clearance
 Defective valves
 Piston ring leakage
 Restriction in intercooler
 Restriction in air intake filter
 Abnormally high intake air temperature
 Restriction in discharge line

What are the different parts /components of air compressor?

The parts/components of air compressor are:

 Intercooler/after cooler: the function of the cooler is to extract heat and reduce
temperature of air. The volume of air also reduces due to reduction in temperature and
pressure. Moisture is extracted at each stage of cooling. The intercooler acts as a receiver
from air discharge between two stages. Cooling water for the coolers is supplied either
from an integral pump or machinery space system. The water passes into the cylinder
block which contains both stage coolers. A water jacket safety valve prevents a built up
of pressure, should a cooler tube burst and compressed air escape. Cooler drain valves are
also fitted to compressors when these are open, the machine is unloaded and does not
produce compressed air. A compressor when started must always be in unloaded
condition. This reduces the starting torque for the machine and clears out any
accumulated moisture in system. This moisture can effect lubrication and may produce
oil/water emulsions which line the air pipe lines and could lead to fire or explosions.
Various methods of unloading can be used but marine designs prefer for either depressors
which hold the suction valve plates on their seats or a bypass which discharges to suction.
 Safety devices:
 A water jacket safety valve prevents build-up of pressure should a cooler tube
burst and compressed air escape (a spring loaded relief valve or bursting
diaphragm is used).
 Relief valves are fitted to the first and second stage air outlets and are designed to
lift at 10% excess pressure
 A fusible plug is fitted after second stage cooler to limit delivered air temperature
and thus protect the compressed air reservoirs and pipe work.
  Loader or Unloader: With these, cylinders can be loaded or unloaded during starting and
stopping. Its purpose is to delay compression process until motor is accelerated to
required speed by overcoming frictional and initial load. Unloading of air compressor
while starting also prevents air reducing starting torque on the machine. This is also
provided to prevent over loading or slippage of belts. A compressor should be operated in
unloaded conditions before starting and stopping. This will clear the coolers of any
condensate air mixture.
 Air reducing valve: This allows to maintain constant low pressure at set value,
irrespective of rise or fall on high pressure side. Double sided, flexible diaphragms are
used to obtain desired pressure.

What is the difference between single stage and multi stage air compressor?

Multi stage air compressor have an advantage over single stage air compressor since high
pressure can be achieved with less possible work input.

In multi stage air compressor, the compression ratio at each stage is lower and so
the fuel temperature of air is lower. This reduces problem with lubrication. Compression is more
near to isothermal line. Less air temperature in multi stage due to pressure of coolers reduces the
problem of carbonizing of valves, deposits in coolers for multi stage compression, the unit is
bigger in size as compared to single stage and the maintenance costs are also high for the same.
Efficiency of multistage compressors is higher than the single stage compressors due to presence
of intercooler but wear and tear is more in multi stage compressor.
 ASSIGNMENT NO. 41

SUCTION AND DELIVERY VALVES

What defects are usually found in the valves?

The valves used in air compressors are plate type valves. The plates are subjected to shock
loading both on opening and closing. To reduce this the buckets are shaped so that impact is
reduced. The impact of closing can`t be avoided. For this reason, plates may eventually crack at
sealing surface. Lapping should be done to obtain a mirror finish for less drag to the air flow to
keep temperature minimum and to improve efficiency. To reduce friction through valves, the
tapered parts should be well rounded off and polished.

Due to excessive wear, the valves may start leaking, giving loss efficient output. Leaky discharge
valve results in air flowing back into the cylinder on suction stroke. This will result in reduced
efficiency and high operating temperature. Leaky suction valves results in air returning to suction
space during compression. This will result in reduced air delivery and increased running time. If
second stage valve is leaking, it will cause high pressure in the intercooler. The compressor will
virtually run in unloaded condition if the suction valve leakage is high.

Cleaning and inspection of both the suction and discharge valve is done carefully
after a regular interval of 150 hours of running time. Overhauling of valves and changing of
rubber rings is done annually.

What precautions are taken while fitting back the valves?

Most important part of air compressor, that regards efficiency in the valves, the suction and
discharge valves usually are of some type, the only difference being in spring load and the lift.

Parts of suction and discharge valves should not be mixed when dismantled for
overhauling. Parts must be assembled exactly in same order. Spare parts must be clearly marked
‘Suction and Delivery’.
 ASSIGNMENT NO. 42

AIR COMPRESSOR MAINTAINENCE SYSTEM

What maintenance is required on air compressor?

Maintenance schedule
1. Check lube oil level - daily
2. Clean suction filter - 3 months
3. Clean and inspect valves - 150 hours
4. Check water jacket safety discs - 3 months
5. Safety valve check - 6 months
6. Check auto operation gauges - 6 months
7. Change crank case oil - 6 months
8. Overhaul valves, change rubber rings - 1 year
9. Change oil filter - 1 year
10.Change holding down bolts - 1 year
11.Check coupling alignment - 1 year
12.Clean coolers - 2 years
13.Complete overhaul - 4 years
14.Piston and main bearings change - 10000 hours
15.Suction and discharge valve overhaul - 2000 hours
16.Inspect the L.O pump and jcw pump - 5000 hours
17.Bumping clearance should be checked
18.Check that connecting rod is free to slide on crankshaft.
Complete overhauling of main air compressor

I. Put off the power to the compressor and put a note ‘MEN WORKING’ on the power
panel.
II. Shut the air bottle filling valve and compressor delivery valve
III. Isolate cooling water system
IV. Open crankcase door and drain out the oil from sump
V. Remove the cylinder head nuts and bolts
VI. Remove all connections like jcw outlet pipe, inlet pipe, pressure gauge line on cylinder
head
 VII. Lift the cylinder head from its place and keep it on wooden piece on floor
VIII. Move the piston to TDC and fit the piston lifting tool
IX. Open the bottom end bearing of bottom half
X. Remove the piston rings, clean the piston, piston groove, old piston rings, and new piston
rings.
XI. Clean the liner and calibrate the liner.
XII. Remove the piston rings from its place and place it on stand.
XIII. Clean the crankpin, bottom end bearing and calibrate.
XIV. Calibrate piston ring grooves, old piston and new piston rings.
XV. Put new piston rings on the piston.
XVI. Lubricate the liner, crankpin, bottom end bearing and fit back the piston and connect the
bottom end bearing.
XVII. Clean the cylinder head landing area and renew the gasket
XVIII. Put back the cylinder head after cleaning its landing area and tightened.
XIX. Clean lube oil pump suction filter, clean crankcase and take fresh L.O into crankcase
sump.
XX. Give all cylinders head connections.
XXI. Clean the intercoolers s/w passage. Clean the jcw spaces with descaling liquids.
XXII. Open compressor delivery valve and air bottle filling valve.
XXIII. Open intercooler drain.
XXIV. Connect the electrical supply and try out the compressor.
 ASSIGNMENT NO. 43

AIR COOLER
What is function of air cooler?

The function of air cooler is to extract heat and reduce temperature of air. The volume of air also
reduces due to reduction in temperature and pressure moisture is extracted at each stage of
cooling. The intercooler acts as a receiver for the air discharge between the two strokes. Drop in
pressure accounts for the initial pressure of one stage being lower than delivery pressure of
preceding stage.

 First stage cooler: this is a single pass cooler in which the air passes from an inlet cover
through a bank of tubes to an outlet cover. The cooler is mounted in the cylinder block.
A tube plate into which the tubes are expanded is secured to the inlet cover. At the outlet
end, the cooler tubes are expanded into a similar tube plate. This is attached to the outlet
cover. Outlet cover carries a drain valve for draining the cooler of any condensate from
the air. This can also be used for unloading the compressor during starting. The cover is
fitted with air pressure safety valve to protect the air system.
 Second stage cooler: these are double pass type for high temperature of compressed air.
Delivery side fitted with a drain valve and air pressure safety valve. Air at higher
temperature is less dense, so for a given volume, there is a reduction in mass. Terminal
temperature is limited in stage compressor as each stage is subjected to low compression
ratio and work input also reduced with intercoolers.

How many air coolers are there on multi stage air compressor?

The number of air coolers on a multistage compressor will depend on the number of cylinders in
which air gets compressed. The number of stages in a multi stage air compressor, In a multi stage
air compressor there is an intercooler fitted between each stage and an after cooler at the last
stage

Why is safety valve provided?

The fact that water is in compressible, account for bursting of intercooler casing or tubes. When
the tubes give out or get damaged spring loaded valve has not proved to be sufficient under
conditions of sudden rise of pressure. Hence disc type is more suitable. Safety disc with large
area can give immediate relief when sudden pressure rise occurs by bursting of disc, it activates
when air pressure exceeds more than 1.2 bar.
 ASSIGNMENT NO. 44
AIR PRESSURE SAFETY VALVE AND WATER JACKET SAFETY
VALVE
What do you understand by air pressure safety valve?

An air safety valve is fitted into each of the first and second stage cooler. Each valve comprises a
body, cap and seat which together house a plunger and spring. The spring pressure is set by
means of the associated stage operating pressure.

What do you understand by water jacket safety valve?

It protects the compressor water jacket cooling system against excessive pressure.
The valve comprises of a body housing a backing disc, spring and spindle. A groove
machined in the face of the backing disc locates a synthetic rubber seal bonded in piston, the disc
and seal are held against the seat by a spring. The spindle also forms a handle for manual
operation of the valve if required.
 ASSIGNMENT 45
OIL SEPARATOR

Q. What is an oil separator? On what principal it works?

An oil separator are used to ensure that ships do not discharge oil when pumping out bilges from
tanks or any other oil contaminated space. According to International Legislation, clean water
suitable for discharge is defined as that containing less as 15 ppm of oil. Oil separators using the
gravity system can only achieve 100 ppm & must therefore by some conjunction with filter be used.
A complete oil/water separator & filter unit for 15 ppm purity is first filled with clean water. The
only water mixture is then pumped through separator inlet pipe into the coarse separating
compartment. Here some oil, as a result of its lower density, will separate & rise into oil collection
space. The remaining oil/water mixture now flows down into the fine separating compartment &
moves slowly between the catch plates. More oil will separate out onto the underside of these plates
& travel outside until it is free to rise into the oil collecting space.
Where greater purity is required, the almost oil free water passes to a filter unit. The water flows in
turn through 2 filters & the oil removed passes to oil collecting space. The first stage filter removes
physical impurities present & promotes some fine separation. The second stage filter uses
coalescence inserts to achieve the final de-oiling.
Current legislation requires the use of monitoring unit which continuously records & gives an alarm
when levels of discharge in excess of 15 ppm occur.
Q. How is the oil separator cleaned?
1. Turn off the influent water to unit.
2. Open the unit cover.
3. Remove any oil & dispose it off in a way that compiles with legal procedures.
4. Drain the water from separator.
5. If necessary, dispose of the solid water.
6. Clean the media plates using a low pressure hose while taking extreme care to avoid getting
discharge on ground where it has access to ground water.
7. Remove all the sludge & oil build up.
8. Assemble all parts that were removed.
Coalescence type filters are also sometimes back flushed in order to remove foreign contaminate
& sludge that may collect on surface of cartridge.
Q. How many types of separators are fitted onboard ship? Write down its function of each?
There are two types of oil separators used onboard ships. They are;
Purifier:
When a centrifuge is arranged to separate impurities & two liquids, it is known as purifier.
Clarifier:
When a centrifuge is arranged to separate the impurities & small amount of water from oil, it is
known as a clarifier.
Q. Write a short note on following:
Gear & Gear Box:
Considerable amount of torque is required to directly drive the bowl up to normal speed using an
electric motor. The load on the worm wheel would be very heavy, which would lead to breakdown
of gears due to lubrication failure. Otherwise it would require a big sized worm wheel to drive to
meet the torque requirement which again will increase the starting torque requirements. The gear
train is generally a single sized worm wheel arrangement with the wheel being made of a softer
material. Oxidation have industrial gear oil because it can form sludge that can shorten both oil &
gear life.
Gear Oil Separators:
Industrial gear oils must contain high performance additive chemistry. Goal is to keep lubricant
thoroughly stable & robust enough to ensure that it least longer, protects better & performs more
efficiently, while at the same time keeping the system clean & carrying away heat &
contaminations.
Oil Level & Sight Glass:
An inspection glass, fitted in the overboard pipe of oil/water separator permitting sighting of flow.
The discharge is illuminated by a light bulb fitted on the outside of glass part opposite the viewer.
The separator is shut down if there is any evidence of oil carry over.
Oil In Water Monitor:
Current legislation w.r.t the discharge of oily water set limits of concentration are between 15-100
ppm. A monitor is required in order to measure these values & provide both continuous records &
alarm when the permitted limits exceeds.
A sample is drawn off from o/b discharge & passed through all. As ultraviolet light is directed at
the sample & the fluorescence is monitored by a photoelectric cell. The measured value is
compared with the maximum desired value in the controller. When an excessive level of
contaminate is detected an alarm is sounded & diverting valve operated. The discharging liquid
then passed to the slop tank.
 ASSIGNMENT 46
OIL SEPARATOR PARTS

Write functions of following parts:

Gravity Disc:
It is used to maintain the interface for separating the light & heavy liquids in the bowl. The gravity
disc with different inner diameter are used according to specific gravity of fuel to be treated these
by changing both interface position.
Discharge Collar:
It acts like a guide for the liquid to pass through.
Bowl Head:
It is a bowl body & looks like a large using to form a housing for distillation & disc sets through
which the liquid is passed & separation takes places.
Top Disc With Neck:
The top disc stack is known as top disc & is heavier & has neck & collar fitted at top in case of
purifier. It acts as a barrier between the two separator phases at outlet.
Top Disc Without Neck:
The top most disc stock without neck is similar in function to that of a purifier but is used in
clarifier.
Distribution:
It leads dirty oil from the bowl inlet to separation chamber.
Disc Set:
It consists of a thin conical disc of stainless steel. The separation tube is placed between the discs.
What is a water seal?
In a purifier bowl, the water seal prevents the light phase from passing the outer edge of top disc.
Thus the bowl must be fitted with sealing liquid before the process liquid is supplied. The sealing
with sealing liquid before process liquid is supplied. The sealing water is subsequently forced
towards the bowl periphery so as to form a liquid ring confined inwardly by interface between the
light & heavy phase.
Distributor:
It is used to feed purifier supply to disc stack. The holes drilled in conical bottom sections of
distributor are distributor holes. It has guide vanes in inner periphery that convert axial fluid flow
inlet to circumferential flow causing centrifugal separation. It acts as a seal for disc stack.
 ASSIGNMENT 47
PURIFIER & CLARIFIER

What is the difference between purifier & clarifier?

Purifier:
Liquid-liquid-solid separating operation for separation of oil, water & solid content out. The
purifier bowl has two liquid outlets. The dirty oil flow through the center to the interspaces b/w the
bowl disc. Where the liquid phases are separated from any solids moves along the underside of
bowl disc towards the periphery of the bowl, where the solids settles on the bowl ball. The heavy
phase proceeds along the upper side of top disc towards the neck of the bowl hood & discharge over
gravity disc.
The light phase moves along the upper side of bowl disc towards the bowl center & discharge via
the hole in the top disc neck. In a rapidly rotating bowl force of gravity is replaced by centrifugal
force which can be thousands of times greater.
Clarifier:
Two phases (liquid-solid) separating operations is carried out for separation into solid & liquid. The
clarifier bowl has an outlet. The process liquid flows through the distributor to the interspaces b/w
bowl discs. Through the action of centrifugal forces, heavy particles moves along the underside of
the discs towards bowl periphery where they settle on bowl ball. The liquid proceed towards bowl
center & discharge through the bowl hood.
What is the rpm of separator? How it is checked?
The speed at which bowl of the separator rotates is called as rpm of separator. Its range is from
5000-7000 rpm depending upon the size. A constant speed electric motor supplies the motive power
for the wheel & worn drive for the centrifugal bowl.
The rpm can be measured with aid of revolution counter.
After dismantling how will you identify the purifier & clarifier?
After dismantling the oil separator, check for dam ring, if dam ring is present, it is purifier, if it is
not present then it is clarifier.
PURIFIER
 ASSIGNMENT 48
OIL SEPARATOR INSTALLATION

Where is the purifier system?

It is the room or place where the purifier is installed or fitted.
What is sludge? When cleaning the separator why is sludge found inside?
The sediment accumulation along the bowl wall is called sludge. Due to the centrifugal force of the
separator at periphery of bowl it is found there so, during cleaning the separator the sludge settles
down at the bottom of the bowl.
What is the function of following?
HO/DO Settling Tank:
It is a tank in which fuel oil is started at a certain temperature to maintain the viscosity of fuel. The
impurities of fuel will be settled down at bottom of tank which can be drained out.
HO/DO Service Tank:
It contains the fuel from settling tank. Fuel oil is fed to cylinder of the engine through fuel pump by
maintaining the temperature & viscosity at certain pressure.
Lube Oil:
It is a reservoir of lube oil usually found at the base of engine in which lube oil gets accumulated.
The lube oil is supplied from sump to maintain the lubrication of engine parts by a separate pump.
 ASSIGNMENT 49
DRY DOCKING

What is dry docking?

It is the process of resting the ship on blocks & carrying out the maintenance of the ships under
water portion of the hull.
Explain the following:
Keel Block:
The ship rests on the dock on a block of wood or cement which are 1.25m-1.5m high & these
blocks are placed on docking floor.
Docking Plan:
The ship owner gives the sets of the drawing of the ship to the docking master which gives the
location at which keel blocks are to be placed. It also gives the information about sea chest erosion
& underwater portion projected. This is called docking plan & based on this keel blocks are placed.
Grit Blasting:
It is the process of blasting with abrasive material that implies, it is done on the underwater portion
of hull.
Sand Blasting:
The sand particles are used as abrasive material & blasting is done on the underwater portion of the
hull.
Sea Chest & Filter with Fitting:
Sea chest is the opening in the ship’s hull from which sea suction for cooling & other purposes is
taken. It consists of filter which traps large particles on it & is cleaned periodically with compressed
air. There is a quick closing valve in it.
Overboard Discharge Valve:
There are valve are used to allow water to O/B. there are non-return v/v & will not allow the sea
water to enter through it into ship.
Emergency Sea Suction: It is the valve which is connected to a high capacity in the engine room,
which will suck water from lowest point in the engine room of emergency like flooding.
Tail Shaft: It is also called propeller to the main engine through the intermediate shaft.
Under Water Hull: It is the portion of the ship’s hull which is immersed in water when the ship is
in sea.
Stem Tube Seal: It is the seal around the end of tail shaft which is used to prevent oil leakage to
sea & sea water entering into engine room.
High pressure hosing down/washing: It is the process of injecting high pressure water on the hull
for the purpose of washing of dust & marine growth in order to clean it, it is done before blasting.
Anchor & Anchor Cable: As ships do not have breaks, it uses anchor to hold the position when it
is not propelled. Anchoring cable is used for lowering or hoisting up the anchor.
Hull Points & Protection:
a) Primer: It is applied immediately after the process of lube oil overhauling to avoid rust
formation after the ship hull has exposed to environment’
b) Anti-fouling: Prevents algae/marine growth formation on hull. Ingredients present in this
are toxic to marine growth.
c) Cathodic protection: Anodes may be sacrificial or non-sacrificial, is fitted to prevent hull
form undergoing corrosion. Impressed current cathodic protection also be used to prevent
the corrosion of hull.
d) Anti-corrosive: Prevent corrosion of ship’s hull from sea water.
Swinging Of Rudder: It is normal turning of rudder or actuation by steering gear from port to
starboard side.
Draining & Oil Bath To The Rudder: When rudder is dry, friction plug is removed after opening
vent plug. Check whether any water comes, prevent leakage then fill the water till top. Fill out
through vent plug till rudder is fitted completely. Now, drain the water leaving the thin coated on
the side of rudder.
Aft Peak Tank: aft most tank of vessel is used for staring sea water known as aft peak tank.
Fore Peak Tank: The tank in the forward most part of the ship which is used for ballasting
purpose.
Chain locker: It is compartment where anchor cable is stored.
Docking Survey: This survey is carried out for all underwater parts of hull including propeller,
rudder, and sea-chest. Classification society: Organization which does the initial survey & periodic
inspection to maintain ship into class & clarifies whether the ship is in sea worthy.
Load Lines: It is the set of lines marked on the ships side showing maximum draught to which the
ship can loaded in water & at which the ship is presently sailing.
Free Board: It’s the distance from water line to the upper most continuous deck.
Propeller: It is a solid piece of nickel bronze or capper, cast iron designed so that rotation can
produce a thrust force required for movement of ship.
Bow Thruster: It is a small propeller usually fitted in bow side of the hull of the ship which gives
sideways ship movement during maneuvering.
Propeller Drop: This is because of wear in stern tube & because of this wear, there is drop in
portion of propeller from feedback which is measured using poker gauge.
Rudder: It’s used for deflecting thrust produced by propeller which helps to turn the ship while in
motion.
Poker Gauge: It’s a device used to measure the propeller drop.
Rudder drop: Wear in rudder comes, bearing can have a vertical drop in height when seen from top.
It is usually between 15-16mm.
Rudder Pintles: It is provided at the bottom of the hull. There are fins around which rudder rotates.
They are two types.
1) Heaving pintle
2) Locking pintle
Pintle & Locking Arrangements: It’s located at the bottom of the rudder so, it’s called bottom
pintle. The nut is located by plates.
 ASSIGNMENT NO -50
CENTRIFUGAL PUMP

What is centrifugal pump?

A centrifugal pump is a rotodynamic pump that uses a rotating impeller to increase the pressure of
fluid. The fluid enters the pump impeller along or near to the rotating axis & is accelerated by the
impeller. Flowing radially out wards into a diffuser or volute chamber, from where it exits into the
piping system. Centrifugal pumps are used for large discharge through smaller heads.
Principle: A centrifugal pump works by importing kinetic energy to a fluid through centrifugal
force & then converting it into pressure energy of fluid. The fluid is drawn from the inlet piping
into the impeller eye & is accelerated out wards through impeller vanes to the volute & outlet
piping. As fluid exits the impeller. If the outlet piping is open at a lower level, the fluid will be
released at greater speed.
Centrifugal Pump discharge characteristics:
The theoretical relation of between head (H) & discharge/capacity (Q) is a straight line. The
minimum discharge occurs when the head is maximum. Impeller blade thickness & other materials
considerations cause shock & eddy losses. Friction losses due to fluid contact with pump casing.
The actual HQ relationship shoes that there is drop in heat at the moment valve is opened to release
fluid due to shock. Minimum power is consumed by pump when discharge head is at its height i.e.
discharge valve closed. Maximum pressure with discharge closed is moderately above working
pressure, hence no relief valve is required.
 Discharge characteristics of centrifugal pump

Material specification for parts:

Parts Materials
Impeller Aluminum bronze
Shaft Stainless steel
Wear rings Renewable aluminum bronze
Casing Bronze or cast iron
Shaft bearing Phenolic resin asbestos
Shaft bearing for high static lift Grease lubricated bronze bearing

Material for sea water:

Parts Materials
Casing Gun metal (CI for fresh water)
Impeller Aluminum bronze
Shaft Stainless steel
Ring seals Leaded bronze

What liquids can be handled by centrifugal pump?

Onboard centrifugal pumps are mostly used for handling sea water for ballasting or de-ballasting.
It’s also used to handle the water for the fire main. A centrifugal pump handles water, swage,
petroleum & petrochemical liquids.

What is the function of wear rings?

Centrifugal pump contains rotating impellers with in stationary pump casing. To allow the impeller
to rotate freely, within the pump casing, a small clearance is designed to be maintained between the
impeller & pump casing. To maximize the efficiency of a centrifugal pump. It is necessary to
minimize the amount of liquid leaking through this clearance from the high pressure on the
discharge side of the pump back to the low pressure or suction side,
Some wear or erosion will occur at the point where the impeller & pump casing nearly come in
contact. This wear is due to the erosion caused by liquid leaking through these tight clearances&
they become larger 7 gradually rate of leakage increases. Eventually, the leakage could be
unacceptably large &maintenance would be required on the pump. To minimize the cost of
maintenance, many centrifugal pumps are designed with wear rings, wear rings are replaceable
rings that is/are attached to the impeller or the pump casing to allow small running clearance
between the impeller & pump casing without casing wear of the actual impeller or pump casing
material. These wear rings are designed to be replaced periodically during the life of a pump &
prevent the more costly replacement of the impeller or the casing.

After dismantling, what defects will you leak for in centrifugal pump?
After dismantling the pump, various checks can e carried out
 Impeller, pump shaft & internal volute/ casing can be inspected for erosion, pitting & wear.
 Check wear drive shaft bearings & thrust bearings for wear.
 Checks wear rings clearance using feeler gauges.
 Check impeller/shaft key & keyways for damage & under wear. Check threads of impeller
shaft to be in satisfactory condition.
 Checks the motor drive/coupling for excess axial & longitudinal movement. Checks if there
is excess noise from bearings.
 Megger checks the motor to ensure no dampness is present.

Explain the following:

Impeller: An impeller is rotating element of centrifugal pumps, usually made up of iron, steel,
bronze, aluminium or plastic which transfers energy from the motor that drives the pump to the
fluid being pumped by accelerating the fluid outwards from Centre of rotation.

Wear rings: Wear rings are replicable rings that are attached to the impeller or the pump casing
to allow small running clearance between the impeller & pump casing without causing actual
wear of impeller pump casing material.

Volute casing: The volute of a centrifugal pump is a casing that receives the fluid being
pumped by the impeller slowing down the fluids rate of flow. A volute is a curved funnel that
increase in area as it approaches the discharge part. The volute converts K.E into pressure by
reducing speed helping to balance the hydraulics pressure in the shaft of pump.

Stuffing box: A stuffing box is an assembly which is used to house a gland steal. It is used to
prevent leakage of fluid, such as water or steam or sea water between sliding and turning parts
of machine elements.
Mechanical seal: In some situations packing material is not sufficient for sealing a centrifugal
pump shaft. In this case, a mechanical seal is used. A mechanical seal consists of two basic parts
attached to pump casing. Each of these elements has a highly polished seal surface. The
polished faces of rotating & stationary elements come into contact without other to form a seal
that prevents leakage along with the shaft graphite & ‘o’ rings are used for axial & radial in a
mechanical seal.

Bearings: A bearing is a machine element which transfers the load on the shafts & provide
rotary relative movements & reduces friction between moving parts to only desired motion.
Bearing are usually roller bearing on ball bearing if externally located or else brass/bush/sleeve
if internally located.

Coupling: A coupling is a device used to connect two shafts together at their ends for the
purpose of transmitting power. Couplings do not normally allow disc disconnection of shafts
during operation. However there are torque limit is exceeded. Mostly flange coupling or jaw
type coupling are used. Coupling bolts are fitted with rubber sleeve to provide. Cushioning
effect on the bolts due to high starting loads & high speed if rotation.

Capacity: the amount of liquid a pump will move is determined mainly by width of the
impeller & the shaft speed. It is mainly measured in gallons per minute or cube meter per hour
(m3/hr.). High capacity pumps require wide impeller & that’s why most designs include double
ended type impeller at high capacity.

Head: If you point the discharge of a centrifugal pump straight up into the air, it will pump the
fluid to a certain height or head called the shut off head. This maximum head is mainly
determined by the outside diameter of pumps impeller & the speed of rotating shaft. The head
will change as the capacity of pump is altered. The head is measured in either feet or meters. A
pump will pump all fluids to same height as long as the shaft is running at same rpm. The only
difference is the amount of power required by the pump. The higher the specific gravity of the
fluid, the more the power required.

Priming unit: Pumps may be moved above the level of the liquid to be pumped even through
placed low in the ship. Bilge pumps for this reason, must be self-priming or equipped with a
means of priming unit, to create a vacuum in the suction pipeline. A centrifugal pump placed
above the liquid to be pumped. Is not self-priming as it cannot pump the air contained in the
casing & suction pipe.
Shaft: Marine pumps are usually installed with the shaft vertical & motor above the pump. The
material used for shaft is stainless steel is supported by bush bearings or both sides of pump.

Suction valves: The suction is connected to the eye of the impeller, there is a valve to regulate
suction pressure in the suction line. There is also a foot valve in the suction line being emptied.

Discharge valve: Near the discharge side of the pump, there is a discharge valve. It is used to
regulate the flow of fluid at discharge side. On the discharge side of pump, energy is covered
into pressure rise & fluid velocity. Pressure head produced will get lost in overcoming the
friction of discharge pipe, static head etc.

Centrifugal pump
 ASSIGNMENT NO -51
CENTRIFUGAL PUMPS (MULTISTAGE)

What is a multistage centrifugal pump?

A centrifugal pump with a single impeller that can develop a differential pressure of more than 150
psi between the suction & discharge is difficult & costly to design & construct. A more economical
approach to developing high pressure with a single centrifugal pump is to include multiple impeller
on a common shaft within same pump casing. Internal channels in the pump casing route the
discharge of one impeller to the suction of another impeller. For higher pressure, impellers can be
connected in series for higher flow output impeller can be connected in parallel. A common
application of a multistage centrifugal pump is boiler feed water pump.

What is the difference between a horizontal & vertical pump?

Horizontal pump: A horizontal pump is the one whose shaft is horizontal position. It can be on
overhang or between bearing designs a radially split or horizontal split case design.
Advantages:
 A horizontal pump is one whose shaft is in horizontal position.
 It is easier to install, inspect, maintain & service because its rotor & internals are easily
accessible.
 It can be coupled to a variety of drives directly such as electric motor, engine or turbine.
 It can be supplied in either overhang design for low suction pressure service or in between
design for high suction pressure.
 Its low head room requirement makes it for most indoor installations.
Disadvantages:
 It has low NPSH & on auxiliary booster pump is required
 Maximum allowable operating temperature & working pressure are lower than that of
vertical design.
Vertical pump: A vertical pump is when shaft of pumps is in vertical position. It is always on
overhang or radial split case type design.
Advantages:
 It requires smaller foot print & suitable for installation where the ground surface area is
limited.
 Gives high NPSH since the pump is submerged.
 It’s suitable for high temperature service. It is suitable for high pressure service because of
its simplified bolting and confined gasket design
Disadvantages:
 Most vertical multistage pumps require large headroom for installation, service &
maintenance.
 Usually suitable for driving with electric motor. For other drives it may require a right angle
gear drive or a universal shaft joint & a clutch.
 Being of an overhang design, its axial hydraulics thrust is difficult to balance in high suction
pressure service.
 Its prone to mechanical seal problems when pumping liquids with high dissolved gas which
accumulates at top of stuffing box, where venting can be difficult.
What do you understand by:-
Water head: Pump head is the liner vertical measurement of the maximum height, a specific
pump can be deliver a liquid to the pump outlet. Pumps are able to deliver more volume of
liquid at a lower outlet height or ‘head’. Pump measurements are given in volume flows at
various head heights. The additional work required to push the heavy column of water up with
each cycle pump mechanism requires proportionally more energy to move the same amount of
water to greater heights. Head is the total amount of energy stored or contained per unit weight.
It is measured in meters of water.
Kinetic energy: energy possessed by the liquid by virtue of its motion is called kinetic energy.
The rotating impeller imparts K.E. to the liquid to be pumped. It’s measured in terms of head.
Pressure energy: Energy possessed by liquid as it leaves the volute casing of the centrifugal
pump is pressure energy. The volute casing is used to convert the part of K.E. into pressure
energy. Similarly, diffuser pump also converts large amount of K.E. in to pressure energy.

Multistage centrifugal pump

 ASSIGNMENT NO. 52
SCREW PUMP-USES, PARTS/COMPONENTS

What is a screw pump? Which duties is the screw pump used for?
A screw pump is a positive displacement pump that use one or several screws to move fluids or
solids along the screw axis. A screw pump is often used to pump high pressure viscous fluids. Some
type of screw pumps are suited for a variety of applications such as fuel injection, oil burners,
boosting fuel, lubrication, circulation, federate.
In a screw pump, the pump fluids is moving axially without turbulence which eliminates foaming
that would otherwise occur in viscous fluids. They are also to pump fluids of higher viscosity
without losing flow rate.
How does a screw pump functions?
In a screw pump, the inlet of the fluid is at bottom most part of pump. Then the driven screw rotates
in opposite direction to the driver screw, they tend to build up the suction pressure at the bottom
part. This suction pressure makes the fluid to move upwards. Fluid passes through the small
clearance between these screws & also the centrifugal force is experienced by this fluid. Both of
these factors contribute towards the force which in turns results in the development of pressure in
the fluid.
What defects you normally link for in a screw pump? How will you check the correct
direction of rotation of the pump?
When a pump is overhauled, following needs to be checked:-
 Clearance between the screws which may result in decrease in pressure.
 Wear out of bearings.
 Functioning of relief valves.
 There should not be any leakages from pump shaft seal.
 Temperature of mechanical seal should not be high while working.
 Wear & tear of screw shat must be checked.
What is a mechanical seal? Where it is used in a pump?
A mechanical seal is a device that helps join system or mechanisms together by preventing
leakages, containing pressure or excluding contamination. The effectiveness of seal is dependent on
adhesion in the case of sealant & compression in case of gaskets. It is placed in between screw
pump & coupling for motor to seal the fluid from flowing towards motor.
What are the safety features provided on a screw pump?
For safety on excessive pressure build up, a relief valve is fitted in the pump. It consist of a valve
plate held against the valve sealing with a spring. A relief valve is a mechanical device or mounting
which guarantees that fluid increase then automatic relief valve will direct the excess pressure oil
into the inlet or suction side.
What do you understand by positive displacement/self-priming pump?
Positive displacement pumps are these which provide a fixed displacement per revolution of fluid &
within mechanical limitations, infinite pressure to move fluids from the inlet pressure section of the
pump into discharge zone of pump. They are generally used in hydraulic system at pressure ranging
up to 5000psi. They can be reciprocating, metering & of rotatory types.
How will you check the correct direction of rotation of pump?
To check the correct directi0oon of rotation, give attention to read narrow marking on pump outer
casing as indicates the pump direction of rotation.
 MATERIALS

SCREW IN A CASING FORGED STEELS

SCREW SHAFT HG CARBON STEEL
CASING BRONZE
BEARING ROLLER TYPE
THRUST BUSH WHITE METAL
 ASSIGNMENT NO. 53
FRESH WATER GENERATOR
What is a fresh water generator? Why it is required on a ship?
Fresh water generator is a setup that involves heating & evaporation of sea water vacuum
conditions to prepare fresh water by using the waste heat in the jacket cooling water of the diesel
engine.
Fresh water a need on board ships. It is useful for various purposes such as drinking, for preparing
food, in laundry services & in many other day activities. In the past people used to carry tones &
tones of fresh water in barrels or in special made tanks. This is because there was no other source of
fresh water once the ship was in sea, except rain which is quiet unpredictable. But this activity,
reduce cargo carrying capacity of the ship. In order to overcome this difficulty fresh water generator
were started to being used onboard ships.
How is fresh water generated?
Fresh water generator has two parts:-
 EVAPORATOR
 CONDENSOR
The boiling process is done with heating coil or by using high temperature main engine jacket
water. In some fresh water, heating is done by superheated steam. Generally water boils at 1000c at
atmospheric pressure. Thus eductors are used which reduce pressure to such a point that water starts
boiling at a temperature of 600-700 c. a flow meter is used to regulate the flow of sea water into the
generator. The fresh water generated in condenser is later collected by distillate.
The water vapors passes through demister. The demister is knitted metal wire or polypropylene
collects the water filled solid droplets as they are carried through by air. They coalescence forming
drops large enough to fall back against the vapor flow. The vapor which passes the demister reaches
the condenser. The condenser condenses the vapor to the water which falls in a tray from which
distillate pump takes suction.
What are the major components of fresh water generator?
Following are the major components of fresh water generator:-
1) Centrifugal pump supplying seawater to the
a) Two ejectors, normally brine & air ejector.
b) Heat exchange via feed valve.
2) Fresh water generated has three main division
a) Heat exchanger with ME JCW inlet & outlet, bypass connections.
b) Evaporator with demister screws, vacuum breaker valve.
c) Condenser with cooling sea water inlet & gauge on condensate side.
d) Feed regulating valve for heat exchanger.
 e) Distillate pump with salinometer & associated accessories.
What is a salinometer? Why it is required?
The condensate or products, is delivered to the appropriate tank by using the distillate pump only if
it is of acceptable quality. Water purity in terms of salt content is essential where it is to be used as
boiler feed. The quality is continuously tested by a salinometer both at startup & during operation.
If the device registers excess of salinity it will dump the product & activate the solenoid valve. The
product is recirculated in some installation.
Pure distillated water may be considered as non-conductor of electricity. The addition of impurities
such as salts in solution increase the conductivity of water. The principle is used in salinometer. A
conductivity motor can be used to monitor the salinity of water. The units can be calibrated in units
of conductivity or direct salinity units.
What happens if salinity is high?
If salinity high, the salinometer will dump the product & activate alarm, using its solenoid valve.
The product is recirculated in some FWG.
How the fuel controlled?
Fuel supply rate to the evaporator is fixed to evaporator by orifice plant & sufficient water goes to
the ejector to ensure high vacuum condition in the shell at all times & that the brine is easily dealt
with.
What type of alarms are provided?
If the salinity in the fresh water is high, the salinometer will activate the alarm.
What do you understand by capacity of FWG?
The amount of fresh water generated by a FWG per 24 hours is the capacity of FWG. The capacity
depends on the heating medium & cooling water temperature. Example the aqua series covers a
capacity range from 31 to 61m3/24 hours.
Is it possible to use steam for FWG?
Yes it is possible to use steam for FWG. Instead of JCW, steam can be used as heating medium for
the evaporator side. It is possible by using T-pipe having jacket water connection & steam
connection with valves. By using the valve of jacket water & opening the valves of steam, it is
possible to use steam.
How is vacuum created? Why it is required?
Vacuum is created by the brine or air ejector. It is required to evaporate the liquid at lower
temperature, say 400-600 c. If vacuum isn’t at created, water will vaporize only at 1000c.
What is brine?
The low density, unevaporated water, strongly impregnated with salt which is at the bottom of the
shell is termed as brine.
What is demister? What is its function & where will you find it?
Vapors evolved at a very rapid rate by boiling of sea water fuel, tends to carry small droplets of salt
with it which must be removed to avoid contamination of the product.
The demister is a knitted Monel metal wire which scrubs the vapors of sea water droplets in the
standard internal fitting. It collects the salt filled water droplets as they are carried through the air.
These droplets coalesce forming droplets large enough to fall back against the vapor flow. The
demister is fitted between the evaporator & the condenser section of FWG.
 ASSIGNMENT NO. 54
FRESH WATER GENERATOR FLOW DIAGRAM

What are the faults which can occur that decrease the fresh water generation?
On many vessels sailing today the FWG can produce at least 1m3/24 hr. under normal running
conditions.
Most plants which under pressure are fouled either on the jacket water side of the element or on the
external side of their element & demister. In many cases the ship staff often acid clean the seawater
side & yet still suffer from poor production.
Being part of the main engine system, it could have contamination from hardness, salts, oxides, oils
etc.
Any other case can only be mechanical & plant must be maintained to a high standard.
Scaling of element in the evaporator is the result of elevated temperature in sea water feed. This
causes the precipitation of hardness salts, which is aggregated by the concentration effect in the
feed as the pure vapor is boiled off most plants increase the feed density by 100% resulting in 1 part
of distillate for every 2 part of feed.
The buildup of scale on heating surface is mainly calcium carbonate with a small percentage of
sulphate & silicate. It rapidly reduces heat transfer, decreasing production & inner casing foaming
in the plan. This results in carryover of solids which foul the demister & ultimately causes
contamination of distillate.
How will you rectify the same?
Most modern poly electrolyte based treatment react immediately when introduced to the mineral
salts in sea water. They are designed to modify the crystal structure as the temperature rises &
precipitation is imminent.
The result crystal is simplified in form, non- adherent & will remain in suspension in the brine. This
completely avoids sealing of elements. Proper use of treatment can result in clean element for years
of operation. The unit is for more likely to foul mechanically, before it fails.
What maintenance is required in evaporator, condenser shell?
The tubes of evaporator & condenser should be cleaned periodically.
Test the FWG for leaks by following
1) Close the outlet valve of distillate pump, vacuum breaker valve, bottom blow off valve &
feed water enter valve. Inspect air to evaporator seal.
2) Keep the shell pressure of about 1kg/cm2 gauge.
3) Spray soap solution to packing & joints.
Carry out descaling of GWG evaporator periodically by following methods
1) By continuous chemical inspection (eg. AMEROYAL 30ML/TON)
2) Operate the plant under prescribed capacity
3) To feed the seawater as much as possible, the ejector operates properly.
4) During stopping FWG, continue to feed water until the heat energy of shell temperature
reduces.
5) Avoid running FWG in near coastal areas.
 ASSIGNMENT NO. 55
OILY BILGE SEPARATOR FUNCTION
What is oily water separator? Why it is required on a ship? On what principle does an oil
bilge water separator works?
It is a device which will prevent the discharge of free oil & oil emulsion in the oily water mixture
overboard mainly when pumping out bilges. It will allow the mixture if its oil is 15ppm or below, if
the oil content exceeds 15ppm, it will obstruct the discharge.
The free oil or water emulsion discharge in a waterway can interfere with natural process such as
photosynthesis, which can destroy the life of algae & planktons, which will result in the disturbance
of food chain & food web. The discharge oil in the shore can cause damage to bird’s life & mass
pollution to beaches. The international legislation does not want this to happen & so they are clearly
mentioned in MARPOL ANNEX-I that the oil content in the oil water mixture should not exceed
15ppm.
The main principle for separated of oily bilge water separator is the gravity differential between oil
& water. Generally oil is less dense than water & this is the basis of such drives.
In oily water mixture, oil content exists as a collection of globules of various sizes. The force acting
on such a globule causing it to move in water. When this mixture having different density of liquids
in it is rotated at very high speed, liquid with higher density will have tendency to move a
maximum distance away from the center due to its density & because if centrifugal force acting on
it. The oily bilge separator also uses the same principle for separating bilge & water.
What do you understand by MARPOL?
MARPOL 73/78 is the international convention for prevention of pollution from ship, 1973 ad
modified by the protocol of 1978. MARPOL is a short term for marine pollution.
It was designed to minimize pollution of the seas, including dumping, oil & exhaust pollution. Its
stated object is to preserve the marine environment through the complete elimination of pollution
by oil & other harmful substances & the minimization of accidental discharge of such substances.
LIST OF MARPOL 73/78 ANNEXES
ANNEX-I: - REGULATION FOR PREVENTION OF POLLUTION BY OIL.
ANNEX-II: - REGULATION FOR CONTROL OF POLLUTION BY NOXIOUS LIQUID
SUBSTANCES.
ANNEX-III: - REGULATION FOR PREVENTION OF POLLUTION BY HARMFUL
SUBSTANCES CARRIED IN PACKAGED FORM.

ANNEX-IV: - REGULATION FOR PREVENTION OF POLLUTION BY SEWAGE.

ANNEX-V: - REGULATION FOR PREVENTION OF POLLUTION BY GARBAGE.
ANNEX-VI: - REGULATION FOR PREVENTION OF AIR POLLUTION FROM SHIP.
What is ppm?
It is defined as no. of parts of particulars substances in 1 million parts of water suitable for
overboard discharge must have or contain less than 15 ppm of oil.
What is a test cock?
Test cock is a arrangement to view the level of oil in the oil accumulation spaces ex-coalescence
filters. Usually two test cock or cork are fitted. Where oil reaches lower test cock, the oil is drained
by opening the oil drain valve.
What alarms are fitted on OWS system?
A ppm alarm on OCM (oil content monitor) system is fitted which checks the oil content in the
water flowing out of ows.
If oil content is less than 15 ppm, then it allows the water to be discharged overboard else if it is
>15 ppm, it diverted the flow by opening a valve to sludge tank. The oil discharge monitors may be
any of the following:-
1. Monitor for oily water using direct light.
2. Monitor based on scattered light.
3. Series monitoring system for tanker ballast.
All the monitoring system use one photo diode in simple way or other to monitor the oil content in
the discharge mixture. If oil content in the mixture exceeds 15 ppm, it will rise the alarm. This is
because the light intensity falling on the photo diode is less than the other photo diode. So the
current produce by both of them differs, which will be used to trigger the alarm.
What happens when the oil content in overboard discharge exceeds the limits?
When the oil content in overboard discharge exceeds permissible limits, any one of the following
will happen:
1. The only water system may trip the bilge pump & raise the alarm.
2. It may bypass the oily water mixture to the oily bilge tank. Generally the permissible limit
of oily content in overboard discharge is 15 ppm.
 ASSIGNMENT 56
OILY WATER SEPARATOR INSTALLATION
How is an oily bilge separator operated?
A vertically mounted bilge pump pumps the oily water mixture from the bilge holding tank to inlet
equalization chamber and directed downwards to the conical plates. The rising velocity of globules
carries them upward where they become trapped by the under surface of plates and coalesce until
the enlarged globules having significant rising velocity to travel along the plate surface and break
away at periphery. The oil rises and is caught underneath an annular baffle and then led up through
turbulence inlet area by risers to collect bin the dome separator.
Two test cocks are provided to observe the depth of oil content in separator dome. When oil is seen
in the lower test cock, the oil drain valve must be opened. An electrically operated drain valve must
be opened. This works on electrical signal given by liquid level probes in the separator. Visual &
audible overload indicators may also be fitted to assist separation.
Stem coils or electrical heaters are fitted in the upper unit of the separator. The conical plates are
generally self cleaning. It is important that the OWS is not run at overload.
What is an oil collecting tank?
In OWS, the oil separated from the water will get accumulated in the oil accumulator space. When
this oil is drained off, it will pass into an oil collecting tank which is often called oily bilge tank or
oil collecting tank.
How is automatic oil drain control achieved?
In the upper part of OWS there is a probe which is constant with the conductor water. When oil is
surrounded the probe, the conducting properties discontinuous and the probe get insulated. The
probe transmit this signal to the control of switch which will energize the solenoid coils which
opens the valve to drain the oil in the accumulator space. As soon as the oily water level increases,
the probe get conduct it.
What is the electronic level control? What is the function?
Electronic level control or control electrode which controls the level of the oil collected in the oil
collecting drain domes of plug or two level electrodes to control the level of oil and water. They
comprises of level probes, control system and solenoid valve.
Whenever the level of oil increases the discharge valve increases and vice versa.
Oil in water monitor:-
Current regulation with respect to the discharge of oily water set limits of concentration are between
15-100 ppm provide both oily water limits. In order to measure these values provide with the
continuous records of an alarm when they permits limit exceeds.
The principle used in that of ultra violet fluorescence. This in the emission of light by a molecule
that has absorbed light during the interval between absorption emission energy is lost and light of
larger wavelength is emitted oil flow readily than water this properly provides the means for its
detection.
A sample is drawn off from overboard discharge pass through sample cell. A UV light is directed of
the sample of fluorescence mounted by a photo electric cell. The measured by a photo electric cell.
The measured value is compared with max desired valve in the controller recorded when an
excessive level of contamination is detected on alarm is sounded is diverting valve are operated.
The discharging liquid is then prepared to slop tank.

OILY WATER SEPARATOR

 ASSIGNMENT-57
SWEAGE TREATMENT PLANT
Aeration:-
The process of supplying air oxygen to continuously in order to provide similar climate which
aerobic bacteria live and digest the sewage that converting into sludge.
Settling:-
In the conical shaped tank, the sludge from aeration tank is allowed to settle down and then will
have a clear effluent in the tank.
Air compressor:-
It is a chamber of perforated cylinder consisting of chlorine tablets.
Chlorine contact:-
The clear effluent flowing out of settling tank contains bacteria. To kill the bacteria the effluent is
brought in contact with chlorine.
Discharge pump:-
It discharge the treated, clear effluent from chlorinated tank opening on the level. It is operated by
level switches.
Level control/float switch:-
These determine the level of effluent contain in chlorine contact compartment and control the
discharge.
Soil inlet:-
It is one which untreated sewage running of the air compressor control the control unit.
Control panel:-
It is the passage for untreated sewage to part into aeration chamber.
Aerobic principle:-
Some bacteria called aerobic bacteria that sustain on oxygen and begin biochemical action by
consuming dissolve oxygen into water and breaking down the sewage into simple, clean and
component with release of CO2.
Internal watering of tank:-
Since sewage waste in corrosive, the sewage treatment plant in internally treated with epoxy resins.
Gas vent:-
During biochemical action as on sewage some gases are released which are toxic. These fatal gases
are escaped from treatment plant via gas vent.

SWEAGE TREATMENT PLANT

 ASSIGNMENT-58
TURBOCHARGER FUNCTION PARTS
What is the difference between neutrally aspirated and supercharged engines?
If the charge of air entering the cylinder during the induction stroke is drawn by the piston
environment outlay without being assisted in any way then two engine is said to be naturally
aspirated.
The cylinder can be charged with greater mass of air by supplying it under pressure. The air is
pressurized is a compressor, sometimes termed as blower and fed to the induction manifold of the
engine. In some special cases compressor is driven mechanically. In help of crankshaft.
More usually some of the energy present in the exhaust gas in utilized by passing it through a
turbine which is directly coupled to the centrifugal compressor.
What is exhaust gas turbocharger? Why it is fitted on engine?
An exhaust gas turbocharger consist of a turbine which is directly coupled to the centrifugal
compressor. The exhaust gas in at a pressure and temperature higher than the surrounding
compressor and so it can be made to work by expanding to a lower temperature and pressure. As
the exhaust gas passes through the turbine it makes the turbine rotate by using its energy. As the
turbine creates and include air from the atmosphere and compress centrifugal fully and discharge it.
As the air gets compressed its pressure will be slightly more than the atmosphere air. When the
scavenge ports are opened this air force the exhaust gas out of the engine and accommodates much
larger space than the atmosphere air.
The pressure of air in the inlet scavenge manifold to the cylinder to turbocharged engines is termed
as boost pressure. In engine having a high boost pressure the air leaving the compressor and
intercooler. The quantity of air provided by turbocharger is so great that the amount of fuel that can
be in each cylinder per cycle is not limited by this account but there by the temperature and which
the exhaust valves cylinder and piston can withstand turbocharger improves the power to weight
ratio.
Turbocharger function parts
 ASSIGNMENT-59
TURBOCHARGER – AIRCOOLER BEARING
What is charge air cooler? Why it is fitted? What are the inlet and outlet temperature of air?
Charge air coolers are specific heat exchangers that are used in internal combustion engines with
turbocharger or super chargers. They are fitted/located between the turbocharger and the engine air
inlet manifold. When the air is compressed by turbocharger, it is also heated, which causes its
density to decrease cooling the combustion air by a charge air cooler prior to sending it to the
engine, the density of air increases which permits more air to enter into the engine and increase
power & efficiency of the engine. Besides it also lowers the amount of NOx generated during
combustion.
Charge air coolers are basically heat exchangers facilitating the heat transfer between two fluids of
varying temperatures. The basic function of charge air cooler is to facilitate specified cooling
function. Charge air coolers are basically manufactured in two types “air-air” & “water-air”.
The charge air cooler cools the air at high speed from 200 degree centigrade.
Since the cooler operate under high temperature and with sea water, the construction and materials
used must be selected from high quality materials capable of withstanding the severe conditions. It
should be considered that damaged or a leaking cooler will cause power loss, increase emissions,
fuel consumption and will damage engine by increasing exhaust temperature.
Aluminum, copper and tin plotted copper are commonly used materials for charge air coolers. Most
charge air coolers operate at temperatures range of 45-300 degree centigrade. Since durability drops
a temperature higher than 150 degree centigrade, aluminum is not preferred as a material over this
temperature.
How is the bearing of turbocharger lubricated?
Turbochargers have various types of internal bearings, with either rolling element or journal
bearing being common. They all are subjected to very high load and temperature variations. A
turbocharger can spin at anything up to 100000rpm under some conditions, thus consistent
lubrication is used and is vital. The turbocharger must also be lubricated during the run down period
(i.e. when the engine may be stopped because of some failure), the turbocharger would run for some
time and bearings would need lubrication during the mean time.
 In one type of piston, the main bearings are located in the cold side compressor housing
rather than between the compressor and turbine housing. A cavity is built into the front
portion of compressor housing in which high speed bearing oil residues. This oil is
transferred to the bearings via a pair of wicks through which a mist of oil is drawn. As the
bearings are not flooded with lubricant, temperature is also kept low.
 However in most conventional turbochargers, the bearing are located between the hot and
cold side of turbo and are subjected to much greater heat transfer from exhaust gas. Thus a
 constant flow of oil is needed. This flow lubricates the bearings and contributes to cooling.
The bore of the exit pipe work for lube oil must be far larger than that of inlet to
accommodate any aerated oil.
 On models with plain bearings, where quantity of oil required is large, these are fed from
the main engine lube oil system.
 The VTR series turbocharger have external bearings which are self-lubricating anti fraction
bearings. Sleeve bearings with external lubrication are available as alternative for large
turbochargers.
 The TCA series of MAN B&W has bearings points which are supplied with oil by a ring
channel arranged inside of bearing casing. Oil feeds is given either from the right side or
left side of turbocharger lube oil distribution to all the bearing points and supply from the
emergency lube oil service tank is taken via this ring channel.
How is the air and exhaust gases sealed?
Labyrinth seals are fitted just inboard of the bearings to seal the shaft against the air leakage. To
assist this seal and to help to cool the shaft, particularly at turbine end, labyrinth is supplied with
pressure air bled from the compressor discharge volute.
How is the casing of turbocharger cooled?
The casing of turbocharger area of aluminum alloy light weight and corrosion resistant at air side
and with cast iron at the high temperature and water cooled turbine end. The casing is either water
cooled or oil cooled depending upon the design.
 Ex-uncooled casing: - VTR4 turbocharger, TPL series turbocharger, S-type turbocharger
(MAN B&W), MET turbocharger (Mitsubishi).
 Water cooled turbochargers: - Napier Turbocharger, VTR turbocharger.

What is scavenge pressure?

Scavenge pressure is the pressure required to remove the exhaust gases out from the cylinder and
fill it by fresh air charge. The scavenge air pressure is above atmospheric pressure is about 1.8-2
bar.
How is the thickness of casing determined?
Thickness of the turbocharger casing is determined by either thickness gauge or by ultrasonic test.
What do you understand by cooling water spaces in a turbine casing?
The turbine casing with the gas inlet and outlet passes is provide with jackets for circulation of
cooling water. Rotor spindle is sealed at both ends. The seal of the compressor end consists of
sealing bush and in the turbine end two sets of labyrinth packing and sealing bush.
After how many running hours is the turbocharger to be overhauled?
After 8000 hours and before 1600 working hours, turbocharger is overhauled, during which
turbocharger gas side is cleaned, compressor side is cleaned, filter is cleaned and cooling water
space is cleaned. Ball bearings are renewed depending upon speed and thrust.
 Regular checking of oil level in bearing sump and changing of oil after 500-1000 running
hours.
 Water washing of compressor should be repeated at intervals of 250 working hours.
 Water washing of turbine side must be repeated from 48-150 hours at 5-10 bar.
Explain the following:
Nozzle Ring:
It is a small opening from which the exhaust gas enters the turbocharger and falls on the turbine.
There is a sudden pressure drop across this opening while the nozzles of large turbochargers in 2-
stroke engines are generally pitched, the nozzle with small turbochargers with 4-stroke engines are
narrow. Further narrowing of the nozzles will affect the performance of the engine causing high
back pressure, loss of power, increase in thermal loading, frequent turbocharger surging etc.
Turbine Blades:
On the rotor of turbine, special shaped structure or obstructions are made which are called turbine
blades. It achieves rotation by changing gas momentum. They are subjected to by vibrations which
can’t be eliminated especially in those that are employing pulse system. The flow through the
nozzles and the pulsating flow of exhaust gases admitted partial are regarded as vibration of
blades.
Unbalance of rotor due to depositing and fouling can be the cause of vibration. Unburnt carbon,
sodium, vanadium, sulphur, silicon matters are contained in oil ash which are deposited on the
blade surface in molten state. Fatigue failure may be occur at blade root & on the binding wire.
BEARINGS:
In order to provide smooth operation of turbine & reduce friction during rotation of shaft, bearing
are provided. Bearings may be ball bearings, roller bearings or sliding type. Erosion of the balls or
roller caused by impurities present in the lube oil may reduce their service life.
Heavy momentary loading by vibrating forces, bearing running dry, or contaminated oil,
overheating etc. can also damage bearing. Metal fatigue also causes general deterioration.
 ASSINGNMENT NO. 60

GLOBE VAVLE & GATE VALVE COMPARISION, COMPONENTS

Describe the direction of the fluid flow in globe valve?

The direction of fluid flow in globe valve is from below the valve seat, so that the gland is not
subjected to higher statics pressure when the valve is closed.

What is the valve lift?

When the valve of lobe is fully open then the distance from the top of the valve seat to the
bottom of the valve disc is known as valve lift.

How much is the valve lift minimum requirement for the flow of liquid?

Globe valve can be kept open at any degree from full close very little valve lift is required to
obtain the flow of fluid.

What is the difference between globe and gate valve?

GLOBE VALVE GATE VALVE

 Valve seat is horizontal mounted.  Valve seat is vertically mounted.
 They can be kept open for few  More degree of rotation required
degree of rotation from full open to open from full close position.
to full closed.
 They can control the flow of the  They can’t be used for flow
palling liquid. control.
 Very little valve lift is required for  More valve lift is required for full
full flow. flow.
 Globe valve disturb the flow.  It allows full flow of liquid
without any disturbance.
 ASSIGNMENT NO. 61

PROPELLER AND RUDDER FUNCTION

What is a propeller?

Device used to move the ship in ahead or astern direction. It is fitted in the aft side of the
ship.

How does a ship move in water?

When the propeller rotates, it pushes the ship the pulling water from forward side and
throwing it to the aft side. Thus a propeller producing thrust to move the ship.

What is a rudder?

It is a pad like structure fitted on the aft behind the propeller. It is needed to turn the ship to
the right direction.

How does it affect the steering of the ship?

When the rudder moves to certain angle it act as an obstacle, for the propeller, so the thrust
developed by the propeller with rudder on its way is lesser than the other side and thus the
ship turns due to thrust difference.

What is meant by rudder movement?

It is the normal turning of the rudder on activation by steering gear from port to starboard and
starboard to port.

What is rudder drop?

The rudder carrier bearing angle, vertical drop in height of bearing known as rudder drop.

What is rudder stock?

The stock in which the rudder is connected is known as rudder stock.

What are the rudder pintles?

There are pintles fitted on the ship’s hull around which the rudder is fitted on the rudder
pintles.
 ASSIGNMENT NO. 62

PIPING SYSTEM FUNCTION & MAINTENACE

What are the main functions of the various piping system?

 FRESH WATER SYSTEM: It is used for cooling min engine and auxiliary engine,
liner jacket cooling, cylinder head cooling, exhaust valve cooling, turbocharger
cooling, piston cooling, fresh water generator, evaporator side, used for feeding boiler
valve , domestic purposes.

 LUBRICATING OIL SYSTEM: supply oil to the various machinery such as M/E,
A/E, LO purifier, stern tube lubrication.

 SEA WATER PIPING SYSTEM:

Piston water cooling

Fresh water cooling
Lube oil cooling
General services –generations of F.W. tank ballasting.

 FUEL OIL SYSTEM: Supply fuel o various machinery such ass M/E, A/E,
Incinerator, boiler. Carrying fuel oil from double bottom to the injector through
heater, purifier and full pump.

BILGE WATER SYSTEM: To transfer bilge water from bilges to oil water separator.

BALLAST WATER SYSTEM: Ballasting and de-ballasting dedicated tanks for stability
reason.

FIRE AND GENERAL SERVICE SYSTEM:

1. For fire fighting

2. For general purpose like cleaning decks.

COMPRESSED AIR SYSTEM: Delivering compressed air from air compressor to bottle
supplying compressed air from air bottle to:

1. Master air starting valve

2. Distributor
3. Incinerator
4. Local tubes for cleaning purposes
 5. Air starting valves
6. Pilot air starting valve
7. Control air from pneumatic system
8. Hydrophore tank

MAIN ENGINE AND AUXILIARY ENGINE EXHAUST:

Takes the exhaust gas from M/E to,

1. Turbocharger – turbine side

2. Exhaust gas boiler and out through funnel

STEAM SYSTEM: taking steam from the boiler for heating coils

1. Fuel oil
2. FWG evaporator side as a substitute for JCW
3. Domestic water

Q. Note down the colour schedule for the above piping system

PIPING SYSTEM COLOUR CODE

1.Bildge Black/ brown
2.lube oil Yellow
3.fire line, co2 Red
4.freshwater Blue
5.diesel oil brown
6.ballast water Green/black
7. sea water & general service Green

Q. Write the types of valve and filters on the system?

1 Globe valve

2 Gate valve

3 Butterfly valve

4 Pressure relief valve

5 Swing check valve

6 Safety valve

7 Quick closing valve

8 Pressure reducing valve

9 Flow regulating valve

10 Needle valve

11 Angle stop valve

12 Hose valve

What kind of different joining and packing material are used in above system and
reasons?

1. Steam line: lead coated compressor orbit of graphite coated.

2. Exhaust line: copper laminated in between compressed orbit.
3. Oil line: oil restricting orbit

What kind of defects are noticed in piping system?

1. Rust formation in pipes

2. Damaged valves
3. Cracks in pipe lines
4. Chocking of filters
5. Leaking ‘o’ rings
6. Chocked pipe lines

What is the PCD of the flange?

PCD stands for pitch circle diameter, a circle drawn from the centre of the flange in which
holes are drilled equidistantly to carry the bolts.

Which is blank flange?

It has a nominal flange and a flange as one part. Thus when registered either normal or blank
flange.
 EXPERIMENT NO. 63

DECK MACHINERY AND ANCHOR

What do you understand by deck machinery?

The machinery which are in the deck operated and controlled in the deck is called deck
machinery. It includes windlass, capstan, warping cargo winches, automatic constant tension
mooring winch, cargo winch there equipment are used to handle cargo, dropping and lifting
anchor.

WINDLASS: A ship windlass is designed primarily for handling the anchor, but it is
frequently used for handling lines and wraps as well. It may powered byy steam engine,,
hydraulic motor, or electric motor.

MOORING WINCH: Mooring winch is a mechanical device used for securing a ship to the
berth, an equipment with various barrels used for pulling ropes or cables, mooring winches
plays important role in berthing the ship ashore.

CARGO WINCHES: The simple rigging system has the capability of performing their basic
function to handle the cargo.

1. One function is the ability to raise the boom to that

2. Second function is the ability to raise the boom to as to control the transverse location
of the boom head
3. The last one is their ability to hoist and lower the load.

DECK CRANES: They are used to discharge or shift cargo provision baggage supplies from
inside of the vessel to the shore or to load the cargo provision by lifting from shore to ship. It
is also used to shift the cargo inside hatches.

What is an anchor?

A ship is helpless when she comes to the concept of breaking even though ship has all the
controls and automation she has no brakes and an anchor is used to hold her from drifting.

Why it is required on ship?

It is used to hold the ship from drifting astern, when it is stationary and where the moving
winches cannot used.
What is an anchor cable?

A chain which is connected to the anchor and to the ship hull and made of shackle is an
anchorage.

What is a chain locker?

It is compartment at the aft of fare peak used to stone the anchor chain. The chain locker has
performed plate at the bottom through which all need and sea water can be drained which is
pumped overboard.

What is a D-shackle?

The D shackle is used to connect the anchor cable to the anchor end to fasten the cable at the
filler end of the cable.

How is the length of cable measured?

The length of the cable is measured in term of shackle.

1 shackle=15 Fathom

1shackle=27.5m

1shackle=6 feet

How many anchors are provided on ship?

A minimum of two anchors are provided on every ship one on port side and other on
starboard side of the ship’s forward.
 ASSIGNMENT NO. 64

DECK MACHINERY WINDLASS

Write down the various compartments of the windlass?

1. Hydraulic motor
2. Dog clutch
3. Gear
4. Locking pin for cable
5. Brake assembly
6. Wrap drum
7. Rope drum

What do you understand by hand operated clutch, brake and spur reduction gear?

CLUTCH: it is used in the windlass to engage and discharge rope drum shaft from motor
shaft. It is known as dog clutch. They are hand operated by the mean of hand lever clutch and
is provided between motor and gear box in order to avoid inertia of dwelling.

BRAKE: a manually operated hand brakes is used to control the speed of the running cable
and used when having anchor. The brake is positioned in such a way that windlass operator
cam see the anchor for having purpose.

SPUR REDUCTION GEAR: While having anchor fly gypsy wheel rotate at vey low speed
rotation of 2 rpm but hydraulic motor or electric motor at high speed in order to achieve the
slow speed rotation of the gypsy level, high gear reduction is required.

What do you understand by heavy anchors?

It means to lift the anchor the power is applied in hosting direction. When anchor is
approaching house pipe, within about 6 feet the windlass is slow down to creeping speed.

Note down various speed of the windlass?

The speed varies to 9m/min to 15m/min for mooring lines varies between 0.7/1 m/min
creeping speed of the windlass 7.5m/min.

Full load varies between 6-9 times the weight at one anchor and speed at full load varies 0.12
to 0.2m/s.
 ASSIGNMENT NO. 65

DECK MACHINERY MOORING WINCHES

How is mooring winch driven?

Mooring winch is drives electrically, hydraulically or sometimes may be steam driven. Most
modern especially tankers are hydraulic driven or electric driven involves risk of life.
Hydraulic drives are more reliable efficient.

How variable speed is obtained?

Variable speed are obtained by using variable delivery pump are fixed delivery pump with
control lever.

The pump are driven at constant speed by an Ac indication motor. The rate of the oil from the
power unit controls the speed of hydraulic motor driven which in deck machinery axial
position are used to obtain and maintain constant pressure.

What is gear case? How is the lubrication of gear obtained?

The caring in which reduction gear train is located between driving motor and the winch unit
is known as gear case. Lubrication of gear case is carried out from lube oil sump located at
the bottom of the gear case by splash lubrication on a shaft driven gear pump.

What is a barrel and a wrap end?

The drum around which ropes is called barrel and rope and fixed on drum is known as warp
end.

What kind of bearings are provided?

Ship are provided between drive motor and gearing to avoid transmission of inertia the event
of shocks loading of ropes winds it consist of no of frictional collars which are mounted
alternatively in series with a shaft and pressed by springs.
What kind of maintenance is required on mooring winch?

1. Lubrication of gear case at periodic intervals per instruction manual.

2. Check lube oil level in sumps and leaks
3. Inspect the brakes lining by applying the brakes and checking for lightness
4. Wear down of heating checked and gear tooth are checked
5. Any rusting is scrapped off and reported with point having weather proof quali
 ASSIGNMENT NO. 66

DECK MACHINERY CARGO WINCHES/DECK CRANES

What is the difference between cargo winches and deck cranes?

Cargo winches are used only to lift on lower by means of a fixed rope and a barrel, for
moving the load around the winches is used in the conjunction. This arrangement requires
more time setting up before working of cargo.

Deck cranes are required for the convention cargo handling and grabbing this requires less
time to prepare working cargo than derricks.

Deck cranes are required to burst, half and separate electric and hydraulic motors are
required for each motion cables is only required to lift the tip not the load.

Some cranes are mounted in pair on a common platform which can be rotated through 360
degree. The cranes can be operated as a twin crane or a double capacity.
 ASSIGNMENT NO: 67
INCINERATOR
What is incinerator? Why it is fitted on board ship?
Incinerator is the equipment which is capable of burning waste oil water mixture (upto 25%)
galley waste sludge etc. expect plastic and sewage.
IMO rules stated in MARPOL Annex v (ph level from the garbage and other garbage, oil waste
mixture solid waste and other to the stage of discharged. But waste storage need a lot of space.
Thus it is essential to have such device a board which helps in burning oil residue and other
waste parts of ship
WRITE SHORT NOTES ON THE FOLLOWING INCINERATOR
 COMBUSTION CHAMBER :
It is a chamber which has been design to short out the oil to be burnt is injected and all other
waste are kept for burning as oil is injected ,the material start burning after introduction of
spark with aid of electrodes. The combustion chamber is lined with refractory material to
product against the high temperature and also cooled by air circulated within the jacket
 FROCED DRAFT FAN:
It is the motor driven fan which supply the adequate air from the surrounding atmosphere to
the incinerator for combustion to take place in the furnace and also used to surge out the
system
 auxiliary burner :
It is the burner used for burning the oil during the starting and stopping of incinerator. It
may also used in assist mode in case sludge oil is unable to burn on it own due to
conditioning. It has a spark ignited attached and also furnace failure system.
 SLUDGE BURNER :l
It is a burner used for burning the sludge. It is a rotary cap type or simple tube type, capable
burning of sludge delivered to. Sludge heat in sludge tank before bring to sludge burner.
 LOADIG DOOR:
It is used for loading waste into incinerator. The door is pneumatically locked and cannot
open till the furnace temperature fall below limit of 100°C.
 SLUDGE TANK:
It is the tank where sludge is collect and transmitted to incinerator for required
7) ROTARY ARM:
It the provision providing for mixing of waste oil in the combustion
 FLUE GAS EXTRACTYION FAN:
The belt driven fan is located on the incinerator uptake and clears all out the vaccum in the
combustion space.
8) ELLECTRICAL CONTROL:
The electrical panel control the combustion chamber and the oil supply and alarm and trip
panel part are also used in this control panel to safe guard the incinerator
 ASSIGNMENT NO: 68

REFRIGERATION- PROVISION REFRIGERATION PLANT

Where and at what temperature are the food product stored?

A] Refrigeration prevent or checks the spoilage of refrigeration cargo. The important causes
which are :
 Excessive growth of micro- organisms ,bacteria and fungus
 Changes due to oxidation, giving off bad odors
 Drying out
 Enzymatic or fermented process during rancidity
 The metabolism of bacteria products e.g. fruits &vegetables
 The cargo refrigeration plant should be able to handle cargo in following condition:
 Precooled
 Hot
 Frozen

Meat , fish, butter, cheese etc. area usually carries in frozen and a my be regarded as dead
cargoes .Fruits and vegetables are lives, absorbing O2 and CO2 and thus procedure heat
.Each commodity has its own specific storage condition for the test results of capable .the
following are ranges of temperature for various commodities:

Apples (1-2)C Fish -10C Bacon-used (1-5)C

Plumps <0 C Lamps -29C unused (9)C
Grapes (0-1)C Pork (-12—13)C Eggs-frozen (9-20)C
Bananas (11-14)C Pears (7-10)C chilled (0-1)C

The following functions of the cargo refrigeration are:

 Control of temperature
 Control of humidity
 Control of air distribution
What are the equipment and machinery for them?
1. Compressor
2. Condenser
3. Expansion valve
4. Evaporator
5. Refrigeration fluid
What is meant by defrosting? What are the reason and result of defrosting?
Defrosting is a method of removal of frost buildup evaporator coils. Defrosting should be
done before the thickness of ¼”.
 Reason for defrosting:-
 Frosting affect heat transfer properties
 It affects the air flow circulation
 Liquid back to compressor
 Types of defrosting:-
 Water wash defrosting
 Hot gas defrosting
 Electric defrosting
 Manual shutdown defrosting
 Warm brine defrosting
 Various methods of defrost brine system:-
1. Hot brine throwing:-
Best and powerful method of using full brine heater with separator throwing
system. Water tight plates under the trays to collect the dripping water.
2. Hot air at from atmosphere:-
It is the important that isolating doors into trunks are perfectly that so as to
prevent hot air going into the cargo spaces.
3. By shutting off brine:-
Allows the snow to melted by the heat of air circulation very slow operation and
tends to throw back great deal of moisture into cargo spaces.
 How leak of refrigerator is tested?
A Leaks in the cargo refrigeration system, ship store and air conditioning system
Are down constantly. They are charging in magnitudinally to temperature, pressure, vibrations,
and leaks detections is different manual leak detection provides only a shop view of situation.
The presence of leak detection is permanently fixed onboard ship. Sample air from collection
point in the refrigeration system is taken in the present interval of time of CFC, HFC, HCFC is
recorded.
A significant advantages of the system is that the traces the development of leak and preventing
the loss of refrigerant and the breakdown of plant.
The system comprises the series of samples which run from refrigerant plant back to detector
is independent powered by so to 264V 40/60Hz.
The refrigeration detector have been designed to regain CFC, HFC, HCFC and down to
concentration of 50PPm.
Brief notes:-
 Compressor :
Refrigeration compressor are usually either reciprocating of rotary screw
displacement type centrifugal vane compressor have also been used.
 Condenser :
They are generally water cooled close shell type .The shell type is welded of mild
steel with vapor inlet purge drain and liquid outlet connection of the main body.
 Evaporator :
The most simple of the refrigerating air type form of bank tubes with extended
surface of fins.in these the refrigerator is expanded in the tubes while the air is
passed over the fins by the circulating fans. This type of until to be found in the
domestic cold store and coil unit and larger tension the removed.
 Expansion valve:
The expansion valve is the regulating through which refrigeration passes from the
high pressure side of the system to the low pressure side. The pressure drop
causes developing the temperature of refrigeration to fall below that evaporator.
 Solenoid valve:
For the regulating refrigerating flow a solenoid valve used as control valve in
liquid line prior to expansion valve thermostat in the spaces to the cooled.
 Thermostat :
The most common regulates in the thermostatic expansion valve .The meaning of
the “thermostat” being designed to maintain constant amount of heat temperature
at the evaporator outlet.
 Oil seal:
Where the motor and compressor are separated, a mechanical seal is fitted around
the crankshaft at the drive end of the crankcase .It consist of the closed vessel
fitted with the series of baffles or a knitted wire mesh through which oil vapour is
passes out.
 Oil separator :
Oil separator is the important type of that may be fitted in the hot gas discharge
line from the compressor. The oil is then drain by de4nsity gravity to the bottom
of vessel when the float6 valve controls the compressor crankcase.
 Refrigerator used in plant :-
Generally refrigerator are subdivided into primary and secondary refrigerator.
 Primary refrigerant plant :-
Essential properties are:
 CO2 – used for many years in ship.
 Methyl chloride –CO2 and the present refrigerator, methyl chloride and NH3 is
sued.
 Ammonia – This is still in use4 of but requires special ventilation toxic nature
leak.
 Freon - Modern refrigeration are hydrocarbon compounds of various formula
with the exception of SO2which is Oxo tropic of refrigeration 22 and 115.
Common refrigerant configuration:
 R11-CCL3F-trichloro mono fluoro methane –CFC
 R12-CCL2F2-dichloro di-flouro methane-CFC
 R22-CHCl2F2-monochloro diflouro methane –HCFC
RSo2- azeotropic mixture of 48.8% R22& R115 51.2%.
 ASSIGNMENT NO: 69
AUXILIARY BOILER & MOUNTINGS

Why auxiliary boiler is required onboard ship? What do you understand by boiler
mountings? Name all mountings.
A boiler is one of the form of another will be found on every type of ship. Where the
main machinery is steam powered by the large amount of water machinery of maintained at a
high temperature and pressure, on a diesel engine vessel, a smaller boiler will be fitted to provide
steam for the various ship service .A boiler is used to head feed water to order to produce steam.
 Boiler mountings:-
Certain fitting are necessary on a boiler to ensure its safe operation. They are usually
referred to a boiler mountings .The mountings usually found on a boiler are;
 safety valves:-
These are mounted in the pair to protect the boiler against one pressure. Once the valve
lifted up is set in the pressure in the presence of a set pressure .It is the locked and cannot
be changed .The valve is arranged to open automatically, at a pressure to be blown out.
 Main steam valve :-
This valve is fitted in the main steam supply line and it is usually of the non –return
type.
 Auxiliary steam stop valve:-
This is a smaller valve fitted in the auxillary steam supply line and in usually of non-
return type.
 Feed check(or)Control valve:-
A pair of valve is fitted on the main valve of the other in the auxiallry .They are non –
return valve and must give an indication of other open and closed position.
 Pressure gauge connection:-
Where necessary in the boiler drum, super heater etc., pressure gauge are fitted to
provide pressure reading.

 Air release cock:-

There are fitted in the heads boiler drum etc., to reduce air, when filling the boiler (or)
initially raising steam.
 Blow down valve:-
This valve enable water to be blow down (or) emitted the boiler, It may be used when
partially (or) completely emptying the boiler.
 Scum valve :-
A shallow dish permitted at the normal water level is connected to the scum valve
.This enable the blowing (or) removal of scum and impurity from the water surface.
 Test pressure:-
 It is the pressure (man) up to which the boiler is tested after manufacturing, normally
test pressure will be higher than the working pressure.
TEST PRESSURE =1.5*WORKING PRSSURE
 Burner type :-
It is the burner used to inject the fuel in the form of droplets. Burner can be divide into
following types:-
 Pressure test type oil burner.
 Rotating lap type oil burner.
 Steam blast test type oil burner.
 Furnace lining:-
This is refractory material mounted on the wall of combustion chamber where the fuel
is burnt to produce heat energy.
 Water tubes:-
The fuel will be burn around the tube which carry the water in the furnace.
 Smoke tube :-
The hot gases are for the combustion chamber passes through the smoke tube surround
by water.
 Man hole doors :-
It is the arrangement made on the circumference to enter into the boiler for cleaning of
the boiler.
 Super heater:-
Super heater is used in boiler to the steam at high temperature.
 Air Heater:
It is mainly used to pre-heat the air for in increasing the efficiency of combustion.
 Forced Draught Fan:
It is used to remove the combusted fuel gas from combustion chamber for cleaning
 Condenser:
It is used to condense the steam by the bowler sea water circulating in the condenser.
 Auxiliary Boiler BLOWING Door:
It is the process of removing accumulation of suspended particles may be from the boiler
water
 Boiler WATER Treatment:
Raw water is in sufficient pure for use in boiler plant water treatment is used to procedure
desired water condition.
 Objective Of Boiler Water Treatment:
Precaution of corrosion deposit within boiler itself
Precaution of damage of machinery DUE TO IMPROVE STEAM BEING GENERATE
Precaution of corrosion of the fuel condensate system
 Feed Pump:
Feed pump supplier the feed from storage tank to a boiler.
 ASSIGNMENT NO. 71

STEERING GEAR FUNCTION

What is a steering gear? Why is it required on the ship?

A: In the steering Gear system, steering gear provides the movement of rudder in response to a
signal form the bridge.

The steering gear is used to direct the ship in the required direction by alternating the
propeller thrust.

what are the types of steering Gear?

A: Electro- Hydraulic Ram Type

Electro – Hydraulic vane Type

Electrical – Ward Leonard Type

What is a telemotor & the function of same? Where it is located?

A: Telemotor comprises of a transmitter on the bridge & receiver connected to a variable

displacement pump through the hunting gear liquid displaced in the transmitter causes
corresponding displacement on the receiver end of pump control. The receiver is the steering
gear & has two fixed rams with moving opposed cylinders.

The telemotor transmitter is situated on the bridge & receiver is at the steering flat.
Mechanical movement is transmitted hydraulically are electrically. The telemotor is connected to
the hunting gear through control spindle. By switching the changeover pin the control spindle
can be operated form emergency steering gear platform.

How is the Movement of rudder obtained through the steering gear?

A: The bridge steering wheel is moved to starboard or part. The rotating pinion causes
corresponding ram to move down, pushing oil out to the receiver unit along the corresponding
pipe. The other ram moves up, allowing oil to come from receiver unit .The depressed ram in
telemotor transmitter pressure the corresponding side of the system. The pressure force acts on
the control web of the moving cylinder until the movement caused corresponds to the movement
of ram in the steering telemotor, oil is pushed back on the other side of the moving cylinder to
the steering unit. The moving cylinder is connected by a linkage to the central unit of steering
engine. The any movement of bridge telemotor unit by wheel rotation is almost directly
operating the control device which causes the rotation of the steering gear & hence rudder
movement.

Rudder Actuators:-

The different means by when hydraulic power can be converted into torque at rudder stock
can be summarized as:-

 Two or four ram gear incorporating raphosm slide acting on:-

Round arm tiller or fork tiller.
 One, tow or four oscillating cylinders with singled doubled acting piston driving crosshead
or tiller.
 Two or four ram gears connected to crosshead by links.
 Single or duplicated rotary van gears.
 Rotary Piston operating direct onto the tiller.

What is heard part & Hard Starboard?

A: The maximum displacement of rudder form center line to the port side is called hard board.

The maximum displacement of rudder from center line to the starboard side usually is called
Hard starboard.

What is maximum movement of rudder permitted & how much time it takes form hard
port & hard starboard?

A: The main steering gear with the ship at her deepest sea going drought must be capable of
putting the rudder form an angle of 35deg on one side to 35 deg on the other side with the ship
running ahead at maximum service speed.

It must be capable of putting the rudder over form 3g deg on either side to 30 deg on the
other side in not more than 28 sec under some conditions.

What kind of oil is used in Electro Hydraulic Steering Gears?

A: The oil should have the following properties:-

 Low power point

 Corrosion protection for surfaces of metal
 Preservation qualities for leather cup packages
 Should have no deposits in piping
 Non- Freezing
 Non- Sludge Forming
 Low Viscosity & high Flash point
In case of steering gear failure, what means are provided to steer the ship?

A: In the event of failure of telemotor system, it is requirement that the ship can be streed
directly form aft.

 This is actually carried out by a direct gear form the aft steering system station to the power
unit control both the receiver unit & the hand gear unit can each operate the pump control
rod through a rod.
 When the telemotor pin is fitted to receiver cylinder yoke hale receiver motion is given to
the pump control rod screwed tube, merely allowing sliding rod to move freely through it.
 In the event of failure of power unit, the emergency steering system may be affected in
following manner.
 For plunger type telemotor transmitter by running wire rope from tiller to aft mooring
witches, once cylinder by pass valves steering operating mooring winches.
 For pump type transmitter. By running wire rope on ram cylinder from type pump & open
these to telemotor oil pressure rotor steering wheel for many turns until desired angle is
reached.

Write down functions of following:-

A: * Hydraulic Ram:-

The function of Hydraulic ram is to push on the ram crossed for moving the tiller arm, the
arm sliding through swivel bearing. The rams are machined & Ground to slide in the gunmetal
neck bushes & Chevron type seals of cylinder.

# Swivel Block:-

In case of forked tiller arm, the thrust from arm is transmitted to the tiller through swivel blocks
.one advantage of the arrangement is that over all length of pairs of rams is reduced compared to
the round arm tiller designed & this can be important considered in same cases. A disadvantage
is that where there is any miss-alignment case of rounded tiller arm is not vital. it could lead to
unveiling that the line of rams be exactly at right angles to the rudder stock center line if this is
to be avoided.

 Rudder Tiller:-
This is a design in which rudder acts upon a piece which sliders in slots which are machined
into upper end & lower jaw pieces of tiller.
The tiller is keyed to the rudder stock & is of forged are cast steel with one or two arms,
machined smooth to slide in a swivel block arrangement to convert linear movement of the
rams to the rotary movement of tiller arm & rudder stock .
 Floating Lever :-
The function of floating lever is control the discharge of variable delivery pump according
to the movement of telemotor receiver. It adjusts the eccentricity of swash plate & thus
controls discharge of pump.
 ASSIGNMENT NO: 72
HEAT EXCHANGER FUNCTION AND TYPES

What is a heat exchanger? Why is it required?

Heat exchanger is an equipment in which two fluids that are separately circulated in
separate adjacent spaces, so that some of the heat in the fluid at higher temperature is
transferred to the low temperature fluid and therefore cooled and fluid having lower
temperature is heated. They are used in
 JCW system
 Piston cooling water system
 Scavenge air system
 Reduction gear oil cooler
 Steam and feed water system
How many types of heat exchangers are there?

They are either multi tubular type or plate type. There are various types of multi tubular heat
exchangers classified by flow arrangements and tube arrangements .By arranging headers, the
flow of liquid is such that the liquid to be cooled is passed between one pairs of the sheet and
coolant between the adjacent pairs of plates.

What is plate type heat exchangers? On which system, it’s tilted?

It consists of thin rectangular metal sheets in which a corrugated plate has been found by
precision pressing. One side of side of each plate has a peripheral gasket. The complete unit
comprises of a number of plates mounted on a space between adjacent plates from a flow
channel and system is arranged that the hot and cold fluid pass through alternate channel.
What is the difference between tube type and plate type exchangers?
In plate type, high heat transfer coefficient of both fluids are achieved. The heat transfer
coefficient achieved is three times higher than that of shell and tube type. Plate type has low
fowling characteristics than the shell and tube type.
 Compact in volume, weight and liquid holdup are the advantages of plate type heat
exchangers
 They are costly because the plates are expensive
How are the leaky tubes detected?
Small leaks are extremely difficult to find particularly if time does not allow for proper drying of
sea water cooling space. The damp tube plates unfortunately make only small amount of
leakages. In such cases a small amount of fluorescent sodium crystals can be dissolved in water
within the space surrounding the tubes. The plates then viewed under a source of UV light where
leakage is present and its sharply delivered on a fluorescent area at the point of leakage.
Ultrasonic testing equipment can also be used to detect the location of leakage. This equipment
consists of a detector or ultrasonic microphone or a sound concentration.
How are leakage tubes plugged?
Plugs used as a temporary measure may be made of soft wood or hard wood often in the handle
turned down in the ships lathe to the required size. The material used to manufacture the plug is
nonferrous metal as alloy, the same as tube materials. It’s a common practice for manufacturer of
heat exchangers to supply some plugs for this purpose.
What is Fowling factor?
When the capacity of heat exchangers are calculated, the calculations are based on various
conditions applicable when it becomes fouled or dirty. This capacity becomes reduced and in
such condition it would be necessary to reduce power of the engine to suit the capacity of heat
exchanger
What is the purpose of zinc blocks? Where are they fitted?
Cathodic protection system using sacrificial anodes are used in sea water spaces of heat
exchangers. The material used are such that they are higher in the electromotive series of metal
that which they have to protect. Zinc blocks are used for this purpose as the sacrificial anode.
Materials Used
Shell: Generally cast iron
Tubes: Aluminum brass or copper nickel
Tube plates: Naval-brass tube plates are used with aluminum-brass tubes
Water boxes: Cast iron or fabricated steel
 ASSIGNMENT NO. 73
POWER GENERATION AND DISTRIBUTION
How is the electrical power generated on board the ship?
Power is generated with the help of generator. The generation can be driven by
prime mover like diesel engines, turbine etc., The generator consists of two windings namely
armature winding and field winding.
The field winding is excited by a DC sources to procedure alternate north or south
poles by the principle of electro-magnetic induction. When a conductor moves in a magnetic
field, an EMF is induced in the conductor.
 ASSIGNMENT NO. 74
GENERATOR
How is electrical power distributed onboard the ship?
A distribution system, means by which electrical energy is produced by the
generator is distributed to the ships electrical load. This is routed through modules such as MCB,
modules, switch gear, power and lightning distribution system, test panels and shore connection
boxes.
The switch board receives power directly from the generation. In general, feeders
extend from switch board circuit breakers to power distribution panel, lightning distribution
panels, or large motion circuit. Branch circuit breakers and provide power to individual loads.
Power distribution systems are:
Radial Distribution:
In this system, a no. of independent feeders branch out radially from a common
source of supply (i.e., a substation or generating station).
One of the main disadvantage is that, the consumer has to depend on the feeder
Only, so if a fault occurs in the feeder, this power supply is cut off till fault is rectified. Hence
there is no absolute guarantee of continuous power supply.
Bus Bar Distribution:
It has bus bars running along length of ship. From this bus bars, the individual
consumers take their power.

Cross-Linked Distribution:
In this type, individual consumers are connected to two or more independent
power supplies, so it has got less chance.
The circuit breakers and switches are the means of controlling flow of electric
current. Fuses and relays protect the distribution system from the damaging effect of large fault
currents. The electrical load is divided into essential and non-essential services. Essential
services are those required for the supply of personal, safe navigation and propulsion of ship.
They include certain supplies to acids machinery spaces, control stations and steering gear.
Parallel operation on generator:
Main generator units have to be run in parallel to shore a load in total that exceeds
the capacity of a single machine especially when discharging cargo, loading cargo, tank cleaning
and maneuvering.
 Changeover of main and stand by generator units require brief parallel running
period to achieve smooth transition without a block out situation. Parallel running is achieved by,
 Synchronizing
 Load sharing
Methods available on main switch for parallel operation.
 Manual synchronizing
 Auto synchronizing
V1 – Incoming voltmeter
F1 – Incoming frequency meter
Vs – System voltmeter
Ms – MSB source lamp
Fs – System voltmeter
Es – ESB source lamp
LVS – Low voltage (24V) source lamp
KW – Kilowatt meter
GSP – Generator status panel
PF2 – Peripheral trip stage 2 lamp
EGS – Emergency generator running pump
LT – Lamp test switch
AR – Alarm reset switch
GCM – Generator alarm control mode switch
AC – ACB close switch
SY – Synchronoscape
AO – ACB open switch
SYL – Synchronizing camp
Conditions to be satisfied before putting the incoming generator for parallel operation?
 Voltage
 Frequency
 Load
 Phase

Safety devices on MSB for generations:
 Preferential trips to protect the general from overload.
 Over current relay
 Under voltage relay
 Over speed relay
 Reverse relay
 Thermal relay
 Interlock b/w main generator and shore supply
ESSENTIAL SUPPLY:
Users, which needs to be in continuous operation, are duplicated. These users
have separate supplied from the main switch board. Consequently, a main system black out will
interrupt the operation of a main system black out will interrupt the operation of these users.
Such failures are very relay and if they do occur they are not considered likely to have major
damage in most installation.
IMPORTANT FOR NON-ESSENTIAL SUPPLY:
Users, which are essential to maintain the main functions of installation, are very
often duplicated or partly duplicated. They are normally supplied directly from the MSB or from
dedicated distribution switch boards.
PREFERENTIAL TRIPS:
It is essential to prevent interruption of services necessary to maintain propulsion
and navigation. There must be safeguarded even as other services such as domestic supplied are
temporarily sacrificed.
If the current on the running generator exceeds 120 % of rated current for a period
of 10s, the PMS will initiate the release of preferential trips, thereby providing protection against
over current which would otherwise trip the ACB. Preferential trips are released in two stages
separated by a time of 5 sec. If the overload condition is removed after the release of the first
stage, the second stage is cancelled.
ALARM PANEL:
In ships, there is a dedicated panel for the alarm system. It indicates the various
alarms in different location. It is easier for the alarm which is very important in UMS ships to
have an alarm panel, which has all alarm that has been maintained carefully.
In case of main generator failure, how is the emergency generator started up and
load taken by the same?
Many vessels regain their control of their electrical system through the use of
emergency switchboard. The emergency source of electrical power may be accumulator battery.
The emergency source of electrical power will be capable of supplying all these devices that are
essential for safety in emergency with due regard being paid to services that may have to be
operated simultaneously. When the emergency source of electrical power is a generator, it must
be.
 Driven by prime mover with independent supply of fuel having a flash point of
not less than 43°c.
Started automatically upon the failure of main supply.
Started automatically, connection to ESB is not more than 45 sec.
The air circuit breaker of EG is interlocked with the bus bar couples from MSB.
Normally the ships service generator supply power to the ESB through MSB utilizing a ACB and
ABT switch that is protected against overload and switch circuits.
When power from MSB is soft, the ABT switch automatically connects the EG to
the dedicated ESB. This special condition breaker would i.e., all distribution breakers are open .
the ABT simultaneous by disconnecting the MSB from ESB. THIS allows the emergency power
to be supplied to all essential services connected to the ESB.
Which machinery and services are connected to both mains and emergency switch
board and why?
Service which needs to be continuous operation for maintaining propulsion and
steering are connected as primary essential services. These services are connected to both MSb
and ESB. Some of them are ..
 Emergency steering gear
 Pumps for CPP
 Scavenge air flowers, F/O supply pump, L/O pumps, cooling water pump
for M/E and A/E and turbines necessary for propulsion.
 Fire detection and alarm system
 Navigational lights etc.,
TRANSFORMER:
A transformer is a device that transfer electrical energy from one circuit to
another by electromagnetic induction. It is most often used to step up or step down voltage. It
occasionally, is used as isolating device to eliminate a direct connection between the power
source and loads. The electrical energy us always transformed with the change in frequency but
may involve in the effective valve of voltage and current.
EMERGENCY BATTERIES:
If the emergency of source is an accumulator battery. It is to be capable of
automatically connecting to the ESB in the ESB in the event of the failure of main source of
electrical power. Carrying the emergency electrical load without recharging while maintaining
the voltage of battery throughout the discharge period within 12% above or below its nominal
voltage.
One method of testing 24vdc power supply to navigation, communication and E/R
control in case of power failure is to drop the main supply to the rectifier, the main failure relays
would operate and connect the battery supply.
 ASSIGNMENT NO. 75
FIRE FIGHTING SYSTEM AND APPLIANCES
What is a fixed firefighting system?
In order to fight fire, particularly in engine room, pump room, cargo spaces paint
room and accommodation. There are pre-determined extinguishing mediums and releasing
mechanism kept in separate room like CO2, high expansion or low expansion from extinguishers
and sprinkler system. This method of fine fighting is called fixed firefighting system.
What is a CO2 room?
The room where CO2 bottles, for total flooding system are stored in a safe and
secured manner is called CO2 room. The carbon dioxide storage rooms should have access from
the open deck in emergency for personal be will illuminated, dry and well ventilated and there
should be no risk to personnel from leakage or from bursting disc rupture. The storage room
should not be accessible directly from boiler, machinery or cargo spaces. The space should be
reserved solely for the purpose of CO2 fire extinguishing system. Suitable means should be
provided for the cylinder to be weighed as necessary.
Count the total number of CO2 cylinders available in the CO2 room and distribution of
same various locations?
As per SOLAS and FSS code book issued by IMO, the criteria for CO2 total
flooding system are as follows:
 For cargo spaces the quantity of CO2 available shall, unless otherwise provided be
sufficient to give a minimum volume of free gas equal to 30% of the gross volume of the
largest cargo space to be protected in the ship.
 For the machinery spaces the quantity of CO2 carried shall be sufficient to give a
minimum volume of free gas equal to the larger of the following volumes-either.
 40% of the gross volume of the largest machinery spaces so protected, the volume
to exclude that part of the casing above the level at which the horizontal area of
the casing is 40% or less of the horizontal area of the space concerned taken
midway between the tank top and the lowest part of the casing.
Or
 35% of the gross volume of the largest machinery spaces protected, including the
casing.
 The percentages specified in the paragraph above may be reduced to 35% and 30%
respectively for cargo ships of less than 2000 gross tonnage provided that, where two or
more machinery spaces are not entirely separate, they shall be considered as forcing one
space.
 For machinery spaces, the fixed piping system shall be such that 65% of the gas can be
discharged into the space with 2 minutes.
How is CO2 released if required?
In case of a large fire in the ER and in ability to contain and extinguish locally,
CO2 flooding may be necessary,
1. Chief engineer to take charge of operation.
2. Electrical officer to isolate all non-essential electrical circuits from emergency switch
board to engine room before starting and taking the emergency generator on load.
3. Activate CO2 release alarm by opening the box door.
4. All persons report to EHQ. Ensure all engine room entrances are shut while leaving
ER and also on all decks in accommodation.
5. Take a head count and ensure all presents or accounted for.
6. Confirm engine room ventilation tripped.
7. Confirm remote stops for all FO for ME, AE, BLR’s purifiers and incinerated
activated.
8. 2nd engineer to trip all quick closing valves for FO, DO and LO tanks.
9. 3rd engineer to start emergency fir pump and ensure proper operation and on started
by further instructed confirm isolating valve to E/R shut.
10. Support squad to close all flower flaps, funnel flaps, all E/R and funnel doors.
11. Emergency squad to start boundary cooling as required.
12. Confirm E/R is sealed and final head count.
13. Request permission from master to discharge CO2.
14. Confirm CO2 releasing system panel door is open and CO2 audio visual alarm is
activated,
 Open the master valve using servo cylinder.
 Operate CO2 bottle release mechanism using the servo cylinder.
 Observe the CO2 getting released by seeing the pressure gauge and feeling the
pipe.
15. Incase remote release of CO2 fails, prepare to trigger CO2 cylinders manually after
confirming the master valve is in OPEN position.
16. Re-entry to E/R is prohibited till E/R is SAFE in all respects for inspection.
Ventilation fan to E/R with ESBD supply and to be run on exhaust mode.
17. SCABA to be mandatory during the entire re-entry procedures and subsequent
inspection.
18. Continue boundary cooling and take all necessary step to avoid spread of fire to
accommodation constantly monitor engine room boundary temperature.
How are CO2 cylinders weighed and what other system is available for ascertaining the
weight of CO2 cylinder?
The level of CO2 the cylinder is ascertained by meant of a radioactive level
detector or a standard weighing scale. It must be carried out an annual gain by an authorized
agency and certified. If loss is >/= 10% bottle must be charged.
What do you understand by portable fire extinguisher? Write on which type of fire the
following fire extinguishers can be used method of using and chemicals used in these fire
extinguishers?
Foam, CO2 portable, soda-acid, dry powder portable fire extinguishers are smaller
extinguishers that can easily be transmitted to fire. IMO resolution A605(15) defines a portable
extinguisher as one which is designed to be carried and operated by hand and which in working
order has a total weight of not more than 23 Kg (50.66 Lbs.).
FOAM EXTINGUISHERS:
These type of extinguishers are used on class A, class B type fires i.e., involving
solids usually organic, wood, paper and involving flammable gases CNG, propane, LPG
respectively.
Method of operation:
 Remove the safety tip on the plunger and strike the plunger to pierce the CO2
cartridge.
 Direct the foam on a vertical support with a sweeping action so that it can flow on
the burning fuel smoothly.
 The jet should project to a distance of at least six meters for at least 60 seconds.
Chemicals used:
Chemical type : potassium sulphate & sodium bicarbonate.
Mechanical type : 97% water and 3% aqueous film forming foam solution.
CO2 PORTABLE EXTINGUISHER:
CO2 extinguishers are used for extinguishing fires on energized electrical and
electronic equipment’s.
Method of operation:
It consists of a pressure cylinder, a control valve for releasing and discharging the
gas in the cylinder under 51 bar pressure in liquid state.
Due to drop of pressure at the time of releasing through the discharge hour to CO2 liquid
from a gas larger by taking heat from the surrounding and is about one and half times heavier
than air.
Chemical used:
Carbon di-oxide.
SODA-ACID EXTINGUISHER:
This type of extinguishers is used for class A. i.e., involving solids usually wood,
paper etc. and class F type i.e., cooking oils and fats.
Methods of operation:
When the plunger is struck, it breaks the acid bottle the sulphuric acid and sodium
bi-carbonate solution react together to release CO2.
Chemicals used:
- Sulphuric acid
- Sodium bi-carbonate
DRY POWDER EXTINGUISHER:
Dry chemical powder extinguishers are used in all class type of fire.
Methods of operation:
- When the plunger is hit on the head, the pin pierces the seal of the CO2
cartridge.
- The gas then passes through a tube to the bottom of the casing where it enters
the dry powder forces it out the discharge tube.
- The pressurized CO2 forces all two powder out of the discharge nozzle.
- The powder forms a blanket and envelops the fire.
Chemicals used:
- Potassium sulphate
- Sodium bi-carbonate
EMERGENCY FIRE PUMP:
Emergency fire pump is used in case of an emergency when main fire pumps are
dry function. They shall be concept of supplying two jets and capacity being 40% of the total
capacity of the main fire pumps but in any case not less than 25 m3/hr for passenger ships of less
than 1000 gross tonnage and upwards.
15 m3/hr for cargo ships less than 2000 gross tonnage.
FIRE HOSES:
These are made from synthetic woven textiles, lined with rubber and PVC coated.
They are strong and are not affected by oils and chemicals. These are generally of 18m length
and 64 mm diameter and provided with coupling and nozzles. They are louspicuously kept at
strategic positions as per the fir plan and near the hydrants either rolled or flaked in a clearly
labelled fire hose box.
NOZZLES:
They should be of approved dual purpose type i.e., spray and jet also in corpora
ting a shut-off. They are kept with hoses in the fire hose box. Fire boxes with nozzles shall be
fitted above the bilges, tank tops and other areas over which oil fuel is liable to spread and also
above the specific fire hazards in the machinery and deck spaces. The number and arrangement
of the nozzles shall be such as to ensure an effective average distribution of water at least 5
litters/m2 /min in the space to be produced.
FIRE MAIN SYATEM:
A fire main system must have at least two independently driven fire pumps that
can each deliver water as a continuous jet of 12 meters with a pressure of at least 3.5 kg/cm 2
from at least two.