Q1.

With regard to keeping the gas side of boilers in good condition discuss EACH of the following:

(a) The mechanism of combustion, stating the factors which are important to good
combustion (6)
(b) Oil fuel treatments (5)
(c) Soot removal equipment. (5)

In boiler furnace, chemical energy in the fuel is converted into heat by the process of combustion.
The forced draft fan supplies the primary and secondary air required for atomisation and
combustion. The primary flame heats the heavier constituents of the fuel to their ignition
temperature. The larger oil droplets are heated in their passage through the primary flame zone,
vaporised and burnt.

For good combustion:-

(a) oil should arrives with the correct viscosity and pressure for the atomizing system in use for
proper atomisation.
(b) The pipe system conducting the fuel is arranged so that prior to lighting up, adequately
heated oil can be re-circulated providing a supply at suitable conditions as soon as light-up is
attempted.
(c) The choice of combustion equipment and design of combustion chamber are important for
the attainment of the time, temperature and turbulence to a degree necessary for good
combustion.
(d) High temperature is needed to vaporize the fuel and to ensure rapid ignition.
(e) Turbulence is necessary to aid intimate mixing of fuel and air so that complete combustion
can be achieved without the need for more air than that required to consume the
combustibles carbon, hydrogen and sulphur.
(f) The design and performance of the burner fuel atomizer for efficient, complete combustion
of heavy fuel oil is required.

Fuel Treatments cleans the entire fuel system while the furnace is in operation, eliminating gums
and resins from the fuel lines and tank. It also extends the life of integral and active furnace parts.
Once the system has been cleaned, rough operation will no longer exist, and fuel consumption will
be reduced (with the exception of being a new system, already free from dirt and resins). A furnace
with a clean fuel system will perform at an optimum due to proper missing of fuel and air.

A soot blower is a device for removing the soot that is deposited on the internal furnace tubes of a
boiler during combustion to prevent plugging of the gas passes and maintain boiler efficiency.

Types of soot blowers:

1. Wall Blowers also known as IRs (Insertable Rotating)

2. Long Retractable Soot blower (LRSB) or IK (Insertable Kinetic)
3. Part-Retractable Soot blowers
4. Oscillating Soot blowers
5. Rake Soot blowers
6. Air Heater Blower
7. Rotating Element Soot blowers
8. Multi-Media Soot blowers
9. Fixed Rotating
Q2. (a) Outline the advantages and disadvantages of a planned maintenance scheme for an
auxiliary diesel engine. (6)

State the advantages of condition monitoring as a method of deciding when auxiliary engine
component overhaul is necessary. (5)

Suggest the means that are normally available (i.e. without the need for elaborate or expensive
equipment) to check the condition of a diesel engine as a guide to ascertain the maintenance that
is actually needed.

A. Planned Maintenance

Advantages

1. Fewer breakdown and reduced down time produces higher level of operating efficiency.
2. Maintenance is well planned in advance, Provision for labor and material are carried out at
times favorable to the plant.
3. More effective labor utilization because maintenance is carried out at favourable times to
the ship's staff.
4. Replacement spares can be condensed in advance
5. The equipment is maintained in a safe condition with reduced possible damages.
6. When a special manufacturer's services are required. These can be obtained at convenient
times to suit the ship's operation
7. Replacement of short-life components at scheduled interval.

Disadvantages

1. Maintenance activity and costs increased

2. Sometimes unnecessary and invasive maintenance carried out.
3. Applicable only to age related deterioration.
4. Maintenance sometimes induces failure.

B. Condition Monitoring

Advantages

1. Equipment is not subject to unnecessary maintenance thus saving in man power and down
time.
2. Maximizes equipment availability minimum production loss.
3. Since the running condition of equipment is known it ensures safe and efficient operation
with reduced possible damages
4. Allows shut down before serious damage occurs.
5. Cause of failure can be analyzed and successfully rectified.
6. Maintenance can be planned, labor can be organized and spares can be arranged in
advance.
Q3. (a) Describe with the aid of a sketch an evaporator for the production of fresh water. (6)

(b) (i) Explain how scale is formed. (5)

(ii) State measures to reduce or remove scale.

(c) Show how the water is made potable. (5)

Basic principle of all low pressure freshwater generator is that, boiling point of water can be reduced
by reducing the pressure of the atmosphere surrounding it. By maintaining a low pressure, water can
be boiled at low temperatures say 50 degree Celsius. The source of heat for the fresh water
generator could be waste heat rejected by main engine jacket cooling water.

Hence using energy from a heating coil, and by reducing pressure in the evaporator shell, boiling can
takes place at about 40 to 60 degree Celsius. The fresh water generator uses the heat from main
engine jacket cooling water to produce drinkable water by evaporating seawater due to the high
vacuum, which enables the feed water to evaporate at a comparative low temperature. Steam can
also be used as a heat source instead of main engine jacket cooling water.

This type of fresh water generator is based on two sets of shell and tube heat exchangers, one acting
as evaporator or heater and other as condenser.
The combined air/brine ejector creates evaporator chamber vacuum condition by driving sea water
pass through air/brine ejector, and sea water supplied by the ejector pump to be delivered to
ejector for taking out the brine (concentrated seawater) and air.

While entering to the evaporator chamber temperature of feed water will be around 50 degree
Celsius. Feed water supply rate to the evaporator is fixed by an orifice fitted at the feed inlet.
Because of the vacuum condition inside evaporator feed water evaporates at this temperature. The
water spray and droplets are partly removed from the vapour by the deflector mounted on top of
the evaporator and partly by a build in demister. The separated water droplets fall back into the
brine, which is extracted by the water ejector.

The desalted vapour, which passes through the demister, will come in contact with the condenser,
where it will be condensed by means of incoming cold seawater.

The distilled water is then taken out by integral freshwater pump (distillate pump) and controlled by
salinometer and solenoid valve. If the salt content of produced water is high, solenoid valve diverts
the freshwater to the shell side of freshwater generator, and issues an alarm signal. In order to get
better suction head, distillate pump is placed at the lowest possible location in the fresh water
generator plant. This is because the fresh water generator shell is at a lower pressure. Distillate
pump get maximum net positive suction head with the height of liquid column in the suction line.

Scale formation occurs due to salts that are not completely insoluble in the water. Hence the salts
reach the surface in a soluble form and precipitate. The presence of calcium and magnesium salts is
the main cause of scaling in evaporator. Scale salts generally consist of carbonates, bicarbonates,
and sulfates that form slowly in a concentrated pattern, reducing the heat transfer. If overlooked,
scales can be extremely difficult to remove even by using chemical treatment.

It is recommended by the manufacturers of the freshwater generators to run the freshwater

generator at its rated capacity. The freshwater generator must never be run more than their rated
capacity similarly, if the temperature of the shell increases then harder scales are formed in the
shell. This will be very difficult to remove. All these together may cause a drop in the freshwater
generated efficiency significantly. Some chemicals which are safe for human consumption are used
to minimise the formation of scales in the freshwater generator. Most of the chemicals contain poly
sulphate compounds with anti foaming characteristics, these are preferred by most of the
freshwater generator operators.

Two commonly used chemical names produced by chemical companies are Vaptreat and Ameroyal.
Q4. (a) Sketch a transmission shaft coupling which enables the propeller shaft to be withdrawn
outboard. (8)

(b) (i) Describe the coupling and the method of fitting and dismantling. (4)

(ii) State how the grip of the coupling can be checked when fitted. (2)

(iii) State what safety precaution should be taken when dismantling the coupling? (2)
c. The grip of the coupling is checked by measuring the diameter of the outer sleeve before and after
tightening. The diameter increase should agree with the figure stamped on the sleeve.

d. To disconnect the coupling, oil pressure is brought to a set pressure in the hydraulic space. Then
with the shafts supported, oil is forced between the sleeves. The outer sleeve slid ,off the inner at a
rate controlled by release of the hydraulic oil pressure. - Care must be taken to release the hydraulic
pressure very very slow to avoid and prevent the propeller jumping at the release of the hydraulic
pressure. - When it is required to remove the propeller, the process is equally simple and even
quicker with the injection of oil between the surfaces obviating the need for any form of heating or
mechanical withdrawal equipment. Precautions are necessary to prevent the propeller jumping at
release.
Q5. During your watch you observe that Main Engine L.O, sump level is rising due to
contamination of lubricating oil. Describe the procedure to

a) Identify the contaminant. (6)

b) Locate the cause of contamination (6)
c) Action to make the oil suitable for its continued usage. (4)

If lube oil is contaminated by water then following effects can be observed :-

1. Reduced cooling efficiency.

2. Increased acid formation in trunk type piston engine.
3. corrosion on m/c parts.
4. Microbial degradation, [Reduced centrifuging efficiency; increased local pitting and
corrosion]
5. Reduced load carrying capacity
6. Reduced L.O properties, and TBN of oil
7. Formation of sludge due to emulsification

If contaminated by fuel oil then following effects could be observed:-

1. Fuel dilution usually by diesel oil.

2. Lower viscosity and low flash point
3. Lower viscosity LO reduces this properties ( e.g load carrying capacity )
4. Lower flash point will case crankcase explosion.

The cause of contamination:

a) Poor atomization of a fuel injector and back leak through the fuel injector p/p plunger and
barrel can cause the lube oil contamination.
b) Condensation of water vapor within the crankcase
c) Leakage from the cooling water system for cylinder or piston
d) Leakage from the sump tank heating steam coils.

Action to make the oil suitable for its continued usage:

1. Take the immobilization permit from the port authority since your propulsion power is not
available

2. The entire oil charge should be pumped by the purifier or by main circulation p/p into settling
tank.

3. It should be allowed to settle for at least for 24 hours with heating about 60° C .

4. Water and sludge should be drained out periodically.

5. Clean the interior of the sump tank and carefully examine.

6. The oil should be passed through the purifier at its optimum efficiency and then pumped back into
the sump tank.

7. When sump tank empty, its interior should be cleaned and examined.
Q6. (a) Describe, with the aid of a sketch how the weight of the rudder is carried (8)

Explain how replacement of the bearing is catered for (4)

Explain how the rudder stock is located (4)

Rudder may be hinged on the pintles and gudgeons, or the may turn about an axle which passes
down through the rudder. The weight of rudder may be taken by bearing pintles, or by a bearing at
the rudder head (rudder carrier), or by a combination of both.

Replacement of the bearing

1. Lock steering gear in mid position

2. Remove the earth wire
3. Measure clearances ( rudder drop and jumping clearances )
4. Fix eye bolt to rudder stock and take load with the help of chain block at strong point
provided
5. Remove the bolts of gand housing and remove gland packing.
6. Remove the locking ring
7. Remove grease plug
8. Remove the moving cone which is in 2 pieces( bolted with each other). Put eye bolt
diametrically opposite
9. Remove the bottom half which is also in 2 pieces and attached to ship structure via chocks

The rudder carrier bearing (Figure below) takes the weight of the rudder on a grease lubricated
thrust face. The rudder stock is located by the journal beneath, also grease lubricated.
Q7. With reference to a rotary vane steering gear

1. State, what symptoms would indicate leakage across vane seals (8)
2. State what steering gear tests you would carry out before a voyage begins (8)

Main steering gear and system

1. Auxiliary steering gear and system

2. The remote control systems of steering gear
3. The steering position indicator on the navigation bridge
4. The emergency power supply to one of the steering unit
5. The rudder angle indicators showing actual position of the rudder
6. Power failure alarms for the remote steering gear control system
7. Power unit failure alarms for the steering gear unit
8. Automatic isolating arrangements and other automatic equipment

Following listed procedure must be included along with the check and tests described above:

1. The full movement of the rudder as per the required capabilities of the steering gear system
present on board
2. A visual inspection of all the linkages and connection in the steering gear
3. The means of communication between the steering gear room and navigational bridge must
always be operational
Q8. To achieve the optimum performance from a main air compressor, describe the routine
maintenance necessary on the following components;

1. Unloader (4)
2. Air intake filter (4)
3. Suction/Discharge valves (4)
4. Intercoolers (4)

Unloader

Dirt in the valve: Sometimes external agents (dust, Teflon, etc.) contaminate the inside of the
solenoid valves and cause a device malfunctioning. To confirm this is the cause of the problem,
disassemble the valve, inspect the internal condition, perform a suitable cleaning (if required),
reinstall the solenoid valve, and test it to check performance.

Internal components damaged:

During the internal inspection of a solenoid valve, any piece (membrane, seals, or o-rings) found
damaged must be replaced.

Electrical issues:

1. Confirm that the voltage and frequency are correct.

2. Check the condition of the coil and measure its resistance, in case it tends to zero, this coil is
burnt and needs a replacement.

Air intake filter:

The air filter must be checked at frequent intervals and approximately at every 250 hours or
whenever the air discharge temperature becomes high. The air filter element must be replaced with
a new one and sufficient spares must be available onboard.

An air filter is the first step to keep the compressor healthy.

It must be noted that the air compressors are installed at a place where there is sufficient air supply
to ensure the suction is never devoid of air.

ONE MUST MAKE SURE THAT THE OLD CARTRIDGE IS NOT BLOWN WITH AIR AND RE-USED, AS THIS
MAY DAMAGE THE AIR FILTER.

Dirty air filters affect the volumetric efficiency of the compressor and so does the temperature of
the inlet air to the compressor.

Suction/discharge valves:

Different types of compressors have different types of valves and removal methods for different
stages

The valves must be removed and should be checked for leakage with diesel oil or water

The valves must never be held on vice but should rather be held on the tool given for the same.

All the parts must be properly cleaned after opening the valve and they must be checked for the
carbonization as well.
Over carbonization reveals that the oil topped up is more than required. This would lead to the
sticking of the valves and eventually they would break. Sticking of the valves will also reduce the
volumetric efficiency of the compressor as the quantity of air discharged would be comparatively
lesser.

The valve plate should be checked by pushing the valve plate from the side of the valve seat by a
screwdriver. The valve plate will move a distance which is equivalent to a valve lift.

The springs and valve plates should be changed if required.

The plate could be lapped as well if no spares are available.

Intercoolers

The intercoolers are generally opened up as per the maintenance frequency and are supposed to be
cleaned by a solvent and the integrity of tubes to be checked as well.
Q9. With reference to exhaust valves:

1. Describe how valves are reconditioned. (8)

2. Explain how valve timing is checked and corrected. (8)

a. The process of Reconditioning Exhaust valve spindle & seat;-

1) Sandblasting
2) Testing and inspection of markings to determine is Stellite type or Nimonic
3) Machining of the seat surface
4) Machining of fire side face (up to 6mm)
5) Preheating
6) Gradual build-up of fire side face using original material (up to 6mm)
7) Gradual rebuilding with Nimonic 80A (for Nimonic Type) or
1. Stainless steel with Stellite #6 in way of seat area (for Stellite Type)
8) Gradual cool down and stress relief after all welding procedures
9) Final machining to makers standards
10) Dye check for crack detection on completion of work
11) Grinding of the seat to makers tolerances

b.) The valve train is geared or has a chain drive with sprockets on the camshaft and crankshaft.

Any slight variation from the correct timing setting will result in loss of power and overheating.

Any large variation and the engine will not start.

To accurately check the valve timing, it will be necessary to remove the timing cover to gain access
to the timing gears.

The gears or sprockets are fitted to the crankshaft and camshaft by keys so they can only be fitted in
one position.

However, they can be incorrectly lined up to each other. It can be varied by modifying the camshaft,
or it can be varied during engine operation by variable valve timing.

It is also affected by the adjustment of the valve mechanism, and particularly by the tappet
clearance.