f oq General =a Engineering aq Knowledge Third Edition H D McGeorge BiGeneral Engineering Knowledge THIRD EDITION H. D. McGeorge, CEng, FiMarE, MRINA BUTTERWORTH HEINEMANN AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYOElsevier Butterworth-Heinemana Linacre House, Jordan Hill, Oxford OX2 8DP 30 Corporate Drive, Burlington, MA 01803 Previously published by Stanford Maritime Limited 1978 Reprinted 1981 Second edition 1984 Reprinted 1987, 1989 Third edition 1991 Reprinted 1992, 1904, 1997, 1988 (twice), 1999, 2000, 2002, 2003, 2005 Copyright © 1978, 1984, 1991, H. D. McGeorge. All nghts reserved The right of H. D. McGeorge to be identified as the author of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England W1T 4LP. Applications for the copyright holder's written d permission to reproduce any part of this publication should be addressed to the publisher Permissions may be sought directly from Elsevier's Science & Technology Rights Department in Oxford, UK: phone: (+44) 1865 843830, fax; (+44) 1865 853333, e-mail: [email protected], You may also complete your request on-line via the Elsevier homepage (http:/Avww.elsevier.com), by selecting ‘Customer Support’ and then ‘Obtaining Permissions’ British Library Cataloguing in Publication Data McGeorge H. D. (H. David) General engineering knowledge — 3rd ed. 1. Marine engineering I, Title 623.87 Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 7506 0006 3 For information on all Elsevier Butterworth-Heinemann publications visit our website at www.bh.com Working together to grow libraries in developing countries www.elsevier.com | www.bookaid.org | www.sabre.org ELSEVIER Lists Hele bana G Ween ee Ute OTe ay Printed and bound in Great Britain by Biddles Ltd www. biddles. co.uk Contents Preface vil Centrifugal Pumps and Priming—Coolers 1 and Cooling Systems—Pipelines and Corrosion Hazards in Enclosed Spaces—Tankers— 16 Cargo Pumping Fire Protection - 33 Fuel—Handling and Treatment— 50 Self Cleaning Purifier—Automatic Combustion System for Auxiliary Boiler Refrigeration Air Conditioning—Heating 61 Metallurgical Tests 81 Stern Tubes, Seals and Shafting Systems 95 Steering Gear 118 Pollution Prevention—Monitoring— 131 Oily Water Separator—Sewage Treatment Production of Water 144CONTENTS 11 Noise and Vibration 151 Index 155 viCHAPTER 1 Centrifugal Pumps and Priming— Coolers and Cooling Systems— Pipelines and Corrosion CENTRIFUGAL PUMPS The simple centrifugal pump is used for sea water circulation and other duties where self priming is not a requirement. When installed for bilge pumping or ballast duty, these pumps require a primer i.e. some means of removing air from the suction pipe so that the liquid to be pumped is caused to flow into the pipe and so to the eye of the impeller. SINGLE STAGE CENTRIFUGAL PUMP For general duties the impeller is of aluminium bronze keyed and secured to a stainless steel shaft. The impeller shown (Fig. 1) is fully shrouded and of the Pump shaft Coupling spacer Gland Gland — packing Lubricator Shaft bearing Drain connection ‘O' ring Securing washer S Lower wear rings Fi ; ; 8-1 Single stage centrifugal pump (Hamworthy Engineering Lid) ImpellerPUMPS AND COOLERS single entry type. The renewable wear rings are of aluminium bronze and the casing is normally of bronze or cast iron. The cover has a hub containing the shaft bearing at the bottom and, above, either a packed gland or a mechanical seal. The shaft bearing is of phenolic resin asbestos, lubricated by the liquid being pumped except for pumps operating on high static lift. These have grease lubricated bronze bearings to ensure adequate lubrication during the priming period. A spigotted coupling spacer connects the motor half coupling to the pump shaft. When this is removed, the pump cover, together with the impeller and shaft assembly can be lifted out of the pump casing for inspection or mainte- nance. IMPELLERS The fully shrouded, single entry impeller in the pump shown (Fig. 1} is the type most widely used. It consists of a number of vanes curving backwards from the direction of rotation. The vanes are supported on one side by shrouding connected to the hub. The shrouding supporting the vanes on the other side, has an entry at the centre. When the pump is operating, liquid in the casing is swirled by the rotating impeller. The swirling action causes the liquid to move towards the outside and away from the centre (in the same way that stirred coffee moves to the side of the cup, tending to spill over the rim and leaves a dip at the centre). The backward curving vanes and the rotation give the liquid a combined radial and circular motion. CASING The section of the volute casing shown in the sketch (Fig. 2) increases, thus allowing unrestricted flow from the impeller. The volute also acts as a diffuser, Shroud NAS Wanes a { Eniry t Shroud Volute ; Discharge casing Fig. 2 Section through impeller and casing PUMPS AND COOLERS converting kinetic head into pressure head. Some pumps have a double volute casing which gives radial balance and reduced wear on the bearings. Pumps designed to produce high pressure, have a diffuser ring so that a greater quantity of kinetic energy in the liquid can be converted to pressure. SUCTION When a centrifugal pump is operating, the liquid leaving the impeller produces a drop in pressure at the entry or eye of the impeller. This causes liquid from the suction pipe to flow into the pump. In turn, there is a movement of the liquid to be pumped. The latter is normally subject to atmospheric pressure. A centrifu- gal pump will maintain a suction lift of four metres or more once it has been primed, because of the water passing through. The water in a pump acts like a piston for water in the suction pipe and an empty pump will not operate. A pump which is required to initiate suction from a liquid level below itself, must be fitted with an air pump. AIR PUMP ARRANGEMENT The diagram (Fig. 3) shows a primer coupled to the top of an electric motor and centrifugal pump set. A pipe from the pump outlet, provides cooling water for the primer. This returns through another pipe to the pump suction. ‘The main pump suction pipe has a float chamber fitted. The float operates a vaive on the pipe leading from the float chamber to the air pump suction. With no liquid in the suction, the float drops, opening the valve and allowing the air pump to evacuate the air from the suction pipe. This partial vacuum causes the atmospheric pressure to force liquid into the suction pipe. The rising liquid will lift the float and close the valve on the air pump suction. Air pumped out, passes to atmosphere. AIR PUMP PRINCIPLE The ait pump or water ring primer, as the simple plan view shows (Fig. 4) consists of an elliptical casing which contains a vaned rotor and has a covering plate with ports cut in it. The casing ts partly filled with water. The rotor is coupled to the electric motor so that when the pump is running the water spins with the rotor and being thrown outwards, takes up an elliptical shape. The tips of the vanes are sealed by the water and the volume between them varies during the rotation. Beneath the suction ports, the volume increases so that air is drawn from the float chamber. Under the discharge ports, the volume decreases, forcing air out. Cooling water ts necessary to prevent overheating of the sealing water from the action of the vanes in the liquid. Interruption of the coolant supply results in vapour from the sealing water destroying the vacuum effect, so that air is no longer pumped. The internal passages of a typical air pump are shown in the sectional sketch (Fig. 5). The right side shows the operating passages and the path of the air being pumped. It is drawn from the suction float chamber of the main pump and through the pipe and passages to the suction ports of the primer. The dischargePUMPS AND COOLERS Shae Water cing primer Py Seal level es tT ] Coolant return Coupling Electric motor Airc discharge to atmosphere Eat Cooling water valve . . to primer Weight of load taken by Bronze spring Tinned copper Atmospheric SUETOH PIPE pressure Fig. 3 Centrifugal pump with primer | supe ports are not shown but the air from them is discharged into the top of the outer | casing. From the outer casing the air is discharged to atmosphere. The primer runs continuously but can be unloaded, when the pump has been ; primed, by the arrangement on the left. The shut-off handle rotates a ported Ports in cover plute Rotor Waier ring seal Elliptical casing Fig. 4 Water ring primer or air pump PUMPS AND COOLERS Unloading handle Nut Ag from discharge ports pecs ~~ : Sealing Hl water levei e-em s y ‘ | , BIEN Ls} Atr discharge to atmosphere | Coupling Air suction from Float chamber Fig. 5 Air pump showing operating passages chamber to the position shown, so that the partial vacuum is broken and the water is free to circulate. OPERATION Centrifugal pumps for bilge, ballast and general service are usually fitted with primers. Before starting such pumps, the primers must be checked, to ensure that the sealing water is at the correct Jevel. Fresh water is used for topping up. Suction vaives between the liquid and the pump are opened and a check is made that other valves on the suction side of the system are closed. The delivery valve i we shut and the pump is started. The centrifugal pump can be started with aie valve closed, but it is an exception. (A propeller pump should not es Started with the discharge shut or overload results. This is shown by : a of characteristic curves. Obviously positive displacement pumps Ould not be started with closed discharges.) If priming takes a long time, the ee will become hot unless cooling water is passed through it. The sea water ction can be opened to allow cooling. EXHAUSTER FOR CENTRAL PRIMING SYSTEM Sever ; dhe pumps can be primed from a central vacuum tank as an Soares to being fitted with individual water Ting primers. The pumps are €d to the vacuum tank through the same sort of float chamber arrange-PUMPS AND COOLERS 1750 1.p.m. Electric motor wiih automatic starting by vacuum switch Mechanical seal Coupling Buna Port plate plate and rotor about 0,15 mm Sealing water level Quidevfoverflaw pipe _ Connections from the Vacuum Cooling coil of various gauge centrifugal Vacuum tank with pumps cleaning hand hole Fig. 6 Exhauster for central priming system ment as is used with the individual water rmg primer. There is also a shut off cock for isolating the pump and a non-return valve. ‘The primer has two electrically driven air pumps (Fig. 6) which evacuate the tank. Starting is by means of pressure switches through suitable starters, and air pumps are automatically stopped by the switches when the required vacuum is reached. The pumps run intermittently as demand makes necessary and not continuously. Thus, on a vessel where priming is needed for a number of pumps, the use of a central primer would reduce the number of air pumps and the running time for them. The primer shown, consists of a gunmetal casing of oval shape with a rotor and ported plate, as described for the individual water ring primer. Water in the casing forms a seal and, because it takes up the elliptical shape of the casing when the rotor turns, produces a pumping action. The two suction ports are connected by passages in the cover to the suction pipe from the vacuum tank. The two discharge ports are connected via an aperture to the sealing water tank. Air from the vacuum tank, together with make-up water, is drawn into the suction and discharged to the sealing water tank. The water remains in the tank, while the air passes to atmosphere through the outlet/overftow pipe. The sealing water reservoir also keeps the air pump cool and is cooled in turn, 1 , 4 1 float chambers % i ! 1 PUMPS AND COOLERS by a sea water flow through the cooling coils shown. If the water ring tempera- ture rises, then the function of the primer wil! be destroyed by the presence of water vapour. TUBE COOLERS Tube coolers for engine jacket water and lubricating oil cooling are normally circulated with sea water. The sea water ts in contact with the inside of the tubes and the water boxes at the cooler ends. Two pass flow is shown in the diagram (Fig. 7) but straight flow is common in small coolers. Oil in Ol out Sea wiler out i Ring and disc baffles Siidingsabe piute Shell Sea water in Fig. 7 Tube cooler with two pass flow (Serck) The oil or water being cooled is in contact with the outside of the tubes and the shell of the cooler. Baffles direct the liquid across the tubes as it flows through the cooler. The baffles also support the tubes. Tubes of aluminium brass (76 per cent copper; 22 per cent zinc; 2 per cent aluminium) are commonly used. Ordinary brasses and other cheap materials have been used with unsatisfactory results. The successful use of aluminium brass has apparently depended on the presence of a protective film formed along the tube length by corrosion of iron in the system. Thus unprotected iron in water boxes and other parts, while itself corroding, has prolonged tube life. This was made apparent when steel was replaced by other corrosion resistant materials or protected more completely. The remedy in these systems has been to fit sacrificial soft iron or mild steel anodes in water boxes or to introduce iron in the form of ferrous sulphate fed into the sea water. The latter treatment consists of dosing the sea water to a strength of i ppm for an hour per day over a few weeks and subsequently to dose before entering and after leaving port for a short period. Early tube failures may be due to pollution in coastal waters or to turbulence in some cases. Many coolers are fitted with tubes of 70/30 cupro-nickel. More expensive materials are available. Tubes are expanded into tube plates and may be further bonded by soldering.PUMPS AND COOLERS Leakage tell-tale i g Shell | ~~ Expunsion tube plute Fixed tube plaie Tubes fixed by expansion Fig. 8 Detail of cooler expansion arrangement TUBE PLATES Naval brass tubeplates are us made up to have a fixed tube p which is free to move with the expansion of th found in service are gunmetal, aluminium bronze an ed with aluminium brass tubes. Tube stacks are late at one end and a tube plate at the other end e tubes (Fig. 8). Other materials d sometimes special alloys. TUBE STACK The tube stack shown is fitted with alternate disc and ring baffles. The fixed end tube plate is sandwiched between the casing and the water box. If the joints leak at the other end the special ‘tell tale ring will allow the liquids to escape without mixing. The joint rings are of synthetic rubber. WATER BOXES AND COVERS Easily removable covers on water boxes permit repairs and cleaning to be carried out, The covers and water boxes are commonly of cast iron or fabricated from mild steel. Where they have been coated with rubber or a bitumastic type the iron or steel has been protected but has provided no protection for Uncoated ferrous (iron) materials in water boxes tubes as the unprotected iron itself corrodes, the the tubes. The iron also gives some measure of coating, the tubes and tubeplate. provide a protective film on the products of corrosion coating cathodic protection. Water boxes of gunmetal and other materials are used but these, like the coated ferrous metals, give no protection. Soft iron or mild steel anodes can be fitted in the water boxes and provided they cause no turbulence, will help to give cathodic protection and a protective film. SHELL The shell or cylinder is fabricated or cast. It is in contact with the liquid being cooled. This may be oil, with which there is no corrosion problem, or water, corrosion. The material is not critical which is normally inhibited against (provided it is not reactive with any inhibiting chemicals) because it is not in contact with sea water. PUMPS AND COOLERS INSTALLATION Manufacturers recommend th I at coolers are arranged verti i cture cally. If ho aaa eee ee water should enter at the bottom ind ee - system will encourage corrosion and air } i cooling area and cause overheatin juldie dere g- Thus vent cocks should be fitted f i : or air. Clearance is required at the cooler fixed end for removal of the file Gee SEA WATER SIDE Only the minimum of salt w i ater should be circulated in cool iti ers. Thus it oe bpp by means of the salt water outlet valve, the inlet bong len ae pen. : ee is maintained by adjustment of the oil or jacket inex s ull How on the sea water side, there is a i greater corrosion risk. eee ee sea ie pump suctions should be cleaned and ete ly, age will starve the system of w i ag ater. Damage to th PI ea mae sarki which will block the end of the sale The caulee ective in either case i i ' i ee and partial blocking of the cooler tends to to wa i i side should be disturbed only when necessary to avoid dama fee =e film on the inside of the tubes. If cleaning is needed to reas -. ain sige be made of the special soft brushes. Chemical cleaning ma oe mended particularly where hard deposits have acmumaniee The ee see ae ene os list acceptable cleaning chemicals. For the sea olers, an acid such as hydrochloric acid ) may be the a de eae, pean Mas dealing with corrosive hemi: ro for : is avoided by wearing gloves and i shield. Should the chemical c i Oh fbecuineieie tein - Si ome into contact with the ski Heep caeliee © skin or the eye, the b ly to wash the affected parts i i i - . s parts immediately with w opel is necessary this can be found from the medical book Hetore landline a the instructions should be read and the type of first aid that aught a = ease There are now such a variety of chemicals in use ahr an S are needed. Mixing instructions must be followed by ae : Se oo a isolated from the system by valves and blanks or pipes and blanking the cooler flanges. Flushing i - Flushin the cleaning agent has been drained from the vaailcr Bis necessary after PLATE TYPE HEAT EXCHANGER Plate t igi oe diy clase eee were originally developed for the milk industry H ecessary. , incor Poe y. They were first used at sea, as coolers, in the The pla i i Stent oe — ee eee (Fig. 9), corrugated with horizontal or chevron ofthoae rug 4 a ese make the plates stiffer and therefore permit the use se rg a ~ - They also increase the heat exchange area and produce ; bbulene fe ee factors contribute to the efficiency of heat eansion ; osed to smooth fi iqui en pp 1 ow, causes more of the li i oe ree plates to come into contact with them. It also waaKs ist the aan feieg a liquid which adheres to the metal and acts as a heat bosttier in - However, the turbulence can cause plate damage due ta MG nl