Professional Documents
Culture Documents
It must be fitted to press up the emergency air bottle and to start auxiliary
engine of a dead ship.
At starting this valve must be opened, this reduced the starting torque for the
machine and clear out any accumulated moisture and oil in the system.
The valve will be late in closing and this would reduce the volumetric
efficiency of the machine.
The valve experience greater force and therefore are more liable to break.
Bursting disc
It permanently damaged.
Fusible plug
When the air temperature from compressor is high (above 105 C) pressure
is released by melting (fusing) the metal.
Saving in power.
Reduced the volume of air delivered and also reduced the compressor size.
Due to less temperature suction & delivery valves remain cleaner without
being fouled with carbonized oil.
It also enables to deal with a greater weight of air for the same energy
expended.
To reduce final discharge air temperature thus air bottle size can be reduced.
To reduce air volume after it has been compressed to the final pressure.
Fusible plug is fitted under side of the pipe between relief valve and air
bottle.
A fusible plug is fitted after the second stage cooler to limit the delivered air
temperature and thus protect the compressed air reservoirs and pipe work.
Can you fit the relief valve at the space of bursting disc and why ?
At the compressor, relief valve can not be fitted at the bursting disc, because
of their difference operation.
Bursting disc is fitted for totally release and stop operation circuit.
Release valve opens excess pressure at compressor running and reset when
pressure reduce or when the compressor is stopped. Thus cooling water can
enter to compressed air space; it can cause water hammer when the next
start of compressor.
Air Compressor
Total no. of Air Compressors must be sufficient to fill the empty Air Bottle to maximum
pressure within 1 hour.
Must be sufficient to start at least 12 times for Reversible Engine, and at least 6 times for
Non-Reversible Engine.
Bursting Disc:
1. Fitted on the shell of Intercooler at waterside.
2. Relieves pressure if the tubes burst.
3. Rolled Copper Alloy and relief pressure is set while the disc is at softest condition.
4. Material tends to harden due to time and surrounding temperature, and set pressure also
increased.
5. Bursting Disc needed to be annealed, to regain correct relief pressure.
Compound Valves, why used in Air Compressor?
1. Give large area of opening and small amount of valve lift.
2. Improve Volumetric Efficiency, as valve open and close in minimum time.
3. Reduce bumping clearance.
4. Reduce wear and tear.
LP Relief Valve opening:
Causes:
1. HP suction valve
2. Intercooler choked.
3. Relief valve, jammed by foreign particles, in open position.
HP Relief Valve opening:
Causes:
1. HP discharge valve, in closed position.
2. After cooler choked.
3. Relief valve, jammed by foreign particles, or spring sticking in open position.
(Relief Valves opening pressure are set at 10% above stage pressure.)
Why Intercooler is fitted?
1. Reduce air temperature and volume, and increase air density for next stage.
2. Increase Compressor Capacity and Volumetric Efficiency.
3. Better lubrication for cylinder and rings.
4. Water and excess oil can be drained out, preventing fouling of Intercooler and pipes, Air
Bottle corrosion, and starting airline explosion.
5. Work done is saved.
6. Metal stresses reduced, due to control of temperature.
Volumetric Efficiency:
VE = (Volume of Air drawn into Cylinder) / (Stroke Volume of LP Piston)
and
VE = (Volume of Air discharged as free air) / (Stroke Volume of LP Piston)
Why Multistage Air Compressor is built?
1. To obtain near to ideal isothermal compression, compressor is to be constructed of
multistage with inter-stage cooling.
2. Inter-stage cooling reduces air temperature and volume after 1st stage compression, thus
increase mass of air for 2nd
3. Workdone is saved and air compressor efficiency increased.
Other advantages are:
1. Easy to get high final air pressure.
2. Easy to control air temperature.
3. Easy to maintain correct lubrication.
4. Better compressor balancing.
5. Reduction in size.
6. reduction in clearance volume loss.
Capacity of air compressor:
1. Capacity is checked upon how much filling time is lowered.
2. Compressor should have enough filling capacity so that sufficient stopping time should be
provided between fillings.
General Service (Whistle, Pneumatic Tools, Lifeboat , service air for cleaning and Pilot
ladder) 7 to 10 bar
Air Filter:
1. Material: Felt, Metal gauze or Nylon strands
2. Removes contaminants from air. Dirt and dust act as abrasives and increase wear.
3. Contaminant deposits on valves can become hot and source of ignition.
Hazard of Dirty Filter:
1. Very dirty filter or muffling a filter results in large pressure drop.
2. Air has to be compressed over higher range.
3. In extreme case, discharge air temperature may exceed flash point, or auto-ignition
temperature resulting in an
4. As a safety against explosion, air temperature is limited to 93 Fusible Plug (121C) or a
High Temperature cut out (93C) is provided on Compressor.
Pressure Test on Air Compressor:
Cylinders, cylinder cover, Inter & After coolers are hydraulically tested to:
Air receiver:
Total capacity of air receivers must be sufficient to give at least 12 starts for reversible
engine, and at least 6 starts for non-reversible engine, without refilling the receivers.
There must be two identical main air receivers and one emergency bottle for every vessel.
Melting point: 220F (104.4C). Fitted at the reservoirs bottom or on reservoir at ship
side, when relief valve (safety valve) is not directly fitted on the reservoir.
2. Atmospheric relief valve: provided for back-up of fusible plug. In case of ER fire when
CO flooding is required, this valve is opened before evacuating ER.
3. Spring loaded safety valve: setting pressure: 32 bar (for 30 bar working pressure), with
10% rise in accumulation of pressure. May be fitted directly or with extension.
4. Compensation ring: when a hole is cut or machined in pressure vessel, higher stresses
will subject to the material around the hole, and to reduce this, compensation rings are
fitted. It is a flange on which a valve or fitting is usually mounted.
5. Manual Drain valve or Automatic Drain valve.
6. Pressure gauges.
7. Access doors.
8. Main starting air valve, auxiliary starting air valve, filling valve, service air or whistle air
valve.
Internal surface coating:
Graphite suspension in water, Linseed oil, Copal vanish or Epoxy coating having basic properties
of anti-corrosive, anti-toxic or anti-oxidation.
Safety devices on Main Air Bottle:
1. Fusible plug.
2. Pressure Relief Valve
3. Atmospheric Relief Valve.
4. Low Air Pressure alarm.
5. Automatic or remote control Moisture Drain Valve.
How does emergency alarm ring?
Ans: Continuous ringing of bell. Emergency situation is explained at the muster situation.
Pattern of Emergency signal is indicated on Muster list
Q. Explain the Fire Tube and Water Tube Boiler.
Fire Tube Type: Due to simple design of the tubes effective heat transfer takes place, but
periodical cleaning/maintenance is slightly difficult. Soot blowing is not effective for regular
cleaning. Used with low pressure boiler
Water Tube type: In comparison to fire tube type heat transfer is not so so effective. Gas side
cleaning is easier, sometimes fixed water spray design is used for cleaning. Soot blowing is
effective , used with medium high pressure boiler
Q. What is Ogee ring?
Ans: Connects the bottom of the furnace to the boiler shell plating.
Ans:
i. By means of steam, soot blowing
ii. By injecting soot remover powder (chemical) to the system.
Sketch a gauge glass and explain blow down procedure.
Ans: a) Close steam and water cock, open drain cock, nothing should come out the cocks are
not leaking.
1. Open and close steam cock to check cock is clear.
2. Open and close water cock to check cock is clear.
3. Close the drain
4. Now open water cock, water should gradually rise up the top of gage glass.
5. Open the steam cock, the water should fall to the level of the water in the
boiler.
What is the consequence of low water level? What is your immediate
action?
Ans: Boiler running without water will cause overheating the tubes, tube plates and shell, that
will lead the boiler to face thermal over stress damage, crack or rupture to the tube, tube plates,
shell plates.
However, low water level alarm should be activated and boiler firing will shutdown. If the boiler
water level found minimum at the water cock level it is safe to put feed water in the boiler. If the
level is below this line care has to be exercised not to thermally stress boiler while putting water
into boiler.
What is the consequence of high water level? What is your action?
Ans: This will cause priming of the boiler, loss of heat from the heaters, possibly loss of steam
pressure.
As per as possible steam heating to be minimized temporarily, carry out partial blow down to
normal level. Then introduce normal heating again.
What is the purpose of treating boiler water?
Ans:
a) Prevent scale formation
b) Prevent corrosion
c) Control of sludge formation and prevent carry over to the system
d) Prevent entry of foreign matters to the boiler.
What type of chemicals are used to treat low pressure boilers?
Ans:
Lime Ca(OH)2 and soda ash are used Na2CO3 are used to deal with calcium and magnesium
compounds in the boiler water.
MgCl2 + Ca(OH)2
Mg(OH)2 + CaCl2
CaCl2 + Na2CO3
CaCO3 + 2 NaCl
Ans:
i) Create layer on the boiler plates, tubes etc and reduces heat transfer and thermal stresses are
induced.
ii) initiates corrosion
With regard to capacity state the regulation for steering gear?
Ans: A vessel at deepest draught and at maximum service speed should be able to
move rudder angel from 350 one side and to 350 other side. It should be capable to move 350 one
side to 300 other side within 28 seconds.
The auxiliary steering gear should be able to move from 150 one side to 150 other side at half
service speed or 7 knots whichever is greater in 60 seconds.
Describe steering gears routine checks before departure and arrival ports.
Ans:
Alarms
How often the emergency steering drill is carried out? How you used to
carry out in
your last ship?
Ans: By pass valve are used to open circuit any particular unit.
Relief valves are given to relief over pressure, especially during rough sea undue movements of
rudder created extra oil pressure which is relieved by them to avoid any rupture, leakage,
damage.
Care and management of pumping systems:
Candidates should remain aware of various pumps working principle.
Q:
Classify pumps.
Q: A centrifugal pump not taking suction, what action you are going to
take?
Ans:
Q:
should the above not complying check the wear ring clearance excessive
Ans: with the pumping action, pumping rate is same but if the delivery is obstructed the pressure
will be built up gradually, which will damage line, casing etc. To protect from above relief valves
are required to be fitted.
Q: What type of pump is used for Oily Water SWeparator? Is centrifugal
pump is suitable for the above?
Ans: positive displacement pumps e.g. rotor line screw, reciprocating and gear pumps are used
for the above. Centrifugal pumps are not suitable for above because they produce large quantities
of small oil droplets.
Q:
Ans: Bilge injection valve is used for in case of serious flooding in the machinery space.
Diameter of the valve should be 2/3rd of the diameter of main sea inlet, valve spindle should be
clear of engine platform.
What is the function of oil sensing probe in OWS?
Ans: The Capacitance probe in 1st stage senses and causes the solenoid to be energized through
control switch. Hence control air access to the diaphragm controlled piston valve to drain oil to
bilge oil tank.
Q:
Ans: Removes fine solids up to certain extent. Small drops of oil coalesce to form larger drops.
These rise up to oil collecting space.
Q: How to ensure no accidental discharge O/B will take place from O.W
separator?
Ans: i) 15 PPM alarm monitor will activate and discharge P/P will stop automatically.
ii) Three way valve will activate on reaching effluent content 15 PPM, will divert the flow to
bilge water tank instead of O/B.
Construction, maintenance and operation of fire fighting equipment, fire
prevention:
detection and
Candidate should know the basic principle operation of portable extinguishers, fixed fire
fighting installations and fire detector sensors.
Q:
With regard to capacity state the regulation for emergency fire p/p.
Ans: Capacity should be at least 40% of fire pumps but not less than 25m3/hour. To
supply 2 jets 13 mm dia with a horizontal throw of 13 m.
Q:
Ans: smoke is sensed by the photo electric call, this signal is transmitted to trigger the
alarm. It can be tested by (i) Smoke (ii) Spray can
Q:
Ans: Sprinkler heads are fitted with quartzoid bulb. Heat expands the liquid and
shatters the bulb. Water strikes a deflector to ensure a cover of floor area of 12m2. On dropping
system pressure sprinkler P/P starts automatically.
Used for accommodation, alleyways of passenger ships and some cargo spaces.
Q:
Ans: It is to be provided to enable water to be supplied from another ship or from shore
to the fire main.
PCD 132 mm, Outer dia of flange 178 mm, Bore (inner dia of flange) 64 mm.
4 bolts are required of 16 mm dia and 50 mm length.
Q:
Ans: 85%of the gas must be released within two minutes. The quantity of gas carried
1. must be sufficient to give a free gas volume equal to 40% of the volume of
the space except where the horizontal casing area is less than 40% of the
general area of the space.
2. Must give a free gas volume equal to 35% of the entire space whichever is
greater.
Q:
Ans: CO2 room visual inspection is carried out regularly (say weekly), CO2 alarm checked on
monthly basis and servicing and others checking of the system is carried out annually by
authorized work shop.
Modern vessels maintain routine check lists of weekly, monthly, quarterly, 6 monthly and
annually.
Q:
Ans:
a) A safety lamp
b) A firemans axe
c) A breathing apparatus or ii. Smoke helmet, or A smoke mask.
Q:
Ans:
i) Pressure normal; 140-210 bar
ii) Test alarm whistle working
iii) Check mask seals, not leaking
Alarm comes when air contents are brought about 80%.
Q:
personnel counted
shut down all fans, blowers, pumps, purifiers, motors by remote stop device
follow operating instruction for operating pilot cylinder for gang release and
there after the master valve
Q:
co2 cylinders are stored to maintain temp below 55c and at 52 bar. If pressure rise above 177 bar
at temp 63c or above, rupture disk on cylinders opens. This gas is released through safety v/v on
manifold.
When the co2 cyl require recharging? How the content be checked?
Ans:
Re-charge when weight reduce by 10%
Q:
Ans: To be complied with company check lists but in the general it will cover followings:
1. Assessment of atmosphere
2. Ventilation
3. Illumination (safety)
4. Permit to work
5. Self contained B/A set stand by
6. Ladder required as appropriate
7. Man standby at entry position
8. Communication should be established
Q:
Methods of manicuring, including bridge control Systems and Variable pitch propellers.
Engine should be tested from ECR first to ensure safe operation. If satisfactory, control is change
over to bridge and engine tested ahead and astern, telegraphic printer checked working Properly.
Bridge alarm panel checked, in order. During maneuvering speed program may be cancelled,
while at full away condition load up program should remain on to speed up gradually. Maximum
rpm can be limited from ECR.
Variable pitch Propellers:
While testing engine/vessel ahead and astern movements, only propeller pitches are adjusted
to get desired movements. Engine need not to stop for ahead/astern moves. Engine
clutch/declutch mechanism can be utilized as appropriate. Hydro oil level, pressure, and pumps
should be checked.
Pitch control tried out from bridge/control room as well from local control.
Emergency Control:
Q:
Ans: Should M/E remote operation is not working, it may be operated from emergency / local
control stand which will cover following:
1. Manual Fuel Control
2. Manual Air control
3. Manual Reversing
Q: What action you are going to take in the event of a black out/M/E
failure?
Ans:
1. Inform bridge/chief engineer
2. Engineers alarm may be raised for additional help
3. Emergency lighting/emergency generator will be active
4. identify the problem, preferably start other generator which was not in
service and restore power.
5. Run appropriate cooling P/Ps, reset all needful breakers, start all other plants
6. Prepare M/E and restore same after informing bridge
7. Check all Standby machineries and emergency equipments at ready mode.
Working principle and constructional details of a compressor, air receivers, and associated
equipment:
Candidates should have understand the efficacy of inter coolers, P-V diagrams gain in efficiency.
Q:
Ans: Reciprocating motions are used to in conjunction with spring loaded non -return suction
and delivery valves to achieve compressed air. Intercoolers are used to acquire gain in efficiency.
Q: Describe the construction of a main air compressor you used in our
last ship.
Ans: It was a in line reciprocating 2 stage compressor. 1st stage piston relatively larger and 2nd
stage piston smaller in comparison, materials respectively aluminum and cast iron. Both stages
were having spring loaded suction and discharge non-return valves. Inter stage cooler and after
coolers were there.
Q:
Ans: Tandem type compressor are the other type commonly used. 1st stage piston relatively
larger, 2nd stage piston exists on top of above relatively of smaller size.
Q:
Ans: Bumping clearance should be optimum. The more clearance volume increase, volumetric
efficiency and hence capacity decreases.
Q:
Ans: Remove suction or disch valve assy from the unit, place a small ball of lead wire on the
piston edge. Then rotate the flywheel by hand and to take the piston at TDC. Remove and
measure the thickness of lead wire ball.
Q:
Ans:
Intercooler:
Ans:
i) Low pressure alarm, stop for lube oil
ii) Jacket high temperature/air discharge high temperature, alarm, stop.
Q:
Ans:
i) Manhole door elliptical, for the ease of opening and consider strength of the pressure vessel
ii) Circumferential and longitudinal welding seams are existing.
iii) Relief valve fitted (if isolated from relief valve, fitted with fusible plug, melting point 1500
C.)
iv) Drain valve, pressure gauge
v ) Pressure switch for cut in /cut off air compressor auto running.
Ans: i) If the parameter goes beyond limit, that case engine power/rpm may have to be reduced
informing bridge and chief engineer. Need to find out fault.
ii) check the funnel smoke and check the pyrometer is correct, fuel rack in order.
iii) Fuel injection equipment, fuel valve, fuel P/P may be faulty. Take power card to understand
fuel injection, all units peak pressure may be compared
iv) Compression pressure can be checked from above, to have an idea about liner wear/piston
rings.
v) Exhaust valve operation can be checked visually (through glass) or light spring card can be
taken to ensure the problem with exhaust valve or not.
vi) check particular unit scavenge drain line
vii) Should all above are in order, consider mistiming for late injection or mistiming of early
opening.
Q:
M/E all units exhaust temps are high what could be the reason?
Ans:
Consider it is a common problem for all, hence it can be of followings:
1. Faulty governor or fuel linkage
2. Fuel quality to be assessed
3. Problem with T/C, scavenging not enough
4. T/C Air filter dirty
5. Scav. Air temperature high
6. Residual temperature low, responsible for incorrect injection
7. check fuel load, if the vessel at shallow water
8. Ships hull fouled
9. in worst case due bad quality fuel injection equipment may be worn.
Q:
F0 = 1.22 (mean), pos of load indicate pos corresponding to FO P/P idle stroke
N = Engine speed (rpm)
r
Hu
Effective Power
818.70
N=
P1-- KW
42.50
candidates should remain aware of the working principles of various main and auxiliary
machineries. Should know how to decarb a particular 2 stroke/4 stroke engine unit and relevant
inspections. To be familiar with operation recommended by the manufacturer, specially while
during operation with defective components.
Ans: Black smoke indicate incorrect /incomplete combustion. Blue smoke indicates
of LO with the combustion. Smoke should be clear.
burning
Ans:
i) Blow past through liner and piston rings
ii) Due to incorrect fuel injection
iii) Due to lack of cooling, breaking of Cylinder LO film
iv) Excessive cylinder lubrication give undue fuel and cylinder film breakage will cause hot gas
to blow by, consequence scavenge fire.
What action you are going to take with above?
Ans:
i) Inform bridge/chief engineer officer
ii) Slow down engine to extinguish fire
iii) Scavenge drain can be checked carefully
iv) shut off fuel to the particular unit
v) Increase cyl lubrication to give adequate sealing
vi) check funnel, scav drain, scav temp if satisfactorily return to normal with appropriate rpm.
vii) if above are not successful, not extinguished, stop engine, engage turning gear, mask T/C air
filter, use fixed CO2 / steam to extinguish.
viii) On completion, inspect, rectify the fault then start engine.
Candidates to know starting air explosion and c/case explosion, causes, remedy and action.
What inspection is carried out on piston ring?
Ans:
i) Axial clearance .
ii) Butt clearance
iii) Ring thickness
iv) Radial thickness
v) ring tension
What inspection should carry out with cylinder liners?
Ans:
i) Check the ridge on top, remove by grinding if any
1. ii) check for crack, oilyness
Ans: This makes use of the engine bedplate and seatings to distribute the propeller thrust to the
ships structure.
What is the function of flywheel?
Ans: i) Store energy while acceleration and releases while deceleration, smooths out fluctuation
of engine speed.
1. ii) Turns the engine for maintenance
Electrical shock and fire can cause loss of life and damage to the equipment, hence in general
following should be complied :
1. To be familiar with ship electrical equipment and diagram.
2. Operate as makers instructions
3. Maintain as per makers instruction
4. Guards, covers, doors etc securely tightened
5. While shutting off the power, inform duty officer/engineer of the watch
6. While maintenance being done, remove fuse etc.
7. Before working with the equipment confirm circuit is dead.
8. Do not leave live conductors or rotating parts exposed
9. Avoid overloading equipment
10.Use appropriate warning notices
What are the conditions of electric shock?
Ans
:
Minimum 15 mA AC or DC current is enough to cause an electric shock.
Circuit may be from hand to hand or hand to foot. Shock current is related to
the applied voltage and body resistance. Unfortunately if the applied voltage
goes up, body resistance goes down, that means shock current is further
increased.
Ans:
Guarded
Insulated barriers
During a watch you find low insulation resistance alarm, what is your
action?
Ans: Inform chief engineer officer and electrical engineer officer. Meanwhile take following
actions to find detect the faulty equipment.
After the faulty equipment is isolated, insulation indicator will restore back to normal.
How do you check insulation resistance?
Ans:
i) Phase to phase
ii) Phase to earth.
In dry dock while connecting shore electrical power, what will you check?
Ans: Two lights bright and one light goes out (dark), synchronizing method is sequence
method.
Same phase of the bus bar and incoming generator are connected across a 500 V voltmeter.
When voltmeter indicates 0 to maximum slowly and when voltmeter shows at zero, breaker to be
closed. This is the point where they are in correct phase sequence.