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1. What does 3/8 or means in thread nomenclature? 3/8 or means the nominal OD of the bolt. For Course threads the TPI will be 16 and for fine threads the TPI will be 20. Actually thats according to the American standards. Metric standards define it in eg. M10 * 1.5 where, 10 is the nominal diameter and 1.5 is the pitch. If Pitch is not mentioned, then we take it as that thread is belonging to the course group. 2. What does 15W40 denote? Here 40 is SAE number. SAE number like SAE 10, SAE 20 corresponds to that having kinematic viscousity at 100C. Likewise W denotes the winter grade for cold start. Thus SAE 15W40 denotes that the lube oil of this grade has kinematic viscosity of 40 cst at 100C and its winter grade is 15W ie, the cranking and pump ability of this lube oil grade has passed tests of 20W and 15W but failed test of 10W at below zero temperatures. 3. Actions to be taken during boiler uptake fire? Boiler uptake fire is because of wet soot deposited during low steaming and also during uptakefire do not carry out soot blow reduce the load and stop the engine , cover the m/e t/c with thecanvas so that no air is supplied 4.How much is Needle vv lift? Generally 1mm maximum for 320 bar lifting pressure. 5. Boiler corrosion how it happens and how to prevent? The most common causes of corrosion are dissolved gases (primarily oxygen and carbon di oxide), under-deposit attack, low pH, and attack of areas weakened by mechanical stress, leading to stress and fatigue cracking and pitting corrosion: scales such as calcium and magnesium salts.Many corrosion problems occur in the hottest areas of the boiler-the water wall,screen, and superheater tubes. Other common problem areas include deaerators, feedwater heaters, and economizers. Prevention: Maintenance of proper pH and alkalinity levels between 8.5 and 9.5 control of oxygen and boiler feedwater contamination (less than 7 ppb oxygen for a 900 psig boiler) Reduction of mechanical stresses Operation within design specifications, especially for temperature and pressure proper precautions during start-up and shutdown effective monitoring and control 24. Accumulation of pressure test in boiler? Classification Societies require that that when initially fitted to boilers safety valves must be subjected to an accumulation of pressure test to ensure the valves are of the correct discharge capacity for the boiler.
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Anoop Vijayakumar
40. How aluminum is welded? TIG (Tungsten Inert Gas) welding, also called a GTAW (Gas Tungsten Arc Welding), is the best method of welding aluminum. Spray the aluminum with acetone Rinse the aluminum in water, just in case theres any nasty residue. The aluminum should be completely dry before welding. Use a stainless steel brush to scrub the aluminum shiny clean around the area to be welded in one direction Clamp your work to a heat sink made of copper or aluminum Preheat before welding upto 275 deg to 500 deg but optimum temp. is 350 deg. If the tungsten gets contaminated, stop welding and fix it. When the tungsten gets touches the weld pool or the filler, the arc becomes unstable and the weld quality goes way down. The best method for fixing this is to remove the tungsten, lay it on a flat surface with the contaminated part hanging over the edge, hit the contaminated part of the tungsten (it will snap right off), reinstall the tungsten, change the polarity to DCEP (direct current electrode positive), strike an arc on some scrap metal to re-ball the tungsten, switch back to AC high, and you're ready to weld again. Fit the parts together as tightly as possible leaving no gaps. The tighter the pieces are pressed together and the fewer the gaps, the easier the welding is. Use one amp per .001" of material thickness. Set the amperage a higher than the maximum you expect to use and use the foot pedal to back it down. Use pure tungsten for aluminum. Use a 1/16" pure tungsten for 30 to 80 amps Use a 3/32" pure tungsten for 60 to 130 amps Use a 1/8" pure tungsten for 100 to 180 amp Use 15 to 20 CFH Argon flow. Use a filler rod size equal to the tungsten size. Adjust the tungsten to project from the hood a distance roughly equal to the diameter of the tungsten. The arc length should be roughly equal to the diameter of the tungsten.
46. What is setting for safety valves? One safety v/v is to be set at 3% of working pressure and other v/v slightly more (0.5bar) and superheater safety v/v at lesser pressure (sup v/v= blr v/v 0.35bar pr drop across superheater) CRANK CASE INSPECTION (20 points) 1. Firstly check the oil condition for any smell,discolouration or degradation. 2. Turn the Engine to BDC & start checking from under stuffing box area for any signs of black oil, if so indication of stuffing box leaking. 3. Check piston rod surface for scoring marks & roughness. 4. Check Piston palm bolts & locking device for slackness & fretting. 5. Check guide & guide shoe bearing general condition & area around frame where guide is attached for any visible cracks. 6. Check guide shoe end cover bolts in place & notslack. 7. Check cross head general bearing condition.
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Anoop Vijayakumar
Anoop Vijayakumar
72. Why ME foundation bolts have long sleeve? Long sleeve bolts have high resilience. Also they have higher value of elastic strain when in tension. Owing to the length bending moment is reduced in the bolt because radius of curvature of the bolt will be much larger when bend. 73. ME main bearing removal? Top Main bearing clearance: max- 0.58mm, min- 0.40mm. The procedure for opening of the main bearing is as follows: 1) Inform company and take permission. 2) Take immobilization certificate from port state Authority stating that the main engine will not be available for a particular period of time. 3) Read the manual and have a toll box meeting with everyone involved in the job. Discuss the procedure. 4) Prepare important tools and spares to be used in operation. 5) Prepare risk assessment with the personnel involved in operation. 6) Shut starting air valve for main engine. 7) Open indicator cocks of all the units. 8) Engage turning gear and put it in remote control. The remote control switch to be operated by in charge of the operation. 9) Stop main lube oil pump. 10) Open crank case doors.
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Anoop Vijayakumar
75. How to order hydraulic pipes? For ordering hydraulic pipe, we need working pressure, symbol of standard ( ost1/ost2). Schedule 80120, manufacturing process s-c, e-c, outside diameter, thickness and length is optional because standard length is 4 metres and sold by weight, and made of carbon steel 76. Difference between ship side v/v and overboard v/v? SHIP SIDE VALVE IS A BUTTERFLY VALVE I.E, sea suction valve, where as overboard valve is a screw down non return globe valve, as per the classification society requirements and overhauling procedure is same like checking for corrosion and pitting marks and checking the rubber lining in case of butterfly valve. Material is copper nickel alloy or monel metal for disc and seat and body is nickel alloy. . 110. Reefer system meat room solenoid coil burnt... no spares...how to maintain meat room temp? There will be a bypass v/v, if it is there then bypass the v/v, if not then close the main v/v before that and open the solenoid v/v and take out v/v assembly with the spring, put back the cover and open the main v/v,after achieving the desired temp close the main v/v, after some hours when the temp. is up again open the v/v and regain the temp
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Anoop Vijayakumar
Anoop Vijayakumar
112. What is the course of action after finding that a bottom end bolt is slackened? a. Check the length of the bolt b. Check whether it is within the limits c. Check for cracks / surface finish. Check the threads d. The tie rod can be rolled over a flat surface coated with Prussian blue. Any twists in the rod are revealed by the Prussian blue lines on the tie rod which get adhered along the twisted plane e. If found alright, tighten the bolt and check the remaining bolts Gear pump suitable for operating up to 25bar and can achieve displacement volume of 0.35~1.0 liters/revolution Clearances between the gear teeth and the housing are of the order 0.02~0.03mm 119. What are the reasons for short cycling of a refrigerant compressor? a. Refrigerant charge is too low b. Frosting or clogging of the evaporator c. Dirty suction strainer d. Low pressure control differential too small e. Wrongly adjusted capacity regulator f. Refrigerant vapor in the liquid line g. Too much cooling water h. TEV faulty i. Too high compressor capacity What actions do you take incase of an EGB Soot fire? The oxygen levels in the EG Boiler/Economizer is about 14~16%, so this can support combustion. The nature of combustible deposits include soot from the combustion of fuel in the plant as well as some amount of unburnt oil (fuel and lube oil), particularly at low loads . Ignition of soot may arise at sufficient high temperature of the layer of the soot whose surface temperature may go up to 300~400C, but presence of unburnt oil may lower this temperature to about 150C and under favorable conditions to about 120C. SMALL SOOT FIRES: Mainly occurs during maneuvering with the engine being operated at prolonged low loads. The situation may arise even at short low load running if the fuel is bad. Indications: a. High economizer exhaust gas outlet temperature b. Sparks from the funnel c. Engine running parameters showing deviations due to increased exhaust back
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136. Air bottle maintenance and inspection a. Regularly drain the bottle of water and oil b. Regular inspection to ensure that the internal condition of the bottle is good c. Check for corrosion both externally and internally d. Inside coating, COPAL varnish condition to be checked to ensure that it is unbroken and no peeling is taking place e. Welding seam to be checked, carry out dye-penetrant test at suspected areas f. The tell tale hole between the lap welding seams of the doubler plate / ring to be checked for leaks in service to ensure that the internal welding is intact g. Face of the man hole is to be checked for pitting marks h. Drain should be clear i. All points of high stress and corrosion are to be thoroughly checked viz. welds, supports braces, the bottom of the bottle where water/oil is collected. Pay attention to the zone of water line. j. Check for leaks at the mounted valve glands/flanges, carry out inspection of the valve face and seat for wire drawing effect k. A timing check with the air bottle completely charged and isolated will give a good idea of the intactness of the pressure vessel l. The safety/relief valve setting to be inspected as per the class requirement m. Regularly check the alarms and monitoring equipment for proper functioning 137. Explain the air bottle entry procedure a. Inspection is to be carried out when the receiver capacity is not required for maneuvering b. Receiver properly isolated, depressurized and notice pasted c. The internal pressure is to be checked by the pressure gauge and by opening the drain valve d. Open the manhole door carefully and ventilate the air bottle e. Obtain an enclosed space permit and comply with it f. Ventilation is to be maintained during the entire time of enclosed space entry
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138. What action should be taken in case of corrosion/wasting observed on air bottle? MINOR: clean the site of corrosion, observe the varnish manufacturer instructions for surface finishing prior applying the coat. Apply new coat of the varnish. MAJOR: The site has to be cleaned and revarnished as above. The air bottle has to be derated. Incase of excessive the entire bottle has to be replaced. The derating procedure should be carried out as follows: a. The extent of the derating is determined by the class surveyor to a value which ensures the safe limit of the hoop stress at this reduced thickness of the shell plating b. The derating should not violate the starting air requirements for consecutive starts of the main propulsion engine c. The setting of the safety/relief valve, should be set not exceeding 10% of the maximum working pressure after derating d. The cut in and cut out pressure switches for compressor automation should be readjusted For these reasons the air pressure vessels on board ship are fabricated to allow for derating in future still complying with the consecutive start requirements of the propulsion engine 140. What is the routine maintenance, checks on the PV breaker? CHECKS: a. Check the seal liquid periodically and replenish the liquid in case Liquid levels of inner and outer pipes do not coincide 0 points of inner and outer pipes do not coincide when the pressure inside the cargo tanks is atmospheric pressure b. Clean the flame screen in the cover at the top when the ships makes a dock-in CHECKING PROCEDURE: a. Checking the liquid level of the inner pipe (open the vent cock located at most top of the gauge, close the upper gauge cock and open the lower gauge cock) this is also termed as bigger range b. Checking the liquid level of the outer pipe (close the vent cock, open the upper gauge cock also open the lower gauge cock) this is also termed as smaller range Two distinct scales are provided for the liquid gauge one higher and other lower the respective readings (as in a and b) should match numerically 144. Soon after complete overhauling a generator engine, its lube oil consumption increases. What checks do you carry out in this regard?
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The method of turbocharger isolation may be done in a number of ways depending on the nature of damage. Bypass arrangement: Turbocharger is bypassed of exhaust gases by a suitable bypass pipe. Turbine inlet and outlet are isolated by fitting blanks and by pass pipe is fitted to give a suitable gas path. The compressor side also requires isolation to prevent loss of scavenge air due to back flow from the receiver. Cooling water and lubricating oil systems may also require isolation if casing and or seal is damaged. Rotor removal: If the rotor is damaged it should be removed for repairs. The openings of the casings should be blanked to prevent internal and external leaks of exhaust gas or air. Cooling of the casing should be effected as exhaust gases still pass through the casing. Locking of rotor: If requirement of propulsion is of concern and time is limited, rotor is locked into position by attaching the appropriate fixtures provided by the maker. An orifice plate should be inserted on the compressor side to allow a controlled amount of scavenge air to effect cooling. Cooling water to the casing should also be continued since exhaust gases pass through the casing. Isolation of the lubrication system may be necessary due to lack of sealing air. The limits of engine load depend on the actual configuration of the system and how many turbochargers remain in operation. A broad consideration of the following points should be made: a. The actual operating temperatures should be taken into account and limits should not be exceeded b. Condition of the exhaust should be monitored to ensure acceptable combustion inside the cylinder c. Allowance should be given for rate of change of air supply during acceleration of the engine d. Remaining turbochargers should be also monitored for abnormal operation due to altered gas flow e. Auxiliary air supply should be provided where possible, but this may be effected by remaining turbochargers in operation Internal water leaks: In the event of a holed water jacket it is possible to operate the turbocharger as an air cooled unit by supplying compressed air as the coolant after isolating the water supply. Attention must be paid to the operating temperatures of the casing, and bearings especially turbine end.
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183. How is an engine lube oil sample collected? Sampling points for an engine lube oil are clearly mentioned by the maker of the engine. In any case, the following points are to be adhered to a. Sample of lube oil should be drawn from the inlet to the engine b. Before collecting a sample some amount of oil is to be drained from the sampling point. Later sufficient amount of oil should be collected into a clean container, decanted and collected in a clean sampling bottle c. Engine should be in operation as close as possible to the MCR for some time before collecting a sample d. The sampling container should be unused one specially produced for lube oil sampling e. After collecting a sample in the bottle, it should be stored in a cool dry place to let the oil cool down before securing it with cap/seal. This is essential to prevent slight condensation in the bottle f. The sample should be fully identified with the date, vessel name, running hours of the engine, lube oil running hours, sampling point identification g. Each time the sample should be drawn from the same point 184. Explain onboard testing of lube oil Some or all of the testing explained below is done onboard ship. 1. FLASH POINT (Pensky Martin Apparatus) This method determines the flash point of the lube oil sample in a closed cup. This gives the lowest possible ignition point of the oil. A portion of the lube oil sample is slowly heated at a constant rate, whilst continual stirring is provided. A small flame is directed through an open shutter at regular temperature intervals, with simultaneous interruption of stirring. The flash point is the lowest point at which the application of the test flame causes the vapor above the test point to ignite. For a new oil the flash point should be above 220C, and any reduction would indicate fuel oil contamination. 2. BASE NUMBER BN tester kits are provided onboard to determine the alkaline properties of the lube oil. These testers use the chemical reaction of a reagent with the alkaline lube oil additive (calcium) to produce a pressure rise. 10ml of oil is mixed with equal volume of a reagent. 10ml of another reactive reagent is placed in a plastic cup, which is floated on top of the oil and reagent. The testing unit is sealed and thoroughly mixed. The resultant pressure rise is directly read on an calibrated pressure gauge against base number. 3. KINEMATIC VISCOSITY Onboard testing lube oil for viscosity is by the use of a comparative flow stick. This measures the relative flow between two oils, usually a sample of the in-use lube oil is measured against a fresh unused sample of the same grade of lube oil. The flow stick is filled with 3ml of each oil in each reservoir, once both the oils are at the
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