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ECSU (M & S)/Function 1 EKG/Vers No.1/April 2013 1
To Be A World Class Maritime Academy
LEARNING GUIDE
Name of Course : Combined Chief and Second
Engineer Unlimited Voyage
For 3000 kW or more
Course Code : ECSU
Module : Function 1 (EKM & EKG)
Subject : Marine Engineering (EKM/EKS & EKG)
Instructional Hours Lecture : 180 hours
Practical : 0
Total Contact Hours : 180 hours
Self Learning : 300
Total Hours : 480 hours
Entry requirements : Watchkeeping Engineer 750
kW or more
Subject Aims :
The course is designed to provide the students with the knowledge and
understanding necessary to prepare him/her for the Chief and Second Engineer
Officer (Motor/Steam) Certificate of Competency for Unlimited Voyages.
Teaching MethodThe course shall be conducted in a combination of classroom lectures, and self-
learning exercises.
Self learning topics are identified in italics.
Assessment MethodLecturers’ Class Assessment : 20%
Mid Course Test : 30%
Final Exam : 50%
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ECSU (M & S)/Function 1 EKG/Vers No.1/April 2013 2
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Recommended Texts
1.
Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical.
2.
Dr J Cowley (1992), The Running and Maintenance of Marine
Machinery, Marine Management (Holdings) Ltd for The Institute of
Marine Engineers.
3.
Leslie Jackson (1992), Instrumentation and Control Systems, Thomas
Reed Publications Limited.
4.
MARPOL 73/78 Consolidated Edition (2002), International Maritime
Organization.
5. Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine Engineering,
Science and Technology.
6. http://www.imo.org
7.
http://www.dnv.com 8.
http://www.imarest.org
9.
http://marineengineering.org.uk
10.
http://www.engineersedge.com/pumps/pump_menu.shtml
11.
http://www.navis.gr/safety/occupatl/safety_m.htm
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Note 1: The letters K, U, A and I in the table of specifications
denote the K nowledge, Understanding (Comprehension),
A pplication and Integration (Higher than Application) levels
of Bloom’s taxonomy in the cognitive domain.
Note 2: In the following detailed syllabus, all objectives
should be understood to be prefixed by the words “At the endof the lecture, the learner should be able to…”. In the second
column, L : SL denotes the number of instructional hours
devoted to lecture and self learning respectively.
Main Objectives
Fundamentals of Instrumentation, Automation and Control SystemsAt the end of the course, the learner should be able to:
1. Describe the function of a transmitter or transducer
2. Describe the flapper and nozzle arrangement
3. Describe the conditions which may dictate the need for a positioner
4. Describe the principal features of a positioner
Table of Specifications
TopicsWeightage%
Total K U A I
A. Propeller and Shafting, ShaftFittings, Thrust Block and
Bearing
1 11 0 0 12
B. Pumps 1 6 1 0 8
C. Steering System 1 5 0 0 6
D. Hydraulic Gear 0 1 0 0 1
E.Refrigeration, Air Conditioning
and Ventilation 1 6 1 0 8
F.Heat Exchangers, Evaporators
and Domestic Water Supply0 4 0 0 4
G. MARPOL 73/78 1 7 0 0 8
H.Chemistry of Fire and
Extinguishing Agent 2 9 2 2 15
I.Fundamentals of Instrumentation,
Automation and Control Systems 0 14 1 0 15
J.Physical and Chemical Properties
of Bunkered Fuels and Lubricants 1 13 1 0 15
K. Technology of Materials 0 8 0 0 8
Total 8 84 6 2 100
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ECSU (M & S)/Function 1 EKG/Vers No.1/April 2013 4
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5. Sketch a graph illustrating control by a two-step controller
6. Make a single line sketch of a self-operating liquid level controller and
explain its proportional control action
2.
Explain the meaning of proportional band
3. Explain that the object of integral control is to reduce offset to zero
4.
Sketch a P & I control loop for controlling liquid level
5. Explain that the object of derivative control is to give quicker response
to a large change of load and to supplement inadequate proportional
damping of control
6.
Sketch a (P + D + I) control loop for controlling liquid level
7.
Describe applications of split-range control
8. Describe the cascade control of the outlet temperature of diesel engine
jacket cooling water with varying engine load and varying supply of
cooling water
9. Describe the lighting-up sequence of an automatic combustion system
for an auxiliary boiler
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be
provided during lectures.
1.
Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical.
2. Leslie Jackson (1992), Instrumentation and Control Systems, Thomas
Reed Publications Limited.
Students are advised to study the relevant Chapters in the above mentioned
books and ensure the following aspects are understood:
Fundamentals of Instrumentation, Automation and Control Systems
1. Telemetering, Chapter 11, Page 452-457
Study signal transmitters and transducers.
2. Terminology, Chapter 11, Page 457-458
Be familiar with control terminology.
3.
Control Actions, Chapter 11, Page 458-463
Study the three basic control actions: proportional, integral andderivative.
4.
Control Systems, Chapter 11, Page 463-470
Study typical control systems such as fluid temperature control,
automatic boiler control, and bridge control.
5.
Final Control Elements, Chapter 8, Page 115-126
Refer to the operation of control valves, valve positioners and
servo-motors. 6. Process Control Theory, Chapter 9, Page 127-155
Further reference to terminology, and proportional, integral and
derivative control actions.
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ECSU (M & S)/Function 1 EKG/Vers No.1/April 2013 5
To Be A World Class Maritime Academy
7.
Pneumatic Control Principles, Chapter 10, Page 157-169
Study pneumatic two step control, and pneumatic proportional, integral
and derivative controls.
8.
Electronic Control Principles, Chapter 11, Page 171-183
Understand electronic two step control, and electronic proportional,
integral and derivative controls.
9. Actual Controller Types, Chapter 12, Page 185-202
Refer to actual types of controllers used in practice such as
mechanical-hydraulic controller, electro-pneumatic controller,
electronic P.I.D. controller, pneumatic controller for fuel-air ratio and
pneumatic controller for viscosity.
10. Typical Control Circuits, Chapter 13, Page 203-237
Study typical control circuits such as sootblower control, steam
temperature control, jacket temperature control, bridge control and
refrigeration control.
Key Questions1.
Give a reasoned explanation of how Wheatstone Bridge networks are
employed in circuits of electrical resistance thermometers.
2.
Sketch and describe an explosive gas sampling device illustrating the
function of the Wheatstone Bridge.
3.
Sketch and describe a remote boiler water level indicator explaining its
principle of operation.
4. Illustrate how a Venturi tube or orifice plate can be used to generate a
pressure drop for fluid flow through a pipe. Express Bernoulli’s
equation in terms of kinetic and potential energy, and deduce therelationship between mass flow rate and differential pressure.
5.
Illustrate how a Bourdon tube can be used to convert a pressure
variable into an electric signal for pressure indication.
6.
With reference to control system, explain with the aid of simple
graphs, the difference between:
a. deviation and offset,
b. proportional without integral action and proportional with integral action,
c.
integral action and derivative action.
7. Sketch and describe a pneumatic flapper nozzle mechanism in which accuracy
is of importance but speed of action is insignificant.8. Explain what is meant by the following terms:
a.
Fail Safe
b. Ratio Control
c. Hysteresis Loop
d. Proportional Band
9. Explain briefly what is meant by the following terms:
a.
Cascade control system
b.
Split-range control system
c. Valve positioner
10. Sketch an auxiliary boiler automatic combustion control system.a.
Explain how it operates.
b.
Specify typical safeguards and interlocks provided.
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Additional Questions
1.
Explain the principle of operation of an oxygen analyser.
2.
Explain the difference between level type and comparator type of oil
mist detectors.
3.
Explain the principle of operation of a viscosity controller.
4.
Illustrate how a square root extractor may be used to eliminate the non-
linear relationship between flow and differential pressure.
5. Describe the requirements for UMS operation.
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Main Objectives
Heat Exchangers, Evaporators & Domestic supplyAt the end of the course, the learner should be able to:
1.
Understand how heat exchange is effected using various types of heat
exchangers.
2. Explain the constructional features of regularly used heat exchangers
such as shell & tube design, plate type and extended surface types.
3.
Explain what types of exchangers are best suited for cooling duties,
heating duties as also depending on the fluids involved.
4. Explain normal maintenance of heat exchangers such as mechanical
cleaning and chemical cleaning.
5. Explain operational problems such as tube leaks and methods of fixing
them.
6.
Understand methods of producing fresh water on board.7.
Explain the working of a typical, low pressure fresh water generator
employed on board.
8.
Explain normal maintenance such as SAF acid cleaning and chemical
dosing.
9.
Explain operational problems such as loss vacuum and methods to
overcome.
10. Understand that water used for human consumption needs to be treated
and the methods employed on board such as carbon bed filtering, silver
ion sterilizing and UV.
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be
provided during lectures.
1. Leslie Jackson and Thomas D Morton, General Engineering
Knowledge for Marine Engineers, (2003), Adlard Coles Nautical
2. McGeorge H D, Marine Auxiliary Machinery, (2002), ISBN 0 7506
4398 6, Butterworth Heinemann
Students are advised to study the relevant Chapters in the above mentioned
books and ensure the following aspects are understood:
Heat Exchangers, Evaporators & Domestic supply1. Students must understand the various expansion arrangements
provided in the heat exchangers.
2.
Students must be able to explain the construction and function of
regenerative condensers.
3.
Students must be able to explain the relative advantages anddisadvantages between shell & tube design and plate type of heat
exchangers.
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ECSU (M & S)/Function 1 EKG/Vers No.1/April 2013 8
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4.
Students should be able to estimate the normal fresh water
requirements for personnel as well as machineries.
5.
Students should be able to explain the limitation of fresh water
generator operation close to coast line.
6. Students should understand and explain the use of eductors in air and
water side of the shell as also the importance of maintaining the brine
density.
7. Students must be able to explain the harm of excessive Chlorine dosage
in fresh water treatment
Key Questions
Heat Exchangers, Evaporators & Domestic supply1. Sketch & label a shell and tube heat exchanger. Show the provision for
expansion as also protection for corrosion.2.
Plate type of heat exchangers are limited in their application.
Discuss how the limitations are being overcome by way of design.
3.
Explain the principle of reverse osmosis. Sketch a simple RO plant
circuit, labeling the relevant parameters.
Additional Questions
Heat Exchangers, Evaporators & Domestic supply
1. Illustrate the following flow patterns used in heat exchangers with
sketches:
a. Parallel b. counter c. cross d. mixed2. Tabulate the materials and components commonly used in heat exchangers.
3. Describe a central cooling system, explaining how coolant temperatures are
maintained.
4. Explain the purpose of: the demister, eductor, salinometer and a relief valve
in an evaporator.
5. Explain how the density is controlled in a two stage flash evaporation plant
6. Briefly explain with sketches how automatic fresh water and sanitary water
systems work
7. Explain how additives in diesel engine cooling water and seawater
inhibitors could be harmful to drinking water.
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To Be A World Class Maritime Academy
Main Objectives
MARPOL 73/781. Summarize the implications of MARPOL 73/78 with respect to the
various annexes in relation to marine engineering processes
2. Describe, in principle, how bilge and ballast water are discharged
3. Describe the requirements for oily-water separators
4. Explain the purpose of the oil record book and how it is used
5. Describe a sewage retention system
6.
Explain why vacuum transportation systems are used
7. Describe the processes in a biological treatment plant
8. Describe the operation of chemical treatment plants
9. Explain how liquid and solid waste are prepared for combustion in an
incinerator
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be
provided during lectures.
1.
Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical.
2. MARPOL 73/78 Consolidated Edition (2002), International Maritime
Organization.
Students are advised to study the relevant Chapters in the above mentioned books and ensure the following aspects are understood:
MARPOL 73/781.
Oily Water Separator, Chapter 10, Page 381-388
Study the IMO requirements for oily water separators.
Study the operation of automatic valve operation combined with alarm
and protection circuits.
2.
Sewage and Sludge, Chapter 9, Page 390-393
Study the various types of sewage treatment plants.
What are the advantages of chemical treatment plants?3.
Regulations for the Prevention of Pollution by Oil, Annex I, Chapter I
– General, Page 45-50
Refer to Regulations 1 and 2 on definitions and application for Annex I
4. Requirements for Control of Operational Pollution, Annex I, Chapter
II, Page 58-95
Study Regulations 9 to 20 on the control of discharge of oil outside of
and within special areas, exceptions, reception facilities, segregated
ballast tanks, dedicated clean ballast tanks and crude oil washing,
segregation of oil and water ballast and carriage of oil in forepeak
tanks, retention of oil on board, oil discharge monitoring and controlsystem and oil filtering equipment, tanks for oil residues, pumping,
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ECSU (M & S)/Function 1 EKG/Vers No.1/April 2013 10
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piping and discharge arrangements of oil tankers, standard discharge
connection, and oil record book.
5.
Regulations for the Control of Noxious Liquid Substances, Annex II,
Page 243-253
Understand Regulations 1 to 5 on definitions, application,
categorization and listing of noxious liquid substances, and the
discharge of noxious liquid substances.
6. Regulations for the Prevention of Pollution by Harmful Substances
Carried by Sea in Packaged Form, Annex III, Page 363-366
Understand Regulations 1 to 8 on application, packing, marking and
labeling, documentation, stowage, quantity limitations, exceptions, and
port state control on operational requirements.
7. Regulations for the Prevention of Pollution by Sewage from ships,
Annex IV, Page 373-379
Study Regulations 1 to 11 on definitions, application, surveys, issue,
form and duration of certificate, discharge of sewage, exceptions,reception facilities, and standard discharge connections.
8.
Regulations for the Prevention of Pollution by Garbage from Ships,
Annex V, Page 385-392
Understand Regulations 1 to 9 on definitions, application, disposal of
garbage outside special areas, special requirements for disposal of
garbage, disposal of garbage within special areas, exceptions, reception
facilities, port state control on operational requirements, and placards,
garbage management plans and garbage record- keeping.
9. Regulations for the Prevention of Air Pollution from Ships, Annex VI,
Chapter I – General, Page 399-401Refer to Regulations 1 to 4 on application, definitions, general
exceptions, and equivalents.
10.
Regulations for Control of Emissions from Ships, Annex VI, Chapter
III, Page 408-416
Study Regulations 12 to 18 on ozone-depleting substances, nitrogen
oxides, sulphur oxides, volatile organic compounds, shipboard
incineration, reception facilities, and fuel oil quality.11. Amendments/Changes in Calendar Year
Key Questions1. With respect to Annex I of MAROL 73/78, identify the special areas?
2. In accordance with Annex I of MARPOL 73/78 concerning special areas, what
restrictions apply with respect to the discharge into the sea within such areas of
oil or oily mixture other than processed bilge water from a ship of less than 400
tons gross tonnage other than an oil tanker?
3. With reference to Annex I of MARPOL 73/78:
What are the conditions as per regulation 9 which need to be satisfied before an
oil tanker could discharge oil or oily mixtures into the sea?
4. With reference to Annex I of MARPOL 73/78:
State the “Exceptions” to the control of operational discharge of oil such that
uncontrolled discharge may be justified.
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5.
What are the conditions which need to be satisfied with respect to Annex I of
MARPOL 73/78 concerning special areas before discharging processed bilge
water from machinery spaces into such areas?
6. What is the role of Port State control on operational requirements as specified in
Annex I of MARPOL 73/78?
7. What type of oil filtering equipment is needed to satisfy the requirements of
Annex I of MARPOL 73/78?
8. List out the machinery space operations which would require entry into the
ship’s Oil Record Book Part I.
9. With reference to Annex IV of MARPOL 73/78, explain the regulations
governing the discharge of sewage waste from a ship into the sea areas outside
special areas.
10. In accordance with Annex VI of MARPOL 73/78, state the global limit for the
sulphur content of any fuel used onboard ships, and the sulphur content limit
within a SECA.
Additional Questions1.
What is the specific restriction with regard to the discharge into the sea of oil or
oily mixtures within the Antarctic area as stated in Annex I of MARPOL 73/78?
2.
Which authority has the right to inspect the Oil Record Book Part I, and
subsequent to such inspection, what other actions may be taken by such
authority with regard to this book?
3.
What are the various annexes specified under MARPOL 73/78?
4.
Which are the annexes of MARPOL 73/78 to which Malaysia is a party to?
5.
Sketch and fully label a biological treatment plant that can satisfy the
regulations of Annex IV of the MARPOL Convention.
6. List five problems that may arise during the operation of a ship’s biological
sewage treatment plant which may cause the effluent to be unsuitable to be
discharged overboard.
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Main Objectives
Propeller and Shafting, Shaft Fittings, Thrust Block & BearingAt the end of the course, the learner should be able to:
1.
Describe in principle how shafting is lined up at the initial stage
2. Explain how the propeller is secured to the tail shaft
3. Sketch a coupling arrangement which would allow outward removal of
the tail shaft
4.
Given a drawing of a water-lubricated stern tube as fitted in a ship with
its tail shaft and propeller, name and explain the function of all of the
components and their features
5. Given a drawing of an oil-lubricated stern tube, name and explain the
function of all components and their features
6. Describe the typical seals used at each end of the tail shaft
7.
Describe the arrangement of a withdrawable stern gear.8.
Given a diagrammatic arrangement, explain how the pitch of a
propeller is controlled
9.
Explain the principles of a torsion meter
10.
Explain how the propeller thrust is transmitted to the ship’s structure
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be
provided during lectures.
1.
Leslie Jackson and Thomas D Morton, General Engineering
Knowledge for Marine Engineers, (2003), Adlard Coles Nautical
2.
Dr J Cowley, The Running and Maintenance of Marine Machinery,
(1992), Marine Management (Holdings) Ltd for The Institute of
Marine Engineers
3. Christensen Stanley G , Lamb’s Questions and Answers on Diesel
Engines (2000),ISBN 0 852 643071, Arnold, Hodder headline Group
4. McGeorge H D, Marine Auxiliary Machinery, (2002), ISBN 0 7506
4398 6, Butterworth Heinemann
Students are advised to study the relevant Chapters in the above mentioned
books and ensure the following aspects are understood:
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Propeller and Shafting, Shaft Fittings, Thrust Block & Bearing
1.
Shafting: Alignment,
Older alignment methods used piano wires and micrometers and feelers
between coupling faces, whereas modern methods utilize optical
telescopes/lasers and targets giving accuracies of 2m per 1 m
length. To fully describe the methods it will be assumed that the
shafting and engine are first lined up by the older method, being
checked at each stage by the modern method. Students should
understand the alignment concept and the adjustments made in the
stern tube by slope boring.
2. Shafting: Bearings, Couplings and Bolts
The concept of fair curve alignment must be studied and Students
should be able to demonstrate how load-Deflection curves are
generated in dry-docks. Students should be able to explain the concept
of Poisson’s ratio and how it relates to bolts as also how this problemis overcome by designs employing hydraulics.
3.
The Propeller Shaft and Stern tube:
Water lubricated stern bearings are being employed with better
sophistication in design and materials to mitigate the problem of oil
pollution. Study the water lubricated type and the oil lubricated type of
propeller shaft and stern tube, and their sealing arrangements. Students
should be able to explain the concept of a withdraw able stern gear
system and the alternative stern gear with shaft withdrawal aft or
inboard. Students should comprehend the function of inflatable seal
and advantages of such arrangements and also the importance ofachieving nil leakage if the seal gives way.
4. Propeller Mounting & Removal:
Students should be able to describe the various methods of fitting the
propellers and removal procedures adopted.
5. Controllable Pitch Propeller:
Students should be able to cite reasons for using controllable-pitch
propellers. Students should be able to describe the mechanism for
changing the pitch as also the emergency arrangements in case of
hydraulic system failure.
6. The Thrust BlockStudents should be able to explain how the concurrence in the thrust
surfaces help in forming the wedge and the hydrodynamic lubrication
film.
Key Questions
Propeller and Shafting, Shaft Fittings, Thrust Block & Bearing 1. Sketch and describe a Pilgrim nut for a propeller. Explain how it is
used when fitting the propeller on to the shaft taper. State two
advantages this type of nut has over a conventional propeller nut.
2. What is the purpose of putting a thrust bearing between the mainengine and the propeller? How is the thrust bearing cooled?
3. Sketch and label a lip seal arrangement employed in a stern tubes.
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4. With sketches, explain the advantages of a radial shaft seal fitted on tail
shafts.
5. Sketch and list down the procedure for tightening and releasing a muff
hydraulic coupling
6. Explain how following clearances are taken:
a. Propeller drop or Stern bearing wear down
b. Thrust pads
7. Explain actions taken if: a. Stern tube tank levels are dropping b. stern
tube tank levels are increasing.
8. List the advantages and disadvantages of a Controllable Pitch
Propeller.
Additional Questions
Propeller and Shafting, Shaft Fittings, Thrust Block & Bearing
1.
Sketch and write brief notes on different types of bolts used inshafting.
2.
Sketch and label a self-aligning type of line shaft bearing (axial)
and briefly describe its construction and working.
3.
Sketch and label a tilting pad type of line shaft bearing (radial) and
briefly describe its construction and working.
4.
Sketch and label a roller type of line shaft bearing and briefly
describe its construction and working. Point out how minimal
misalignments are accommodated in this type of bearing.
5. Draw the line sketch of a conventional stern tube oil lubrication
system. Discuss how leakages are noticed and how they may bedealt with.
6.
Sketch the hub detail of a controllable pitch propeller. Explain, in
steps with simple sketches how the pitch variation is
accomplished.
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Main Objectives
Physical and Chemical Properties of Bunkered Fuels and Lubricants1. Name the three types of crude petroleum and state the characteristics
constituent of their residues after distillation. Name the four main
series of hydrocarbons that are in petroleum.
2.
Define Viscosity- kinematics viscosity and dynamic viscosity. Explain
“viscosity index”.
3. Explain fire point, flash point, pour point, carbon residue, CCAI,
cetane number. Explain the ignition quality of a fuel. Explain how
‘knocking’ occurs. Explain that the higher the cetane number the better
the ignition quality. Describe the common relationship between
density, viscosity, flash point and calorific value of common marine
fuels.
4. Describe oil filtration methods. Explain the principles of an oil and
water centrifuge. Explain the factors which govern the limiting particle
size in a large bowl centrifuge. Describe the operation of a self-cleaning purifier.
5.
Explain the parts played by the oiliness and viscosity of a lubricant.
Describe boundary lubrication and where it occurs. Describe
hydrodynamic lubrication and the type of bearing where it can exist.
6.
Sketch a graph indicating the effect of viscosity, speed and pressure on
the lubrication of a bearing. Explain the effect of viscosity, surface
speed, bearing clearance and pressure on the lubrication of a bearing.
Describe the generation of oil films in both a journal and a Michell-
type bearing.
7.
Explain the meaning, causes, effects and remedies of: scuffing, pitting,emulsifying, oxidation, lacquering.
8.
Describe how to test lube oil for: viscosity, alkalinity, dispersiveness,
contamination, water.
9.
Explain the factors which contribute towards the formation of tin
oxides in white metal bearings, describe the effect of tin oxides present
in bearings. Explain what can be used to prevent or alleviate the
problem of tin oxides in bearings.
10.
Describe the means by which microbial degradation may be prevented
or remedied.
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be
provided during lectures.
1. Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical
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Physical and Chemical Properties of Bunkered Fuels and Lubricantsa. Liquid Fuels, Chapter 2, Page 47-50
Crude petroleum is taken under distillation processes at various pressure and
temperatures and the valuable distillates like gas oil, kerosene , lub oil extracted .
Residual fuel tapped off from the bottom of the distillation tower. As a result
Residual Fuel will carry the Asphalt and other unwanted presence of water,
aluminium and silica. Student will learn the composition of fuel oil and realize
the importance of handling residual fuel with care to prevent damage of engine
and equipments by presence of harmful objects.
b. Testing of liquid fuel and oils, Chapter 2, Page 51-65
To ensure compatible quality of fuel for the engines, certain test of fuel
properties and quantitative test of certain harmful constituent is very important.
From this chapter student will understand terms such as viscosity, viscosity
index, flash point, fire point, pour point, “carbon residue”, knocking, ignitionquality, cetane number and calorific value. And understand the common
relationship between density, viscosity, flash point and calorific value of
common marine fuels.
c.
Combustion of Sulphur, Chapter 2, Page 67-68
Presence of sulphur in fuel may finally causes corrosion on the engine
components and on the exhaust system. Student will understand the mechanism
of corrosion and how to prevent this acid corrosion.
d. Filters, Chapter 10, Page 406-412 Minute particles while penetrating to the surface like- between fuel pump barrel
and plunger, damage the components severely. To protect the machinery from
such damage filtration is of prime importance. In present days particles of 5 – 10
µm is claimed to be separated by filter technology. Students will be able to
understand the construction and operation of different type of filters.
e.
Centrifuges, Chapter 10, Page 416-425
Separation of minute particles in residual fuel and other fuel and lubrication oil
finally occurs inside the centrifuge. Students will understand the principal of
separation, operational procedure. Operational and design parameters that willaffect the limit size of particles, will be well understood. Student will be able to
distinguish a purifier from a clarifier. Student will understand the self cleaning
mechanism of a purifier.
f.
Bearing Lubrication, Chapter 10, Page 425 – 431
Oiliness and viscosity are the two most significant properties of lubricants,
contributes in boundary and hydrodynamic lubrication. Student will understand
the mechanism of both boundary and Hydrodynamic lubrication. Students will
also understand the other factors related to hydrodynamic lubrication. Student
will be able to realize that hydrodynamic lubrication exists in journal bearing andMichell bearing.
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h. Definitions, Chapter 10, Page 431-432
Student will understand terms such as scuffing, extreme pressure lubricant,
pitting, emulsion, oxidation, and lacquering, and know as how to combat the
phenomena by using quality lub oil and by maintaining the qualities of
lubricating oil.
i. Lubricating oil Tests, inspection for Microbial degradation and corrosion in
white metal bearing Chapter 10, Page 432-435
Test for TBN, Viscosity, presence of water would give early indication of failure.
Students will know as how to test for these parameters. Student will learn the
way of detecting Microbial degradation and as to the preventive and remedial
actions of Microbial degradation. In the presence of electrolytic corrosion (sea
water contamination), tin of white metal may form hard tin oxide. In this pages
student will learn the mechanism of formation fo tin oxide, appearance of tin
oxide, harmful affect of tin oxide and actions to be take to prevent formation of
tin oxide.
Key Questions
1. How was fuel used to be ordered in the old days? Explain why ordering based on
viscosity is not practiced nowadays. How is fuel specified in the present days while
placing order to the bunker traders?
2. It is necessary to define the fuel-quality over a range of parameters to which the
engine plant is sensitive. State the important parameters of marine residual fuels.
3. Proper Bunker Calculation can save a good amount of money for the company.
Explain how you will convert the volume of sounding to the volume at 15oC and
how you convert the density at vacuum to the density in air.
4. With regard to bunker, what is a representative sample? How long the sample to be
kept on board. Briefly describe the procedure of sampling in modern practice.
5. What is Bunker Delivery Note (BDN)? What parameters are to be laid down in
BDN in compliance with MARPOL Annex-VI?
6. With regard to lubricating oil properties define oiliness and viscosity. Describes
how viscosity and oiliness achieves hydrodynamic and boundary lubrication
respectively.
7. Define each of the following terms in relation to lubricating oil: pour point, flash
point, auto-ignition point, State, with reasons, when will each of these
characteristics be of primary importance.
8. Give the approximate composition , and the properties of the following metals:
manganese bronze, cupro-nickel, Babbitts metal. In each case give two examples ofthe metals in use on board ship, and explain why the metal is chosen for the
applications you mention.
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Acknowledgement
1. Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical
2. Dr J Cowley (1992), The Running and Maintenance of Marine
Machinery, Marine Management (Holdings) Ltd for The Institute of
Marine Engineers
3.
Leslie Jackson (1992), Instrumentation and Control Systems, Thomas
Reed Publications Limited
4. MARPOL 73/78 Consolidated Edition (2002), International Maritime
Organization
5. Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine Engineering,
Science and Technology
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Main Objectives
Propeller and Shafting, Shaft Fittings, Thrust Block & BearingAt the end of the course, the learner should be able to:
1.
Describe in principle how shafting is lined up at the initial stage
2. Explain how the propeller is secured to the tailshaft
3. Sketch a coupling arrangement which would allow outward removal of
the tailshaft
4.
Given a drawing of a water-lubricated stern tube as fitted in a ship with
its tailshaft and propeller, name and explain the function of all of the
components and their features
5. Given a drawing of an oil-lubricated stern tube, name and explain the
function of all components and their features
6. Describe the typical seals used at each end of the tailshaft
7.
Describe the arrangement of a withdrawable stern gear8.
Given a diagrammatic arrangement, explain how the pitch of a
propeller is controlled
9.
Explain the principles of a torsion meter
10.
Explain how the propeller thrust is transmitted to the ship’s structure
Pumps1. Name the two basic types of pump
2. List the factors which influence the selection of a pump
3. Explain how characteristics curves are obtained
Steering System
1.
Describe the basic control system for a steering gear
2.
Describe the principle of operation of an electrical telemotor
3.
Explain how a ship is steered if there is a failure in the telemotor
system
4.
Explain how, in a Hele-Shaw pump, the volume and direction of oil
discharge are controlled
5. Explain how, in a swash plate pump, the volume and direction of oil
discharge are controlled6.
Sketch a diagrammatic arrangement of a four-ram steering gear,
illustrating:
a.
connections from two hydraulic oil power units
b.
emergency hand pump connection
c.
rudder-shock relief valves
d. all isolating or bypass valves for emergency operation
7. Describe a rotary vane unit
8. Explain that both the main and auxiliary steering gears, which could be
identical units, must be kept operative and maintained in proper
working order and that both need to be in operation at the same time in
some situations
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9. Explain that control of the steering gear must be available both on the
navigating bridge and in the steering compartment
Hydraulic Gear 1. Describe the common uses of hydraulic power on ships
2.
Describe the type of pump, fittings and equipment used in hydraulic
systems
Refrigeration, Air Conditioning & Ventilation1. State the function of each of the components, and briefly describe their
operation
2. Describe the controls used to operate the plant automatically
3.
Describe the symptoms of the following:a.
undercharge of refrigerant
b.
overcharge of refrigerant
c.
oil in the system
d.
presence of air in the refrigerant
e.
a partial blockage at the regulator
f.
leakage of refrigerant
4. Explain what is meant by:
a. direct expansion
b. secondary coolant
c.
grid coolingd.
battery cooling
5. Describe a simple air-conditioning system suitable for supplying a
living space with conditioned air and using recirculation
6.
Describe the areas in a psychrometric chart which is known as the
‘comfort zone’ , being the air condition necessary for personal comfort
in living spaces
Heat Exchangers, Evaporators and Domestic Water Supply1. Describe the following flow patterns as used in heat exchangers:
a.
parallel b.
counter
c.
cross
d. mixed
2. Explain the factors which decide whether flow is streamline or
turbulent
3. Explain how the differential expansion and contraction is allowed for
in heat exchangers
4.
Describe the materials commonly used in heat exchangers
5.
Describe the attention required to maintain the efficiency of a heat
exchanger with reference to:a.
corrosion
b. erosion
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c.
fouling
d.
leakage
6.
Describe a central cooling system, Explaining how steady coolant
temperatures are maintained
7. Explain why central cooling systems are installed
8.
Describe the scales which are deposited in evaporators
9. Describe the principal methods used to reduce scale deposits in
evaporators, i.e.
a.
low pressure, including high vacuum
b.
magnetic treatment
c.
flexible elements
d. continuous chemical treatment
10. Explain the safeguards necessary to ensure that the water produced is
safe to drink
11. Describe how automatic fresh water and sanitary water systems work
12.
Explain the requirements for drinking water13.
Describe a system which is capable of supplying satisfactory drinking
water
MARPOL 73/781. Summarize the implications of MARPOL 73/78 with respect to the
various annexes in relation to marine engineering processes
2. Describe, in principle, how bilge and ballast water are discharged
3. Describe the requirements for oily-water separators
4. Explain the purpose of the oil record book and how it is used
5. Describe a sewage retention system6. Explain why vacuum transportation systems are used
7. Describe the processes in a biological treatment plant
8. Describe the operation of chemical treatment plants
9. Explain how liquid and solid waste are prepared for combustion in an
incinerator
Chemistry of Fire & Extinguishing Agent1. Explain the conditions required for fire to occur as:
b.
the presence of materials (gas, liquid or powder) which acts as a
fuelc.
a source of ignition, e.g. chemical, biological or physical
d.
the presence of oxygen, as air or from oxidizing agents
2. Describe the use of water as a fire-fighting medium
3. Describe the use of carbon dioxide as a fire-fighting medium
4. Describe the use of foam as a fire-fighting medium
5. Describe the use of chemical powder as a fire-fighting medium
6.
Describe methods of detection, and determine the suitability or
effectiveness of:
a. smoke detectors
b. high-temperature probesc. rate-of-rise-of-temperature probes
e. patrols
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7. Describe fire fighting systems, appliances and equipment, and identify
the best possible approach or action in combating fire using:
a.
fixed systems, e.g. water, foam and carbon dioxide
b.
portable appliances, e.g. water, foam, carbon dioxide and powder
c. mobile equipment, e.g. foam, carbon dioxide and powder
8. Explain how fire alarm tests are carried out to ensure alarms are in
working condition
9. Explain how fire detector tests are carried out to ensure detectors are in
working order
Fundamentals of Instrumentation, Automation and Control Systems 1. Describe the function of a transmitter or transducer
2. Describe the flapper and nozzle arrangement
3. Describe the conditions which may dictate the need for a positioner
4. Describe the principal features of a positioner
5. Sketch a graph illustrating control by a two-step controller6. Make a single line sketch of a self-operating liquid level controller and
explain its proportional control action
7.
Explain the meaning of proportional band
8.
Explain that the object of integral control is to reduce offset to zero
9.
Sketch a P & I control loop for controlling liquid level
10.
Explain that the object of derivative control is to give quicker response
to a large change of load and to supplement inadequate proportional
damping of control
11. Sketch a (P + D + I) control loop for controlling liquid level
12.
Describe applications of split-range control13.
Describe the cascade control of the outlet temperature of diesel engine
jacket cooling water with varying engine load and varying supply of
cooling water
14.
Describe the lighting-up sequence of an automatic combustion system
for an auxiliary boiler
Physical and Chemical Properties of Bunkered Fuels and Lubricants1. Name the three types of crude petroleum and state the characteristics
constituent of their residues after distillation
2. Name the four main series of hydrocarbons that are in petroleum3.
Define viscosity in simple terms
4. Explain “viscosity index”
5. Explain what is meant by the fire point of an oil and relate this to the
flash point
6. Explain the importance of the pour point
7. Explain “carbon residue”
8.
Explain how ‘knocking’ occurs
9.
Explain the ignition quality of a fuel
10.
Explain that the higher the cetane number the better the ignition quality
11.
Describe the common relationship between density, viscosity, flash point and calorific value of common marine fuels
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12.
Describe the harmful effects of sulphur trioxide in the products of
combustion
13.
Explain that fuel sample analysis may reveal:
a.
low flash point
b. high sulphur content
c.
high water content
d. high vanadium content
e. high aluminium content
f.
instability and incompatibility
14. Explain the actions to be taken to overcome the problems encountered
as stated in objective 13.
15. Describe oil filtration methods
16. Explain the principles of an oil and water centrifuge
17. Explain the factors which govern the limiting particle size in a large
bowl centrifuge
18.
Describe the operation of a self-cleaning purifier19.
Explain the parts played by the oiliness and viscosity of a lubricant
20.
Describe boundary lubrication and where it occurs
21.
Describe hydrodynamic lubrication and the type of bearing where it
can exist
22.
Sketch a graph indicating the effect of viscosity, speed and pressure on
the lubrication of a bearing
23. Explain the effect of viscosity, surface speed, bearing clearance and
pressure on the lubrication of a bearing
24. Describe the generation of oil films in both a journal and a Michell-
type bearing25.
Explain the meaning, causes, effects and remedies of:
a.
scuffing
b.
pitting
c.
emulsifying
d. oxidation
e. lacquering
26. Describe how alkalinity can be checked for lubricating oil
27.
Describe how to test lube oil for:
a.
dispersiveness
b.
contaminationc.
water
28.
Describe how viscosity can be checked for lubricating oil
29. Explain the factors which contribute towards the formation of tin
oxides in white metal bearings
30. Describe the effect of tin oxides present in bearings
31. Explain what can be used to prevent or alleviate the problem of tin
oxides in bearings
32.
Describe the means by which microbial degradation may be prevented
or remedied
33.
Relate typical test analyses to sources of problems on board ship34.
Determine the action to be taken to overcome the problems
encountered in objective 34
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Technology of Materials 1. Relate the approximate carbon content and use of:
a. mild steel
b.
medium carbon steel
c. high carbon steel
d. cast iron
2. Sketch a load - extension diagram for mild steel in tension
3. Describe how proof stress is obtained and why it is sometimes
necessary
4. Describe the principles of hardness testing
5. Explain the purpose of an impact test
6. Relate results from impact tests on common materials to their use in
marine engineering
7. Explain the meaning of brittle fracture8. Describe the factors which affect the tendency to brittle fracture
9. Explain briefly what is meant by creep
10. Describe metal failure due to fatigue
11. Explain what is meant by fatigue limit
12. Describe the factors which affect the fatigue limit
13. Describe the bend test
14. Describe the following methods of non-destructive examination of
surfaces for cracks:
a. visual
b.
oil and whitewashc.
fluorescent penetrant
d.
red dye penetrant
e.
magnetic detection
15. Explain the principles of non-destructive examination for defects
within a metal, using the following methods:
a. hammer
b. radiography
c.
ultrasonic
16. Describe the process and the effect on a medium-carbon steel of
hardening and tempering17. Explain the purpose of annealing
18. Describe the process of annealing
19. Describe examples where annealing might be necessary
20. Explain the difference between annealing and normalizing and their
applications
21. Describe conditions in marine applications where work hardening
occurs
22. Explain the measures taken to rectify or reduce the effect of work
hardening
23. Explain that the welding process involves heating, melting and coolingmetals, which affects the structure and properties of the resulting
materials
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24. Explain the principal reasons for adding the following elements:
a.
cobalt
b.
nickel
c.
chromium
d. molybdenum
e.
vanadium
f. tungsten
g. copper
h.
manganese
i.
silicon
j.
titanium
25. Give examples of marine applications of the above
26. Explain the reasons for adding the following elements to bronze:
a. manganese
b. phosphorus
c.
aluminumd.
zinc
27. Describe in general terms the range of copper-nickel alloys and their
applications in marine Engineering
28. Compare the approximate analyses of both tin and lead based white
metals and the use for which they are suited
29. Describe the applications of and the reason for using the following
materials:
a. nitrile rubber
b. neoprene
c.
P.T.F.Ed.
epoxy resin
e.
rubber
f.
asbestos
g.
cotton
h. silicon nitride
i. glass reinforced plastics
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be provided during lectures.
1. Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical
Propeller and Shafting, Shaft Fittings, Thrust Block & Bearing
a.
Shafting Alignment, Chapter 6, Page 211-224
Older alignment methods used piano wires and micrometers
and feelers between coupling faces, whereas modern methodsutilize optical telescopes and targets giving accuracies of
2m per 1 m length. To fully describe the methods it will be
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assumed that the shafting and engine are first lined up by the
older method, being checked at each stage by the modern
method.
b. The Propeller Shaft and Sterntube, Chapter 6, Page 231-236
Study the water lubricated type and the oil lubricated type of
propeller shaft and sterntube, and their sealing arrangements.
Be familiar with the withdrawable stern gear system and the
alternative stern gear with shaft withdrawal aft or inboard.
c. Controllable Pitch Propeller, Chapter 6, Page 237-238
What are the reasons for using controllable-pitch propellers?
d. The Torsionmeter Chapter 6, Page 238-241
Why the electrical torsion meter is used in preference to
others?
e. The Thrust Block Chapter 6, Page 241-243
What is the Michell principle?
Pumps a.
Types of Pumps: Classification, Chapter 9, Page 350-351
What is the difference between the two basic types of pumps?
b.
Selection of Pumps, Chapter 9, Page 350-361
What are the criteria for the selection of a particular type of
pump?
c. Characteristic Curves, Chapter 9, Page 357-360
Careful study of characteristic curves would assist the reader to
answer some of the questions.
Steering Systema. Steering Gears, Chapter 5, Page 175-200
Study the various types of steering gears available on board.
The two main types are electro-hydraulic and all electric.
Reader should pay attention to emergency operation.
b. Some Rules Appertaining to Steering Gears, Chapter 5, Page
200-201
Be familiar with rules governing the operation of steering
gears. Rules are subject to change and one must be wary of the
latest development.
Hydraulic Geara. Hydraulic System, Chapter 9, Page 379-380
What are the main advantages of a centralised hydraulic
system? Items that can be operated by such system include
pumps, which are submersible or line-shaft driven from deck
motors, and deck machinery such as winches, windlass, cranes,
derricks, hatch covers, ramps, water tight doors and bow
thruster.
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Refrigeration, Air Conditioning and Ventilationa. Common Faults and Simple Detection, Chapter 7, Page 264-
265
Familiarization with these faults would help one to
troubleshoot problems encountered.
b. Direct Expansion Units, Chapter 7, Page 276-281
The control automation required is start, stop, superheat
control, emergency cut out, cooling air or water circulation,
and oil separation.
c.
Brine Circuits, Chapter 7, Page 283-284
The colder the brine circuit, the greater would be the density
required of brine in circulation to avoid any freeze up.
d. Air Conditioning Circuit, Chapter 7, Page 289-291
When heating is required, the cooling unit would be shut
down, and the air would pass over heating elements, andhumidity is regulated by controlled water spray.
e.
Psychrometric Chart, Chapter 7, Page 288-289
The chart gives a quick performance check on the air entering
and leaving the cooling coil.
Heat Exchangers, Evaporators and Domestic Water Supplya. Heat Exchanger, Chapter 9, Page 370-376
What is the flow pattern used in most heat exchangers?
Study the difference between streamline and turbulent flow.
Study the difference between shell and tube type and plate typeheat exchangers.
b.
Evaporators, Chapter 3, Page 129-131
What is the consequence of scale formation?
c.
Drinking Water, Chapter 3, Page 137
Study the safeguards necessary to ensure that the water
produced is safe to drink
d. Automatic Domestic Water Supply Systems, Chapter 9, Page
377-378
Study the automated control system common for either
sanitary or fresh water supply.e.
Water Purification, Chapter 9, Page 378-379
For domestic purposes the water used must be slightly alkaline,
sterilised, clear and pleasant tasting.
MARPOL 73/781. Oily Water Separator, Chapter 10, Page 381-388
Study the IMO requirements for oily water separators.
Study the operation of automatic valve operation combined
with alarm and protection circuits.
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2.
Sewage and Sludge, Chapter 9, Page 390-393
Study the various types of sewage treatment plants.
What are the advantages of chemical treatment plants?
Chemistry of Fire and Extinguishing Agent
a.
Principle of Fire, Chapter 8, Page 301
Understand the conditions required for the occurrence of fire.
b.
Fire Prevention and Precautions, Chapter 8, Page 301-302
Cleanliness, vigilance and common sense are the principal
weapons with which to prevent fire.
c. Types of Fires and Methods of Extinguishing, Chapter 8, Page
302-303
Be familiar with oil fires, coal fires, material fires and
electrical fires, and how they can be extinguished.
d. Fire Detection Methods, Chapter 8, Page 303-310Study the various methods of fire detection.
e. Critical Analysis of Fire Extinguishing Mediums, Chapter 8,
Page 310-312
Study the characteristics of various fire extinguishing mediums
for fighting various fires. The use of halon has now been
phased out.
f. Fire Extinguishers and Fixed Fire Fighting Installations,
Chapter 8, Page 313-340
Study the operation, maintenance and testing of fire
extinguishers and fixed fire fighting installations.g. Merchant Shipping (Fire Appliances) Rules
Be familiar with rules with regards to fire fighting equipment
such as international shore connection, water pipes, hydrants
and fire hoses, firemen’s outfits, breathing apparatus, and
emergency fire pump.
Fundamentals of Instrumentation, Automation and Control Systemsa. Telemetering, Chapter 11, Page 452-457
Study signal transmitters and transducers.
b. Terminology, Chapter 11, Page 457-458Be familiar with control terminology.
c. Control Actions, Chapter 11, Page 458-463
Study the three basic control actions: proportional, integral and
derivative.
d. Control Systems, Chapter 11, Page 463-470
Study typical control systems such as fluid temperature
control, automatic boiler control, and bridge control.
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Physical and Chemical Properties of Bunkered Fuels and Lubricantsa. Liquid Fuels, Chapter 2, Page 47-48
Understand that crude petroleum is classified into three main
types. Understand that hydrocarbons are divided into four
main series
b. Testing of liquid fuel and oils, Chapter 2, Page 51-65
Understand terms such as viscosity, viscosity index, flash
point, fire point, pour point, “carbon residue”, knocking,
ignition quality, cetane number and calorific value. Understand
the common relationship between density, viscosity, flash
point and calorific value of common marine fuels.
c. Combustion of Sulphur, Chapter 2, Page 67-68
Understand the harmful effects of sulphur trioxide in the
products of combustion.
d. Filters, Chapter 10, Page 406-412Study the different filtration methods.
e. Centrifuges, Chapter 10, Page 416-425
Understand the factors affecting the limit size particle path.
Understand operation of the centrifuge either as a purifier or a
clarifier. Study the operation of a self-cleaning purifier. Study
the variation of throughput rate against the quantity of
impurities in the system.
f. Bearing Lubrication, Chapter 10, Page 428
The two most important properties of a lubricant would be
oiliness and viscosity. What are boundary friction andhydrodynamic lubrication?
g. Factors Affecting Hydrodynamic Lubrication, Chapter 10,
Page 429-430
Understand that factors include viscosity of the lubricant,
relative speed of surfaces, bearing clearance, and pressure.
h. Journal Bearings, Chapter 10, Page 430-431
What kind of lubrication exists in journal bearings?
i. Michell Bearings, Chapter 10, Page 430-431
What kind of lubrication exists in Michell bearings?
j. Definitions, Chapter 10, Page 431-432Understand terms such as scuffing, extreme pressure lubricant,
pitting, emulsion, oxidation, and lacquering.
k. Shipboard Lubricating oil Tests, Chapter 10, Page 432-434
Be familiar with qualitative oil tests carried out on board ship.
Tests for alkalinity, dispersiveness, contamination, water and
viscosity are usual.
l. Corrosion of White Metal Bearings, Chapter 10, Page 434
Study the factors which contribute towards the formation of tin
oxides.
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m. Microbial Degradation of Lubricating Oil, Chapter 10, Page
434-435
State the remedy and prevention for bacterial attack of diesel
engine lubricating oils, crankcase and cylinder.
Technology of Materials
a. Simple Metallurgy of Steel and Cast Iron, Chapter 1, Page 5-9
Refer to diagram on microstructure variation with increasing
carbon content for examples of applications of mild steel,
medium carbon steel, high carbon steel and cast iron.
b. Testing of Materials, Chapter 1, Page 9-23
Understand the stress-strain diagram, and the significance of proof stress. Understand destructive tests such as tensile,
hardness, impact, creep, fatigue and bend tests, and non-
destructive tests such as visual inspection, penetrant test,
magnetic crack detection, hammer test, radiography and
ultrasonics.
c. Treatment of Metals, Chapter 1, Page 23-28
Understand the different heat treatment processes such as
hardening and tempering, annealing and normalizing and work
hardening, and the applications of these processes.
d. Welding, Chapter 1, Page 35-43
Understand that welding processes can change the
microstructure and mechanical properties of the base metal.
Understand that welding of metals may cause imperfections on
the surface or internally to the weld and adjacent metal such as
overlap, undercut, spatter, blowhole, porosity, inclusion,
incomplete root penetration and lack of fusion.
e. Elements in Irons and Steels, Chapter 1, Page 30-32Study the effect of alloying irons and steels with elements such
as manganese, silicon, sulphur, phosphorus, nickel, chromium,
molybdenum and vanadium.
f. Non-ferrous Metals, Chapter 1, Page 32-34
Study the properties and uses in marine applications of non-
ferrous metals such as copper, brass, bronze, aluminium,
copper-nickel alloys, white metals and titanium.
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g. Non-metallic materials, Chapter 1, Page 34-35
Study the properties and uses of non-metallic materials such as
plastics, nitrile, P.T.F.E., Epoxy resin, rubber, asbestos, cotton
and silicon nitride.
2. Dr J Cowley (1992), The Running and Maintenance of Marine
Machinery, Marine Management (Holdings) Ltd for The Institute of
Marine Engineers
Pumpsa. Pumps, Chapter 10, Page 333-338
Refer to the various types of pumps.
b. Common Uses of the Various Types of Pumps, Chapter 10,
Page 338-340
Study typical applications of the different types of pumps.
Refrigeration, Air Conditioning and Ventilationa. Marine Refrigerating Plant, Chapter 8, Page 270-276
Refer to system components such as oil separators, condensers,
evaporators, air cooler batteries and filter driers, and controls
such as defrosting and refrigerant flow controls.
Physical and Chemical Properties of Bunkered Fuels and Lubricants a. Marine Fuel Oil characteristics, Chapter 4, Page 160-177
Further reference on terminology such as viscosity, flash point,
pour point, “carbon residue” and ignition quality.What are the actions required to overcome problems
encountered due to low flash point; high sulphur content; high
water content; high vanadium content; high aluminium
content; instability and incompatibility?
3. Leslie Jackson (1992), Instrumentation and Control Systems, Thomas
Reed Publications Limited
Fundamentals of Instrumentation, Automation and Control Systems
a. Final Control Elements, Chapter 8, Page 115-126Refer to the operation of control valves, valve positioners
and servo-motors. b. Process Control Theory, Chapter 9, Page 127-155
Further reference to terminology, and proportional, integral
and derivative control actions.
c. Pneumatic Control Principles, Chapter 10, Page 157-169
Study pneumatic two step control, and pneumatic proportional,
integral and derivative controls.
d. Electronic Control Principles, Chapter 11, Page 171-183
Understand electronic two step control, and electronic proportional, integral and derivative controls.
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e. Actual Controller Types, Chapter 12, Page 185-202
Refer to actual types of controllers used in practice such as
mechanical-hydraulic controller, electro-pneumatic controller,
electronic P.I.D. controller, pneumatic controller for fuel-air
ratio and pneumatic controller for viscosity.
f. Typical Control Circuits, Chapter 13, Page 203-237
Study typical control circuits such as sootblower control,
steam temperature control, jacket temperature control, bridge
control and refrigeration control.
4. MARPOL 73/78 Consolidated Edition (2002), International
Maritime Organization
MARPOL 73/78
a.
Regulations for the Prevention of Pollution by Oil, Annex I,Chapter I – General, Page 45-50
Refer to Regulations 1 and 2 on definitions and application for
Annex I
b. Requirements for Control of Operational Pollution, Annex I,
Chapter II, Page 58-95
Study Regulations 9 to 20 on the control of discharge of oil
outside of and within special areas, exceptions, reception
facilities, segregated ballast tanks, dedicated clean ballast
tanks and crude oil washing, segregation of oil and water
ballast and carriage of oil in forepeak tanks, retention of oil on board, oil discharge monitoring and control system and oil
filtering equipment, tanks for oil residues, pumping, piping
and discharge arrangements of oil tankers, standard discharge
connection, and oil record book.
c. Regulations for the Control of Noxious Liquid Substances,
Annex II, Page 243-253
Understand Regulations 1 to 5 on definitions, application,
categorization and listing of noxious liquid substances, and the
discharge of noxious liquid substances.
d. Regulations for the Prevention of Pollution by HarmfulSubstances Carried by Sea in Packaged Form, Annex III, Page
363-366
Understand Regulations 1 to 8 on application, packing,
marking and labeling, documentation, stowage, quantity
limitations, exceptions, and port state control on operational
requirements.
e. Regulations for the Prevention of Pollution by Sewage from
ships, Annex IV, Page 373-379
Study Regulations 1 to 11 on definitions, application, surveys,
issue, form and duration of certificate, discharge of sewage,exceptions, reception facilities, and standard discharge
connections.
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f. Regulations for the Prevention of Pollution by Garbage from
Ships, Annex V, Page 385-392
Understand Regulations 1 to 9 on definitions, application,
disposal of garbage outside special areas, special requirements
for disposal of garbage, disposal of garbage within special
areas, exceptions, reception facilities, port state control on
operational requirements, and placards, garbage management
plans and garbage record- keeping.
g. Regulations for the Prevention of Air Pollution from Ships,
Annex VI, Chapter I – General, Page 399-401
Refer to Regulations 1 to 4 on application, definitions, general
exceptions, and equivalents.
h. Regulations for Control of Emissions from Ships, Annex VI,
Chapter III, Page 408-416
Study Regulations 12 to 18 on ozone-depleting substances,
nitrogen oxides, sulphur oxides, volatile organic compounds,shipboard incineration, reception facilities, and fuel oil quality.
5. Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine
Engineering, Science and Technology
Chemistry of Fire and Extinguishing Agent
a. Fire Extinguishing and Extinguishing Media, Section 3, Page
25-42
Further reference on methods of extinguishing fires and properties of extinguishing media.
b. Fire Extinguishing Equipment, Section 4, Page 44-65
Further reference on fire extinguisher performance, portable
extinguishers, foam-making equipment, fire hoses and nozzles,
fire-fighter’s outfit and breathing apparatus.
c. Fire-fighting Arrangements, Section 5.8, Page 78-89
Further reference on operation and maintenance of fixed
installations, and operational requirements of fire pumps.
d. Automatic Sprinkler Systems and Fire Detection, Section 10,
Page 147-171Further reference to the operation of sprinkler systems and
types of fire detectors.
Key Questions
1. Sketch and describe a Pilgrim nut for a propeller. Explain how it is used
when fitting the propeller on to the shaft taper. State two advantages this
type of nut has over a conventional propeller nut.
2. What is the purpose of putting a thrust bearing between the main engineand the propeller? How is the thrust bearing cooled?
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3. Describe with sketches a super-cavitating pump. State the purpose of
such a pump and gives an instance of current shipboard application.
4. Describe with sketches an axial flow pump. Explain its principle of
operation. State what important advantage and serious disadvantage it
possesses compared to other pumps. Explain the effects of throttling
either the suction or discharge valve.
5. Describe a simple test to ensure that steering gear hydraulic telemotor
systems are ‘air free’.
a. Define two ways whereby air enters such systems.
b. Give reasons why it is essential that such systems be ‘air free’.
6. With reference to electro hydraulic steering gears explain how the ship
can be steered in each of the following circumstances:
a. Destruction by fire of primary supply cables
b. Destruction by fire of telemotor lines
c.
Bearing failure in running pump7. Sketch and describe a centralised hydraulic system. What are the
equipment which can be operated by such a system?
8. Briefly describe how in main refrigeration plants:
a.
sea temperature can restrict plant operation
b.
the limitations in (a) are overcome
c.
short cycling occurs
d. short cycling is avoided
9. With respect to heat exchangers,
b. What is the difference between streamline flow and turbulent
flow?c.
What are the principal advantages of the plate type heat
exchanger?
10. With respect to Annex I of MAROL 73/78,
a.
What are the special areas?
b. What are the restrictions with respect to the discharge of processed
bilge water from machinery space into the waters of these areas?
11. Differentiate between fixed temperature and rate of rise types of fire
detector. Sketch and describe a fire detector of the rate of rise type and
explain how a gradual rise of ambient temperature is accommodated.
12. Sketch diagrammatically an auxiliary boiler automatic combustioncontrol system. Explain how it operates. Specify how ‘fail safe’
conditions are ensured.
13. Define each of the following terms in relation to lubricating oil:
a. pour point
b. flash point
c. auto-ignition point
State, with reasons, when will each of these characteristics be of primary
importance.
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14. Give the approximate composition , and the properties of the following
metals:
a.
manganese bronze
b.
cupro-nickel
c. Babbitts metal
In each case give two examples of the metals in use on board ship, and
explain why the metal is chosen for the applications you mention.
Acknowledgement
1. Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical
2. Dr J Cowley (1992), The Running and Maintenance of Marine
Machinery, Marine Management (Holdings) Ltd for The Institute ofMarine Engineers
3.
Leslie Jackson (1992), Instrumentation and Control Systems, Thomas
Reed Publications Limited
4.
MARPOL 73/78 Consolidated Edition (2002), International Maritime
Organization
5.
Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine Engineering,
Science and Technology
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Main Objectives
Technology of Materials
At the end of the course, the learner should be able to:
1.
Describe the properties of steel and the steel making process.
2. Describe the material testing (destructive) and the properties being
tested.
3.
Describe the Non-destructive testing (NDT) and their principles.
4.
Explain the heat treatment process of metal
5.
Explain the reason for adding alloying elements in steel.
6. Describe the application of non metallic materials.
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be provided during lectures.
1.
Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical
Technology of Materialsa. Simple Metallurgy of Steel and Cast Iron, Chapter 1, Page 5-9
Refer to diagram on microstructure variation with increasing
carbon content for examples of applications of mild steel,
medium carbon steel, high carbon steel and cast iron.Understand the properties of steel and steel making process.
b. Testing of Materials, Chapter 1, Page 9-23
Understand the stress-strain diagram, and the significance of
proof stress. Understand destructive tests such as tensile,
hardness, impact, and fatigue tests, and non-destructive tests
such as penetrant test, magnetic crack detection, hammer test,
radiography and ultrasonics. Understand the differences
between the destructive tests and non-destructive tests.
c. Treatment of Metals, Chapter 1, Page 23-28
Understand the different heat treatment processes such ashardening and tempering, annealing and normalizing and work
hardening, and the applications of these processes.
d. Welding, Chapter 1, Page 35-43
Understand that welding processes can change the
microstructure and mechanical properties of the base metal.
e. Elements in Irons and Steels, Chapter 1, Page 30-32
Study the effect of alloying irons and steels with elements such
as manganese, silicon, sulphur, phosphorus, nickel, chromium,
molybdenum and vanadium.
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f. Non-ferrous Metals, Chapter 1, Page 32-34
Study the properties and uses in marine applications of non-
ferrous metals such as copper, brass, bronze, aluminium,
copper-nickel alloys, white metals and titanium.
g. Non-metallic materials, Chapter 1, Page 34-35
Study the properties and uses of non-metallic materials such as
plastics, nitrile, P.T.F.E., Epoxy resin, rubber, asbestos, cotton
and silicon nitride.
Key Questions1. Give the approximate composition , and the properties of the following
metals:
a. mild steel
b. medium carbon steel
c.
high carbon steelIn each case give two examples of the metals in use on board ship, and
explain why the metal is chosen for the applications you mention.
2.
Define ‘mechanical property’ of an engineering material. State any six
mechanical properties and give their definitions.
3.
State the alloying elements added to steel to get alloy steels and the effect
they produce. Give at least one example of each.
4. Briefly explain the differences between destructive testing and non-
destructive testing (NDT).
5. Explain the following heat treatment processes:
Normalising Hardening
Tempering
Additional Questions1.
Describe the classification of materials for engineering use.
2. List the most commonly used engineering materials and state at least one
important property and one application of each.
3.
Define the following properties of a material:
Ductility
Toughness
Hardness
4.
Discuss the effects of nickel, chromium and manganese on steel.
5.
Explain the determination of the fatigue resistance of a material.
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Main Objectives
Refrigeration, Air Conditioning & VentilationAt the end of the course, the learner should be able to:
1. State the function of each of the components, and briefly describe their
operation
2. Describe the controls used to operate the plant automatically
3. Describe the symptoms of the following:
a.
undercharge of refrigerant
b.
overcharge of refrigerant
c.
oil in the system
d. presence of air in the refrigerant
e. a partial blockage at the regulator
f. leakage of refrigerant
4. Explain what is meant by:
a.
direct expansion b.
secondary coolant
c.
grid cooling
d.
battery cooling
5. Describe a simple air-conditioning system suitable for supplying a
living space with conditioned air and using recirculation
7.
Describe the areas in a psychrometric chart which is known as the
‘comfort zone’ , being the air condition necessary for personal comfort
in living spaces
Study GuideStudents are advised to pay particular attention to following reference material
listed under “Recommended Texts” over and above the notes that will be
provided during lectures.
1. Leslie Jackson and Thomas D Morton (2003), General Engineering
Knowledge for Marine Engineers, Adlard Coles Nautical.
2. Dr J Cowley (1992), The Running and Maintenance of Marine Machinery,
Marine Management (Holdings) Ltd for The Institute of Marine Engineers.
Students are advised to study the relevant Chapters in the above mentioned books and ensure the following aspects are understood:
Refrigeration, Air Conditioning & Ventilation1. Common Faults and Simple Detection, Chapter 7, Page 264-265
Familiarization with these faults would help one to troubleshoot
problems encountered.
2.
Direct Expansion Units, Chapter 7, Page 276-281
The control automation required is start, stop, superheat control,
emergency cut out, cooling air or water circulation, and oil separation.
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3.
Brine Circuits, Chapter 7, Page 283-284
The colder the brine circuit, the greater would be the density required
of brine in circulation to avoid any freeze up.
4. Air Conditioning Circuit, Chapter 7, Page 289-291
When heating is required, the cooling unit would be shut down, and
the air would pass over heating elements, and humidity is regulated by
controlled water spray.
5.
Psychrometric Chart, Chapter 7, Page 288-289
The chart gives a quick performance check on the air entering and
leaving the cooling coil.
6. Marine Refrigerating Plant, Chapter 8, Page 270-276
Refer to system components such as oil separators, condensers,
evaporators, air cooler batteries and filter driers, and controls such asdefrosting and refrigerant flow controls.
Key Questions1. Briefly describe how in main refrigeration plants:
a.
sea temperature can restrict plant operation
b.
the limitations in (a) are overcome
2. Briefly describe how in main refrigeration plants:
a. short cycling occurs
b. short cycling is avoided
3. With reference to refrigeration system, what are the causes of the followingfaults?
a.
Loss of lubrication oil
b.
Knocking
4. With reference to refrigeration system, what are the causes of the following
faults?
a. Suction pressure too high
b. Compressor cut-out
5. Explain the purpose of the heating element of an oil separator
incorporated in a refrigeration system.
6.
With respect to refrigeration system, explain how icing on evaporator coil mayor may not be detrimental to the operation of the system.
7.
With respect to refrigeration system, explain how you would charge up the
system with refrigerant from zero charge to full charge.
8. With reference to the psychrometric chart, explain the significance of the dry
and wet bulb temperatures.
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Additional Questions
1.
Explain how a refrigeration compressor could short cycle due to loss of
refrigerant.
2. Explain how a refrigeration compressor could short cycle due to a
heavily frosted evaporator coil.
3. What are the factors which could cause a refrigeration compressor to run
continuously?
4. With reference to refrigeration system, what is the function of the oil separator?
5. Explain how the air in an air-conditioned room becomes dehumidified.
Acknowledgement
International Maritime Organisation (IMO), IMO Model Course (3.09), (7.02),
(7.04) (2001)
DNV Seaskills Learning Guide
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