A POCKET BOOK OF MARINE ENGINEERING Questions & Answers iii Published in 2009 ISBN:- 978 1 905331 80 2 © Witherby Seamanship International Ltd 2009 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the publishers. While the advice given in this book ‘A Pocket Book of Marine Engineering Questions & Answers’ has been developed using the best information currently available, it is intended purely as guidance to be used at the user’s own risk. Witherby Seamanship International Ltd accepts no responsibility for the accuracy of any information or advice given in the document or any omission from the document or for any consequence whatsoever resulting directly or indirectly from compliance with or adoption of guidance contained in the document even if caused by failure to exercise reasonable care. This publication has been prepared to deal with the subject of ‘A Pocket Book of Marine Engineering Questions & Answers’. This should not however, be taken to mean that this publication deals comprehensively with all of the issues that will need to be addressed or even, where a particular issue is addressed, that this publication sets out the only de?nitive view for all situations. The opinions expressed are those of the author only and are not necessarily to be taken as the policies or views of any organisation with which he has any connection. Printed and bound in Great Britain by Bell & Bain Ltd, Glasgow Published in 2009 by Witherby Seamanship International 4 Dunlop Square Deans Estate Livingston EH54 8SB United Kingdom Tel No: +44(0)1506 463 227 Fax No: +44(0)1506 468 999 Email: info@emailws.com www.witherbyseamanship.com iii CONTENTS QUESTION 1 Fire?ghting ............................................................3 1.1 Questions - Fire Prevention and Sources of Ignition on Ships....3 1.2 Questions - Inert Gas and Extinguishers .....................................3 1.3 Questions - CO2, Sprinkler Systems and Detection .....................4 1.4 Questions - Classi?cation Regulations .......................................5 2 Safety ..................................................................7 2.1 Questions - Enclosed Spaces and Entry ....................................7 2.2 Questions - Lifting Plant and Welding ........................................8 2.3 Questions - Pollution and Harmful Substances ..........................8 3 Materials ............................................................11 4 Auxiliary Machinery ...............................................15 4.1 Questions - Heat Exchangers ...................................................15 4.2 Questions - Pumps ...................................................................15 4.3 Questions - Filters ....................................................................16 4.4 Questions - Stabilisers .............................................................16 4.5 Questions - Refrigeration ..........................................................17 5 Engine Room Systems .............................................19 5.1 Questions - Bilge And Ballast System.......................................19 5.2 Questions - Fresh Water and Seawater Cooling Systems .........19 5.3 Questions - Fuel Oil System .....................................................20 5.4 Questions - Engine Room Systems (General) ...........................21 6 Ship Construction ..................................................25 6.1 Questions - Ship Construction .................................................25 7 Steering Gear .......................................................27 7.1 Questions - Steering Gear.........................................................27 8 Shafting ..............................................................29 8.1 Questions - Shafting .................................................................29 ivv 9 Electrical.............................................................31 9.1 Questions - Switchboards, Circuit breakers and Switchboard Instrumentation .........................................................................31 9.2 Questions - Parallel Operation of Generators ............................31 9.3 Questions - Motor Starters .......................................................32 9.4 Questions - Shore Supply .........................................................32 9.5 Questions - Electrical (General) ................................................33 10 Electrical Protection ...............................................35 10.1 Questions - Electrical Protection (General) ...............................35 10.2 Questions - Fault Protection .....................................................35 10.3 Questions - Circuit Breaker.......................................................35 10.4 Questions - Overcurrent Protection...........................................36 10.5 Questions - Fuses .....................................................................36 10.6 Questions - Protection Discrimination ......................................36 10.7 Questions - Loss of Excitation ..................................................37 10.8 Questions - Undervoltage Protection ........................................37 10.9 Questions - Reverse Power Protection ......................................37 10.10 Questions - Motor Overload Protection ....................................38 10.11 Questions - Earth Faults ...........................................................38 11 Electrical Safety ....................................................39 11.1 Questions - General Electrical Maintenance..............................39 11.2 Questions - Switchboard Maintenance .....................................39 11.3 Questions - Motor Maintenance ...............................................40 11.4 Questions - Motor Control Gear Maintenance ..........................41 11.5 Questions - Maintenance of Lighting ........................................41 11.6 Questions - Electric Shock ........................................................42 11.7 Questions - Circuit Safety Devices............................................42 11.8 Questions - Earth Safety Devices ..............................................43 11.9 Questions - Welding .................................................................43 11.10 Questions - Static Electricity and Interference ...........................43 11.11 Questions - Emergency Power Supplies ...................................44 12 Instrumentation and Control ......................................47 12.1 Questions - Control (General)...................................................47 ivv 12.2 Questions - Control Systems ....................................................47 12.3 Questions - Measuring Instruments..........................................48 12.4 Questions - Automatic Control Theory .....................................50 12.5 Questions - Types of Control Action .........................................52 12.6 Questions - Automatic Controllers............................................52 12.7 Questions - Control System Components.................................54 12.8 Questions - Supply Systems.....................................................56 12.9 Questions - Practical Control Systems .....................................56 12.10 Questions - Alarm Indication Systems ......................................58 12.11 Questions - Operation And Maintenance ..................................59 13 Diesel Engine Theory & Structure ...............................63 13.1 Questions - Engine Types .........................................................63 13.2 Questions - Engine Construction ..............................................64 13.3 Questions - The Crankshaft ......................................................64 13.4 Questions - Connecting Rods and Crossheads.........................65 13.5 Questions - Pistons ..................................................................66 13.6 Questions - Cylinder Diaphragm and Piston Rod Gland ...........68 13.7 Questions - Cylinder Liner ........................................................68 13.8 Questions - Cylinder Cover ......................................................70 13.9 Questions - Camshafts and Valve Gear .....................................70 13.10 Questions - Turbocharge Systems ............................................72 14 Fuel Systems ........................................................75 14.1 Questions - Fuel Oil ..................................................................75 14.2 Questions - Supply of Fuel Oil ..................................................77 14.3 Questions - Fuel Pumps ...........................................................78 14.4 Questions - Fuel Injectors .........................................................79 15 Combustion..........................................................81 15.1 Questions - Fuel and Fuel Burning (Diesel Engines) ................81 16 Lubrication ..........................................................83 16.1 Questions - The lubricating oil system .....................................83 16.2 Questions - Lubricating Oils (1) ...............................................83 16.3 Questions - Lubrication Fundamentals .....................................85 16.4 Questions - Lubricating Oils (2) ...............................................86 vivii 16.5 Questions - Shipboard Lubricating Oil Tests ............................89 16.6 Questions - Grease ...................................................................89 16.7 Questions - Oil Drain Tank ........................................................90 16.8 Questions - Pre-Cleaning and Corrosion Protection.................91 16.9 Questions - Rotary Displacement Pumps .................................92 16.10 Questions - Coolers ..................................................................92 16.11 Questions - Oil Maintenance ....................................................94 17 Starting & Manoeuvring Safety ..................................97 17.1 Questions - Starting Air ............................................................97 17.2 Questions - Manoeuvring/Direct Reversing Engines.................98 17.3 Questions - Safety Systems (Crankcase) ................................100 18 Boilers ..............................................................103 18.1 Questions - Boiler Types ........................................................103 18.2 Questions - Evaporators .........................................................103 18.3 Questions - Boiler Mountings .................................................105 18.4 Questions - Water Gauges ......................................................106 18.5 Questions - Boiler Operation ..................................................108 18.6 Questions - Tube Failures .......................................................110 ANSWERS 1 Fire?ghting .........................................................113 1.1 Answers - Fire Prevention and Sources of Ignition on Ships ..113 1.2 Answers - Inert Gas and Extinguishers ...................................115 1.3 Answers - CO2, Sprinkler Systems and Detection ...................119 1.4 Answers - Classi?cation Regulations......................................123 2 Safety ...............................................................129 2.1 Answers - Enclosed Spaces and Entry ....................................129 2.2 Answers - Lifting Plant and Welding .......................................135 2.3 Answers - Pollution and Harmful Substances .........................136 3 Materials ...........................................................143 vivii 4 Auxiliary Machinery ..............................................151 4.1 Answers - Heat Exchangers ....................................................151 4.2 Answers - Pumps ...................................................................157 4.3 Answers - Filters .....................................................................163 4.4 Answers - Stabilisers ..............................................................167 4.5 Answers - Refrigeration ..........................................................170 5 Engine Room Systems ............................................173 5.1 Answers - Bilge and Ballast System........................................173 5.2 Answers - Fresh Water and Sea Water Cooling Systems ........176 5.3 Answers - Fuel Oil System......................................................179 5.4 Answers - Engine Room Systems (General)............................184 6 Ship Construction .................................................191 6.1 Answers - Ship Construction ..................................................191 7 Steering Gear ......................................................199 7.1 Answers - Steering Gear .........................................................199 8 Shafting .............................................................207 8.1 Answers - Shafting .................................................................207 9 Electrical............................................................213 9.1 Answers - Switchboards, Circuit breakers, Switchboard Instrumentation .................................213 9.2 Answers - Parallel Operation of Generators ............................214 9.3 Answers - Motor Starters ........................................................214 9.4 Answers - Shore Supply .........................................................215 9.5 Answers - Electrical (General).................................................216 10 Electrical Protection ..............................................221 10.1 Answers - Electrical Protection (General)................................221 10.2 Answers - Fault Protection ......................................................221 10.3 Answers - Circuit Breaker .......................................................221 10.4 Answers - Overcurrent Protection ...........................................222 10.5 Answers - Fuses .....................................................................224 10.6 Answers - Protection Discrimination ......................................224 viiiix 10.7 Answers - Loss of Excitation ...................................................225 10.8 Answers - Undervoltage Protection ........................................226 10.9 Answers - Reverse Power Protection ......................................226 10.10 Answers - Motor Overload Protection .....................................227 10.11 Answers - Earth Faults ............................................................228 11 Electrical Safety ...................................................231 11.1 Answers - General Electrical Maintenance ..............................231 11.2 Answers - Switchboard Maintenance ......................................232 11.3 Answers - Motor Maintenance ................................................233 11.4 Answers - Motor Control Gear Maintenance ...........................235 11.5 Answers - Maintenance of Lighting ........................................236 11.6 Answers - Electric Shock ........................................................236 11.7 Answers - Circuit Safety Devices ............................................237 11.8 Answers - Earth Safety Devices...............................................237 11.9 Answers - Welding .................................................................238 11.10 Answers - Static Electricity and Interference ...........................238 11.11 Answers - Emergency Power Supplies....................................239 12 Instrumentation and Control .....................................243 12.1 Answers - Control (General) ...................................................243 12.2 Answers - Control Systems ....................................................243 12.3 Answers - Measuring Instruments ..........................................245 12.4 Answers - Automatic Control Theory ......................................252 12.5 Answers - Types of Control Action..........................................255 12.6 Answers - Automatic Controllers ............................................255 12.7 Answers - Control System Components .................................258 12.8 Answers - Supply Systems .....................................................260 12.9 Answers - Practical Control Systems ......................................262 12.10 Answers - Alarm Indication Systems ......................................265 12.11 Answers - Operation and Maintenance ...................................267 13 Diesel Engine Theory & Structure ..............................271 13.1 Answers - Engine Types ..........................................................271 13.2 Answers - Engine Construction ..............................................272 13.3 Answers - The Crankshaft .......................................................274 viiiix 13.4 Answers - Connecting Rods and Crossheads .........................276 13.5 Answers - Pistons ...................................................................277 13.6 Answers - Cylinder Diaphragm and Piston Rod Gland............280 13.7 Answers - Cylinder Liner ........................................................281 13.8 Answers - Cylinder Cover .......................................................283 13.9 Answers - Camshafts and Valve Gear .....................................284 13.10 Answers - Turbocharge Systems .............................................287 14 Fuel Systems .......................................................291 14.1 Answers - Fuel Oil ..................................................................291 14.2 Answers - Supply of Fuel Oil ..................................................294 14.3 Answers - Fuel Pumps ............................................................297 14.4 Answers - Fuel Injectors .........................................................298 15 Combustion.........................................................301 15.1 Answers - Fuel and Fuel Burning (Diesel Engines) .................301 16 Lubrication .........................................................305 16.1 Answers - The Lubricating Oil System ....................................305 16.2 Answers - Lubricating Oils (1) ................................................306 16.3 Answers - Lubrication Fundamentals......................................308 16.4 Answers - Lubricating Oils (2) ................................................310 16.5 Answers - Shipboard Lubricating Oil Tests .............................314 16.6 Answers - Grease....................................................................315 16.7 Answers - Oil Drain Tank ........................................................316 16.8 Answers - Pre-Cleaning and Corrosion Protection .................317 16.9 Answers - Rotary Displacement Pumps ..................................319 16.10 Answers - Coolers ..................................................................320 16.11 Answers - Oil Maintenance .....................................................322 17 Starting & Manoeuvring Safety .................................327 17.1 Answers - Starting Air .............................................................327 17.2 Answers - Manoeuvring / Direct Reversing Engines ...............329 17.3 Answers - Safety Systems (Crankcase) ...................................332 x 18 Boilers ..............................................................337 18.1 Answers - Boiler Types ...........................................................337 18.2 Answers - Evaporators ............................................................338 18.3 Answers - Boiler Mountings ...................................................340 18.4 Answers - Water Gauges .........................................................343 18.5 Answers - Boiler Operation .....................................................343 18.6 Answers - Tube Failures .........................................................349 97 17 STARTING & MANOEUVRING SAFETY 17.1 Questions – Starting Air 1. What is the method used to start main propulsion engines? 2. What dictates the opening of an air start valve? 3. In modern practice, when is air introduced to the cylinder? 4. In indicator diagrams, what does the area under the curve represent? 5. Where should the non-return valve be ?tted in the air start system? 6. What should be ?tted between the non-return valve and the cylinder? 7. At what pressure is starting air stored? 8. What are the two connections on the air distributor for? 9. What keeps timing valves clear of the starting air cam? 10. In multi-cylinder Vee engines, what is a possible arrangement of starting the air valves? 11. How is a leaking air start valve detected when the engine is running? 12. What is the capacity (in starts) of starting air that must be stored for a reversible engine? 13. What is the preferred method of ?tting the air receiver’s ?ttings? 14. What must the pressure gauge on the receiver be directly connected to? 15. What size of drain valve should be ?tted to an air receive? Engineering Pocket Book – Questions 98 Engineering Pocket Book – Questions 99 16. In what condition should air be received from the compressor? 17. What must be done before opening a receiver’s manhole door? 18. What must be avoided during the internal clearing of an air receiver? 19. What must be looked for during internal inspection of an air receiver? 20. What precautions must be carried out when applying protective coatings? 21. How many starting air compressors must there be? 22. What is the maximum compressor delivery air temperature? 23. Why is manual starting attractive? 24. What type of drive is used in gear drive starters? 25. What voltages are electrical starters? 26. How are batteries connected for starting? 27. What are the two types of batteries used for electric starting? 17.2 Questions – Manoeuvring/Direct Reversing Engines 1. What must be reversed to manoeuvre a ship? 2. What timings must be adjusted on a four-stroke engine to run in reverse? 3. What are used on four-stroke engines to allow ahead and astern running? 4. On large two-stroke engines, what is adjusted to allow astern running? 5. Why are gearboxes ?tted to medium-speed engine drives?