Marine engineering practice 1.

Explain how will you overhaul a fuel injector remove injector with tool, fix on vice, remove spring compression nut.turn the injector and slacken nozzle holding nut, remove nozzle, intermediate spindle, needle valve, lapping of needle valve and nozzle sealing face. Clean holes, check with go-no go gauge. Assemble and Pressure test. Adjust spring compression nut to vary the lifting pressure. 2. Explain how you will change gland packing of a pump stop pump, close inlet and outlet valves, remove gland cover. Take out glands, cut glands slightly larger than used glands, fix in gland housing, tighten with gland cover and nuts, open valves run pump and check for leakages. Check for smoke or steam from gland while running. 3. What is SDNR valve? Screw down non return valve. Floating valve on valve spindle. 4. How do you overhaul a globe valve? Chang gland packing, clean valve and spindle assembly, clean valve seat, lapping, grease spindle. Box up 5. How does a gate valve work? Operates by lifting or lowering a gate in the line of flow. Suitable for straight line flow and not for throttling. 6. If a gate valve is stuck, what could be the reason? Valve stuck in valve seat wedge due to overtightening or foreign material lodged between faces. 7. How is a job centered on a chuck in a lathe? By using the tail stock or by using a dial gauge. 8. What safety precaution will you take if working on a lathe? Ppe, safety guards in place, remove chuck key before starting 9. What is a reamer? Where it is used? Used to create an accurate sized hole, smoothing of the hole bore. 10. How does a Quick closing valve work? Air pressure acting on a servopiston mounted on the spindle keeps the valve open against spring force. When air supply cut off, spring force causes valve to shut. 11. How do you reset a QC valve after operation? Lift handle of air piston and open valve manually. 12. Is there any difference between relief valve and safety valve? Relief valve used in liquid systems, safety valve in gaseous systems, relief valve depends on pressure rise, safety valve opens at set pr, relief valve discharges back to suction line while safety valve vents off. 13. Explain how will you prepare for Bunkering? Add amergy 222 to the empty bunker tanks to facilitate settling of sludge and water. 14. How do you set tappet clearance? Allow engine to cool down completely. Trun engine to tdc, check both valves closed, turn push rods. Adjust nuts to zero tappet, then start opening for required tappet. 15. What are the steps to take after a blackout at sea? 16. How do you pressure test a fuel valve? 17. How will you replace an exhaust valve seat? Open the valve seat holding nuts form the valve assembly and tap with mallet for removing old seat, grinding of valve seat and valve done as required. Fix new valve seat after applying copaslip, check for leakage 18. How do you install a bearing on a shaft? Put bearing in hot well or oil heater or flame heating. Put shaft in fridge room. Insert immediately and slightly tap by using brass pipe. 19. How do you specify pipe size? Nominal pipe size/ nominal bore(us system) DN (nominal dia European system)in Inches and schedule. 20. What do the numbers on bearings mean? Ex 6203ZZ. 6 type single row deep groove ball bearing, 2series which indicates robustness of bearing, 8 Extra thin section 9 Very thin section 0 Extra light 1 Extra light thrust 2 Light 3 Medium 4 Heavy Last two digits indicate bore dia, 00-10mm01-12mm02-15mm03-17mm subsequently * 5. Z Single shielded ZZ Double shielded

21. What is the common size between different schedules of a pipe? Internal dia same. 22. If an A/E does not start what will be you action? Blow through again, turn engine by hand, ease up fuel racks, lubricate. 23. Your action if TIC is surging? Avoid sudden changes in load, reduce load, do water washing, blowing off air from air receiver valve but it leads to increase in exh temp. 24. Why is a steam trap used in condensate return lines? Maximum utilization of steam. 25. How is gas cutting done? By burning lp mixture of acetylene and oxygen the temperature of metal is raised to 1500-1600 f, then by supply of hp oxygen, burning of metal occurs. 26. How many valves are there on a gas-cutting torch? Oxygen regulator, acetylene regulator, flame arrestors, check valves, 27. How do light a gas-cutting torch and adjust the flame? Open acetylene, light with lighter, open oxygen and adjust flame. 28. How do you set up a new pipe for welding? Surface preparation, support for pipes to be welded, tack weld, single run weld. 29. What is GPRJ GPO ILH electrodes? Low hydrogen electrode, 30. How do you select the correct current setting for welding? Mentioned on electrode box. 31. Crank pin bearing clearance tdc- bottom end, bdc- top end bearing clearance. 32. Telescopic feeler gauge It is also known as tongue gauge and it consists of long feeler gauge inside a cover with tongue or curved edge. The long feeler strips protrude out of the cover so that it can be inserted in to remote places where feeler gauge access is not possible. 33. Piston removal procedure 34. Welding defects? Undercut, splatter, blow holes, slag inclusion, root penetration, fusion 35. Bridge gauge main bearing clearance 36. How does a Stud extractor work? Punch drill, stud extractor, turn. 37. How does a chain block work? Motion from hand chain transferred to load chain through gear arrangements. Rachet arrangement to avoin slipping. 38. What are the safeties on cargo cranes? Hoisting slewing luffing limit switches, overload protection, slack wire. Emergency stop.slip clutch 39. What are the safeties on ER crane? port stbd fwd aft limit switch, overload trip, emergency stop, hoisting limit switch, chain slack, 40. How is the load controlled during lowering? Regenerative breaking to prevent overspeed during lowering, reversible pole multi speed motor. Friction brake. Plugging by reversing magnetic field flux or armature current, dynamic breaking 41. How is the E/R crane load tested? 125% of swl, 1 mm deflection for every meter of chain length. 42. Fuel valve not coming out? 43. Setting exhaust valve timing 44. Pumps overhaul? 45. Type of drill bits? HSS, Brad point drill, masonry drill, spade drill, counter shank bits, self centering bits, oil bore, centre bore, taper shank, twist dirll 46. Types of threads? BSP britsish standard pipe, BSW british standard whitworth, winch thread, metric thread, square thread, v thread, acme thread. 47. Pipe Schedule? Wall thickness, 5/10/30/40/80/160 48. Important dimensions of flanges? Types of flanges? Od , Id, PCD, no of bolts, bolt circle dia, bolt dia, thickness of flange, welded, slip on, blind, threaded, reducing beck flange, spectacle flange, 49. Indications of scavenge fire? What action will you take? 50. Where are wear rings used? What is their purpose? Centrifugal pumps, 51. Boiler gauge glass? Reflex type? Blow through procedure? Reflex type- single glass. 52. ISSA code book? International ship supplier and services association. International marine purchasing association 53. SG hunting gear? 54. Axe blade? How fitted? Blade edges pointing outwards. 55. Load test? 56. SCBA pressure testing every 5 yrs, hyd pr test, 57. Welding surface preparation mill scale, weathering, pickling, flame cleaning, shot blasting, edge preparation,

58. No water in GG, What will be the action? Blow through, check second gauge glass, confirmed no water, shut down boiler. 59. Flaring tool expanding the end pipe section 60. What is an armato joint? 61. Why is a copper gasket annealed? Heated by flame and cooled suddenly for softening 62. How will you supervise a lub oil filter cleaning? Engine shut, c/o to secondary filter, 63. What precautions have to be taken during cleaning of SW line filters? Isolation, drain, vent, cleaning, fitting back, filling, venting, 64. What is a Dead mans alarm? Fitted in e/r must be acknowledged every 15 minutes, must be activated when entering er during ums condition. If not acknowledged wud give an alarm on bridge. 65. What will be your action if your Reliever appears drunk? Do not hand over watch, inform chief engineer. 66. Your oiler appears drunk. What is your action? Relieve him of work, call another oiler, inform chief engineer. 67. Compound gauge. 68. Method of blowing through gauge glass. 69. Pump shaft broken? Suggest repairs. Spare available change, not available order for new. 70. What is Gear Back Lash? 71. What are different types of gears seen in ship? Bevel, spur, worm, planetary, helical, rack and pinion 72. What is hunting tooth? Relative prime no of tooth on each gear, any tooth on one gear will contact all tooth on other gear, uniform wear and load distribution 73. What is gear oil different others? Load carrying capacity, resitance to oxidation and degradation, resistance to rust, resistance to faomin 74. What are the different types of Taps and Dies? Taps- rough(taper, plug, finishing), intermediate, fine tap.internal threading, die-external- adjustable and solid 75. Why do you take Ullages? How do you calculate liquid quantity? 76. What is VRF? Variable refrigerant flow 77. What do you check up while opening piston? Oil grooves free, deposits on cooling surface, template profile check, cracks 78. 0 closing valve operation? Why do you shut the valve again before opening? Locking devices and piston studs 79. Start airline getting hot. What action? 80. Draw a LS of ball bearing fitted on a shaft. 81. What is lip seal? Sketch. 82. Sketch a mechanical seal. 83. Exhaust bellow sketch? 84. What is a dresser coupling? 85. What is Bumping Clearance? How do you measure it? 86. Why is a centrifugal pump started with its discharge valve shut? Pressure on dish side max, dish head max, power consumed by pumop min. 87. How will you align a pump to its motor? By using a dial guage. 88. What checks will you make on a bottom end bearing bolt? Crack detection, elongation, damage to threads, ovality. 89. How do you measure ovality of a crank pin? 90. How does hydraulic tightening work? 91. Why is the jack turned back a little while slackening? since u r slackening the nut , there has to be a clearence between the bottom of the piston of jack and the top of the nut, or else both will get jammed...so u always loosen the jack a little 92. What will you check in Under Piston space inspection? Carbon deposits, oil, scoring marks on piston rod, diaphragm and stuffing box, scavenge ports clear, 93. How will you do crankcase inspection? 94. Shipside valve is leaking into E/R. What will you do? 95. What is the starting procedure for COPT? Fire boiler, start boiler feed water pump, open master steam valve fully, open sea water inlet outlet valves for copt lo cooler, start condensate pump, open steam inlet valve of copt gradually and put copt in rolling rpm, give control to ccr,

96. How to reduce prcssure in SCABA. Pressure reducing valve on face mask- 180 bar to 1 bar, 97. Portable CO2 extinguisher (test pressure) 98. Checks while 0/H centrifugal pump. Clearance between wear ring and impeller, shaft trueness, impeller for damage, pitting, seal, bearing, casing, difusor vanes, alignment. 99. Checks on steering gear before departure. 35 deg to 30 deg in 28 secs, communication, gyro sync, power failure and control failure alarm, rudder angle indicator, steering gear motor amperage, replenishing tank level, pump running, grease of rudder carrier bearing 100. Steering motor stripped out,actions taken. 101. Vessel is at anchorage for a month (outside the port) engine room is flooding suddenly. What actions will you take? emergency bilge suction. 102. Why are indicator cards taken and how many cards are there? Draw. Power card, compression dia, draw card, light spring. 103. How to indicate if power is reduced in the diagram? 104. ISM code in which SOLAS chapter? chapter 9. 105. Any pump overhaul (Screw, gear, centrifugal) 106. Removal of broken stud from pump casing. 107. Fire main system. 108. Pump not taking suction, reasons. Suction valve shut, hole in the line, air ingres from gland of pump or valve, npsh low, impeller damaged, priming system not working, obstruction in suction line, 109. L.O. Test onboard. Alkalinity, water content, drop, viscosity, contamination 110. Checking of connecting rod. Ovality, cracks, slipping of bolts, bolt tightness, fretting 111. Gland packing. 112. Cargo hold bilges, action. Odms, not to be mixed with e/r bilges. Slop tanks. 113. How to repair hole damage within pump? 114. Heavy weather, actions taken. Lashing of all loose materials and gear, reduce engine rpm if required. 115. White metal found in C/C. What are actions taken. Take all bearing clearances, identify source of white metal. Remedial actions. 116. PMS. Planned maintenance system, time based running hours, reduced down time, efficient utilization of labor, spares required can be preorderd, specialized work required can be pre ordered. 117. E/R crane maintenance. Greasing of wire, greasing of guide rails and gears, motor gears greasing, testing of limit switches, 118. M/E liner removal. 119. A/E bearing removal, installation. 120. Checks made after removal of cyl head. Pressure testing, crack testing, valve seat, injector seats, all mountings to be checked. 121. Crankshaft Deflection. 122. Emergency fire pump overhaul. 123. Liner removal. 124. Piston removal. 125. Connecting Rod removal. 126. 20 points in A/E Crankcase Inspection, when its is taken. 127. State reasons for scale formation in boilers. Reasons and effects. Presence of calcium and magnesium carbonates, sea water ingress, dissolved solids, overdosing, use of shore water, improper or inadequate chemical dosing, insufficient blow down. Effects- low conductor of heat, reduction in heat transfor, overheating of tubes, boiler collapse, steam production reduces, thermal efficiency reduces, quality of steam reduces, pitting corrosion, acidic corrosion. 128. If water level in boiler gauge glass can not be seen , what action will you take? 129. Before taking water in boilers, what will be checked by you! Quantity of top up required, if too much, reason for loss of water/steam, 130. What action will you take if you observe oil in hot well? Leaking tank heating coils or heat exchangers, if lube oil then check lo heater steam outlet valve and take sample from drain. If fo- check main engine fuel oil heater, tank drains, boiler fuel oil heater. Remedies- trace fault, rectify. Filters in hot well, skimming from top, skimming line, draining from top, siphoning by siphon tube in observation tank. Absorbent pads, news paper. Do not blow down boiler, surface blow down, do not blow down gauge glass, scum blow down, coagulants, maintain high alkalinity. 131.How many safety valves are there in a boiler? 3, 2 on main steam drum and one egb outlet.

132. How will you press up boiler from cold state? What is to be checked and done before bring? Fill boiler with hot deaerated water, initial dose of chemical, continue filling till water shows in gauge glass, close vents, ensure fd fan working, check fo system, start fo pump, check for leaks, heat fo to req temp using recirc line, or fire on MDO, raise sufficient steam for heating of fo, start fd fan, prepurge, ensure gauge glasses functioning, steam drum vents opened. Use lowest possible firing rate, adjust air supply, as boiler heats up, water level must rise, when steam shows in the vents, when steam enough, run circulating pump and circulate water in egb, close vents. @ 3 bar blow through gauge glass, remote indicator put in service, @10 bar follow up nuts and bolts of new joints. @ 14 bar, open drains on aux steam lines, crack open aux steam valve and warm up line. Close drains and fully open aux stop valves. Steam service can be now opened. Drain main steam line, warm up, open fully and close drains. 4-6 hrs. 133. What tests are carried out for boiler water? Alkalinity, ph test, total dissolved solids, conductivity, chlorides, phosphates, sulphites, hardness, dissolved o2, hydrazine test. 134. How much chloride content it present? How to reduce? <200ppm, blow down. 135. How many blow down valves are fitted in boiler? 136. If oil is present in boiler, what action will you take? 137. Effect of vacuum in boiler. Boiler will implode, collapse. To avoid open vents before full blowdown. 138. How do you find out that tube is leaking in a boiler? White smoke in funnel, loss of water 139. What are the sequenced of auto firing during starting and stopping? 140. State cause of back fire. oil dripping from fuel injector/atomizer, combustible gases accumulated in boiler furnace, improper pre purging, improper post purging, improper fuel preparation, manual start bypass purging, c/o do to ho or vice versa. 141. How will you blow through a boiler gauge glass? 142. What tests are done on boiler water and why? 143. How will you test the boiler water? 144. What does the term pH value mean? Negative logarithm of hydrogen ion concentration. Indication of degree of alkalinity or acidity of a substance. 7- neutral, 1-6 acidic, 8-14 alkaline. 145. What are the maximum values of alkalinity, pH value and chloride? What types of feed pump is fitted for a boiler? 10.5 to 11 ph. <200ppm, multistage centrifugal pump, water cooled. 146. If during blow through we find no water in a boiler, what action will you take? Check gauge glasses, Shut down boiler immediately, do not take water, check blow down valves for leakage, stop main steam stop valve, c/o engines to d/o. cool down boiler, check reason for low level. Fill water slowly and fire. 147. State safety device on a Boiler. Safety valves, gauge glasses, blow down valves, water level alarms, feed water regulator, check valves, scum valves, drains and vents. 148. How often is a boiler blown down and procedure? Partial every day. 149. Lift of a boiler safety valve. At least 1/4th of the valve bore. 150. State difference between smoke and water tube boilers. Smoke tube- combustion gases inside tubes, low efficiency, uneconomic, large size. Water tube- small size, economic, steam generation high, efficiciency high, water inside tubes.