HANDBOOK IT Kffi ENGINEERS

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Cuide Review

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" PH IL IPP IN E OP Y R IGH T 1993" C @

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By

C } i I E F E N G R . F E R D I N A N DG . M A R C O S

No port of this book moy be reproduced ony form, by mimeogrophinqor in by any meons without permissionin writing from the author

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Printedby: 55P Makati

ACKNOWLEDGEMENT

the whilere0ie(Ding dffient to prepared hetptheMarine Engineers bookwas exclusiaery This by licursur,,ro*lnofion conducted theProfessional in fo, subjects preparation tlreglorrrnnr*,t gul Re ationCommission' examination' duringtherecent encountered ,[.t compilation solutions tlrcproblents to of is a as an instant to includingan outlineto examinees, serae que.stions Tltereare alsoexercise of with in accordance the scope and principles concept on *ru iost iitndanrentnl refresher at of giaenby theRoarcl Examiners thePRC' usually theexamination and shippersonnel engineers cadet, apprentice guide -to.arl practical It is arsoa complete of possible high coaerage up-to-dafe t0 technology bring yiu the most on on board, the ratest on standard theiobaboardshiP' of thesupportof the staffand students and authorgratefullyacknowredges appreciatcs The INC' SERVICES' SEALANc COrvSuirancY AtlD GEAIERAL

Sarah lane'Christine to dedicated my wjf!, Terry-y"lryVdaughters' ts Thisbook roaingty in inspiration my tt N[arcoi *ho iort bien constant r-rrainond Ferriiianrtr' Ir., andmysans loy of to *y iourneY thePort success'

FERDINAND G. MARCOS Chief Engineer 1'981' PMMA, Class

Monilo,PhitiPPines 1129le6 l

PACE
PART I MATHEMATICS . Basic Futrdanrental of Flatlrenratic:, (l n c l u d e s : Al g e b ra , Ari tl ttneti c, !)l tysi :r, S trel rgth of l ' dateri al ) ,t r l Bo a rd P ro b l e ms a n d An s w ers: 19tt7--91 ,A ,!ll arrl ts(48, 3F-,2E , C E ) . Board Multiple Choice: All Ranks . Useful Engineer Fr:rmulas o Conversion Tables - Cuide C)rrlrl" A D ....... E LEC T R IC IT Y N D El -[C ]' ttl (:A t-!-V R I\i It.,] [-' r{i(F l l .l l .5l Ol { -l-errrrs . Definitions, Functions of Electlic-;rl . Board Questions ancl Answers: All Rarrks o T ro u b l e S h o o ti n g o f El e c tri calC onrporrerrt ..........71

PART f l

: Ili:,;tJ,.'ru;::"':l i,raLi. and ,.,, H,l?l',.,, r,,re, r

o o . r r Motor: Operation and Mainterranr.-e SwitchboardProtectiorr Electrical Formulasand Syrnbols Board Problem Solving: All Ranks Board Multiple Choice: All Ranls

PART III STEAMBOILER, TUIIBINIiS II{'TERhIAT. COI\,{iIT'5]-!ON ENGINES Sectlon | : Steam Boilers . Type, Uses,Classification . BoilerMountings,Accessories l:unctiorr:; and r BoilerTerminology,Usesand Functions . Safety Valves . BoilerWater Level Gauges . Maintenanqe Operation . Boiler CorrosionWater l-reatlrrerrt o BoilerWater Testing Procedures . Waste Heat BoilerProblems arrcJ Mairrtenarrr-e . Boiler Safetyand Descriptiorr . Procedures Emergency S e c t l o nl l : I n t e r n a l C o n r b u s t i o n[ , n g i n e . Definitions, Classifications o Principles Operatiorr of . Component Partsand Uses o ScavengingProcess U-'-c TurbochargingProcess . Definition of Terms . Board Questions and Arrswers a Fuel,Lube Oil, FreshWater Systerrr -lrouble o Standard OperatingProcedures, 5lrooling Sectlon f l l : S t e a mT u r b i n e s ,E n g i n e s . . " . . . . " O Definition,Classification, Operation o Fittingsand Functions o Board Questions and Answers- All Ranks

......191 .

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..,,722

IV

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' . PART IV

Reciprocating SteamEngine: Definitions, Advantages, Construction and Operations . Board Questions: lr4ultiple Choice : All Ranks ,...,...,.261

R E F R I G E R A T I O N D A I I I - C O N D I T I O N I N CA C H T N E R . . . . . . A M .Y ' Defiuitions, characteristic, [:r'r'rctions Typicalparts of . SafetyDevices . Definitionsof Technicall-errns o Operationand Maintenance Systerrr problems " Trouble shooting cuide to llefrigeration . Board ProblemSolvinqs All Rarrl<s . Board Multiple Ctroice: All Ranf<.s

PART V

P R A C T I C AE N G I N E E R T J I D E S L C ..",,..,,317 . Main EnginefndicatorDi;rgrarn Test " Main Engineperformance Oil " Fuel-Lube Tank Calculation o Inspection, Measuremertt, Proceclures, Cylincler Liner, piston Rings . Crankshaft Deflec -ion of Bearinc-;, " ClreckingClearances lr.,lairr Crosslread, CrankpinBearing . Readingon Enqirru Cclnclition Procedures Lngine Cylincler in " Emergency ' Draw Diaqramsand Interpretation o Monthly Reports, Maritime Reqr_rlations, Survey e Board Question and ,Answers: Ranks All o Test Procedure: SafetyMaintenanceprograrn |' Principles, Operation and N4aintenar.lce: purifier FreshWater Distiller, Cornprcssor, A,ir OrderingSpareParts,liafeti,tlill o B a s i cI n s t r u m e n t a t i o r - r o Welding SafetyarrrJ o Tr:clrrriclues DRAWING

PART VI P/\RT VII

| : Safety of t.lfe lt lt, F ire fi g h ti n g a rrd p re v r.l rl i o rr " F irs t Ai d " S u rv i v a l a t S e a " . Life b o a t H a n d l i n g Sectiorr !l : Oil l-arrker l;lfety Sectlorr lll : l r u e l - tC a s S y s f . e t r r PAi{"nvill Section I : I V l a c h i n eS l r n p I W e l d i n g T e c h n i q u e s , I' ri o l s a r rcJl i rl ui prnerrts, yrnbol s S S ec t ion ll : F u m p 1 -l re o ry , OJ l erati on and Mai ntenance section lll : control Autornationr Introduction....... Secti<lrr lv: orqanization of F.ngineDcpartrnent ....... W a tc h l < e e p i n q ,Sa fe O l te ra ti o n, B unkeri ng procedures o Board Exams Regulatiorrs rrr.l tequirements a Sectinrr V : Cocle arf F.tllicl

Sectlorr

,,,,,,,,,,428

........,474 ...........4g7

....503 ...531 ....5s3 ..s65

..........5g1

MATHEMATICS shipwe and engineers' crewaboard personnel' as our conln performing daiiyduties ship horsepower' speed, sl'rip jn"or"ing iant< calculatiorls, learning often solve simpleproblem, which need ou. b"ric fundamental sumptionsunJ-ruinematicarcarcutJtion everyday problems: pio.ttt in solvirr$ OF BASIC FUNDAMENTAL MATHEMATICS MULTIPLICATION is t h e p r o c e s s i n w h i c h i t i s d e s i r e d t o k n o w h o w m u c h o n e numberls time another' Examples:

2 x 432 x x 0.32 3.9472 x

= 1 2 g20B = 19 = 0.001472 0.0046 170.36115 43.16 =

one tc it is desired know how many times in DIVISION this is tlre process which numberwill go into another' ExamPles: 6 B1 18653 1121 3 9 18 3314 = = = = 2
cl

6/3=

1036.28 298.93

in eachcolumn termsand add the numbers in ADDlroN - addingnumbers similar separatelY.

Examples:
81 + 6.5 +

5 3

+ 1 2 =
F " 5 =

9B 10 946.75 8.42 .00842 : 955.17842

2a 5a

7 a +

7b + 2b + 5 b +

3c 6c 9c

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the terms,change signof theterm or numbers algebraic subtract SUBTRACTION-Io and to be subtracted then add'
ExamDles:

gztz8* -

12 2.s
(-5x)

= 8o = s.5
=

I
I
I

t*-

5x

13x

3x

t
I

wlrH slcNEDNUMBERS oPEBATIoNs

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ADDtrloN

la.rornumberswithsamesigns,addtheirabso|uteVa|uesandprefixthecommon to sign thosum.

Examples:

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I

I l;? lti : :i:

Examples: (+B)+ (-B) + (-4) (+'4) = = +4 -4

. b . F o r t w o n u m b e r s w i t h d i f f e r e n t s i g n s , s u b t r a c t t h e | o absolutes o | to thev a | U e | r o m w higher e r a bvalueU t e pt.ri" tnesignoithenumberwith ausotu;;"ir. ,nutrigner I ' "na ditference.

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to absolute the difference' withhigher ulfu" inJ pr.tir tn" signof the number aU.ofut"
Examples:

2- suBTRACrI9N lrom higher absolute the the subtract lower signs, with a. nnu niilO.rs same ii"o

valuesand prefixthe signs,add the absolute with different b. Any.lwonurnbers valueto the sum' with the higherabsolute sign of the nu!'nber
S Fxample :

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3.

MUI.TIPLICATION positive' havingthe same signsis always of a. The product two numbers Examples: (+6) (+3) = (-6) (*3) =
(+18) (+18)

signsis alwaysnegative' with different of b. The product two nurnbers Examples:

(+6) (-3) : (-6) (+3) = 4. (-18) (-1B)

DIVISION i s a l w a y sp o s i t t v e ' a, The quotientof Wvon u m b e r s h a v i n gt h e s a r n es i g n s

Examples:
(+9) i (+3) = (-t3)

(-s) /

(-3)

(*3)

negative' signsis always withdifferent of b. The quotient two numbers Examples: (+9)/ (-3) =

n, / ..,

(+3)

(3) (-3)

SCALECONVERSION TEMPERATURE 1'o convert 212"Fto "C 32 Subtract from Ex: 'F bY bY and divideremainder 9 and multiPlY 5'

212-32 = 180+9 = 20x 5 = 1 0 0 " C

To convert 260 "C to "F bY bY Divide 5, multiPlY 9 and add 32 Ex: 260*5 = 52 x 9 = 468 + 32 = 500"F

$i [t

r E t s N, I \

or as maybe expressed a fraction number less DECIMAL$ a number thana whole as a decimal.
onetenth = , 1 = 0.1 10 1 -= 0.01 o n e h u n d r e d t h= 100 = 0.001 1 o n e t h o u s a n d t h= 1000 o n e a n d t h r e e t e n t h= 1 3 = 1 . 3 s 10

the or numberare addedtogether subtracted, decimalpointmust Whendecinral be placedone belowthe other. Examples: a) Add to 4.3785 29.46 4.3785

-?9-49_ 33"8385
b) from48.82 Subtract 3.8648

48.8200 3.BS4q_ 44.9552

Converslon of Percent to Declmal E:<amples: EB% :: 0.35 1. S B : 99.34% = 0.88 15% 1SB% 0.9934

fr
Conversionof Fraction to Decintal 1 1 2= 5/B = 314 = 0.5 0.625 0.75 by rnultiplied itself a of powER - an indexis a shortmetlrod expressing quantity o number f tirnes" amPles: F.x
Z 3 X X 2 3 4 2 = = = 2 3 7 3 26

H h h
I

3 5 (2r).

indices) (addirrg indices) (a surtrtracting indices) (multiPlYing

il

is sYrnbol Jof ROOTS- is the opposite a powerand the root ExamPles: tl'resquareroot of 49 the cube rootof 27
6 --T 2 = 3 2

= = {g - \/27 :
= 9

7 3

y r q u a n t i t w i t ha n o t h e q u a n t i t o f t h e y e n R A T I S- i s a c o m p a r i s oo f t l r em a g n i t u do f o n e in fractional stated 6f the expresses retationship oneto theotherandtherefore kind;it sarne fortn.The ratillsignis the colon:
--r.r hp 2 meters. o o n a n t i r r o l v tthe ancl m a l a r o ,respectively, of Thelcngths twobarsare250millimeters expressed' of ratio oneto another must bothquan'tities be sameunits note: 250 . , 2C00 B 1: or Exarnple' \

of rhat expresses ratio onepairofquantities of pRopoRTloN- is anequation ratios, colon: thedouble sigrr pair. Tlreproportion is of to is eqrral the ratio another
Examples: 5 : 10 10 20 2 C : 2 0 :

or or

40 40

5 = 10

40

o. A pumptakes55 minutes deliver to 4400titers water. of Howtongwo'Jld take it to deliver6000liters? = t i m ei n m i n u t ets d e l i v e6 0 0 0l i t e r s . L e tX o r Ratio tirnes of taken : : F:latio quantities of deliver 55:x ::4400 : 60C)0 X x 4400 = 55x 0000 x = 5 5- x 6 0 0 0 4400 = 7 5m i n u t e s . x METI'loD OF UNITY- dealsto proportion problems especially compound with proportion morethantwopairquantities. with
Example: A shiptravelling 12 knotscancomplete certain at a voyagein 16days.How m a n yd a y sw o u l dt h e s h i pt a k et o d o t h e s a m ev o y a g e t a s p e e do f 1 5 k n o t s ? a A t a s p e e do f 1 2 k n o t s t i m e , A t a s p e e do f 1 k n o t ,t i m e A t a s p e e do f 1 5 k n o t s t i m e , = = = = 16 d a y s 16 x 12days 16 x 12 15 1Z.B ays d

PERCENTAGE is another rnethod expressing ratioin fractional of a formusing100 as the denominator symbol"/o. and Ratioof 4 to 21i = 4 i n fr a c t i o n a l r . m fo 25 = l 6 d e n o m i n a to f 1 0 0 r 100 "ll6"/,, percentage in fornr.

FACTORiING-is reverse multiplying,is tlreprocess finding the of it of the nurnbers or quantities which,when multiplied togethei will constitute expressio]r the given to be factorized.

rF
Example:

2 2
3x

3
F

(3

5) xz z)

ZxY + ( 3 + 2 Y 16

Y2

(y +

4) (v

4 )

value of the algebraic the numerical EVALUATIoN- is the processof substituting expression' and woikingout the valueof the whole symbols Examples: Evaluate3xY+X2-4Y whenx--ZandY=3 4Y 3xy"r x2 3 x 2 x 3 + 2 2 - 4 x 3 12 4 18 + 10

in andtimeinvolved of the amount labor is LoGARrllMs - purpose to be reduced and of po\^/ers root' and and multiplication division thesotution
Examples: 1. F i n dt h e v a l u eo f 0 ' 0 4 2 1 8x 4750 = 1.37489 B L o go f 0 . 0 4 2 1 (add) = 3.67669 4750 Log of 1 =: 2 . 3 0 8 Sum .4 200 ans. o antilog f2.3018 = 240 bY 4345 2. Divide Log of 240 Log oi 4345 difference of antitog -1 '2578

2.3802 3.6380 -1.2578 a 0.05524 ns.

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o t ) P O W E R F i n d h ev a l u e f ( 4 . 1 8 9 '
= log of 4.1Bg bY multiply' the Dower =' o antilog f 1.2442 = 0.6221 1 1.2442 1 7 ' 5 5a n s '

ROOT- Findthe squarerootof 7365 = 3'8672 log of 7365 1.9336 3.B672.divicJebY2 = = 8 5 . 8 2a n s ' o antilog f 1.9336 of consisting two sides,one sidebeingequalin EqUATION- is an expression other. v a l u et o t h e 4x + 4x = 4 v = X = l0 = 18 B 2 18 10 14x-2x-5x=B-15+28 7x = 21 x - 3

Simplify the following equations: a) (a+b)z a a + + il b

b? b2 a2

b)

(a-b)' a b b
ab a b + b 2 Zab + b2

Ans. x

x
a2

a 2 + a b -r- ab + Zab -r' a2 +

b)

g i F i n dt h e v a l u eo f x a n c y i n t h e f o l l o l t ' i ne q u a t i o n s : llx 5y = 50

Ir--r _9r*-:--i! -- 2
l2x ( )( = = 180 180 12 15

Substitute:
5 x 5 y = 5 0 50 5(15) 5Y = 7 5 5 y = 5 0 5 y = 5 0 -Zs y = * 5 5 c) m Add the following i x e dn u m b e r s . 3 5 3/8, 1 2 1 1 4 , 3 1 4 4 3 + B LCD 4 9 +
A &i

75

15 4 9 8 + 3 0

4 3 + 171

B o r 2 1. 3 7 5

MATHEMATICS(AL\3EBRA)

1.

t h eu n k n o w n ? r a r i o n e n u m b e rs g t i m e s n o t h en u m b e a n dt h e i rs u mi s 4 5 .F i n d

Let

B x = 8 x = 9 x =
X =

s m a l l en u n t b e r r largernumber 45 45 4 5 = 9

number 5 srnaller

B ( 5) =

n 40 bigger umber

10

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I I I I I I I I I I I I I I I I I t
I t

is 60 ft. Findthe as is 2. lf a rectangle 4 tinnes long as its width and its perimeter lengthand the width. L e t x = width 4 x = length 2(ax) + Bx + (2x) = 2x= 10x-| = 60 60 60 6 width

therefore:4x =.

,4(6) =

24 length

oscar can to it 3. How long4ryill takeoscar and Bong,together plowa field which do alonein dOays,an6 Bongdo the iob in 8 days? Letx
_1 x 1
q
v

=
= =

numberof days Oscar& Bongcan plow the fieldtogether' w o r kd o n eb y O s c a r& B o n gi n o n e d a Y work doneby Oscarin one daY work doneby Bongin one daY

B Equation:
_1
q
v

*1_.
R

{
X

LCD:

+ 40

B
1 X 40

,\

13
40 1 3x
X

X = 40

13
3.08 days

4.

tn" sum of two consecutivenurnberis 26. What are the numbers.

Solution:
X

Let x
X X + +
1 1
I

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I

2x

r-

I I
ll

1 s tn u m b e r 2 n dn u m b e r 26 26 26-1 25 2 12.5 11

tl

il

h
what wlll be the sum? and 11124, Cl. When you add 5lB;7112

lL 5r'L+ 8 1 2 2 4
15 + 14 + 11 =

Find: LCD = 24 4O or12 2 4 3

t t
I

24
O.

When you subtract 5/6 from B/15,what will be the dlfference?

.L_3
6 15

LCD = 30

2s - 16 30
Q.

-.lx or .3
30 10

What ls the product of 5/B and 417?

* x+=
Q. The quotlentof 13 divldedby 317l s :

-Y-

6 r n

\-/

1 -

J-

-tl,

z.

14

13+&
7

1 3 ^ v 3 - - - 9 1 o r 30 J J 1 3 3 2

Cl. Solvefof x ln the equatlon 12x + 25 -- 35 ;= 14x + 2 2 x 1 2 x + 2 5 - 3 5 = 1 4 x r 22x 2 1 2 x- 1 4 x- 2 2 x = - 2 2 + 3 5 - 2 5 1 2 x- 3 6 x = 3 5 4 7 -24x = -12 X = - 1 2 -24 x = J 2

12

O. A wire ls to be cut so that one pieceis shortenthan the other by 8 meters.How long are the piecesif their combinedlengthis 24 meters. x + 2 x 2x x B x = B = = 4 2 4 = 24 + I 3 2 2 = 16 meterslongerwire = 8 metersshorterwire 2

x - g = 16 - I x FACTORS CONVERSION TemperatureScale: 't. 1000C Convert

Ans. oF = g

oF and 212oF
C + 32

oC
oC = -5(oF 32)

= = -oF :

g x 100 + 5 + 900
S

32 32 32

= _5_ (212 9 = 5 (180)

g

32)

180
212

=
oC =

900
I 100

z.

convert s;o'c
4000F BOOC

oF
0c OF

Answer: 572.'F 204.44 "C 1760F

Measurements: 't. the follo'wings: Convert a) b) c) d) 60 mi/hr. 6.56 km/hr. 375 hp 700 mm FtlSec,meter/set-;. FVSec. watts feet

13

Answer: a) 60 ti hr =

x 1 . 6k m )( 1000m 1 km. 1 mi. 314880

x 3'28ft' x t hr' x 1 min. 60 min' 60 sec. 1m

= 87 '47tVsec'

6,o
= m/sec 87.46tvsec= 26.67 3.28fVm x m 100-0 1 km = x 3'28 ft' x -]-!1!3600soc' 1m ft./sec. 5.gB

b) 6.56km/hr =

tt. 21516.8 3600sec

hp c) 375 . z4l,ff*
= 279,750watts" d ) 7 0 0 m mx = 2.30ft. 1cm x 1 0m m . linch x 2 ' 5 4c m ' x 1ft" 1 2i n '

seconds' from 36 km/hr.to 108km/hr'ln 20 unirormry speedrncreases o, A trucKs determlnethe: \ (velocitY) sPeed a) average in b) the acceleration meter/sec' c)thedistancesinmetercoveredduringthisperiod. 36 Solution: km/hr= 10 m/sec ; a) != Vf + Ve 2 30 + 10 2 = 20 m/sec. != 36+ 108 2 ' 72 km./hr. 108km/hr = 30 m/sec. b)a = Vf - Vo t = _30 -_ 10 20 = 1 m/sec.2 c)S = Vt = 20 (20) s = 400m.

J J J J I

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PYTHAGoREANTHEoREMoTRIGHTANGLETR|ANGLE of the l. The baseof a trlanglels 5 ft. and altltudele 8 ft. What ls the hypothenure glven trlangle? Figure \ a = 8,ft. |

t
l-

e= ?

t\

b = 5ft.
A2 +ba 8 2 n 5 2

Formula:
c2

\ffi
c
Z. vfgg 9.43ft.

functlonsof an angleA ll lts elnelg U5" Flndthe valuesof the threetrlgonometrlc B

8 = 3

c
\

: By PhythagoneanTheorem
C 2 = b 2 =
h v

Note:

SOH Sine Cosine

a2 + C2

b2 a2

b b
l"r u

= vlfzs =

Tan

TOA CAH opposite = alc E! 3/5 hypothenuse 4t5 =__ggisgnt = b/c hypothenuse 314 = opposite = alb adjacent

\fJ6
4

t9!he I,r that Theorlnexpressed thehypothenuse equal the e. State phytagorean Cl rlghtanglewhoseformula s called 8umof the squaied'tttretwo ht.. tt ts itso andbase. acent adf ar + br; anbthe anglesldesCreopposlte,
15

3. The diameterof a round steetbar is 50 mm.Whatis the biggestsizeof square nut that can be madefrom the bar.

t
d = 50mm

By: Phythagorean Theorem.

a 2 + a 2 = d 2 2a2 = (50), a2 25002

a =\m-oa = 35.3555 mm. size of the square a2 = 1250 m2 4. What is the circumference a circle whose radius is Tllrnrcters? of

Formula: Circumference circle of a where r C

21lr r
7'', = 7'5 2 ( 3 . 1 4 1 6()7 . 5 ) (6.2834) (7.5) 4 7 . 1 3m e t e r s

5.

Whatis the lateral areaof a spherewhosediamete'r 10 f t. is Solution:

Area of sphere = =,

ff o,

4 3 . 1 16 ( 10 ) ' 4 3 . 1 16 ( 10 0 ) = 31 .1 4 6

J J J I I I I I I I

16

6.

Findthe areaof a circlewhosediameter 3 ft. Whatls the areaIn mllllmeter? is Ans.

= n
4

d 2

A= 1I d2
4

=tti"
= ? 7.

(3)'

.7854(914.4mm)2 sq. 056694.42 mm.

.7854(g) { 7.068sq. ft.

Flnd the helght of a cyllnder tank whlch hold 250 gallons and dla.24Inches? Volume height

= .7'854 h D2 = volume .7854D2 = 2 5 0( 2 3 1 )

.7854 (24\'

1 g a l . = 2 3 1c u .i n .

= 127 approx. 0 1/, 1 ft. "6' 8. A cylindrical tank 12ft. longholds 2600galswhenfull, what is the dlameter of the tank? Volume (D)' .l .795,4 Diameter \ = Vo!u[e (H) .7854
D2

1 g a l . = 2 3 1c u .i n .

2,600 x, 23_!_
( . 7 8 5 4 1 2x 1 2 )

D2

= 600 600 11 3 . 0 9

D D
= 7 2 . 8 7i n c h e s

17

;n
cm' lst95 in g. A hexagon equat sidesis inscribed a circlewhoseclrcumference of Whatareth6 lengthof the sldesof the hexagon? Area = z i I R , erence = z f r r Circumf Radius = -- C
2ll 95

H T

IJ

1 2 ( 3 . 1 46 ) 95 6.2832 c 15.12m.

H
{

t
* {

cm' is equal 15.12 length therefore sides has hexagon 6 equal Since hlgh'How and shipis 15ft. in diameter 7 meters tankof a container 10. Theservice no gravlty a fuel ls 0.95assumlng of lc lf muchf ueloll can lt accommodate the speclf volumeerpanslon. Given: h dia. Solution: Volume = areaof base x height = =

7m = 22.96ft. SP.gr"= 0'95 1 5f t .

,
{ {

e6) = itrrli;i,, x (22

(0.e5) (22.e6) (225) .7854 ft.3 8354.5
{

= Volume =

to of diameter a roundstocknecessary makea squarekey 11. what ls the minimum 5" on eachslde? By: PhythagoreanTheorem.

(s)' + (5)',
25 inc.z

ffi;

q E

I I

x = 7.0'/inches

18

r 12. Flnd the volumeof the given c y l i n d e a n d its contentIn metricton of fuel oil whose speclflcgravityis 0.96? dia = 5 ft. Volume :
=

5 . 2 5m

where ft. = 1.52m 5

Volume =

Areaof base x height ( ( . 7 8 5 4 1 . 5 2 ) '5 . 2 s ) ( ) . 7 8 5 4 2 . 3 1( 5 . 2 5 ) 9 . 5 2m 3 x . 9 6s . g . M 9.145 T

PROBLEMS PUMPS 5" 200rpm has dlmensions x 6" x 4"" Slip 1. A slngleactlngpowerpumpmaking (G.P.M.) In 4.57o. Whatls lts actualdischarge gallonsper mlnute? ls 1 g a l i o n = 2 3 1c u .i n . GPM = 'rol. cyl. x no.of strokes x Efficiency of 231 = .7854 x 62 x 4 x 200 x 0.955
231 -= 21601"64

GPM

231 = 93.5

pump8" x 6" gallons. duplexdouble-actlng A 2. A doublebottomtankholds6530 1Oo/". How long will lt take to x 10" makes35 doublestrokesper minute.Leakage purnpout the tank? GPM = vol.of cyl. x no.of strokes x Efficiency 231 =: .7854 x 62 x 10x(35 x 4) x .90 231
= 35625.74 GPM

231 = 154.224
42.34minutes

therefore 6530 i- 154.224 -

19

&
H

t,
il
i 1

t
25 RPMslip ll%' what ls lts 3. A duPlex double acting PumP4" x 6" x 6" makes actual discharge ln G.P.M?
GPM = .7851 x 231 (6)'? x . 6x(25 x 4) x 231 '96 l

iJ'l ir

I
I

GPM

16286 231 70.502

pitch of the proPeller lf 4. A ship covers 242.6actual miles in a day. Firrd the efficiency is 87'/"and speed ls 98 RPM? Formula: Pitch

miles = 6080 x observed N x 60 x 24 x E = 6080 x 242.6 98 x 60 x 24 x 0'87 = 1475008 1 2 2 74 . 4 7 = 12tl.

Find the average s 5. A ship travel 5742miles in 26 days, 16 hour and B minutes. voyage. speed in knots for the.entire N o . o f m i n .p e r v o y a g e = t(26 x 24)) + 16 x 60 + =640 x 60 + B = 38400 + B -- 38408min. 5 7 4 2r n i l e s = 0 ' l / 9 5 M i l ep e r m i n u t e = 3 8 4 0 8m i n s . 6C x 0.1495 Mileperhour = = 8 . 9 7o r 9 k n o t s .
i

i #
t] tl

F $

per hour.The englnespeedls 17'5 6. A ship makesan observedspeedof 17 knots ohandhow many nautical miles the ship makes knots. what is the propellerslip ln in 24 hours?

20

%slip

=jS

OS x 100

ES = 17.5 17 x 100 . 175 = 0 . 0 2 8 5 7x 1 0 0 = 2.857% speed x 24 hours miles = observed Nautical 'x 24 hours = 17 .= 408knots or = 408lrtM mlles ln 22 days,12 nautlcal ol a shlp navigated distarrce 7,2O0 T. A merchant for the wholevoyage. speed the Cornpute average hoursand 30 minutes. Ans. S t t Ave.sPeed = = 7200NM Z2daYs x 24 + 12 + .5 h 540.5 ours = mi. distance 7,200 5405 h*. tl'". = 13.32 nots. k

o t b l B . A s h i pc r a n el i f t sa 1 , 5 0 0b s .s t e e t e a m o a h e i g h t f 4 4 f t . i n 1 0 s e c 'F i n dt h e powerdeveloped.
Given: \ F = 1 5 0 0l b . x 1 kg = i-;2k,. M 13.415 6 8 1" 8 2k g .

d = t Power :

44 ft. = 10sec. wOrkdone t*- .ll"p*d

lg:t
=

- ottt*_

time m 2 6 8 1. 8 2k g .x 9 . 8 m / s e c -x 1 3 " 4 1 5 . 1 O- t " per sec.or watts 8963.68 ioule

verticallywhen a load g. A wire 120 inch long with a cross sectionof 0.125in2hang of of 480 lbs. is applied to tt'tewire it streches 0.015 inch. Find Young Modulus Elastlcity.

21

y=_Stresq=rc
Y = Y Y = = AUL Strain in'z 450lbs'/ 0'125
5 O.Of in. I 120inch'

3600Psi 0.000125 Psi 2'BBx 107 Psi or 28'800'000

consumptlon 18knots'th'e barrelof f ueroil on boalt$ ,'iruc'-*-iiJt theeteamlng ls port wrth12000 A 10. shrpleft has tneGsser trilJir"o aooo

p"i 400 rs barrer dry,arter

radlus?

'= 1Bknots x 2'l = 432miles = 400 + 432 Cons' of oil Per 1 mile barrel = .9259 = 2000 x .9259 Fuel cons' at 2000 mile .B = 1851 barrel ' 18 5 18 Fuel on board = 1 2 0 0 0 = 10148"2barret SPeed Remainingsteamingradius =

1o1gl.2
.9259 miles 10,960

what ls the propellerpitch of 21 ft' mr/dayat z0 RpM with 11" A ships make310 etflclencY? proPeller Eft. Propeller

ED x qqqqft'
P * R P M x T i m e

320 {_ 6099 i : x 7 0 x 1 4 4 0
= 194560L 2,116,800 = .9191x 100 "/" = 91.91 fuel Howmaly oallonsof of luel 130grat::t{uer perBHp.-HR' o"trv'riirtlp"t*l;ravlty 12.your engineconsumes e*p, fi;ffi"

ii06o Jeveroprng wl* yourengine

at .92?

ii ii
$i
$,

22

-,-

,,

il lltIIf4E

cons./day =

f3Ogt./BHP-HR grms. .92 x 1000,000 3744q000. .

e2q000
= in cons/day gal = = 40.7m3 40'7 x 1090 1m3 10,752.94 x -O'ZAQg^l 1L

r 7 ft. Every4 hours watchthe helght 1g. your dally use f uel tank has or dramete or hourlyconsumptlonln llters? level goes oown 15 lnches.what ls your average Given:

Tankdia. = 7 ll. = 84 inches diff Height . = 15 inches Vol' = ll D2h ConsumPtion 4 (84)'"(15) = .7854 in3 = 83126"736 Per4 hrs' in3 = 20791.684 Perhr" = 20781.684 {.-llI9ICons.in liters i 6 1. 0 1 2 8n 3 = 340.61 Liters hour 1 Pe."

ON FOR COMPUTATION FUELCONSLIMPTION BOARD lc salllngwhosef uel speclf gravltyat 150c 20 I . MVDonaEvelyncbnsumes MT/day Flnd the cons' lrl llters' per neiteA ls-'9542. - .g780and correctlonlactor at 85oC mlnutes. watch hour and So|ution: 1. 20 MT x jjgq! 1 Ton = 20p00Liters

2_,.,?loog:!= =
' 3.- 21'541 L 6 watch/daY

uters 21.*1 ffi

= 3590 lJwatch a 997 UHr' = 15 Umin. 23

whosecons. per day is 27.10MT in 2. Find the tuel consumption GRMS'BHP/HR (metricton) and actualBHPls 7109.52. Solution: kg/day = 27.10 kg = 27'100 MT x 1000 1 to" = 1,129kg/hr. = 27100kglday 24 Wlday = 1 , 1 2 9 k 9 x 1 0 0 0 g r m g =1 , 1 2 9 , 1 6 6 g r m s / h r 1 Kg Hr. = 1, 129.1 = luelcons. grms 66 in 7109.52 actualBHP = 158.82 gms-bhp/hr.

tl h
I

t
I
I

'::D

O. Find the cytinder oil in grm-bhp/hr.whose consumption 189.36liters/day, maximumBHP8200; gravity= .95iave.rpm 'l41.30 shoptrial rpm = 150 = Speclfic and Form ula: . Cyf oilcons.

= =

Nex Vd x V'x 1000 W 1 5 0x 1 8 9 . 3 6 . 9 5x 1 0 0 0 x 14W

Cyl.oilcons.

-eA,9g9,B0A27,807 ,840 = 0.970 grms-bhp/hr.

where Ne=shoprpm - a c t u a lr p m N = rated utput n" o l ViJ =cyl.oicons. \u/o = sPecific \ gravity

BUNKERING WHEN TANKS CALCULATIONS (cubic f meter) 100% ull.Howmany at is O. Yourf ueltankon board capacity 1500M3 at metrictons areyou required fuel whosespecificgravityis .9768 15"Clf tank to of ls of ls coefficient expansion full be filledup to 95o/o of f uelwhosetemperature 45oC, givendata: .000720 Formula: Netvol.M3 First Second

= = = = = T ob eb u n k e r =

x (Tr-- T., coef. expansionvol.m') x of 1500m3x 95%= 1425M3 -. x 1425) .00072Cr 1425 (450 15ox - 30.78 1425 (0.9768) 1394.22 at 15"C m3 1 3 6 1 . 8M T 7

24

per , Cl. FuelConsumption voyagedistance? of to consumed coverthe distance 7,000miles? How muchfuet be efficiencY_= mechanical Givendatas:Bore=680mmistroke= 1250mm;6 cylinder = gSo/o,MEp Kg/cm2; cons.gr-BHP/Hr 156,F.O. M, RPM= 140;Pitch= 3"15 F.O. = g.5 propeller slip =50/otemp.of F.o. + 850c, Heatlng = s.G. at 150C 0.9700, = w h e r e B o r e= 6 8 c m ; S t r o k e 1 . 2 5 ;A r e a= 3 , 6 3 1 . 6 8 9 : ns: Solutio = 1 . c y ' l i n 6 e r c o n s t a n tL x A = 1 " 2 5 x 3 ' 6 9 1 q
4500 := 1.0088 4500

' 2 ' P r o pd i s t '

6 3 ' 1 5M x 3 ' 2 8F t '= l ! ' 3 9 F ! . = ' 0 0 1 6 9 7 3M i l e 6080FVM|. x 3 . B H P = c y l .c o n s t a n t R P Mx P . x M Ex n o ' o f c y l . 100 = f . 0 0 8 9 1 4 0x 8 . 5x 8 5 x 6 x 100 BHP = 6122 x 4 . F . O . o n s . / H r . = 6 1 2 2 1 5 6g m s C : = 9 5 5 , 0 3 2 +! . 0 0 0 , 0 0 0 -- 0.95503 MT m x P r o p d i s t a n c e / m i n = " 0 0 1 6 9 7 3 61 4 0R P M= 0. 2 3 7 6 ? i " " . m 2 P r o pd i s t a n c e . h o u= 0 . 2 3 7 6 x 6 0 = 1 4 . 2 5 i . . t with Prop. distance/hr. 5% slip =

: ffJ;;::
'\

=1354mi

13.54 i/hr. m = 516.9,8Hours. (516.98) Mr;/HR) Totalconsumption = (0.95503

:i 493"74 MT

0 . A 1 , 5 0 0H P t u r b i n eo p e r a t i n ga t f u l ! l o a d f o r a n e n t i r ed a y r e q u i r e st h e b u r n i n g the o{ 6.5tons of f uel oil. Calculate f uel consumptionirrpounds per horsepowerhour. Given: F u e lc o n s . = 6 . 5 t o n s HPofturbine = 1,500 l G . r t o n sx 2 0 0 0 l b s . = 1 3 , 0 0 0 b s . S 1 ton l F u e lc o n s . = 1 3 , 0 0 0 b s . 15 0 0 H P = t].666lb. per horsepower-hr. 25

Findthe average O. A ship travels5700milesin 26 days'16 hoursand I minutes. speedIn knotsfor the entlrevoyage'
Given: distance time 5 7 0 0m i . 26 days,16 lrr.and I mins. 26x24+16+.133 h 640.133 rs. travelled distance timeellapsed 5700miles

h h

It

speed Ave;.

6 4 0 . 1 3h r s . 3 = 8.90knots at counterreads 69,985 8:00 am at 11:00am the clock was O. A revolution and at noonthe counterreads87,319.Whatwas the average d advance 1Tmlnutes speedon the 8 to 12 o'clockwatch?
Formula" Ave. Speed

reading in advanced counter in minutes watch 87,319 69,985

\ A v e .s p e e d

+ 3 h r s .( 6 0 ) 4 3 m i n s . 17334 223 R 77.73 PM.

Whatls lts speciflcgravltyat al Q. A fuel oil has a sPecificgravityof 0.948 24'C. p 15"C?Correctioncoefficient i s . 0 0 0 6 3 e r 1 " C . Given: S G = 0.948 = 24.50c T1 150c T 2 = = 0.00063 corr.coeff. Solution: a. T., T, =' 24.5- 1 5 = 9 . 5 0 C x b. 9.5"C .00063 = .005985 = S + c . 0 . 9 4 8 . 0 0 5 9 8 5 0 . 9 5 3 9 Ga t 1 s o C

26

dig::l o i l i s 0 . E 6 5 a t 3 0 " F . W h a t i s i t s g r a v i t y a t S 4 o F ? S . G . Q. SPeclflcgravitY-of Per1"F' correctlonls .00037 Given: SG

T1 T2 corr. coeff' Solution:

= 0.865 = 300F = B4"F : = 0 . 0 0 0 3 7 e r1 " 1 : P

g4-30 = 54"F a . Tr- T', = = b . 5 4x 0 . 0 0 0 3 7 0 . 0 1 9 9 8 - 0 . 0 1 9 9 8= 0.8450at B4oF

0.865

supplyyou suppller wiil shipownner roseif F'o' how much Bunkering, g0'9785at 15oc; r"rl'p;t" o. Durrng thederivetv f Thesupprierigure_s.o_nYour t"q'i*htnt i 500 MT' Before is F.o. at $g0per MT. 515 rn3' was pumping temp. 25.C; l:9i uotui',. o.g;is at 35"cuittt'unkerirrgsounding s.G testsnows: hydrometer bunkerrng ship trim ccrrection' apptying rounJ itt *. at 40"cafter takenand will if figure, rrot youuseinterpolated usesupplier if w'r shipowner rose you NoTE: figure: hydrometer Solution: Tons: irr figure Metric a. SuPPlier x511)l .

000720 15x Mr ==::;:*;u1i]lT;;i(40

( : . 9 7 8 55 0 1 ' B o 2 ) = 491.01 MT

b . U s i n g S h i p F i g u r e b y h y d r o m e t e r t 0 0 0 7S 0G . 9 5 2 5 a t 3 5 " C e s t : 2. ) - : = ' 9 5 2 5 ( 3 5- 1 5 x' + S . Ga t 1 5" C

s.G

Mr

ooo72ox511) = ::::l;ii finJu.

' 9 6 6 9x 5 0 1 ' 8 0 2 -485'19 - ShiP Figure fi 4 9 1 ' 0 1- S r r p p l i e rg u r e I 485.1 5 " 8 2M T s h o r to f d e l i v e r Y $523'80Losses x 5"82tr4T $90nr =

: =

+ .9525 0'0144 0.9669

: MT = Therefore:

27

c.

figures: UsingAll SuPPliers x - 1 5 x' 0 0 0 7 2 0 5 1 5 ) M T = ' 9 7 8 5x 5 1 5 ( 2 5 x = . 9 7 8 5 5 1 5- 3 ' 7 0 8 = . 9 7 8 5x 5 1 1. 2 9 2m 3 = 500.30 500'30- MT SuPPlier OwnerLosses = - S h i P{ i g u r e - 485"19 t5J 1 MT x $90 := $1'359'9C MT

+ f
i

specific gravity: Formula of fuet mixed with

rl5)-(S B S.c. = (Oty. efo re L-oading MTXED ived m3

= = S.G. =

100 ms(.950\+ 200 q3 ("960\ 100 m3+ 200 m3 95+ 192 300 0.956

gives a 6 to prev'entcavitation and is fitted with a raised reservoir the pressure worked o. A hydraulic rp."itic giavity 91o r.g/r*3.'Deteimine meter column of oil "t at the pump intake port' ' Solution: l. Force = 6x910x9'81 = 5 3 , 5 6 2N = 53,562 = ll. Pressure Force 1 m2 Area

=-ll'-li ?l

largeoistondiameter . ratio the_area is 100:1 The 400 system Q. ln a rorcemurtiplication a drstance 130mmii il; fiatipt'ston stroke or moverh;;;h rs 150mm and rt iitravel per stroke' tlmes'Wrrat,O'itntt does Solution: t l . V o l u m eo d i s p l a c e l a r g e p i s t o n i n v o | u m e d i s p l a c e b y a s m a l l p i s t o n :

A = 3o'n
4

28

il.

1 ( 1 1 0 . 7 8 5 40 . 5 X 0 . 5 X ( ) .3 ) m3 =, .0022972 x Piston= _ l x 0 . 1 5x 0 . 1 5 0 . 7 8 5 4 Areaof Small 100

= .0001767rnz m2 Volume= 2.2972jx 10-3 Ar*

lll. TotalStroke=

lV" SingleStroke

m2 767x 10'3 0.1 1 3m e t e r m 1 3m = 32.5r 10-3

TIJV

,,4 nn

= 3 2 . 5m m LAW: BOYLES .l. An accumulator a hydraulic to systemls precharggd 900KPaandls thenfllled in KPa.Howmucholl has been shows2,700 gas pressure fluld until the wlth hydraullc i v p u m p e d n , i f t h e a c c u m u l a t o ro l u m e s 0 ' 4 m 3 ' I V ' =
P1 = Pa = Formula: V r =

0.4m3 K 9 0 0+ 1 0 1 . 3 P a + 2 , 7 0 0 1 0 13 K P a P1 V2 =V' P,

v2

Pr

= .t .3KPa 0.4m3 x oli

. 2801 3 KPa = 0.1 3 ms 4

\ CHARLESLAW: -14"C.lts temperaturels raised z. A rubber gas reservoirhas a volume of 0.1 m3at to gO"c.whatls it volume increaseif the pressureremainsthe same?
V 2 =

I I I I l I

V',x T,
T1

= 0.1 m3x (90 + 273) - 1 4+ 2 7 3 = = 0.1m3 (363) 259 0.1 m3 4

you eheckthe oil contentln f O. Two daysaftera tank\^rasilledwith arrivalballast of water.Dimenslon the tank L = 43 m the tankand fourrd0.5cm. of oil on top of the jl';;l the amountof oil to dlscharged regulation = ;t di 6li;k.y ro marittme ii': 29

F
tl

ti

you do? lf canbe discharged overboard? no.what shall by totaloil,roiume Parts Required-Iof NOTE: By Regulation: 30'000

ii sea.
Solution: x '. Lengthx BreacJth DePth I Totalvolumeof tlrc tank = 4 3 x 2 1x 2 2 m 19,866 3 = < =-43x21 0005nt irrthe tarrk l l . Totalvolumeof oil = : 4 . 5 1 5n r 3 c a nb e n l l l . B YR e g u l a t i ov o l u n l e discharged

= I i_966m'
30,000 = 0.6622m3

1989 ENGINEERJanuarY FOURTH and 5/B' 8.3/1'.10 5314 measuring withsidesin meters f plane igure areaof the 1. A trapezoidar mixedn'ilnt']wrtut it the Give per.imete.r. yourunr*"r'in and the 21 114' the 211r4.Find arethe 10 5/B abovefigure?ine paraller;iJJt Solution:
211 4

Bt/o

5t/o

Perimeter

P Area

53i4 + 2 1 1 1 4 B 3/4 {' 10 5"8 + 8 5 + 3 5+ 8 5 + 2 3 B 4 4 4 = 1 7 0+ 7 0 + 8 5 + 4 6 B or 463/8 = y

B = 112 + b) (d) \a = (21 1/a+ 10 5/B)(5 3/aJ 2

30

= 85+85 23

=,B!+Ql?3 rG 4 B = 1 7 0+ 8 5 ? 3 4 16 = 5865
64

= 91 1] t'
64

of couttter the revolut]gl of the watch, reading the i; 026'430' what is the 2. At the startof your1:lo* enct youiwatch n" or whatwillbe At.ihe is d;;;;the watch' mainengine 996,430. zoi',in,it', ""iiil witi'n-e-uouunied rpm.irin"tirne average watch? ai the readtng theendof the
Given: =' 996430 reading Previous = 026430 End o';watch 20 Advanced mins'

Solution: s e tt o 0 i s 1 , 0 0 0 , 0 0 0 t R e v o l u t i ob e f o r e h e c o u n t e r n = 3570 1 , 0 0 0 , 0 0 0 9-9 6 , 4 3 0 ' 'i' = 026430 3570 afterthe watch Totalrevolution

r = 3 0 , 0 0 0e v '

\ RPM 3.

r = 3 0 , 0 C 0e v ' - 29 mins' advanced 2a6 = 136'36

,nu so n" of rever hrseyesabout *"ilr. "uou" i;;ihe rookoui ableto seea floating height rnJ-,t* lromthebridge? the bridgeis 160meters rioutinioni"tt what i, *.,udistancJoil'r* obiect?
50m

with the standing in the brldge ttre bow of the strip is bowf rom ol A rook out rookirrgtowards 'Jutti'iin"'rnt diJtance the

31

By SimilarTriangle: 50
1 6 0+ d 50d 50d 50d

30
d ( 1 6 0+ d ) 3 0 4 8 0 0+ 3 0 d = 4800 30 d = 4800 20 d = 4800 d 20 frombow' = 240 m distance

t t t

of The distance objectfrombridge: =

2 4 0+ 1 6 0 = 400M

4.

and nauticat-miles gx oi a distan., o,zso to her navigate ror the is ruerabout ano arrowance

How manydayswill it take 125MTof f ueroir per d.ay. ship consumes A 12-knot nolmanv;1:y'i,,f;:fJJffl

ffil:;l?'i'S;J".il:"#'l?",ii# 'be encounteredis "ilfiq"[r" that may to bad weatherderay due the to ,equitement comPlete voYage?
Given:

what ls the fuel 20o/o'

Shipspeed Fu0lcons. Distance 3"/"

20o/"

12knots 125 MT/daY 6 2 8 0n . m i l e s for allowance unpumPable and weather for allowance clelaY

Solution: to DaYs navigate

6280miles x 12n.m/hr. 628! miles 288hrs. lday 24 hrs.

Total allowance f Fuelconsumedor the voYage

2 1 . 8d a 1 ' s 3 + 2 0 = 23n/" 2 1. 8 x 1 2 5 x 1 . 2 3 M 3351.75 T

32

1989 ENGINEER JanuarY THIRD along nut a to bar cl. what slzecircular is required make hexagonal of 16mm sldes the clrcumferences? 16mm

b = 1 6m r n d - - 2xa 2x 16 32 mnt

S i n3 0 o =

8 a B a = sin 30o a = 16mm

metrlcbrake of ic 2. The specif f uel consumption the mainengineratedat 12000 metrictons to make in ls horsepower 155g/Bhp- hr. Whatis the f uel consumptlon for miles at the speed of 14 knots? Allow 10o/o the a voyage of 6,280nautical tank. in unpumpable the fuql storage Given: Bhp S p .f u e lc o n s Distance Shipspeed \ 10"/"
Solution: F u e lo i l c o n s . = x g-BFIP/HR 12000bhp x 34 h/day 155grm/tott 1,000,000 44,640,000 1,000,000 44.64M.T"/day

12 0 0 0 1 5 5g - b h p / h r n 6,280 m 1 4k n o t s allotvance

travel Daythe ships

n.q x l_gsy_ 6,280

24 hrs. 14knots 18.69 ays d ( x 44.64 18.69 1+ 10%) x 4 4 . 6 4 " l8 . 6 9x 1 . 1 M 917.98 T. 33

F u e lo i l c o n s .

;F.

r 1

ll
At watchis 996'430' ta at counterreading ttrebeginning-o 4 hour 3. Therevolution was the watchthe tlme ' the the end of the watcrp counterieading02"6,43orq,urinO of the mainenglne? what is the uu*rui" rpm by retarded z6tninu't"r.
Given: r p r e v i o u se a d i r r g: : 9 9 6 , 4 3 0 = 026,430 endof watclr 2 retarded 0 min. r T l t ec o u n t e r e s e t o 0 @ 1 , 0 0 0 , 0 0 0 r t l r ec o u r t l er e s e tt o 0 : R e v .b e f o r e = 1 , 0 0 0 , 0 0- 9 9 6 , 4 3 0 3 5 7 0r e v 0 + e E n d o f w a t c f t n g .r e v . = 0 2 6 4 3 0 3 5 7 0 = 30,000 RPM = _3_0r000*Ey 2 4 0 r - 2 0 m i n .r e t a r d RPM = 115.38

Solution:

c y c l e d i e s e lw i t h a 4 . T h e m a r n e n g i n e i s a n g c y t i n d e rs i n g r ba c l i n g , . 2 - s t r o l < e wnat iJtne cylinderconstant' what ls cyllnder of 650 mm bore x 1,3s0mm strot<e"" t 0 i s 1 1 k g / s q . . i c m ' a1 1 1 r p m ? i t h e i n d i c a t e dh o r s e p o w e r f t h e i n d i c a t e dp r e s s u r e Given: N o .o f c y l . Bore Stroke B cyl.2 strol<e 6 5 0m m = 6 5 c m 1 3 5 0m m = 1" 3 5m . 11 k g / s q c m .
r 1 n
I l\./

rUEP
Rpnt Solution: c y l .c o n s t a n t =

To,
^ +

4500

! (os)'(t.gs)
4 4500 7854(4225)(1 35)4500 c y l .c o n s t a n t IHP 0.9954 c t x N 4 E P c Y l . o n s t a nx R p m x n o "o f c Y l . ( ( . 9 9 5 4 ( 11 o ) B ) ) ( 11 k s / c m ' ) 7 I H P = 9 6 3 5 " 4H P .

34

mm.Whatis theengine ship of 5. Thepitchof thepropeller an ocean-going is 3600 slip rpm?lf theapparent is mlnus3ol" i propeller makes te hoursit tf'tb mifeageli,n24 sPeed? Whatls the observed
Given:

P i t c h = 3 6 0 0m m = 3 . 6m R p M = ' i1 B Slip = -3% E n g . S p e e d= P i t c h x R P M x 6 0 18 5 2

Solution:

W
v

Q lr ir n H

- 0.03 - o.o3 13.76) ( OS

= O b s er v e d S p e e d =

1852 1 37 6 k n o t s E n g . p e e d O "S p e e d S Er,g.Speed 13 . 7 6 - o s 13.76 13.76 o.s. + 1 3 : 7 6 ( 0 . 0 3()1 3 . 7 6 )

+ 13.76 0.41 1 4 . 1 7k n o t s .

1 E S E C O N D N G I N E E-RJ a n u a r y 9 B g 4 a h f w 1 . A c y l i n d r i c a l a t e r t a n k a sa d i a m e t e r o3 m e t e r s t t h eb a s e a n d 1 / 2m e t e r s into the tankIn orderto Howmanymetrictonsof freshwaterls to be pumped high. into the gravity to be pumped is specific lf havean ullageof 1 meter? f ueloil of 0.86 h a v et h e s a m eu l l a g e ? t t t a n k ,h o w m a n ym e t r l c o n s a r er e q u l r e do

l_
lm

-r
I

3*t

f"-

3m

35

Solution: a) Volume f tank o

i

= 'iTo'
4

t t
= 3 112 m = 1 l ( g ) , ( 3 . Sm ) 4

F o ra n u l l a g e f 1 m ; o h V o l .o f t a n k@ g 1 t 2m h e i g h t

t
I

F o ra F . W .S p "g r .

= .7854 (3.5) (e) = 24.74 m3 1000 9 = lton 1

m3 m3

F . W .t o b e p u m p e d = 2 4 . 7 4m 3 x 1 M T / m 3 = 24.74 MT b ) S p .g r . o f o i l = 0.86 M . T .o f f u e lo i l = 2 4 . 7 4 m 3 x 0 . B G( S . G . ) = 2 1. 2 8 M T .

2' A vesselmakesan obs_erved speedof 12 knotswifh an apparent slip of plus 12o/o' propeller The turns110rpm.Whatis the pitchof the prodeffeiin mmt
Given: S h i p ss p e e d Slip RPM = = = = = 12knots 12"/" 110 P x R P M x 6 0 18 5 2 ES-SEx100

Solution:
Engine peed S \ % Slip

ES = E S- 1 2 k n o t s 0.12 ES E.S" 0.1 ) ( 2 = E S- 1 2 E . S .( 0 . 1 ) - E . S .= - 1 2 2

- O . B B . S , = - 12_ E E.S. = - 1 2 - O.BB

E.S, = 13.63 nots k = PxRPMx60 E.S.

1852 m

36

= 13.63knots
p

Px110x60 1 8 5 2m

( 1 3 . 6 31 8 s 2 ) 'l 1 0x 6 0 P = 25242.76 6600 P = 3.83m = 3.830mm.

3. A shlp's provlslonls loadedon boardfrom a motor launchby meansof a m a n u a l l y p e r a t e d i n c hw h i c hw o r k o n t h e s a m ep r i n c i p l e s t h e w h e e la n d a x l e o w a maehlne. revolving The drumof thewinchis 30cm diameter thecrankattached and t o t h e e n d o f t h e d r u m i s 4 0 c m . l o n g f r o n it h e c e n t e ro f t h e d r u m .W h a tf o r c e i s r e q u i r e do l i f t t h e p r o v i s i o n e i g h i n g 0 0k g ? t w 3

*-l

t
40 cm ]_

,s I l.- rs -'l* o n t c r n t

fTol Ks
T a k i n gm o m e n t@ t h e c e n t e r f t l r ed r u m : o
Fx40cm= F \ =

1 5 ( 3 0 0k g ) 1 5 c m ( 3 0 0k g ) 40cm 12.5 g. k

4 . T h e m e a n i n d i c a t e d p r e s s u r eo f a n B - c y l i n d e r - s t r o k ec y c l e , s i n g l e - a c t i n g 2 e n g l n e w i t h a c y l i r r d e rc o n s t a n t o f 0 . 9 9 5 4i s 1 1 k g / s q . c m . W h a t i s i n c l i c a t e d h o r s e p o w e ra t 1 0 0 r p m ? Given: = I c y l. 2 c y c l e s i n g l e c t i n g N o .o f c y l " . a - 0.!)954 C y l .c o n s t a n t 1 MEp - '1 Kg/cm2 RpM = 100rpnt M E P x C y l .c o n s t a n x R P M x N o .o f c y l i n d e r t F o r m u l a : l HP 1 1 K g / c n rx r . 9 9 5 4x 1 1 0 x B ' 8 7 5 95 2 l - r P

37

r a l f n 5 . T h e s p e c i f i c u e l o i l c o n s u m p t i o o f t h e n t a i nd i e s e e n g i n e t 1 2 , 0 0 0 n e t r i c metrlctons? Wlratis the dailyconsumptionrln horsepoweris 155g/BHP-hr. brake in Whatls the equivalent consurnption gra;nper kw-hr?
Given: S p . f u e lc o n s . BHP 15 5 g / B H P - l t r 12,000 0 1 5 5g r . x 1 ? - , 0 0B H Px 2 4 h / d a y Bhp-h r

Solution: a) Daily Cons.

= ff19800_qrtday
= b) grams Kw-hr 1 , 0 0 0 , 0 0g r / t o n 0 44"64MT

lg!.s'l9I,P-!L
0 . 7 4 6K w / 1H P 207.77gms/l(w-ltr.

E C H I E F N G I N E E-R a n u a r y 9 8 9 J 1
1" The cross-sectionof a hollow brassslraftinghas an outsidediameterof 50 mm and an inside diameter25 mm. lts length is 2 meters.What is the weight of the s h a f t i n gi f l t s d e n s i t yi s 8 g r a m s p e r c u b i c c m . Given: Outside ia. d rlnsidedia. Length Density 50mm : : 5 c m 25 mnr = 2 . 5 c m 2 m = 2 0 0c m B grlcm3

Solution: D = Weight Vrlrte Volume I oo,

5nt

I o t ,(Length)

- [ ( o o ' - D 1 , )( L )
A r+

1 tt'
4

(2oo) 2.s')

(200) (25 .7854 - 6.25) ( ( . 7 8 5 4 18 . 7 5 ) 2 0 0 )

':
iii

38

cm3 2,945.24

I t I t
I

w.igh,
'

= Density Volume x
=
-

8 gr/cm3 x2g45'24 cm3

23,562 kgs.

= 23,561'9 grams

|-2 . T l l e c y | i n d e r b | o c | ( o | a d i e s e | e n g | n e i s h e | d b y 4 rthe tie rods.The yield polnt of . | f t h e oundm||dstee|t|erods toadon eachtie rod ls 66 MT,what Is tne aiameteiot safetyls 6' the rod ls az,oooibl' pli sq"fncn and the factor of r

Given: = 4 No. of tie rods Load on each tie rod = 66 MT. Yieldpointof the rod = 47,000lbs/in2 = 6 Factorof safetv Solution:

Stress Working

Stress Working Area

\

Yield Point of Factor safetY p = 47000 si 6 psi := 7,833.33 = Load

= = areaof rod Load workingstress 145,200lbs. 7.833.33PSi = 1 8 . 5 4i n ' z

Area
0.7854D2

:= 1l o'
4 * 18"54inz 18.54
n2 L:'

0.7654 = l] = 23.6 inz 4.85 in 39

3. A 12-knot ship left Manitaon Jan. 19, 1989 at 2:00 a.m. for San Francisco' a distanceof 6,280nauticalmiles. Find the ETA at San Franciscofirst by disregardlng the dlfferenceIn tlme betweenthe two ports and second by taking lntoiaccountthe dlfferenceIn tlme. Glve the date and time of arrival in both cases. lf the ship consumes 25 MT of fuel per day, what is the quantity requlred to completethe voyage.Allow 25%forthe unpumpablequantity in ttrestoragetank and delays that may be encountereddue to bad weather. Given: S h i ps p e e d T i m eo f d e p . Distance Solution: By disregarding diff time erence T i m eo f v o y a g e = 6 , 2 8 0N . m i l e s 12N.M./hr. h 523.33 rs. 2 1. B d a y s 2 1 d a y sa n d 1 9 . 2h r s . E T A = F e b . 1 0 1 9 8 9@ 0 9 0 0h r s . , i By takingdifferencen t i m e- - 16 h r s .b e h i n d - F e b .1 0 ,@ 1 9 0 0h r . ETA * 1 6 0 0h r s . = = = 12knots 2 : 0 0p m - J a n . | 9 , 19 8 9 6 , 2 8 0N . r n i l e s

hr. ETAby timedifference 09 @ 1700 Feb. Shipcons/day = 25 MT/day (1 rVoyage cons= 25 MT (218 days) + 25%) fuel d"y = 2 5 ( 2 1B ) 1 . 2 5 ) . ( = 6 8 1 2 5M T . slngleacting,2-stroke of 4. Solvethe metricindicated horsepower an B-cylinder, ls propulsion at with MEPof 1 I kg/crn2 145rpm.Thecylinder 650 cyclediesel engine mm bore x 1350mm stroke. horsepower hr, lf the specif f ueloll consumption 153gramsperindir:ated is ic per What.is tuel consumption day? the
Given: N o .o f c y l . MEP Bore Stroke S p . f u e lc o n s . RPM 40 B; 2 stroke 11 Kg/cm2 650mm =

65 cm. 1 3 5 0m m = 1. 3 5 m . 1 5 3g / l H P - H R . 145

I
I

I I I
I

Solution:
IHP = = M E P ( L x AN x R P M ) 4500 (11 Kg/cm')('Tl 10S1' (1.35)(145)(8)

4500 = IHP Fuelconsumption: 5 7 16 1 2 9 2

4500 1 2 , 7 0 2 .h p " 5 153 gr./lH P-hr.x 12702.5 x 2.1 hp 10 0 0 0 0 0

I I

_166,S!_
1.000000 46.64 MT/day. 5. Thepltchorf propeller an ocean goingvessel 3,600 the of is mm.Themainengine dlrectlydrlvingthe propeller makes145rpm. Whatis the observed speedof the vessellf the slip is minus3%. How manyr nautical per day? rnilesis covered Given:
P i t c h = 3 , 6 0 0m r n . RPM = 142 Sfip :: - 3%

Solution:

\ % Slip

Irul-gggg

- shipspeed

Enginespetld=

Engine peed s Pitg!xRPMx69 18 5 2 ( 3 , 6 0 0 m x 1 m ) ( 1 4 5 )( 6 0 ) m 1 0 0 0m m

18 5 2 16.91nots k - 0.03
16 . 9 1 - S h i p s s p e e d 16 . 9 1

* 0 . 0 3 ( 1 6 . e 1 ) 1 6 . 9 1- S h i p s p e e d - 0.5073 1 6 . 9 1- S h i p s p e e d

41

+ = 16.91 0.5073 = 17.42 knots Nm/Hr'x 24 hrs'ldaY = 17.42 Distancecovered/daY = 4 1 B . ON M B ShiPsPeed

1990 FOURTHENGINEER JanuarY to grams Per cublc is 2,699Kg/m3'Converttttis of 1. The densitY aluminumper cubicfoot' and to Poundmass centimeter,
Solution: 2,699grm/cnr3 t' grn 2,699kg x 1C00 - x ' . ], ^= cm3 1,000,000 ll1g 1 m3 = 168.26lb/ft.3

kg 2,699 x 2.2lbs.x
1 m3 1 kg

:+g- ft3 35.29

exerted Findthe pressure waterto a depthof 42feet6 inches' 2. A tankis tiiledwith on the tank bottom? Solution: x Pressure= height 0'434 = (42 tt. x 0.5ft') (0'434) ft.) = (42.5 (0.434)
= 18.44 si P

is 70 RPM'Findthe sllp' tf pitchpropeller. thespeed sliphasa 16r.eet 3. A 10-knot or ts the sliPPositive negative? Given: of Pitch ProP'= 1 6 f t . RPM = 70 = SPeed 1 0k n o t s Engine

tt
I
{

I I

Formula: SPeed 1. Engine

I
6080 ft. -- 16 ft. x 7! RPm x 60

6080ft' k = 11.05nots

I
42

I I I I I I
I I I I I I I I I I
I I

% slip % slip

% slip

speedx 100 = engine speed observed sPeed errgine - 10 knots 100 x = 11.05knots 11.05 = 1.05knots x 100 11.05 knots = + 9.52

whoselnslde areaof a rubbero-rrngpackrng 4. what rS the cro33sectronar ls dlameler 64mm? ls dlameter Agmmandlts outslde
Givendatas: dia. inside dia. outside 49 mm 64 mm

Find;

area z=jT (do, d,,') Crosssectional 4 = .7854 (64)',-(49)'I [ = .7854 4096- 2401I [ (1695) = .7854 = 1 3 3 1 . 2m m z 5

5.

y = Flnd the valueof r? nz Solvethe followlngequatlo 2x+ 5y = 20; Glven 5' : ution Sof 2x + 5Y 2x + 5(5) px +25 \2x
)i

:i =: = =
=

20 2C 20 Z}-Zs
-5

lf Y = 5 X = ?

2 =- 2.5

1990 ENGINEERJanuary MARINE THIRD .g. At a certarnInstant,a shrp was 4 miles south of a llght house.The shlp was was-s zs"t5'wfrom the llght tt. bearlng trave*ng *rJ;aru ano afterio mtnute, hout". iind the speedof the shlp per hour'
= tan25o15' b _ a

tan 25o15' b b b

= p
4

a=4 mi

) = (4 mi)(tan25"15' = (4)(0.47163) miles = 1.BBO 1 0m i n hr .10= 0.167 60

buttime b=?

Speed =

distance time = 1.886 i m h 0.167 r. Speed = 11.29knots

vertlcallY.When hangS of longwltha cross.sectlon 0'125Inch2 2. A wire120Inches 0'015Inch' Flnd the Young a load of 450 lbs. ls applledto the wlre, lt stretches of Moduh,rs ElastlcltY.
Giveit;

length initial area cross-sectional aPPlied \ force in change length

1 2 0i r t i 0 . 1 2 5n 2 450 lb. i 0 . 0 1 5n c h .

Find:

(E) of Modulus ElasticitY Young's stress lonqitudinal strain longitudinal force/area length .ht[t i. length/initial
450 lb' 2 0.1 5 inz

1 Solution: . e e

= 2. stress Force
area

strain =
e

n 0 . . 0 1i5 = 0 . 0 0 0 1 2 5 L 1 2 0i n psi '= 28,800,000 = _:Jress 3600Psi strain 0 . 0 0 0 1 2 5

aI-

r.l

44

deck,a dlstanceof a horlzontal 3. A force of 10 lbs. ls usedto movea box across floor,how muchwork ls done? *rtn the s ft. lf the forcemakesan angleof 30 oegrees

5 -.--.--.{r

FT.

F Cos 30' Solution: Work = Forcexdistance

== ,u,,, llffli3:J:lll
(5) = (10)(0.866) : 43"3 ft.-lb.

of a street.what ls the angleof on 4. A house 15 metershigh stancls one slde of the street,lf the streetls 20 elevatlonof the top of the lrouseI'romtne oiner slde meterswlde?

A'-r l \

1sm ll i

ll

--l

'-'.
\

- L - . - \ ' :
20m

ll

o)--

Formula: givenside given side

lgm
tan 0

tan 0
A

20m 1 5m 20m 0.75 36052'

of trigofunction angle unknown = opposite adjacent

tan 0

45

I
J > *
i
I

................ r
I

'.

ry ENGINEER Janua 27' 1990 MARINE SECOND Howmuch wort lbs./lnchr. watermarnsls 3-s 1. The gaugepressureof waterrn the il;ir"gpnerrl'piessute, lnto the malnr? ft.r rr requrredto pirmp 500,ooo of water, Given: Pressure= 35 lb./in.2 ft.3 Volume = 500,000 lt.3 500,000 to in3 Convert in.3 in.3 = 8.64x 108 ft.3 1728 = 5O0,OOO x 1 ft-, in'3) (8'il x 108 work Req = (35lb/in'z) lb'in' = 302.4x 108 convert'o-: t:J::: ft'-lb' x rb-in. 1 ft. = 2s.2x 108 ' 108 l2 i..

Find:

surfaceof the ooBan'lf the welght ls 2. The hatchof a submarlne 100ft. underthe the hatchdue to the water,and tnr pi.rrir: at densltyof sea water gc tus,rtt.!,Frnd Inslde and3 ft. long.T[repressure the netlorce on the hatchu iiir r.ctanglJiit. *ror the submarlnels the sameas that at the surface' Given: height= 100tt" = wt. of densitY 64 lbs./ft"3 = 6ft"2 = e d i m e n s i o nro fc t a n g l e 2 f t ' x 3 f t ' Solutionl r x a) Pressure= densitY height = 64 x 100 = 6,400lb/tt.z x = Pressure area b) Force (6 lb./ft.2) ft.o) = (6,400 lb. = 38,400 3.4.{lqge-1.e$lPFDgum.es--1/!.to.lgftYqlollpe-rdav'whenltlsoperatlngatfull Increalesby consurnittonper BFIP at load.whenthc unlt b operatlng halt load,the toad,allowlng2'2{' orc per hour ai one-rraft the 2loh.Determlne lull consumptlon lbsJton ln thls case. at Given: Cons. = 1/2ton/day fullload by Cons.lincrease 21'/"at halfload Find:Consumpdonrateperhouratha|fload

46

t
I

Solution: I 1/2ton x 1 day * W' day 24 hrs. 1 ton

= 46'67lb'/hr'

t
I

oj'ou u; iln;;Hj;X1;ni#hl:':T
= 56.47lb./hr.

t t t

lbs. and that on the other rlde ls 150lb3' 4. The tensronon outsldeol a belt lg 350 to the pulley' tt./mrn.rrno the horse pdwer dellvered The belt ls moylng at 3OO = 500lbs' Acting = 350 + 150lbs' Given: TotalForce SPeed = 300ft'/min' HP delivered Find:

== Power ltT,jnlJi:t!t/min)
*it Convert: Ft. lb to FIP

h h

x 1HP l't;5o,ooott.-tb
ft.-lb min. 33000 150,000 33,000 = 4.5 FIP

h h I I I I I
I I I l I

1990 ENGINEER January, MARINE CHIEF aqd at polnl plr 2lncht. lt the .!. The cro83 r"",,on or the tube at pornt A 1o Inch2, what ls lt at polnt B? verocrtyof the .tr"r ano pot;i A rs i z ft./sec., = '10 in'2 Given:i areaat Pt'A = 2in'2 areaat Pt.B at velocitY Pt.A = 12 ft'/sec' 'l at velocitY Pt.B = BYratioandProPortion at = velocity A areaat A

=ru iil';'1?,,

areaat A 17

2 12in.2(1 ft./sec.)
10in.z at velocitY B = 2.4 tt.lsec.

per tons ls shlp'smainengine consuminE;74 of fu_el day contalner 2. A refrlgerated and hotelloadareconsumlng^l!tonsper at 21 knotslthe ref.plant,aux.machinery tne day.Whatl"s nautlcalmlle radlusof tiavel?The shlp has to travel1'875mllesto tlratthe conlumP. Assumlng fuel reachFort,andonly 275tons of avallable remain. speed,can the shlp makeport with the fuel on board tlon virles as the cuUeof the to lf the speedls reduced 19 lcnots?
Given: cons.A cons,B distance fuel left

74 r 10tons/day SpeedA SpeedB ? m 1875 i. 275tons

21 knots 19 knots

Find:

mption B. Consu C l = Speedo C, = SPeed,

left hr. mi. 1,875 x t hr. = 98.68 voyage f g mi.

84 tons cB cB
Vt, =

v B =

l o 9 8 . 6 8 = 4 . 1 1 d a y s f v o y a g ee f t 24 hrlday (19 (84tons) knots)3 tonsx 4.11days = 255tonsreq. 62.21 (21knots)3 to reachport. dty 'Iherefore the fuel (84)(685e) since leftis275tons, ship portwithstillenough fuel. canreach 9261 62.21 tons/day

3. A barge ls 30 ft. long and 16 ft. wide, and has vertlcal sldes. When two How furtherIntothewater. slnks2Inches the on are automoblles drlven board, barge weight? muchdo the a'rtomobiles = f w h e r e i n c h 0 . 1 6 7t . 2 Solution: of Weight automobile

water wt.of displace (density water)(volume water) of of (62.4lb./f (80.1 ft3) 6 13) .984lbs. 5001

48

4.

Flnd the specltlcgravltyof API 18.5at 60"F Formula: Apl 19.5 = = . 1 4 15 S.G.at 6CoC . 1 4 1s S . G .a t 6 0 o C . 1 4 15 S.G. . 1 4 15 150 0.9433

131.5 . 1 3 15

. 1 3 1 5+ 1 g . 5 = S.G. s,,G. = =

ENGINEER ANDTHIRD FOURTH May 1991 is tank whosediameter 10 feet. Q" What ls the volumeof a spherical

Given: Formula:

diameter Volume

= =
= = =

10ft. 1T - 6o.
( 3 . 1 4 1 61 0 ) 1 6 4 3 . 1 16 ( 10 0 0 ) 6 3140 6 523.33ft3

Volunle

lf Q. A 1 1 knots shlp has a 17 f eet pltch propeller. the speedls 75 RPM.Flnd the sllp. ls the sllp negatlve or positlve? Given: Pltch of proPeller = = Rpm EngineSpeed = Find: a) Speed Engirre 16 ft' 70 l0knots :: . Pitch x RPM x 60 6080 ft. 17ft. x 75 RPM 60

6080ft.
49

b) % slip =

= = Slip% =

= 17 lt. x 75 RprnT 99 6080ft. = 76500 6080 = 12.58 nots k Eng.Speec obs. speed x 100 E n g .S p e e d 1 2 . 5 8 - 1 1x 1 0 0 12.58 1.58 x 100 12.58 0.1255x X00 (positive) 12.55

O. The Indlcatedhorsepower an englnels 15.448 of and thc brako horsepowerlt 12. What lg the mechanlcal efflclencyof the englneand what ls thc MEP.lf tho cyllnderlr 0 by 12 In and epeedlg 240Rpm? Given Datas: IHP = 15.448 BHP = 12 RPM = 240 RPm Mechanical Efficiency = tsHP x 100 IHP = 12 x 100 15.448 = 0.776 100) ( .= 71.69 %

Formula:

Find:

Area = iT O'

7
= = = IHP = PLAN .7854(9)' . 7 8 5 4( 8 1 ) 63.62in.2

33,000 P = 33,000x|HP LAN = 3 3 , 0 0 01 5 . 4 4 8 ) ( (240) (1 FT.)(63.62) P = 33.38kg/cma 50

o.

How many gallonswlll g, In dlameter. A cyllndrlcaltank ls 4,,hlgh 3' z" Glven: 'diamete = g' 7' f 'height = 8' 4' = 43 inches = 100inches 'iT 1 Ot n

lt hold?

Formula:

of volume cYlinder =

:1llffi{fir
@
gallons 628.66 ls pltch of propeller 16'2ft' RpM lor 24hrs,and 18 mlns.ls 102, o. tt thc averags Whatls the sllp In percent' it g6O UVloUsErvatlon mlles, Dlstance = Given: Pitch Dir;t.= Obg. = Rpm = Time Formula:
Tiry x Distance = lP,itch Ave' Fprl x Engine 6080ft. = 1 6 . 2x 1 9 2x 1 4 5 8 6080ft. miles = 3'96.25 S|ip%=EngineDistance-observeDistancexl00 Distance Engine 360 x 100 = 396.25 396.25 = 36"2 x 100 396.25 = 0 " 0 9 1( 1 0 0 ) 3 = 9.1%

ft' 16.2 360miles ",02 24hrs'+ 18mins'

51

?* t:

;-

il
o.l.Whatarethefour|undamentalso|Mathematics s' See temPerature'

il
scareg temperatureand abrolutc h. ::,::T"?Tnil:'$:::"'1"'unsurar' noteS'

,l

I I

1991 ENGINEER MAY SECOND/CHIEF o.Flndthecircum|erenceofacirclewhosediameterislglnches? 19 ( diamete - 'ii inches data: Given D = Formula: circumference = 3 . 1 4 1( 1 9 ) 6 inches = 59.69 place' circreto one decrmar inchesdiameter Findthe areaof a 13 Formula: Dt Areaof a circle = -1T 4 ( = 3 . 1 4 1 61 3 ) ' ?

e.

(169) = "7854 A = 132'7in'z

o . A c y l i n d r i c a l t a n k l s i n c h e s linches?e t e r , l s 4 f t . l n h e i g h t . ndiam cublc Whatis the volumeln a' ln gallons? b' Whatls the caPacitY Given: ( diamete = height = = 1 gal' a' Volume 18 inches 4ft' = 43inches 231cu' in' D2 = '7854 height

Formula "

(48) (18) == i::;il;l

in b' Volume gallons: = 12,214'54 231 gatlons 52.87

52

Q. Thestrokeand boreof an Bcytind dieset engine 1l;'; rr and650mm are "i,rstroke IHPis tg,SO0 154RPM.Whatis the respectlvely from the engineindicator cardsthe at Indicated pressure? meaneffective Datas: Length stroke = 1 3 5 0 m = 1. 3 5m of m = 650mm = 65 cm Cylinderbore I H P = 13 , 9 0 0 RPM = 154 Solution: a) FindtheArea = i T o ,
4

3.141(6s)' 6 4 = ,7854(4225) A = 3 3 1 8 . 3c n r z 2 = PLAN b) IHP 4500 P = 4500xlHP LAN 4 5 0 0x 1 3 . 9 0 0 1. 3 5 x 3 3 1 . 3 2x 1 5 4 8

= _qaggqq_
e,BgB7B.72 P = 90.66 kg/cm2

I I I I I I

0. A tank is filtedwith'water depthof 40ft. 6 Inches. to Findthe pressure exerted the on tank bottom?
\ Given data: Depth,of tanlt = Formula: Pressure 40 ft., 6 inches = 0.5 ft.

h c i g h tx 0 . 4 3 4 (40 ft. + 0.5 ft.)(0.434) (40.5ft.) (0.434) 1 7 . 5 7p s i

o.

What is the volume of a sphere whose diameterls 70 Inches? Given data: Diameter,= 70 inches 'iT = d' Formula: Volumeof sphere

I I
I

I 53

F!t

(70)' = 3.1416 6

p13'999 3.1416
cu' in' Volume = 179,594'8 o.Whatlgthetateraleur|aceofaspherel0lncheelndlametgr?

Formula: Area = 1TO'

( E 3.141610)2 ( z 3.1416100) 6 = 314.1 in"z

&12 tne o.Arcvolutloncounterread6gsgsstsioqlryLlljgoAl|theclocltwa!advanarlT \lvtiat:was s'orago'p""d on tho ez,glb. the couniJr-ri,roi mrnl.andat noon clocltwatch?
Solution: readi'ng RPM= Present Previoqs Average Timein watch-advanced = 87319 69895 240- 17 = 17424 223 RpM = 78.13 "lur. knO'' tb ftnl of fuer o* on board- At-15 tho A rhrp reaves qort wrth Tz*Obarrervesset tiriirro lgP mllst' whatlr nr. the

o.

x*r rg con8ump$onioo'barrers/;rv. radlus? ng remainf rteamlng

Solution:
1 . Total speed/day

15 knotsx 24 hrs' _ 360 miles -= 360 * 360 2. Cons.of oil/1 mile 1.0 barrel x miles = 1642 1'0 3, F.O.consat"1642 = 1642banels 72OO 1642 4. Fuelon board 5558banels

64

boanDeuEsTloNs

cxterEnctrueen secoND, Txrno, Founnr,

MATHEMATICS
1. the anct Whenyou add 518;7112 11fz4,whatwill sumbe? a/i 2. and2t3 B. 1 and3/2 c. 1 and 1/3 D. 1/3

whatwillthe sumbc thedifference? 5/6 Whenyou subtract from8/15,

rf\

A. 1/s 3.

e.'ilro

c' 2/6

D' 214

of What is the Product 5/8 and417? A" 4n a/inq c" 10/14 D' 4t6

4.

b)' of The quotlent rl3 divided 3fl is: A . 1 5 a n d ? 1 B . 3 0 a r r d 3 / 6 c . 3 0 a n d 1 E D . 2 | 3 o

5.

by ol36.744divided 24 is: The quotlent A. 1531 B' 15.31 c:' 1'531 D' 153'1

55

6.

is: .397bY41 the Product Multiply

'l A;' 6.277 B. 162.77

c. .16277

D. 1627.7
{

7"

is: the 96.307, difference From 128 subtract

A ' ,3 1 . 6 9 3
B.

B. 316.93

c. .31693

D. 3169.3
{

Solvefor x in the equation12x+ 25 - 35 = 14x + 22x 22 A.y=11 B.y=12

C.'u:x 112

D.X=6

9.

by of The quotient 2.5 divided .05 is: A. .50

8.4'o
. B . - 1 7 77 7d . C

c. .0s

D" 5.0

is: in 1 0 . -180degreesfarenheit centigrade nJ r fiJ7 d.C C. 68d. C 12x - 1B. C. x -4 D. X= -4 D . - 6 8d . c

Bx 1 1 . Solvefor x in the equation - 22 : AYx=-1

B.X=1

its alonQ height intervals at measured regular diagram of 12. The height an indicator F t g g , 4 7 , 5 , 4 8 , 9 2 , 2 0, 1 1, 8 , 5 , m m .r e s p e c t i v e l yi'n d h e 1 2: a r ea Sf O l l O w S 7 , in of meanheight thediagram millimeters' m A. 2BB m. m B. 2.88 m.

mm. c/ za,a

mm. D. .0289

the pumpcanempty sametankin 4 another a 13. A pumpcanempiy tankin 12 hours, pumps setworkare lf allthree this can and hours, another empty tankin t hours. on ingtogether thistank,howlongwouldit taketo emptyit?
/A. 4/9 hours B. 2 and 1/4 hclurs C' 2 hours

I I I
l

I I I I I

D. 3 hours

14. -243degreesfahrenieitin absoluteis: A. 217d" A B. -217d. A d' c. 217.29 A

.29 D. -217 d. A

is: in centigrade fahrenheit 15. -65 degrees A. -60d.F B.85d.F c. -85 d. i:

D.60d.F

Findthe circumference' Pi 16. Given7.5 cm. radius is 3.1416.

cm. cm.B, 23.562 A. 47.1238

C: 47.124cm.

D.

]2

cm

56

I I

I
I

l I
| t

17. GivenI cm.diameter.Findthe circumference. a. 25.1328 cm. B. 12,5652 cm. c,.'a50.2656 cm.

D. 50 cm.

18. Negative Fort;r million eleven minus thousand is: Six one o.t -40,006012B. -gg,gg4,01o c. 3g,gg3,010 D. 40,006012

I !

-14x - 15x + 29 =: 2x - 91 -11 19. solveforx in theequatron A. X=-1and4/27 B.u' x=2andgl31 c. x = 27131 D. x=l

20. Negative Sixteen million minus one negative Ninehundred ninety-nine equals: A. - 15,ggg,002 i5,ggg,002 B/ C" 16,00c,g01 D. - 16,009

21. Thedistanceicovered shipon foursuccessive were320,300,310 by a days and 330 nautical milesrespectively. the average Find daysrun. A. 5040naut;miles B. 2520 naut. mites 1260naut. C. miles O,fStSnaut.mites 22' An automobile battery supplies current 7.5ampsto a headlamp resistance a of with of 0.84ohms.Findthevoltage detivered thebattery. by A. 7"93volts B,'G.3volts c. B.g3 votts D. 6.395 votts

23' A wireis to be cut in sucha waythat.rnepieceis shorter thanthe otherby B meters. Howlongarethepieces, theircombined if renght 24 meters. is A. 1tjm shorter piece; m longer B piece B. 14m shorter piece; lZmshorter piece C. 12m longer piri.; 12m shorter piece 16m longer g D. piece; m shorter piece 24. A revolution counter reads 69,985 8 a.m.at 11a.m. clock at the wasadvance 17 d min.andat nooncounter reads 87,316. whatwastheaverage theB-12 on o,clock watch'? A. 135.6 rpm a/);2.t1 rprn c" 78"1210 rpm c. 156.2 rpm

25. Findthevalue a in equation: of 2(a+3)+ 3(2a-a\= 4(1 1-3a)

A. ?=-2 112 B. A=7 C.rIa=2 1/Z D. A=4

26. A ship makesan observed speedof 17 knotsper hour.The enginespeedis 17.5 knots.What is the p,ropeller in percent? slip A. 28.5 "

B. 28s./"

c. .ozgsy"

ntr.as/.
57

{ {

and 600tonneof oil at portql 960pertonne at of o* werebought one costof oil pertonnb? 2 7 . 200tonne portat g70pertonnu]wn"t'*", tne-av;rage another D' $ 68 c' $ 67'60 B. $ 67'8s Ay $ 67.50 at fromonepointto another alspeed current agains.t.the up-river at p-oilt a speed boattravers 28. A motor int otiginal oacr to withthecurient and of 6 knots, thendowntheriier ino 1/2rLouii.niruting-theipeied ot the current takinga totartims oiz of 9 knots, points. between ,n.n"ni"o, tinothedistance remains D' 13 naut'miles miles c' B naut'miles mtles B. 10 naut. A. 9 naut. to that of liters mixture is 80%alcohol to muchwatermustbe added 400 zg. How it reduce to a 60%mixture? D. 50 liters C. 20 liters
A. 80 liters B' 70 liters

rd
{

il

620 alolhel holdB' contains tonne' of 250 hold,A, contains tonne cargo' intoA so thatA wiil contain flve ship's 30. A put muchcargomustoel"r.n frome ;E How as times muchas B? D. 300tonne C" 570tonne A" 275tonne B' 475tonne in current' a 3 againstthe mile) mile (onenautical themeasured with 31. A shipcovers samedistance ther and seconds, thenIn theopporittoirection-over 20 minutes Findin knots: exactly" in the current 3 minutes the ga'rPst current A" The sPeed withthecurrent The sPeed B. sPeed C. The average knots 2) 20 knots 3) 18knots A. 1) 18.95 knots 2) 18 knots 3) 18'95 B. 1) 20 knots knots 2) 20 knots 3) 18'95 C. 1) 18knots D. 1) 2 knots 2) 13knots 3) 18knots an andhaving the is the renght fourtimes breadth is 32. A rectangurar to cutso that and length breadth' areaof one.qr"i, 'neter'Findthe 1 and5 meters D. 2 and0'5 meters 4 meters B. 2 and.2 meters c. A. 3 and 12'5 wasfoundto be approximately by delivered an engine horsepower efficiency' 33. The actuar *"r is.g6. Findthe mechanical from horsepower diagram the indicated
A. 19.2"/" B' 50 "/"

I I I

c. 81.3',/"

D. 1.23h'

58

with is tilledto v'ithin16 in' of the top tankis 14 ft, 4 in. highand diameter 34. A 56 in. water.Howmanycubicincheso|waterareinthetank? .3575 D. 162,018,0242 c. lB.384, 2g0.2464 495,341 A. 285,340,3673 emptied lrt 6 hoursrespectivery'can-be three {i*edby two pipe: il. 1 ii1 the tenk be filledin 3 5 . A tank can be tn what time ."n "n empty by a third pipe in 5 rrours. pipes are oPen? D. 4.0 hours 4 4ft pipealone'it the tank...Using smaller storage pipesto a rarge The tank 36. Therearetwo intake the it ooei using laigepipealgne' only twiceas longto fillthe tankis ittakeusing tat<es Ho* io"ng'would areused. in 12 minuteiif bothpipes canbe f'red pipe? thesmallsr D. 20 minutes C . 1 Bm i n u t e s B' 36 minutes A.24minutes miles'another 330 shipto traver nautical a certain . rn 5 hourslesstimethatit takes what arothe 37 further' miles cantrav.i+ niutical shipwhichis 3 1/2knoilaster of sPeed thetwoshiPs?
A . 1 ) 1 3 . 5k n o t s 2) t6.2 knots B . 1 ) 1 3 . 9k n o t s 2 ) 1 6 . 1k n o t s C . 1 ) 1 4 . 1k n o t s 2\ 15.9knots D. 1) 13.2knots 2 ) 1 6 . 7k n o t s hours A. 4 217 hours B' 4 8113 C'

after er for anoth 41/2 hours one at 17.5knctsreaves portbound portseton thesamecourse' 38. A shiptravelring the leaves same ,p..J is 16knots ship another wirose from portwill the fast ship overtake distance Afterhow manyhoursan,r"t what
the slower one? A. 1) 48 hours 2 \ 8 4 0n . m ' B 1) 24hour:; 2 ) 1 6 'n ' m . \ C " 1 ) 1 6h o u r s 2 ) 1 2n . m " D . 1 ) 1 2h o u r s 2 ) 1 0n . m . what is the mechanical D . . 0 8o r 8 / "

2500 rHp and the BHp is 2000" 39. An enginedevelops efficiencY?

1o/o A) 12.5or 12o/" B . 1 . 2 5 o r

C' '8 or B0%

in milesPerhour? 45 mins'Whatis its sPeed 40. A shiPtravel9 milesin D. 2 miles C . 1 2m i l e s B. 6 miles 3 miles A. 59

FORMULAS Area of rectangle A Area ol circte = = -: tengthx width L x W 'il R'

ff o'
4 z'il r

circle = Circumference of = Area of square =

=

ITD
side x side
S X S

Area of trlangle

1 ab 2

of Area ElliPse

==

fi 31
4 h 1 (b''+ b'?) 2 1 radiusxarc 2
-1 12 0

t
I

= Area of TraPezoid A A =
A =

AreaotS."tol

AreaofParallelogram=baseXperpendicularheight Areaof Parabola = basex 2 height

Areaof cyrinder Areaof sphere

= =

+ areabothends x circumferenceheight dt x'[i where{l = 3'1416

Volumeofrectangular=Lengthxwidthxheight. solid

60

I I I I I I I I I I I I I I I I I I
I

V = Volumeof cyllndrical = vessel V = V =

LxWxH areaof base x height .7854D2h flR'h

Volumeof coal bunker(trapezoidal end) = V Wr+WbxHxL 2 Volumeof Sphericgt tank = ? O, 6

TEMPERATURE SCALES
oF= oC= Deg.absolute = Deg.absolute = Phythagorean Theorem RightAngtes: /
C2 = a2 I b2

' I C + 32 5 5 (oF- 32) I oC+ 273 oF+ 460

Trlgonometrlc FJnctions :
sinee =
COS'& =

o h
3

= cosecSeCe =

=*

=+
h

h tan o = _o, a = opposite

cote =
lr =

'T"
tane

i
a

h
aCjacent

whereO

hypotenus

Physlcs,Strengthof Materiats formulas:

TOrque

= ForcexDistance

61

t
AverageSpeed = Distance-lgvelled time ellaPsed Velocity = Distance time miftr' -9- = m/sec'Ft'/sec' t

t
I

Force Work Power

= MassxAcceleration = ForcexDistance dong = Worked time = Velocitv Time = Outputlnput =.1 MVt 2

Acceleration

EfflciencY

KEenergY

in StreSS Tube = P., x P^ x P D2x .7854

\

Volume

= Weight Volume = - Mass Volume

Dens:tY

gravitY = IgSPecific V ldealGasequation: = mRT PV Law: Avogadro's VaMa = VoMo

62

I I
I
]

Enthalphy h

Energy: . Potentlal = mgz EP lnternalEnergy: = CvdT du BoyleLaw Charles Law: = Vr x V, Pr = T., Vrx P2

I I I

%= ,,
Gay-Lussac [-aw: Pr T1

pressure

E =\
= rqlqglht) nrcr trtl

Pre C o m p r e s s i v e= -lrea s s u r e = P -IStress = Tensile = T Tensile A Atea Stralrr = Yield pt. = limit Flastic Y L

I
F RE ENGTNE/LOG-BOOK PORT ORMULAS: lndlcatedhorsepower: lHp = PLAN 33^000

x w h e r eP = 3 3 , 0 0 0 I H P :
LAN A = 33,000x|HP PLN

63

t
P where: L A N 4 stroke IHP/cYlinder der IHP/cYlin 2 stroke Press meanetfective of length stroke Rrea l. D2 4 Rpm colstantx RPM = MEPx cYlinder x constant RPM = MEPx cYlinder L where: A L where: A

t I
Meter
Cm2 Ft.
in.2

I
I

of Urrea (Metric) = length stroke constant Cylinder 4500 x of stroke area (English) = lenoth constant Gylinder 33,000 MEP =

I
I

const'ant of height the cardx Spring Average height = (lt*t),',n:i nveiage Where: in' (length) = distance ED4D Enq.distance Observed ED distance Engine dist' x gist?nce'-'Obs'erved Engine distance Engine 100

Slip

Slip%

ActualSliP BHP Actual EfficiencY % Mech.

sPeed sPeed Actual Engine efficiency ioiur IHPx Mectranical BHP x 100 IHP BHP Actual trial) shoP constant (8HPmax'
readbg in Advanced count-er

Ratio OutPut

RPM Average

in Minutes watch

SPeed Average

in trayg].E'd miles = Distance Timein hr.

(Ave' RPM\ (Time) = -(Pitchof the propeller) \ t 6080ft' or 1852m/mttes

Distance Engine

64

II
r r
Tr
T

Propeller (60) Constant = (Pitch)

ft. 6080
Propeller Speed = Propelteu' x constant RPM

I I I

Propeller % Slip

= speed shipspeed x _Prop. sPeed ' ProP'

100

I
I I I I r

rl

PUMPS FORMULAS: G.P.H. = rr4ANg 231 G.P.M. = -ALNE 231 G.P.H. = ALNEx60 231 M A N S E = = = = = min.in t hr. arealiquidcylinder no.of stroke length stroke of efficiency

I
I I

Taper formula Lathe for Work:

Taperperinch = D- d L x 12
where: D = cl =

dia,neter largeend at diametera( smallend

Taperperfoot = D-d L

L = lengtSininches

C O N V E N S I O NA B L E T ThePrincipal of themetric units System are: 1. Themetric lengths for 2. Thesquare meter surface for volumes 3. Thecubic meter large for 4. Theliter small for volume 5. Thegramforweights I I I .1millimeter" 1 centimeter I meter
1 kilometer I inch il foot 1 yard

= 0.03937 inch = 0 . 3 9 3 7n c h i = 39.37 yards inches 1.0936 or

=: = = = 0.6214 ile m 2.54centimeters 304.8millimeters; 0.3048meter 0,91 meter 44 65

tu
kilometers = 1.609 1 mile (cm) (mm) = 1 centimeters 10 millimeters (dm) = 1 decimeter 10 centimeters (m) = 1 meter 1 0d e c i m e t e r s (dm) = 1 decameter 1 0m e t e r s (hm) = t hectometer 1 0d e c a m e t e r s (km) 1 0 h e c t o m e t e r s = 1 kilometer = 1 myriameter 10 kilometers inch 55 millimete(= 0.001 square 1 square inch s = cerrtimeter 0 . 1 5 5 q u a r e 1 square feet square = 10.764 meter 1 square feet square = 107.640 t hectare mile square kilomete( = 0.3861 1 square centimeters square = 6.452 1 squareinch centimeters = 929square 1 squarefoot meter square = 0.836 1 squareYard kilometers square = 2.5899 1 squaremile inches cubic = 61.023 1 liter quarts U.S. = 1.0567 U.S''gallons = 0.2642 centimeters cubic = 16.383 1 cubicinch meters cubic =- 0.02832 1 cubicfoot liters 28.317 meter cubiC = 07645 1 cubic Yard liters = 3.785 U 1 gallon "S. liters = 4.543 British it gallon troy ounpe = 0.03216 1 gram AvoirduPois ounce = 0.03527 grains = 15.432 avoirdupois pouqds = 2'2045 1 kilogram = 2204'6 Pounds ton 1 metric gram = 0"0648 1 grain = 31'103grams troY 1 ounce -- 453'0granis 1 pound '2 kilograms f U.S.ton of 2000lbs= 907 liters = 158'9828 oil 1 barrel iiters = 1000 meter 1 cubic barrels = 6'2899 meter 1 cubic MT - 1'016 t 1 long on

H H H H

tl

H T

t
{

t
I

t
I I I I

66

t
)

N C O M P U T A T I O NiS V O L U M E :

I I

x 6.2899 To geI:BARPELS = m3 ' = m3 x S . G . x C . F . lrletricTon = MT + 1 . 0 1 6 LongTon . S.G. Meter' = MT Ctrbic & WEIGHTS MEASURES SYSTEM METRIC LENGTH f e e t '1 0 i n c h e s = r 1 k i l o m e t e= 1, 0 0 0m e t e r s 3 ' 2 8 0 1 inch = f = t h e c t o m e t e r 1 0 0r n e t e r s 3 2 8 e e t ' = 1 m e t e r= 1 0 0c f i ^ l . 3 9 ' 3 7i n c h e s = 1 c e n t i m e t e r , 0 1 m e t e r= ' 3 9 3 7i n c h = 1 rnillimeter '01 meter= '0394incft inch m = 1 m i c r o n . 0 0 0 0 0 1 e t e r= ' 0 0 0 3 9 n = ' 0 0 0 0 0 0 0 3 i9 c h 1 1 m i l l i m i c r o= ' 0 0 0 0 0 0 c 0 m e t e r n SUHFACE = '3861 q'mile s q = 1 s q . k i l o m e t e r1 , 0 0 0 , 0 0s0 "m e t e r s =2'47 acres = s t h e c t a r e 1 0 , 0 0 0 q "m e t e r s ' 1 " 6s q ' y a r d s = 1 a r e = 1 0 0s q . m e t e r s 1 9 inches = = 1 c e n t a r e 1 s q . m e t e r S 1 ' 5 5 0s q ' = 1 5 6s q ' i n c h = 1 s q . c e n t i m e t e r ' 0 0 0 1s q ' m e t e r s = ' 0 0 1 5 5 q 'i n c h s =.0 1 ; s q . m i l l i m e t e r 0 0 0 0 1 q 'm e t e r VOLUME y a r d so r 2 6 4 ' 1 8g a l l o n s = r 1 k i t o l i t e= 1, 0 0 0l i t e r s 1, 3 0 8c u ' or 26'418gallons = = t hectoliter 100 liter,s 2'83Bbushels quarts t 1 l i t e r= 1 l i t e r= . 9 0 8q u r r r o r 1 ' 0 5 7 i n c ho r ' 3 3 8f t ' o u n c e = 1 c e n t i l i t e r. 0 1 l i t e t= ' 0 6 1c u ' '271ft' dram cu" = 1 millilitel .001litcr=''i1$1 inch or WE:CitIT pounds = 1 kilograrl= 1,000grarns 2'205 = = t hectogrsul 100 gran''$ 3 '527 ounces 'l gram = .035oLlnce 1 gram = (Troy) = 1 centigrs,ffl .01grarn= '154grain (Troy) = 1 miligra;p .001grarn''-'015 grain
67

\.'

t' (u 1sars) = 13? l;l;,lu

1 c u .f t . = = 0 . 8 3 3g a l .( B r i t . ) 7 . 4 8g a l .( U . S . ) OF WEIGI.IT WATEB 1 cu. ft. at 50"Fweighs62.41lb. 1 g a l .a t 5 0 " Fw e i g h s8 . 3 4l b . 5 1 c u . f t . o f i c ew e i g h t s 7 . 2l b . greatest dcnsityat 39.2"F Wateris at its 1 c u .f t . a t 3 9 . 2 " F l w 1 c u . f t . a t 3 9 . 2 " F e i g h s6 2 " 4 3 b . WEIGHTOF I-IQUID 1 g a l . ( U . S . ) = 8 3 4l b .x s p " g r " = 62.4lb. x sp. gr. 1 cu. ft. = 0 . 1 2U " S " a l .+ s p .g r . g 1 lb. = 0 . 0 1 6 u .f t . + s p . g r . c FLOW = 0 . 1 3 4 u .f t .p e r m i n . c 1 gpm = 5 0 0 l b .p e r h r .x s p .g r . 5 0 0 l b . p e r h r .= 1 g p m + s p . g r . 1 c u f t p e r m i n .( c m )= 4 4 8 . 8g a l .h r . ( g p h ) WORK 778 ft. lb. 0.293watt hr. to 1/1 of heatrequired change B0 temp.of 1 lb. waterfrom 32oF lo 212"F 2545BTU (mean) 0 .746 kwhr" 3 4 1 3B T U ( m e a n ) POWER 0.293watt f 1 2 . 9 6 t . l b .p e rm i n . h 0.00039 p.

VOLUME

= 1 BTU (mean) = =

t hp. hr. 1 kwhr

= = =

1 BTU per hr. = = =

68

t I
I

I I I I I I I
I T

BTU (U.S.)= 2BB,0OO per24 hr. 1 ton refrigeration hr. BTUPer 12,000 BTUpermin. 200 8333lb.icemelted ltr. Per fromandat 32oF 550ft. lb.persec. thp 746watt 2545BTUper hr. BTUPerhr. 33,480 evap. hr. 34.5lb.water Per 1 b o i l eh p r and frcrm at 212'F 9.8kw. 3 4 1 3B T UP e rh r " 1kw w 1000 att MASS 16 oz.(Avoir) lb. (Avoir) = 7000grain ton (short) * 2 0 0 0l b . t o n( l o n g ) = 2240lb. O T H E RUSEFULil/IEASUREMENTS (Metric System) LONGMEASI.JRE = 1 2i n c h e s = 3 feet = 6 feet = yards 5 112 = 40 poles = 8 furlongs = 3 miles = 69 1/2miles MEASURE CUBIC inches= 728cubic = f eet 27 cubic f 1 2 8c u b i ce e t = feet = 24 1/4cubic

) S5/l,)

1 foot (ft.) 1 yard (yd") 1 fathom l nucle 1 furlong 1 rnile l league 1 degree

1 c u b i cf o o t 1 cubicyard 1 core of wd. 1 p h . c , fs t o n e

T I M EM E A S U R E 60 seconds 60 minutes 24 hours 7 days 30 days 12months 365 days 366 days 10years 20 years 1 0 0y e a r s

1 minute t hour 1 day 1 week 1 calendar month 1 year y 1 common ear 1 leapyear 1 decade 1 score 1 century

SQUAREMEA.SURE 1 4 4s q . i n c h e s = 1 s q . f e e t = 1 sq.vard 9 sq.feet 30 1/4 sq. Yards = 1 sq. Pole

69

t
FACI'ORS CONVERSION GENERAL
Conversionto Linear Meagure mil (0,001inch) inch foot yard mtle mtlc nautical SquaroMoasuro squareinch squareIncn loot square squaroYard acre acr6 squaremlle squaremile Volume cubicinch cubicfoot cubicfoot cubrc(oot cubicyard ( o u n c e U . S .l,t q , ) q u a r t( U . S , l,i q . ; ( gallon U.S") ( g a l l o n U . S) barrol(U.S"Petroltlum) b a r r e ( U . S .P e t r o l e u m ) l Mass graln ounce(oz) ( pound lbs) shortton longton Work, Heat and EnergY t l B r i t i s hh e r m au n i t( B l u ) footpound'force calorie Btu krlocalorie Btu 8tu Perhour watthour horsePower Miscellaneous poundPergallon(U.S.) poundmole(gas) grammole(gas) boardfoot milliamPere fool' Per ( g a l l o n s U . S . ) e rm i n u t e P oound-force (KP) kilopond millimetre millimetre rnetre metro kilometre kilomstre 0,0254 ?5,4 0,3048 0,9144 1,6093 1,8532 Reclprocal 39,37 0,03937 3,281 1,0936 0,6214 0,5396

squaremtlltmetre squarecentimetre squaromctrs squarometre squaremelre squarefclot acre squarekilometre

645,2 0,452 0,0929 0,8361 4047, 43560, 640, 2,590

0,00155 5 0,1 5
10,764 1, 1 9 6 0,0002471

0,00002296 0,001562 0,3863 0,00102 3 5 ,1 3 3 0,1 37 0,03531 1, 3 0 7 9 0,03382 1,0566 1,2009 D,2642 0,0238 0,00629 0,01543 0,03527 2,205 1, ' 1 0 2 3 0,9842 0,0009479 0,7375 0,2389 I 0 , 0 0 1 2 8i 5 0,252 0,009297 3,414 0,0002778 1,341 0,00835 0,00279 0,0446 423,7 0,0929 8 0,1 35 0r2248 0 0,1 2

centtntgtre cubrc cubrcmetre ( gallon U S ) Irtro cubicmetre cubiccentintetre litre ( gallon lmPerial) litro ( gallon U.S.i litre

10 , 3 8 7 0,02832 7,48 ,21J,'J2 0,7646 29,57 0,9464 0,8327 3,785 42, 158,98 64,8 28,35 0,4536 0,9072 1.0161 10 5 5 , 1,356 8 4,1 7 8 77 , 3,968 107,56 0,2929 3600, 0,7457

milligram gram kilogram metricton metricton

ioule ioule ioule footpound-force Btu metre kilogram watt joule kilowatt

gramPerlitre cubicfoot (STP) litre(STP) cubicmetre milliamPere metre2 Per metre3 daY Per newton newton(N)

11 9 , 8 359, 22,4 0,00236 10,76 5,451 4,448 9,81

70

Part II

ANd ELECTRICITY ELECTRICALLY PROPULSION DRIVEN

point to point or thq excessor in ELECTRICITY the effectof electrons movingfrom or mechanically by chemical ihermally, in lackof electron a material.lt may be prodr.rced consist by its effects. Electricity action. on board as engineersimplycan be defined magnetic becomehot,whichproduced of a flow of energyin a wire that causethe wire to equipments pumps,auxialliaries fieldaroundthe wire and can be put to workslikedriving, etc. BE PRODUCED 6 SOURCES OF ENEITGY T}IAT ELECTRICI'IY CAN another' Example: Friction- chargedcaused by rubbingone materialagainst wood/stone to pressure- produced by erectricity applying a crystalof a certain,or by speaks in telephone. 3. 4" 5. 6. producedby heatingthe iunctionof a thermo-couple. Heat - electricity material Example:iron, producedby strikingphotosensitive Light - electricity seleniumalloy. result of Magnetism producedby relativemovernent a magnet and wirerthat ir, the cuttingof line of force. producedby chernicalreactionin an electriccell' Chemi;al action - electricity Exampte: Battery DEFI}I-IIIONS AND FUNCTIONS OF EI.ECTRICAL TERMS GIVEN TO ALL RANI$ PREVTOUS EXAMINATIONS zero ALTERNATINGCURRENT- is a currentthat clrangesits directionrisingfrom and back to zero and cycle repeats' to a maximumintensity of used to measureamperes/rate flow. AMMETER- instrument current. AMPEBE- unit of electrical eitherby the can of AMpERE TURNS - the strengtlr an electrontagnet be determined of numberof turns of wire or by the strength the current' readings. by AppARENT powER - the power indicated arr ammeterand voltmeter field magnetsand betvl'een ARMATUREWINDING is to cut linesof forcespassing commutator' force to the eletromotive the developed transmit can be divided. particleinto whiclrt;lement ATOM - the smailestphysicat against if the in CoNTROL- a system wlrich valueof a process compared AUTOMATIC withoutthe use of actiontaken to correctthe deviation value and corrective a rJesired h u m a nh e l P . both units are alike,used in some wire, BALANSER SET - it is a motorgenerator, of the circuit' w-voltage system to help the load balancedbetweenthe two side

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BATTERY - a series of two or more cell that are capable of producingelectricityby electrochemical means. lt is charged by reversingthe current through tire battery by nraterial back on the plate in position. using DC to restore'the depositedin the electrolyte - cannot be recharge. Secondary- can be recharged. Type of Battery: Primary ,CAPACITANCE when voltageacrossan electric currentchanges, the circuitopposes Farads. this change called and measuredin CAPACITOR- is a device for storingan electrostatic charge.

CIRCUITBREAKER - a mechanical safetydevicethat open a circuitwhen the current in the circuit exceeds a pre-determined amount. CONDUCI'OR- it is a substancethat offers a lorv resistance the flow of current. to Example: Aluminum, Copper,Silver,Steel. COMMUTATORI-is to convertthe AC from the armature windinginto directcurrent and transmitit throughthe brushesto the externalcircuit. CONVERTER- an electrical device used frr convertir.g alternating current to direct current. plate separatedby an insulator. CONDENSER- a combination conrJucting ol CONTACTORS- consist of two broa'Jflat copper surfacesthat are pressedtightly togetherto close the circuit. COUNTEREMF - is counter voltage indu:edin a conductor whichopposes change or a in flow of the currentin the cond.rctor. electrical lrr motor,CEMF is the voltagegenerated in the armaturewhich opposes the supply voltage. DC GENERATOR- is a mechanical powerturn the armature and the movingarmature generateselectricalpower. power forcesthe armature turn throughmechanical DC MOTOR - etectrlcal to system, belts, gears which producedmechanical load, DEAD BAND - a zone within a changeof value of an input signaldoes not cause a changein the controller.lf the dead band is too small,the steam valve may h''nt. lf the dead bano is too large,speed regulation be poor. will DEAD SHORT* is a shortcircuitthat has such low resistance that the circuitis made inoperative. DIRECT CURRENT- the currentthat flow only in one or constantdirection. EDDY CURRENT- inducedcirculating currentin a conducting materials causedby a varyingmagneticfield, Eddy currentsare reducedby laminating the armaturecore. ELECTRON- small negativechargedparticleof a nucleus(-), ELECTROLYS1S is the chemical actionrelatedto the conduction electricity of through acid or salt solution.

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by thatis magnetized havin$a coil ELEcrRo MAGNET a pieceof softsteelor iron is whencurrent shutoff' the iron or steel it, wire*r"pp"o around carrying of current
becomesdemagnotlzed" rthrough is current passed when electric orocluced ELECTROMAGNETISMmagnetism a coil or wire. ruhningin capacities of betweentwo generators different EQUALIZER a connection the tuto' bewveen parallelso that the runningload is dividedproportionally or to current the rotorof an A.c. generatolr, the EXCITATIoN the processof exiting; i field' a of currentfor the purposecl prgducing rnagnetic supply of electrical tlre excitingcurrentto the A'C' whicirsupplies EXCITER- a small D.C. generator generator. circuitleadingfrom thersource EXTERNALclRculT - it is the part of the electrir:al of supplyback to the sourceof supply. will curr:ent FARADAY LAW - statesthat if a magnetis movedpast a wire, electrical witl stop' start throughthe wire. lf the magnetis stoppednear the wire, the current lines of force arb being field or magnetic *itt Electricity flow only when tlre magnetic wire. cut by the F R E O U E N C Y m e a n st h e n u m b e ro f t i m e sp e r u n i t o f t i m e t h e c y c l e i s r e p e a t e d . is repeated. of 60 cycLE - meansthe number timeswhichis 60 timeper seconca cycle cf safetydeviceto breakoff the circuitin case of overioad current, FUSE - electrical caused tomperature metalin serieswith the line at predetermined consitof low-melting ittome|tthusbreaking\thecircuitandstoppingthef|owotcurrent' currentby moving or to GALVANOMETER instrument measure detectsmalllelectric field' coil in a magnetic magnetic energy' energyintoelectrical mechanical whichconverts GENERATOR it is a machine eitherby clRculT - a circuitthat has corne in contactwith the earth GROUNDED itselfor leak off to the ship hull directly' Typicalsigns comingin contactsomewhere also shock and readingis, voltage,resistance of a ground are abnormalamperage, abnormalcircuitPerformance. r ; h e c k i n g r o u n d so r l o w GROUND LIGHTS- set of two lightsw h i c h a r e u s e c lf o r circuits. of insulation electrical pole piecesfor finding devicewith two adjustable GROwLER - an electromagnetic and demagnetizing' coils and for magnetizing short circuited equalto 33,000 to equivalent t horsepower energy HORSEpOWER unitof rnechanical ! ft. lbs. per minute. use for checkingthe chargedcapacityof a batterywith HYDROMETER instrument 1,300s.G. and low 1,000 spec;ficGravity" full chargedapproximately

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current linesof forcethatcut a wire,electric of CURRENT Consist magnetic INDUCED to is induced flow in the wire. when voltage and givesan instantaneous on colL -Loperates DC current INDUCTIoN the primarycircuitis made or broken' to is speed notproportionalthefrequency wnose MOTOR- is an AC motor INDUCTION stationary hollow, is of type squirrel-cage consist statorwhich outer, of thesystem;Mostly motor' lt an and having innercylindrical for steel,slotted armiturewinding laminated current. is found on;boardwheresources alternatirrg is usually xl effecisof resistance and Xc and with combined IMPEDANCE in an AC circuit bY measured ohms. opincorrect to mechernicallyprevent leversare interlocked INTEHLoGKS operating asternor ahead' erationlike reverses, and reaction givebetter armature in INTERpcLEs- usedon DC rnotor crderto offset commutation. to that ,rffersa high resistance the flow of current' it INSULATOR is a substance Examples:rubber,cork,Porcelain. DC for equipment converting to AC. INVERTER is a pieceof electrical in resistance series serveas cevicethat inserts JAMMINGRELAY- fittedon rnotor thus motor and overheating, overloacls in with a motor armature case of excessive is cut down to a safe value. current armature power of the the meterthatshows operator amount electrical K.W.METER- electrical in Kw. the fieldwhichopposes motion sets up a magnetic LENZ LAW - an inducecurrent that causesthe currqPt. resistance of the usedtO measure effectiveness an insulation MEGGER instrument equiPment. of electrical ohms' to MEGOHM equivalent orremillion ohms' to MILLIOHM equivalent thousand of MOLECULE combination truoor more atontsenergy' Intomeclranical energy electrical whichconverts device MOTOR- a machine and proton' of consist electron in particle the nucle'ls NEUTRON neutral resistance' OHM - unit of electrical energy' of consumption electrical to USed measllre oHMETER- instrument proportional is circuit directly in flowing a electrical oHMS LAw - statesthatthe current to proportion the resistance' volt4geand inversely to the implesqed
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current if tlre breaks current an excessive autonratically RELEASE device ovERLoAD is drown bY the motor' partsare so in connection whichthe various 'ARALLEL ctRcurT is an erectrical one patn tor ine flow of currdntor when that thereis morethan together connected side by side are connected the apparatus and placedunder ttrathas been hardened oJ MAGNET a piece. steer of 'ERMANENT its magnetisnl the tield it fisrd, when removecl, rotains a magnetrc or the Infruence
through its llfe.

breakeron the transformer pHAsE BALANcE RELAY- lt act to trip out the circuit excessof 2S percent if and motorfield contactor, unbarance openthe generator and or groundin one phase' It showsshortcircuitif phaseunbalance power' lt is expressed true powerand apparent powER FACTOR- ratiobetween power' of as a percentage the apparent PRoToN-positivechargedparticleofanuc|eus(+). current' to current undirectional alternating to used change device RECTIFIERanelectrical moving b1' is inducecl a conductor HANDRSLE- in everycasewherean EMF RIGHT Place be foundas fQllows: of the of rines rorce, direction thisEMFcan stationary through rightqnglesto one and middlefingerall at the righthand with the thumo.forefinger in direction tnJtinesof force.nithumb alongthe arong pointthe forefinger another; the EMF iing.t will then showthe direction th; is whichthe conductor moveJ, middle inducedin the conductor' of in a variation the condition one electric RELA' - is a devicethat is operativ,gy circuit' electric another in the sameor of the\ circuitto control operation otherdevices usedfor regulating of by composecl a combination resistance RHE.'TAT - an instrument of generator" the through fieldwindings a current of the strength an electric in remaining the.fieldafterall exciting RE'ID'AL MAGNETI5M is the magnetism g.nrritor could builtup a voltage not the because D.cis current shutoff. rt is important withoutit. heat' produces etlways curt'ent - a cevicein whichthe flow of electric RESlsroB from a powerreversal' the powER RELriy - protects generator REVERSE RoTABYcoNvERTER-usedtoconvertACtoDo. so together that are the circuit connected cr'curr - is onewhichail partsof sERrEs of current. there is oniy-onepath for the flow botfrin series partsare connected clRcurT - is one in whichthe sERrEs-pARALLEtand parallel combination.

withtoo sHoRT crRcurT- is a circuit to pass from positive .tr.tric wirespermitthe current of t*o beingdamaged "op.rnt
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signsof shortcircuit Typical passing usualresistance. the wirewithout to the negative and smokeor burn. high amperage fieat,low voltage, are blown tuses,increase SLlp BING - purposeis to supplyD.C. currentto the fieldwindingof the motor. plunger. a coil SoLENOID- an electromagnetic that contains movable magnetic the motorwhichproduces rotating part of an electric STATOR- stationary field. two usedin synchronizing or more D.C. apparatus syNCHROSCopE an electnlcal generator. proporis operation exactly speedof normal MOTOR- the average SYNGHRONOUS in and whichconnected, theirmain application of tionalto the frequency the system parts. AC generator as is motor. lts construction similar workas mainpropulsion marine a whenheated, voltage together; are metals joined THERMOCOUPLEtwo dissimilar is produced. voltage or deviceusedfor increased decreased TRANSFORMER it is an electrical current. of alternating the and increase the sTEp DOWNTHANSFORMER is one that lowers AC voltage proportional the turnsin the primary as is ampere. The changein amperes inversely in the secondarY. are to the turns the and decreases sTEp up TRANSFORMEH is one that raisesthe Ac voltage are proportional, turnsin the primary to as amperes.The changein voltsis directly the turnsin the secondarY" pressure, or temperature levelinto of capable converting TRANSDUCERS a device equivalent. an electrical by TRUE POWER- actualpcweras measured watt-hourmeter. WATT - unit of electriPal Power. energy. of consumption electrical usedto measure WATTHOURMETER instrument pressurs. VOLT - unit of electrical pressure. volVelectrical usedtc measure VOLTMETER instrument limits within specified voltage the to REGULATOR rrsed maintain generator VOLTAGE loaci. with different at constant

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ouEsTloNs ANDANSWERS (1987'1991) .t ENGINEERS. SEcoNt| ANDCHIEF TH|RD, FoURTH, of generator' to whlchmayresurt a poorcommutatlon Dc 10 Enumerate causes

1. Overload brushes 2. Hard or high resistance bars 3. Roughcomrnutators grounds mica on th'r commutator 4. High 5. Shortcircuitin the armature 6. OPencircuitin the armature 7. Poor brushcontact air 8. Uneven gaP field 9. Weak magnetic brushsPring 10. Inaccurate to generator bulld uP? Q. What are the causes of fallures of a DC reversed 1. Fieldconnection not in properposition are 2" Brushes of 3" Wrongdirection rotation 4. SPeedtoo low oPen 5" Fieldcircuit magnetism 6" Not enoughresidual shortcircuit 7. Machine o. Name the causes of low voltagesIn generator" 1. Overload 2. Low sPeed of setting brushes 3. lmProPer O. What are the bauses of too hlgh voltage? 1. Fieldtoo strong 2. SPeedtoo high (generator) o.Whatarethecausesofhotcommutators? underbrushes 1. SParking 2. Poor contactof brush 3. Nearsome hotterpart of machine' O. Causesof sparklngat the brushes? 1. 2. 3. 4. 5. 6. Overload settingis wrong Brushes Poor brushcontact Roughcommutator Weakfield brokenor shortcircuited' winding Armature

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Causes of too low generator speed? 1. 2. 3. 4. 5. Overload Brushes settingwrong Excessive,friction Short or giound in armature Too littlefield resistance

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Causes of too hot fleld? 1. 2. 3. 4. Overload Dampwindlngs Too largefield current Shortcircuited coil.

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What general care should a generatorrecelvewhlle In operatlon? 1. lt shouldbe kept cleanand dry. 2. The bearing shouldbe kept well oiled. governor 3. The shouldbrekept in good condition" Causes of too hlgh generatorspeed? 1. 2. 3. 4. Brushes settingtoo forward. Open fieldcircuit" Wrongconnection Too much fieldrheostat resistance.

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What are the results of shorts In DC armaturecolls? 1. Overheating 2. Sparking brushes. at 3. Burning 4. Discoloration. what are some\causesof fallure of a generator bulld up? to 1. Fieldconinection reversed 2. Brushes in properposition not 3. Wrongdlrection rotation of 4. Speedtoo low 5. Fieldcircuitopen 6. Not enough.residr{al magnetism 7. Machine rshort circuited. Reasonswhy a self-elrclted generatormlght fall to come up to lts rated DC voltage when startlng up?
1. 2. 3. 4. Brushes not in proper position. Field connectionreversed. Wrong directionof rotation. Speed too low. 5. Field circuitopen. 6. Not enoughresidualmagnetism. 7. Machineshort circuited.

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o. 5' before changlng ups should be made ls vlbratlng, what check -"ni A generator \ I balance welghts 1. 2. 3. 4. 5. Misalignment SPring shafting the rotatingelement Somethingschangrng Foreign matter shaft' Uoose bolts' foundation

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rather the rn byrotarns *erd anAcgeneiator

circuit to directlv theexternal is the rrom stator connected

field' revolving withoutusingsliPrittg' t9''up-qll*:*tit"tionto the two slip rings3re nTT?:'y that are due to 2. onty stresses to subiecreo mechanicar 3. The stato'windingis not ' force centrifugal and amperes? the amount of lnducedvoltages four thrngs determrne o. what of 1. The strength the field of 2. The number conductor the fields of cutting 3. fne sPeed have to the field" conductors 4. The anglewnicrr-irr; once a month' whrchshouldbe rnadeat least check-ups generator o. Namesome 1. Checkload condition oPeration sYstem 2. Uubrication actionof Primemover 3. Governor and temperature vibration 4. Bearing by the use of bright lamp lmethod' o. Gtve the methodof synchronizing connection the method, paralleling by the use of the brightranrp brilliancy' maxirnum ln synchronizing at tn"iiri, rampsrrines their at be compreted ih; instant shourd o.G|vethemgthodofsynchron|zlngbytheuseofdark|ampmethod. should connection the method, paraileling theuseof thedarkramp of the last glow rnsynchronizing the between disapperance of the intervar at bo compreted the *iiJre andthetimethesameamountofglowreappear. o.NamethematorpartsofanACandDcgenerator. I r 5C)generator the armaturewirrdings' 1. Tl,e statorwhich contains tield windings' the 2. The rotor*ni.n contains B. DG generator' the field windings' 1. The statorvrhichcontains armaturerrvindings' the 2. The rotorwhich contdins
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O. Namethe ktndsof AC and DC motors; AC motors 1. Wound rotormotor 3. Repulsion motor geries 2. Universal motor 4. Synchronous motor oC motors 1. Series motor 3. Compound woundmotor t ah''tt motor -' '"-' 4. Universal series motor O. What are the types of transformer accordlng the methodof wlndlngthe to coll? r. core type 2. Shelltype 3. H{voe ''
O. Upon what factors does generated voltage depends? 1. Speedthat the magnetic linesof lorce are cut 2. Strength the magnetic ot fietd. 3. Numberof turns ot wire. Q. What protectlvedevlce are InstalledIn an electrlc drlve system?

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Fuses, circuit phase breakers, balance relays, power reverse relays, ground relays, interlock alarms suchas klaxons bells. and O. 1. 2. Q. Whatare the Instruments usedIn synchronlzlng or moreAC generator? two Voltmeler Synchronoscope Namethe Instruments tound In DC and AC swttchboard panet.

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Circuit breaker, voltmeter, ammeter, rheostat ground tight, synchroscope, vottage p.F. regutator, mete( Kw meter.
O' what condltlon must exlst In order that two Ac generatorwl operate In parallel? They must have: 1. Same voltage 2. Same frequency 3. Same phase rotation. O. What are the factors that effect reslstance on a wlre? 1. Lengthof wire. 3. Type of materia Z. Cross sectional area of wire. 4. Temperature wire. of g. What are the condltlons \irhlch would cause an AC generator to overheatt 1. Overload 2. Short clrcuitin coils 3. Damp colls 4. Dirtywtndings S. Fan or air coolerdefective 6. Low oowcr factor load
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changlng shourd be nrade before ls vrbratrrrg. what check-up o. A generator " balance welghts' mattgr "nY f oreign element' ciraf sornetrring ingthe rotating shafting, sprung Misarignment, faultyspeed governor' loosel-'olis' on shaft,overfoading, once a day' which shourclbe made at reast some generatorcheck-ups a. Name governor systemoperation' rubricatror, condition, cornn-lutator check roadcondition, actionofprimemover,|rearingtemperatureandvihrration' front overheating? to prevent tlre outer circuit o. what means are emproyetr to of ar*ount current be supplied' sizcof wireto tireproper 1. rt musthavea proper 2. Overlcad connection 3. Short circuited genwhen synchronizingtwo or more o. what are the tactors to be considered erators? TheY must l'rovthe following: 1. Samevoltage 2. Same frequencY pnase 3. Same phase rotationand be in

a 50 Hz generator?

o.Whathappenswhena60l.|zmotor|oaclisconnectedto caPacitY or underated less to its rotational to The motorratedcapacity drivewill be is frequency low' becauseof the generator of speed and be smoothrycontroiled In terms o. whlch motor (AC or DC) can \ why? Dc motors;Ac in controted ternrsof speed. Un'ke motorcan be smoottrry in AC encountered the troubles most occured therefore motorsdoes not use commutaiors oJerationof DC motors are eliminated' preserve the you are duty bound to malntarnand o. As a marine engine officer, what you know state brlefly power system on bouro youi'uesser. erectrrcar about electricitY? on equipment to erectricar my officer dutiesin regards As a marineengineer board ship are as follows: , - r,--.^rr^a|n{ erectron Inovlng effectof ur may Erectricily be defineg the basicaily By definition thermally' produced in staiicform whichmay be from one pointto pointand exist actions mechanicltfyand throughchemical anc auxilliary motors, of methods a[ generators, propererectrical maintenance megger overloading' circuit, grounoeo for such as checxing st oit and machineries and startingmotor wiringiystem for lighting battery, resistances test for insuration etc.

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be shourd done on boardregarding test maintenance and records checkrist like and overhauring repairs.Instrumentation records, test,,insuration ararm safety gauges,alarmsmust be in good order' pressureand terlperature Advantagesof turbo-electrlcdrlve shlps' effieciency' at propellbr highest andlow-speed mover prime highspeed 1. Allows when astern' 2. Allowsfull powerof turbine 3. Less noise and vibration' to from turbine propeller' 4. Does away,withline shafting andcanbe usedto improve output the indicate power instruments 5. The erectric oPeration. lt mathematlcally' what ls meant by power factor? Express power' lt is expressed apparent Powerfactor- is the ratioof truepowerto power. of as a Percentage the aPParent = Watt = Kw true Power P.F. = Volt-AmPere KVA apparent Power How does the slze of wlre affects lts reslstance? of to proportional the square thediameter' of The resistance a wireis inversery the the lengthremaining same'

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G|ve4|actorsthataffectres|stance|nawlre. 1. Lengthof wire area of wire 2. Crosssectional 3. Type of material of 4. TemPerature wire. what happensto lts reslstance? lf the 0 . As the rength of a wrre Increases, whtlt happensto the reslstance? cross sectlonal area Increases, the same. remain the As the lengthof atwire increases, resistance decreases' the area increases, resistance AS the crosssectiOnal fleld' of generator a. What klnd of metal ls used for pole pleces abouta wirewrapped copper and rectangular square of Metalconsist rouird soft iron core. In serles' are clrcult when resistance connected a o. Degcrtbe serleselectrlcal What mlght be sald about:
1" Current Flow 3. Total,voltagedroP 2. Voltageacross each 4. Total resistance

1. The currentin every circuitis the same' of the voltage across each 2.Thevo|tageacrossthe.circuitequa|totheSum seParateresistance' I \ ..
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by multiplied totalresistance' to dropis equal thetotallinecurrent voltage 3. Totat resistancs' individ,rar of the is 4" Totarresistance equarto the sum voltage what can be sald about (1)"lthe In when reslstance parallel.. o. Descrlbe (2) vortagedrop acrosseach branch; drop acrossthe enilr" pur"riercrrcurt; (3) amount of currentito* through each branch' is circuit the sameas the voltage the dropacross entireparallel 1. The voltage
across each branch' is the same. 2. The voltagedrop across each branch is the sum of the currentthrough 3. The totaliurrent throughthe combination each branch. a voltage in a wlre? what are the three thlngs necessary to Induce

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a) Magneticfield bi A conductorin a closed circuil the two c) Relativemotion betvveen of DC motor. Glve some characterlstlcsand appllcatlons of types no loadit oversPeeds, SERIESWOUND MOTOR- speedvarieswith the load,at torque.Used speed. This motorhas a veryhighstarting at full load it decreases locomotives' for street cars, cranes,elevators, constantload over SHUNT WOUND MOTOB - constantspeed over load range, variable toolswlhere and used mainlyon machirte speed range,has a good contror speed is desired. of features both aboveltypes. 9.oo9 coMpouND WOUNDMOTOR has desirable constantroadspeed applipation.Used of flexibility speed contror, startingtorque, drive' pumps,cargo winches,boat hoist, air compressor for centrifugal generator' Glve some characteristlcsand appllcations of DC

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coils woundedin series sERtES ry9UNDED GENERAToR which has its tield largewire. The voltagewill with the armature. The field coils has a few turns of be use, but malir used for in rise with an increase load" They are not in general of boostingvoltagein transmission D'C" wounded which has its field,coil SHUNTWOUNDGENERATOR it is a generator in parallelwithlthearmature with the armature.The lield coil wounded in parallel The voltage droqt .:JL-Y',h an consist of large number of turns of srnall wires. chargingand A'C" generatorexcitation' increasein load. Used for batter:y on each pol piece' Olg COMpoUND wOUND GENERATOR has two fields and woundedin serieswith of the coils is made up of a few turns or heavywire This kind of generator of armature.The othercoilsis composed a greatarmature. and also voltage where oc currentis required purposes generar is used for armost - is fairly constantfrom no-loadto the full-load. Describetheir chanacterlstlcs o. what are the two general types ol Ac motors? and thelr uses? field with salientpoles which are excited motor- has a rorating 1" synchronous

is and speedis constant torque moderate.lt is suitedbest by directcurrent for shiPProPulsion. part the motor- has a stator, stationary and the rotoras the rotating 2. lrrduction current. and torque highstarting lowstarting constant, is part. Thespeed nearly It is usedforrgdneral PurPoses. o. what are the two'dlfferenttypes ol Inductlonmotors,and lts appllcatlons? has barsand end rings but CAGETypE - lrasno winding rather 1. SQUIRREL in the core of the rotor. generator fans. and gear,motor steering shopmotors, machine Uses- hrlower, 2. on TypE - haswindings the wireof the rotorand sliprings wouND ROTOR to resistances vary its speedand for inserting on the shaftwhichare used for starting. and elevators. cargowinches Uses - Boat hoist,capstans,

current? O. What ls the meanlngof alternatlng of instants time is either any two consecutive that between It is the current in or in decreasing strength, reversing direction. in lncreasing strength, O. Descilbeone cYcleof A.C' in to in and Startat zerostrength increases strength maximum one direction, increases direction, to in in decreases strength the samedirection zero,reverses to in decreases strength zero,where in to in strength maximum the newdirection, direction. original againto the it reverses O. What ls meant by frequencyof A.C.? What ls 60 cycle A.C.? of meansthe number timosper unitof timethe cycleis repeated. Frequency 60 G0 CycleA.C. meansthat the cycleis repeated timesper second. of Gl" What ls meant by "staggerlngthe brushes'n a generator? so them on the commutator thatthey are not in line,so as It meansplaclng grooving commutator. the thenrfrom to prevent O. What ls the effect of brushesahead or behlnd neutralIn a DC generator? must be used to get morefieldcurrent will not be lts lrighest, The voltage will at up the tieldpoles" Sparking the brushes voltage thusheating the required to causethe commutator run hot. e. Why do most DC motors deslgnedto operateat varlous speeds have compensatlngcolls and Interpoles? the the miclway Thesepolesare placed 'l-his between mainpolesto induce voltage in rsal in the coilbeingcomrnutated. helpsin a quickreve of current thatcoil sparklng. which reduces O. How does a DC generatordlffer from an AC generator? has has a commutator, AC generator a slip ri,tg. the The DC generator
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most commonlYused on Expla|nwhycompoundwoundDCgeneratorsare \ snips and now ls the voltage controlled? at all loads Voltageis voltage a develops constant This type of generator of rheostat' bY controlled msans to vary the strength of o. state two ways to reversethe polarlty and two ways an electromagnet. the of the eitherreverse winding the coil 0r reverse the To reverse polarity, directionoftheflowofcurrentinthecoil. of the change number turnsof wireor change either the To change strength, wire, the through if the amount .urrrnt flowing compoundwound dc generator? of 4-pore the e. Howwourdyou reverse porarrty a an eachbrush'connect outside untJer of and Liftthebrushes places cardboarcl the and throw.in switchfor or generator a battery, eitheranother suppry erectricar machine' and the cardboard startrthe remove a few seconds.pulrout the switch, current motors? speed control tor for o. How rs speedcontrol obtarned drrect DC motors obtalnedbY: of the 1. Varying strength the field' in the armature' the voltage 2. Varying in connected series. shuntfield nls a rheostat 3, The of a DC mptor? o.Glvesomegenera|ru|esto|ollowlntheoperat|on smooth 1 " Keep the motorcleanand the commutator point' spaceand on the neutral properry in 2 . Keepthe brushes goodcondition, e the Do not overload motor' voltage' the ProPer 4 . Use which it is designed. 5 . Use the motoronly in the temperature armatureto Prevent o.Howwouldyoutemporar|lyrepalr.anopencol||nan reachesport? sparktng-rni {ashlng untli the shlp both encjsof tl'lecoil and taPethoroughlY' by lsolatethe coil completely cutting molsturegrounds,what o. lf you fo,rnda generatorhad beenwet and had heavy wou|dyoudo-togetthemach|nereadyforservlce? run a low voltage in gridsare instal|ed the unit,use them. |f nc,t, |f heating the through windings. shown by ground lamps on a o. How would you proceedto locate a ground bus? PCIwer 240 volt DC auxitttarY disappears' the boardurrtil ground on line cut outdifferent suritches theswitch box and cut out each individual go circuit, to.that circuit the To rocate groundeo this finalcircuituntilthe ground work disappears. switchuntl the ground "iong is located. motors controlled? O. ln general,how ls the sPeedof DC of by il varyingthe strength sPeedof DG motorsare controliecJ In general, shuntfieldhas the armature.Usually, in the the fied-or by varying voltage the in cont'rected serieswith it. a rheostat
86

o. what ls meant by overloadand no-load protectlonof a Dc motor? shut off if the load meansthat the cunentls autonatically Overloadprotection motor ls built. becomesgreaterthat which the is protec.tion meansthat if the load falls off, the current shut off to No-load iiself. away and damaging preventthe moto(from running to O. Supposeyour motorfalledto start,explalnthe sequence correctthe trouble. up may to leads themotor,fortheconnection be hooked wrong. 1. Lookfor broken 2, Fieldmay berweak. 3. MotormaYbetoo overloaded frictionin the bearings. excessive 4. There maybe, Q. What four thlngs determlneths amount of Inducedvolts and amperes? of 1. The strength field of 2. Number conductors the through field 3. Speedof conductors haveto the field 4. Angleof conductor would you glve a lead acld battery? O. What care and malntenance 1. Avoid high ratesof discharge gravity less than 1,150 to a. Z. Neverdischarge bettery a specific condition idltl in discharge 3. Neverallowa battery water 4. Use distilled 5. Neveradd acid to electrolYte cell rapidlyat high rate 6. Avoid charging of temperature 1100F nevere>lceed 7. Whilecharging 0. Descrlbean alkallne type storage battery? soda, caustic of consist nickelplates, usually battery One of the type of storage and cannot life longer but a lowervoltage case. lt has a and waterelectrolyte rubber rate. discharge standnigh current O. Descrlbea lead acld storage battery? plate negative platesare leadperoxide, wherepositive battery A type of storage and waterand activematerial of are are pure lead. Thetelectrolyte mixture sulfuric to qualities similar a sponge.The poresarefilledwith porous and haveaOsorptive are into change combination formchemica acicJ discharge contact, battery as elecirolyte the positive of material when gr.avity cJecreases fullycharge specillc Thusresult leadsulfate. platepure l:ad" platesgain lead and negative a. what causes short clrcult In storage batterlesand how are they detected? contact forming particles, and lead Causes by faulg separators, particles metallic crackin sediment, excessive of plates, buckling plates, anOhegative positive between water' imPure and use of partition, gravity electrolyte. of andlowspecific drop, voltage by Shortaredetected overheatrng, Cl" What are the tlve reasonswhy a lead acld batterywlll not developlts rated capacltY? at discharging high rates 1. Contirruous time 2. Longerage of service will 3. Sultation form lead sulfate
87

-'' r--

o.

in electrolytes 4. lnternalshort circuitcausedby impurities crack and buicked plates. faults cause by poor connection' 5. Mechanical in operation required? what general care does a storage battery
1 . KeeP cool and well ventilated the Plates. coverl 2'Maintainp,op"'|eve|ofe|ectro|yteat|eastl12inch electrolyte 3. Maintainproper specificgravity of 4. KeeP terminalsclean'

d d

i I

COMPONENTS OF ELECTRICAL TROUBLESHOOTING 0. breakdown? What are the causes for electricalequipment ts which the thus increases ourrent of the 1. Heat -. increases resistance the circuit rnuch quicker and wear down cracl<, cause the materialto expand,clryout, andSooneror|aterthedevicewi||breal<down. ore{09y1' and eventually to z. Motsture- causealso circuit draw morecurrent current warpingand abriormal causeexpansion, lilte Moisture waterand liquids flow or short circuit' grease'oils etc that vapors, 3. Dlrt and other contamlnants such as fumes, until breakdevlcsto crogo, lunl up and operateabnormalty causeelectrical down. of breakdown' 4. Vlbration - and physicalabuse can cause also these types who is careless personllel 5" poor Installation whichoftenwork of unqualified orinahurrycancausealsobreakdownSoon.I What are the effects of breakdown causes and their characterlstlcs? a. the preveirts current wl-rich circuit, of open clrcult - is the result an incomplete reading. resistance path. lt has a infinite from flowingin a complete ?,:d l?'o like multo brokenwhen checking instrulnent currentsincb its pathhas been timeter. a direct path across its Short circuit - often resultwhen the currenttakes in the circuitdecreases source. lt drawsmorecurrentbecausethe resistance of short circuitsare: -high and as a resultthe voltagedecreases" Typicalsigns amperageand smok'e' heat, low voltage, blown f uses, increased of br placement a Grounded clrcuit - resultof a defectin the insulation or to the causes current takean incorrect abnormal component wireor equipment windingsmake electrical route in the circuit. lt resultalso when part of the body. when grounded contactin the frameof the motoror otherequipment voltage and amperage, in a circuitit shows the followingsigns. Abnormal shock' readings, resistance are clftenresult c,f too much friction,wear or Mechanical breakclown bearing' wot'|1 which movingparts like brokenbelts,worn contactss vibration of mechanical examples loose belts damage 6lectricalcontrolsare some failure circuit abnormal, by meansof noise, you problems,which can determine throughour senses' duringoperations and visualinspection

I I

O.

b.

c.

d.

88

I I I
]

Sourc e

Open wire

MOTOR GOOD CIRCUIT

OPEN MOTOR

I 1 I I I I
I I I I I I I I I

TED I'4OTOR SHOR

G R O U N D E DM O T O R

e.

What are the baslc methods In troubleshootlngan electrlcal or electronlc devlces? 1. t i t V o l t a g e m e a s u r e m e n - o f a c i r c u i t s u s u a l l y a k e nb y u s i n g a v o l t m e t e r , reading whilea low-voltage an indicate opencircuit, reading voltage which zero alwaysconnecta voltmeter Remernber, a may indicate shortedcomponent. voltage' in parallelwith the circuitwlren measuring Amperage measurement- of a circuitis usuallytaken by an ammeteror faults, such and lccatescommoncircuit whichindicate a "clamon" ammeter in the connect ammeter series grounds.Alwaysromember, as short,open and c w with the circuit hen measuring urrent. trrasurement -- an ohmeteris used to n easurethe continuity Reslstan"a grounds, shorts, lt or of resistance a circuit a component" is used for locating alwaysshut off the power beforemeasuring Remember, and open circuits" resistance. with faultycompolrents a of Substltution- is a technique replar:ing suspected faults. ro a good spare component save time and effortin locating to like a suspects component a capacitor, be faulty, Brldglng- whenelectrician faulty component suspected across goodcomponent "jumps" places known a or he bridging. fronr the circuit,tnus save time by comintermittent therrnal hr:at,to a suspected Heat ._ by meansof applying in ordernot to damage usinghot bloweras device ponentwill breakand mostly plastictype, especially component

Z.

g.

4.

S.

6.

B9

investigate probrem is: define.theNote: one approach lilr^"ubroshooting

:3:?ft i3;lfil'l"l"il3'li 7g.x1,ff :lliii{iJT.lt,f ilTnLIifl :?:$il1ffi in' a circuit' the every'o*Po*nts
ls important see n.*unilLl,lirp ov,trp'pil"ro*" available' ano which *r,ere. what, when, wiilrt.,e'-aio'oilr*i*-i"g'"ms prourl'm, whenapproaching "
figure below'

yff 'll:'l';q:?'$iil: t, id1;!;i*:t.;:!jilft B:t;;1.!"irjrT;"ilt'rffi

voltmeter Always connect a with the circuit' ;;;;i.l

in the connect ammeter AlwaYs seriescircuit'

tl' turn AtwaYs offthePowel.lirethe measuring fii.uit before

sistatrce-

90

It

I
h

ofrN *flrcH

CtOSfO Snrrcr/

I l I
l l r
I

r.$

KI
q+J
i;Oh;;.
.C,arrlinuitu

Checkinga switch for continuity using an ohmmeter

No turirui\

-OP?n

No

Continutg

bttinuity

Checking fuselor continuity a usingan ohmmeter

I r
I
r
I t f t I

F'^._- the __,_ Reversing rgtation a three_ptrase of indudion motorby switching c,uter the two leads wliriledc motor simply reversethe polarityeitherthe field or brushes.

-{ -{
-a

-{
-a

91

OF AND TROUBLESHOOTING REPATR DC MOTORS

given below' dc In Thesymptomsencountered defectlve motorsare
1. lf the motorfails to run when the switchis tumed on, the
v . v r v . . . . v r Y v t ' r

troublemay be

device d. opan fieldcircuit a. open fuseor protective e. Shortedor groundedfield brushes b. Dirtyor clogged f. Shortedarmature circuit Openarmature

g. Wornbearings
h. Groundedbrushholder j. Defectivecontroller

2.

3.

lf the motor runs stowly,the troublemay be e' overload coils a" shorted amtatureor commutator c. open armature set off-neutral f. wrong voltage d. Brushes b" worn bearings speed,tho troublemay be lf the motor runs fasterthan nameplate field c' shorted or groun*1ed circuit a. open shunt-field in connec;tion a compoundmotor d. Differential a load b. series motor runningwithout lf the motor sparks, the trouble may e. a" Poor brush contact f. b " Dirty commutator c. Open circuit in the armature g . h. d . Wrong interPole PolaritY

4.

be field or Shorted grounded leads aimature Revorsed Wronglead swing; Brusriesset off-n-eutral

i' Openfield circuit i' High or lolv bars X"lfiqn .mica, -._armature l. unbalanced

5 " | f t h e m o t o r i s n o i s y i n o p e r a t i o n , t h e t r o u b | e m a y b e unbaranced armature d. commutatar b. a. wom bearings High or row bars c. Rougtr maybe 6. lf the motorrunshot,the trouble brushpressure coilse. Toornuch b. sparking c. Tightbearingsd" shortecJ a" overroad are: The typlcaltroublesoccur In manualDC Controller the points, troublemay be: is movedseveral 1. rf the motordoes not startwhentrrehandre or Openfuse, breaker, relaY' a. contact acrossadiacent test unit: test by placinga 11S-volt lamp Open resislance b. is polrnts open' the between two pointt;the lampshouldlight: if not' the resistance contactPoints;arcingmay occur' tlre Foot contactbetvyeen arm and the c. starter' connection d " Wrong circuitsin the armature or field circuits' e. Brokenwires may causeopen load' Low voltageor excessive f. connections' g . Looseor dirty terminal circuit' neld
h.

an oause open win h?"n"il;:H,j|',Jlil1:'i;;;",nt box:this

-) Afraaa connection' d. lWrongn n n n a n t i n n

2.

lf ,^;;;';;;";-il;;" a. ^rffi"ffi,lg""il"or"-ro b . Low voltage Shortedcoil c.

mav point, troublel be: the to it is brousht^- the last^" r1rrnr cnntaetSr^aic
, L - ,

contacts' or broken ourn-out, leads, poor

e. Overload contacts open

3.

| f t h e f u s e b | o w s w h e n t h e h a n d | e or m o v e d u p , t h e t r o u b l e m a y b e : is units'contacts wires' resistance Grounded ;. b. HandlebroughtuP too quicklY' box; circuiton starting open shunt-iield ;: shortedout' d. Resistance the troublemay be: 4 . lf the startingbox overheats, motor. a. Overload uP brought too slowlY' b . Handle unitsor contacts' resistance Shorted c.

92

I h l-

l P r o c e d u r eo r u s i n g m u l t l m e t e r s : 1. of ZeroCorrection Indicator t p l a c e , l t E o i n t eo n , , 0 , , o n h e l e f th a n ds i d eo f s c a l eb y t u r n i n gh e z e r o t p r
corrector.

2"

Red lead ptug into positive(+) jack Black lead plug into negative(-) jack connection.

tl lI

a o 3 . S e l e c t i o n f F u n c t i o n n d n a n g e . N o t e : P u t y o u rs e l e c t i o n a) D C v o l t ( D C V )

f i r s to n h i g hr a n g e '

c . 1v 0 . s)

)
) ) ) ) )
show maximumvolt readingfor that range" FiOures

2.5v 1 0v 50v 250V v 1000

1 0v 50v 250V v 1000

I I I I I t I
I

b) A C v o l t ( A V C ) f v f i g u r e ss h o w m a x i m u m o l t r e a d i n g o r t h a t r a n g e .

t D C c u r r e n( D C A ) A 50u f c f i o u r e ss h o w m a x i m u m u r r e n tr e a d i n g o r t h a t r a n g e ' 2.5mA 25 rnA 0 . 2 5A

d)

Resistan0e X 1 x 10 X 1K X .1 0 K

f of m indicates ultiplication reading or that range.

I
I

4. Measurement t h a tt h e m t, a v F o r r o l t a g e n d c u r r e n t e a s u r e m e nc a r e m u s tb e t a k e nt o e n s u r e set to the highestrange. lt is then to be switch range ,*lt.r, is first of errl i d d o w n t o l o w e rr a n g e su n r i lo p t i m u m e f l e c t i o ns o b t a i n e d . a) 1. Ammeter a C u r r e n tm u s t f l o w t l r r o u g h m m e t e r '

r r

93

Note:

to ranges a voltage in be connected thecurrent must lf murti_meter never maxi-muml current The atto*aole thatcansuppry righ., ,urrgntitiun izo V mains' the'apparatus source " oireciri io ro, rangeis connected e*irnple, rn" operator would be in extreme ili;&'Ji. be immediately woutd danger.

n
t t

B) Voltmeter 2 pointsin a circuit. simply ernf is usedto rneasure across measured' A voltmeter to tho voltage be Prodthe voltmeter ".t"tt
c) Resistancean O Q adiustment

must t t e r i e s . F o l . R e s i s t a n c e m e a s u r e n t e n t i s p o w e r e d . b y i indicator l . b abeladiusted r of the n t e r n " a of reading resistan.r,tti, sensltiv:rty correct by batteries' accordingto in" voltago supplied be power supplyto the circuitmust 'switched To measurereslstance the multimeter with

zerc rr,'lrir adiustment tnu apprying *uitimeter. betore offtirst shorted' Probes

2 . T h e r a n g e s e l e c t o r i s p l a c e d a t t h e r a n gtowards .O is e d ' W i t h t h e + a n o g movinge b e i n O u s adiusted tl9 together: pointei -comterminal shorted praceit exactlyon or tett in orr,erto by turningo o ADJ to in, right eachtimethe range mustbe adiusted right.The pointer scare o o of th-e
is moved.

fr=:
L*-'

17'

/i'\
?

<

MULTIMETER

94

tr
h

Enumerate some test equlpments and used In troubleshootlng electrlcal clrcult I' and cbmponents. 1. - usually Dlgltal.multlmeter usedfor electronic technician needextreme who accuracy workanddigital in equipment testing servicing. measure and lt correct valueof voltage, resistance current. and Oscllloscope usedfor measuring visible peakto a display waveform, of peakvoltage, phase frequency, periods, time angles andfrequency response. Tube tester - is a fairlvaccurate way of testing electron tubes. Translstor tester- usedto checkin accurate suchas diodes andtransistors with theirperforfflance, alsorneasure and transistor leakage, collector leads, base and identify emitter. Capacltor tester- checkthe qual;ty the capacitor alsodetermine of but the value unknown of capacitor. alsoidentify lt power factor values, leakage, open" Remember remove the circuit checkthe correct to to valueand don'ttouch the terminal capacitor of tester whe'lthe voltage turned is up. Severe shock can result. Frequencycounters- are usedto measure frequency hgrtzof an the in electronic cor,rponents. Usually used adjust frequency radio to the of receivers andr transmitters" Megohmmeteris atrinsulation-resistance used check electrical meter, to the resistance an insulator indicating resistance a scale it supplies of by the on as a voltage. lt is a self-contained operated hand generator. powersupply or source.

t
I

2. 3. 4.

L
I

L
l.

5.

6.

L
L
t
7.

B . Voltagetesters- commonly usedby electricians measuring voltage. in ac Thesete.sters portable, are easy to use.
9.

Growler consist two l<inds:internal of and external, usedto test are armatures stators electric and of generators otherequipment. motors, and

10. Test lamp - is a sirnpletest deviceused to check continuity a circuitor of rrrhich component easilyshows illuminance the bulbs. of 1 1 . Clam-on ammeter - used to measurethe currenton a circuit,conductor withoutinterrupting circuit" the

1 2 , Neon voltage tester - is used to checkthe presence voltagein a circuit of

w h i c n o f t e nu s e d i n t r o u h l e s h o o t i n g u s e w i r i n g " ho

95

SAFETY ELECTRICAL not fatalto thosewho do and dang^erous even can Erectricity be

jilm:'lir*:ulK'1ll':g j::T.i'-'n'iirli*::##l -P"'o Rr$L:il:i":,IBf, ErY narsAF ;;;i;"ot ?rlt-tH,

or onlyonqtenth above100milliamperes milliarnperes 200 damage.gurr-ults above currentthatdoesthe n *"iri""" whorr".io"t"cted"';;;;tt below100 milliamperes are c"rrrir of an ampere fatar. dav'iru;;; to get any in iigio.trr"tnirnt. yourself a position to ,"i may rive oo-nntplace "notner and painfur.n J"t. rule: can be serius kind ol a shock

and underdtand

$ + + L

Nlneruleslorsa|epractlceandtoavoldelectrlcshocks: killedby supposedly l . B e s u r e o t t h e c o n d i t i o n s o t t h eManyrponrrln l | t h e d a n g e rcircuits' e r r t B E F o R E equipmenta s.pres or equipmgnt.' "tr on working a prece [*rdo uv *pJtsed "dead" guns;,"ny tochnicia;;;;; rrnloaded systems and interlock such as fuses,rerays protect whenmost on safetydevice.s to z. NEVERrery unJ'mayiair you. ir,ry may notbe working to protect ' needed shockhazard' 3 ' N E V E R r e m o v e t h e g r othedJqriphent g ' ] - 1 . I ',, e w i r e i n p u t p l u g . T h i s e l i m i n a t e s u t ] n g p r o n matiing : trrtr* of "'potent'lal the grounding thinking'm e s 4 ' D o N o T w o R t ( o N A C L U T T E R E D B Eieaor toAcaieressa n i z e dshort q o f c o n . onty N C H . d i s o r g and reads,conrponents toors i;i;;t 3; oevetop necting systemized organized shocksand accidents. circuits, of procedures work' ' is to ;tance ground -. -^A.,, \./arr 5 ' D o N o T w o A r o N w E T F L oonR S . Y o umat or tancinsulated o a rubber r c o n a t r e S | S floor' reou..o. work substantiarry 6 . D o N , T w o R K A L o N E . l t , s i u s t g o o g :and' to callva doctor"o n e a r o u n d t o s h u t rispiration9 T t o h a e S o m e ofi the power,to give artiticiai A current You oR oN YouR PocKET' technician BEHTND be lethal'A wise 7. woRK wrTH oNE HAND .rorrJ, vo* heart;;;;; members two between hand" ;l*;tt workswith one be ret yourserf diswHrLEwoRKrNG. Don't ANyoNE equipmetrt' ondanger'us B" NE'ER TALK To if tl'"nvone, heir *.*rg you-talk don,t Also, tracted. accident' Don'tbe tha causeof an circuits' 9 ' A L W A Y S M o v E S L o w L Y io'"r.iornt"ishocks andrshort. I . ' u l c i r c u i t s . V i o | e n t readw h e n w o r k i n g ? . . o Y y - ' ] : and rapidmovements Burns The serious' canbe painfully usua'ynotiatar, by caused burns,,a\l:rgn at' Accidents e icarunetgy produces h oir-o dissipat:r i " ruttt
96

'd

J J

Fourrulesfor safe practice and to avoidburns: 1' Fesistors veryhof,especially get thosethatcarryhighcurrents. Watchthosefive and ten watt resistors. Theywill burnthe skinoff yourfiigers.Stayawayfromthem until they cool off, . Be on guard'forall capacitors whichmay stitt retain charge.Not only can you get a a dangerous and sometimes fatalshock,you may illso get a burn froman electrical discharge.f the ratedvoltage electrolytic f of capacitors exceeded theirpolarities ii or reversed they may get very hot and may actually burst. Watchtha.t.h2t.soldering orgun.Don't iron placeit on the benchwhereyourarm might accidentally it. Neverstore it away whilestillhot. Some innocent hit unsuspecting s t u d e n t a y i p i c kt u p . m i HOT SOt-DERcan be particularly uncomfortable contact in wit\ ,,our skin"Wait for joints cool.VVhen soldered to joints, de'-soldering don'tshakelrctsolder so thatyou off o r y o u r n e i g l , i b o u ri g h tg e t h i t i n t h e e y e so r o n h i s c l o t h e s r b o d y " m o

2'

3'

4.

S E C T I O N A L I A G R A M F I N D U C T I OM O T O R D O N PART LIST AND M A T E R I A L S

,l

TERMINAL OX B LOCKNUT & WASiHER FAN BoSS FAN C O V E R F O R C O O L I N GF A N I

C PS T I R O N MILDSTEEL CASTIRON M I L DS T E E L MILDSTEEL CASTtnoN CASf IRON S,ILICON TEEL S i SILICON TEEL S

10 ]1 12 13 r4 ,5 irl )] 1B

FRAME S T A T O RC R A M P E R I ] O T O R8 A R END RING S T A I ' O RC O I L END DNACKET BEARING OVER C BALLBEARING SI-IAFT

CAST IRON MILDSTEEL COPPER COPPER INSULATION IRE W CAST IRON CAST IRON CARBON CHROtvilUM B E A R I N GS T E E L C A R B O NF Q R G E D

2
2

6 7
6

END BRACKET R O T O RC H A M P E R ROTORCORE S T A T O RC O R E

97

and AssemblY DisassemblY

d an o res u proced 1i1i::T ifiil"^i"'T,?:'"ssembrv " 1:l;"::: ii u n,n'rar the stariing before rie suretJ reaothemtnoroughrv
of assombry *otoi.
' out bY two or more PeoPle to preverlt order and well arranged I in of disassembry good efficiency' z. Keep the place and to i,riirou" the work mixing up of other;;rt, rotatingparts such important the parts, particurarry 3. cover the disassembred or jotlr to protectfrom dust, vinyt stator'fit their shaft as bearing,etc., with the rotor from or into the care not puilingout'o,' inserting 4. Betore in contact. Take particular that the two may not corne ring, core, etc. centers so coil, rotor bar, shortcincuit Statorwincting to scratchthe or cloth, and wrap sure to coverwith vinyr rotor on u stand,and be 5. Lay the t h e b e a r i n g p " , " t o t s h a t t w i t h c | o t h f o sure to put.fittingmarks' and use rstorage fan boss, be ir,. when separating fan and 6. u,

bv J: 1 3'::T,?*?,ili'f::l?ilo', r* io it that the job is carried ?l:,l^u"31i'^:':",'J',t"'il','ffi'',1'.i:t,;; to tfre machine. Hence, cause fatal damage

g:;,k*.Xl'.1'I,:di

orthe toset outrine carerurtv the T."i;8TlY,;'

constructionbeforestartingdisassemb|y, DisasseHjl.", to connected the motor' cabres ail externar

stand machine with ,n,motor auxiriary ? ffilil: lH ffi:t;'.',|JlLn and carry to the place of disassemb|y' motor unit,

4, Suspendthe whole 5.lnthecaseofverticaltypemotor,|aythemotordorvnhorizontally. nipple and 6. Pull out the couPlirtg' removethe grease with open type bearing, 7. ln the case of motor

ili Bhd;ili iil3':x^:Ti:?li*H'i{,'::}:':H il:f:F,#'[':xf

g " R e m o v e t h e b e a r i n g c o v e , , o n bhavetthesecovers') 1 1 : : i . t h e o p p o s i t e s i d e . oth hecoup|iig: may not witr smattJapacity (Motor side' when the opposite side on the coupring and the and, 10" Remove endbrackets ,'n, ,pigbtiJinidetachecj at the sametime' are the thesebracKets removod, bqrivaleni the air gap' causing rotor to coils' downto the rrulr andwinding the rotordrops and (in viotentty, thismaygumust-ry::^;t or with rrar'd to andstator collide *itn a *ane or iack, ,t ends both support Hence, "tt l-ryoyr1olhe qtd-brackets' "tin, motorwith smail .up'".iii _oetor.e case ot the stator' 11' Pull out the rotortrom

Assemb'::ffT:::y.:rbry

thoroughry reassembly, 2.Donotforgettoreplenishgreaseafterinsta|lingthebear$g.

98

Before of order disassembrvnorm",y^,LI:, parts' :u,",."e fromthe disassembly *ipe ortthe dustoir-rt..,

I J

3.

' ,n r I section Remove protectors the beforeinstalling parts,and the aftercarrying corre out of directcoupling, make connection of electric circuits. This ends tne ,-*.3SrTlblt^ Troubleshootlng Trouble Cause
Countermeasure Rewindor repair Carry out additional tightening the of slackenedportions.

Failsto start.

Disconnection shortcuircuit or of winding coil and leadwire Slackening connecting of terminals,etc.

Disconnection nrisconnection Repair disconected or the of starter part or make change Inadequacy unbalance cr voltage of supply Single-phase operation
accordingto the con nectiondiagram Measureterminalvolt age and adjust it to the specifiedvoltage lf the motor snarls, after the power is turnedon, but fails to rotate,check for disconnection repair. and Check the auxiliary machinery side " Measurethe terminal and adjust to the norrnalvoltage Measure frequency the and adjust to the normalfrequency Checkthe rotorbar for breakage checkthe on jointof shortcircuit ring. Measurethe terminal voltage, and adjustto t h e n o r m a lv o l t a g e . Check the auxiliary rnachinery side. Rewind Remove lhe obstruct tion pre!entinghe a v e n t i l a t i o n ,n d c l e a n
99

I
Excessive over-load

The rotation against lnadequate supplyvoltage rpm is abnormal specified

Variationin power frequency

Excessive slipping

Inadequacy unbalance or of Motorgets heated supply voltage excessively Excessiveover-load betweenphases Shortcircuit ventilation Defective

#'
rt reliabledirect-on-ttnt ,,hips i, popurarbeca:,' controlledby
is also readily " sources available "'tir*

lnductlon Motor Three-Phase usedlotot onboard is themostcommonly motor induction cage-rotor, ^l The3-phase, 'i*Pl"r;;dt In"i::i;i:g'-:H',3i!:'.x:l iiJ' ?"-1

t'l # #
if

stator Thel Constructlon and the,stator thelo^tot' components, t*o motor.ha: main Theinduction

r i'il; : rn:Li J?ffll i:,#]$.'1r,l[:$lr'll.ffi ril:',[# r,t :? f,rxil,!

for specitic *inoings stator -i"n delta connection' 3-phase--ffiit.r"b]?r-^;;; in either ttut or"'*.,*o:nd to the incoming ou .onnttt"t
ano numbers of pole-pairs the rtpp in the airgap]titttoy,minimizing

trt

H ,u*,1"'i:?JJ:':J'J3[ilFHq]:i"hlttiffilft,:H"
opun ;f..'iillil6[*;'n nduclti bars ,..l;se jl?'T ffT:,;,['lJ:lJJl ;: il, "consisting,;i;ilput aluminum trl'.'"in'r"*i1*utt shortrcircuited ot ffi
Theconor.il,,

u * possiPlus i: Inu ;wu' :,Jffi ? ;';s'*Mn y;J J :il :ffiff r# Ji*or* anot1;I small 'i it *tghtlltully :i:ilfandirrestatori,fr i Tfrmal;ii;;:l this'ry;;oi ti*prt' tougtrrotorwhich "'1' ["uing therotor ;;i;;'.0*., t,.oio otirreinduction reriability
hasnoinsuiationandoouJ.noitrouote;;,bruches,:-',.i.'-%

J J I

6a

7 5/ S o 5

ig"

8oa

6b

DIAG'''tAM STAR.DELTASTARTER 100

operatlon of star'Delta Motor starter control clrcult-schc mailc Dlagram Circuitbreakerr is closed. 52 when BS 1 start.push buttonis pressedreraycoil 6 is energised. Contact6a closesand 6b opens. Main contact6 0n motorsuppryrinearso croses. Timerderaycoir1g anrd main contactor gg get energised. coir Maincontactor on the motor 88 supply circuit closes andmotor runsstarconnected. Auxiliary contactgga afso closes. ,!tj3[*?us l:::: contact timer retav a closes. lt is of 1e a hotding contact when BSI

predeterrmined delayof 25160 tirne sec.,detaycontact 19b opensand 19a

opensand contacts closes. 42a The main contacto42 on the moto,. r suppry rinectoses. Motoris now nunning delta_connected. with 42b open'timerdelaycoil 19 gets de-energised ail its contacts and return to its original position. contact42a now functions a hording as contact. indicating lamp L is now on. To stop the motorpressBS2. Comparlson of star delta and dlrect-q.n-ilne starilng methods: Advantages: Dlrect On Llne
1. starterat full phase voltage. 2. starting current6 to B timesfull load current. 3. startingtorqueabout r.5 timesfull load torque. 4. motor can be startedon full load if required. 5. high acceleration torqueso has low startingtime.r

Relaycoif6 getsenergised its contact and d.2tb

Star Delta
starterat reducedphase voltage V3. starting currentZ to 2.5 times full load current. startingtorque less than half full load torque. n'lotor can be started only on no load or l i g h tl o a d . low acceleration torque has longstart_ so ing time.

101

motors are giu"n below' rn defectlve three-phase The symptoms encountered po"*rit" troutlres and remedles' symptom are *sted the under each l . l t a t h r e e . p h a s e m o t o r i a r | s t o s t a r t , t n e t r rotorltrars (6)' e oub emayb Open i' i(8)' fuse (1)' a. Burrred-out ilrong internalconnections g (2). b. worn bearingi t' l ii. Frozen bearing (9)' c. Overtoad(3). d.openphase(4).i.Defectivecontrol|er(10). e.Shortedcoi|orgroup(5).i.Groundedwinding(11). 2 , l f a t h r e e . p h a s e m o t o r c | o e s n o t r u n p r o n e ! , 'parallelconnections: | u . . ' o u b | e m a y b e(13)' open I. fuse (1). a. Burned-out winding (11)' g' Giouncled ' b. worn bearings(2). open rotor bars (6)' [' c. Shortedcoil (5)' d.Reversedphase(12)'i'lncorrectvoltage(7)' e. OPen Phase (4)'

Tnnee Pnnse Morons Repruns AhrD TnouBLEs Goumo'r

trouole nray be: 3" lf the motor runs slowly' the d. Overload (3) a" Shortedcoil or grouP (5) e'Wrongconnection(reversed]phase)(12). (u) b. Reversedcoils or groups L.ooserotor bars (6) f. c. Worn bearings (2) be I \vvvvr v'r. hot, the trouble may 4. rf the motor become$ excessively phase (4) d. Motor runningon single (3) .' a" overroad b.Wornbearings(2)ortightbearing(9).e.Looserotorbars(6) c. Shorted ccil or group (5) larnp lights'the and test with test lamp, if the Burned-out Fuse. Removefuses 1" lamp does not light' fuse is indicatedwhen the test is good. A burned-out fuse must be used' the horder,a vortr:neter fuses without removingthem tior To test 460 volt$' it will blow vofts is mistakenlyused on there will rf a test right designed for 23d exprosion. lf the fuse is open' erectricar out and may trigger a severe it' be a line voltage read across the stator and cause is worn, the rotor wirr ride on firmly on the worn Bearrngs. rf a bearing z. ,o worn that the rotor restsl operation. when the b-earings noisy "r" To chect< asmat motor for"thiscondition' stator, rotationi, irporlibi;. core of the a worn bearing' Motionin this mannerindicates shaft up the try movingthe spots. These indicate that "nJoown. the rotor for smooth, worn the bearings' Remove and inspect The or,ryremedyis to replacei has been rubbingon the stator. rotor removethe mctor is'overroaded, whethera three-phase part 3. oVerroad. To determine of trre load by hand a broken motoi,andturn-ine-shaft method is bert or roadfrom the from *ouing freely. Another mechanir* *iiilrevent the shaft nameplate or dirty on the wire" A highercurrentrJadingihan to use an ammeteron ""irn rine aY indicate an overload'

4'

open Phase' lf an open occurs whife the motor is running,it will continueto run but will have less power. An open circuitmay occur in a coil or group connectionl The motor will continue to run if a phase opens while the mot6r is in operation but will not start if at a standstill. Ti'reconditions are similarto those of a blown . fuse.

5.

ShortedColl of Group..Shorted coilswill catrsenoisyoperation and also smoke. After locating such defective coilsby means of the eye or balancetest, the motor shouldthen be rewound.
when the insulation the wire fails,the individual on turns becomeshortedand cause the coil to ibecolneextremelyhot and burn out. other coils may then burn out, with the result that an entire group or phase will becornedefective.

6.

open Rotor bars' open rotor bars will cause a motor to lose power. one sign of open bars is when a motor is conne.tg.dto the right voftage at no load, it has a very low'amp reading. A light load will prrll oowri the speed, and at full load the motor wirr run berow the namepratespeed" lncorrect voltage' some T-ft'anre motorsare designedfor a definitevoltage" Thus a motor designedfor' 208 volts wifl overheat when operatedon 250 volts, and a motor designedfor 250 volts will not have enough power if operatedon 20g volts. ff the motor is rate 208-220-440 volts on the nlmeplat", it will operate well on a range of voltages. wrong Internal connectio rs. A good method of determiningwhether or not a polyphasemotor is connectedproperly is to remove the ball bearingin the stator. The switchisin"n .rotorand place a large .roiilrrpprl, currentto ne winding. ff the internalconnections are correct,the ball bearingwill rotate arr.rund core the of the stator,if the connections incorrect, are the bail dearingwittremainstationary. Froz:en Beartng' lf oil is not supplied to the part of the shaft that rotates in the bearing' the shaft will become so hot that it will expand sufficiently prevent to movement in the bearing. This is caffed a frozen br.,aring.

7.

8.

9.

10.

fl""T],f

contaos thecontroner notmake e_?,ir{:,,,i:rJjj:. on do good contact,

This will produce a shock when the motor is touched. lf the windingis groundedin more than one plac, o short circuitwill occr-,r which will burn out the windingand perhapsbtow a fuse. Test for a groundedwinding with test lamp and repair by rewindingor by replacingthe defectivecoil. 12. Reversed Phase' This wil! cause a motorto run more slowlythan the ratedspeed and produce arr electricalhum indicativeof wrong connlctions. check the connectionsand reconnectthem accordingto pran. 1 3 . open Pardltet connectlon- l'his fault will produce a noisy hum and will prevent the motor firom pulling full loacJ. check for complete parallelcircuits.

1 1 . Grounded wlndlng'

103

AND TnouBLESHooTlNG ReprunAC Conrnolrcns

Assumed that the motor and fuse are in good condition. To make certain that whether and determine at the motoris not at fault,connecta voltmeter the motorterrninals are of the controller closed. lf theie is no voltage, when the contacts voltageis available ltke push button switch starters,drum, wyethe trouble probablylies in the controller, delta, braking controllers. proa Becausethere are many differentkinds ancl makes of corrtrcllersr general cedure for locatingthe source of trouble is given. may be 1. lf the motor does not start when the main ccntacts close, lhe trouble
a. b. c. d. e. f. g,

Z.

Open overload heater coil or poor connection' Main contacts not making t!'recontactsbecome dirty, gritty or burned' Broken,loose, or difi terminalconnection' Loose or broken pigtailccnnection' Open resistanceunits or open autotransformer' the contactsfrom closing. on Obstruction the magnet core, preventing gummy pivots,and poor interlocks, trouble,suChas mechanical Mechanical springtension. lf the contactsdo not close lvhen the START buttonis pressed,the troublemaybe a.

Open holdingcoil fflris can be tested by connectinga voltmeteracross the coil terminalswhen the START button is pressed. lf there is voltagewhen the the START button is Pressed,but the coil does not becorneenergized, coil is defectil'e.) Low ,voltage. b. Dirty sTART-button contacts or poor contact. f. g' Shorted coil. contacts. c. Open or dirty STOP-button h' Mechanicaltrouble. d. Loosb or open terminal connections. contacts. e. Open overload'relaY may be 3. lf the contactsopen when the START button is releaseo,the trouble or contactsthat do not close completely are dirty, pitted,or loose. a. Maintaining b. Wrong connection of station to the controltier. be 4. lf a fuse blows when the STAR'I button is pressed,the trouble may c. Shorted contacts. b. Shortedcoil. a. Groundedcontacts. 5. the trouble may be: lf the magnet is noisy in operation, a. Broken shaded pole causing chattering b. Dirty core face 6. lf the magnet coil is burned or shorted,the trouble may be: a. b. c.
104

Overvoltage. gap causedby dirt,grit,or mechanical currentdue to a largemagnetic Excessive trouble. t oPeration. Too-frequent

PROGEDURE OF SAFETY Or^--_{.TfONS

S I N G L E G E N E R A T O RR U N N T N G Beforestartingthe engin.for drivingthe required generator, confirmthat the circuit breakersfor loads, ,air circuit breaku,', 61.., are "oFF;. Then start the engine. By virtue of thq under-voltage trippingdevice (uvc), the air circuitbreaker(AcB) has been put to itsiOPEN (tripped),iate. As the enginerspeedrisr:.s, RUN pilot lamp ,,GL"(green)will light. Then, adjust the voltageto the rated on

the voltmeter meansof the voltmeter-transfer.*,rcn by rVS)and the frequence the to ratedvalueby meansof the frequency nreter transfer switch (FMS). The ratedvalues are indicated red markson the corresponding by meters. After rated the frequency3nd voltage have beenreached, ctose aircircuit the breaker (AcB), and the pilotlamp'i61" lgreeil wittlight. Then,clossthe objective MCB to feed power when the ACB'isclosed, the hreaker it (McB)of circuit closed, is the generator immediately loaded.Thisinstant, the feeder will be a smallvoltage oiop will be found. However' there occur quick will a voltage recovery. there no needto worry so, is about it.
S T O P P I N GO F G E N E R A T O R In order to stop the generator operation, in first unloadit and then push the ACB oPEN push buttonswitch,for manualopening. Thereafter, stop the engine,in doing so' it the ACB shouldbe openedwhilethe generator is loaded, therewould occursuch adverse effects as an instarrtaneous i; the rise engine speed. so, it is advisableto lessenthe load to a lowervalue(the lowerthe bettef beforetripping ACB, because the the engine,the generatorand tt'reACB will then be less affected lnd will be capable of stable operation a long time. for PARALLELRUNNING start the secondgenerator foilowing same procedure by the as for starting first the generator'Afterconfirmation the voltageof the of secondgenerator, alignthe voltages of bothgeneratoltby meansof the voltmeier transfer switch (vs). simultaneously match the frequencies means of the frequencytransferswitclr(F'NIS). by once ilre voltage and frequency_ toln generatorsare identical, change over the synchroscope (Sys) 3! to the secondgenerator and checkthe synchronous stJteby meansof the synchroscope (SY). ln accordance vyith the lighting and goingoff of the synchronizing lamp the pointer needlewill revolve.See the direcrtion the revolution, if it is reuoliring of and to the ,,FAST,, s i d e , i n c h t h e g o v e r n o r w i t c h( G S ) o f t h e s e c o n dg e n e r a t otro t h e , , L O W E R , , s i d e . s lf -is the opposite true, then inch it to the "RAlsE" sicje.
105

I ?:'$" #l''f,i .Tl JiH'? iliHi:i:i?ili$ili fr 3l'.i'J:'!$ilil,}fi1 iTi'I:':J; T ,he,:,.ffi ,,?::ixr,,.*,,':in?udllj.;py#rui*l"iT*iff orthereverse by *itt't"ip means Hsft ,il,reth3J',-, nr."lr'i inceJ ,ir.,,ii is notmaintainJJ, ;'q:*:il1.:::::,'::'l!it",::.?ri;.'pFT$:;5f I
*il pointer (Gs)todecrease tnego;;rri* tiitth w,ri ,ni,in n,,ino,;Jrr* I .lol,luorur.
meter to . --- ra rho hrrs and the otherfrequenctl this difterence.

!ii[Fii*'""**;if'$ i,iir-F:nir*q.'"wilrir' Jr*il,JiJ*'i,l"if;t"I{iulf ::'fil: ffi :tilfl :ffi:'^ii'"x"fl *";r?:,3ru;iff "ilffi ip:,p:ilTfi
the atter-run"n"ig

rrequencv -gtn"rator' T*:tJffi one swnch otthe and compa

?i'ioilnt

t"^"; #:operatiorr

,ffr?irff ,rj,?xJ,rli!1$}$;;H:{ri$tr$::;.l; .^ {-${'n

so mentioned lar' 'Then bv procedure achieved the. hasbeen

:"r 4lgi.i;ilft'jffi {ff :it:ri.'{;:fr. $;.r'ffi

alsott"t tt"ttload t? 'gtt"ut* of thetrequJnry Ii?3:,, the ,,LowER"';il;. This. ha:,:::"firi'io-rstago p:-::, "'iion n"t tow1r1;':'";;"il;;, thesenerator enblegthei;;i sharing' be turned must firstg.;;u.l' ^y:'il' the procedure to transrerred rhe tn, op,,.iion,ieuerse opu,ation. .ro,,iop parallet Runnlng: for value' Procedure Parallel to riseto the rated a*owthe speed and "VR" regulator a. startthe generator of by means the voltage varue to the rated to be put the b. Raise vortage o'i vottage t'hegenerator the equars thatthe bus vortage c. confirm

e r nrato . s cvqu n ea generator ffi:i ilT:::: freque to : l':::' : ,,l secondi i'::::':,T ,,sys" the side of the
switch switch governor set the synchroscope by meansof the enginespeed adiust_the -tontii* To synchronize, of voltage' tht equality "GS" "nO
pttfttt synchronism' indicating '

e. f.

ffJ:3'J,:'i#'is:'i ?l;'l3lia',rJ"li'J.:' s i,::,JTJ.ll?,;,:ii TjlH;'

106

h.

towardthe "RAISE' Inch the governorswitch"GS" of the secondgenerator side to have a small portionof the load shared. slde the toward "LOWER" "GS"of the firstgenerator switch Inchtho govelnor the load By of to havea smailportion the loadalleviated. so doing,equalize generators. of the two procedure. the preceding reverse a In stopping generator,

i.

I I

t.

EARTH LAMP CIRCUIT lampsif the circuit on to The earthlampcircuitmakesit possible examine display switch(ES). The circuit tho voltage , the or is earthed not, by,manipulating pushbutton to will be apptied each of the three lampsso that the lamp for each phase of El 3 whichis a littlelowerthanthatof otherdisplay will lightup with the'samebrightness, condition). of lamps(regardless the earthing will point tlrestarconnection be earthed. of is Whentheswitch setto "ON"theneutral of does not causea changein the brightness the lamps,the clrotlt ls lf this setting Thenthe lampfor phase thatthe lineof phaseR is earthed. normal.Nowwe assume and wllf go of of with R will be suppliecJ a voltage the samevoltage the samevoltage S to E off,whlchthe voltage is applied the lampsfor phases andT, whichwill therelore brighter. beeome (lampoff). The threelampcmay earthed is It is rare that the circuit completely ver change-( of the switchbgtween by in brightness.Ho',vever, repeating be different checks. lf, uPon can "OFF"evenslightearthing be found. Makeperiodical "ON" and lessbright, evenslightly, han when to the setting "ON",any of the lampshas become to the switchis "OFF",the line of the phasecan be considered have been eartterl. of without delayto inspection the circuit. So, proceed AND O)U,".S INSTALLED INSTRUMENTS meter, frequency voltmeter, wq[' with panelare equipped ammeter, The generator the of the hourmeterfor measuring output the generator, alr drcult and running meter protection, deconthe breaker,reversepowerrelay,over currentrelayfor generator the protection fuse,the transformer, spacsheateratd the bar necting for main circuit, 'fhe wire external connection termlruXs lamps, etc. typesof signal various switch, transfer are on the back side of the Panel. vol[neter double frequency-meter, with panel The synchronizing is equipped double relayandfrequeney generator, voltage the of the for andwattmeter measuring output the equlpment tho switchand auxiliary transfer alarm,the instrument relayfor generator lamp, prolectoft the and operation thesynchronizing for necessary parallel synchroscope are terminals on the backSfdo wire etc. fuse,the transformer, The e,xternal connection of the panel.
107

t
I

$ HuecrRtcAL cHunnAflfiLlncnnnn oF Flne Pump Reanrruo

B9

CPI

ti

{
i

t
i ,t

h-r*
I l

r,

3-o

tr

(-.

METHODOF OPERATION: LP lamp Source glow, 89 When circuitbreakeror line s'ruitch is put at ON position, power at controlcircuitfrom 440V to 220V which is step-downhy control introducing power transformerCPT. coil the contactor @, closingnormallyopen 3C To start, pushtbutton energizes coil the thus energiz-es contactor sirnultaneously, 4,4133-34 and 4143-44 4/13-1 contacts supply to (5g-\ open contactor anOclosingnormally @, then 3-phasemotoris connected on line 440V and runninglamJ:L inclicated operation. opening coil @ is cle-energized, tlre To stop, push button3-0 is presserJ, contactor thtjs de-energized simultaneously, the closeclcontacts4/13-14,4/33-34 and 4143-44 coil contactor @ and openingtlre closed contact88, and the 3-phasemotor is disconnectedfrom supply line and runninglamp off. Symbols Designaticln R.S,T U,V,W A 1, 4 2 01, 02,- 10 95, 96
108 Star'.;a:Jil',3irrLg'l;: S..pp,' SJuice

I I I

.forMotor connection Standardmarking Standardmarking for Contactorcoil number of Wires Designated closed OverloadContact for mart<ing nornrally Standard

q I I

I I I I I I I I I I I I I I I I
l I

FORMUIAS FOR ELE.CTRICI\I, PROBLEMS

a) Ohms law i ' Ampere Volts Resistance
b) Power Rule volts

resistance amperes resistance x volts amperes volts x ampere.s watts amperes watts volts output -17rput true power apparent power

V R

R A x V
A

Watts \/otts Amperes

W V A

= = =

V x A

W
A W V

c)

Efflclency

d)

Power Factor

volt-ampere
=

kva

e)

Frequencyof AC Generator = loof_glles1_rpm

120

P x N 120

f)

DlrectCurrent
746 hp

AC - Three phase
746 Hp 1.73 x E x Eff x pf. 1000 l(w 1 . 7 3x E x p f 1000 Kva

E ) :e n 1000 kw

E l x E 1000
HP

I Kva t(va l-lp

lxExeff
746

1.73 x E I x E x 1 . 7 3x p f 1000 I x E x 1.73

1000 lxEx efxpf f

746

109

I
H,

where:
I E eff pf amperes volts in efficiency decimals power factor in decimals
l<w Itva ht:

{r $.

s..
il,, Iir
ri

kilowatts . \ kilovolt- amperes horsepower ouput

;
I

I
it J
,t

],
T ii I

s) laws

on Serles circuit:
= = = 11
'r lz '::

Current ,o,o Resistance ro,n Voltage ,o,, h)

[11 'f

R, n"

R...

-3 El -+- E, *- F

Laws on Parallel clrcult:

1
R,o,"

1 R,

{-

1 -t-Flz R 3

V ,o,n
I biul

=
=

E1
11

=:
+

E2
l2

= E 3 + 1 "

i)

Frequencv
\

no. of polesx rpm 120 120 x frequency

poles

Rpm

Poles

120 x frequency

rpm

110

BAgIC SYUBOLS SYIIBOL DESCRIPTION ONE CONDUCTOR OR A GROUP OF SEVERAL CQNOTJCTORS TWO CONDUCTORS (MULTILINEREPRESENTATION} (MUL']TILINE EPRESEiTTATTO R N n CONDUCTORS (srNcLE.t-lNE REpRESEitTA'nON) CROSSINOI\'ITHOUT EI.ECTRICAL CONNECTION JUNCTIONOF CONDUCTORS TERMINAI.CONNECTION CONDUCTORS OF JOIMTTERMINALS RESISTANCE RESISTOR OR INOUCTANCE OR INbUCTOR WINDINO CAPACITANCE, CAPACITOR R E L A YC O I L ,G E N E R A LS Y M B O L H U L L C O N N E C T T O(N A R T H ) E MECHANICAL OUPLING C G E N E R A LS Y M B O L TERMINALS TERMINAL ARK M CABLENO C A B L ES I Z E
I YY{.,g(JNUUg|9H5

DESCRIPTION

DESCRIPTION DISCONNEE.TINO SWTTCH OR MOLOED CASE CIRCUIT BREAKER

=f,-&
-t9_"i-

--qtts;l

MOLDEDCASE CIRCUITBRAKER (wrTHSHUNTTRTP OtL) C UNDERVOLTAGETRIPPIN.3 COIL OF CIRBUTT EREAKER

-+I

,f,

---hc--

c
_-9_9
..1- R
-r$ftn_

swrTcH(GENERAL) SINOLETHROW
SW|TCH(OENERAL) D O U B L ET H R O W

{Yl=

-v\AAA/-

-G-

t-

=5
-d:+_-o.''^o_
+O szCr.i_ +o o{-

{_g_o_9-

\-e-9-9r r -r- - l i =

EOUIPMENT OUTSIDE OF EAUIPMENT OTHER UNTT OF

SWITCH,GENERALSYMBOL T H I I E E P O L ES W I T C H S I N G L E . REPBESEMTATION CIRCUTT REAKER B CHANGE OVER CONTACT B R E A K EB E F O R EM A K E M A K E B E F O R EB R A K EC O N A C T (gvER LAP CoNTACT) C o N T A C T O RN O R M A L L Y P E N( M A r N ) O C o N T A C T O RN O R M A L L Y L O S E( M A I N C P O W E R& R E L A CONTACT

Joe

_q__ -.dc.
-t--o O-

__!_
@

coNTACT (CENERAL)OF MANUAL CONTACT IIANUALLY OPERATED AUTO RESETCONTACT (wrTH LOCKINGDEVTCE) MECHANICAL CONTACT
H.ANO BESET CONTACT NELAY CONTACTOR OR AUX. SWITCH CONTACT CONTACT WITH TIME LIMIT OPERATION (oN DELAY TYPE)

_&ot-

-Grf-

-o o,
*O (}-I

llEl

*as-4-8-

4?
-Q O-

--{--o-

-<e_r={--.f-_

MAKE CONTACT(a CONTAGT) G E N E R A LS Y M B O L EEEAK CONTACI (b cONTAc'r') G E N E R A LS Y M S O T PLUOANOSOCKET LM4(E AND FEMALE)
RESISTOB WITH MOVING CONTACT GENERAL SYMBOL

-<l cr-. I -.(x--OI

. _ _ . t I _ _

-<) O-- --A-$1 I

FUSE
OENERATOR

CONTACTWITH THE LIMIT OPERATION (oFF DELAYTYPE)

@
a4a8-,Ef|-

-tr!r
_-tt l

i::::
/ r I I

NUCHINGRELAY CONTACT
MAIN CONTACT OF ELECTFO MAGNETIC CONTAdOR

MOTOR
SINGLE PHASE TRANSFORMER WITH TWO SEPARATE WINDINGS

I -,-*-

,-4lrM\A--

-:.a#.

A U T OT R A N S F O F M E R H R E EP H A S E T
SEMICONDUCTOR DIODE OR RECTIFIEN CENERAL SYMBOL

O A N OS W I T C H M A N U A LO P E R A T E O RESIDUAL ONTACT C

-__)f-

o
-ff_

VOLT METEB
AMMETER CURRENT TFANSFOBMER

-n\-

):{O-----

C CONTACT CONTROL SWITCH OR CONTROLLER CONTACT

PILOT LAMP (FOR EUECTRIC SOURCE "ON")

ELECTRICAL SYMBOLS

@
@

INDICATINC AMP L (FOR MOTORRUNNjNG) l S T A N D - B Y N D I C A II N G L A M P

_-

111

SOLVING PROBLEM ENAMS ' FOURTHENGINEER 1989'90BOAI:ID total at zzg v- Flnd the Kw output ahd A generatorls producrng150 Amp. external reslstanoe' SOLUTION: p = Voltsx ArnPeres (150)(220\ watts100U = 33,000 33 l(w P R = -fz33,00

f q I

1.

( (1s0) 1s0) 1 . 4 6o h m s . g0 percent,efflclent220-v generator' Flnd the A 150 BHp engrnedrrvesa current Produced. = SOLUTION: of hp outPut gen" watt outPutof gen. current current =
=

input 150 13s watt = voltage

efficiencY . 9 = =
h 1351 p 0 100i,71 watts

= = =

746 10 0 , 70 1
220

amPS' 457,772 ln parallel'

rn serreswrilr3,4and 6 0hms or A resrstance 1g ohms rs connected Wn"i ls the total reslstance? SOLUTION: 1 + 1 +
' f = 4 + 3 + 2 = I

1
R"
RT

= = =, = = 1

3
I

4
2

6
1.333

Rs+R" 18 '+ 1.333 19.333

112

I I I I I I

4.

Twenty 100-Wbulbs anclFourteen60-Wbulbs are In a 120-Vclrcutt. Ftnd the current. SOLUTION: Total watts ( 2 0 x 1 0 0) 2,000
t-.

( 14x 60 ) 840 = 2B4O W

_?q{a_
120

23.660 amp.

Ampere

\v611

voltage 284A

t
I I I
'r' f ;ii"ii',L33lV
SOLUTION: output watts in

120 23.666 rnp. a

Tl-fI FID HNGIf',,|[: tjl H

is motor 75percerrt erricierrr. thecur.ent I?incr required to

drive

I
I

o u t p u ti r rfr p ; : T 4 g 1 0 0x i 4 6 74,60A ntts w

I I I I I I I

inputin watts

elJtpu.l
e ff i c i e n c y 99,46{:j.(ifl

"zil,s!_()
7l:

current

watf
volt

:: 9"9,"4$.C*f,i(1
. (\..1

113

r
z. voltageis 120 v' The operating to is A 40 ohm resistor connected a 20 ohm relay. the Determlne currentand powerin thls relayclrcuit. SOLUTION:

Rr=
= a) Current = = = b) Power =

?ol la
60 ohms. VPlt Resistance 120 60 2 amperes current x

I I

'o i*^r,r' 7oo

volts

of 3. A 50 Hp englne drlves a DC generator. lf the generator has an efflclency 840A. How many a) Kw b) HP. does lt dellver. a) Kilowattdelivered = =
\

50HP

x 746w x 1kw 1OOw O 1 HP 5 0 x 7 4 6

1000 = 37.3 Kw

delivered b) HorsePower = = 4. 50 x 0.84

42 HP

Kw ls An AC generator ratedat 227KVA at 86% powerfactor. What ls the

ratlng. POwerFactor = Kw = = = .Kw KVA Power Factor .86 x 227 195.22 x KVA

114

SECOND ENGINEER 1989-90BOARD EXAMS:

f'

wrth and In il::Tj"ll,T lJ;:i :s:5""""i"ectedInserres 4,5 60hms pararer.

SOLUTION: 1 R a 1 q r . R 1 r + 1 %

,=+ + + + +
1 5+ 1 2 + 1 0 60 = = 37 60 60 37 Ra = 1 . , i 2o h m s

1/Ra Ra RT

:=
2' IIo",TrlJ#:"Kw
SOLUTION:

'r::,

.i, I_1b

J;j
[vz \r,L

generators in parauer" maximum are Find current, vottage

current sen. = in
\ Current ,o,-u =
:J Resistance,o,, = =
= Voltagel'otal = :: =

!g Ilgg_?
220 zz7.27arnps.
227.27 +

Jg __T *\/
227 .2V

,i

454.54amps. V _ ZZ0

fia

0.494 clhms. lrXRf 454"54 x 0.484 22A V

115

whoseemfsare 5 and 12 3. srrnpre serlescrrcuitIn whrchtwo batterres, Negrectlng reslstbnce the ohms. of vortsand two resrstors 4 orrmsarrdB clrcult'
ln the of the batterles, determltte tlre current GIVElI: El F:2. SOLUTICIN: = = 6V l2V Fll ltz = = Q oltrtls B oltttts;

Er =
E, ::

T;:
6V

r'r' T;"11,
--

CunentTotal

El | ^ o

1 t I I

i
Total Current 4. = 0.5 anrp. efflhavlng 80o/o Determlnethe requlredhorsepowerof a prltrlelrlover l(W generator' clency to drlve a 5OO GIVEN:
\

= Gen.output 500 kw EffeciencY = 80% Ef{iciency = output input = B0 " 500

1kw= 1'34 hp

Checked: El1 = 500 kw

x
HP HP

loo = 50000
80

625kw too : ;u^.1

= 500 kw B0% of 625 B0%of 837.5 = 670 HP 1.3$ 500 kw

= 625 kw x 1'34 = 8375 Requirecl

116

CHIEFENGINEER 1. Reslstance 4,5 and 6 ohms are of rlr serles wlth another In a Z2OV. Cfrcult. Calculatel a) Total resistance b) Line current; c) Vortage drop acrosseach resistance d) Totalpowerconsumed SOLUTION: a) Rr
RT
.[d\t,,t"

\ ''

Yl

'

\,r' ,'J t'

-.--21,,'\,i\,-

I II

,.----,nrr\u\---

= ' R 1+ -12
-=Q + l +

+
b

_--*/

R3

= 1i5ohms

b) A

= y
HT

= 3 j
15

14.66 amps,

c) V1
VZ V3

= ra.be;r

Fl1

14,66x 1466 x 14.66 x

4 s 6 \v /l .

= 14.66 X R ? = 14.66 '( [':j

58.64V 7 3 . 3 0v 8 7 . 9 6V 219.90

d)Power = ilJl 21e so

3,223.7 watts. 2" A s l n g l e p h a s e A , C generator.rupplles 400 aunp at A2,\V wlth a p.F. . Flnd apparent and true powe,? of 0.9S. SOLUTTON: Apparentpower
6

V x A 100c)

- !eo_:fJgn_
| 000 = BB KV/\

l-rue Power :: app.powerX power factor -= BBx.gs : 83.6 ltw

117

d
value ln parallel'PqtPrmlne ohms arg.:onnected or 100,120,150 Threeresrstors
{

otcurrenttopar4|lel"y"."ii;;i;h*rrrmal-e"u,,entinrzo.oh}nsreslstors
equal to 1'0 amP'i

GNEN: -'Rl= 1oo

ri" -- 120
l"'

t"*tiltto= 3. F E" = Ib'Rb *o

=

I I

H: = 1?o = 1A
R t =
Ro RB Rc

E, E;

=
=

(1) (120)

lt:: Ea

Ec= Et= 120\

7,.d;,, t vt., t 1) #ui'. t
" ti
E E

l;",

m.(R'RA)
I I

\ ,,t', \
''
T

t I /r.

100(120x150) + ( 1 5 0x 1 0 0 ) x 5y.620x150) (100

lr

\ /i

w,
. l r

1800000 5000 12000+ 18000+1

| -\
' ' ,ql ,:

R,

1 2 0V 40

, I

r - \ r Y ,

i,.'r -'r

= ---1800000 45000
. f.

= = 40

3 amPs'

Y1

't1"
t . '

v r

4"

ohms ls reslstanceBi 0'2 ut rlri qvrA storage qa$er! :.-rvto llmlt 'ii'u, supply as shown-ln the batt ii'uji. I' turles cfr.argect crtardeJlrom I rnrrette iiaieO ln serleswlth to be to I91]^ ot#ei"rn

Rt

f'1[f eattry Astorase 9tjyl,.?,? #l",T:JTf;trl *:*il,*

n1I iig,;i..w re-1:l'.1' amPere' 15 o . rateto : Ji,l,,* u
ltil';;tg"s
Solutlon:
lr droP

= ; t t zv ti d1o.p o ST'il;='?".1'ffit d r o p = i 1 1 7 ?* potentiarl1^c'lTJt rotar droP + Potential

15R ( 1 5 ) ( 0 ' 2 )+ 2 4 = 3+ 24+15R = 27+15R 15R = 15R = R = R 117 117 90 90/15 6chms

11B

BOARD QUESTIONS Founrn ErucrNesR .

1.

ElEcrRrcrrv

lf two genratorsare connectedin series: A../voltags is added and currentstays the samo B. current ls added and voltagestays the same C. both current and voltagestay the same D. none of the above

2.

A generatorintorpoloalways has lhe same potarityas tho: 4. pot" preoedingit B. pole following it C. oppositethe main pote D. none of the above

3.

Interpoles conn,cted ar6 in; A. serles with the armaturs B. sgrleswith the shunt lield C. parallelrvith the armature D. parallel with the seriesfield

4.

A.DC.compoundwound generator that has a voltage drop trom rio load to tu,, load is said to be: A./ under compounded B. over compounded C. flat compounded D. none of the abovs

5.

The part ol a D.c. generator into whichthe workingvoltageis induced the: is A. yoke B. field poles C.r armature D. commutator The propersequence securing D.c. generator paralel operation to: for a in is A. reducecurrentto near zero,open circuitbreakerand switclrand securethe drivingunit B' open the circuitbreaker, securethe drivingunit and cut in resistance the io field. c. opeirthe circuit breaker, reduce current zero and securethe drivinounit the tr D. none ot the above Interpoles icommutating polesare connected compound or in D.c. generators in: A. B. Cl D. E. serieswilh tho shunt fleld serleswith the seriesfletd sories with the armature serieswith shunt and serlesfield serieswilh the armalure but in parallel with each other

6'

7'

&

119

o
4 e

+
T il
q

8.

The clnlytyptrof compoutlrl rslrunt A. stabilizecj B. flat comPoundetJ

usecl (;or-lltl'l()rrly t$oilrd ship is the: gunelratnt

C' ovet'comPounded . \ Il' cumttlativecomPounded

* {
I

It t

9.

trltltla of i What aro contrnutatot's tnica A. soft coppor bars ittsulattldwith witlr rnica insulateld B. hard drawn copper [:ars slott: for tnica C. soft soliO copper witl'r cutaw'gY cutaway slots for mica D. hard drawn solio copper with

windingsare in parallelwith is gerrerator one i^ wlrich *re field 1 0 . A shunt-worrrrcl the: D' field poles C' r;ontntutator B' brttsltes f\. arrnature to: is current" required 11. Arl "exciting circrrit up A. L,uilcj a cleacl fierd rnagnetic B. create a motor u" excite a synchrorrous in a battery tl. btrirtjup the vortage

and armature? are not in a L)'C t;otnmtttator 12" wl,ich of the followirrg A . i n t e r p o l e B ' t n i c a 0 0 o p | . / 0 r b a r s D . V e e r i n g plane' sparkingmay to are not positionetl the neutral 13. lf the brushesin a gerrerator occul'betweenthe brushesand the: A . y t , . k e C . a r r n a t u r e w i nwirrdings s d i n g D. field pole B" commutator by: tlre strengthof an electriccurrent 14. A rheostatis aleuire that regulates cireuit in A. varyingthe resistance the in the circuit B. uatyingthe voltage in. tfre circuit c. increaiingthe magneticfield D. varying tfre current in tlre clrcuit founcjon a D'c' generator? is 15. which of the following not A. pigtails B. brushes

armature C. stationary D. brushholders

will not cause a generatorto vibrate? 16. Which of the lollowirrg C. rnisalignment A. loose Pigtails sPeedgovernor D. trrritY B. loose bolts

t t t

of as overload : will \7 . Mostgenerators withstand A.15percentB.zspercentC"30percentD.35percent

120

I I

1e' o.. seneraror uporsheet are ,lliJ:?,5;3'?,inf6:?ff,1',J, buirt steel

A' fit the curvature of the c. afrowfor necessary B. reduceeddy current frarne air gap losses D. allo,vfo,,ear' assernbly 20' what is the prima4r t'eason commutating for poresin a D.c. generator? A' preventsparki'g of the brtlshes c. neutrari::e B' rncrease armature iielo srrength reaction D. aid in a commutat,on 21. sparkingand grooving of commrtator may be causedby: A. overfoad C. B. strength fietd of 22' The voltage a of D'c' generator depends whichof on the forfowing? A. speed; armature of C. nurnber arnrature of B. strength field conductors of D. alt of tire above 23. To correct the pofarity a generator, of you shoutc!: A. Rotatearmature B. fift brushr, rotatearrnatur.e C. fift brushr, "nJ apptyD.C D. lift bru1sh", "nJ l'rn generator "nJ 24" which of the forowing groupsof motorsar' D.c. motors? A' series, shult and compouncr B' seriesano l'nouttion c. compound and synchronous D. indr-rction synchronous ano 25' motor

18' A series-wound generator rrss tfre fiefdwinclings in serieswith the: A. armature C. comrnutator B. Orusn{s D. fietdpotes

D. ffiT',il1"'J,::,'n"

ffTfi;ytffl

A. overspeedand run out of corrlro, B. stop C. slow down D. keep runningat the .sarne speecl

is usec, ^rrr pll*p driven t' a with bert.rfthebert a breaks,

26" AC circuits jcontainresistance, incJucti anrl cetpacitance. ance tance of a circuit is The capacitive iupresser.l in: reacA. ohriis B. mhos C. lrun ry,s D. farads 27. A shunt motor woufcjbe best ruitecl lor.: A. constant speed resufts

B. an ancllor'winotrlJ"""

c' a cargo winclr [). any of ilre above

121

motorwill in the shunt tield uf a motor' the is 28. lf the resistance increased C. run at the same sPeed A. sPeeduP D. stop B. slow down shuntmotor?
29.Whichofthefo||owingisthedistinguishingfeatureofa A. it has a high stading torque if runningat high speed B. a lead wiil not affeci it G.ithasastab|espeedthroughawideloadrange if overloaded D. it wili not drop in speed will not cause a lrot mcltorbearing? 30. Which of the tollowing C. overload A. loose brushes D. misalignment lubrication B. insufficient in the rotor by: rotor currentsare circulated 31" ln an inductionmotor' flux action of the rotatingstator and brushes C. lnductive A. sliP rings D. externalvariableresistors B. armature and brushes

conditions required until occurirrg allother an prevents actiolr normaily which 32. A device are met is a{an: D' limit C' nrotjulator A' interlock B' monitor 33"Acircuitbreakerandafuseares;imi|arbecausetheycoth: the circuit A. can be resetto energize when overloaded B. sfroJOopenthe circuit flows C. burn out when an over current D. anY of thb above of batteryconsists water and: storage in 94. The erectropryte a read-acid chloride c' hydrogen acid A. sulfuric acid D' muriatic chlorid B. calcium by the: is battery best indicbted of chargeof a readacid storage 3s. The state A . s p e c i f i c g r a v i t y o f t h e e | e c t r o | y t e total cellv i d u a | c e l l v o | t a g e D' C . i n d i voltage amperehour capacity B. with: shouldbe painted or' leadsand insulation a motor 36. Electrical enamel C' heat-resisting varnish white'lead A. insulating D' insulating aluminum B. heat-resisting to fromthe machine the bus is by mostAc generators brought generated . Vortage 37 by meansof: C. sliP rings on a commutator on A. brushes a commutator {rom the stator D. direct connections on sliPrings B. brushes
122

38. A degreeof controlover the speedof a slip ring induction motorcan be obtained by: A. B. C. D. inserting resistance into the rotor circuit c h a n g i n g h e n u m b e ro f p h a s e st o t h e m o t o r t inserting resistance into tire statorcircuit g adjusting overnorinkage l

39. A circuitbreakerdiffersfrom a fuse in that a circuitbreaker: A. melts and must be replaced B. is enclosedin a tube of insulating material with metal ferrulesat each end C. gives no visual indication havingopenedthe circuit of D. trips to break the circtritand may be reset 4 0 . T h e b a s i c u n i t o f i n d u c t a n c es t h e : i A. coulomb B. ohm C. f arad

D. henry

4 1. B a t t e r yr o o m s m u s t b e w e l l v e n t i l a t e do : t A . p r e v e n ts u l p h a t i o n u r i n gd i s c h a r g e d B. supply oxygen C. dissipate explosive gases D. preventmoistureforrnation 42" The alarmsystemfor an engineordertelegraph uses smallselsynmotorsattached to the indicators. The alarm soundswhen the rotorsare. A. B. C. D. not synchronized, currentis flowing,and the relaysare closed i n s y n c h r o n o u p o s i t i o nn o c u r r e n ti s f l o w i n ga n d t h e r e l a y sa r e c l o s e d s , not synchronized, currentis flowingand the relaysare op.n in synchronous position, currentis flowingand the reiayr are open no

43. As a generalrule, the first troubleshooting actionto be taken in checking faulty e l e c t r i c o n t r o la p p a r a t u s s t o : c i A. draw one line..diagram the circuitry of B . t e s t a l l f u s e sa n d m e a s u r e h e l i n e v o l t a g e t C . t a k e m e g g e rr e a d i n g s D . i n s u l a t e h e a p p a r a t u sr r m t f r e g r o u n d t f 44. The most commontype of AC servicegenerator ound aboardship is the: f A. armature'rotating electromagnetic type field B. electromagnetic field-oscillatory armaturetype C. armature-oscillatory electrornagnetic tyee field D . e l e c t r o r n a g n e t i c l d - r e v o l v i n g r m a t u rte p e f e ar y 4 5 . T h e m a i n p u r p o s eo f t h e a u x i l l i a r w r n d i n 0o n a s p l i t - p h a ss i n g l e _ p h a s eo t o r 5i e m is to: A. limit the startirrg current B. increasehe starting urrent t c C. starl the rnotor D . k e e p t h e m o t o r r u n n i n gi n l l - i ee v e n tt h e m a i n w i n d i n gs h o u l df a i l 123

maiol consideration application batterYfor et particr-rlar 46. When You are choosinga should be given to the trilttet'y'si A. amP-hour
B. terminal PolaritY

clrarge uncJer u " stabilitY

rise temPerature D . ambient

4 7 , Of what significance i s a r n b i e n t
comPonents?

t t h e s e r v i c el i f e o f e l e c t r o n t c r t e n t p e r a t t t t 'i0t r e l a t i o n o

A. B.

to driveioff moisture [:e stroul<J as higlr as possible comAmbientternperature electronic tlre Oecruases servicelife of ambientternperature lncreased

is hrumiditykept as as significant lorrg therelative is c. l"ffi:ti temperaturerrot

low reduoedservicelife a carrses corresponding temperature A reducedanrbient witlr a circuit? in arwaysbr cclrrrrected series 48. which device srrourd C' Wattmeter A. Ammeter D' Voltrnoter B. Megohmeter would indicatea grounddet;ctiorllamp on a D() systern A fliclsering 49. D, A , g r o u n d i n a n a r m a t u r e c o i | o f a n o p egeneratol' t t a c h i n e r e r t i r r q lcomlrlutator ,.,voacijacent r:ars of the B. short between c " m u l t p | e g r o u n d i n t h e d i s t r i l : u t i o n s yshort l sten witlr a ground in a motor accompanied D. 50. A fuse will "blow" if A . t h e e | e c t r i c a | c u r r e n t e x c e e ( J s t h e ris treversede o f t h e f u s e a edvalu device protect" B. the flow of current to tlre in parallel C. un.quJ lesittots ttt connected by sudclenly openi'g a switctt D. an electricatmotoi is stopped locatedin the ntain switchboard? 51" Which bus is norma||y

A the 24 volt DC bus B. the shorePcwerbus

Powerbus C. the emergency bus D. the lighting generator current in hrushes a direct

52.Etchedorburnedbandsontlrecontactfacesort could be caused bY A. B. C. D. copPerembeddedin tlre brushes Positioned brushesimProPerlY on tlre cornmutator copper drag high mica segments

when it is first Put batterybegirtsto gas violentlY if indicated a leacl-acid 53. What is on charge? circuilin a cell C. Insufficient A. normal chargingrate D. A short circuitin a cell B. excessivechargingrate

124

J J I

54' An accidentat path of fow resistarrce whichcaususalr abnormal ltow of current is known as a/an A. ground, rgfgrence point B. open circuit C. polarized ground D. shortcircuit

55' Whena megohmeter usecl testinsufation, is to the initial of the pointer dip toward zero is causedby
A. B' C. D. the dielectric-atrsorption effect of the insulation the leakageof currentafong the surface of nearby insutation good insulation the capacitance the circuit of

56. The main purposeof an electricspace heater installedin a large AC generator is to A. prevent the wincrings fronr becorningbritile B' prevent moisturecondensation tie wirrrjirrgs in during shutdown keep the tube oul warm for quick stafiing 9 D. prevent acidic pitting of the ,iip rings 5 7 . v1/hen flourescent a lamp has reachecl end of its r.rseful the life, it shoufdbe replaced immediately, the resuftant or flashingmay A. blow the famp's breal<er ? explode,causingglass trc fly in all di'ections C. short circuit the bittast transfornrer D. damage the starter ancJilre ballast 58. when you are choosinga battery iclr a partictrfar appficatlon major consideration shoufd be given to the battery's

I I I I

I I I

A. amp-hour capacity B. terminaf pofarity

\

5 9 . What statement is true concernirro tlre cleaning of contacts? A' the contactsurfacesshould Lregreasecl increase to contact resistance Magneticbrushesshoul<J ,r*J.Jto renrovemetaflic be I dust c' Delicateparts shor-rld cleanedwith a bruslr be and an approvedsafetysolvent D' Compressedair shoulcjbe usecjto blow out metalficclust 6 0 . What do you call values rnrhich ()atl change continuously such as temperature, pressure,or level? A. digitalvdlues B. hunrpless values (-:. birraryvalues il. analogvalues

C stability uncler charge D. ermbient temperature rise

61' what type of battery charging circuit usecJ rnaintain wetcelllead-acid is to a storage battery in a fuilrycharged state over rong periocrs of disuse? A. Normal chargingcircuit B' High ampere charginocircuit (). euicl<chargingcircuit il. l'rickle chargingcircuit
125

I I

62. The vultageof all the

adiustedbY varylng l t gerrerallY a t ii ( ; l t t r r t : : l t e r t t a i t o s ollei'ulitrt

(; tl t l r t t r r t ' l ct-' l{r sr:riesconduictors Illaljttetit:iielcjstrength

I I

A. number of poles B. prirne mover spe'lc'l

63.

ts wl'lts iii {)iltr itc>tsepowt:l The total number of

A. 746 watts B, 663 watts

| ;' 500 watts watts li' l'()0(')

6 4 . W h y a r e t r a n s f o r m e r a b o a r d s | r i i . l t r s e d w i t i . t A 0 g e n e r alighting for t o r s ? circuits A'topermithighervoltagettlt'ttttltctrc:petaltitttlirndlowvoltage B. to changefrequencY outPttt C. to increlse Power PowerotttPttt D. to decrease

I I

THtno Exctnesn
1" be on the what woutd the eiffect rJischAr$es' l-rartluil' stora-qe When a lead-acid electrolYte? A. B. C. D. gravitYdecreases sPecific gravitYincreases sPecific tfie :";i'lrl'le specific gravity remains none of the above

2,Theleadp|atesinastorage'..rirt|etiesal,u:;eparatedb,,y: C . !tlass \ A. rubber D. any ot the above

B. Wood

gtavitlrof a battery: specitic 3. In cold weatherthe the same C. rernalns A. nses D . n o n e o f the above lowers B" readingwill be what hYdrometer battery? 4 . A c c c l r d i n g t o b a t t e r y m a r l t t f a c t u r t i t , ,lead-arcid a t i o n s sspeci|ic 1;ortable obtainedf;;; u tirv clrar:gecl C ' 1 ' 1 0 0t o 1 . 1 5 0 1 . 2 8 0t o 1 ' 3 0 0 5 A. t D ' 1 ' 7 5 0o 2 . 7 0 B. 1.180to1'182 off be clearred with: type batteriessltoirlcl 5. Dirty lead-acid A. B. C. D. soap and water sodium chloride iticirlt-ronate) baking soda (sodiurn hYdroxide Potassium

126

t
t
I

6. A fullycharged batrery rearJs frr:rl: A . 1 . 2 8 0o 1 . 3 0 0 t B. 1.025 1.075 .to O, l.()ir0o 1.350 t D. I l;l(l() 1.S00 to

7 . A dead cell of a reacj-acicj batter;ris c;rrer..i.0rt hy: A. megger B. hygrometer 8. C . r r r s tt i g h t D. hvrlrcrrreter

t
I
I

How many 1.5 vortbatteries req,irecJ are ro s;tr1:1.rry of 'tr2 a road voltsif the batteries are connected series? in

A . B
9.

8 . 6

(i

!,',1

D. 10

H o w m a n y1 . 5v o l tb a t t e r i ea r e r e q t i i r u r l s l o J i o ; ; r r 1 r 1e lrly a co f 12volts thebatteries if are connected parallel? in A. 12 3. 6 O, ti

I
I

I I

D. none of the above 10. The rating of a storage battteryl r i l l d e l i v c r $l 5 a l l l [ ) s l c t r i 1 Z h o u r si s : A. 180 ampere hours i.l. :i i antf)erehours B . 1 5 0 a m p e r eh o u r s l) t,l{i(J ;tfllperehor:rs 11. Whichof the following items; ne,c;essi.rrv is lr.r lll:i,ir stgrage lt tiattery goc,,d in operation? A. maintainproper specificgr;,lvity ? keep cool ancrwell-ventilatecl C. maintainproper fevel of r;lr:ctrolyle D. afl of the above 12' what typeof battery-charging c'ir*ttil ri:,;r:ri is rf.r'arrlsrrip rnaintain t' storagebatteries in a condition readi,lLr*ov(:rj cf ic.rrrcJ rtf Ireri,rr,lq rJisrrse?
A. trjckle charging circuit B. quick charge circuit :-' i) , - ) (.)r 1 y 1r :1 a - g i n gr a t e c i i , c u i t Jh f r r ' : :rf l i s c l t a r q eC i f C u i t

1 3 . HrSoois. A. sulphuric acid B. hydrochloric acid

1 4 . The total rroltaoe and a m p e r a C J e
I. i) l r y ri i , ; ir l t r ;a C i C J trtirri:'iltr,ri:ifl ;: c,nnected in Series

rs:

o f i w r , rl l 0 - . t r l J ; { i . , , o l tl l a t t e r i e s

12 volits, amps 50 | B . 1 2 v o l t s ,1 0 0 s r n p s

(-:. i.r.

vollq, l0() amps r.'oll.r, AmpS i.;f)

127

in c 6-volt batterieso n n 15.,Thetotalvoltage anrperalle two-50 ancl of arrrp Fcted parallel w i l lb e :

A . 6 v o l t s ,1 0 0a m p s B. 6 volts,50 amps

O. D.

llit.volts, 100 arTlPS li) volts,50 alnps

16. The voltageof a battetyis equal to the: A. B, C. D. t:f tlte ttutttltelr cells in series voltageof a singlecell tirrres of amperageof a singlecell tirnesthe rtuntbel' cells in series of the nurnberclf cells times tlte resistance efficiency of voltageof a singlecell times ttre ttuntber cells in parallel

will irr conrrecterl ylerrallel give you a total voltage batteries storage 17. Three 12-volt of: A. 12 volts B. 24 volts
O. li(i volts

D. 48 volts

bntteryelecttolyte: for the properprocedr:re rrrixing 18. Indicate A. B. C" D. use distilledwater, add acio to water use alkalinewater, add acicjto water use distilledwater, add water to acid use alkalinewater, add water to arcid

to ied are classif accordirrg the tranner in which: 19" D.C. generators A" B. C" D. they are used to the field windingsare conrtected tlte load circuitis connectedto ttte lclad the armature circuit to the field windingsare connected tlre artttature

is ot"t arrd if 20" The purpose ,f,, conrnr:rtator brusltetJ a D.C. generator to: A. B" C" D. changeA.C. to D.C" current changeD.C. to A.C. neutralize armaturereaction carry currentto the outsidecircuit

againstmotorizing ttreyare protected operateirrparallel, 21. When two D.C.generators

by: A. blow out coils relay B, gov?rnor

triPs C. undervoltage D. roversecurrenttriPs

reversed? of 22. How is the rotation a D. C. generator

l ' l i il

fieldconnections A. reverse leads B. switcharmature

C. switclt armatureleads D. botlt B and C

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L r ,

t ll :

128

i rt. 1i l, .ii i1 rl il: rt il i ,i llt

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ifr [i

23. On la D.C. generator vrhere the pigtarllocated? is A. feather spring B. condu ctors
C. bruslr holtjer D. spriral adjustingspring

24' which of the following D.c' gene,'ators the largest has percentage voltage of drop betweenno load and full load?
A. under compounded B. flat compounded C. shunt D. stabilizeid shunt

25. A.D.C.generator that has a vollage rise frorn no load to fufl load is said to be: A. under compounded C. flat compounded B. over compoLtndecJ D. urrderflat compounded

26, l f a D.c. gener'ator rotated the wrong was irr direction, w'urd faif to come up it to voltagebecause the: A. armature fieldwourdopposeilre fierdcur'errt B . generatort wouldburn out c. brushes wouldburnout D . circuitbreaker wr,rulcJ enerqize not 2 7 . A generator operates the principle on that: inducecj voltageis induced when a conductor cuts a magnetic ftux D . a smallvoltage the prirnary in highvoltage the seccndary in because the of largenumber coifsin the seconclary of
A . when a fieldrevolves, current generated is B . when an armature revorves, magnetic a fierdis

c.

28. With an increasein load on a flat-r;ornpor"rncled D.c. generator, the vortagewiil: A. remain the same (l increase B. decrease It reclrrce lralf tcl 29. D.C. generators are ratecJ irr A. KVA B. KwA
(i" l(w

n. [-lr)

30. The voltageogtputof a cornpclu^rll].C. gr:neratoris adjusted by rtreostat placed: A. in series with t h e s h u n t f i e l c ! C. across the serir.sfield B. in series -with t h e s e r i e s f i e t d n across the shunt field
129

is battery hydroxide. I usedin a nicl<el-cadmium 3 1 . The electrolyte ' \ C' sodium A. potassium D' calcium i B. cadmium induction of the uiilizes principle electromagnetic whichmostcommonly 32. The device is the: ormer A. transf B. diocle C' transistor D' rheclstat

from a fuse panelwith: be fuse shouldalways removed 33. A tubular object C" any insulate A. a screwdriver pullers D. fuse pliors B. a pairof irrsulatod
by is of frequency an alternator controlled the: 34. One of the factorswlrichdetermine A. B. C. D. numberof magnetio Poles number of turns of wire in the armaturecell strengthof the magnetsused output voltage

bulldingblock to g5, Whlch of the followlng logicgates islare consicJered be a BASICI (basic logic gate) used in logic diagrams? A. OR B. NAND c. NoR D. All ot the above

overloadrelay? 36. Which motor is fittedwith an instantaneous A" winch B. PumP c' Farr T D' Machine ool

againstshort circuitsbv using g7. A molded-case circuitbreakerprovidesprotection aJan:.

A. B. C" D.

electromagnet coil shading arc quencher burn away striP at ambient recordhold rise temperature abovethe standard normar of temperature any givenlatitude average overload at rise uuar"!, temperature due to resistance 10"/" due to weather of temperature the rnotor in oifference ttreambient permisliole

motoris the: rise 38. The ratedtemperature of an electric A. B. C" D.

is: battery of 39. The number cellsin a 12 volt lead-acid

A.
[,
I

three

B.

four

C, six

D. twelve

I tri
lll

$r !i

130

fit

HI fi:

t
T
I I I I I I

40. The Wheatstone bridqeis a p r e c i s i o nn s t r u m e nu s e d t o m e a s u r c : i t A. resistance C. inductance B. capacitance D. arnperage

41. The greatestdetrimental effer:ton idle electrical equipment such as cargo pump mot,:rs is: A. B. C. D. loss of ,residualmagnetisrn absorption moisturein the insuration of insulation varnishflaking dirt collecting the ruinclings on

42. The frequency an operating of arternator controlred y t h e : is b A. B. C. D. relativer speed of the rotor rroles number of turns of wire irr the armaturecoil strengthof the magnetsusecl output voltage

43. What does a wound-rotor incjuctiorr motorhave whicha squirrel cage motordoes not? A. slip rings B. end rinos C. a centrifugal switch D orlcJ plates

I I I

4 4 . The current whicha milgnetic 'at typeoverload relaytendsto tripmay be decreasec, b y r a i s i n gt h e p l u n g e rr u n t h eirn t o t h e m a g n e t i c circuit f the relay. Thisaction: o increasles magnetic pull on tlre plurnger and requires less currentto trip the relay B' reduces magnetic pull on tlie plunger and recluires current tripthe relay less to c' increases magnetic pull on t',e plirnger and requires mors crirfertto trip the relay. \ D' reducesmaoneticptrll orr lltt,;plunger i-rncJ requires rnore currentto trip the relay 4 5 . Protection againstsustainecJ clverloarJs r"nolclecl-case breakers providec! iri circuit is by an/an: A. overvoltage release ts" thermal acting tr-ip C . t h e r m a lo v e r l o a d e l a v r D. crtrrent clverload relav A'

4 6 . M o t o r i z a t i o no f a n a l t e r n a t o ri s r r r r i J e s i r . a t l l e r)oce.luse
A. B. C. D. it puts an ac1ditional load on ilre i-rus all of tlre above t h e a l t e r n a t o rw i l l b e d a r n a g e r J h i g h v o i l t a g ep u r s e s a r e i r r c J t r c eirn t h e b u s j

131

to equivalent 47. The unit "hertz"is Per A. revolution minute Per second B. cYcles
rated? 48. How are fuses

Per C. revolutions second Per secono D. coulombs

A.ampsandvoltsB.alnpsonlyC.wattsD.voltson|y resistanceis the 49. Ttre unit of electrical D' volt C' amper B' watt A. ohm the by acliusted varying -r-heline voltage generatedby arl alternatoris so. A" B" C" D. Prime mover sPeed equalizerbus excitationvoltage the tield resiOuJ magnelismof

tatrlesis thd vvire C. cubicinch nril D. circular

Sl"Tltestandardunitotwirecross-sectionalaroausodirrAmerican

in criticar cjetermining is characteristics most Which of the following 5?. circrrit? to be u,uJ in a Particutar A" B. C" D. voltagerating currentrating fer inductance unit length WeightPer unitlength

A" AWG B" squaremillimeter

the sizeof cable

The first steP in tocating

5 3 , A g r o u n d i s i n d i c a tto d b y t h e g r o u r r d - d e t e c t i r r g s y s t e m . e the actualgroundis with a megohnteter circuit A. ChecK indicates detector B. changeovergenerators untilthe grournd in'itruoirtriuuti'npanel c. crosealr switcr,es normal D . o p e n t h e i n c J i d u a l c i r c u i t s o n e b y o r | e u r r t i l t h e l $ r o U ois d e t e c t o r fleld d (nown an to maintain gonerator current cJirect supprying s4. A Dc generator
as alan =A. stator B' rotor C' armature

D' exciter of the

bY is adiusted means of an AC generatcr 55. The frequency field rheostat

A. equalizingreactor control B. Prime *6uet goverrlor

C. main alternator field rheostat D. exciter

132.

56' The inductance a conductor of is measurecJ i' A. henries c. ohms B. vortsohms D. amperes 57' The voftage an operating of AC turboCIerrerator is raised rowered adjusting or by
A. generator field exciter B. phase sequenceswitch

governor controfs 9 generator :). synchronizing switch

I I I

58' Under normal conditiofls, Storage batteries s.tarting emergency for the are maintained a chargecl in stateoy wrrichor ine foilowing diesergenerator methods: tricktecharging l. equafizing charging B. r{}verse I charging D_ rear charging

5s' fiJg[l'-3it3'tn
A. B. C. D.

conductor makes ttrat ere*rical contact a wiring rvirh conduit is

reading 1.0 on the pclwer of factormeter totafry dark switchboard ground-detecting fight low iwitchboarO-*lttrrter reading high switchboarcJ wattmeter ,*rJing 60' what statement true is concernincr cleanirrg the of contacts? A' deficate partsshoulcl cleatrecJ be witha brushand an approved B' compressed sfrourd safety sofvent air he ,r*o to browout metarfic dust c' the contact surlaces shoulcj greased increase ne to D. magnetic contact resistance brushes shourd ,irJ,r to ,'rr,,ouu be nietailic dust 61. Whatis the preferred methocJ cleaning o'f dust and foreignparticfes equipment? from erectrical A. wiping B. cleaning sofvent
r- cor,'lpressed air D . vacuum slrctien

62. Sparkingat the brushes of a runninqmotor coulcj be an indication af A. flofn",?l operation

B. increased capacfty brush

fr fljl$rrfinifflonl,,nn

63' what is the overallresult of increa:;.rrcl roar]orr the the seconc]a ofa transformer? ry A. decreasetinthe prirnary curref lt B. decreasein the primary voltage C. increasein the jrimary vr:ftage D. increasein tfre primary r:rlrrerrrl

133

coil the currentin an armature a brush 6 4 . W h a t i s t l r e p r o c e s s o f r e v e r s i n g t h e d i r e c t connected i c l r r o f Pass undeq asthecommutatorsegmentstow|ric|rthecoilis \ called? A. dynamic excitation reaction B. artnature C' c;onttrutation U ' sliP

rt r{ r{
f{

with periodically a feelergauge be srrourd checl<ecl motor.s gap in i.cJuction I 65. Trreair air gap and to guard againstan uneqrtal
l

A. increasedPowerfactor B.decreasedmotornragnetizirrgcurrent loses C. lrYsteresis darnageto the rotor D" meclranical used with Ac generators? regurators 66. whictr is a functionof vortage A . t o c u t i n g e n e r a t o r s a u t o n r a t i c a l l y a S t l r e y a r e n e e d indparallel e operating betweengenerators B. to dividethe KW roaoequally when they are no |ongerneeded C, to cut out generators operatingin parallel reactivecurrentbetweengenerators D. to crivide machine'thg currertt testeris being used on a direct 67, When 'r meggerinsulation graduallyrise tc the true resistance will diP toward zero and then meter Pointer is value if the motor insulation D " grounded C ' gooci B" dirtY A. shorted of tne temPerature an electrolYte? tneasure 68. What sirouldbe used to G' mercurythermometer A. alcoholthermqpeter D' potentiometer pyrometer B. thermocouple 69.Vo|tagefailureofanACgeneratortnaybecatt.;edby A. B. C. D. bus circuitbreaker a triPPed excessive Prime mover sPeed tailure of the excitergenerator hrusbar on high mica segments the stator

r{
{

h{

d
{

I q

TO,Whyaretransformeraboardshipusedwit|iAC'qenerators? A. to decreasePower outPut circuits B. to increasePower outPut lighting c.topermithighervo|tageformotoroperationandlowvo|tagefor D to change frequencY the best Procedure to exposecl low temperatures' 71" when a batteryis continuously to keeP it from freezingis to: charge tlre batterY C. furllY the A. disconnect battery cover t'he battery D. securelY caPS the battery

q I

B. remove

134

72'

A three-phase, squirrel-cage, incjuction motor could rLtnhot due to alan A. B. C. D. high power factor reversedcommutatino oolrr improper6rush positi-on shorted stator

7 3 . The reversalof an AC,3-phase irrcluction motor is accornplished bv:

A. changingall three motor leacls B. interchanging any two of the three motor leads reversing the positionof the slip rings 9 D. interchanging any two brushes

74. Brushesin a generator must be positiorred the neutralplaneto avoidsparkling in

betweenthe brushesand the A. commutator B. yoke C " f i e t dp o l e w i n d i n g s D" armature windings

7 5 . The cyclesper seconJ of tire altcnrating clrrrentfrom the alternator aboardvor.rr boat are determined by A. B. c. D. the the the the resistance appliedto ilre filed rheostat adjustments made to the roltage regulator speed of the enginedrivingilre arternator synchronous speed of irrcJuction

Seconro EruclrurEn
1' what happens a series in circuit when voltage the rernains constant theresistance ancJ increases?
\

A. current decreases B. currentincreases

C. current remainsthe same D. currentincreases the square by

2 " The magneticf ield arouncl cut-rent,carriripg a wire:

A. exists at all points along tlre lr:rrgilr tlre wire of is parallelto the currentflorru ine conrJuctor in I C. moves in the directionc,rf currentflow D. exists only at the beginning electronrnovement of
J,

Electriccurrentis the f l o w o f e l e c t r o n s t h r o r r g ha c o n d u c t o r . Tlris is commonly called: A. voltage B. antperage tl. coulornbs D. resisiance

135

4.

One megohmis equal to: ohnrs A. 1,000,CI00 ohms 10,000 B. C' D' '100'000 ohms I '000 olrms

cable: 5 . A multiconcjuctor A. B' c. D. has a number of sepat'atecircuits of a trutnberof strands is a singie 'i"uit ca'otecontpt"o6 current ii a ttexiutecable to carry motor is a sPecialheatingconductor

6. lrrD.C.eircuits,p.)werisexpressecJast|teproclurctof: C' volts and coulombs A. volts and amperes D' amperesand coulombs B. ohms and amperes

7.

A mil is: 0 A. 1/1 inches 1/100 inches B. , C . 1 / 1 0 0 0i n c h e s n D . 1 / 1 0 0 0 , 0 0i0 c h e s ,

is 8. One l<ilowatt equalto: A. 1"34horsePoviter B. 1.25horsePower 9.

C. 1.50horsePower D. 2.00 horsePower

to another before current of junrp trom one wirer Defects in wiring which permit ars callad: the intende{ puin has besn completocj D' breaks 0' opens B' shorts A" grounds not a gootJconductorof elelctricity? 1 0 . which of the followingis D' raluminum O' silver B' copper mica A. equals: 1 1 . One horsePower

is the of mot.r shaftmisalignment the oftenusedto checr< degree rz. An instrument

A. 1,000 watts

B'

'746watts

0'

100 watts

D' 94Cvratts

i"
I

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ili
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A. B. C. D. E.

Voltmeter ammeter ClamP-on Growler Megohmmeter Dial indicator

'

ili'
il1 il1 $l: g!f

136

!lr a

13. The electrical poweris kilowatts usedby a 220 volt motordrawing ampsis: 15 A. 3.3 B. 3.6 C. 3.8 D. 4.0

14. A horseshoe magnethas: A" two potes B. threepoles C. four poles D. one pole

15. Retentivig the powera metalhas to retain: is A. B. C. D. in the current a circuit magnetic lines of force flow withintlre circuit electron electricity when movingat high speeds

16. Whenselecfing size of wire to [:e usedin a circuit, most important the the item to consider the: is A. amperage the circuit of B. voltage thc cil'cuit of C. resistance the circuit of D" amountof wire to be used

17" lf a wire is increased circular in rnils. A. B. C. D. E. its sizo is largerin diameter its resistance fowerper foclt is its size is smaller diameter in AandB BandC

18. The following formr:la usedlo compute is power:

A. P=l2R B. P=R2E 19. \ C" p=F_2F-l D. P=E+R

High voltage and low current gain are characteristics f the: o A. B. common base circuit common emitter circuit 0. contmon collectorcircuit D" boilr A and C

2 0 . W h i c h o f t h e f o l l o w i n g s t a t e n r e n i si s t r t r e ? A. B. 2 1. like poles repel each other like poles attract each otlrc, C" t). u n l i l c e; r o l e r e p e l e a c h o t h e r none of the abovt:

How is a lead-acidcell tested'i

A. hydrometer B. hygrometer

(). tl.

lrogorneter rregornr:ter
137

of" 22. A 24-voltlead-acidstoragebatteni cr:rtsists A. 12 cells B. 6 cells

(.; Ll cells l-). rt0ne of the above

trigh,it would: 23, lf the chargingrate to il batterywils tor.t A. B. C. D" voltage the terrninal increase gravitY sPecific the increase liberatron the rate of hydrogen increase voltage decreasethe terntirral

I I I I

9 b 2 4 . I n a 1 2 - v o l t a t t e r yt l r e l oi t r e l t O wr i ' l a r l y l ; l l s ? A. 6 B. 4 c. ';). D' B

iit ZS. lf the specificgravityclf er l2-volt L-rattery 800 is 1.225,tlre battery is: A" dead B. fully charged C. shorted charged Li. partially

by batteryis detei'mined the use ?_6.The state of chargeof a nickel-cadrniurn of alan A. voltmeter r B . hydromete O. arnmeter D. potetttiorneter

to the that cleterrnines abilityof the resistor size of a resistor 27. The ohysicat abslrb heatris rated in : A. Ohms B' Volts C' Watts D' Farads circuit.

r e 28. A circui that has infinite esistancis called A. A short B. A ground C. An Open D. All of the above

cell? the vottageof a lead-acifl determines 29. Whart A. the type of electrolyte B. the strengthof the electrolyte c;. the size of the plates D' rroneof the above

will develop: 30. salt water in contactwith storagebatteries gas A. chlorine gas nitrogen B. C, carbonmonoxide D. carbondioxide

138

31' Whichstiatement true.concsrning maintenance is the of solid-silver contacts ,rly, in and auxiliary controlcircuits? A' When nqcessary, they shouldalwaysbe dressed with a wire B' They shouldbe filedwith a fine-cut when pro.lections wheel file extendbeyondthe contactsurface C' Whenbtacksilveroxide is present, should it always removed thecontact be from surfacewith coarsesandpaper D' lf necessary, should heldtogether m,cderate they be with pressure whileemery paper is drawnbetween contacts the 32' Whlleyou arestarting malnpropulsion a synchronous motor an induction as motor, the ampere pegsout at maximum thenreturns the proper meter and to valueafter synchronization. This meansthe: A. B. C. D. ntotor has start,ad properly fiefdwlndings are grounOeO slip rings are dirty power transmisslon cablesare grounded

33' The purpose a shortcircuit of forcing module (short timetrip)instalted a branch in line is to provide: A' B' c' D. high speedclearance tow impedance of shortcircuits the branch in continulty sen'iceon main bus undershort of circuitcondition a branch in lsolatio4 short circuits selective of by tripping branchcircuitbreakers of all of the above

34. Efectrolyte a nickel-cadmium in batteryis: A. potiassium hydroxide B. suffuric acid C. slip ringsars dirty z

35. A soft iron corewith wirecoiledaround and it directcurrent passing through the wire is the description a simple: of A. magnetic shield B. electromagnet
C. piezoetectric device D. electromagnetic domain

36. To properlyuse a hook-on-volt amnreter when checkingcurrentflow, you must FIRST: A' hook the Jawsof the instrument aroundthe conductor B' de-energlze clrcult allowconnection insulated the to of the instrument series in c. connectthe vortage test reacJs the appropriate to terminafs D. short the test teacjs and caribrate instrument zero tne to

139

37, Autotransformer startersor compensators sometimes are used with,polyphase inductlon motorsto: reduce the voltage applied the motorduringthe starting period to increase voltage "across line starting" the for the provide back-up a meansof voltage regulation emergency for starting allow voltagr be either the to stepped or downdepcnding theapplication up on to ensurefull torque function 38. A magnetic blou,out couldin a DC contactor to: A. preventcontactmelting B. open contactrapidly C. adjustopening sprilrg tension
D. provide "srrap-action" the contactor in powerplant,propeller speedis controlled motorTurboelectric 39. In an AC synchronous

A. B. C. D.

by varyingthe: A. B. C. D, speed turlrine fieldstrength electric coupling number energized main motorpoles of generator propulsion fieldstrength

provides protection 40. A molded-case breaker against short circuitsby using alan: A. electromagnet B. arc quencher
C . shadingcoil D. holdingcoil

4 1" The method usedto produce electron emissionin most vacuum tubes is:

A. photoelectric' B. secondary is: 42" A microprocessor A. Another namefor a computer B. A CPU integrated circuit

C. cold cathods D. thermionic

I I I I I I I I I

C. A namefor a calculator D. A smallscaleintegrated circuit

pressure it signal? and converts into an electrical 43. What devicemeasures A. transducer B. reducer C. transfbrmer D. rectifiel'

caused failure usually are due maclrinery to insulation foundin electrical 44. Grounds by:
due to age A. deterioration B. excessiveheat C. vibration D. all cf the above

140

I
I I I
I

45' The amount of v-oltage inducedin ttre windingsof an AC generator dependson: A. B' C. D. the number o conductors series per winding in the speed at which the magnetictieio passes 'the the strengthof ".ros magnetictielf all of the above the wincJing

46. The type of motorthat uses a rheostat the rotorcircuit in to vary the speedis calleda: A. wound-rotor induction B. regenerative braking the jog buttonis pushed, motor: the
C . squirrel-cage induction D . synchronous

4 7 . A motor controller ,,jog,,and,,stop,,. contains three pushbuttons labeled,,start,,,

when

A. B. c. D.
48.

will run continuously the ,,jog" after buttonis released will run untilthe ,Jog,' button released is cannotstart untilboth the 'Jog"and "start" buttons pushed are cannotstop unlessthe "stop"-button pushecJ is

which of the following precatrtions shouldyou take when securing propulsion generators and motorsfor an extended periodof time? A' B' c' D' Lift the brushes from commutator collector ringsand use the built-in heater to prevent moisture accumulation Disconnect.the pigtails brush frorntheir contacts discharge and carbon dioxide into the unitsto keepthem dry Disconnect brushpigtails the fromtheircontacts circutate through and air the units Liftthe brushes fromconrmutator collector or ringsand circulate cooldry air through units the ampere

49. Non-adjustable tolorJ casecircuit breakers classified framesize, are by

ratingand interrupting capacity.l'he framesize is expressed in:

C. amperes D" volts

A. degrees centigrade B -.circular mils

5 0 . What is the purpose of the capacitors the output of on the power suppfie.s used in today'sconsotes? A. B. C. D. They filter out ripple They act as a permanentload They prevent overloacJs They increasethe outputfrequency

141

n
and adjust cJetec;t ,ril v0ltagerergirl*lrnri UL {.tr}hti)rittol's voltagechange$ S1. Autornatic

the
A. B. s p e e d o f t l t s P r i t t u l i i tr l rr l l resistance rrf tltet itttttilLttte;

. \ (;" centertapof the balance coil in U. r'esistance the field circuit

is being charged too quickly? (r';) 5?. What condition irr,.Jicatcl tlr;'ri ;r k:rlrl-t'rt;irlt.lattery A. C. D. r u n u s u a l l y l r i g h e l 8 < ; l r ' i i i i r i ';:t'' t " r : : i i i 1:l 1 i ' | r r i { 1 ' s p a r k i n g a t t l r 0 5 ; o u i i i ' ' ' ' . . rr i I i ri ' t ! J . g x c g s s i v g t g m p g l f l l l l i ' t : r , , l l l l i : x r ; { r l l : ' ; i r ri r ri l s s i f l 0

B. low Plate 1:otentialsi

t 5 3 . H O W S I t O U I ClJf e S l t t t t t t9 l r i { , r i i i i l r i : i r l r l i t , r r r i l ) l i f l e C t e d ' ? A. ts. C. D. In In In In vvi r p a f a l te l n ri ttr tl rr.: l r:,i i i . rir,, i tr ;r;t,rri ul ; tl .Ithre ntetef mOV ement p a ra l l e l w i tl r tl ts l ();t(i i .ri rrj i i r pi l i al l cl w i tl r ttre meter movement movement $ e r i e $ v v i t h t l r e l t , i r r l i l r r r t l r r 1 : a r a l l e lr r v i t ht l r e m e t e r mOvement w S e r i e S w i t l t t l r s l i . , ; t t ji t l r t l i t t l " : c r i c ; s i t l t m e t e r

may b(} remediedby oi r r of 54" Chattering cr:llsctur ilrg l.ii rslrer; r a (ltlnerator O. cleaningthe collectorrings ttte A. reinsulating brttslros length of Pi$tail D. increasing bruslt holclers B. lubricating r.:orrtrril switclt is nloved to "raise",this willl goverfri;r' 55. When an alternator A. B. c. D. tirtritcorrtrol lower the percentags0{ slreeel of :;etiittg the governor lower the no-loadslrcud raise tlre no-loadsettingof tlto goverrrol cvcle raise the percentageof freqtrency

wilil good insulation be inclicated to s6. when you sse a rnegolr;rreier tur;tinsrtlirtion, by: true resistancevalue A. a downwarddip foltowedt-rya graclualclirnb to the B. the initialdiP of tlre 1>ointer scale C. slight kicks of the rteedlecJowt't at gradualrise in the poilrterreadincl tlte outset D. a bulkheads' cables pass througltwatertight 57. when electrical packingshould be ernploYed stuffingtube capableof till<ing A. A 'vatertight of B. they musi be bent to a rac1ius six diameters C. they should be secttredby a clarnp bulkhead D. tl-,eyshould be groundedon either side of the

142

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I I I

58. The forcethaticauses efectrons urove a corrriuctor free to ilr as an electric current
is called force. A. die-electric B. an electromitiue C. resistarrcr: n. inducf ive

59. The resistance erectricar in wiringrJr:c;ruase irrc;rease as in A temperature 0. rnetal ilrrrrr lrities B. cross sectional areii it. lenoilr 60. What is the first step in removittc, gorrerator i:r frorl paralleloperation? A. removethe load from the ol.tcloirrg qcrrr,rrtlor B. trip the generatoroff the switr:hf:oarri C. turn off all electrica, equipnrelr rt D' increasethe cyclesof the qoncr.rrtrlr {)n stl,rTrrrr.rttrc line

Cnrrr ETcINEER
'4

t .

A standardwir:eis given the slirrrt A,,?oss.sectional area B . w e i g h tp e r f o o t

wire if it has the same:

2.

C o u n t e re f e c t r o m o t i vfe r c e i s n r t , r ; r r ; r l ' r l o iir: A/-volts (; ;:ttfil)lj B. ohms i ) l.lr

i l r , i r i,

3'

oorrrili'}iir,,''r)" frrr':i111rri.ri is dorrbred, vorrasc current ,t'f :t:1,ntit:,::il,"';iil9

A,r double B. remain tfre same
i l i i , ; , l i \ , , i , , :lr 1 , , , ,l r y i r t i , l l ' J r trru r ) l , t r i o l t t l

4" The resistance a copperurirr;l , l of A{ncreases as ilre lenotfrol B. decreasesas ilre diJmeter C. decreasesas theilengtlrof D. increases the clianreter as
l\

i i i , : l i r , r , ' n ,l , r l r, . : l i i < : i t y : .

W h i c h o f t h e f o l l o w i n gf o r n . r u i i t w rr r i l r ,, s A. R divided by E B. R times E

(\l\/{j l{)i lltllit)i,lrl(r,i

' , f l , r t i r r i r t c lt ri y l l jr ti rrrirtlr:; I

143

tn
o.

Ohm'sLaw? states correctly expression whichof the following resistance A, voltsequalampstime.s by ebuarvoltsdivided resistatrce ;hilt by voltsdivided amps equals C. resistance
D. alt of the above correct

hq h

the circuit? is the sane throughout pararercircuitwhich of trre fortowing 7.ln a C' voltage A. imPenoance D' resistance
B. currenterrvv

tl
I

B. When using Ohm's Law' A,/ampelage B. voltage

tor: E dividedby R would solve c' resistance D' watts

for: E dividedby I would solve 9. When using Ohm's Law' C/resistance A. amperage D' watts B" voltage measure: 1 0 " A w i r e g a u g ei s u s e dt o aGize of wire value B" insulation C' current carryingcapacity D' tensilestrength

,I 'l

currentf low is the : 11. The unit of electrical a C' watt B. volt A./amp is resistance the: 12. The unit of the electrical C' volt B' watt' e6frm 13. Volts times amPSequals: A. kilowatts B'lwatts C' ohms

D' ohm

D' amp

D' watt-hours

, I I I

is pressure the: 14.The unit of electrical

I
D' ohm

which and silver, aluminum, 15.|fthetemperaturevarieswithsuchconductorsaE,copper' is statements correct: of the following increases resistance increases' A. as temperature decreases resi$tance decreases' B. u, trt[u'"t"t decreases resistance increases' C. a, trtbtttt"t resistance on has D. temperature no effect
144

RJvott

B' am

C' watt

1 6 . A circuitth'atdoes not provide complete a' path for the flow of current is:
Ar' an opencircuit B . a closed oircuit

C. as series circuit D. a grounded circuit

1 7 . l n a seriesof circuit the totalcurrent is:

A. the same as that of the largest branchcircuit Bfthe samethroughout partsof the circuit all c. the sameas that of the smallest branch circuit D. noneof the above 18. staticelectricity mostoftenproduced is by:
A. heat B. pressure

C" magnetism D. friction

19. The totalresistance a parrallell of circuit always: is A' B C' D' largerthan that of the branch with the greatest resistance equalto the sum of the rndividuat oranJhresistance equalto the reciprocal the sum of the individual of branch smaller than that of the branch with the lowest resistance

20. Dielectric strength the: is A ability the insulator withstand potential of to a difference abilityof a conductor carrylargeamounts to ? of current C. opposite potential of difference D. strength a magnetic of field

21' Ir:hiTifrtil|t.of
A. doubled B. quadrupled

a circuit cloubled theapplied is and voltase constant, kept the

C. the same D. cut in half

22' ff the length of a wire is doubled and tlre cross-sectionaf area is reduced oneto half, the change in resistance will be: A. quadrupled B. halved C. doubled D. quarterecl

23. The purF,|ose a rectifier to: of is A . c h a n g e . C .t o D , C . A B. changeD.C.to A.C. the frequency A. C. current of 9 change D" change the voltage D. C. currenr of
145

I
wire? diameter 24. Which is the smallest

I
D.4 to C. resistance tlre flow of current D. currentPasslngthrough them

A.4B

B. 10

c.6

have the sarne: , 2 5 . l n a D . C , s e r i e sc i r c u i t a l l t l i e conductors in A. power exPanded them B" voltagedroP acrosstheltt 26. An increasein current: tetnPerature A. increases temPerature B. decreases C. has no effect on temPerature D" will doublethe temPerature

motor is: 27. The horse power of an 1,800 (kilowatt) A. 1,800 t 3 .2 , 1 4 2 c. 2,412 D. 2,421,

for 28. Soft iron is the most suitable use in a: magnet A. temporary t B . p e r m a n e nn t a g n e t C. naturalmagnet D . s o l i dm a g n e t

i 2 9 " R e s i d u a m a q n e t i s ms t h e m a g n e t i s m : l A . i n a f i e l dc o i l B" in the motor in after it has been removedfrom a magneticfield C. remaining a substance D D . g a i n e di n c o n v e r t i n g . C . t o A . C . b f 3 0 . M a g n e t i cl u x i s b e s t i n s u l a t e d y : A. ceramic B. cambric C. rubber

D. porcelain to E. impossible insulate

is in with i or 3 1 . A s e m i - c o n d u c t t h a t d e c r e a s e sn a resistance an increase temperature known as a:

A. resistor B. thermistor C. diode D. thermopiie

in: should be connected 32. The shunt of anrmeter with the meter movement A. serieswith the load in parallel B. parallelwith the load and in serieswith the meter movement C. parallelwith the load and in parallelwith the meter movement D. serieswith the load and in serieswith the meter movement

146

I ,

ll 1'.,'

generators without use of: the operate 33. Brushless A. brushes B. slip rings C.4ommutators D. all of the above

plates shipboard motors AC which on of characteristics appears thename 34. An operating is: C. the type of winding D. lockedrotortorque I polyphase motors withfull linevoltage induction can be started by 35. Low horsepower meansof : rise A. temperature B. Inputkilowatts A. compensator B. autotransformer C. across-the-line D. primary-resistor

propulsion installed a large turbine on electric current alternating 36. Whatitemis normally generator? A. coilsinserted the statorslotsfor measuring in detector temperature stator temperature B. A CO2 fire extinguisher system C. electric spaceheaters prevent to condensation moisture of D. all of the above

37. Whattypeof battery charging circuit usedto maintain wet celllead-acid is a storage in battery a fullycharged stateover longperiods disuse? of
A. normalchargingcircuit

B. quickcharging circuit

C. trickle charging circuit D. highampere charging circuit

can be defined an electrical 38. A ground as connection between wiring a motor the of and its: A. metalframework B. circuit breaker C. shuntfield D. interpole

39. External shuntare sometimes usedwithammeters to: A. B. C. D. increase rneter sensitivity permits resistance be utilized s[unts with larger to prevent damage the metermovement to fromheatgenerated the shunt by enable the construction a compact of metervritha virtually unlimited range

40. The output voltage a 440,60 hertz, generator conirolled the: of AC is by'
A. B. exciteroutputvoltage prive move speed r C. load on the alternator D . n u m b e ro f p o l e s
147

to be: 41. Any electricmotorcan be constructed

A. short

B. ground

C.

exPlosior

D, overload

betweena relay and a contractor'/ 42. what is the main difference A. contractorscan handle lreavierloads thatt relays' is parallelconnected' a B. A relay is series connectecJ; contractor controlcurrent;relayscontrolvoltage' c. contractors are made from silver;retaysare made from copper' D. contractors motor? propulsion synchronous a is 43. Whichof the following trueconcerning polyphase A. B. C. D. motor. The motor is startedas an induction is Resistance graduallyadded to the rotor circuit' currentis held beiow the rated current' The starting purposes only. for The field windingis energized stetrting

breakermust be used in an area of usuallyhigh' low, or 44" Where a thermal-acting must be used consisting element compe,rs?ting an temperatures, ambient f luctuating
d,"

A . s e c o n db i m e t a le l e m e n t B" conicalspringon the contactarrn springon the contactarm C. cylindrical D, secondelectromagnet rectilier? for 43" What eou'd be an application a siliconcontrolled motor A. to providepower for a main propulsion Ciode B" for use as a voltagereference bu \lame is an automated rner C. f or sensing hum oowel suPPlY D. to etiminate

indicate: should reading the a to 46" When usingan ohnrmeter identify short, ohmmeter
A" B. zero infinite

C . 1 0 0k i l o h m s . D. 1 megohm

of amount current. .r whichpasse._ abnormal path of low resistance 47. An accidental is known as alan: g polarized round it A. open circu D . groundreference Point B. short circuit
method'The the 'roltmeter in 48. An unknownresistance a circuitis to be testedusing such that: metersshouldbe connected with the resistance is A. the ammeteris in seriesand voltmeter in parallel with the resistance B. both metersare in parallel witft the resistance c" both metersare in series is and the voltmeter in serieswith the resistancP D. the ammeteris in parallel
r{8

49. How is the Dc outputobtained from a brushress exciter? A. from coilector rings mountedon the armature B' from the'semiconductor rectifier mountedon the exciterarmatu re c. direcilyr from the commutator indication by D. from a semiconcuctor rectifier mountedon the stator 5 0 . l n general,polyphaseinduction motorscan be startedon full l i n e v o l r a g e y m e a n s b of starter,s: A. B.

across-the-line autotransf ormer

C" compensator D. primary-resistor

5 1 . T h e s p e e dr o f a s y n c h r o n o um o t o ri s s v a r i e db y : A. changingthe voltageof the system B . c h a n g i n g h e i n p u tf r e q u e n c y t c. interchanging two of the three rive any reads D. increasing the field excitation. 52. The frequency an AC generator of is adjusterl means of the. by A' equalizing reactor, c. main alternator files rheostat B' exciterfield rheostat D. prime mover governorcontrol 53' The true power indicated the pointer by moveinent a wattmeter of dependson the c u r r e n tt h r o u g ht h e l o a d ,t h e m a g n i t u d e o f t h e p o t e n t i aa c r o s st h e l o a d a n d t h e : l A. power factor of the load c" inertiaof the movablecoil B" angle of coil disprlsssment D. high resistance from the load.

54'

switchboard suppries rorararm power sisnars under H:?!rrt#'tl,"'tJ,,ilr!f;t'otncv

A. B. C. D. t h e 1 2 0 v o l t , 3 p h a s e ,60 cycle bus t h e g e n e r a t o a n o b u s transfersectlon r t h e 4 5 0 v o l t , 6 0 c y c l e ,3 p h a s eb u s the 24 volt,DC bus

55. Which insulation rryill begin to deteriorate first as a resultof heat generated in the c o n d u c t o rt s u r r o u n d s ? i A. B. vanrshed lothes c asbestors C. D. rubber silicon

5 6 . W h i c h c o u l d y o u u s e t o locatea grounded fiercj coir in a synchronous motor? A. voltmeter C. f requencymeter B. rnu ltimetbr D. megohmeter

149

mid-position is circuitbreaker in thei of ' \ h,andle a morded-case s7. when the operating is: inat tne 'i"u-if oieaFer it indicates , reset D' C' triP B' on A. off has milliampe.les an accuracy of reading 1.00 defrection between: witha fu* scale a linecurrent 5g. A miriameter muriam}reJwould-inJitutt of + or -z%.A mete*u"lY,,ig-o]io C' 9'8 10'0 milliamperes ] A. 9.8 and 1O'2milliamperes ;: B.c and 12.0miltiamperes B' 8"0 and 10,0milliamperes its wire increases' a ttrrough copper the current 59, When will C' insulation burn will will A. temperature increase D' resistance decrease will conductivity increase B. wire connection? be usedwhen soldering which type of flux should 60. C" Acidflux flux A. Rosin llux D' Silver B, Solidflux permeability? highest will what material havethe tield, in a magnetic 61" when praced B. bakelite 62"Ashorepowercircuitbreakershouldbeclosedonly
A" i n a s h i p y a rd . L -..^ rranr" ,rorn^V A q from thg bus

A srass

3: 3:llil'J

B . w h e n t h e s h i p . s g e n e r a t o r s lbeenb e e n r e m othoser o m t h e a v e para||e|ed v e s f on shore to c" when the ship.s[enerato|,-:,I.uu is used D. it'a quicktisconiectcoupling with the with the load and parallel in a shuntconnected series 63. whicn meteruses metermovement? C' voltmeter factormeter A" Power D' wattmeter B. ammeter lorward in rowresistance boththe you to testa diode, finda an 64.when using ohmmeter bias and revers-e directions'

diode--^n A. open 3: !:%Tlri.',ilHff;o''.n nrra,irv paner arternator istotrip service reray power inship's 6s ?;, ;ffi::Ttili#?::: of

i.
l ii l1
il

in circuit the event C' high powero'/erspeeding motorization A. alternator overspeeding D' geneiator overload of which main circuit B. withthe metermovement in be wourd praced series resistance 66" An internar instrument? ! C, DC voltmeter A. AC ammeter D. generatorcversPeeding overload B. main circuit
150

ii

ii,

1i

49' How is the DC outputobtainedfrom a brushless excite r? A. from coilector rings mountedon the armature B' from th+ semiconluctor rectifier mountedon the exciterarmature c. direcily: from the commutator indication by D. from a semiconductor rectifier mountedon the stator 5 0 . I n g e n e r a l polyphase , induction motors can be started furll i n e v o l ( a g e y m e a n s on b of starters:

A. across-the-line B. autotransf ormer

C" compensator D. primary-resistor

5 1 ' T h e s p e e d ' o f a s y n c h r o n o um o t o r s i s v a r i e db y : A . c h a n g i p g h e v o l t a g eo f t h e s y s t e m t B. changingthe input frequency c. interch'anging two of the three rive any reads D. increaging field excitation. the 52. The frequency an AC generator of is adjusteci means of the: by A' equalizing reactor^^ main alternator files rheostat B. exciter: field rheostat D. prime rou., governorcontrol 53' The true power indicated the pointer by moveinent a wattmeter of dependson the c u r r e n tt h r o u g ht h e l o a d ,t h e m a g n i t u d e o f t h e p o t e n t i aa c r o s st h e l o a d l and the: A. power factor of the load C, inertiaof the movablecoil B' angreof coir disprracement D" high resistance from the road.

54'

switchboard power ararm suppries ror sisnars ff|?!rr?}t'il,,iJ,uTr!f;t'o"ncv under

A. B. C. D. t h e 1 2 0 v o l t , 3 p h a s e ,60 cycle bus t h e g e n e r a t o a n o b u s transfersection r t h e 4 5 0 v o l t , 6 0 c y c l e ,3 p h a s e bus the 24 volt,DC bus

55. Which insulation rryill begin to deteriorate first as a resultof heat generated in the c o n d u c t o rt s u r r o u n d s ? i A. B. vanrshed clothes asbestots C. rubber D. silicon

5 6 . W h i c h c o u l d y o u u s e t o rocate grounded a fielcl coil in a synchronous motor? A. voltmeter C. frequency meter B. multimeter D. megohmeter

149

mid-Position is circuittlreaker in thei h,aldleof a molded-case 57. Whenthe operating is: breaker inat it indicates the circuit reset D. triP
readingof 100milliamperes between: a with a full scaledetlection wouldindicare linecurrent 58. A milliameter ol 10 milliamperes meterreading of + or -2o/o'A C' 9'8 10.0milliamPeres l A. 9.8 and 10'2 milliamPeres D' B'C and 12.0miltiamPeres 10'0 milliamPeres B. 8.0 and its a copperwire increases' When the currenttfrrough 59. will burn C' insulation will increase will decrease i A. temperature D' resistance will B. conductivity increase 60.Whichtypeoff|uxshouldbeusedwhensolderingwireconnection? C" Acid "'*, A. Rosinflux D" Silverflux B. Solid flux permeability? will have the trighest tierd,what material magnetic 61" when pracedin a A. off B' on C'

has an accuracy

B" 62.Ashorepowercircuitbreakershouldbec|osedonly

A srass bakelite

3: SLiiI|HJ

fienerator:,l.ui c, when the is coupling used ctisconilect D" if i quicx with the with the load and parallel in series shuntconnected 63" which meterusesa metermovement? C' voltmeter factormeter A" Power D" wattmeter B. ammeter the forward in a lowresistance both you to testa diode, find an 64.when using ohmmeter bias directions' reversL and

bus senerato':6il '"'*iH:"J1'JtJle llni.'l,lrt?"lo'' i. li:.: P:::paralleled thoseon shore to ship,s

diode-A. open ^ nrra,irv

65 ?;, :::,1,::':?ilT:?:y. of

rerav power

3. lfl.ryH.,i;fiffit''n paner to trip arternator is service in ship's

in circuit the event C' high powero'/erspeeding motorization overspeeding A. alternator D' generator of which B. main circuitoverload withthe metermovement in praced series wouldbe resistance 66" An internar ! instrument? C, DC voltmeter A. AC ammeter D. generatorcversPeeding overload circuit B. main
150

I I I I

t
I I I

PARTIII

STEATVI BOILERS, ENGINES, TURBINES, INTERNAL COMBUSTION ENGINE.

THEORY, OPERATIONS AND MAINTENANCE

I
l
I

t
I I I t I
I

151

I I l

*i
STEAMBOILERS

hi

t{

ht

o . W h a t a r e t h e t w o t y p e s o | b o l | e r b a s e o n t h e l r w o r k l n g p r l n c |product ple? plants lht pressure Td the tubesis tubes l:-ling of i::ry Frretube- consist rarge of rnsif,e thetuorr,?[J outstoe the p"rr-thror.rgh of combustion bY sorrounded water' of production higher etficient - constructed .Til tubesand insioe tubes, withproduct the water tube ry.ith *n.ru thewate,ir-.ont"ined steampressure, tubes' of the p"tri^g around the outside of combustion

H tJ I

J J

J
VESSEL ON MOTOR A. USEOF STEAM cargo oil purifier.heater, tank heating' Fueroil hea.ter, sea-chests' duties:ME cuttty supply' 1" Heating caroriti.i, and.heating'pi;i, Rirconditioning neatinJ, etc' heating' tt".ttTin" tot pipeline Qenerators 2. RunTurbine in 'Jargo pumpturbines Tankers 3. Run 4.Drir,esteamdrivendeckmachinerieslikewinches,etc. 5.Operatebilge'strippingandothersteamdrivenpumps 6.Driveboilerieedpun.|pturbines media heating generator water . Evaporator/Frcsh 7 cleaning andgeneral ships in 8. Tankwashing tanker g.ForboilerSootblowingandforthesteamatomisedburners system smothering in steam as 10. Firefighting used ant,draintanks and oii surnp F.w. preheater rub Jacket 11. Mainengine 12.Useinthewasteoil'incinerator'sloptanks l3.UseasasteamejectormediaforeiectorpumpsandVacuumdevices etc' ship)' (lF propulsion Turbine 14. Mainturbine

152

CLASSIFICATTONBOILERS OF

Classif ication Crlteria Capaclty

ForSteamships
HighCapacity

For MotorSh'ps

Additional Information

Worklng Prlnclple Clrculation l Type

BOILERTYPES

Lowor lr,ledium Units tons/hr in Capacity OI, 100,000 kg/hr 1,000-5,000 kg/hr kg/hour HighPressure LowPressure Lowpr. on most 60 barsand 6-15 bars motor vessels; above Medium Pressure Med.Pressure 17-30 bars usedon tankers Drum Type, Cylindrical, Package, Tubular, D-type Vertical both of Coiltypeare Tank rypeor, other shapes for D-lypeon tankers Lowpr. units MainPropulsion Auxiliary Boiler; Assist Propulsion Boiler Mn Blr or Donkey boiler Hotel Purpose Heavyuef f l-ight Dieset, Coaf, Electric, Gas Heavy fuel, Gas Exhaust Gas Water Firetube, Steam raising Watertube method
lrlatrrral Natural Forced

T a n k& D r u m ; ExhGas,Coil

Main Boiler - proputlionof ilre vessc,l. A u x i l i a r yB o i l e r- A i d st h e p r o p u l s i o n i n s o r n e a y ;e . g . ,h e a t i n g f h e a v yf u e l w o o i l u s i n ga steamheater'nec.essary propulsion toi wouldqualify tht'supplying boiler be referred to as an auxiliary to boiler.

isused ror "hotet" of ship; supptyins onlv the needs the o.s., ffiH,f,T'fi:tffJ:twtiich
Tank Boller- Arboiler withlargewatercarrying capacity wherethe shellis beingusedas the pressure vessel.Mostlow pressure auxilia-ry b'oileri comeintothis category. will VerticallEoiler Any boiler wherethe shellis upright andthe furnace usually is contained withinthe shellat the lowerhalf . HorlzontalBoiler- Thisis alsoreferred as cylindrical to boiler; here,the boilercylindrical -shellis lyingacrossits lengthparallel the structure the ship to of or ittr grouhdl'euer.

153

gas exhaust sour@$ or by operated hotgasfromengine other GasBoller- Boiler Exhaust Tllty arealso drumq. and steam watbr employing tubeboilers DrumTypeBoller- Waier boilers. as known benttubetYPe a inside boxtypecasing' packaged boilers packageBoller- Fully low automatic, capacity be could coil anywhere; oringpositiirred and proouction trexinie'in steam of capable quick tyPe. typeor firetube of a Flretube and o. Glvethe advantages dlsadvantages of Advantages FlretubeBoller: damage' serious water,without canusoimpure boiler 1. Firetube supervision ex-acting require of a Z. Theycontain largeamount waier'-{lg^9":not is pressurs steadier' Alsosteam level. to aSregards wate? low" 3. Theirfirstcostis relatively for Theyareaccesible maintenance' 4" losses radiation bywater and of fire s. Because isontn. inside boiler is surrounded are lower. boiler: of Dlsadvantages Flretube ol interval time theyrequire of amount water, a llolg they 1" Because contain rarge demand' in to as noiflexibre regards cnahges dteam volume to raisesteam the in suchas a case, rarge ino "nJ"rJ to.erpiosion, 2. Theyaremostsusceptibre might the reacning atmosphere wateifllining into steamupon of escaping to damage personnel' serious cause thus plate,iand flretubo thick extremely boiler require would g. Highsteam pressure and pressure temporasieamat high bo*erarenoturuliri ."J.orr of prooucing 4. theyaregenerally into largeentrance the fireroombecause HtlS;require section' in snipandshippod large. in riveieO tneOoiier thanthaiof watertubeboiler. 5. T;i;;'rri.L..Vlriu* boller: of Advantages watertube and steamat highprossure temperature' produce 1. fn.i."n of because thelr in steamdemand 2. Theyareveryffe'xible ,.g"ra, [o .n.nges ", of smallvolums water' S . P e r m i t u s e o f n e a r r e c | a i m i n g d e v i c e sshorttimo'e v e u ' y d i f f e r e n t . andsoar raisid in a relatively ;ilil pressure 4. Steam to 5. Theyaie notliable explosion' large entranceinto the fire are .rrr*UtrO iri the fiie room,and so 6. They roomarenotrequired' of Dlsadvantages watertube boiler:

and pressure to asresards steam supervision ,' T[:l T,1:\',::i'lf SXtSi;.,

to insulated minimize be must heavily 3 . Boilers be must emptied' on repaiis tu6tt, boilers 4 . io t"rt ! boilers. than ishigher thatol scotch 5 . iirst Jost temperature. losses' radiation

154

SOMEEXAMPLES POPULAR OF BOTLER INDUSTRY IN Medlum . Pressu re: Watertube, Drum Type Tanker Vessel Babcock & Wilcox M 1 1M 1 1 M , Low pressure: Package Coll type, flre tube type All types of vessels Cochran Chieftain Steamblo: Stone-\'apou r Low Pressure: Tanktype Oll flred/ Composlte All Typesof vessels Aalborg AQ3,AQg,AQ12 AQs,AO2,AQ7 Sunrod CPH,CPDB Osaka HowdenJohnson Hitachi Zosen HV Span ner Swirlyflo Low Pressure: Erhaustgas Forced clrculatlon All typesof vessels Aalborg AV series Sunrod PL,PT

Foster Wheeler D4
Combustion Engineering Kawasaki Aalborg AT4,ATB
l H l :A D M - 6 |

Clayton Miura VWS

lHt-cv
Coch ran Mitsubishi MC, MC-C

MitsubishiMAC

Llst of BolferM.ountings Functlons Each. and of SAFETYVALVE Protects shellor drumagainst the excessive pressure frombuilding up in a steam boiler, thusguarding boifer the fromexplosion. MAINSTEAM STOP VALVE Aliows steam leave boiler go intothemainsteam to the to line,andfromthere, themainengine turbine. to or AUXILIARY STEAMSTOPVALVE- Allows steamto leavethe boilerto passintothe auxiliary steamline,andfl'om there, pumps, to generators, otherauxiliaries. and WATERCOLUMN Provides a-stilling spaceso thatits watertevel not be greatly will affected pitching rolling the snip. by and of Waterirrths column cooler is thanthatin the boilgr shello-r drum. Thus, ictualboiling no place takes inthecolumn, thewaterlevel and is moreeasily detected, GAUGE GLAS$- Attached thewater to cotumn to thedrumandindicates level or the of thewaterin the boiler.

155

to provethe and or to the watercolumn, are used to TRy cocKs - attached the shell '' t glass' by indicated thegauge ieading off to greaste' b'eblown such ilghtimpurities, as oil or vALvE - Ailows suRFAcE BLow of ftot the surface thewaterin theboiler' of bottom theboiler' oft to sediment be blown fromthe of the boiler' BorToM BLow vALvE Ailows water'tev.t a partial emptying o', of a It alsoalrclws rapidreduction the the so off to be drawn fromboiler that of a COCK Ailows sample water SALINoMETER Jtntity of thewatermaybe measured' into of entrance thefeedwater or srop VALVE permits prevents MAINFEF-D-WATER line' 6.ifti fromthemainfeed-water feed-water asthemain f srop vALvE- Hastlresameunction FEED-WATER AuxlLlARy '[located line' feed-water in the auxiliary urt stopvalve, f into otwater theboilerromthe cHEcK vALv E - Regurates,the,tl?* themain FEED-*ATER feedlineinevent MArN up backinf i. in waie,, theboirEitror prevents feed*neand main pump" of of failure the mainfeed-water

feed A U X I L I A R Y F E E D - W A T E R c H E c K V Afeed-waterh e s a m e f thec t i o n l a s t h e m a i n f e e d L V E - H a s t betweeri n auxiliary u line in butis praced theur*iliirv watercheckvarve, pttmp' feed-water stopandthe auxiliary on in prior cutting theboiler theline' to from boiler vENT-Allowsairtobe released the AIR is beingemptied' the andto break vacuut *nln theboilers whistle' for steam the ship's wHlsTLE VALVE- Furnishes in carried the boiler. being pressure pRESSURE GAUGE rndicates

too became low' water when use on pLuG- Installed scothboiler to givealarm FUSIBLE alarm' activate steampasses madeof oionie andmelt, f to water drainromths of f boilersorthepurpose allowing - Fitted scotch on PLUG BELLY into boilers thebilges' to ste-a1 the and - Foundonryon gggrch-boilers, supplies of theboiler VALVE i'leating H'DRO'NETER even and up'.ir.rtation cause whichi, urro to speed hydrokineter, cold. up whenttreiatieris started from marlneboilers? of accessories modern Q. Whatare ihe additional heatin fluegases that accessory utilizes-tfie boiler is - Aneconomizer a boirer drum' the EcoNoMrzERs waterenters thatieed arrd of feed*"t* before tvi-e-*i*' for the y'eaoJr expansion to increase temperalui,loopo, .6niin*us roop single either rts consrruction rePair' maintenance
156

Advantages: a) A saving fueffrom5 to 1Bpercent in resurts. b) Reduction thermat in shock- higher fne th.lurp.rature of feedwater, ttrecontraction stresses uponthe injection *ririinto tne thefess of [flf: hot steam c) Increase storage in cPacitv.The^large quantity water of contained an econoin mizer provides reserve space the-evr'rf;i; sudden in boiler overtoad. Disadvantages: a) Original costis high b) fncreased maintenance cos;ts c) Space occupied therronrrizer also by needed" AfRHEATERS -Air heaters are installed mc,dern on boirers air beforethe air enteit-ir,t often uoireilrrn".r. The mori ,orron to heatthecombustion secured a tubesheetat each in type consists tubes of fu-n forces throuo.n topnalf end.A forceC_draft ,ornted dt tne top of the boiler, air of 9e in halfof thetubes-in ofposite tneluue1anr, oneJiiection thenthrough fower and tne oireciilnl in, r',ot uiiir,rntrrverthrough air the of theboifer proper' an ductoutside arohitr't ,iou, u,ij'ir,rnunder thefurnace chamber. froor, derivered furnace to

Advantages: 1' lt increases boiler efficiency, since the

arereduced. iliTJin;,;u.;;-r-u,l".. Hi:Tuo?n'.[:'trj,:m#HH temperature,

stack temperatures

::T,,:il",::.tJ:,i::':sase,

on a modern water-tube boter and funcron. sTEAn/t DRUM;' a cylindrical forged steelwithbothendfitted withmanhore coverfor repair passage'fnsidethe drummounted with internal fittings drypipe, fike surface browfine, feed waterlineand desuperheater higher on pressure boirer. typicar pressure on row watertube boilersame mountings outside on connection satetyvalves, like mainand aux iliarysteam ai.,arve,

o'

':,iy:'?',' i.i: iffit;1j :m : t*l:' il, i'".e o oL,io,orh uta l' 0 n n r e p [e il'r'""rlfl i "'J
what are boller mountlngs founds

sooT BLowERs - areoften instalfed economizerto on keepthetubes soots freefromcarbon, coming fromexhaust of theengine. gas lt arso fitted modern on in generating marine boiler rocated tubes'*upt't''ater tubes, and air heater orderto maintain in effeciency heat transfer the working of therebyproducing befter a output of the boireroperating performance' f lt uses steam oetter ssuperheated for cleaning method which air heater economizersuperheater start fromtopandgenerating tubes, freepassage burned for gases fromfurnace funner prevent of to to sootfires. SMOKE INDICATOR Thisis apparatus usually consist aseries mirrors.so of of located thatthe firemen can

*iir, rever surrace varve, sase, brow main and

157

LI rl
ofwaterto thegenerating the areto equalize distritrution orsludge functron whichwas solid *ATER DR'M itsmain and orscale other tor space tneaccumul"tion tubesandto provide blow-valve' ;;;. out bYbottom section drumandfront steam between connected tubes strain of nipple without DowN coMER consist to passes heade" lo' expansion the drum, wherewaterreaves headers,
a

occur.

steam part in thehighor of the pipe or srotted placed pipeis a perforated to thedrypipe' are DBy prpE- A ctry ouitrtval'res connected way to the The priming. steam to of intothe drypipeon its space a boirer prevent (o, tnro,in the noreu slots) The steamm,rstpassdown s t e a m v a l v e s . . o n m a k i n g t h e s e t u , n , , t n e m o i s t u r e i n t h e s t o a m i s tinstalled f f b y i n e r t i a . hrowno watertubes or of series vertical inclined of heatof consists a radiant direct WATER*ALL - A waterwail and cnamber "*pot"o to to of ine combustion nipplss' one anci arong or morewalrs headers connecting through directry,or tubes *nnected thefire.These "r, of system the bciler' the circulatory and boiler surfaca heating (1) the waterwat: Added by are boilermay even Two purposes served to an exis'ting and .d;;g waterwalls Revqmping greatly' are capacity secured. wallis reduced (2) ru"",itrn.ice ot the refractory its doubre capacity" perfect thus andatomize creating the ihwhich fuelandairmix space wall water andgenerating F'RNA'E - lt provide to transfer thesorroundec heat totar rtalsoincreased combustion.
t ubgs . ,- -^^ r.naA r in baseheader lower around or bricks tilestitted - is madeof lt alsoserveto F,RNA'E REFRAcToRy providing ;;;; tt*otltion' preventing heat turna* iurperature ln;t and orderto maintain oanr of gellratingtubes the through gases hot boilerefficiency' transter combustion tn"intaining therenv to escaping the "tr;pnere from boilerwhereit on mounting a rnodern mostimportant gasespassing of the combustion supERHEATERs one ,i""lo, beingn""t"ioy pressure tni, constant' rerrlain but steamfromdrypipe receives in "ng increased temperature of near the furnacebut outside thetuds: thereby installed around superheated purpose stage rows of of contact heat'Prime consist of first and second ori* to avoidoitttt prevent tubesin by protected rowsof scieen ,,otion on turbinebladilngs' plant thus eriminate engine thus consumption increases is to use on main turoine ress valve carry-over, steam thanthe safety in steamlines, condensation to varve, be set lower safety with Jro superheaters fitted capacity. steam boiler'wheresuperheated hish pressure drum' onryon - instaned water spaceof lsteam ::::::Jr^TrrR are i-**""d in the equipment tunesthat auxilliaries passesthroughpipingto stea* to thedrumfor steam' to saturation equal the use to reduce temperature wh'rch onlylowtemperature ,oo,iblo*Lrr,rrroiump, "rr. pumps, rikecargo '

158

l I

path of way pass boiler,usedto divertthe GAS BAFFLES- usuallyfittedon three to gasesfrom furnace uptake' combustion returntubesfrom blowing backthrough STEAMBAFFLES-.topreventsteamcoming effect. turbulence directlyinto the water in the steamto avoid to blorvvalveconnec'ed' collect wheresurface SCUM PAN - fittedon steaffidrum such as oil, greaseto overboard' imPurities the floating Q.Whataretherequirementsofe||icientoi|burnlnglnaboi|er? t r 1. P r o P ea m o u no f f u e l of an'ount air 2. ProPer atomization 3. ProPer fuel 4. ProPer andairtemperature temPerature 5. Highfurnace of combustionis varled to meet what are the methods by whlch the rate in changed the steamdemand? thefollowing: by may The rateof combustion be var'ied changing used' 1. The sizeof the atomize used' of 2. The nurnber atomizer used' oilPressure 3. The 4. ThefueloilbackPressure' Whatarethecauseso|excessiveoiltemperature? 1) 2\ 3) 4) 5i 6) 7i B) Insufficienioitcirculation of viscositY oil lmProPer Overloading bearings Overheated not system effective cooling Jacket of fuel. Lateburning on coating the crankcase Sludge Oil cooler.clogged'

I
o.

a.

Q-

whatt\ruopartsdoesaburnerconslst?whatlsthefunctionofeachpart? of consist fruo Parts: The burner fill whichcompletely the ihe - it is usedio aromize fuerintotinyspray 1. Atomizei f u r n a c e o p e n i n g i n t h e f o r m o t h o l | o wwhirling which. c o n e . air the catches fuel of of z. Airregiisterit ailows.entry a stro.gbi".i fog,mixeswithitandentersthefurnacewherecombustiontakesp|ace
159

t
Q. State four operating condition that decreasethe life of the furnace refractory linlngs. The life of refractory liningof furnar:e influenced is by: 1. The high sustained furnacetemperature 2. Rapidchangesin temperature 3. Vibration panting the boiler or of 4. Flameimpingement. Q. What causes panting in a watertubeboiter?

1. 2. 3.

Defficiency air of Excessive temperature oil Poor fuel-air mixture.

cl. what Information foundon the nameprate a boiler? is of Inspection Bureau per Number; ( Tensile Strength ) lbs. sq.inc.(p.s.i.);rHydrostatic ( tost ) p.s.i.;OriginalWorking ( Prsssure ) p.s.i.; By;Steel Date Inspector's Built By; and Initial. O. WhatInformation stamped the bodyof a safetyvalve? is on Name or registered trademark manufacturer; of Serialnumber;Inletdiameter; pressure; Operating Discharge pressure Blowdown psi. capacity; working Safe and in Q. Howwouldyou makea hydrostatic on a boiler? test 1. Clean boiler the thoroughly on thefiresides both andtlrerrrrater sides. 2.. Seethatallworkers clear. are 3. See that all foreignmatter, tools,rags,etc., are removed fromrthe boiter, andclose thdmanholes handholes. up and 4. Allvalves theboiler on must ingood be condition. Allvalves except those through whichthewaterforthetestis to be let intotheboiler should closed. be 5. Themainsteam maybe tested line withtheboiler. thiscase,it maybe along In necessary puta blank thefarendof tlrelineimmediately to at before throttle the valve themainengine auxiliary to or engines. there twostopvalves the lf are in line,it maybe unnecessary blank the line. to off 6. Hydrostatic pressure should be puton onesideof a vatve not whichhassteam pressure theother on side. Thisis important when is steam up on oneboiler or on a donkey boiler while given hydrostaticitest. another is boiler being a Blanks haveto be used if thereare not two valveson the line.Two ,valves may be considered sufficient. 7. Provision mustbe madefor a testgage 8. Thesafety valves mustbe gagged. 9. Theairvent(aircock) thetopof theboiler at mustbe leftopenuntil waterruns out of it. Thenit maybe closed. 10. Thepressure, applied means a pump, by of rnust applied released be and slowly. 11. A hydrostatic mustnever test applied a hotsuperheater boiler. to or
160

il i q q q n q i

I il

q q

It

O.

What ls the procedureIn lay-upthe boiler?

wet storage: Usedforshortlay-upof lessthana month andtheboiler maintained is in a stand-bycondition. suitable boilers Not for exposed freezing to conditions. The boileris cornpletely filled with hot distilled de-aerared alkaline water.The water shotrld overflow through I'entduringfilling-up. the Dailychecksare necessary ensure to f u l l n e s s n d a l k a l i n i ta r e m a i n t a i n e d . a y Dry storage: Usedforlonger lay-upsof morethana month. Theboiler completely is driedout usingheatqrs on lightfireor passing air through or hot parts.Whendry the boiler completely, the boiler all outlots sealed are tightafterplacing - r -. g Iehydrant gel isuchas Silica''i at the rateof 2.7 kglcu.metre)inr;ide boiler. the o. what ls the nrdanrng, functlon of the followlngtenms?

Boller Capaclty- is the amountof work a boilercan producea steam expressed pounds in per hourdesigned generate. to Prlmlng- carryover entrained of waterwiththe steamirrto engines the thataffectthe turbine blade,breakcylirider heads,piston,valves. Flareback- mostlyoccurduringinitialfiringor attempting to relighta burnerfrom a hot brickwall withoutproperpurgingcausedby explosionof mixtureoil vapor or gas in the furnace. water Hammer- consistof condense moisture a steamline,whichformslug aheadof in steamflowing through thatproduce soundr; a hammer like hitting metalagainst a elbows, fittings, valves'lt canbe prevent draining slowpre-heating by and of lineby opening by-pass valves. Foamlng- a process condition producing of steambubbles fromthewaterfevefin a boiler to the steams[racecause.by presence oil thatfeedwatercarriedover from machinery. Plttlng - is a form of localcorrcrsion usually foundon boilei-rvater system. fine Groovlng - usually foundaroundseamsrivetsheador wherethe metalhas been bent or strained. Carry-over- consistof particles water leavingthe boiler,ruith of steam causedby high alkalinity, highdisolved suspended solir1s. Gag-a special clamptoolsforhotding safety the valves closec] rluring hydrostatic a pressure test. Accumulatlon Tesf-'the actua: test of the ability the boilersafetyvalvesto relieve of the boller allthesteam!hatgenerate of during iringat f ullcapacity. f Firing timeforfiretube boilers forcedto maximum capacity 12 minutes is whilewatertubeboileris 7 minutes, cxceeds not 67" above.maximum allowable pressLrre. working
161

wether to buildupto boiler, determine andpressure fest-filledupwithwater Hydrostafrc pressure. its holding working of theboileris tightandcapable safety \ blthe evolution with of combination oxygen fuel,accompanied Combustton-is therapid of fire. heating persquarefootof into waterevaporated steam amountof RateofEvaporatlon-the perhour. surface per surface -the amount fuelburned square of heating per foot of of Rate Combustlon hour. or such of stresses tension, abstretching to of is Tenstte Strengtt> theability material resist pulling apart. it yletdpolnt-sudden without increase any tensile stress, under while yielding thematerial of in load. without can to stress whichthe material be subjected EtastlcLtmlt- is the maximum deformation. its causing permanent tensile stress. under of in Elongatton is theincrease length specimen is awayby thegalvanic in the of actlon- is a fornt corrosion which metal eaten Gatvanlc parts action non-homogeneous of ironandsteel. on occurred usually on that ofmolecules produce metalwhich Embrltttement-nrade Caustlc stress. and joints of concentrationalkalinity mechanical withhigher on riveted parts, for of of away some themetal process deteriorationwearing on of Corroston isth6l of grooving. types corrosion Two and pitting, orwearing rusting forms, in which exists three general local corrosions. and are on by it which allows to be drawn, pulllng itsendsto of Duclllty- is theproperty a material diameter. a smaller working to of strength a materiat itsmaximum of of Factor safety-is theratio theultimate stress. to or forging rolling, a temperature after to material cool, of Anneayng consist allowing the to temperature refine grain,and the it range, reheating to proper belowthe critical it allowing to coolin thefurnace. the to ine reheatirtg ref thegrain, that except after to method annealing Normalztng same it is material allowing to coolin theair" is rivet, placed called length plates. cylinclrical of metal, A metal of Rlvelng-method joining into is forced a shape theneachof therivet to in drilled thetwoplates bejoined, intoholes ! shank. of section therivet cross the of largerareathan
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S A F E T YV A L V E S pressurefrom buildingup in a The functionof a safety valve is to prevent excessive possible explosion" steamboiler, t\us.guarding the ttoileragainst TYPESOF SAFETYVALVES higtrlift;Fulllift;Fullbore; lift; Ordinary Highlift;Inrproved safetyvalve. and Pilot<penated; Electro-magnetic = 10 bar Blr. DesignPress Exampte: = 15 bar : + 50"/" Test Press = Bbar OperatingPress = 9 bar H. P. Alarm 10bar V S e t P r e s sS a f e t y a l v e1 = 1 0 . 3b a r : + 3 / o V S e t P : e s sS a f e t y a l v e2 = 9 . 6b a r : 1 - 4 / " V S Closed afety alve = 10.6bar : + 6'/" Press Accumulation with at leastTWO in of with a heating surface excess 46,4 m2mustbefitted Boilers safetyvalves. pressure the boiler.Since of Safetyvalvesmust be set to liftwithinthe designed to valvemaybe adjusted liftat valves, second normally safety the two marine boilers,l'rave p p r e s s u r e f 3 % a b o v et h e b o i l e r e s i g n r e s s u r e . d o a rangeof safety valves:1 - 4% of set pressure. Nornral blowdowri pressure should operating leaking "weeping" safetyvalves, boiler of the or To prevent p b e l o w e rt h a nt h e d e s i g n r e s s u r e . diameter. The idealliftfor a safetyvalveis 1/4of the valve(throat) D E S I G N E A T U R E S F A N O R D I N A R Y I F TT Y P EV A I . V E F L O 1. Liftof thistype of safetyvalvewillbe 1124 its throatdiameter. of of the 2. A splitcompression is fitted fillthegap between collar the adjusting ring to n n u t ( c o m p r e s s i os c r e w ) a n d t o p o f t h e v a l v e c o v e r b u s h . T h i s p r e v e n t s of any alterati.on the valvesetting. i c s , 3 . T h r o u g h l o t si n t h e c a p a n d s p i n d l ea c o t t e r a n b e p a d l o c k e dn p l a c e . g f a m e t 4 . A n e a s i n g e a rf i t t e d n a b l e sh e v a l v et o b e l i f t e d a n u a l l yr o me i t h e r l o c a l p or remote osition. in so are 5. Adequate clearances provided tlreassembly that the valvecan open f reely. loadsactingon of the 6. A drainfromthe valvechestavoids possibility hydrostatic v a l v ea n d s e i z u r e f t l r cv a l v ed u e t o c o r r o s i o n . o the V S O F DESIGN EATURES F MODERN AFETY ALVES 1. Z. lJ. v I n c r e a s e v a l v ed i s ca r e at o p r o m o t e a l v el i f t . d the the control:Raising ringtowards valvedisc increases ringbtowdown Single a t h e v a l v eb l o w d o w n n d v i c ev e r s a and the rings:The upperringcontrols valveblowdown Upperand lower adjusling the popping actionand removes valvesimmer. tlre the lowerringpromotes
c r h c b ( T h ec l e a r a n c b e t w e e n o t hl n e , e r i n g s o n l r o l t h e u d d l i n g h a m b e p r e s s u r e ) e

4.

for adjustment thevalveblowdown. valvegivesa rouglr control A back-pressure

163

Body 2 Cover 3 V a l v eD i s cH o l d e r 4 V a l v eD i s c 5 S e a tR i n g 6 Guide 7 Spindle B l o wD o w nR i n g I 9 Setting Screw 10 ValveDiscBall 11 S p i n d l e a l l B 12 Spring 14 D o m e 15 Adjusting Screw
I

17 18 20 21 23 24 26 27 28 29

Locknut P Spring late DiscRetaining Clip Body asket G Pin SeatSecuring Securing Plug Pin Body Stud Body StudNut Nameplate Nameplate Screw

SafetyValve
164

PROCEDURE FOR ADJUI}TMENT SAFETYVALVESON TANK BOILERS OF 1. At leasttwo pressure gauges, v.rhose accuracy beenverified has recently, must be madeavailable give the reading boilerpressure. to of 2. Screwdown the compression screwon the valvesa few turnsmore than the previous setting.r 3. Steamipressure the boilerraiseC in and the boilerput on bankedfire. 4- Slowlyrb{ng theboiler pressure thedesired pressure thesafety up to set of valve being adjusted(adjustonly orrevalveat a time). 5. Slacken compression the screwof the safetyvalvestowly the valveblows, till q. Stop flringthe boiler, and notedownthe closing pressure the valve. of 7. Try outagainfor lifting (floating) thesafety of valveto checkthe setpressure and to make minoradjustments the compression to screwas may be necessary" B. The valvesetting donewitha bit of trialand errorprocedure is andwithpractice can be achieved fairlyquickly. 9. On valves withblowdown control, blowdown rhe ringis initially at a particular set position per the maker's as instructions fineadjusted and Ouiing floating ihe valve" the of 10. The safety v'alve adjr.rsted slrould gagged(thegag mustbe f ingertightonly), be and the othersafetyvalveshourd now be floated ind idjusted. 1 1 . T h e g a g f r o mt h e f i r s tv a r v e h o u l d o w b e r e m o v e d " s n 12. Firethe boilerto confirm satisfactory the operation the safetyvalves. of 13. Splitlock ringscan now be made arrdfittedto lockthe compression screwsin place. 1 4 . F i t b a c kt h e e a s i n g e a r sa n d l i f tt h e s a f e t y a l v e sm a n u a l l y . g v OPERATING ROUBLES T C h a t t e r : M e t a l l i c a m m e r i n g o u n d o r v i b r a t o r y 'o i s e .T h e r e a s o n s h s n b e i n gb e n t s p i n d l e , m p r o p e r l e a r a n c e s o o s eb l o w d o w n i n g ,i r p r o p e r p o s i t i o n i c l, r o f u p p e ra n d / o r loweradjusting ring positions, excessive bacl<-pre.iure, etc S i m m e r : T h e f i r s tl e a k a g e f s t e e mb e f o r et h e s a f e t yv a l v ep o p s o o p e r , w h i c hi s allowed within1i.5 2"h of popping to pressure the valve.Prolonged of simmering may be due to impropeq position adjusting cf rings, distorted vafveparts,etc. (no,rmal) Leakage:Constaht hissing souncl. The reasons beingdamagedseating, defective parts,scaleor foreign matteron tlresealing surfaces, distoition due to wastesteampipe fitting, interference from easinggear anclspindle, etc. tlanq:upt Safety valve f ails to re-scat.Tlrc reasonsbeing improperblowdown a d j u s t m e n r , e c h a n i c an t e r f e r e n cfr o ms p i n d l ee t c " tn il e , ROUTINE HECKS C a. Checlqfor leakages daily. Do not stop the leak by over-tightening the of compression scPY olgagginqthgvalve.Try blowing valvewiththe aid of eaJng gear the and turnthe spirirdle possible, low pressure (if for boilers only)alongwith the disc in both directions dislodge to foreign matteror scalefrom the sealing surfjces. b. Manuallylift the vaives(rvhenthe boilerpressureis above 7Sy. of working pressure), checkthat the valvesare operational to oncea month. c . F l o a tt h e v a l v e so n s t e a me v e r ys i x m o n t h s . d . O v e r h a utlh e v a l v e s o m p l e t e lo n c ea y e a r . c y

165

GAUGES LEVEL WATER

REGULATION the t-tat,:f indicating withat leastTwo indeoendent an fitted Everyboileris to be meansis t0 be either to u' a gtassg;Gi T!^"other waterlevelin it; oneof which-tJ areto be independent device' Jhut-off auton:atic alarmt anO audible vfsiOle "ni TYPES glass gauge l. Tubular glass gauge ll. Reflex Plate glass gauge lll. Double Plate GLASS TYPEGAUGE TUBULAR below17'5bar: presisure of boilers design off for lowpressure to Suitable connection shut the ,trit oattvitieln inu *"*r'sde to incruiJ'a iniury the safetyfeatures g6,si r"gtto prevent of grass';,;;kifu and i'itii-iisert waterin the event personnel. GLASS TYPEGAUGE PLATE REFLEX

te io h h j o atr v I e ct operate ffi"- fJffi$;3,; :f ,:U 1ffil \1iSir',"ffi;rw e reedareto nwic j ft ilU;; eotnthesystems of any;;r; mountinq ihr;;lrr'

tfre backofthegrassprate..u* appsarance.to steamspace silvery urignt the in thewaterrp"rr.-ihis-givri " two enables absorbed ,ir6ngcontiasiSrwrrn the waterspaceappears. the !ark".Th, whire

e ris r s th ated' ee oribat e ffi ::iff'Ui{iiffi'n thssteamspaceand i iil[??J'li':',?:'1 be reflect.Jn"tkitot the i,:lfJ :T ine righirrv,to

mica or to type sheetthereflex praced ruil;;;i::iNi$:,T:'[';,{,i:tifi^li:r*n," glass' is be can

on giurrlJ,l. tl tnerih's this forhigher spa-cr'.nitn, pressures' steam/water between is notsuitable t[rruforc useofthisform'JiJroirctio-n, notmake "no GLASS GAUGE PLATE DOUBLE s of34bar' are the when pressures in exces issuitalp use of assembry gauge bv sfreets mica' This lqr nr effectivei;;i$fli:tf, tiotion' plates toughened ptates.un of flatstass two with asthe iittua piece centre directs .onrirt,of a hoilow of glass Theassembry rouvre ir"ir theback the pr"t, A oi cramp uy glow' "t level herd gras;i inprace mein, " tnr ri'rnlrcus thewater of maxe at anangte-io rays theright oPERATINGINSTRuCTIoNSFoRAREFLEXPLATEGAUGEGLASS
holdersontheupperandlowerconnectionpieces.
166

s'ass aid rotatabre tre or :, Vl1;;:.ff::'f,ilS.?il'fi:';,:ed5ffi:?ff1'ilil;

3' Wheneverthe boiler prt intooperation it hasbeencleaned, after some foreign i: matter eould exist theshut-off in valves. Avoid eventual damage frequentiy by draining tXe system thedrainvalve. via 4.
a' ' Closethe steam and waterside vatvesand open the drain valve" b' Blow-through steamsideby opening the the'upper valvefor 1-2seconds and close. c' Blow-through water side by opening lower the the vatvefor 1-2seconds and close. d. Closethe drainvalve. e' Open both steamand watersidevalvesby turning them slowly. Replacemerit gtass of a'r lsolatethe a-qsembfby shutting-off steamand y the waterconnections and by opening drain. the b'l Take off the screwsof the glassholderand remove the pressure ledges. c.l Removethe glassinsert with gaskets. d. pRareglasssurfacesto be cre-aned thoroughry. e' Instail blackgasket, spareglasswitnine grooves the the facinginwards, the red gasketand finaily thin stell sheet. the _ f' Put on the pressure iedgesand tighten screws the uniformlystarting from the middleand proceeding cross--wise and downward, up g' Heatthe new glassslowlybykeeping thewatersidevalveshut,the steam side valve crack-open and the drain-fuily open h' After about30 minutes, screwsshoulo the Uetightened againby applying a torqueol 2.4 kp-nr" i' The assembly nowbe put cn loadby shutting-off can thedrainand opening v the steamand watersidevarves compretery" Reasons for a false water level indicationby a gauge gtass a' Chokedvalves and passages thesteamanoloiwater on sideby sediment, scale,packing use of a rouncl or glasswhichis too long. . br valve or proffusive lteam and/or warer leakagesfrom the *3lI 9:?'t g a u g ea s s e m b l y . c : F o a r n i n g o n d i t i o nn s i d e h e b o i l e r . c i t d ; S u d d e nc h a n g e s n s t e a md e n r a n d . i

Blowing-throughprocedure:

I I I I I

5.

t
I
!
6.

I
I I

I I I I I

167

h
A COMBUSTIONNDEQUIPMENT \ CUPBURNER ROTARY to whichis hinged the a.ir a!.0|t\er, or consists a rotarycup cup asssembry atomising rs The burner The rotary cnamblrwith i.ii".i.i.v lining' v-belts' andthe combustidn register through motor uy electric oriuen shaft, on ritted the burner "n ttreoilinletpipe' flows reguratorand throug.h spread co in out metered the oir ntpund Thefueroiris Herethe fuel oil is inio it oiroisiriuuio. th;';;i;ry .up, i[u uogeof th.e where is and cup the oil nozzre, the and wa-ll ilo*s to on theinner force by rpm)" uniformry centrifugar to ar (rrp-lotutes 4000 6000 at off tangentiaily higtiverocity thrown cup shroud' cup n betwee the rotary anditne veryfine enters air into The atomising (primaryarr) it broken t'u .rp.The ;li rir* as air thebitfilmdirecity it.reavel by primary it where strikes pri,i"iv aitfloi is controlled a through rt'ri tre'ii;"q, ot by dirbcted droprets theimpact "ir. ?rgui"tor.in.pii*"ry uirir nor*ally smallquantity by activated the.on.,5ornJ cup'A damper as the rotary the rotates airin thesame-ctirection operation' a swirlringwhich during coor burner keepthe is air primary (Tertiaryatr)Jir..tuoto of of distribution the tlre box, the_wind where uniform t,o The air guidevanes' Thesecondarv is supprirg *iin ,rnr"r),'n6irl;i'p.-lr''d;J fixed ov a,,7Fa.hieved a rad,iat secondary air adiustable vanes' by into frame individuaity air combustion is guided ltre to contributes which factor important air of thesecondary is themost control correct burner'Draught of turn4owi-rt'ng' th.e' efficir..v th-rolghout-the the highcombustion to the compound au*piitointtted of ,rro,iJ"iy air by is contror performed means a regulatorestablishes the 1o%of totalairrequirements' airinto tess"than "'^l!{"lLro airrepresenting primary high nizztoconvertsJhe piessure the airflow frameTh;;; irrv air primary rotate a stabie r*in btades Jaiottudes"rnr ttrrougrr, thei air, highverocity vrlhich fi;;; fuelburner' by ronuderivered the to'tt direction ui of tn. o'ir in the oppoiite air SecondarY air g07.oftotar combustion requirements' about representing airfrow, to Thesecondary dimensions suit ancl seconoluu!"1, of .orir.t rn"pr secondary to the ,urpunJed a air is usedto estabrish the swirrvanesJeliver as shape, oirru**d earrier. furnace the combustion conrplete to manner promote in furnace thedesired

r{

'l
I

Htfffo*t:rean

any scrapper Do notuse any (caution: smooth without cuts. andclean' dustandcarblnoeposits fordirt, scanner checkflame Monthry: witt notfunction!); interc;;;;'g"i,tie photocett --rf the two cabre connertiii, ib air & Primary secondary switches; interlocks; TestsafetY tube& electrodes the Clean igniter of the Check conditiorr refractory'
YearlY: bearings' burnermotor/shaft Clean& lubricate air Cleanall combustion ducts'

and be of cuprTtustclean edse oil (sharp in thefront ) therota'y cup or anyhardtoo

168

ROUBLE HOOTING S
frouble Indlcatlon Possible ause c lgni ti on burnerf aul ty. Dirtyelectrodes. Too high sec. air pr6s Faul ty burnercontrol . Faul ty transformer. No pi l otfl ame. O i l v/v not opened. O i l prl temp hi gh/ow . B l ockagen oi l systcra i Remedy

No lgnltlon/fallure of lgnlt l o n fl a me

CheckolUalr setting Clean/re-adJust. Close damper" air Check& repair. Replace transformer.
See above Check air pressure. Checldadjust. Check and rectify" R al seoi l fl ow l emp.

M aln f la m e fa l l u re dur lng l g n l tl o n

Unslable mafnflame

Oilllow/temp low. too primary Toomuch air. Cupdirlyor damaged.

lmproper temp/visc. oil lnsul fi ci ent r suppl y. ai I ncreased l urnaceand/or u pl akebackpressure. Poorqual i ty f uel . of

primary Re-adjust air. Clean replace or cup.

Check and re-adjust. Check and re -adJust. Cleanthe gas passags tu rsmoveblockage. Can not be ellminated by adjustment"

B lac k s m o k e / In c o m p l e te c om bus tl o n

PROBLEM ProblemsIn' the botterdue to feed watercan be categorlsedas: 1. corrosion 2. scale formation 3. carry-over I N T E R N AW A T E R S I DC O R R O S I O N L E Electrochem I Corros n ica io lf the hydrogen concentration ph)is increased, rateof corrosion ion (low the . woulcj increase since there u/ould moreH*ionsto receive be elec,tronscathode. at Themetal combines tlreOH'ionsto formatoms ferrous ion with of hydroxide which dissolves thewater in thuswasting rnetal the avvay. Therefore, electrochemical corrosion withcathodic anodic cells and areas have wiil a currentflow through electrolyte anode cathode backthrough metalfrom the from to and the cathode anode;during process, to this material anode transferred'to etectrolyte from is the resulting corrosion theanode. in of F O R M S F E L E C T R O C H E M I C A LR R O S I O N S O CO 1. 2. General astage W Pitting a. iAirbubble pitting b. Scabpitting
169

1.

Corrosion TYPe Wastage Genera!

nature of 'ii'iprie! corrosion a morer'irniformover is wastage a termexpressing.electrorytic Generar reouctionin metal thickness attack tt F-qg. it rather than serective constantly surface ine riinur. Here, anodic un',Torm in large the present' comparativery areas lis oxygen irea. lf dissolved occurs attack hence "Jiirrv over position, of changes the absence and "*iou of ir;;;;;yed by formatioi'' v*,ater euehln values rayer porarising hydrogen below ."n'i"[r pru"ewnenwaterhaspH this oxygen, formof corrosion dissolved 6.5. 2. Pitting formof another corrosion, typeof electrochemical wastage Apartfromthe general due undercorrosion to termed whichformpitson the iretif sr*a.e can be corrosion of Therearetypes typecorrosion' pitting or absorption simpty aeration,,oxygen erential diff pitting corrosion: In in drum theboiler. theairbubble -f of pitting ound.il roof steam (a) Airbubbre the lhg ort*ren theoxygen under surface reach is action initiateJ an typepitting, erectrorytic it By irioxygen' experimentis are which lessricn waterareas and bubble thesurrounding it to inaccessible oxygen' becomes puitiurly of foundthatit a portion a metarbecomer cell' to actitecorrosion rise on levels asurface."n-tiut oxygen and anodic so,differential a forming semioverthe bubble, settle product as The ferrichydroxide the corrosion when oxygen pasrugrof ionsbutnotoxygen' permits.free -o..ur, which ,i.,emorane permeabre the metalunder thuscausingihe .uirent. or ,,ruurrui galvanic a getsexhausted, proceeds' corrosion ,,cap" noble andhen.. niintylocalised less occursin hotterareasof product (b) scab pitting - A hard cap of corrosionrowtubes' is Thehard'blackscab side on found tl-re of thetire moltty surface; generating difficulttodetect,removeandarrest,onceinitiated. WATER oF BOTLER & rN scALE FoRMATIoN BoTLER TRE,ATMENT IN SCALEFORMATION BOILER outofsolution cotlle which satts of various due in scaleforms boilers tothepresence anddensity' oi of because the effects temperature anddeposit of the surface, evaporation waterinvolved formson a heating bubbre when steam noittloittolve lvhenthe bubble 6t sorng *ni.n uo of sorids, rocarconcentration formation causes Repeated oi.rvrl"rr oTthesurface' to but escapes, remain, formsmailcircres of layersof different in often-foiming a series products of these,build up the s.ar, oepoiil, inrieares tnept-$n.e of corrosion u-y of rate ,.irloimation insulating compositions.lh; givefurther but the increase rateof sciting, also wi1 Thelatter notonry andoir. ect. eff

170

Composltlonof scales of showsthat the chiefconstituents hard scalesare calcium analysis Chemical is sludge composed loose the while softer silicates, magnesium and and suphate, calciugr products ironand of Corrosion hydroxide. inrl carbonate magnesium of calcium il;t in are copper also,found scales" Effectsof scallng are: by caused scaledeposition results The serious i) ii) heating across due reduces to poorheattransfer of The efficiency the boiler surface. withpossibility of overheating tubemetal may heattransfer, cause Lackof prqper of of the reducing factor safety theboiler" in and of distoriiori failure, effect

SOLIDS DISSOLVED OF NATURE SCALEFORMING can of solidsin the waterwhichcan leadto the formation deposits be Dissolved groups: ltardness in divided thethree a) of is hardness, due to the bi- carbonates or Atkalinehardnes.s: temporary

in alkaline nature. (Mg), which slightly are (Ca)& Magnesium Calcium then which carbonates COuandcorresponding torming Iporrheaiing, decompose These /' or as deposit a softscale, sludge. Ca(HCO.), CaCO.+ CO, +t-{rO are salts, hardness as Sa/fs:alsoknown permanent Hardness b) Non.Alkaltne of and silicates calciumand nitrates chlorides, of due t; the presence sulphates. magnesiu'Tt" hardthe sulphate, permanent and of Withthe exception silicates the calcium theyare produce but scale, and in are nesssalts allverysoluble water donotnormaly action. by corrosion galvanic favours therefore, andtheirpresence, electrolytes (CaSO) is the worst scaleformingagentin the water, Calclum Sutphate 140 above deg.C, or at densities grayscale temperature at hard as depositing a thin, 96,000 above PPrn. Whena of with of Solubility thissaltdecreases a risein temperature thewater. process alocal causes the surface evaporation on is bubble forrned theheating steam In the in of concentration soliCs the watersurrounditrg bubble. the cdseof CaSO. formsa hardgrey and reached thissolidprecipitate pointis very quickly saturation surface scaleon the heating

171

but conditions canto some normalboiler under Chtorideis soluble Magnestum (which hydroxide to formmagnesium ths inside boiler $enoljjs.3s breakdown extent withthe action corrosion can acid-this sefup an active andhydrochloric a softscale) metal. boiler l-lOl MgCL,+ HrO= Mg(OH)r+ as salt, , hardness by itself deposits I is whiclr an alkaline Catciumcarbonafe, and of carbonate scale forma composite whitesluogsbut with casoo present, softsr' pr{)grsssively the makes scale percentage carbonate of Greater sulphate. especially.when in andis alsopresent theplant, water in Sillca-is founrJ most flux' In low sandandwelding casting (dustparticles), detritus nsw,fromerection and magnesium to formcalcium with SiOz combines Ca anOMg pressure Ooiters silica boilers, and whichcan precipitate, formhardscale.In highpressu.re silicates the efficiency; loss.in severo causing in anddeposits turbines, wirh volatitizes steam toremove"At highpqformance hardanddifficult exteimely scatetaregtassy, silica recommended value over content (highest silica not of say100bar,rnust have boiler, by DrewChemicals). saltswhichremainin of mainly sodium Sa/fs:Theseconsist c) Non-Hardness at out lt density. cancome of solution very boiler under norma! and solution, do notdeposit as ppmanddeposits a softincrustation. 225,000 above highdensities and quantities in water verysmall in maybepresent thefeed salts forming scale Other neglected. canbe generallY of Nature the scaledePosit are: deposits in found scale mostoften The minerals (a) (b) (c) (d) (e) carbonate. Calcium silicate. Calcium hydroxide. Magnesium silicate Magnesium sulPhate. Calcium

deposit' in of amount ironandcopper a scale a possibilitygetting large of is There also copperfrom the circuit; Bothcopperand iron are pickedup fromthe pre-boiter tanlcs. piping andstorage and condenser ironfromthe service evaporator OF TREATMENT WATER a,nd corrosion scaleiformation to has and Boiler thefeedsystem to be treated inhibit particles must gas, in the contaminants formof metalsalts, oil,suspended ittpossible anO treatment. and and against thisis doneby bothextsrnal internal U. gu"'rOed

172

in rnost Contaminants cause tlrat trouble theboiler: frrcm Contaminants Sources External theShip to 1. 2. 3. 4, 5. 6. salts Calcium Magnesium salts Chlorides Silica Carbon dioxide Oxygen from Contaminants Sources I n s i d eh eS h i p t 1. 2. 3. 4. 5. Oir lron Copper Carbon dioxide Oxygen

External Treatment givenbeforefeedwaterentersthe boiler. This refersto the treatment In bothhighand lowpressure waterusedis normally on the systems board, boilerfeed good qualitydistilled water obtainedfrom evaporation sea water by the distiller. of The evaporation itself is a processof gettinErid of many harmfulconstituents by but the make-up feed producedby the evaporator does entrainsome of the salt water particles producean acid feed water rich in carbondioxide. and The feed systemis also proneto atmospheric contamination variouspointsof the feed system. at Evena very good qualitydistillate may not producea pH of morethan 6.5 and would containcertainamountof sea salts of Ca and Mg whiohrnaycauseproblem. In high pressuresystems atlove 20 bars, a mechanical deaeratonby having a Deaeratorhelpsirl'r Imoving mostof the oxygenand the treatment completed is withliquid hydrazine The problemfrom COnand acidityis countered dosingr the deaerator at outlet, pointin the by dosingamines(morpholine monocyclohexylamine and or CHM)at another pH feed systemandramildlyalkaline condition be easilynraintained. can For a lower pressuresystem,the feed system is of an open feed type and the problem provided dissolved oxygendoes not causea serious correctalkalinigis maintained. The make-upwatershould a goodquality be distilled waterwitha lowT.D.S.and the wouldhavesimplefeedfiltersin the hotwellor the cascadetank to keep systemnormally The hotwell under control. should contamination temperature alsobe maintained above60 oxygendeaeration to 70oCto prornote throughthe open vent of the honryell tank. In some auxiliary boilersystem,raw freshwatermake-upis used.This watershould be 'soft'and have minimum 'hardness' of saltsof Ca and Mg. low system,the boilermay expectto have contaminants But in all auxiliary pressure products. gaseous saltsplus a goodamountof harmful of calciumand rnagnesium parameter' limitsare moregenerousin a low pressure chernical The reconrrnended prevailing; the boiler system due to the low heat rate and lower rates of evaporation moderate and someof the salts, low pressure boiler alsoremains the temperatureswithin less of a problem. constitute with higher temperatures whosesolubility decreases down into injection the boilerand regular'blowing of consists chemical The treatment while keepingthe boilerwater within a safe sludgedeposits to removetlre precipitated densityor T.D.S,level,
173

Treatment lnternal
waterandthdchemir:als given llr boiler of to Thisrefers thefinalstage treatment lo obje.ctives: for proper thefollowing lntolneboiler are doged oxygen of and iond-ition removal dissolved att<aline waterin a siignity uoiler 1. t<eep dioxide' andcarbon whichmaybe in solution' salts forming any precipitate scale 2. To formso thattheycanbe sludge in solids a non-adherent 3. Keeptheprecipitated bY removed blowdown' easilY overandfoaming' of 4. Prevbntion carcy t."lF of the are which in use,serve dualpurpose precipitating.hardness Thechemicals hydroxide' sodium Thessinclude in tl'rat any andcounteract acidity develops ttrgsysiern. for'the chemicals f ApartromtheaLrove .uruon"ie. and phosphates sodium sodium various of iremoval sludge, for conditioning otherchemicals and provention scaling corrosion, of are scavenging also added carryover and oxygen preventing slightoil contamination, and phosphates alkalis' withthe along TESTING WATER BOILER level,excess Chloride for Boilerand feed waterare testedregularly Alkalinity, solidsor dissolved andtotal pH-value and phosphate hydrazine alsofor narJness, and conductivity. to one vary waterconditions fro.nr maker the other of limits boiler The recommended pages' in mentioned thefollowing the within givenparameters gsneraily but remainini is and leakage the solution S.W. indicates value andchloride of An increase T.D.S. the plus blow down to ireduce the sourceand isolate leakage the to identify leakage solids. dissolved sodaor sodium in dosing theformof caustic chemieal alkaline Lowarxarinltv ' requires
t phosphate. . - ^ !- - - . , r . . . r r ^ ^ . . n a needof hydrazone and de-aeration further inferior indicate reserve Lowhydrazine addition.

Hydrazlne lesf the To in solub.lewater. safeguard boiler and compound highly is Hydrazine a volatile Thebulkof the pump' a usinq, dosing it fromO,- corrosionis continuoutiYiOig{ system too watei.However,lif much of arr.ari'niivthebo'lter to the turnsinlo'r.rHliiH NoH. ammonia' to it "ioi.g temp. abovi 1750c, candecompose forrn at is of dosage NrH. added, bo]ter ---+ 3N2H1 4NH. N, of systemin the presence alloysin the condensate can attackcopper Ammonia be guarded]against. pprn shouid of of so, oxygen. presencs nvd-[linein e*cess 0.3 DlssolvedSollds of conductahce water lies Thebasisof thisdetermination in thefaotthattheelectrical itl in dissolved of andnature tfresubstance to is proportional the quality
174

per Conductivity microfrms cm at 200C 0.67= TDSin ppm. in x A permanently installed instrument be usedfortheabove giving can reading for direct TDS in ppm. H,ighly alkaline solutions tendto affectthe abovereading and for a more accurate result, (NarCO.) strongalkalis should neutralized be before test. ths Methodsof Drawlng Samplesfor Testlng Anywatersamples testing for mustbetrulyrepresentativethewhole, othenruise the of results wouldbe misleading. A sample cooler fitted withcooling is verygoodfor thispurpose. coil Before waterfromthe boiler runto wastefor a timesufficient drawing sample, the is to flushoutthesampling lines. collecting vessels The withwater should rinsed be twice to be tested, Samples should tested soonas possible be as after drawing. Problemsln Handllng WaterTreatment Bnd Testing Chemlcals Careshould taken dealing allchemicals inwater in be with used treatment testing. and 1. Concentrated lWlneral Aclds. Cancause extensive damage human to tissue, specially the B!s. to 2. ConcentratedAlkalls. CausticSodacan causeseveredamageto human tissue. Substantial is release heat whenNaOH dissolved diluted small is or and controlled additions c0nstant with is stirring recommended" Careful handling storing important and is as spillage causedamage theshipstructure. can to Hydrazone destroyed contact airandthefreshsample is by with (after filtration, if required.) should immediately be tested avoidatmospheric to contamination. of a Use samplecooler obtain to watersample between - 30 deg"C is goodpractice the 2A as waterandambient sampled temperature wouldbe similar. 3. Alkallnlty Test. The two part "p-alkalinity' and 'Total Alkalinity' tests reveal presence hydroxyl (CH),carbonate (COJ,andbi-carbonate of (HCO'), whicharoresponsiblefor making boiler wateralkaline. TheP-test actually finds presence Ol'.|, halfof carbonate thenext the of and and picksutl theprqsence tt:eremaining test of carbonate bi-carbonate. and ln a 'sample, OH and HCO3cannotbe presentsimultaneously. From the respective readings, tairjudgcment be madeof the identity salts,(e.g.NaOH, a Can of NarCOr) responsible alkalinity thesample. for in 4. Chlortde lest. Thisgives quickest indicaticn anysaltwater the of leakage into theboiler andmustbe oarried dailly" out 5., Phosphate Tesf. Presence phosphate sample of in means there won'tbe any hardness saltspresent. Na.PO. is The added theboiler veryefficient preclpltatlng in to all scaleforming hardness or saltsof calbium magnesium. witha phosphate done, So test thereis no needto do a "hardness" test. has is 6. pH-Value.Once alkalinity beennteasured titration the with tests, there no needto checkpH-value alkalinity pH-value proportional. Howe',rer, a quick as & are as compared reference, litmusstripcan be usedusingraw sample a and colourchange givenon the litmus caseto indicate possible the rangsof pH. against ones the
175

n
LIMITS CONTROL RECOMMENDED
Bollers uP to 32 bars

fr
of Means Adlustment
< 1.0 1 0 0- 1 5 0 200- 300 20-40 0 . 1- 0 . 2 300 500- 550 10.8 11.3 700mmho/cm

Totalhardness (CaCO.) P-alkalinitY (CaCO.) TotalAlkalinity Phosphate Hydrazine Chlorides T.D.S. pH-value ConductivitY

GC GC B Adjunct Amerzine Blowdown

tn

TREATMENT OF ADVANTAGES CHEMICAL and problems try the be should to minimize abovo treatment of Thefocus anywater to: surface' heat-transfer scale-free a a. maintain clean, lossdueto corrosion' metal b . prevent or foaming carry-over of production steamwithcutpriming, c. ensureefficient contamination. systems' in of formation deposits steam/condensate d" prevent fromboilers' blowdown excessive heatlossthrough e. minimize cost it of the above minimum andbestefficiency' f. acfrieve-all and p(power) h(H.ion conc') irr pH-value a measure aci"lity alkalinity water. or is of ion of the hydrogen concenof is whicQ th6logarithm tne reciprocal the makes pH-value in tration water.
$+ 1 0 - 5x OHs 1 0 - e o l u t i o na c i d i c ' Ph = 5

h h h

10'7x 10'ex

Neutral' Ph= 7 10'7 solution Alkaline. ph = 9 10's solution

1.

TESTPROCEDURE SAMPLE. AFTERDRAWING pH CoNDENSATE TEST: TESTIMMEDIATELY and sample pourintodish' condensate 1. collect50 ml cooled 2,Add3dropspheno|phthalein.Sarnp|eshoyl!turnpink dropby dropuntilpinkcolordisappears' acidf.fliO 3. Addsulfuric adjustment" to 4. Refer chartfor dosage TEST HYDRAZINE two every weeks. Reagent prepare iresn Hydrazine bottle' A Reagent intoamber of onecelpsule Amerzine 1. Empty and cyrinder add to the graduated B 45 z. Measure ml of A[erzine Reageni in a in Powder amberbottle'

2.

176

3.

' rr: Shaketo dissolvo. Keptightly in closed a coolplace. AlternateMethod:Measure1 plastlcspoonful Hydrazlne of RsagentA. Measure and add 45 ntl Hydrazin out Reagent B. TESTPROCEDURE: TESTIMMEDIATELY AFTERDRAWING SAMPLE.

1. 2. 3. 3.

Collecta coolodboilerwatersampleand fill amerzine tube to 5 ml mark. test Add preparedHydrazine Reagent 10 ml mark. to Compare bolorwith standards block.Referto chartfor dosageadjustment. in

EXCESSPHOSPHATETEST 1. 2. 3. 4. 5. 6. Collectand tiltercooledboilerwaterto 5 ml mark on phosphate tube. test Add molybdate 17.5ml mark. to Add one brassspoonfulDrv Stannous Chloride. Stopperand mix well. allowto stand3 to 5 minutes. Compare'color standards block. with in Fleferto chartfor dosageadjustment.

'T. PHENOLPHTHALETN ALI(ALINITY ('P") TEST 1. Collect ml.of cooled 50 boiler samole. 2. Pourintodish.Addfourdropphenolpthalein. ,'p" 3. PinkcolorAlkallne. color- alkalinity No zero. 4. Add sulfuric acidN/10untilpinkcolordisappears. 5. Notethellevel ecidin buiet.convertml to ppm usingchartat rightand record of result ppmas"P"alkalinity. in Keep sample lor'T" alkalinity Reter chartfor test. to dosagoadlustment. 5. TOTAL ('T') ALKALI$IITY TEST 6. Add 3 dropsTotalalkalinity Inclicator-cP. 7. Addsulfuric pinkcolordevelops. acidlrl/10 until 8. Noteths levelof acidin buret.Convsrtml to ppm usingchartat rightand record resultin ppm a{ 'TotalAlkatinity". Koepsamplefor Chloride Test.Referto Chart lor dosageadJustments. CHLORTDETEST 9. Addonedropper Potassium lull chromate Indicator. 10. Add silvdrnitratoN/10untilfirst permanent yollowto red browncolorchange. 11. Notelvelof silvor nitrate buret. in convort mltoppmusing chartatrightand record resultIn ppm as chloride. Refsrto chartto adjustblowdown. CONDUCTIVIiTYTEST 1. SEEMETER INSTRUCTIONS. 2. Fillcylinder 100ml (top)markwithcooled to boiler sample. 3. Add2 drgpsphenolpthalein mix. and 4. Addgallib acidto pinksanlpte,w mixing, hile untitcolordisappears. 5. Measureitemprature sampleand adiusttcmperature of dial. 6. Rotrate conductivlty untilboth tightsremainlightedat the sametime. dial 7. Referto chartto adjustblowdown.
177

:l

6.

l 'l

7.

CHART AND DOSAGE BOILERWATERTREATMENT CONTROL psig,3200liN/m3) (450 Equipment up to 32 kg/cm2 steam Generating
(control OF MFANS limitrin Bluel oos{ef CALCULATIoN RESULTS TEST AtUUSTMENT
NO PINKWITHPHENOI.PHTHALEIN CONDENSATE PHTEST BY INCREASED 25J6 SATISFACTOTY NOCTIANGE ]BY DECREASEO 25*

sLcc-A
Condenrrte Corrorion lnhibibr

COLOR PINK TO N/IOACIO CTARIFY I.2 DBOPS OR PINKCOLOR-3 MORE N/IOACIDTO CI.ARIFY DROPS 0.15 10.3 D0SAGE LTR PTIX T0NS= lNlTlAL
l,fSSTHAN0.10PPrn

NSEDBY2515 INCR SATISFACTOTYNOCHANGE BY DECREASEO2595

ppm 0.10 0.20 HYDRAZINE TEST AMERIZINE Corrosion lnhibitor 0.20 OVER pprn 0.15 (0.3 lNlTlALDOSAGE LTR Pf l XTONS=
0 - l0 pptt l0 - 20 ppm

30 gm (1 oa x TONS
r
,

i
l

15 gm (0.s Oa X TONS
f

PHOSPHATE TEST

ADJUNCT.B Phorphcte Watrr Bciler TreaEnent \ 20- 10ppm 10+ppm st ll lNlTlALDOSAGE GRAM 0Zl X TONS= MLSULfI,|RIC N/to ACID 0-0.3 PPM 0-3 l0 - 70 80-m lm- lgl 150+ 0.15 hr. (0.3 PT) X TONS
I

SATISFACTORY

i mrcxBLowNDowN I neouceDosAcE

.P- ALXAUNITY TEST

0"t-ot GC Concontrrtod Alkrlinc Uquid 0.E -0,9 1 . 0 -1 . 5 1,5+

0.10 ttt. (0.2 PT) X TONS

r

0.05 hr (0.1) X TONS SATISFACTORY HIGH. BLOWNDOWN REDUCEDOSAGE IF NOT, OOJ I LTR (2 PTS) OF GC OF REGAHDLESS THE .T ALKALINITY. TEST AEilIN IN 2 I{OURS

TOI'ALATJGUNITYTEST THAN MUST RESULT BEI.ISS AUqUNITY, TWICETHE'T

178

SA'I'ISFACTOBY NOBLOWDOWN CHLORIDE TEST

BLoWDowN
UP 7$ pmhos T0

Blovdown should carried ar perbcfler be out manufacturer,s instructions. Elqrdownir necermry roduce to dirrolvsd and suspended solidr" lf rrponded rolidrarenoticed boirerwaterrampler. in blo,vdo$rn regardless of chlorides rerultr. test weekfy flarhblowis advirable remove to normal sludges to ensuro and clear operational lines.

NOTE: - NO LIOUIDI COAGUIAMT TEST REOUIRED Daily dosage ml (1.0 ounce)perday for eachton of watercapacity 28 to condition suspended sofids(oiland sludge) removal bottomblowdown. for by Flashbottombfow and scum blow severaltimesat 20 minuteintervals afterdosingthe liquidcoagulant. Dosetor 2 weeksor untiloil renioval compete. severe is lf contamination persists, the possibifity continulng leakage of oil shouHbe inveslijated and etiminated. WASTE HEATBOILER PROBLEMS ANDMAINTENANCE Probfems exhaust conomizer bo classified in gas can under categories suchas: a. lowtemperature end corrosion. cqld b. fouling the gas andthewaterside. of c. tubefailure dueto vibration. Gassldefoullngcould keptunder be controt wider by pitching in-linefitting or finson to ther of tubel and use of regular soot-blowing lube at individual tube' ;il:;. ffi! quality combustion goesa longwayin reducing the arthough the qualityof fuel is constantly "roi,ni;;1'giilpol,r, oeteriorating, propercentrifugirg woutdbe helpful reducing harmful in the combusiiod "rfJ-tl"iirrnt shipping piocucts promoting fouling. Many companies somefueltreatment use chemicals reep the harmful to contaminants under control' Tubeexternals would getfouled periodic still and cleaning water by washing the is mosteffective of keeping tubeexternals way the clean. Cleanin! eitnlr donethrough il fixednozzles inside boiler the banks donethrough or spgy nozztes connecting and pipes which moved are around required. as Water about at oooO ihouldbeusedtor cleini;g 5ro precautions should taken ensure thedrained be to that water '"'v' acidcontent not withhigh do flowintothe mainengine exhaust cluct.

179

of to attributed the poorguality. feecl Waterslde scalingand corrosionis mainly haslesscontamination.ftgt arrd with waterused.lf ths waterusedis alkaline lowT.D.S. But, giving_ any.problem. the run tubesshould for longtimewithout boiler o*igrn, tubular and hotwell scaling/corrosion system the waterusedis normally waterfromtheopenleed and improvementrs reasonCertain completely. to problem would impossibte overcome be and content chloride the by be period however aclrieved keeping T.D.S. could ablerunning chemicals of and and blowdown chomicaltreatrnent dosing appropriate level byi6gular low be leveloould kept condition;oxygen in the iould maintain water analkaline (e.g., NaOHI temp. thelhotwell (hydra-ine) keeping and treatment by margin chemical witflin acceptable the draining boileror whilestarting, precautions venting like operatiinal high.Certdin corrosion. wouldhelpin reducing down kelpingit fullup,as shutting cleaning. by cleaned chemical onlybe effectively watersidecould Fouled are made boilers Modern a fromvibration sometimes problem. is Tube problem box-type partof tlre uptake. The supporting largeand takesup a sizable considerably is arrangement too rigid' rigid.lf the fairly are of casing builton i system beams rnade and steelwork support l-'leavily stiffened problem failure againpossible. is fromfatigue to solution avibration gasstream. There noeasy is tne ect do casings reduce eff ofpulsating stage. at problem it starts, thisis a problem considered thedesign better if but mai steps lmportant ntenance 1. 2. 3. 4. Regular blowing soot goodmain combustion engine Maintain methods f and centrifuging otherueltreatment Adhere correct to on treatntent the gas side (e.g.,soot chenrical Takeadvantage additional of etc. sticks, procedures and water treatment testing 5. Correct temperature right 6. Maintain hotwell exit particularly rnonitoring gastempfromthe EGE in 7. Vigilant\watchkeeping, of wash portinspeition manual/water cleaning the gasside and in B. Rdgular g" Coirect etc. by-passing, sftutdown, in of operation terrns circulation, OF ANDMAINTENANCE BOILERS SURVEY of to Boilerare surueyed maintainthe classificatiort a ship.Regularinternaland schedule maintenance the surveyconstituta preventive duringsuch examination external condition' for theboilergoes through t safeworking OF FREOUENCY SURVEYS boilers All intervals. other at2yearly propulsion are boilers surveyed Water tubemain yearly until intervals theyareI yearsold at2 gas are exhaust boilers surveyed incf uding annually. andthensurveyed may of For auxiliary boilers watertube type,the classrfication allowthe 2-year period. . of the even after expiry 8 years to inciden:e continue
180

SCOPE SUHVEYS OF A complete boiler survey allows to check if anybuildrrpof deposits taken us out has place, anddeformations wastage platework, or of piping E,1t thevarious or of parts, which may compromise saieworking the orderof the unit.ine.survey should inciude iinoing reasons anyanomalies for found andshould atsoensure anyrcp"ircarried does that out not affect s,afe.working cf the hoiter. compiete the order n survey meansful internal and external examination ail partsof the boilerand accessoriei of suchas superheaters, sconomiser, air-heater and all mcuntings. examination leadthe surveyor The may to require hydraulic te.sting pressrtep.ais or thickness of gaugings plateor tubesthat of appear bewasted ev'entually to and asiigna lower working pressure. collision The chocks, seating stools androlling staysarealsito be checked goodworking for condition. Thesurvey notconrptbte theboiter beenexamined is untif has under steam andthe following itemsdealt with: 1. pre.ssure gaugechecked against testgauge. a 2' testing waterlevelindicalors protictiiedevices. of and 3' safety valves adjusted under steam oio* otrrt therequired io pressures; 4. theoil fuelburning system examined. 5' testing remote of 6ontrol gearforoil fuelshutoffvalves" ARRANGEMENT BEFORE SURVEY a' Boilerl rnust sufficiently be cleaned driedto makea thorough and examination possible' Sludge d.eposits continue be the primr mrrc of non-operation internal to of

Incaseofdifficulty manual.cleaning, in a chemicat cleaning hydrochloric plus with acid an inhibitor prevent attacking rietalwithout to acid the affecting removal deposits the of is bestprocedure. For oil contaminaticn, alkaliboil-out.using trisodium phosphate sotution (which produces detergent a action). essentiar tiacid cteaning. is prior A thorougtir waterftushing mustbe carried afteracio cleaning avoid out to acid concentrating crevices clptivespaces. in and b' Alf internals whichmayinterfere the inspection to be removed. with has c' whereveradequate visuatexamination hot possible, is surueyor may have to resort drilling, to. ultrasonic hydraulic or testing. d' All manhole doois and otherdoorsmust be openedfor a reasonabte tinre previous sunrey ventilation. to for e' lf another boiler under is steam arrangement locking andother of bar security devices must in posjtion be preventing aomission steam hotwater ine of or to the boilerundersurvey. The srnoke. trilnking devicel,exhaust-gas lseparating shut-offs mrrst etc. alsobe jn pos.ition ploper working condition. f' Ship's staff repairer's should "no"in manhole iase of emergency or staff rt"nJ6v tii* in andto noteanyrepairs required. SURVEY SUNROD OF CPI{TANKBOILER Poorcondition thistypeof boilermay stern in from: Poorwerkmanship during constructionrepair. or Deterioqation to leaks deposits. due or

b"ir;; should $.i[gr:,,illiJ:i!:,?ilg fl:H$?i?,j:,1:;,,;;i Boirers bemanuany

181

Localoverheating' andcorrosion' stress of effects mechanical Gornbined up wouldshow lntheformof condition Damage 'grocving' or corrosion or'pitting' wastage, or distortion crack. SurveYBoutes Almost mustpr1l out a route.for Jnollement' the fis the Any boilerto survey, inspector reveals furnacs the The,r"ron being, mus.t the arways, inspection start tnef urnaci.o]ltogo.nat the crownor the tube walls "t aiv or quarity comLrriionano itJerr.tJ ano withno wai;r side.In fact,a goodcleanrlurnace the signifying prourrrs originating condition' goodru.nning ttie inspu.toiin"iin" boileiis-in aJsure "1tne coutd signsof distortion bottom' and header theboiler the be should theburner-unlt, bottom Thenextin succession the is madethrough beforeentry on attachments tn. iJnllsheil *iil lorrow Mounting wil be checked ;p".r. Top mountingl the to manhore inspect watersibbor the ri;;r tubes' doorfor a lookat the sunrod the entering gas,p.., iniorgntheinspectibn mounting before in order partsarranged the Jnd The inspection-will witha check-on dismantled thegasuptake be could done on checks oig,, side.orro.ion, rf forthepurpose. in doubt route" as a finalstePin thesurvey I. FURNACE

or of t9.a is crown duemainly deqosit oil'scale on distortion thefurnace overheating impingement flame Direct shortago. to 6n oeposiis theneatiigrrirr.r orduie water sludge the opposite burner in witt tubes of in resulting oeioimation the crownot rro..l bulge around u-+hapedareais the crown of rf is opening arsopossibre. ih; to*., section the boilsr overheating causing bottom on the deposits be it affected, could dueto thesludge to u is conrrected the shell'theremayalso In distortion. thesam, .rr.-*hrrc tFefurnace of results stresses' mechanical oiin.rmal and due cracks to rapidfluctuation be welding downprocedures' itartingup/shutting improper can deformation be iackedbackto a whichhavesuffered gradual crowns Furnace to the may deformation require plating witho, *iifiort heat.lsnirper shape theiroriginal Theslot heatin6,and Jacking' inio g.p during so be srotted thatthemetailanextrude fi; areaand 6rtn ouitne aifected repiit is to A is buttweldedon completion. muchnr.iri For furnace' a severely cut insertsection froma satvaged with uuttwerdeJ replace be'theonlyanswer' could Gtty, replacement large with pionounced furnace damaged " " by tubescaused flameimpinge' or crown thefurnace mouth, in Drycracks furnace Areas of sideandforcing theboiler' water encrustationJaiihe due mentispossible toscale to areasare alsosusceptible the ;a frompoorcircutaiion; rrt"ti'i.! unrooiro suffering failure. above up end,opening a by be shourd stopped driiling hgleat each on cracks prating Deep andthenwelding.
182

Indifferent watermaycause feed pitting thefurnance of crown. careful A examination through bottom the manhote doorwouldbe required detect above'grooving' to the Furnace tubesmustbe inspeeted correct for alignment thetubes and together must forma circular tub6wall:anywhere tubes deformed, furnance the are the shafie show will up as missaligned. Distortion a verysmallextent to couldbe accepted, beyond but that renewal tubes be mandatory. of will Furnace (cracked, hoted deformed) or needbe renewed new with lube , if damaged tubes;only under emergency conditions, could allowed operate one be to boilerat load, tow *'.thplugged furnace plugging tubes; could carried withtapered be out plugs ejch steel on tubeends.The, plug botto.m will haveto be inserted through bottomheade]; thd difficulty in doingthat may also compell cutting windows tubis from the furnance on end and manipulating tapered the plugin position (similar thatdonein membrane boiler to walt panels). Brickwork protecting foundation,damaged, oause the if may distortion thebottom of platingunderneath furnace. the Damaged brickilorkne'ed removed inspectthe be to plating distortion bottom for beforerepairs the brickrruorkuarried to is out. on should chipped be cteanbrushed llY signof corrosion plating clear.lt is also possible build.up weakened to the. aieasby means'of electric weldinj.-eittrd areasare difficult protqct to fromfurther corrosion to the difficulty maintaining protective du6 in thc magnetic oxidelayer. II. BOTTOM iHEADER

This contains furnace the tubesand the downcomertubes" of handhole lrlo dcorsare provided illepal.inspection repairs thetubes. for and to Inspection deposits sludge for of must be carrierJ during.th.e out gurvey. Regular utowinfdownfromthis header be will necessary keepit clearof sludge to deposits. III. SUNROD TUBES Internalwasta$e towaterside due corrosion pitting themainreason renewal. and is for It isdiffucult tq'determine conditiorr tubes visual the of by eiamination thetubes and suffer rnore endstowards fire;A metal inserted thetubeendsandworked at the rod at uporCo*n mayreveal weaktube- a method a sometimes employed tubesselected random. to at The reason corroded for tubes almost is always badquality the feedusedgiving rise to heavy scaling andcorrosion. Thermal cracks maydevelop thetrrbe at endsat the hotgas entryzone. Theelements could corroded theoutside to thehotgascontaining be on due Sodium (Na)andVanadium referred as hightemperature (V), to corrosion;Tn collection ash this of containing andV maypromote Na nrelting oxide of deposits across tubesandcause the scoring metalat thetubeexternals. of IV. SHELL Internal examination madefor cracks, is corrossion wastage deformation shell or of plating.
183

Any oil tracemustbe removed alkali-boilout. at may be expected by Corrosion positions poorcirculation places with which and canharbour deposits. r \ where Pitting in corrosion wayofwater for, level bechecked speciaily idleboilers on to gaswas not removed liberated fromthe boiler withthe steam.Boilers wlth left Hissolved pitting. undisturbed waterlevel somelength timecandevelop for serious of External corrosion be caused persistent can leakaEe mounting flanges and by at manhole handhole or doors. room Engine floor may underneath boiuer haveoccasional the bilge water possess damp and a rags atmosphore; mayalso oildoposit stored there be and or paints drums; theseareall potential hazards. The wastedshellplating may be reinforced welding in case of extensive by but wastage, renewal plating the onlyremedy. of is V. SUPPORT ANDSECURII'IG AHRANGEMENTS provision Attachment between boiler ship's for and structure should haveadequate expansion. Restriction movement of imposes loaCs the connections if the partis on and unable yieldor bend, to cracking occur. will Weldedattachments suchas cradles, feet and rolling stay lugsshouldalwaysbe inspected carefully. Cracks due to stress concentration the weldedconnections at may propagate the shellplating. into VI. MOUNTINGS FITTINGS AND Majormounting removed, are dismantled inspected. and Gaugeglasses, safety valves, feedcheck valves, steamstopvalves, erll for are checke'd corrosion, erosion, stength pipes inspected oxygen andcorrect operations. Internal andchemical feed injection are for pitting corrosion. pipes hammertested alldrains the exhaust and Waste steam are and in systemchecked. Sootblowernozzles vulnerable burning are to for and to lbe checked pattqrn. airregisters to be checked cleaned. correct sweep The are and at Clearange the manhole and mudhole doorsto be clrocked and shouldhave a spigotclearance not exceeding mm all around. 1.5 Leakage frommanhole doorshasbeendause serious of shellwastage. Where is exceeded, clearance be restored building the this the can by up doorspigot withwelding hand-drossing suit. and to of landing facesis difficult rectify welding fitting false to by a ..Wastage manhole sealing could therecommencJed ring be repair. A careful is stripped slacknutsanddistorted and check made strained lor doorstuds, pressure. doors A badfy . fitteddoorcancausea jointto blowout under Vtr'hen under steam, surveyor the always if checks manhole doorshavebeenpulled up whenhotandthedoors correctly positioned. are Crackscan occurin valvebody due to watercarry--over quenching may and or originate fromshrinkage propagating service. onlypositive in defects thecastirrgs in The solution to replace manifold is the witfr entirely a similar fabricated but Repair construction. by wolding defects thesteelcastings alsopossible thispresents problem the in is but the of distortion.
184

(D

o
S U N R O D I L F I R E DB O I L E R O
.a t .

Furnace

2 . Burner 3. BottomHeader 4, Boilerbottom

5. 6" 7. B.

Gaq1g6 Glass/ F.d. Fan Steam spac FurnacsCrowrr Uppor mountains

9. Gas Space tube 10. Vertical t 1 1 . S u n r o du b e 12. Gas uptak

T'ROCEDURES ROI.JTE SURVEY

185

,\ND SAFET.V BOILEROPERATION ouli it is firsttrrTre, to be boiled fo' removal for is the Before boiler putintoservice the and in impurities tubes drums' it*;Ofui anO of allprotecting O BOILING UT: 1. (Na. Phosphate Po.) 4-5 containing kgTri-sodium a solution is Boiler filleclwith

gauge' level in justvisible thewater and maintain pressure in pressure the boilerto working 3. Raisethe steam uirue, afiel which fat and to, the pressure 6-g hrs with crosedmain stop of surtaces the boiler' f;;'" snlutobe boilecJ theinterioi impurities other off andskinr the mrn is level 20-30 abo've scumfunnel surethatthewater 4. Make blow' scum through contaminants thefloating the waterin the boiler has out 5. Afterthe boiring operation beencompreted, illed treated withfresh now The is internar fluinecr. rroiieiis f out, isblown theboiler water normal br:low waterto a little to it to a shows tende.cy priming, is recornmended boiler the service, 6. lf ouring after a periodof 2-3 months out an extraboilingout..ln any case'. cara] for recommended is oui uoiling op.raiion strongly another commissioning, after newboilers. (withno "superheater") A porNTsro NorE wHrLESTARTTNGBoTLER: repairs)' (after closed-up is 7. checkthatthe boiler properly areshutor openfor safestarting valves g. check (physically) all approJri"tr that of theboiler. level. normal below filtelto slightly 9. Aoiter l0.Startingtreatmentchemicalsmaynowbeaddedtotheboilerwater. materials' of lnt andcleat furnace anyflammable 11. Check is clear. passage uptake 12. Eniurethattheboiler to of amornt timeis necessary cleartha ior pre-purging furnace a specifiJd of 13. explosion! starting to gases, avoid oiflammable gar-riOd up mustnctuespeaded too muchl1-119-:::.:tto the boiter, firing-up 14. on a cotd ralses' temperature uneven by ,nnrrcrsarily quick, mateiial the overstrain boiler (until pressure a out steam is florving iet a u.nt, of rn until hoavy the 15. Keep boile, using."tinf gearandtry outthe valves THEBoILERlS oN LoAD: To PoINTS NoTEWHILE

is until solution rvater the top with z. i:'Ji*tJf#ti,ii:';?tti?'tl''unnoruancJ up

saretv testthe the slasses' blow-throushsause isput 16. Blrl;l;ttfiSoirry ontoad, cutouts' safety
highest' is llhe its at the 17. Operate boiler a loadwhere efficiency of hazycolour a perf under ectconditionsbrownish air/f correct uelratio; 1g. Maintain fromuptake'. is smoke noticed exhaust the indicate in aS monitored the exhaustgas wilt 19. co, Co,, 02 contents the inside boiler. iondition combustion

186

20. Every morning mudis blorvn fromtheboiler through bottom the blow--off valves ichambers. andfloat 2 1 . Ensure thatall safety cut-outsareoperational. 22. Maintain feedwaterqualrty recommended the manufacturer. t[e as by BOILERDATAS SunrodCPFI-45 Capaclty OperatlngPressure DeslgnPressure Feedwater temp. Efflclency(F/Load) F.O.Consumptlon Watervolume Outsldedlameter Helght Dry welght BOILER DESCRIPTION Vertical design with2 combined steelcompartmenrscylinders or Lower cylinder contains furnaco the Upper cylinder usedfor steam evaporation of piping connects upper thelower the and cylinders forwater circutation 9Vstem Furnace watercooled is withriser tubes forming wall the distribution header the furnace at bottom supplies waterto the Fing shiaped furnace watercall 7. The lowerend of the uppercylindricat compartment dome shaped is which makes furnace the roof 8 . The bottom sUpport the boiler provided thesupport andsteelptate for is by ring fabrication 9 . The support is welded thedistribution ring to header 1 0 . Fluegas flowsthrough vertical the uptakes 1 1 . Verticaliuptakes contain sunrod tubes whichis connected thewaterandthe to steamplace 1 2 . Each vertical uptake itssunrod and tubes makes sunrod one element, acting as convection unit 1 3 . Fluegasis discharged fluegasreceiver thento theatmosphere into and viathe funnel 1 4 . Downcomer part tubesarefitted between lowermost of the pressuro the vessel andthe distribution header improve circulation to the THESUNROD EUEMENT {t . Thesunrod element consists a plainsteel of pin tube,enclosing Sunrod tube a 2 . Large pinsarewelded n,umber steel of around outside theseamless the of steel nin.tube
187

SunrodCPH-S 5,000kg/crn2 6.0 barg 1 8 . 0 a rg b 85-900C 85"8% 360 kg/h 5.7 m3 2,600mm 5,720mm 13,000 kg

45,000 kg/cm2 1 6 . 0 a rg b 1 8 . 0 a rg b 85-900C 81.4% 3,440kg/h 17.1 3 m 4,100 m m 9,660 m m 50,000 kg

1. 2. 3. I. 5. 6.

3.

in turbulence the areaandalsocreates surface tlre increase heating TheStuds the sunrod and making uponthe heattransfer improving gas flow,thereby \ plain than moreefflcient a conventionai tubing element capacity on depends theboiler elements of 4 . Thenumber sunrod

AND STEAM ITAISING CIRCULATION 1. Z. 3. 4. 5. of difference ordensity circulation of is Watercirculation on the principle natural feed water walltubes, tubes,the furnace vessel, sttnrod the the Wateroccupies pressure header tubesand the distribution the downcomer will heat of the frurnace of Understeadystateoperation the boiler,the radiation and the fluidwill risethrough water-wall withinthe createsteamwateremulsion header fronrthe distribution vessel,drawitrg the risersintothe pressure at a suctionisrcreated header, f As wateris fed intothe risers romthe distribution whichfeedthe header the downcomers the roofand lntothe sunrodelements; the risesthrouglr furnace The emulsion vesseltendsto be denserand flowsdown to water at the sidesof the pressure

6.

thedowncomers formedand the and steambubbles insidethe elements Rapidevaporation in rapidly thetube greatly fluid density rises decreased end, at effort thelower a creates suctiorr mixture flow 7 " Theupward ofwater/steam water flowintothetube to causing boiler the where treavier the space, into mixture discharged thesteam is 8 . Thesteam/water andfallbackintothewater particles fromrhesteam separate water and tubes therestby radiant the generated through Sunrod is 9 . 50%of thesteam heatfromthefurnace

G L AN E M E R G E N C Y DA B N O R M AR U N N I N C O N D I T I O N { i to on for lines an engineer dutyto respond emergency are Thefollowing theguide plant: in situation a boiler Highwaterlevel: rate. firing andreduce a. Check sYstern. blowdown b. OPerate valves. feedcheck c. Throttle valve outlet close is due hammer to carry-over experienced, steam water cJ. lf bad and to damage pipe|,ines macltinery. to prevent Waterlevelbelowgaugeglass: (if burner notcut-outautomatically)' a. Shut-off oui b. Takethe boiler of load. due damage to overheating. no c. Ensure internal downpartsarecooled the until boiler the bring-up wateilevelin haste d, Do not
188

J J J J J

Tubefailure: Small leak: 1. Moremake-up feedrequired. 2. Dropin totaltissolved content feedwater. solid of 3. Difficulty water in level maintenance. LargeIeak,: 1. Water level vanishes. 2. Bursting noise. 3. Dropin steam pressure. 4. Flamemaybe put-offby steam. Actions: 1. Putofffire, stopping burner necessary). (by the if 2. lsolate boiler" the 3. Tryandmaintain water the level until boiler cooled. the is 4. Testandplugthetubeas pertherecommended procedure.

E M E R G E N C YP E R A T I OD I J E O F I R E O N T Fires occur theairheaters, can in economisers, superheaters exhaust heat and gas exchangers. Theseheatextracting areallsituateO thepathof combustiJn units in gases andunder certain conditions, fortunately canexperience rare, disastrous These fires. fires aretwo types: 1. 2" Sootfire Hydrogen fire

Soof F[res: 1. The ignition ?Fr of sccurTlulation immediately lighting-up during of soot after or periods lighlload of operation. 2. Air heaters pin-tube and elements prone thisfire. are to 3. Indicatel a veryhighuptake bv temperaturegases. of 4. Shut-off andairsupply theburners Jlose dampers. fuel to and all 5. Flood areawithwater the andcjonotusewatcrspray. Hydrogen fires: 1. Steam breaks intoHydrogen Oxygen a tempof 25000C. up and at 2, lron bufn insteam reproduction Hyclrogenmuch will with offree at lower temperaturesof about7000C. 3 . lndicated a tuberupture veryhighfluegastemperature. by and 4 . cut-outtheburner andstopfeedwater supply theboiler. to 5 . A Hydrogen stops fire onlywhenthesupply steam/waterexharlsted. of is

189

HEMICALSELECTIONGUIDEUSE ON BOARD
fypo Syctom Problem

Drew ChomlcalUge
rtxl AEROVA|. treolflFfil errpo.dot

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i

INTERNAL COMBUSTION ENGINE

Cl. What ls the diflerences between followlng? the INTEBNAL COMBUSTION ENGINE anengine which fuelis bumed in the within directly the working Bothgas and dieselengines examples internal cylinder. are of combustion engines. EXTERNAL COMBUSTION ENGINE is onein whichthe fuelis bumedoutside the of power cylinder. example, a steam For in engine fuelis bumedandheats waterin the the whichproduces steam a boiler the thatis sentintothecylincler DIESELENGINE- ls an enginewhichuses a tow grade oil for fuel and igniteit directlyin the cylinder the heat of air compression. by GASOLINE gasoline fuelwhich ignited an electric ENGINE requires high-grade for is by sparkafterthegasoline beenmixed has withairin a carburetor, injected the cylinder, into andthe mixture compressed. FOURCYCLEENGINE fourstroke thepiston required complete cycteor of are to one series events of whichnrust in takeplace, regular order, operate engine. to the TWO CYCLEENGINE two strokes thepiston required complete cycteor of are to one serles events of lnusttakeplace, regular in order, operate engine. to the SINGLE-ACTING ENGINE is onein which pressure produces power the the stroke is exerted upononlyonesideof thepiston. DOUBLE'ACTING ENGINE is onerryhich operates similarly a single to acting engine, producing power except pressure that the strokes exerted on onssideof thepiiton, is first thenon the otherend,whichmakes eachpiston stroke power,stroke. a O, Cfassiflcatlon Internal of Combustion Englnes . c. X-type 1. As to power motion d. radial a. reciprocating e. barrel type b. rotary 7. As to method cooling of 2. As to cycleused 5" As to general a. liquid-cooling design a. otto a. single-acting b. air-cooling h. diesel b. doubf e-acting c. brayton 8. As to method supplying of air 3. As to method charging 6. As to cylinder of arrangement a. naturally aspirated a. two-stroke a. in line b. supercharged b. four-stroke b. \/-type c. scavenged , 4" As to ignition a. spark-ignition b. compression ignition

191

Q.Wtratarethe|ourstrokeslnthe|ourcycleD.E..? air into the cytinobr piston - meansdrawingor supplyilg. the motion-ot 1. |ntakostroko aiiuy upwaro stro\e- moa*s.orpi..rin" prooutu'po*"r bv the buming z. oompression _ ;i;;.; ruri',i,ilo 3. pcwer stroke hot
gasgs '

4,E>chaustst.'oke-expe|orreleaseotproductofcombustion Q.LlsttheseriesofBVi}I.ltSirrthe4stroltecycleD.E. cycleengineand making of a lour-stroke of eventstakingplacein a cylinder s The serie

-^r^^^n " ,{ rrrncl trct of combusl l orl '

bvthe upon,'.*?f5,:il:?ff"f:il'Iil!:s, permittins be into cvrinder to air drawn the

air the ror compressins ?2 S:*ln:ffi'l'ff,'lJ:i.3:i'l;9 9:Jl::ol,:l",,upward, where air

the into isinjected hot lm'lxir:3::;""fJi.frJi3Jl3li 3. ?',.'..'#'lffi

t e m ff,'ffJ.,th re ai ss :.lil:i. i,"T"ti a?f,,11rui;?"[: 3

it ignites' 4.Fourth,theburningfuelformg'1S9S*'h.'.:|::1?t'pressureandsendthepi

open exhaust the varve lli nil::ru1iiiq"l'ffill'?l3i'oke' ecvrder' ; PikH?'s; e i nn assinth in

Theexhaustu"ru''rose-sandthecyclerepeats. ln a two cycleD'E"? Q. Whatare the tluo strokes l . o n e s t r o k e c o m p r e s s e s a ovin-JUurnir,g d e r trt is thetporver u e l o i | . i r i n , t h e c y l ig;*r. o i g n i e t h e stroke' n f produ.uo is otherstrokJ Th-e 2. Q.Llsttheseriesofeventsint|retwo-strokecycleD.E. throughthe f'rs the cylinder is pressure, blowninto and 1. Air, undersright the in heatto ignite ;pt. valves thehead' the for producing to upward compress air is z. Thepiston starting fuel.

illl;' *? send;the down. l'" fue| ?xT I'3' : Theburning : formgasesi3' L *'= and:SffJ'J*IT ? i[: ffi :iHrT'flif':whichcreatc" p,.,,,reJ:ffi piston: 5.
forceJout oressure

and under head opn air u"ly:,:liin' then cylinders' leaving +f,:'#JlJ?irt:ff:i':?Xilr grr!r',""vur in the 7u*uining whateuu,.
:i;;ffi compression' iotint next

engine? of a.'cycleDiesel and advantages disadvantages relative Q. what arethe 'ltii*eight Advantages: power' per'horse andspace 1. 2.Greaterhorsepowerpercylinder.
192

3. 4.

Moreuniform turning effect. Lesscomplicated cylinder head.

r,

Dlsadvantages: 1. Lessvolumetric efficiency. 2. Greater consumption the4-cycre. fuer ttran 3. A scavenging pumpis required. air 4' Trouble cylinder with liners to intake exhaust due or ports. cl' Whatarethe relative advantages r:tisadvantagesa 4-cycle and of Dieselengf ne? Advantages: 1. Better umetric vof efficiency. 2. Lower fuelconsumption. 3. No airs.cavenging needed. pump 4. Lesscyfinder iinelirou6le, since thereareno ports" 5. Higher engine speeds. Dlsadvantages: 1. Moreweight an,C spacethanthe2_cycle. 2. Morecomplex cylinder_head casting. 3" Morevarves moving and parts thanthe2-cycfe engine. Describe operating the princrpre an opposedprston of engine.

All opposed'piston ertgines the2 stroke are cycletype" Theyhavetwo pistons in eachcylinder as theycometogether, is and air compressed tretween them. when the pistonsreachesa point ai which tfrev are closestiogether, maximum compression pressure reached. pornt referred is This is t.o gs-;;rrp;;=.ion dead..nirr." As thepiston approach combustion the deadcenter is injectecliDue theheatof conpression fuel to the mixture fuelandairburns of andexpands forcing pist,cns the outwarrl dcllverthe to power. Q' Statethe advantages and disadvantBges an opposed-piston of engine. Advantages: Lightweightper horsepower; absence complicated of casling(no cylinder heads); absgnce vllves andvalve-operating convenience of gear; anc; easein overhaul, repair andrinspection, to accessibility f.*er parts. due "ni Dfsadvantages: The principal disadvantage the inaccessibility the tower is of crarrkshaft' The.opposed-piston engineeliminat6s most of the difficulties, however, encountered design double-acting in of engines, exposureof the pistonrod to the temperature combustion, of unsatisfacto-ry combustion the-lower - ' piston in cylinier, cooling and'seizure thepiston in the loweicylinder-head of rocJ stuffing box. 0. Describe Ottocycle? the

Theotto cycle a 4 stroke is cycle wl"r;ch volume thecylinder constant the in the of is at pointof ignition' The firststroke(down)of the pistonsuct in the gas-air mixture and
193

clmpressit duringthe second stroke(upward) igniteit at approxinrately dead and top gas The expansion the ignited dri'res pistondownward center. of the agaipand on the gas return upward forces burned fromthe cylinder. stroke the O" What are the two types of llner? which withthe Dry Llner- usually verythinliner, a doesnotcomein direct contact water. coollng Wet Llner- a cylinder usedon larger which engines, comes direct in contact the wlth coollng portion the linerIn waterandfltted somorubber sealing topandlrottclm on of order prevent leakage cooling to of water theengine into surnp might that contaminate the lubeoil system. Cl. Whatare the typesof plstonusuattyusedon merchant shlp now? -fitted on slowandmedium Crosshead-UPe speed engines, consist a shortskirt of andhasa plston either rod bolted screwed thepiston. plston or to The rod,ls connected to theconnecting at thecrosshead. rod Usually stroke two cycte engine builtthistpe likea mainengine. Trunk-type'plston-usually onsmall used high speed engines, which a longskirt has and connected directly rod attached it by meansof osciltating to wristpin the tb crankshaft. stroke Four cycleengine arrxiliary like engines design it. to o. what are the two mafortypesof f uel Infectlon system? Alr Inlrctlon type- an air compressor produce at a constant pressure 600 air of psl to 1000 to allspray valves theengine" fuelpumpdischarge on A enough amount lueloilintothespray valve chamber, proper at timeinthestroke, valve gearcauses ths theneedle valve openandairblows oilin thechamber tb the violently ihe cylinder, Into breaking up intoa finemistparticles. lt Mechanlcal solldlntectlon type-usuallyitted individual pumps f on fuel eachcylinder of theengine,consistplunger barrel, of and whentheinjection checktiming occurred bythocamshaft, inJeutlon fuel valve check pressure openproducing higher leading Into pipe highpressure to fuelInjoctor valvefor atomlzation. Q. Descrlbe varlousmethodof plston-rlng constructlon and folnts? @mpresslon rlngs- usually close-grained iron,square section cast in witha thicknessof approxlmatoly of thecyllnder 1140 bore.lt ls alsotapered topof thecrown on vicirtity allow to expansion being introduced thehottest where part to combustlon take place. Tilepurpose to have tighisealduring process'in gas is the ordero havehigher engineoutput. Scraperrlngs-isbeveled thebottom forma scraping on to edgeanda number small of holes drilled through plston the skirtto drainofftheoil scraped fromthecylinder wall. Fitted mostly a trurrk on type,highspeed cycleengines. 4
194

Plston rlng deslgnends cut as follows: a. b. c. d. Squarebutt jointed Bevel Stepcut Overtgpped

O. What Upes of metalare used In the fotlowllng dleselenglneparts? a. b. c. d. e. f. g. h. -cast ironor steelplate Bedplate Holdlng Down Bolts highcorrosion resi.sting steel Framgs alloyed castironor wefded sterel fiame -cast or forgedsteel Crankshaft Connecting rods- soft steel Plstoins,farger engine: hoadforgedsrsel,skirt- eastiron smaller engine:aluminum alloy.

Llnelg closed graincastironor caststeel - cast iron Watar Jackets Cylinder head- castironor aluminum ailoy. I J. Fueltvalves forgedsteelor castiron k' lnlet'- Exhaust'valvescastironcageor carbon steelwithstellite seatsused" f. Cams- forgedsteel m. Camis roller- forgedsteel n. Valvesprlngs- springsteel o. Piston rings- caststeelor castiron p. Bearlngs shell;castlronor caststeel;surface babbitt coppernickelatfoy. or
I A

Gl' Descrlbethe operatlngprlnclplesof a governors;types and klnds? Govemors-consistof twoweights attached a splndle, to drlven theenglne. the by As englne speedup andslowsdown,centrifugal forceactuates fuelcontrol the lintcage by means attachbd of weights, thereby control fuel,measuring stabilizing ther and engine speedby varying fuelflow. Types: a. Centrifugal b. Inertia c. Inertia centrifugal and combined d. Hydrautic KINDS l. lsochronus Govemor- maintain constant speedfromzeroup to fullload. % speed Reg. = no roadspee.cr; roadspeed x fuil fullloadspeed 100

195

to shaft(fuelcontrol) output speed rotating governor dropactuate Speed hunting causes changed speed movefromfullopento fullilosed.Momentary \ for andquickaction correction. dueto sensitivity 2. S. 4. -single speed typefromno loadsto fullloadvice Governor Speed Constant versa. from idling can Variabte Speed Governor speedregulation be selected, sPeed. (zero) full(max) to -control minimum maximum speed. to Limiting Governor Speed

speef,but.it will the TypeGovernor does not regulate enginet S, Overspeed maximum certainpredetermined a prevent enginefrom exceeding ine propulsion engines. foundon main speed,usually chamber? typesof pre'combustlon at Q. Describe teastfcur different the in to chamber themainchamber which fuel it is The antechamber- anadded burning. for chamber complete into and burnod thoninjected themain ispartially crown in lt is of is modificationtheantachamber. placed thepiston Z. The air cett-it on chamber the upward air t'rrbulent to the combustion highly and furnished of stroke the piston. the g" The energycett-used thelanova lt is of system combustion. similarto airin throat. by into thatit is divided two sections a narrow cellexcept to that chamber is placed onesideof it is an auxiliary chamber4. The turbulence turbulence. giveincreased headandis usedto the cylinder 1. functions? and operational partsof a moderndieselengines Whatarethe different I. DOWN ARRANGEMENTS AND* HOLDING BEDPLATE

structural saddle) the (especially mainbearing loaded is Bedptate the mostheavily ars berJplates fabricated engine Propulsion engine" of component the mainpropulsion Mainadvantage together. and girder steelcasting welded is cross frommildsteelplates, withflat cost.Theseareof deepboxpattern andlower is bedplate lightiess of fabricated bottom. down are which partof holding chocks through seating to Bedplate connected engine downarrangements Holding or madeof slee/ epoxyr9si.n. are Chocks eithei arrangement. to andendchocks takeup sideand end usessides Engine use ldngboltswithspacer. and bedplate tanktop. the Boltsarefreethrough chocks, loads. girder portion thetransverse of is part loaded of thebedplertecentral nd Mostheavily partsof bedplate girder..All girOer longitudinal and transverse weldsbetween thejunction to The to contribute strenght. crossgirdeiismadeof caststeelaccording requirements. twistingalong ilt length.[ongitudinal to The construction lrovides good resistance Bedplate in eachsideof thebedplate theformof girder. by obtained makingine strength

196

fr il5?:fftJ[:?:t

chocks the atons lonsitudinaf tthas sLrpport sirder. no atthe centre

Folrowirrg partsotbedptaterequi.eutmost care: 1' of cross girder bearing or saddle which veryheavity is toaded hasno and :.#Hiart 2' Junction weldsbetween cross girder andlongitudinal girder; 3. Allwefded joints; 4. Alf tightening holes,tie boft lroies. Followlngpartsof hofdfngrlown arrangements requlreattention: hording downborts often trose; 1 Bedplate run 2. Loose chocks (supportirrg, anO sicle end) i 3" Crack spacers ; 4' Boltsare hydraulicalfy,tig.h.tenecJ (never tighten a running in 5' Theseare heavily loadelbo'ts, Lottaiis andnrt rrrtingengine) so to be normat; II" FRAMES

on large main propuf engines sion frames basically are transverse members straddi'g on eachcrossgirder'Theyare strong trans'rersely to impart and longitudinar girder strength, typeof construction b;;;;Jopted iaue in fongitudinat direction Frames wayof guides in areextremely. heavily loaded. during engine operation. sidethrust The due to ine donnecting too is transritted through guideto the the frame'Frames needto be stronglongitu?inaflygiur:the "rgularity to cyfinder blocka substantial support thatcylinder so liners remain clamping it points. Frames are proneto cracking behind guides, way of wetds, in any bolt holes,at change sections' of Pronb frettinion topanobottom to if tie boltsarerunning foose. III. TIE BOLTS The firingfoad' fromthe cylinder coversis transferred. through cylinder cover blockior beams' beam rne tranrters loadthrough tiebort studsto the the the to ther nutsandtieborts bedplate crossgirder. Ttrbri[ krrp il e strucirie'Jno* compression. Tiesbolts subjected severe are to tensile loads mocern on highly rated tendtovibrattglggsdively engines. They during r*on"nrr ronr, soguide bushes pinching or provided' screws slacktiebolts are mayresutt fretting seu-ere in and structurar ignment. misaf Refer engine to builder's manuat tiebofts'checking for pretension, o.f tightening' slackening stack tiebolts and *ill tt.rli in'sJr"re structural oarnag;.-ri"tortsrackening, tlghtening shouldalwaysoe oone in ,tlir*, correctsequence and pairs.start trorir mldshipthen athwarship, alternate fromiorwardand aft. cylinders.

197

;l
IV. GUIDES - \ to " withhigh'stroke borr'ratio take type are Guides littedin 2 stkcrosshead engine which Thissidethrustis enormous rod-angulality. due to connecting up the sidethrust loaded. heavily makes guidos the rod dueto connecting gearaligned takeup sidethrust anrJ keepthe running Guides sidethrust. to liner notbe subJected will angularity, in ideal cases so have very little guideand guideshoe clearances Largemdn propulsion engine, hot running and bearing latitude. in crosshead lmproper may clearance result guideshoe, wearof excessive resulting lt in misalignment, crankcase explosion.mayalsoresult piston piston andstuffing rod box. V. BEARING -Bearing Following partsrequire special attention: a. Mainbearing bottom ; half b. Bottom bearing half end top ; c. Crosshead bearing bottom half; d. Bearing surfaces damage marks; for and e. Bearing clearance admissible in (Excessive lessclearance, are range; and both detrimental) f. lmproper clearance result severe may in damage the shaft, to bearing surface andeventual crankcase explosion. VI. BEARINGBOLTS Following to areas bs inspected: 1, In wayof fillets anychange section; and of 2. Boltssurface foilanydamage scratch marks; and gauge; 3. Overall in stretch the boltsby trammed 4. Healthy fromthebolt. sound LINER VII. CYLINDER with Cylinderliners centrifugally withtheupperendlikea flange castintegral are cast Thecylinder coverholdshe restson thecylinder block. the liner. Underside theflange of portion thelineris usually Lower of liner place whenthecover down. in studs hardened are havebeenusingborecooling combat Mostof the modern rto of thinner section. engines linersare of wet $pe where Larger engino bothhighmechanical thermal and stresses. with watercomes In cooling directly contact linermetal. poorquality extremely burning largehighlyratedengines of Cylinderliners modern of and stresses possibilities mechanical thermal and residudl aresubjected severe fuel to wateroutlet temperaand liner is temperature cooling coldcorrosion highif corre<"t metal moment is to flange subjected bending Liner as by turenot maintained specified makers. if the cylinder unevenly especially cover tightened.

J J

J J J J J J J
;

198

tJ tJ

of Durlngoverhaullng unlts 1. oil the ctearing, stateof linerlubricating lPread,carbonwithout linersurfaco Inspect quills,cafionoil pumplubricators eitimatelubricating flowthrough to hand isation,s ports,etc. isatlonIn way oJ scavenge marksat top partof liner,cracks andburning and Cleanthoroughly checkfor cracks in cracks way of linerflange. in way of scaierigeports,scoringmarkson the surfa@, to attention the top givingspecial template usingmaker's linerthoroughly Calibrate hrs). be part(wearratoof linershould <.1 mm/1000 step builde/sinstructions by step. lollow engine In casethe tinerhasto be renewed,

2. 3. 4"

of diameter the be should 1%inside linerbore= 900mm;change Cylinder Exampte; borg-9mm.max. hrs. wear)- 0.1 rnm/1000 For:Slowspeed(liner hrs' mm/1000 wear') 0.015 speed(liner Medium Formula: x in Wearrate= increase dia.(total) 1000 hrs. Running (total) = hrs. mrn/1000

wear for Reasons maxlmum 1. 2. g. 4. 5. gas loadbehind ringminimum in hottest thisregion cylinder high ternperature but maylowerthandew point wear- cylindei cbrrosive film oil viscosity tilmminimum, maybreakdown wearabovoparts havehigher 2 strokeengine 7. f. 9. 10. 1f . pistonringclearance incorrect inadequate supply oil distortion cylinders of of misallgnment piston running-in engine of improper

Causesof excesslvevlear 1. 2. 3. 4. 5. 6. oil fuel lowsulphur withhighTBNcylinder combustion Inelficient too air scavenging temperaturo low engine overloading oil of contamination lubricating material liner unsuitable

GyllnderLubrlcatlon Modernlargeenginesare highlyloadedand at the sametime have been using stableat high o!! lubricating has to be thermally pooi "qraiiti fuel. Cylincler extremety cylinder Roleo.f of the and temperature atthesametimeroduce posiibilities coldcorrosion. with proper oif dema.nqlp. is i'ruri."ti"g oil in modernhighlyratedenginbs extremely S.G.0.948;Flashpt' andat the righttimeare essential. teedraie correct characteristics, TBN70' 89-85, Viscosity 238; Pourpt.-?0o0;
199

LubricantRequirement 1. 2. 3. 4. 5. sliding friction minimurn viscosity hightemperature adequate at effective seal (ringand liner) oil burnwithout deposit neutralize corrosive acids

[.ubricatio Consumption n Depend design, on load,fuelconstruction, quality, gradiont fuel temperature across liner" V I I I .P I S T O N S Pistonsof large highly rated enginesare subjected very l'righmechanical to and tlrermal To stresses. combatthe same,number engine of builders havebeen usingbore cooling.Modernapproachhas been also to ulseforgedalloy steel for piston crown to w i t h s t a n d i g ht h e r m as t r e s s e sn i c k oc h r o m e t e e lo r m o l y b d e n u mt e e l ) . h ( l l s s Duringoperation, the piston is subjected very high compressive to ancJ tensile stresses gas pressures, due to inertia effects and thermal stresses. Gas pressures and inertial result bending effects in actionof pistoncrown. Thermal in stresses pistonset up due to difference temperature in acrossa section.Hottestpart of pistoncrown iq at the junction sidewalland top plate.ldeally, piston not subjected any sidethrustin of tlre is to c r o s s h e a dy p ee n g i n e . t Duringoverhauling: 1 . l n s p e c tw i t h o uc l e a n i n g ,i s t o n r o w n n ds i d ew a l l f o rc a r b o n i s a t i oa c c u m u , p t c a n, l a t i o n r o i l ,w a t e r , u b r i c a t i no i l p r e s e n c e ,i , r g c v e m e n te t c . ; u f l g r m , 2. Thoroughly clean inspect withtemcrownforcracks, contour burning, external p l a t e , n t e r n aa r e af o r c o k i n gc r a c k s ; i l , 3" Sidewall and ringgrooves cracKs; for 4. Wear ridges skirt,iriston rods; on 5. Pistonrodsfor any scratch marks. and scoring Faults: stress. a. Crackin crown- tltermal/mechanical gas wall- fluctuating load. b. Crackin piston Reasons: pooratomization, water Material, inefficient scaling, localinpingement, cooling, infuel. IX. PISTON INGS R Piston ringsare heavily loaded pressure, mechanically maximum with MIP goingup in engines. Ringgrooves caseshavebeenchronre plated increase in wear resistance. to piston Generally, ringmaterial mademuchharder is of thanmaterial theliner control to pressure the linerwall modern highwear ratecompression ringsexertconsiderable in on engines(for 900 mm bore engine). Efficient lubricating film is essential. oil Overhauling internal so longin modern is engines, is advisable renewallthe rings it to during verhaul. o , 200

Thoroughly rneasure. new ringsaxially, all radially and butt clearance a in gauge; ring 2. Check prooves weargiving ring for special attention uneven wear(incaseof to excessive uneven wear,ringgroove be reconditioned); to 3. Rollnewringaround tfregroove, !n makesureringis notsticking out; 4. Withrings place, in gauge axialclearanee makesure check withfeeler the and in admissible range. X. STUFFING BOX Itismounted a flange with bolted thebottom thescavenge box. to of air Topsetof rings aresealing ringsto prevent scavenge flowing air downthepiston rod.Lower of rings set scraper/case off pistonrod. oil Duringoverhaulino: 1. Uppermost scraper andsealing sealing ring ring, rings, lower scraper rings be to checked for: a. clearance between sealing section groove; ring and b. clearance ringends;; at d. totalcleararrce 2 . C h e c k r e a t es p r i n ge n s i o n . g r t XI. CRANKSHAFT Crankshaft largemainpropulsion of engine mostly semi-built are of type. Someof modern engines, namelyMAN- B&W havebeenusirrg welded crankshafts. Moder.n designhas increased fatigue ltrengthconsiderably adopting by grainftow continuous rnethod. Welded crankshafts considerably are lighter reducing inertia the forcel. Analysis stresses the crankshaft of on durinE operation complex, is better are it to consider unitof thecrankshaft. crank is subjected tensile compressive one pin The to and stresses complete reversal. with load Similar nature stresses applicable thewebs. of are to Thecrankshaft subjected shear is to stresses wayof webandjournal. in Thismayresutt in slipping. The web is subjected bending to due to connecting angulariiy. rod The crankshaft subjected fatigue. is to Durlng Overhaullng 1. Crankshaft deflection should taken a condition be in suggested makers (Deby flection readings often are overrated.) 2. Crankshaft deflecticn should inspected cracks wayof fillets, be for in pins, crankpins, portion webs, cerrtral of slipping wayofjournals; in 3. Pinsto be accurately measured o'rality, tor scoring, rubbing marks; 4. No repairs be taken without to up owner's knowledge. XII. CONNECTING ROD Cross sectionadoptedfor connecting followsfrom study of the loads on rod con.necting andthecostof manufactr:re. rods Round section connection areadopted rods for largeengine. rod ,Connectinq is consrdered a struct, pin-jointed eachend and as at subjecled tolateralloading inertia from combined thrust with fromendloading pins. through These mqdeof forged are steel.
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1.

the bearing, swinging rod connecting is swingaboutthe crosshead In operation, set acli.on up inertia on by beingconstrained the bea.rinJ ir,, rr"nkpin._The lengtharestrong movement rodsof normal i6unosection-connecting loads.In slowspeedengines, is whiploading notof sufficient gas coirected roading tt'trineitia the to enough sustain "no consequence. areasor may buckle.Failureof irr or May fail from fracture cracking vulnerable buckling of Cases slight engines. .rtrrrrty tit. in slowspeed rod connecting in operation spaces' into wateror oil leaked cylinder where havebeenfoundin sameinstances XIII.CROSSHEADS andthrough on acting thepiston the llte slowspeedengines, gaspressurs ln targe pins whenlhe 600 pistonrod puts a load of a-pproximat6ly tonneson.thecrosshead value.Loadsof this high value cause soms ir".iure in tne cytinoeris ai maximum enginepinsare and modern has The deflection. pin andthe bearing to be keptaligned to designed be rigid" half at marks thebottom ' to be and for pin Crosshead to be inspected scoring rubbing foranycracks. to Thoroughly be inspected for checked ovality. XIV.CAMSHAFT joinedtogether meansof by sections, of is camshaft builtwithnumber camshaft littedboltsandnuts. using flange couplings drivecam. valveandindicator exhaust iectionhasfuelpuffip, Eachcailrshaft nutsarehydraulic The bearings. bearing shell in is Camshaft carried underslung type \ tightened. camsare shrunkonto the shaftby and fuel and exhauiit The coupling .flanges heating. andflange' shaft oilbetween lubricating by is of Dismantlingftanges effected forcing ls chaln also for of adjustqg-nt camshaft elongated or fuel Adjustmenlof 6amtiming, surfaces. fitted shrink oil lubricating between donebyiorcing are rollers folldwer reversing, During as speed crankshaft. at rotates same Gamshaft timing. the to disptaced alter pump DRIVE XV. CHAIN drive' by is Thecamshaft driven a chain over chainwheelsfittedon chainsrunning of Chaindriveconsists iwo identical and camshaft camshaft. and the placedbetween crankshaft by Chainsare kepttightened chaintightener wheelintermediate and distributor lubricator, cylinder a From camshaft, smallchaindriveoperates governor. bls' cladguide by are of Longfreelength chains guided rublrer at p'pesfitted theguidebdrsandchainwheels' spray by oit Lubricating is supplied 202

SCAVENGING Pushinrg o.ut,exhaust gases withthe helpof freshair intake thata fresh so charge pureairis available-for of compression follows. that TYPES DIREcTSCAVENGING-thedirect in scavenging inletports tocated onssideof the are on the.cylinder opposite exhaust the ports. fldw6atnofthescavenging isfrom The air oneside to the otherside. LooP SCAVENGING- tlrel.oop.scavenging in theintake exhaust and are Forts located at oneside,theexhaust overtheintake ports.inl tlowpartoiairisfromtnbintate port across to theopposite anduptowards cytintler side rire headandthrn makea loopto theexhaust portqabovethe intakeports" uNlFLow SCAVENGING-theuniflow in intake ports focated are atthesideof thecylinder and exhaust the cylinder at head.The air enters intake the and movesup towards the cylinder headwhereexhaust valveareinstailed" The Actualprocess Consists partially perfect of scavenging, mixing short-circuiting. and

orinf;iill$il?*ntf:mbustion

products isinitiallv pushed ofthe out cytinder without

Gradually' mixing sho.rt-circuiting theoutflowing and causes products bediluted to moreandmorefresh until situatioi by air the is sarne forperfect as mixing.

process isPerfect scavensins then which chanses into iolJ?r1iH1ll3?::::::"sins

Scavenglng Stages 1. 2. 3. Blow own d Scavenging Containingair of

lmportance Scavenging of 1. 2. 3' 4' 5. E n g l l ge f f i c i e n c y p e n do n s c a v e n g i n g de s Ineffici_ent scavengin.g 6;s poweroutputper weight _gives Incomplete scaveigi;g resultsin in.rr"sed fuel consumption per unit power Incomptete scavenging leadsto greater pistonring and liner wears. Inefficient scavenging giues higher mean temperatures
203

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CROSS SCAVENICJE

LOOPSCAVENGE

/' S LINIFL.OW CAVENGE

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ADVANTAGES

DISADVANTAGIiT;

of Examples Use "Sulzer * R D ,R N D

CrossScavenge .Simple *Less Maintenance *LowCost Loop Scavenge \ ' H i g h eE f f i c i e n c y r

.Slrort Circuit *Lcrwer Efficierrcy "l-ess BMEP . Pisto Distortion n/l-iner g d u et oT e n r P .r a d i e n t to fromexhaust s c a v e n gp o r t s . e -Cran ncle kcase/u r rnore piston space dirty. . Exhaust c;arb'rtliPort e sation xcessive. *Uneven Pistoring n wear. 'LessefficiencY cJtte to overmixing

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"Simple . L e s sM a i n t e n a n c e . Reliable . S i m p l e y l i n d e-r c a n C thermal ftigher sustain stresses. UniflowScavenge .No shortcircuiting 'No overmixing .Very highefficiencY 204

. R N D - MS u l z e r

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-B&W "SUIZER-RTA

' M o r ec o m P l e x .Higher ost c ' M o r em a i n t e n a n c e

SUPERCHARGING Processof pushinga higherpressure chargeinto the cylinder air greaterthan pressure, atmosphelic thus increasing poweroutputof the engine. Advantages Gained 1. 2. 3. 4. 5. 6. Higher output Better combustion Lessspecific consrrmption fuel lmproved thermal efficiency Lessweighvspaco/cost to produce particutar power a Lower exhaust temperature

Dlsadvantages
1. 2.

Higher initial cost Higher thermal loading to higher due pressure maximum

Methods Supercharging of 1 . fn d e p e n d e n dlr i v e n o m p r e s s o r t y c 2. Engine driven compressor 3. Underpiston supercharging 4. Exhaust turbochargirrg gas 5 . C o m b i n a t i o nt h ea b o v e of Typesof Equipment that can be useeJ 1 . P o s i t i vd i s p l a c e m e n t m p e pu 2, Positive displacement (roots blower blower) 3. Centrifugal blower (electric cJriven) 4. Turboblower (exhaust driven) gas f-rrinciple Operation of 1. 2. Pulse ystem fUE s * pressure Constant system Generator

V a l v et i m i n g p e r i o d s scavengeportsopenat approxim:tely degrees 35 b.d.c. and close35 degrees after b'd.c.The exhaust valvewillopenaheadofthc r"ai,,nge portsto givea blowdownperiod and closeat sometimeto leavethecorrect ountof airin the cytiiOer an forthe combustion of fuel. The open periodfor the exhaustvalvewill be about B0 to g0 degrees of crank rotation and the will beforeb.d.c.lt shouldbe notedthat .va.lve open about45 degrees considerable variation may be foundin valvetirning figures various for engines.

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TURBOCHARGING gas pressure 20%of wasteheatin exhaust which charging. Utilizes Veryeffr;ctive parts,the blowerand exhaust Contalns35V"of fuel heat. lt consistof two turbtneslde fitted In one motorshaft. Advantagas plantefficiency. 1. Hrgher povver required. source 2. No separate low, demand 3. Power condition" 4. Attempts cater overloading to for fortns supercharging. of thtrn 5. Moreefficient other

PULSE SYSTEM Exhaust Turbocharglng PulseSystem Pulse operation needs: pipes 1. Exhaust short narrow minimum bends Losses pipeminimum. in Small volume flow. pipesconnection same inlet 2. Exhaust to TC fromdifferent unitsto be arranged suchthatno^interference of pulses happen thismayotherwise affect scavengingoperatioh. 3. Period between discharge successive of into cylinders a common manifold be to more than240o a 4-stroko 120o a 2-stroke for and for interference. engine avoid to Not morethan3 cylinders firingsuccessively be exhausted a can into common manifold. Engines morethan cytinders havemore with 3 will than1 TC or 1 TC withmulti-entry arrangement. Advantages a. Highly responsive b. Good turbocharger acceleration performance c. Goodlowloadandlowspeed d. Scavenging not assistance necessary e. Better scavenging Dlgadvantages efficiency highratings at a. Poorturbine roughandinefficient b. Turbine operation piping c. Exhaust complex 206

TURBOCHARGER OPERATING PROBLEMS SURGING

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lf due to any rlason, the air pressure gensrated tho blower, in fattsbetowdellvery pressure, thererwillbe a .sudden breakdown air delivery, of followedimmediatety a by backvvard waverofair throurgh blowe'r the whichwiltcontinub untilthe delivery resi;tance hasdecreased sufficiently air discharge be resumed. for to Thlsperiodical breakdown of air deliveryis called'surE;ing', is manifested irregular and as howlingnoisefrom the Turbocharger. Sfages af surglng l. Humming ll. Snortirng lll. Howling SYMPTOMS SURGING OF 1. Howling Noise 2. Rapidsurges scavenge pressure in air 3. 'Gulping" airby blower of 4. Repeated irregular violent thudfromair intake blower. to 5. Alternate "suck-in" "puih-out" blower intake. and at air Dirtyrair filter Powerimbalance between cylinders Engine racing Faulty injection Fouled/damaged Turbine Fouled Cooler Air Overpressure Scav" at manifold Mismatch Engine/TC. of \ Remedy/Control 1. Proper matching 2. Larger scav.manifold dia 3. Reduce speedandeasepressure
& ,N cj ca' v r P ee s' suae S'-<r, ru,

Gauses 1. 2. 3. 4. 5. 6. 7. B.

TURBO CHARGING SYSTEM

207

T U R B O C H A R G ES U H G I N G R surging can be divided intotwo main categories l. ll. Restrictions the airlgassystem; in Variations cylinder in load.

CHECKTHE FOLLOWING 1' Fuel oil systemsuch as filtors,fuel punrp, fuel injector fuel timing,air in fuel, , fuelviscosity, loaddistribution, etc" 2' ExhaustSystem'Bacf<, pressure. valveoperring tinring, & pressure luctuation, f etc. 3' Turbocharger, Foulscl damageO or iurUine compressor or side,foulect fitter" 4'

5" o.

cfr.t<*.i ports, scavense ,:tr#iff,f,ti"*"1'#,';,L?i:Jii"oorcr, u."uense hish

Governor. Huntir.rg

what are the nreanrngs, furrctrons ure joilowrng or terms?

ff#f"fl"5lT."TrTl;

isthe volunte ortraver the swept by piston top rrom dead center

compression Eatto - the ratio of the piston displacement plus the cfearancevolume to the clearancevolume. Flash polnt - the temperature at wlrich flarnmable liquic will give off sufficient vapor to support a flash flame but will not supportcontinuous combustion. the weislrt of a .solid tiquici conrpared or as with an equat votume :ifl{J:, !{':{+calorlflc value - the highestamount of heat that can be producefrom a given quantity of fuel by compfetecombustion is called heat or caforific value. vlscoslty - is the internal friction resistance flow of a liquid or to at certain temperature. volumetrlc efflctency - the ratio of the weightof the air which is trappedin the cylinder at the beginning the compression of stroke and the weight of air coutd be contained in the cylinderunder conditions of atniosprreric pressure. counter welghts- fittedto the crankshaft of the enginein orderto balancethe revotving weightof the crankpins, webs,and the lowerportion-or connecting tne rod therebyreduci vibration. Jacklng gear - i9.anarrangement gears of used to rotatethe enginecrankshaft" consist of warm gear which e,'rgages gear-toothed a frywheel shims - are piecesof metalor other materiaf use for platingor equalspacingbetween two connecte'J metal parts like the unginu frarne,bearings ancj motor basement. Pyrometer - is a millivolt calibrated temperature in units,attachedthrougha selector switch to each individuar cyrinder exhaustinermo;o;;i;.' 208

Thermocouple - is made of 2 rods of differentmetalsthat are wetded togetherat one end, when heatedat the welclecJ junction,an electromotive force is producedbetween the terminals. lsochronous - governingkeeps an engine runningat a constant speed regardtess of load. This gives perfect speectregulation and nJ spoed drop. SpeedDroop - is a decreasein the speerlof an enginefrom no toadto full load conditions. Sensltlvlty - is the changein enginespeed beforethe governormakes its corrective changeto the fuel control.ft is usuallyexpressed a percentof the normal as or average 'speed of the engine. Stablllty - is the abilityof a governorto settledown to a steady after a change of load. Huntlng - is the unstableoperationof a governor.Jt wiff not maintain a steady speed caused by overoorrection. Deadbeaf- is the inability changethe speedwhen a new loadrequires to such a change.

Oll Mlst Detector - fitted in the main engine crankcase, that give a more reliableand quickerwarningof oil mist formation, whith connected pipe liie samfte air from each crankcasecompartment. The rJetector give an alarm at a mist concentration 2will of 5% of the inflammable quarrtity, safetyprecaution, for haveampletime to stop the engine before ignitionof the mist can tal<eplace. O' When maklng an order or Inqulry for englne parts, what are the essenilal data In order to supply you the correct parts for the Indlvlduat englnes? VVhenorderlng englne spare parts you should state the followlng: 1. 2. 3. 4. 5. 6. 7. B. 9. Q. S h i p ' sn a m e Classif ication Type of erlginesand numbersof cyriirders E n g i n en u m b e r s M a i n e n g i n eb u i l d e r s Nanre of parts requirecl Plate no. of engineparts ltem no. of engineparts Quantityrequired.

In modern maln propulslon engines, what are tlre mafor parts of the englne need proper maintenanceand attentlon?

Moderncrosshead typemair,propulsion engines highly are ratecl, superlongstroks and bearing extremely quality residualuel.Following f components engine neeO riil Poon of propermaintenance attention: and 1. cylinder linertop partsubjected severemechanical thermat to and stresses; 2. Framesand guidesare subjectecJ high side thrustbecauseof super long to strokearranqement.

209

3. 4. 5. 6. 7. 8.

Bedplatecross girdersand at junctionwelds betweenlongitudinal and cross g irde rs; Holding down arrangements; Exhaustvalves,air springs and hydraulic arrangements; actuating Pistoncrownand top of sidewallssubjected severethermalstresses; to Crosshead loaded; bearings and guideshoes heavily are Crankshafts weldedtyoe,specialattention tillets, webs and crankpins. are to

NOTE: No repairs specially invclving welding, work to be carried hot out on major engine components suchas bedplate, f rames,crankshafts without owne/s knowledge etc underany circumstances. O. What are the desirablecharacteristics a good fuel oil (Dieset)? of 1. 2. 3. 4. 5. Q. A n r a x i m u m e a tv a l u e . h A rnaximum water,sediment, of sulphur, sand,and otherimpuritios. A fluidity suchthatit can be pumped without heating too much. it The oil shoul.J be too slow-burning, as to causedelayed ignition tho not so in cylinder. 'The oil should burncompletely without leaving carlcon any residue the formof in ash or soot.

What factors would you say controlledcombustionin a diesetenglne?

Proper amount of air; proper amount of fuel; proper mixtureof fuel and air and proper temperature Fuel and Air for ignition. of O. Dlscuss ways of cleaninglube oii in a dieselen,glne drlven st1lpf

1 . By settling method usedof gravity tank 2 . By cenffifugingusedof centrifugal purifiers 3 . By filtering method usedof filtering material Q. Whatare the effectof earlyand latefuel injection? Early injection fuel causes to ignite soon oil too causing backpressure thepiston a on and a resultant of power. loss Pre-ignition cause may damage cylinder cylinder to and headsor even bent rod. Late ignition causessrnokyexhaust, losses powerand of incomplete combustion. Incomplete combustion resutts carbonaccumulation in which piston affect rings andvalve stems. carbonizer a silencer tmay Will also fire and caused Cl. Whatls the causeof "detonation" "f uel knock"In a dleselenglnecyllnder? or During ignition the delayperiod injection the fuelis contained thatthereis a of so greater prior ignition. amount fuelin thecylinder of Whenignition to the doestakesplace wholeaccumulation burnsviolently. This rapidburning resultsin an extremely high pressure thecylinder in accompanied pressur by waves" rapidincrease pressure This of pressure andvibrating waves results a noise in knovrn fuelknodk. as
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210

Q. lf your eriglne showsa veryblackandsmokyexhaust, wherewouldy trouble? Findout if the engine overloaded, is check exhaust pyrometer the at. cylinders carryarl equalamountof the load and adjustfuelvalvesand spra, accordingfy. Check fueloil forcleanliness water. and fuel Check pumps andirrellines ,entrapped Check air. scavenging ona two-cycle air engine. injection oninjection Check air engines. poorgradeof fueloil mayatsocauie smo'ky A exhaust. O. Descrlbe opencoollngsystem? an The circulating pumptakesuction fromthe seaandcirculate waterthrough satt the engine andthenoverboard engine the being cooled directly saltwater. by Cl. Descrlbe closedcoollngsystem? a is cooled fresh by waterfromthestoragetankwhichis circulated . Tf,t engine beirrg througlt engine a fresh the by w'ater pump. Thiswater cooled-byheatexchanger is a using seawateras cooling medium. ADVANTAGES: 1. 2. 3. 4. No danger scale of formation No danger galvanic of action due to seawater Better efficiency since. engine be operated higher the can at temperature. Theseis better control engine of temperature

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Q' .WqulOYou shut off the cooling water lmmediately after stopping a diesel errglne? Explaln. No.The reason keeping cooling for the watercirculating theengine stopped after is is to prevent the.lubricatingfrom oil beingeuaporated cylinde, from wals anO piston iingr. In casethe engine coofed is directly bylalt water, there wouldbe formation scaleon of account excessive of heataftertheengine stopped. is Q. . Wlthrespect facket to cootlng waterof a dlesel engine; whlchls advlsable;with a hlghertemperature lowertemperature? so, wnir or lf Withhigher temperature because diesel engine a compression is ignition engine and it issusceptible frequent to change temperature mechanical frim higherio of parts on tower temperature thereby prevent to stresses. O. Why ls oll used Instead waterfor coolingpistonsof a dieselenglnes? of lf wateris usedandleakoccured wouldleakintothecrankcase it emulsifying oil the properties burninE bearings causing andspoiling lubricating its thus out great and damage to the engine.

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O'

Why should the lube oil purnpbe run beforestartingand afterstopping a diesel engine?

Before starting ensure cornplete filrnorraltbearings stopping diesel to a oil in a engine, the lubeoilpumpshoulcl untilthedifference temperitrre run in bepveen inletanc1 the outtet is from 20to 50.This allows bearing coolevenly. the to O' How many degrees is the intal(e valve open? How many degrees lt ls closed? lntake valveopens fewdegrees oretopdeadcenter a bef arounc degreos 5 before top doadcenter (TDC)And closes around degrees ter BDO. at 5 af Duration opening 190 of is d e g r e e s n d c l o s i n g u r a t i o ns 1 7 0d e g r e e s " a d i o' What is usual fuel valve timing for lriglrspeecldiesel engine using light fuel?

Fuelvalve timing usually is starteci openat lZdegrees or before deadcenter. top This avoragg. 0' what are the usual anglesbetweenthe cranks of 2 stroke cycte and 4 stroke c y c l e h a v i n g3 , 4 ,a n d 6 c y l i n d e r s ? 2 cycre 3 cylinders- 00 12 4 cylinders-g0o 6 cylinders-600 o' 4 cycre 1200 1B0o 12Oo

what is the valve timing of the air starting varveof two cycle diesel engine?

Air starting valvemustopento acjnrit starting to the cytinder five(5)cJegrees air at after top dead center (TDc) and closes approxirnitely g0 dogr""r" o' state the timing of the differentvalveof 4 cycledieselenginein terms of crank angle in relerenceto top dead center and bottom dead centers.

In two strokecycleengine, intake valveopens48 degreres beforebottomdead center and closes48 degreesafterbottomdead center duratioriof degreesat openposition. 96 The exhaust valveopensat 92.5degrees aFier deadcenter top andiloses at 44.sdogrees afterbottomdead center. Exhaust valveis openedfor a duration 1s7 degreesin the of crankangle.Injection valveopensat 17.5degrees before TDc. o. Describeat reastthree rnethodsof driving camshaft? a) b) By a trainof gear, which drive the camshaftgear on the crankshaftof an intermediate gearsand a drivengear on the crankshaft. By a chainwhichis drivenfromJgrnr on the crankslraft and driven camshaft gear.

212

c)

By gearanda vertical shaft tfrere level is.a gearon boththecamshaft gear,and crankshaft and a slrafthas a pinion guuioneachandis place between the camshaft camshaft and gear.

cl. Namethe types'ofwristpinanc,r describe each 1' 2' SEoURED WRISTPINthistypehasthewristpin secured tighgy thebosses in of thepiston casting. screw'ed A do*ef is useldto secure pin. thi FLOATING WRISTPIN in thistyp.e wristpin freeto movein botheyeof the is connecting and the bosses'of pirtoncasting. rod the A spring retainer clip is placed grooves eachendof thepiston in in oourin orcler prevent pinfrom to the scraping cylinder the wall.

cl " Descrlbe varlousmethodsusedto introduce the wateror oif into diesefengine plstonsfor coolingpurpose. 1' Thepacked andunpacked telescgplc - In thistypethe moving pipe member of thetelescope assembly attached is cfird.iiv ineunddrside thepiston the to of and stationary member ihe engine to housing riame. oi

Theswing-joint - Thistypc' being type is usedon crosshead engines. inlet The andoutfet pipes from thepiiionaretixdd andleadto thecrosshead to the then outer ofthre end bracket boltecJ thecrosshead to where conne.tion made the is to moving member thetelesssric of assernbly. cl' Namethreemethods starting of a dieser engine. 1' 2' 3' cl' Electric motor requiring electric that energybe reidilyavaifable. Auxiliary engine gas maybe attached diriltrvjo dieset "engiri;s engine. Handstarting small foi ano .o*piurred c ' t t previousry - - " " ' r - ' Y s v v v air r T Y r u L stored the Pr pUfpOSg Of for
Stafting.

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Explalnwhy the malrr fournatbearlng caps on 4 strokecyeteengrnearq of heavler made constructlon than those'oJ hM; sirot<e thd cycfeenglne? The mainjour:nat capsof 4 stroke ctcle engines are of construction because during latter oftheexrrouiiutrokdthere rnade heavier the part isanupward thrust thebearing on capsdue to the inertia and centrifugat iorc.e rnoving of parts"ln the 2 stroke cyclethis upward forceis overcome the coirprn*.i.nof the by rir h the cylinder. what arrethe method or reversrng cycre 4 and 2 cycte engrne? 4 cyclo engines can be reverg-9d changing by the timingthrough of a set of reversing cam.The iamshattiJ movedIn-sucha- the insertion mannerthat a set of cams slide underthe valvesso that so th.at firingof any cylinder the is 180 degreesto its formerpositlon with the aheadcam. 2 cycleengines reversing method to rotatethe cranrtshaft is 30-40degreeg putting opposite the flankof the carnunderthe fuel valvesor pump thus similar to stephenson motionrrsocl stearn rink irr unfi,..on.
213

O. Descrlbethe path of the fuel oll from the storagetank to the englnecyllnder? pumbto settling tankby meansof oil transter The fuel is takenfromthe storage purifier efficient for a passed through centrifugal and tankwhereoil is preheated settled, is led to one of the two the tank in operation, oil it cleaning and deliver to the service a through flow pumps, the whichdeliver oil underpressure electrically drivensuppty - viscosity regulator pumps passes through oil heater the it meter, thento fuelcirculating - filters valves to fuel to supplied individual pumpseachcylinder the fuel injector then process. for combustion O. Trace the path of lube oll system 2 cycle dlesel englne. forcesit filters, through suction Lubeoil Pumpdrawsthe oil from the sumptank it passing filter, beforeit deliver to the through lubeoil cooler, the autobackwashing lt supply mainpartwhereoil is sent to whereit is divided engine intotwo branches: piston cooling bearing and manifold, whereit is distributed between to thepiston cooling lubrication. Fromthe crosshead boresin the connecting bearings, oil flowsthrough the bearings, rods, thecrankpin The of oil to bearings. remaining goesto lubrication thernain enginebase and sump tank" lube oil systemis separated from rnainlube oil systemwhichis also Camshaft fitteda tank- suction filters coolers the mainengine thenback c;jlm drivesystent, to the tank passing rnagnetic filters. to Q. Trace tne path of coollng water system 2 cycle diesel englne. by of The freshcooling wateris circulated the through cooler means fresh(Jacket) waterpumpswherethe waterentersthe engine through bottomof each cylinder the jacket and upwardto th: cylinder by head and exhaustvalve if fitted;controlled water proportion the ternperature the outlet of regutating valve, that thermostatically such normal set temp. pointlike80 degrees fromthe mainengine maintained specified ls at acid ot in and to cylinderwear condensationsulfuric onthecylinder centigrade order avoici piping on tankis fitted outlet a walls" prevent accumulation thesystem, venting To air to of changes at in and expansir,,n for make up the difference tfre water volumer tank temperature leaking. or O. Descrlbecyllnderlubrlcatlonsystem of a dlesel englne. gravity which withcil froma day tank,through supplied are The lubricator usually the The andstopvalves. oilis pumped,into cylinder strainers with equipped a builtin float, orificeduring a pumpvia non returnvalve,passing numbercf lubricating by lubricator with the engine the ripwird sirofs. tne oll feed rate or dosagoshouldin accordance and maneuvering large stariing, during be and recommendation should increased builders in changes engineload. from oil by is cylinder lubricated bearing thrown Whiteon lrighspeeddieselengine, engine. foundon a trunktypediesel of metlrod lubrication whichis splash the crankpin,

214

Q. What are the preparations startlngup englnesafter Installatlon, for longer standstlll maloroverhaul? or a) Crankcase should cleaned partswipedoff if necessary. be wellandall internal Userags,notcotton waste. Adjust secure internal and all bolts. aware any Be that loosecotterpirf,bolt,screwor nut mayhaveserious consequences, especially whenthesecannot adjusted be during operation.

STARTINAIR: G pipesshould blown b) Starting bottle air freeof anymud,dirtor water. be c) Checkpressure starting bottles. should between and30 kp/cm2. of lt air be 25 roller in bearing stai'ting relay. air d) Gre.rase LUBEOIL e) Before fillingthe lubeoil, checkoil sump,canalsand pipescarefulty. Remove any mud and rust. When wipingoff use rags. After longerstandstill poriodsdrain any water and mud from oit sump" 0 g) With the pneunratic lube oil primerpump,oil is pumped throughthe engine at the same time as the engineis turned.Checkdrivinggear. See thai oil is forcedthloughto all the lubepoints connected the mainlubeoil system" to h) Check,and if necessary, cleran tubeoil tilter"Checkvalve gear lube oil the tank beforefillingit up. Removeany mud and rust" i) lf the valvegearlubeoil has become mixedwithfueloil aftera longerstandstill (duringoverhaul the fuel oil system), oil shouldbe changed. of the FUEL IL: O Before filling oil,check fuel tanks pipes and carefully. Remove mudandrust. i) any k) Afterlonger periods standstill drainanywater andmudfromoiltanks. Check oil level. l) Disconnect oil pipes fuel fromfilters let theoilflowthrough and untilfreeof dirt fromtankandpipirrg. Check, andif necessary change afteretements. m) Bleedall air from fuel r:ilsystem. Whenbleeding fuel oil system, fuel the the primerpumpcan be used.One mustavoidto dilutethe valvegear lube oil pumpsare bled. oil when the fuel.,.injection STARTINGFENGINE: O a) Openthe fuelvalveand,the cooling watervalve. Close indicator valve. b) Remove turning fromthe flywheel. the ba/ c) Whentheabove mentioned instructions carried openthemainvalve are out, on the starting bottle air andadmitairto thecylinders. soonas the engine As has started, mainvalveshould closed. the be after check manometers, temperatures pressures. all for d) lmmediately starting, and FOR PREPARATION STAFITING AFTER UP SHORTER PERIODS: STAND STILL a) lf the enginehas beenout of operation sometime,it shouldbe carefully for Priming fueloil system checked not before starting. the should be necessary, provided nothing happeneC wouldadmitair to thesystem. has that whenturning engine b) Prime lub.oil system, the the slowly, admitoil to all the to Iub.points.
215

: ATTENTION RII'JG DU OPEF1ATION prcssures tern;:eraturesregular intervals. a) Check engine the speed, and at limit, i.o. b) After eachstart, check thestarting pressure above lower that is the air 1Skp,'cm2. pressure lower, starting bottles lf the is haveto be charged. the air for c) At intervals drainthestarting bottle condensation. air d) Tholubeoilpressure tlremain in afte normally 2.5- 3.0 system r filter should be kp/cm2. thevalve For goarlub.oil system icp/cm2 0.5 minin'ium. e) Thelubeoiltemperaturooutlet fromeng;ine at should normally 600C. be f) J'hecooling pressure water should nornrally 1.0- 2.5 kp/cm2. be g) The cooling watertemperature ot.rtlet fronrengine at mustuot exceed 800C. Normal outlettemperature 70'C. cle;lencl engineinstruction. is ,on '[he h) ctrarge temperature rrot air rnust exceed 600C When charge after cooler. the air temperature increilses, exlraust gas temperature also increase. will tlre Check charge temperature fullload. the air at i) lnstruction turboclrarger intercooler, for and manual. separate service lnstruction Woodward for Governor separate see servico manual,. I k) Measuring pressure cylincler takingpowerdiagram. of in by Occasionally measure pressure arll cylinder of cylinders exanrine thereareany to if faults withthe fuol injection the combustion. or Moasure cornpression combustion and pressure every timethechain, pumps camshaft fuelinjection or havebeen or idismantled changed" S T O P P I NE N G I N E G a) Shorter interruptionsoperation. of Runtheengine noload idle on at untilthe speed temperature stabilized. are Stop theengine. Fueloilandcooling water valves closed,. needed. if are lf danger frost, thewaterin tho engine thbpipeshasto be drained. for all and Faults obeerved during must operation be repaired. b) Longer interruptionoperation. of

Runtheengine no loadat idlespeed rrntil on temperatures stabilized. are S t o p h ee n g i n e . t Thestarting pipes must blown air through. be Theindicator valves mustbe opened. water. Starting bottles drained condensed air for are Thefueloilandthecooling water valves have be closed. to lf danger frost, thewater theengine pipes to be drained. for has in and all Water mudaredrained thefueloilandthelube tank. Thelube must oil and oil off be changed necessary. if it be lf theengine be outof operation a fewvreeks more, must cleaned will for or parts with oil. andall polished mustbe lubricated an anti-corrosive

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1. A.

STARTING DTFFICULTIES TROUBLE AND SHOOTING: The engine does not turn when starting appried. air Possfblecauses: 1. Airpressure low. too 4. Clogged nozzles. fuel 2. Oneor morestarting valve air havestuck. 5 . Pilot vafve shut. 3. Thestarting vatve leaking cytincler in 6 . Starting distributor shut valve The engine does not ignite or firirrg 1. 23. 4. 5. 6. 7. Air in the fuelsystem. The fuel oil firter the fu;r pipesare brocked. or lncorrect adjustment the fuel injection of pumps. Clogged fuel nozzles. FuelBy-pass open, Booster fuel pumpfaiture. Air ccmpression pressure low too

B.

Possible causes: Water thefueloil. in Thecompression pressure too rowcausect is r-ry: a. Woll or broken piston rings. b. Leaking valves cylinder-cover. in c' Leaking gaskets between cylincJer the covers thecylinder and liners. d' Todthick gaskets between tylincJer the liners thecylinder ind block. 2. THEENGINE STOPS 1 . A i ri n t h ef u e lo i ls y s t e m . 2. Faults thefuelsupply. in 3. Water thefueloilin 4. Clogged pipelines fuetoitfilter. or
r\v| t"t ' | |l{\) \)l' laE;t\

3 .( E N G T NR p MD R o p s ) E
\ 1)---En g ine-isor6--rtaded. i o lnj_ection pumpsare workingtirregularly. in fuelsystem. Air f 3' A piston oI,abearing a brerill<cJownto insufficient has cjue tubrication ordirtin lube oil.

PqSsiblecauses il_:.. One cylinder "falls oLtt,,. '2.\ Leakage betuveen cylincJer and the piston. tlre lincr 3: Leakage top gasket. in 4'. Clogged f'-rel filter. oil 5- The inletand/orthe exhaust valye$are leaking.{/ 6. The valveclearances too small are 7 . ' F i l t e r o r t u r b o - c h a r g es c l o g g e d . f i r

217

4.

KNOCKS THEENGINE pre-injection angle. is dueto incorrect 1. Injsction too early, valves. in 2. Faults injection too becomes hotandseize. 3. A piston pin havetoobigcleanances. 4. The gudgeon or big endbearing liner. Wormcylinder clearance. 5. Toobigpiston 6. Overloading 7. Poor fuel/air atomization

5. A.

ABNORMAL EXHAUST GAS Too high exhaustgas tentperature from one cylinder: 1. 2. 3. 4. 5. punrp. Too highadmission fuelinjection on Injection too late. is lnjection pressure. valvehastoolowopening Partial clogged nozzle. fuel Injection valve leaks.

Possible causes 1. Valve clearances big. too 2. Clogged exhaust system. B. Too low exhaustgas temperaturefrom one cylinder: 1. 2. 3. 4. 5. C. Too lowadmission fuelinjection pump. on Injection too early. is Injection pressure. valve hastoohighopening Clogged nozzle holes. Waterleakage thecylinder. in

Too high exha\tstgastemperature all the cytlnders: tn 1. 2" 3. 4. 5. 6. is Engine overloaded. Injection toolate. is Too hightemperature charging air. of pressure too low. is Charge air charge filter. air Clogged gas exhaust system. Ologged

D.

Black exhe.ustgas. 1. 2. 3. 4. 5. 6. is Engine overloaded. are Somecylinders overloaded. gas lnletor exhaust outlet valve leaking. is pumps valves. in Faults the fuelinjection or lgnition timingiauliy. FuelTemperature high. too

218

Posslblecauses 1. Badfuefoil. 2. Piston rings havestuck. 3. lnjection too late. is 4' Exhaust maniford exhaust or pipes crogged. are E. BIulsh exhaust gas. 1.
F.

Toomrrch rube in oneor morecyrinders, oir

Whlte smoky exhaust gas. 1. Engine too cold. is 2. Waterin cylinder. 3' one or more cyfinder gotting rot enough fuer. 4. Too fow compression pressure.

6.

L U B EO I LP R E S S U RD R O P S E Maln sysfem 1. 2. Too littre rube i' circufation. pumpsucks oir The air. Thelubeoil filters cloggeJ. are

A.

:. 6' B.

inside ensine. main Loose bearins l: it#,ffJiJffiti'Jrt;.tt"e pipes the borts. Oil
temperature io high. cooter dirty. is Oil is Theoil relief valveon thebedframe thel"rrty varve or on thepumpis sticking. Valvegear sysfem. Toofitilelubeoifin tank. Drainpipesto tankarectogged. Lubeoitis dilute{with oit. fuet Thelubeoil filter clogged. l's

1. ? 3. {t.

Posslbte causes 1. Thelubeoitpipeis clogged. 2' Theoil rehef valvein tlie filter thesafety or vatve thepumpis sticking. on
7. l

OVERFIEATED BEARINGS I 2. 3. 4. f. 6. that the 9logqi.ng prevents oitsuppty. Dirty filters. Toolowlubeoilpresure. Toonarrow ctearances. Toohighlubeoiltemperature. Theoil cooler dirty. is

219

8.

INSUFFICIECOOLING NT The cooling water temperatureon one cytintler increaies. 1, 2. Clogged lingwater coo pipes. Cyhnder overioaded. is

A.

B.

Increaseof cooting water tenrperature ail on cyrinders. 1 " E r r g i n es o v e r l o a d e d . i 2 " Cooleris clogged. 3 . Air in cooling wa.ersystem.

OPERqTION PROBLEM ANDHAZARDS ENGINE IN "Preventionbetterthan is cure." Problems accirlentsiustdo and nottake placewithout reason'theyarecaused'ln a problern already h.as takei pt??",yi-i nued thinkwhy .case to it hastaken place, yourimmediat"liit< but thoutd quick necessan/ sn"ps that so theplantdoesnotdeteriorate further.For be to t,tke any eriipii,'ii u pirton runs hot do something quicklyso thatit does notrun not any ioro. Nowitartth,inking did it run hot why at alt at first place. EMERGENCY PROCEDURE WHEN PISTON RUNNING FIOT 1" Reduceengine speed immediatery srow) (dead 2" Cutoutfuelto thecylinder troubf ei. quantity thecoorant thepiston. of I 9rpplymax.imum to 4. Increase cylinder lubrication. 5' Higher cylinder cooling temperature, notstoptheengine do immediately allow and gradual cooring. englne r{ stop,turns turning'gr"i by CRANKCASE EXPLOSIONS Initiated a "hotspot" thecrankcase by in which generated vapour. the,'fuel:air,, the As ratio reaches explosive limits, sante the "hotspot" piovides source heat.lt could 1he of be being machinery theabsgnce correct and in of positive steps prevent to :fli$,triuman Safety Features a. Crankcase detector mist b. Crankcase relief doors c. Strong Crankcase chamber sfeps to be taken tmmediatelyin caseof an exprosion immediaiety .a. ltop engine b" Putturning gear"on"& itart turning engine prevent the to seizure q. frcp lubricating andcooling oit pumps on d' Do notopencrinkcase doorfo-r'at least112 hour untiltheengine cools down e. lnvestigate cause the t andremedy 220

AIR STARTING LINE EXPLOSION Thefuelcomes fromtheaircompressor lubrication through bottle andintothe linein theformof oil layer'lf air is present, source heatin theformof hotgasesfromleaky of air starting valve' suddOnly openedtrighfi*.rre air in the line from air botile resuftin explosion. SafetyDevice f. Relief valve ll. Bursting Cartridges Precautlondry Measure freeof oirby regufar 1 Keepair bottfes draining 2. Maintain starting cfean line 3. Maintain starting air valves SCAVENGING FIRE Causes of flre In the scavenglng box. alr 1 . lgnitionof carbondeposits scavenge in air by meansof prolonged btow-by 2 . slow combustion. the cyrinder in oue to incorrect atomization 3 . Blow-back through scavenge portsdue to incorrect air adjusted exhaust cam disc or back pressure
Warnlngs of Scavenge Flre 1. 2. 3. 4. Increasedin exhausttemperature of effectedcyrinder Turbo charger may surge smoke from the turbo ihrrgers air inret firter Hotter $cavenging box csing. air

Measures to be taken \ 1' ? 3 4' Reduce speed to srow and ask bridge for permission step. to Stop the auxiliarybtower if fitted" Stop the fuet oil suppty. Put the scavenging box fire extinguishing air steam equipmentinto func'on.

5' 6'

thetire, removo deposit studge iir tn. scavenge dry ind rrbm respective rod cytinder their piston and tiner, surfaces afignment F':fl:lHinspect llffitinguish

221

TURBINES STEAM
O. What ls a steamturblne? I is of energy a steam changed the in is A steam turbine a heatengine wlrich potontial steps: intotwodistinct work hto useful energy, steam by kinetio of into is energy convertsd snergy moticn, 1. Theavailable at passage, fromwhichthe steamemerges a in or expansion a nozzle suitable highvelocity. energyCIrusefulwork by into 2. This kineticenergyis converted mechanical jet against rotor,or bythe mounted a revolving on blades directing steam the jet itself theexpanding passage the passage revolves. if in reaction the of A to withblades wheel secured theshaft. high TURBINE consist motor of STEAM or in turbine by to steamis directly the nozzles impulse veloclty of superheated fet against bladerow to producerotational , turbine, the bladesin reaction statlonary gear to reduction leading propeller. whichls connected reduce to moUon theshaft of leakage high of It ls mounted apparatus steamsealsin orderto prevent by and pressure pressure side. steamto the atmosphere air intothe low and to O. Whatarethe two basictypesof steamturbineswith respect the actlon of the principle? obam flow Insldethe turbinecasing, operating 1. turblne Reactlon a. b. blades. arrd blades one row of stationary Consist one row of moving of and passes the through rowsof stationary,blade Pressure dropsas steam moving blades. bladesand de* stationary through in increases passage c. Steamvelocity blades. in creases moving equalto the speedof steam. directly varies Olades d. Sleed of reaction than and stationary of of numbers stages moving of e. lt consist several morecargospace. occupying thereby impulse turbine and low usedon low pressure, velocity, largevolumesteam f. lt is mostly on powerplant. unit. are g. Mostfittedlow pressure turbine crosscompound

2.

fmpulseturblne a. but in a decrease pressure, an increase in expands thenozzles',vith Steam the beforeit strikes motorblading. in velocity to oftenpermitted takemorethanequaN turbine b, Thefirststageon impulse are: pressure its drop,thereby advantages shareof the available

222

1. casing subjected lower ls to pressure. strikrng 2. rotational losses lowered to decreased is due steam density. 3. fitted withhighpressure seal.
c. d. e.
f.

Sped of impulse bladesratedvariesas one hatfof the steamspeed. ll permituseof partial admisslon steam, steamchestfitted of on wlthnozrle to increase efficient operation. lmpulse bladearegenerally attached directly thewheels, to madeIn longer fengrth attached. lmpulse blading heavier is and stronger than reaction turbine.

Gl. Whatare the normaloperating procedure startlnga TurblneUnlt? In any unit which isnotfamitiar, engineer he the shoutd thoroughly . In.starting turbine with sludythe manufacture/s recommended procedure. procedure The givenbelowis geieializedandmay differin minordetails fromthatfurnished anypaiicularmanufacturst: by 1. Startup the lubricating pump. Check gravitytank'to see if oil supplyis oil sufficient. thatoilpressure estabtished bearings thatoilis iisling See is on and through sightglasses leading reduction housing. ttreoiltempeiature gear to lt ls lessthan, say, 65i it mustbo passed through heater the untilits temperature g0 reaches to 1000F. 2. open turbine-casing and throttle-valve drains. 3. Theturbine theniacked is over for at leastonehourby usingthe turninggeat. Check withthe bridge thatthedeckofficer watchcanin-vestigate so on m-o6ring linesandwhether notthe propeller clear. or is 4. Start circulating condentsate and pumps. Open the recirculating valvs .the lromfeedtankto condenser thatcondensate so pump assured waler is a supply. 5. Check'level waterin boilers.lf the levelis as it shoutd of be, opentne nidin steamstopvalve" 6. Sfart the second-stage ejector andbringvacuum to approximately air up l5 inches mercury. of 7. lf controlvatve is actuatecj oil pressure,openvalvethat admits to lry oit governingmechanism. 8. Put steamonbealing gtands.Admit steam steam to sealregulator. jackinggear. 9 . Remoue 1 0 . Openthrottlevalvewideenoughto startthe rotorturningimmediatety; then throttle down until the turbine is turning over slowly. On gear-driven installations, steam should firstadmitted the astern be to etement 1 1 . Check'the emergencynovernor mechanrsm. the turbinsout,reset,and Trip readmit steam turnrotor to slowly. tfor 12. Listen unusual noises. 1 3 . On electricdrive, keep rotor turningovbr siowly.Qn geat drive, atternate rotation turbine of slowly, ahead andastern. 1 4 . Startup first-stage ejectorsand bringvacuum normal. air to 1 5 . Circufats waterthrough coolerto maintain sufficient cooling oil temperature of oil entering boarings between 10to 120'F | pressure temperatures seethatthey 1 6 . Stand,by maneuver. Observe to and to normal. remain valveand turbine 17. Whenrunderway, closerecirculating drains. Proper warming of the turbine extremely up is important. Precaution.
223

Cl. Explainhow you wouldsecureyour turbineinstaltation afteryour voyage? Stepsto secureturbineinstallation aftervoyage: a' Startauxiliary condensate system tia;rsfer and auxiliary exhaustandmakeup feedto theauxiliary condenser. b' Use handtripping device slrutt to steamoff mainturbine thenctosethrottle andbulkhead stop ralve. c. secure mainairejector maincondensate the and pump. d. shuttoffgland sealstearn openturbine and drain. e' Rotate main turbine turning w.ith gearuntil coot andthensecurs it off gear turning andthernain lubricating pump. f' Whenmaincondenser coot secure has off, maincircutating punrp. O. What ls meant,functlonof the followlngmountlngs, flttlngson steamturbtne unlt? Turbinerotor -consistof shaft,spindle ringsor wheelsand bladingr The shaftis a steslforglng wlthIntegral thrust collar. WhJels secured theshaftandblades are, to dovetailed the wheels. into Fitted alsodummy piston andglandsealing secure on highand low pressu,.e of the shaft. end Turblne caslng - made in two halveshousing that encloses rotor;for low the pressure made of cast iron, and steel for high temperature. has a lt spacefor receiving steamsealing glandsand extraction connection. t*oln]r[*li The ti.," casing bolted are together a metal metal with to contact required but graphite before assembly. Throttlevalves- provide handcontrol throttling steamto increase of speedand trip quick closingvarveeitherby hand o,' ur"iOency governor. Steam stralner fitted between mainturbine stopvalveandentrance admission of valveto prevent scaleor rustthatcauseerosion breaking turbine or of bladefrom steamlines. Gland SteamSea/s- to preventescaping stearrfrom highpressure of errdand also eliminating leakage air into the low pressure end whifeon standstill. Beductlon gears- it reduce highspeedturnirrg a ttrrbine the low efficient the of to speedof a pfirpeller. consist thrustbearing lt of collar,main reduction gear,and piniongearssecured the shaft.Doublereduction to gearsmosly user crossin compound turbine eithernested, articutated type. Steamextractlon- consist flanged of connection from turbinecasing,usedfor external purposes feedwaterheating, for evaporator steamsuppty, shipsheating, thereby increasing allplant over efficiency reducing amount cooling by the of surface needto thecondenser, actas reducing atso valve lower to pressu?e temperature and used in auxiliary heatings.
224