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Issue 1
SCTC GANNET August 2001
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NAME RATE
_____________________________ _____________________________
ADDRESS
INSTRUCTOR
________________________________
________________________________
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CONTENTS
SYLLABUS REFERENCE
SUBJECT
PAGE
3 ME 1 3 ME 2 3 ME 3 3 ME 4 3 ME 5 3 ME 6 3 ME 7 3 ME 8 3 ME 9 3 ME 10
Health and Safety - General Health and Safety - Workshop Introduction to Marine Engineering Engine Construction Engine Cycles Mechanical Systems Electrical System Basic Electrical Knowledge Power Generation Tools and Fasteners Progress Chart
7 15 21 27 33 41 47 51 55 59 67
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Introduction
The Health and Safety at work Act 1974 places formal responsibility for health and safety at work on all personnel. This act of Parliament applies to civilians and all service personnel, instructors and Cadets. It is the duty of Commanding Officers and superiors at all levels to: a) b) c) Ensure that compartments and access are kept in a safe condition. Ensure that equipment and machinery are operated safely. Inform personnel who may be at risk of the existence of hazards and how to reduce them by taking precautions. Provide training and supervision to maintain safe conditions.
d)
Cadets must take responsibility for their own personal protection, use the correct equipment, and follow the health, safety and fire instructions provided.
Emergency Signs
These should glow in the dark, are provided for your safe exit of the building. Your instructor should take you on a tour of your unit and identify these signs and safe exit routes.
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Use Wood, paper, textiles. Not on electrical fires. Wood, paper, textiles and flammable liquids. Not on electrical fires. General, oil and electrical. Electrical and flammable liquids.
Colour Red
(b)
AFFF Foam
Cream
(c)
Dry Powder
Blue
(d)
CO2
Black
Potential Hazards
There are three types of hazards associated with all engines:-
a) b) c)
Fuels, Oils, spillages and fires. Shock, burns, arcing and fires. Rotating machinery, noise and exhaust fumes.
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Fire Drill
These will be explained by your instructors and should be fully understood as your life may depend on it. a) They will include fire exits and what to do in case of a fire and where to muster when you are clear of the fire. Emergency drills will include the various ways in which to safely shut down an engine. This will be covered before you start the practical projects.
b)
This is an example of a Health and Safety declaration. I hereby declare that I have been informed of the above hazards by the Course Marine Engineering Instructor, and agree to abide by the conditions and limitations imposed as a result of them, during my course. Furthermore, I have been informed of the emergency procedures to be followed in the event of a Fire, Emergency evacuation and personal injury or dangerous occurrence.
Date
Name
Rank/Rate
Signature
Course
Remarks
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Date
Name
Rank/Rate
Signature
Course
Remarks
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Questions : 3 ME 1
1. 2. 3. 4. 5. Who is responsible for Health and Safety in you Unit? Identify the Fire Extinguishers and First Aid Boxes fitted in your Unit. Describe where your emergency assembly point is located. Name 5 PERSONAL SAFETY rules. What is the Emergency Drill for your unit?
Cadet Objectives
Identify all the unit fire extinguishers, and their uses. Recognise potential hazards Explain the actions to be taken in the event of an emergency Take part in an emergency drill
Course Notes
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(b)
(c)
(d)
(e)
(f)
(g) (h)
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Electrical hazards
(a)
Electric Shock caused by electricity flowing through the body, which in turn affects the control of the muscles, it can stop the heart and lead to death. Do not touch the casualty, until he/she is isolated from the power. Isolate the power supply and summon help. Carry out first aid if qualified.
(b)
Electrical Burns Severe burns are caused at the point of contact with the electrical source. Electric sparking and Fires sparks can jump across air gaps, fires can be caused by overheating of cables, poor insulation or by nearby flammable materials.
(c)
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Reporting of accidents
It mandatory that all accidents are reported to your instructor. This is a legal and a SCC requirement. Accidents are to be recorded in the Unit accident book and the Commanding Officer informed.
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Questions : 3 ME 2
1. 2. 3. 4.
What are the 4 main hazards associated with running engines? Name 5 personal safety rules. What is the Emergency Drill for your unit? Where and why do you report an accident?
Cadet Objectives
Know how to reduce the risk of personal accidents (both mechanical and electrical).
Identify the various items of personal protective equipment, and know when and how they should be worn.
Course Notes
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HEAT ENGINES
Steam Engines
Gas Turbines
Steam Engines These can be reciprocating or rotary (turbine). They require a boiler and auxiliary pumps to provide the power, and could be described as external combustion engines, taking up much more space than internal combustion engines. Gas Turbines - These are high powered, expensive and are used to power modern major warships, trains and aircraft. They are not piston engines and are not covered by the course. Internal Combustion Piston Engines (ICPE) This term covers both the Spark Ignition Engine and the Compression Ignition Engine. Spark Ignition Engine (SIE) In the spark ignition engine an easily vaporised fuel, normally petrol is mixed with air and is ignited by an electric spark at the end of the compression stroke. This is the basic motor car engine or outboard motor. Compression Ignition Engine (CIE) In this engine a fuel of a much higher flash point is used, giving a much higher safety factor. The fuel is ignited by the high temperature of the air at the end of the compression stroke. When the air is compressed in the cylinder, by the piston, to several hundred degrees, fuel is injected as a fine spray into the cylinder. This engine is the basic diesel engine fitted in some cars, vans, lorries and most small boats.
Diesel engines are used because they are economical, self contained and are more efficient than petrol engines, are generally cheaper to maintain, and their fuel is less hazardous than petrol.
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Types of movement
There are two types of movement that can transmit power reciprocating and rotary. They transmit power from the piston through the engine to the shaft and propeller. Reciprocating Movement - Movement in up and down motion. An example is the piston moving from the top of the cylinder to the bottom of the cylinder. Rotary Movement Movement in a circular motion. An example is a propeller shaft. In a piston engine, both rotary and reciprocating movements are used to convert power from the engine to the propeller.
2.
3.
4.
5.
6.
7.
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8.
Valves. The valves are usually fitted in the cylinder head, and are called overhead valves. When open they allow the passage of Air, Fuel, and Exhaust gas, when shut they seal the cylinder. Camshaft. Each valve is lifted by a cam, which is pear shaped and machined in an angular position on the camshaft so that it will lift the valve for the correct period. Rocker gear. Overhead valves are operated by rockers with one end of each rocker bearing on the cam or push rod, and the other end on the valve stem.
9.
10.
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Questions : 3 ME 3
1. 2. 3. 4. 5. Who invented the Compression Ignition Engine? What do the letters SIE and CIE stand for? Explain the different types of movement in the piston engine. What is a disadvantage of a steam engine? Name two advantages of a diesel engine.
Cadet Objectives
Describe the main differences between petrol and diesel engines.
Course Notes
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Engine Construction
3 ME 4 General Arrangement of a Diesel Engine
Diesel engines have an infinite number of jobs to carry out and are, therefore, of many various shapes and sizes. From simple single cylinder engines to multi-cylinder engines however, the basic components remain the same.
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2.
2.
3.
4.
5.
6.
7.
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Engine components cont 8. Camshaft. Each valve is lifted by a cam, which is pear shaped and machined in an angular position on the camshaft so that it will lift the valve for the correct period. The camshaft may lie above the cylinder head, when it is called an overhead camshaft, or alongside the crankshaft with push rods to lift the valves if they are of the overhead type. Rocker gear. Overhead valves are operated by rockers with one end of each rocker bearing on the cam or push rod, and the other end on the valve stem. Side valves are usually placed immediately above the cams so that the rockers are not required. Tappets. All valve gear is fitted with tappets, a form of set screw and locknut, which may be fitted to the rockers, the push rods, or the tappet spindle for side valve engines. The tappets are adjusted to give a slight clearance for expansion between the tappet and the valve stem. This clearance is always stated for inlet and exhaust valves of each engine.
9.
10.
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11.
Timing gear. The camshaft must be accurately timed to the crankshaft so that the valves will open when required and for the correct period. The timing gear consists of gear wheels usually mounted at the front end of the crankcase and enclosed by a timing case. The gear wheels are marked to show the correct setting. Fuel pump and injectors. The fuel injection pump may be fitted on the side of the engine, or an individual fuel injection pump may be fitted alongside each cylinder. The pump is driven by the timing gear so that fuel is injected into each cylinder at the correct time. Each cylinder head is fitted with an injector, which consists of a non-return valve and a nozzle which produces a fine spray of fuel into the cylinder. The speed of the engine is varied by a governor which controls the quantity of fuel discharged by the fuel pump. Joints/Gaskets. These are fitted to prevent the leakage of oil, gas or water. The cylinder head gasket is normally made from copper and compressed fibre, whilst other joints are of treated paper or metal-to-metal with joining compound between the mating faces.
12.
13.
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Questions : 3 ME 4
1. 2. 3. 4. 5. 6. 7. What is a camshaft? What is a crankshaft? Name the two bearings associated with the connecting rod. What is the purpose of the flywheel and what is the starter ring for? Name two parts of a piston. On a six cylinder diesel engine how many injectors are fitted? Show your instructor the main parts of the diesel engine on your units diesel, or on a diagram of a diesel engine.
Cadet Objectives
1. 2. Identify all major components and understand their purpose. Know the function of a gasket.
Course Notes
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Engine Cycles
3 ME 5 The Four Stroke Cycle
The four-stroke cycle is so called because there are four distinct parts to each complete cycle. The cycle keeps the piston moving upwards and downwards and the crankshaft revolving, and the sequence is as follows:
The Induction Stroke The piston is moving down the cylinder and sucking in clean air through the air inlet filter, down through the inlet manifold and into the cylinder, via the inlet valve. The inlet valve has opened for this specific operation and closes when the piston is at the bottom and the cylinder is full of clean air.
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The Compression Stroke The piston is now moving back up the cylinder, both the inlet valve and the exhaust valve are shut and no air can escape. The air is now being compressed (compression) and as this occurs it heats up. When the piston is at the top of the stroke and the air is at its most compressed state, diesel fuel is injected into the cylinder as a high-pressure spray.
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The Power stroke The fuel and air mixture compressed within the cylinder, burn rapidly and expand, driving and forcing the piston down, producing the power.
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The Exhaust stroke The piston travels back up the cylinder pushing all spent gases out of the opened exhaust valve, which closes when the piston reaches the top of its travel. The inlet valve then opens as the cycle starts again.
The power produced is, in part, directly related to the volume of the cylinders, although other factors enhance performance. It is the amount of fuel/air burnt that produces the power.
Combustion (the fire triangle) All internal combustion engines require Heat, Fuel and Air for combustion. Combustion takes place when energy is released by the atomising of the fuel under pressure and bringing it into contact with the high temperature of the compressed air. This mix of fuel, air and heat causes an increase in temperature and pressure in the top of the cylinder. The ignition and expansion that occur will push the piston downward.
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NOTE:
THE CRANKSHAFT WILL ROTATE TWO REVOLUTIONS TO COMPLETE ONE FULL CYCLE IN THE 4-STROKE CYCLE AND ONE REVOLUTION IN THE 2-STROKE CYCLE.
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Questions : 3 ME 5
1. a) b) 2. a) b) 3. When the piston moves down during the power stroke is: The exhaust valve open or shut? The inlet valve open or shut? When the piston travels back up the cylinder after the power stroke is: The exhaust valve open or shut? The inlet valve open or shut? How many revolutions will the crankshaft do during one full cycle of a 4-stroke cycle engine?
Cadet Objectives
1. 2. 3. Know the three elements of combustion. Know the 2 and 4 stroke cycles. Describe the relative positions of pistons at each stage of the cycle.
Course Notes
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Tank Filling
Filter
Pump
System
Tank
Tank drain
BASIC MECHANICAL SYSTEM
The tank is filled to the correct working level, excess can be drained away. The liquid is drawn through the filter which removes any debris. The liquid is then pumped up to pressure using the pump and discharged to the system where it is used. Liquid is then returned back to the tank and the cycle repeats itself. When filling any system you must use a correctly labeled container and fill it with the correct fluid. Oil in to the sump and cooling water into the fresh water header tank.
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Beware of filling the wrong tank with the wrong fluid. Your instructor will show you how to replenish correctly all the engine levels. The system pressure can be monitored using a pressure gauge. Oil, water and fuel levels are always checked prior to starting the engine. It is good engineering practice to monitor the conditions of the mechanical systems regularly for problems such as overheating, lack of cooling or leaks on the various systems. Learning the components of the engine will help you identify any problems when the engine is running. Many checks can be done before the engine is started to ensure your engine will run efficiently.
Camshaft
Timing gears
Oil pump
Sump
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Fuel system
Diesel engine fuel systems supplies clean fuel from the fuel tank, through filters to a lift pump and finally to the injection pump, it is then delivered to the individual injectors which spray the fuel into the top of the piston. Fuel systems must be kept clean and free of any water, which would otherwise collect at the bottom of the fuel tank.
Fuel in
Fuel tank
Main filter
Lift pump
Fine filter
Injection pump
Injector
Cooling systems
Diesel engines are cooled by air or by a water cooling system. Air is used to cool the outer fins of the cylinder head. It is directed over the fins giving a cooling effect. Most diesel engines are cooled by fresh water which circulates under pressure around the engine cylinder block and cylinder heads narrow passages, this fresh water is cooled by pumped sea water which also passes through a fresh water cooler. The fresh water is maintained at the correct temperature by a thermostat. WARNING: THERE ARE MANY PARTS ON ENGINES WHICH GET HOT AS THE ENGINE WARMS UP, CARE SHOULD BE TAKEN TO KEEP CLEAR OF MOVING AND HOT COMPONENTS. THE COOLING WATER PIPE WILL GET VERY HOT UNTIL THE THERMOSTAT VALVE STARTS TO REGULATE THE ENGINES TEMPERATURE.
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Sea Cock
Strainer
Water pump
Oil Cooler
Engine block
Exhaust manifold
Freshwater pump
Thermostat
Sea Cock
Strainer
Seawater pump
Oil Cooler
Exhaust manifold
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Questions : 3 ME 6
1. 2. 3. 4. Name the three main systems fitted to a diesel engine. How would you check the oil level of a diesel engine? What are the main components of any basic system? Why are systems checked before and after starting?
Cadet Objectives
1. Describe the purpose of each of the mechanical systems, and the medium used by each system.
Course Notes
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(b)
(d)
(e)
(f)
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Starter motor
Solenoid
Starter switch
Generator
Distribution board
+
Battery
Conductors: Materials which allow current to flow freely. (Low resistance). eg. Metal, water, carbon.
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Questions : 3 ME 7
1. 2. 3. 4. 5. What is the source of power for the electrical system? Identify the major electrical components in your unit motor boat Explain why the electrical system uses a dynamo/alternator? What are the dangers of electrical circuits? What is the function of fuses in the electrical system?
Cadet Objectives
Identify all major electrical components and understand their purpose
Course Notes
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Simple Circuits
A circuit is the combination of several electrical components that when connected together and provided with a power source will cause an action of some kind. This action will be in the form of light, movement, heat or noise. A basic circuit will comprise of:Electrons. Current is the movement of electrons through a material. Before a current can flow in a conductor there must be an applied voltage. This can be produced by chemicals, heat, light, friction, pressure and by magnetism. Conventional current flow is from positive to negative. Current. Is the movement of free electrons, current is measured in Amps. Voltage. Voltage is an electromotive force (or potential difference) measured in volts. Resistance. Resistance is measured in Ohms and depends on temperature. Ohms Law. At a constant temperature, the steady current flowing through any conductor is directly proportional to the potential difference across its ends.
I =
Where
V R
Your instructor will demonstrate Ohms law and show you how to calculate the different methods of calculating voltage, current and resistance.
Electrical circuits can be measured using a multimeter which will carry out the following tests. a) Continuity. b) Measure voltage. c) Measure resistance. d) Measure current. e) Test a fuse.
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Example of a circuit in series Parallel Is where each component has its own circuit, and if one component fails the others will continue to work.
Questions : 3 ME 8
1. 2. 3.
In which direction does current move? Explain Ohms Law in your own words. What is the difference between series and parallel?
Cadet Objectives
1. 2. 3. Construct a circuit to demonstrate series and parallel connections. Carry out practical measurements of current, voltage and continuity. Demonstrate an understanding of Ohms Law.
Course Notes
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Electrical current
Electrical current is the movement of electrons through a conductor, they are moved by an electromotive force (emf), it is measured in volts, this will have been demonstrated in 3 ME 8 using the multimeter when making electrical circuits.
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Battery Maintenance
WARNING: BATTERY CHARGING OR ANY OTHER FORM OF BATTERY MAINTENANCE MUST ONLY BE CARRIED OUT UNDER CLOSE ADULT SUPERVISION
When checking batteries, personal protective equipment must be worn. This includes goggles, gloves and an apron. A battery hydrometer must be used to check the specific gravity of the battery, for a lead acid type the reading should be 1.230 to 1.260. If using a Nickel cadmium type the reading will be 1.160 to 1.230. A discharged cell will read 1.18 or less on the hydrometer. The readings should be taken at a cell temperature of 20 degrees C. Should the electrolyte need to be replenished, distilled water should be used, and filled to just above the plates. Batteries must be charged in a well-ventilated area with the plugs removed from the top of the battery. There must be No Smoking or naked lights when charging as batteries discharge hydrogen which is an explosive gas. Battery terminals should also be checked for tightness and never make contact between the positive and negative terminals as this will complete a circuit. Battery terminals should be kept clean and protected with petroleum jelly (Vaseline), to stop corrosion products building up.
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Questions : 3 ME 9
1. 2. 3. 4. 5. Explain how electricity is generated for a motor boat. What is the difference between a primary cell and a secondary cell? Why must battery charging take place in a well ventilated area? What are the SAFETY rules when working with batteries? Why are battery terminals kept clean and protected?
Cadet Objectives
Describe the various methods of power generation
Demonstrate the use of a hydrometer and personnel protective equipment when checking the condition of a battery.
Course Notes
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(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (l)
Spanners Sockets Screwdrivers Hammers Allen Keys Pliers Hacksaw Files Fasteners Soldering Iron Multimeter
Open ended, Ring, Adjustable, Box and Combination. Various sizes, Metric and Imperial. Cross-head, Flat-head. Mallet, Ball-pein and Claw. Metric and Imperial. Long-nosed, Side-cutting. Standard and Junior. Half-round, Triangular and Flat. Nuts, Bolts, Washers and Connections. Electrical Electrical
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(b)
Gaskets are pre-formed or can be made from commercial gasket material. Most diesel engine gaskets are now compressed fibre and copper, fitted to prevent the leakage of oil, gas or water. Some joints may be metal-to-metal with jointing compound between the faces.
(c)
Fasteners You should be able to recognise and remove/replace nuts, bolts, washers, screws, clips, split pins and common fasteners.
When a project has been completed, return your tools and ensure that the working area is left in a clean and tidy condition. All surplus items are to be properly disposed of.
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Questions : 3 ME 10
1. 2. 3. 4.
Describe what checks you would carry out on tools for before using them. Demonstrate how electrical connections are checked for security. Why is it important to use the right tool for the right job? Why is it dangerous to use a file without a correctly fitted handle?
Cadet Objectives
1. Demonstrate an understanding of the correct use of standard mechanical and electrical tools. Show how awareness of the correct way to loosen and tighten fasteners, and the likely hazards to health when not using the correct tool.
2.
Course Notes
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The Sea Cadet Corps Marine Engineering Specialisation Progress Chart for Class 3 Lesson 3 ME1 Health & Safety 3 ME 2 H & S - Workshop 3 ME 3 Introduction 3 ME 4 Engine Construction 3 ME 5 Engine Cycles 3 ME 6 Mechanical Systems 3 ME 7 Electrical System 3 ME 8 Basic Electrical 3 ME 9 Power Generation 3 ME 10 Tools & Fasteners 3 ME 11 Practical Projects Revision period Examination Instructor Date
Notes:
1. 2. Apply to your ASO(ME) who will supply an authorised examination paper. SCC form T7(MarEng) to be signed by CO and forwarded to ASO(ME) on completion of the examination.
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Printed by SCHQ
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