flash blowdown of a boiler 1.

BOILER BLOWDOWN Even with the best pretreatment programs, boiler feedwater often contains some degree of impurities,such as suspended and dissolved solids. The impurities can remain and accumulate inside the boiler as the boiler operation continues. The increasing concentration of dissolved solids may lead to carryover of boiler water into the steam, causing damage to piping, steam traps and even process equipment. The increasing concentration of suspended solids can form sludge, which impairs boiler efficiency and heat transfer capability. To avoid boiler problems, water must be periodically discharged or blown down from the boiler to control the concentrations of suspended and total dissolved solids in the boiler. Surface water blowdown is often done continuously to reduce the level of dissolved solids, and bottom blowdown is performed periodically to remove sludge from the bottom of the boiler. The importance of boiler blowdown is often overlooked. Improper blowdown can cause increased fuel consumption, additional chemical treatment requirements, and heat loss. In addition, the blowdown water has the same temperature and pressure as the boiler water. This blowdown heat can be recovered and reused in the boiler operations. Boiler Blowdown Benefits Less water, fuel and treatment chemicals needed; Less maintenance and repair cost (minimized carryover and deposits); Saves manual supervision for other tasks (with automatic control); Cleaner and more efficient steam; Reduced operating cost (reduction in consumption, disposal, treatment and heating of water); Minimized energy loss from boiler blowdown can save about 2 percent of a facilitys total energy use with an average simple payback of less than one year. Flash Tank System The flash tank system shown in the figure below can be used when expense and complexity must be reduced to a minimum. In this system, the blowdowns from the boilers are sent through a flash tank, where they are converted into low-pressure steam. This low-pressure steam is most typically used in deaerators or makeup water heaters. see diagrams on post dated 3-02-2011 by me(felix pinto) Flash Tank Heat Exchanger System The system shown below consists of a flash tank and a heat exchanger. The temperature of the blowdown leaving the flash tank is usually still above 220F. The heat of this flash blowdown can be used to heat makeup water by sending it through the heat exchanger, while cooling the blowdown at the same time. Heating boiler makeup water saves on fuel costs. An additional advantage of

cooling blowdown is in helping to comply with local codes regulating the discharge of high temperature liquids into the sewer system.

2.Catalytic Fines Catalytic Fines Origin: By-product from the catalytic cracking process in the refinery Catalyst consists of complex crystalline particles containing aluminium silicate Catalyst fines result from catalyst particles breaking into smaller particles Catalyst is expensive, i.e. refiners minimise loss but not 100% Effects * Severe wear of Liners * Severe wear of Rings * Wear out of Cyl-grooves * Scuffing of liner * Abrasive Wear of Spindle-Guide & cut-off shaft & nozzles * Scuffing of Fuel Pump spindle guide Specification Variable in size ranging from sub microic to about 30 microns even seen larger Frequently considered spherical but this is not necessarily the case Hard particles Hardness not directly related to relative hardness of Al or Si Can cause abrasive wear ISO 8217 specifies the catalyst fines by Al and Si ISO 8217 limit is 80 mg/kg Al+Si for marine residual fuels (Note: ISO 8217 limit is for bunker not at engine inlet) Reduction Gravitational settling Centrifuge (Note: Homogenisers will not reduce the amount of catalyst fines but might instead break them into even smaller particles) Overhaul and maintenance intervals must be kept according to

manufacturers recommendation Temperature control very important The higher the temperature the better the separation efficiency. Both density and viscosity of the oil decrease when the temperature rises, thereby increasing the settling velocity (Stokes law) (If the separation temperature is lowered from 98C to90C the separator throughput has to be reduced by25-30% to maintain the same separation efficiency!!)

3.CRANK CASE INSPECTION (20 points) 1. Firstly check the oil condition for any smell,discolouration or degradation. 2. Turn the Engine to BDC & start checking from under stuffing box area for any signs of black oil, if so indication of stuffing box leaking. 3. Check piston rod surface for scoring marks & roughness. 4. Check Piston palm bolts & locking device for slackness & fretting. 5. Check guide & guide shoe bearing general condition & area around frame where guide is attached for any visible cracks. 6. Check guide shoe end cover bolts in place & not slack. 7. Check cross head general bearing condition. 8. Top & Bottom end of the con rod bolt, nut & locking devices for slackness,sign of fretting etc. 9. Check sliding of bottom end bearing (floating of con rod). 10. Check for slip of web & journal by checking the reference mark. 11. Check the web in the area of stress concenteration & check tie bolts (bottomside). 12. Check cross girder , area around main bearing & bearing keep for signs of cracks & check the main bearing. 13. All bearings to be checked for silvery colour, (indicates bearing wiping) 14. Check all the surrounding oil pan area of all units for any sludge deposits, bearing metal pieces etc. 15. Check crankcase releif door (wire mesh should be wet, spring tension sealing condition etc.) 16. Check the teeth of transmission gears for signs of wear. 17. Check chain drive for tightness. 18. Oil mist detector sampling pipe to be checked for clear passage. 19. Clear all foreign materials from the C.C. & tools accounted for. 20. Start L.O.p/p & X-Hd p/p & check oil flow & distribution. 21Check C.C.door sealing condition & close the door.

4.BABBITTING is a process by which relatively soft metals are bonded chemically or mechanically to a stronger shell or stiffener, which supports the weight and torsion of a rotating, oscillating, or sliding shaft. The babbitt, being softer than the shaft and having excellent antifrictional qualities, prevents galling and/or scoring of the shaft over long periods of use. Compositions and selected properties of babbitts are summarized in Tables and and Fig.. Babbitting is named for Isaac Babbitt, who patented the process in the United States in 1863. Babbitt metals, which are more widely known as white metals, are comprised principally of tin alloys (hardened with copper and antimony) or lead alloys (hardened with tin and antimony and, in some cases, arsenic). In the babbitting process, the relatively soft bearing material (babbitt) is bonded to a stronger supporting base metal, typically mild steel, cast iron, or bronze. The base metal may be in the form of mild steel strip unwound from a coil, a half-round mild steel pressing or bushing, or a bronze or iron casting. The bonded bimetal material is shaped and machined to make plain, fluid film lubricated bearings for a wide variety of automotive, industrial, and marine applications. Babbitt is used in small bearings for highvolume applications, such as electric motors and internal combustion engines, and for large rotating and reciprocating machinery with low to modest volume requirements, such as high-speed turbines and low-speed marine diesel engines. In addition, babbitt has been used for jewelry, shot, filler metals, and various other applications. Lead-base alloys enjoy a cost advantage, while tin alloys offer modest technical advantages, particularly in high-speed centrifugal equipment. It should be noted that government regulations now discourage the use of lead-base alloys for health and hazardous waste disposal reasons. Babbitting of bearing shells can be accomplished by three methods: Static babbitting (hand casting) Centrifugal casting Metal spray babbitting Centrifugal casting and static (gravity) casting are the two babbitting methods used in the manufacture and repair of large, low-volume journal (radial) and thrust bearings. Centrifugal casting of journal bearings offers both technical and economic advantages if special spinning equipment is available. Flat shapes (thrust bearings) are usually statically cast. Repairing of industrial and marine babbitted bearings is routinely accomplished by melting off the old metal and rebabbitting the shells with new metal, following the same basic casting methods described below for producing new products. Emergency repair methods using proprietary tinning compounds, babbitt spray, or welding techniques can be employed. Suppliers of such repair equipment should be consulted for operating instructions. Thinwall babbitted half bearings, rolled bushings, and flat thrust washers are mass produced from bimetal strip stock. The strip stock is produced by continuously feeding coils of low-carbon steel in ribbon form first through appropriate cleaning and tinning baths and then through a stream of molten

babbitt, which is gravity cast on the moving strip. The strip is immediately water-chilled from below. After excess babbitt is removed, the stock is recoiled and is ready for press blanking, forming, and finish machining operations. Details of mass production methods for making babbitted bearings are proprietary to the manufacturers involved, and beyond the scope of this article.

5.Differences between MC/MC-C and ME/ME-C engines The electrohydraulic control mechanisms of the ME engine replace the following components of the conventional MC engine: Chain drive for camshaft Camshaft with fuel cams, exhaust cams and indicator cams Fuel pump actuating gear, including roller guides and reversing mechanism Conventional fuel pressure booster and VIT system Exhaust valve actuating gear and roller guides Engine driven starting air distributor Electronic governor with actuator Regulating shaft Engine side control console Mechanical cylinder lubricators. The Engine Control System of the ME engine comprises: Control units Hydraulic power supply unit Hydraulic cylinder units, including: Electronically controlled fuel injection, and Electronically controlled exhaust valve activation Electronically controlled starting air valves Electronically controlled auxiliary blowers Integrated electronic governor functions Tacho system Electronically controlled Alpha lubricators

6.Actions taken during boiler uptake fire? (Boiler uptake fire is because of wet soot deposited during low steaming and also during uptake fire do not carry out soot blow reduce the load and stop the engine , cover the m/e t/c with the canvas so that no air is supplied)

7.Needle vv lift. (1.4mm for 250 bar lifting pressure) 8. Boiler corrosion how it happens and how to prevent. (Acidic corrosion-CO2, O2, OIL, CHLORIDES, BICARBONATES and pitting corrosion: scales such as calcium and magnesium salts.) 9. Accumulation pressure test in boiler ( accumulation pr should not more than 10 percent of working pr. when boiler is firing on full load for boiler). 10. How to reduce maintenance in exhaust vv (good quality fuel usage , vit adjustment, avoid running engine on low load, check fuel injection system, good scavenging, maintaining cooling water temp, check rotation of exhaust v/v) 11. Refrigeration gases how its classified according to environment hazard (ozone depletion potential- max R11, for R22 is 0.05 and global warming potential- max is R11.and R22 is 0.365) 12. AE inlet vv big or exhaust vv big and y? A/e inlet valves are bigger, no back pressure in t/c free flow, better scavenging exhaust gas expelled easily, and exhaust v/v is smaller due to less power required to open

13.SCR system, ammonia slip, catalyst? (selective catalyst reaction- exhaust is mixed with ammonia and passed through a catalytic reactor, hence reduction in NOx. And soot in exhaust. Temp.-290-450 C. FINAL PRODUCTS WATER AND NITROGEN PG 78-80 POUNDERS) 14.ASTM means American society for testing of materials, it develops standard for materials, product, systems used in construction, manufacturing and transportation. 15. SAE is society of automotive engineers; it gives the viscosity of oil based on a classification involving 2 temperatures 16. composition of lpg, lng and cng (lpg-propane, butane, lng-metane, cngmethane)

17. Maintenance on QCV? Try out once every 3 months, drain air bottle, check hand operation, spring condition, check piston

18.Manhole door elliptical...why? Manhole door elliptical: longitudinal pressure = pd/4t or circumferential pressure=pd/2t where p=pressure, d=diameter, t=thickness...so circumferential pressure is more 19. Why 3 injectors are used in modern 2 stroke engines (There will be better turbulence since three fuel injectors at an angle and the scavenge air enters at an angle so there will be better turbulence, there will be more proper heat dissipation in piston and cylinder head)

20.Why steam is grey in color and not transparent? (water content in soot release) 21. How does MGPS works? (2purpose: Cu kills sea growth and Al stops corrosion, the system is based on electrolytic reaction and dc supplied to anode) 22.What is Muntz metal, monel metal, white metal compositions and which is more electrochemically active of them? Monel- copper-38 n nickel-60,al and manganese-2, white metal- tin-88, antimony-7.5, copper-4,lead-0.35, muntz metal-copper-60, zinc-40 23.A compressor was overhauled and bumping clearance was found to be normal inspite of that piston strikes the head. Give reasons? (in unloaded condition: Bottom end bearing wear down of lower half will cause this-maybe 24.What is dealuminification where is it observed and why? Form of corrosion in which amount of aluminium decreases in an alloy pumps, valves coz Al is comparatively more reactive

25. Function of motor on governor Remote operation of speed setting knob-by adjusting spring pressure 26.How to prevent Dezincification? (put soft iron anodes) 27. How will you make camshaft float while adjusting its position? hydraulic pressure 28.Limitations of ODME Difficulty in analyzing- bad weather, muddy water, discharge capacity increases in bad weather as speed is measured when the ship is not moving as much 29.DESUPERHEATED STEAM. WHY AFTER SUPERHEATING WE ARE USING DESUPERHEATER Desuperheating, sometimes called attemperation or steam conditioning, is the reduction of gas temperature. Its most common application is the reduction of temperature in a steam line through the direct contact and evaporation of water. Most Desuperheaters incorporate the venturi design which uses the velocity of the steam to atomize the cooling water. In addition, Ejector Atomizing Desuperheaters, Attemperator Desuperheaters, Surface Absorption Desuperheaters and Mechanical Atomizing Desuperheater designs are available. In most types, water pressure requirements are the same as the steam line pressure 30.COP OF REFERIGERATION. (A refrigerator is a device for removing heat at a cold temp so heat absorbed in the evaporator fi(in),the cop is also called advantage and is defined as C.O.P. In a refrigeration cycle, the ratio of the heat energy extracted by the heat engine at the low temperature to the work supplied to operate the cycle; when used as a heating device, it is the ratio of the heat delivered in the high-temperature coils to the work supplied)

31. Refrigerant properties? pg-335 mc. G: the heat of vaporization of the refrigerant should be high, the specific heat of the refrigerant should be low. the specific volume of the refrigerant should be low to minimize the work required per kg of refrigerant circulated, since evaporation and condenser temperatures are? xed by the temperatures of the surroundings - selection is based on operating pressures

in the evaporator and the condenser selection is based on the suitability of the pressure-temperature relationship of the refrigerant other factors include chemical stability toxicity cost environmental friendliness does not result in very low pressures in the evaporator (air leakage) does not result in very high pressures in the condenser (refrigerant leakage) OR condensing pressure should be moderate. b) But the pressure should be preferably above the atmospheric pressure so as to prevent air from entering the system in the event of leak. c.) Low freezing point d.)Volume of refrigerant gas need to be pumped per ton of refrigerating effect should be low. d.) it should have high Thermodynamic efficiency - Thermodynamic efficiency is the ratio between heat abstracted by the refrigerating machinery and the heat equivalent of the power supplied the compressors e.) it should not be flammable or explosive. f.) it should not be toxic. g.) the tendency of a refrigerant to leak should be low, and the detection of leak should be easy. h.) for good heat transfer viscosity should be low, thermal conductivity high. i.) it is preferred that there should not be a chemical reaction between the refrigerant and the lub oil. j.) cheaper in cost. k.) non corrosive, non flammable, chemically stable, non explosive, miscibility with oil, ozne depletion potential, high critical temperature. 32.What is lean mixture in dual fuel combustion engine? Lean burn means the mixture of air and gas in the cylinder has more air than needed for complete combustion, reducing peak temp- less NOx, eff inc bcoz of higher compression ratio and optimsed injection timing. 33.Whats the time period to discard a chain and renew with new one in B&W tell the percentage elongation max allowed in 1 inch chain link? Max allowable limit of elongation is 1.2% , chains should be removed once in 8 yrs or 50,000 hours)

Exhaust gas of all units high cause? (bad quality fuel, faulty fuel system, poor scavenging)

34.LONG STROKE AND SUPER LONG STROKE ENGINES CONSTRUCTION DIFF. AND ADVANTAGES OF SUPERLONG OVER LONG STROKE. (super long adv is more time for scavenging and more air so more eff, less speed) 35.SPCV IN SULZER

Spcv is stagnation pressure control valve used to suppress the after injection on RTA engines. If the SPCV is removed, the fuel pump is directly connected to the high pressure pipe allowing stagnation pressure to drop to a level where cavitations can occur. 36. Why AE NOX is less Time is very less for producing NOx as reaction time is less 37 .The m/e t/c lub is supplied by m/e lo p/p, during sudden lub p/p failure how t/c is protected. POST LUBRICATION TANK and lubrication system. During normal engine operation the post lubrication system is continuously filled by lube oil via a small bypass line from the m/e l.o. system that also supplies the t/c. Excessive ...l.o. is unpressurised supplied back to the m/e l.o. circuit by means of a free o'flow.In case of a shutdown or blackout of the m/e where the l.o. supply from the m/e to the t/c is interrupted, the l.o. flows down from the from the post lubrication tk by gravity, ensuring the lubrication and cooling of the two plain bearings during running out of the rotor for up to 20 mins. The m/e should be stopped within this time!! This system features 2 separate oil inlet pipes and 2 running down pipes with different levels from the post lubrication tk to the brgs. This ensures that in case of standstill of m/e and shut off l.o. supply that the turbine side brg is longer lubricated and cooled than the blower side brg. This tk is @ atmospheric pressure.) 38. what is d difference between pipe thread and bolt thread pipe thread is bsp, less deep, lesser pitch and bolt thread is metric

39.what are the safeties on air bottle (relief valve, bursting disc, pressure cut-out switch, low pr. Alarm)

40.Cylinder lubrication, TBN how much it should be (HFO-70, LSFO-30-40)

41.What all checks to be made on liner before giving it for survey

Ovality, wear, surface condition, polishing, glazing, cracks 42.What causes ovality of liner Crosshead guide shoe and guide clearance 43.what are liner ribs and why they are in segments and use Provided at upper parts of liner to withstand combustion pressure and strengthening, in segments for freedom of coolant to flow 44.what is the special construction of pedestal bearing on free end of rotor in auxiliary engine (margin for expansion) 45.What is fitted bolt? How is it fitted? Where is it used? Fitted bolts are used to connect rudder stock with rudder. This is a closely fitted bolt. The holes are initially drilled to undersize and are reamed in the assembling place before the bolts are tightened in place. Accuracy is required in the machining. These bolts could be of two types one having ...a slight taper of about 1:100 on diameter and the other having a large taper of about 1:15 on diameter. However, the holes in either case are reamed in final place. Sometimes an oversized bolt is stretched hydraulically reducing the bolt diameter. When tightened down and the hydraulic pressure is released the final exact fit in the bolt hole is achieved, like a pilgrim nut on coupling shafts. These bolts find place in engine / boiler mountings, coupling shafts etc. and form a rigid fixture. On main engine mounting these are situated aft of the engine in the way of thrust block. 46. Interference bolt and fitted bolt are they same? Fitted bolt dia and hole dia are the same. They are fitted by hammering. Interference bolt dia is slightly bigger than the hole dia and these bolts are fitted by hydraulic stretching and later bolted and the hydraulic pressure released. 47. Waste gas system A waste gate arrangement is a valve in turbocharger that regulate amount of exhaust gases in the turbine side of tc diverting some of the exhaust gases directly in exhaust piping this will regulate the speed of tc and thus the compression ratio on the compressor side of tc. this is sometimes required in winter season as the air is cold thereby dense and less compression is needed as tc are designed on normal temp so this arrangement is sometimes

there for winter season. 48.What is VIT and super VIT. Before the Super VIT was introduced variable injection timing was obtained by means of a special profile on the fuel pump plunger. Hence there was a fixed relationship between the injection timing and the fuel index. Thus it was not possible to adjust the fuel index of the individual pumps without also altering the injection timing. For this reason the Super VIT was introduced, where it is possible to adjust the fuel index and the injection timing independently In VIT beginning of injection could be controlled, but end of injection was fixed, due to profile of plunger n thus amount of fuel injected could not be changed with varying angle of injection at beginning. Thus MAN came up with super VIT where beginning n end both could be controlled by raising or lowering barrel in relation to plunger. Sulzer system when introduced vit way back in 80's it could control both beginning n end. Thus super VIT is for MAN B&W engines only 49. Wat is nitriding? Nitriding is a heat treating process that alloys nitrogen onto the surface of a metal to create a case hardened surface. Three methods are there for nitriding 1. gas nitriding 2. salt bath nitriding. 3. plasma nitriding.) Nitriding is a surface-hardening heat treatment that introduces nitrogen into the surface of steel at a temperature range (500 to 550C or 930 to 1020F), while it is in the ferrite condition. Thus, nitriding is similar to carburizing in that surface composition is altered, but different in that nitrogen is added into ferrite instead of austenite. Because nitriding does not involve heating into the austenite phase field and a subsequent quench to form martensite, nitriding can be accomplished with a minimum of distortion and with excellent dimensional control.

50. What is the similarity and difference between a m/e governor and flywheel (gov maintains speed of engine, flywheel controls cyclic fluctuation of engine rpm, flywheel works on virtue of inertia alone, govnr uses inertia to actuate fuel linkage to counter change in rpm) 51. What is a thermal boiler? Water and steam are typically used as heat carriers in process heating systems. But at high temperatures, water and steam requires a corresponding high operating pressure. In industrial heating systems this high temperature level is often a great advantage in order to get a high output of the process. Thus establishing this

with water and steam, you must deal with systems and components of high pressure. This means large dimensions, weights, more safety issues and thus extra costs. In thermal oil boilers (thermal oil heaters), a special oil-based thermal fluid is used as the heat carrier, instead of water or steam. This oil operates at atmospheric pressure up to 300C. Comparing to water and steam, it would require a corresponding pressure of 85 bar to obtain this temperature. This system is used in ships which carry cargo like bitumin n coaltar 52.What are persistent oils? What are its effects on marine environment? (persistent oils generally contain a large proportion of heavy fractions or boiling materials. Dont dissipate rapidly)

53,TYPES OF TEMPERING : Tempering from outside: The cold workpiece is slowly Heated by means of appropriate heat sources and after having reached the tempering temperature (between 200C and 500C) it is cooled down. Tempering from inside: The workpiece is shortly quenched after having been hardened so that only outer layer is cold. The residual heat penetrates from inside, after having reached the tempering temperature it is cooled down. The same effect can be reached when the workpiece is cooled down only on one side and the heat contained in the other part runs after again.

54. Compression ratio:- The ratio is calculated by the following formula:

, where = cylinder bore (diameter) = piston stroke length = clearance volume. It is the volume of the combustion chamber (including head gasket). This is the minimum volume of the space at

the end of the compression stroke, i.e. when the piston reaches top dead center (TDC). Because of the complex shape of this space, it is usually measured directly rather than calculated 55. Shrouding :- shrouding occurs if mitered valve seats are repeatedly ground and the consequent ridges are not removed. If the material of the valve is harder than the valve seats the shroud builds up in the seat. If the seat is harder than the valve then shrouding occurs in the valve. When a valve and seat are ground together with grinding paste some material is removed and eventually the seating faces become lower than the shrouding material and a step is formed circumferentially. Although the actual distance that the valves opens remains constant the effective opening area across the valve and seats face is reduced by the amount of the shroud. Even small amount of shrouding can seriously affect the air or gas flow across a valve.

56 .Why during rudder test we are doing 35 degree and 30 degree y not both 35 degree The feedback system on the steering gear gradually reduces the speed of the gear with in the last 5 degrees of the gears full rotation. if we put to 35 then the hunting gear will start to reduce the pump stroke and achieving this in a time frmame of 28sec will nt be possible .so the test is done frm 35 to 30....

57. Procedure for CWT test 1. Fill the sample cup to the 25 mL mark with sample (fig 1). 2. Slide the open end of the valve assembly over the tapered tip of the Titret1 so that it fits snugly to the reference line (fig 2). 3. Snap the tip of the Titret at the score mark (fig 3). 4. Lift the control bar and insert the Titret assembly into the body of the Titrettor2 (fig 4). 5. With the tip of the valve assembly immersed in the sample, press the control bar firmly, but briefly, to pull in a small amount of sample (fig 5). The contents will turn a green color. CAUTION: Do not press the control bar unless the tip of the valve assembly is immersed below the surface of the liquid. 6.Press the control bar again briefly to allow another small amount of sample to be drawn into the ampoule (fig 5). 7. After each addition, rock the entire assembly to mix the contents of the

ampoule. Watch for a color change FROM GREEN TO BRIGHT ORANGE. NOTE: Immediately before the contents turn bright orange, they will briefly turn blue. Make further additions with care. 8. Repeat steps 6 and 7 until a permanent color change occurs. 9. When the color of the liquid in the ampoule changes to BRIGHT ORANGE, remove the ampoule from the Titrettor. Hold the ampoule in a vertical position and carefully read the test result on the scale opposite the liquid level (fig 6). See the following chart to obtain results in ppm product. Satisfactory Ranges Scale Figure e Product Scale ppm product LIQUIDEWT 1.2-1.8 3 10,0000 -15000 ^ MAXIGARD1 1.6-3.0 19,000-36,000 ' DEWT NC .5-5.0 3,000-4,300

58. What are the most dimension of engine. Stroke, bore, distance between 2 cylinders,crank shaft dia.

59.what is the advantage of sleeve bearing in turbocharger in man b&w engine?how many hours after u will do major overhaul as per manual. sleeve type brg is in man b&w engines are provided are lengthier and have a stabilizin influence on shaft alignment and long vibrnthey have a face machined to take the thrust similar to thrust pad type..these are supplied by extrnl oil feed and emergncy lo sup tk 60. why jack bolts are provided in sulzer engine?main purpose? To hold the bedplate,frames and entablature firmly together in compression and to transmit the firing forces back to the bedplate long tie bolts are fitted in through this 3 components and then tighten hydraulically. To prevent this excessive bending moment in transverse girder the tie bolts are positioned as centre of the crankshaft as possible. Because of the tie bolts so close to the crankshaft sulzer employs jack bolts to hold the crankshaft main bearing cap in position instead of conventional studs and bolts.

61. How you will purge air from refrigerant compressor? Close condenser liquid outlet valve

Keep cooling water to condenser on till s.w.outlet temp = inlet temp Check condenser sw outlet temp Check correct condenser pr for the corresponding temp Release air ( using purge v/v on top of the condenser) till the pressure in the condenser comes correct.

Law used is Dalton law of partial pressure.

62. Induction hardening Induction hardening is a form of heat treatment in which a metal part is heated by induction heating and then quenched. The quenched metal undergoes a martensitic transformation, increasing the hardness and brittleness of the part. Induction hardening is used to selectively harden areas of a part or assembly without affecting the properties of the part as a whole. Induction heating is a non contact heating process which utilises the principle of electromagnetic induction to produce heat inside the surface layer of a work-piece. By placing a conductive material into a strong alternating magnetic field electrical current can be made to flow in the steel thereby creating heat due to the I2R losses in the material. In magnetic materials, further heat is generated below the curie point due to hysteresis losses. The current generated flows predominantly in the surface layer, the depth of this layer being dictated by the frequency of the alternating field, the surface power density, the permeability of the material, the heat time and the diameter of the bar or material thickness. By quenching this heated layer in water, oil or a polymer based quench the surface layer is altered to form a martensitic structure which is harder than the base metal.[2]

63. Volumetric efficiency. This is the ratio of the volume of air drawn into the cylinder(at normal temp and pressure) to swept volume . In naturally aspirated four stroke engines the volumetric efficiency will be from 0.85 to 0.95.

64. How to order greese?

NLGI Grades 000 to 1 are used in application requirings low viscous friction. Examples include enclosed gear drives operating at low speeds and open gearing. Grades 0, 1 and 2 are used in highly loaded gearing. Grades 1 through 4 are often used in rolling contact bearings where grade 2 is the most common. 65. Compression ratio,Stoichiometric ratio values of your last ship compression ratio min req for combustion of diesel is arnd 16 but is maintained arnd 22 in most of the engines stoichiometric ratio is 14~15. Stoichiometric ratio is around 14 to 15 :1 that is 14 parts of air per part of fuel. It does not depend upon whether the engine is 2 stroke or 4 stroke. It is just the value of right quantity of air required for complete combustion of fuel so it a function of fuel quality and depend upon the chemical composition of fuel. Why piston rings are positioned in a down place in a marine engines as compared piston rings are down in IC engines as the temperature above will be higher and may cause LO particles to break down and hence loss of lubrication while in case of AC compressors temp is not so high as no combustion of fuel is there and hence less temp are experienced so the only criterion is to increase the volumteric efficeincy of the engine.

66.How to measure T/C rpm. Turbocharger rpm s measured on the same principle of induction motor. A magnet is there at the end of the turbocharger shaft and it is rotating in a coil now the emf generated in the coil will be a function of rpm of the turbochager shaft and hence the emf can be calibrated as a function of rpm of turbocharger

66.Bore cooling,why in angular direction bore cooling is in angular direction as it increases the effective heat transfer area and also does not compromise on the strenghth too much\

67.Bumping clearance =so so; but still piston hitting,what are the reasons.

if the bumping clearance is ok and piston is still hitting the crown this means ur bottom end bearing has worn out and clearance has increased and when the piston is moving up its hitting the cyl head due to inertia.

68. Change fuel oil from HFO to DO at same fuel rack,whether speed increase or decrease,Why. The calorific value of diesel oil is higher than that of heavy oil so the speed in diesel should increase but the calaorific value is measured per unit mass and not volume and all ur fuel pumps that is the metering devices of fuel controls the volume of fuel oil injected. now the effective mass of heavy oil is much more than the diesel oil for same volumes of both oils. taking both into account the effective result is that the speed is DECREASED when u changeover from heavy to diesel oil.

69. Hydrodynamic lubrication and boundary lubrication.

Diesel engine bearings are lubricated by fluid films. The journal is always smaller than its surrounding bearing. When the shaft is static it will make contact with the bearing and this contact will be a line. On each side of this line the normal distance betweens the shaft and the bearing will increase gradually and will in effect be a curved wedge. When the shaft revolves in the presence of an adequate liquid supply (lub oil) the oil is pulled into the wedge and pressure is set up. The pressure of liquid in the wedge shaped space sets the shaft over to one side and lifts the shaft away from the bearing so it is supported by an oil film. The position where the oil film thickness is least will be a small distance away from the static contact line in the direction of shaft rotation. For pressures to build up to a value high enough to separate shaft from the bearing, the oil must have sufficient viscosity and the speed of the shaft muct be above a certain value. This form of lubrication is known as fluid film or hydrodynamic.

Boundary lubrication occurs when the rotational shaft speed falls and oil wedge is lost. Metal to metal contact then occurs. To prevent metallic contact under boundary conditions grease may be used or additives may be added to the oils. The bearing of the diesel engine do not work under boundary

conditions. Very highly loaded crosshead bearing in 2 stroke engine may approach boundary conditions.

In diesel engine bearings are supplied with large quantity of oil to maintain the oil film and remove the heat generated.

70.Advantages and disadvantages of single and double volute casing. Yes, single volutes have more radial load on the shaft but the advantage is that the load is very predictable. We may not like radial loads but hey, bearing technology is very well developed. A dual volute is basically two pumps in one casing. At one point or another depending on the design and on the machining quality and precision one of these pumps will shut off the other and radial loads will become unpredictable. However, if your operation point is well known you will be able to stay out of troublesome operation area's regardless of the type of design. *A double volute scroll pump has almost no radial thrust at any point on the curve, from zero flow all the way out to well beyond the BEP. In other words, the double volute pump has little or no radial thrust reaction to operation above or below BEP. But a single volute pump has a very pronounced radial thrust reaction when operated off BEP. If the bearings and shaft are insufficient to withstand the thrust, bearing and shaft life are shortened. *The single volute pump impeller will deflect either 60 or 240 from the cut water depending upon which side of the pump's best efficiency point (BEP) you are operating. *The double volute design is actually two single volute designs combined together. Although this drawing does not show it clearly, the total throat area of the two volutes is the same as the single volute design. Double volute pumps were created to eliminate most of the radial thrust caused by operating off the pump's best efficiency point (BEP). *Testing has shown that the double volute does not entirely eliminate the radial forces, but they are reduced greatly. Although the volute is symmetrical around its centerline, the two passages directing the liquid to the discharge nozzle are not. This means that the radial forces do not exactly cancel and a slight radial force does exist. Testing has further shown that a double volute pump will be 1% to 2% less efficient at its best efficiency point (BEP), but 2% or more efficient on either

side of the best efficiency point (BEP). This means that the double volute will have an overall higher efficiency than its single volute cousin. Unfortunately many pumps are purchased with the efficiency given at the best efficiency point not the actual operating point used to make the purchasing decision. Double volute pumps should never be specified for low flow (less than 400 gpm or 90 m3/hr.) operations especially if there are solids in the product. The narrow passages behind the dividing rib can easily clog with solids. They should, however, always be specified for larger volume applications. The rib can cause some production problems with the castings especially in small sizes. Testing has shown the minimal radial thrust was experienced when the dividing rib did not extend all the way to the volute discharge flange. On large pumps there has been some problems with the rib cracking at the center when the pump is subjected to high hydro test pressures. The reason for this is not really understood. Some manufacturers ignore this because in operation they know that the pressure will be the same on both sides of the rib. Other manufacturers leave a gap of 2-3 millimeters in the center to prevent the cracking. Triple volute casings have been tried, but haven't proved to be effective enough to justify their high manufacturing cost. If you have an occasion to repair the double volute cutwaters (and you can with some of the newer metal repair compounds), be sure the cutwaters are located physically 180 degrees apart. Many large double ended pumps have atrocious L3/D4 shaft numbers and are therefore supplied with a double volute as a standard.

71.Advantages of plate type cooler Plate cooler are smaller and lighter than tube type cooler giving the same performance. No extra space is required for dismantling Higher efficiency is shown by the smaller size Plates can be added in pairs to increase the capacity and similarly damaged plates can be easily removed if necessary without replacement. Cleaning and maintenance is simple

Turbulent flow helps to reduce the deposits which would interfere with heat flow. Flow velocity is not limited as is in the case of al br tube. Mixing of fluids not possible unless plate cracks. Disadvantages of plate type cooler Plates cant be tested for leakage easily hence crack plates are difficult to locate. Deteriorated joint are difficult to remove and hence remove on the site. Expensive due to large number of plates and cost of titanium and joint required. Plates are easily damaged due to over tightening. Operating temp limit (200 deg c) Operating pressure limit (20 bar).

72. High lift and improved high lift safety valve. High lift :- winged valve , waste steam piston and no floating ring. Improved high lift safety valve:- wingless valve , waste steam piston, floating ring. Formula for calculating :C X A X P = 9.81 X H X E Where c discharge coefficient which depends upon the type of valve. c- for high lift 7.6 c- improved h.l. 9.2 A aggregate area through seating of v/v in mm2 P- working pressure of safety v/v in Mn/mm2 H- total heating surface in m2 E- evaporative rate in kg of steam /m2 of heating surface per hr.

Deriving we get D2C=constant D is diameter of seating of one valve.

For super heated steam As A(1+Ts/555) As- aggregated area thorugh the seating of the valves in mm2 for superheated steam. aggregate area through seating of v/v in mm2 Ts- degree of superheat in degree celcius.

73.Laminar and turbulent flow Reynolds number. Reynolds number = velocity of fluid x pipe diameter/ kinematic viscosity. If the number is less than 2000 the flow is stram line If the number is more then 2500 then flow is turbulent.

The laminar stream line flow of a fluid whose velocity variation is approximately parabolic . being a max in center and zero where the fluid is in contact with the pipe or plate surface.

74. Centrifugal pump cannot handle air but turbocharger can? Both cent pp nd t/c does one thing in common ... it addes kinetic energy to the medium by inducing centrifugal force to medium ... due to this cent force , the medium moves out from impellar eye nd this creates a vaccum behind it which causes low press and so the new medium is pushed in to the eye...... so the amount of cent force determines the medium being moved out from eye to the periphery.... but this cent force = mv^2/r=mw^2r as (v=wr) ....... so the cent force depends on mass and velocity ...... in cent pp , the medium being liquid mass is more so the velocity can be less to push the liq out ... but in T/c , the medium being air , the mass is less so since the velocity is high , it can pump out the air..

75. How feed is adjusted in boiler corresponding to demand in auto A drum level is only measured parameter, this type of control scheme is usually referred to as single element feedwater control. An electronic D/P cell monitors the drum level over a span of 2-3m, and provides a measurement signal to the level controller(LIC) The usual feedwater Cv is an to open (A/O) style which will fall closed upon loss of instrument air,An increase in pneumatic signal applied to this actuator will increase with feedwater flow.

76.Two element feed water control. If the true steam flow was measured then a predictive control decision could be made regarding the drum level. Elbow taps could be installed on the steam line to provide a differential measuremtn input to an electronic D/P cell. This differential signal is routed to a square root extractor to provide a linear flow signal. A two element feed water control scheme can be designed .

77.why thrust pad is in pieces, y not single piece. by being in pieces each pad can generate its own hydrodyn film.....so as compared to a normal journal bearing more area can be utilized for the film and taking load.

78. liner bending stress? where and how? liner bending moment is maximum at the liner flange....its bcz the line of action of forces by the cylinder head and reaction force from the entabulature don't pass thru the same line and hence a bending moment is setup in the liner flange..

79. Engine vibrations Axial vibration when the crank throw is loaded by the gas pressure thru the con rod mechanism the arms of the crank throw deflect in the axial direction of the c/s exciting axial vibrations. These vibration may be transferred to the ships hull thru the thrust bearing. Remedy Axial vibration damper. Torsional vibration the varying gas pressure in the cylinders during the working and the c/s conrod mechanism create a varying torque in the c/s. it is these vibration of the shaft system. Tortional excitation also comes from the propeller thru its interaction with the non uniform wake field. Remedy modify c/s natural frequency by adjusting its dia. Use a torsion damper.

80. Under critical running The natural frequency of the one node vibration is so adjusted that the resonance with the main critical order occurs about 35 to 45 % above the engine speed at specified MCR . the characteristic of an under critical system. Relatively short shafting system Probably no turning wheel Turning wheel with relatively low inertia

Large dia shafting Without barred speed range

81. Over critical running The natural frequency of the one node vibration is so adjusted that resonance with the main critcal order occurs abt 30-40 % below the engine speed at specified MCR. The characteristics Turning wheel may be necessary on c/c fore end Turning wheel with relatively high inertia Shaft with relatively small dia (shaft mat with relatively high uts) With barred speed range of about +/- 10% with respect to the critical engine speed.

82. Choke The engine is supported on a series of chocks fitted around the underside of the periphery of the base of the bedplate. The chocks sit on the foundation plate which forms part of the inner bottom platting of the hull structure. The holding down bolts pass through holes in the bed plate. Chocks and foundation plate. When all the holding down bolts are tightened the bed plate is held fast to the hull structure. The choks are fitted in place after the engine has been aligned to the intermediate shafting. The spacing between the choks is approx 250-400mm and they are closely spaced in the ;location of cross girder so that good support is given to the area of the bed plate which is supporting the main bearing and engine A frame. This prevents any localized distortion or sag in the bed plate and so makes the support from the chocks a continuous effect.

83. Light spring diagram :- it is also known as scavenge efficiency diagram. This dig is taken with a light spring. The variation of pressure in the cylinder during exhausting and scavenging is magnified in a separate dig. The pressure during this part of the cycle is low so a light spring is utilized. For most of the time cylinder pressure is outside the range of the spring. The drop in pressure is a measure of clearances of exhaust passages . this dig also shows the pressure of scavenge at cylinder intake.

84. Why governor spring is conical. It seen that variation of spring force is having non linear relation with the variation of speed. The desired linear relation is achieved by designing the spring conical or combination of springs of varying diameter and stiffness.

85. How signal is carried to ecr from rpm indiactor. Magnetic pick up sends signal to transducers, o/p coming from the transducer is filtered signal conditioned and chopped. Finally it is converted into square waves. The square wave is passed through phase lock loop multipliers. The o/p is gated by a precise time base generated through piezo crystal and then counted. This counts are displayed in bright LED. Its nothing but RPM with accuracy of +/- 1 .

86. What are the safeties provided on the A/C or fridge compressor. L.P. cut out H.P. cut out. Relief valve Check valve at the discharge of comp to prevent reverse rotation when stopped. High temp sensor at discharge Oil diff pressure trip Master solenoid valve at condenser discharge to prevent flooding of evaporator in case of comp stop or abnormal stop.

87. Steering gear safeties Hydraulic tank low level Overload Power failure Relief valve

Bypass valve Auto change over 35 deg- telemotor change over switch 36 deg- telmotor limit switch 36.2 deg- ruddr angle limit switch 37deg rudder stopper 39 deg mechanical stopper

88. Windlass safety- electrical electromagnetic brake, motor overload, short ckt protection, restart delay timer, remote stop. Mechanical manual mechanical brake, cable stopper, slipping clutch, relief valve.

89. Zero setting what is the significance of its name? At zero position of the governor the load indicator and cut out servomotor should coincide for zero fuel injection. At zero setting shield position the suction and spill valves must never be closed at the same time i.e. one is open other is closed.

90.Creep:- creep is the tendency of a solid material to slowly move or deform permanently under the influence of stresses. It occurs as a result of long term exposure to high level stresses that one below the yield strength of the material . creep is more severe in materials that are subjected to heat for long periods.

91. In life boat engine if all the flywheel marking have been erased/removed how to check TDC or BDC position of piston. Take out the injector now u can see access or see the piston put the dial gauge with the pin touching the piston take the piston to almost TDC set the gauge to any value say 0.2mm and make a mark on the flywheel rotate the flywheel. Piston will move up will reach TDC and then will move down just as

it comes to 0.2mm make another make on flywheel the midpoint of the 2 marks will be TDC.

92. Offset of propotional controller and how to counteract it. In propotional control the output is proportional to the deviation hence for out put to occur deviation has to be there i.e. a offset has to be there in proportional control. While in integral control rate of change of output of controller is proportional to the deviation .so it is able to minimize the offset.

93. Cetane number it is an index if the ignition quality of the diesel fuel which defines the way combustion proceeds in the engine. It is determined by comparing the ignition quality of standard solution (which is mix of 2 hydrocarbon cetane and alpha methyl naphthalene) with the ignition quality of fuel tested. It is percentage of cetane contaianed in the standard solution which has ignition delay equating the ignition delay of fuel tested. Cetane which has good ignition quality Is assigned the number 100. alpha methyl naphthalene is assigned the number 0 due to its poor ignition quality. Higher the cetane number better is the fuel shorter is the ignition delay.

94. Calculated carbon aromatic index(CCAI):- its is a rating of the fuel which indicates ignition quality because ignition directly depends on the aromatic content in the fuel. Aromatic is the compact benzene structures present in the fuel which effects the ease of which a hydrocarbon fuel molecules can burn. A low ccai means better ignition quality better fuel quality and low ignition delay.

95. There r how many stern tube bearing n how they r connected with stern stern tube bearings generally consists of two ( fwd & aft ) bearings which r pressed in and secured to the stern tube the bearing sleeves r made of high strength ductile iron and centrifugallylined with high tin base babbitt. the bearing bore is normally finish machined to fit the propeller shaft and outside diameter is semi finished for final machining in shipyard Two procedures are

commonly used for fitting stern tubes 1.the stern frame is finish machined.the stren tube is pressed in and secured by bolting or welding .the stern tube is bored and bearings are then pressed into stern tube 2.In the second procedure, the stern tube is bored in the shop and fitted with its bearings then the entire assembly is pressed into the stern frame at shipyard. Boring of stern tube to provide an interference fit

96. ECU- engine control unit engine control system has several integrated units , engine control unit cylinder control unit engine interface control unit and auxiliary unit. ECU- the engine speed reference to the set reference Governor control and functions Engine protection system and faults Optimum condition requirement running for that running condition Control of the function for start stop and reversing Control of the function of auxiliary blower and turbo charger.

CCU- the control of the fuel injection pump the injector , exhaust valve , start air valve and cylinder lubrication for each cylinder.

97. What is RVK in piston ring what it means? It is for surface roughness of the piston rings , RVK means depth of the valleys and RPK means peak height. Rz is the mean highest peak to valley measurement taken from 5 samples. RK is the average core roughness depth.

98. Injection delay :- injerk type p/p spill port or spill valve and suction port both get closed that time injection should start practically but due to inertia of the moving parts and fluid injection doesnt start immediately all though oil is considered in comprissible it get compressed slightly and at same time the high pressure pipe gets an expansion all way and after that injection starts. The potential energy gets released during termination of injection.

99. Ignition delay :- the time span between commencement of injection and start of ignition referred to as ignition delay. During ignition delay large part of charge air is prepared for combustion.

100. After burning :- after burning is said to occur when the third phase of combustion extends over a long period. It may be caused by incorrect fuel grade bad atomization , poor or excess penetration , incorrect fuel temp, incorrect injection timing insufficient air supply or any combination of these. Slow burning high viscosity high density high carbon content may also cause after burning of serious nature leading to engine damage.

101. Bearing faults and defects Abrasive wear due to fine scoring by hard particles and impurities in the lub oil. Corrosive wear due to acidic lub oil Erosive wear due to erosion Adhesive wear due to galling scoring or scuffing Fatigue failure cracks at areas of stress concentration Overheating due to poor lubrication supply or contaminated oil , misalignment, increase clearance ,uneven load distribution poor surface finish and overloading Misalignment of the bearing due to distorted bed plate adjacent bearing failure or imbalanced cylinder pressure. Incorrect clearance or incorrect tensioning of bolts. Housing dimension not suitable for bearing shell especially during replacement.

102. Puncture valve It is device to positively stop engine irrespective of its rack position. It reduces the high pressure of the fuel by connecting high pressure side to the pump body thereby stopping the injection of the fuel.

Engine stops and shutdown is carried out by the use of puncture valve. It allows the fuel oil recirculation even when the engine is stopped as the oil pressure is not totally bypassed It is operated by pneumatic air pressure Its used in MAN B&W

103. Under which condition spring of the stuffing box is changed When oil from the tel tel hole of individual unit of stuffing box lot of oil coming and lub oil loss is there and u dont have sealing ring or lamellae so for time being spring can be changed While completely ohauling the stuffing box When spring elongation is exceeded as per manual. Usually checked by hanging one kg wt at end and new length original original length gives the elongation . check with manual for limit and replace it with new one.

104. Whats the time period to discard the chain and renew with new one in B&W engines . tell % elongation max . Max allowable limit of elongation is 1-2% and chain should be renewed once in 8 yrs or 50000 hrs

105. Distance of the lubricating quills from top of liner in terms of the length . At 20% stroke from TDC . in this case lubrication is most effective especially for single level of quills. Continuous groove row of quills at 30% stroke from TDC. Usually quills are 250mm apart from each other around the liner bore. Grooves are angled downward. The combustion gas pressure differential across the rings assist in pushing the oil downwards in the groove. The disadvantage of grooves is that they increase the area of oil flow. Hence velocity and pressure of the oil decreases there by reducing spreadibility.

106. What is the similarity and difference between governor and flywheel?

Governor controls speed of the engine and flywheel controls cyclic fluctuation of engine RPM. Flywheel works on the virtue of inertia and governor uses inertia to actuate fuel linkage to counter change RPM.

107. R.O. plant treatment? Sea water feed for reverse osmosis plant is pretreated before being passed through. the chemical sodium heat meta phosphate is added to assist wash through the salt deposits on the filter elements and sea water is sterilized to remove bacteria which could otherwise become resident in the filter. Chlorine is reduced by the compressed carbon filter while solids are removed by the other filter. Post treatment of produced water is same as low temp evaporators.

108. Lantern ring A latern ring is perforated hollow ring located near the center of packing box that receives relatively cool clean liquid either from the discharge of the pump or from the external source and distributes the liquid uniformly around the shaft to provide lubrication and cooling. The fluid entering the lantern ring can seal the joint between the shaft and packing against leakage of air into the pump in the event pump suction pressure is less than that of atmosphere.

109. Parts of electric governor Load sensing unit Speed sensing unit Setting control unit Setting for droop or isochronous mode Speed setting signal Ramp generator

The comparator/ampifiler control unit which compares the i/p signal with the reference setting and sends o/p signal to the actuator to change the rack position of the engine fuel pump.

110.Wear ring Wear ring can be defined as a device used to seal the pressure leakage of the liquid between i/l of the impeller and pump casing. Wear rings are typically found on pumps with closed impeller. A similar device that serves the same purpose called a wear plate can be found on some pump with semi open impeller. The typical reason for using a wear ring is to decrease the amount of leakage loss around the impeller. Due to more work available to push the pumped liquid out of the discharge there is slight improvement in the pump efficiency.

111. Motor used in governer Synchronous / sleeping motor Main characteristic of this motor are Suitable for continuous operation Precise variable speed Motor electrically locked in position Instant starting stopping Permanent stalling Easy to interface with any type of electronic interface.

112. What is the name of the instrument that measures vibration? How thus it work and part that measure it? Accelerometer, and working on piezo crystals i.e. piezo electric effect

113. what is the crank pin oil hole position?

when the piston is at TDC the crank pin oil hole position is horizontal, this done to reduce the stresses which could have generated if otherwise, this position is the only position allowed.

114.why shims fitted on the bottom end bolts have to be of exact thickness? This will lead to uneven tightening of palm nuts and they will bend.

115. What 4 criteria s r to be fulfilled for satisfactory working of a journal bearing? Viscosity of oil, clearance, load on the engine, rpm.

116. Sweating of refer compressor crankcase When there is liquid flood back to the compressor the effect can be detrimental. After creating a host of other problem the liquid eventually boils off in that hot crankcase. Boling is possible by taking latent heat of evaporation from the surrounding oil in the crankcase. This leads to a cold crankcase if the temp of the crankcase reaches temp below that of dew point the air outside. moisture on the oil precipitates in the crankcase. This is commonly referred to as sweating of crankcase.

117. What is first order moment. These moments acts in both vertical and horizontal direction. For engines with 5 cyl and more the 1st order moment is rarely any importance to the ship but it can be of disturbing magnitude ti the ship with 4 cyl. Resonance with 1st order moment may occur for hull vibrations with 2-3 nodes. Ist order compensator can be introduced in chain tightener wheel . it comprises of 2 counter rotating masses rotating at the same speed as the crank shaft.

118. What is 2nd order moment The 2nd order moments acts only in the vertical direction and precaution need only to considered for 4,5 and 6 cyl units. Resonance with the 2nd order moment can occur at hull vibration more then 3 nodes. A second order moment compensator comprises of 2 counter rotating masses running at twice the engine speed.

Remedies Compensator mounted on the aft end of the engine. Driven by the main chain drive . Compensator mounted on the fore end of the engine. Driven by the crank shaft with a separate chain drive. Compensator on both aft and fore completely eliminating 2nd order moment.

119. Electric compensator It is electrically driven compensator normally located at the steering gear compartment, Where deflection are largest and the effect of compensator with be therefore greatest. Such a compensator is synchronized to the correct phase relative to the external force or moment and can be neutralize the excitation. The compensator required an extra seating be fitted.

120. Guide force moment Guide force moment are caused by the transverse reaction forces acting on the crosshead due to con rod/ crankshaft mechanism. These moment may excite engine vibration moving the engine top athwart ship and causing a rocking or twisting moment of the engine. Guide force moment are harmless except when resonance vibration occur in the engine. As a precaution top bracing is installed between the engines upper platform brackets and the casing side for all its 2s models.

121. Oros piston With the view omitting the safety valve on the exhaust valve actuator the oros P version of the oros design was chosen for the updated K engines. The reason was the oros piston leaves less room for fitting the exh valve spindle than with the traditional piston design . to prevent contact between piston and spindle therefore a mechanical stop is built into the exh valve air spring thus limiting the max spindle lift. Using oros p version with a slightly lower piston dome creates enough space to allow longer exh valve spindle lift. This makes it possible to exploit the well proven relief bore design of the exh valve oil cylinder and safety valve on the actuator is no longer necessary.

121. Fare line curve , procedure of drawing and what is base line? Where it comes from? Here it is based on the assumption that initially the bearings are in a straight line and then load on each brg are found out and these are called influence number. Using computer application data bank of influence numbers are generated using different lifting condition. Of each bearing and their effect on others and finally taking in to consideration of other external factors a compromise of fair curve for the bearing is found out and shaft alignment is done.

122. Wick boiling:Its a boiling process where boiler water enters the deposit though fine pores drawn through the capillary action. Evaporation takes place at this surface the steam escapes through the larger pores. The evaporation causes concentration of boiler salts and may reach a level of many thousands times the concentration in the bulk fluid as there is no flow at the metal surface to flush the salts away. The concentrated boiler solution rapidly attacks the boiler steel. The deposits has an insulating effect and temp rise accelerates the rate of attack. The tube thins down over the considerable length and eventually fails.

123. Hoop stress

The internal gas pressure within the cylinder liner causes a tensile stress, referred as hoop tensile stress. the cooling water pressure on the outside of the liner causes a hoop compressive stress, which is negligible....but the hoop tensile stress due to internal gas pressure is prominent

124. Cascade system Cascade system is useful when there are more then one variable that influence the single parameter which is to be controlled. The system consists of a pump drawing lubricating oil from the main engine sump and pumping it through the cooler where the oil is cooled by circulating sea water thorugh the cooler tubes . the outlet oil from the cooler is led to the main engine bearing oil and piston cooling oil system. For proper functioning of the system, it is desired to maintain a constant oil temp of 45 deg celcius at the engine inlet. The control is by means of a 3 way valve that allows a certain amount of oil to by pass the cooler . if the engine inlet temp is too high more oil will be passed through the cooler and if too low more oil will bypass the cooler. There are 2main variables in this case that influence the oil inlet temp then engine load and the sea water inlet temp forming 2 loops An outer loop that measures the engine oil inlet temperature and passes the information for the further processing to a controller which is called the master or primary controller. An inner loop that measures the sea water inlet temp and passes the information to a secondary controller . the second controller is called the slave or secondary controller. The secondary controller process the signals from the primary controller and the second sensor and sends an appropriate signal to the 3 way valve to control the oil temp at inlet to the engine.

The main advantage of the cascade system is that it provided a quicker response and better management of the controlled parameter. When the sea water temp changes an immediate signal will be sent to the slave controller for adjustment of the 3 way valve even before the actual oil inlet temp begins to change. The response is therefore faster.

125. Draw back pressure v/v of ref. wat all considerations are taken wen converting an meat room into veg When 2-3 evaporator are used from same compressor temp of rooms are different. Veg room is kept at positive and meat room and fish room are kept at negative. So pressure of gas after evaporation also differs. As veg room temp is maintained at positive saturation temp will also be high. There is a chance of reverse flow of gas from veg room to the other rooms evaporator. So back pressure valve is provided at outlet of veg room evaporator. It is a spring loaded non return valve . It throttles the ref from high pr to low pressure. Back pressure valve regulates pressure in the low pressure section and thes evaporating temp of refrigerant is adjusted. Thats how different temp in different room.

126. Material of fusible plug? fusible plug 50% bismuth, 30%lead and 20% tin

127. Sn(tin) has a major disadvantage in white metal, what is that? tin forms tin oxide,sno2

128. Function of inducer in centrifugal pump? An Inducer is an axial flow impeller with blades that wrap in a helix around a central hub. An Inducer serves as a small booster pump for the main impeller. Usually inducers have between 2 and 4 vanes, although there may be more. The inducer imparts sufficient head to the liquid so that the NPSH requirement of the adjacent main impeller is satisfied. Although the inducer usually has a lower NPSH requirement than the main impeller, it can, and often does, cavitate during normal operation. The key is that there is so little horsepower involved with an inducer that there is virtually no noise, vibration, or resulting mechanical problems. Meanwhile, the higher horsepower main impeller sees sufficient head to operate without cavitation.

129. Why droop is given in governor?

Speed droop is a governor function which reduces the governor reference speed as fuel position (load) increases.

Consider two diesel generators connected in parallel. fig 226 shows the condition just after synchronization has been done to run the generators in parallel. At x, its seen that generator 1 has full load and generator 2 has 0 load. Fig 227 generator2 speed (frequency) control increase so as to take up part of the load. Fig228 once generator 2 has taken some load generator 1 will decrease its speed(frequency) as it takes up the less load . the frequency of generator 1 will now be bought back to 60hz. By comparing 228 and 229 we can conclude that for stable operation droop is necessary for load sharing between generators. In order to achieve sharing of load the generator1 and 2 lines should intersect as in the case of fig 228. this is only possible in case of droop i.e. change in speed of the generator during transient conditions of load change.

130. Umbrella type fuel oil pump :- its sealing arrangement which eliminates the risk of fuel oil penetrating the camshaft lube oil system(a separate camshaft lube oil system is therefore no longer necessary) The uni- lub oil system introduced as standards allows reductions in installation costs,

maintenance and space over the separate systems previously used : tanks, filters, pumps and piping for the camshaft system are eliminated.

131. what are the Advantages of using Wasted studs for securing main bearing top keep in MAN B&W.Why not jacking bolts? The main bearing keeps were held down by Jacking bolts (eg. Sulzer RND ). The reason behind that was the the kind of construction of the bed plate itself. When a cylinder fires, the pressure not only forces the main journals down but there is also a component of force which pushes the cylinder head up. Now the Cylinder Head, entablature and the bed plate is tied and precompressed by the TIE RODS. Now when the firing forces come, then there is a couple formed- a) One component of force tries to push the journal down and b) the other component tries to Push the Tie Rods up. Now at the bottom, the tie rods are bolted to the bed plate so a couple thus formed will try to rock the bed plate and thus the engine. To counter attack this problem, the tie rods were kept as close to the centerline of the engine as possible and due to space restrictions, the jack bolts were used to keep the bearing top covers tight(reaction force through the entablature). Note that there was only one cover for the main bearing having two jack bolts. Now recent development has waisted studs on the main bearing cap but the are OFFSET FROM the transverse centerline of the engine. Waisted studs give more comression as they have more elasticity and resilience. As a matter of fact, from the foundation bolts to the con rod bolts, the x-head bolts etc are all waisted studs. So care has to be taken while working as the necked region should not be marked, scored or cracked as due to reversal os stresses, fatigue will cause a crack initiation and finally fracture.

The use of studs as opposed to bolts provides a more accurate and uniform clamping load pattern..Waisted studs give more comression as they have more elasticity and resilience...Studs also offer component installation advantages over bolts. Studs act as guide pins during alignment.Studs are available with "bullet" noses, where a slightly diminished-diameter bare tip is featured. This greatly eases nut installation, allowing the nut to be dropped into position before thread engagement begins since wasted studs doesnt require any material to be removed from the bed plate ... thus the position of the tie rod is made flexible

132. Difference between mc and mc-c engine?

Shorter cylinder distance Shorter chain drive Shorter connecting rod Longer stroke Reinforced structure Improved bearing material Narrow shells = shorter engine Increased journal diameter Improved axial stiffness Reduced edge pressure on main bearing Easy mounting of second order moment for 4,5,and 6 cylinders engines Straight forward and more rigid housing design Shorter stay bolts Higher natural frequency no bracing required Low postion of mating surface cylinder cover/ cylinder liner Slim cylinder liner Straight forward cooling jacket Cylinder frames smaller and lighter Uncooled and straight forward design Combustion chamber high top land lower mating surface lower heat load of upper piston ring better cooling of piston rings

cylinder frame straight forward casting no cooling water chamber no cut tube for cooling water for telescopic cooling pipe improved drain from scavenge space

telescopic mounting on wide guide shoes no need of dismantling pipe for ohauling piston. Crosshead straight forward design and reduced mass Camshaft arrangement

Bearing located between roller guide Camshaft on shrunk on cams Reversing of fuel pumps only Hydraulic activated exhaust valve With indicator valve

133. Why is 2 stroke connecting rod of circular cross section and 4 stroke conn. rod of I section? In service, swing movement of the connecting rod sets up an inertial load on the connecting rod in a transverse direction, and the inertial load depends on mass and velocity. 1. In 2-stroke engines: The transverse inertia loading is not so much and the round section connecting rod of normal length is strong enough to sustain the connected gas loading in slow speed engines. 2. In 4-stroke engines: The transverse inertia loading is of such magnitude that the weight of the connecting rod must be considered together with its strength to resist these loads. Rectangular and I-section connecting rods fulfill this requirement in the best manner, and this is the reason for using Isection connecting rods in spite of the higher manufacturing cost.

134. When changing a liner, u use an oversize o-ring at the lower end , what will the consequence be ? It will be very difficult to pull the cylinder liner home due to the rubber completely filling the ring groove. If excess pull is placed on the liner drawing gear the load exerted on the rubber may fracture the jacket. In some instances when oversize rings have been fitted, fracture has occurred after the engine has been started and come up to working temperature.

135. Where does the liner experience the maximum bending moment? The liner is supported by the lower face of the flange over a small width at the outermost radius. The joint face between the cylinder cover and the top surface of the liner is usually at or near the bore of the liner. When the cylinder cover is hardened down a downward force is exerted on the joint face and an upward reaction is given on the outer landing face of the flange. As the forece and reaction are not given on the same line , a bending moment is created on the liner upper flange and the cylindrical part of the liner adjacent to the flange.

136. How do u take bottom end bearing clearance in a 4 stroke engine? Take the unit to tdc push the conrod up by a crowbar......take the clearance at top half of the bottom end brg.

137. What is critical speed? The critical speed is the theoretical angular velocity which excites the natural frequency of a rotating object, such as a shaft, propeller. As the speed of rotation approaches the object's natural frequency, the object begins to resonate which dramatically increases systemic vibration . When the rotational speed is equal to the numerical value of the natural vibration then that speed is called critical speed.

138. How will u find the exact TDC of Main Engine, Auxilary Engine and Air Compressor......He wanted 'EXACT' TDC??? In case of aux engine, access the piston top either by removing head or fuel valve.....then take the unit to some angle before the approx tdc and measure the depth by putting a depth gauge on top of piston and make a mark on flywheel..............turnthe engine, the unit will cum to tdc and start moving down............when it reaches the same depth as measured earlier make another mark on flywheel............mid point of both the marks will be the tdc.......... in ME three things shud match.......the markings on camshaft and housing, crankcase markings and flywheel markings...

138. How will u find the exact TDC of Main Engine, Auxilary Engine and Air Compressor......He wanted 'EXACT' TDC??? In case of aux engine, access the piston top either by removing head or fuel valve.....then take the unit to some angle before the approx tdc and measure the depth by putting a depth gauge on top of piston and make a mark on flywheel..............turnthe engine, the unit will cum to tdc and start moving down............when it reaches the same depth as measured earlier make another mark on flywheel............mid point of both the marks will be the tdc.......... in ME three things shud match.......the markings on camshaft and housing, crankcase markings and flywheel markings...

139. What is duplex pump? It consists of two pumps that alternate the pumping process, thereby allowing it to be more efficient than a single version. The duplex pump has a higher flow rate due to its not having a dead spot in the pump stroke. As one pump is completing its stroke cycle, the other is beginning its stroke maintaining maximum pumping action without a break in the cycle. The first duplex pump was steam operated. It consisted of two steam chambers as well as two pump housings. The pumps were capable of pumping twice as much liquid as a single-stage pump. There are no dead spots in a duplex pump. The pumping cylinders are constantly under pressure and operate just enough out of time with each other to ensure that one or the other is always pumping. The steam-operated pump was replaced with a duplex pump, which operates on compressed air. The compressed air acts in the same manner as the

steam and maintains constant pressure on the cylinders of the pump. The original steam duplex pump was created in the 1800s and steam-operated pumps are still in use, but compressed air has taken over as the primary operating system.

140. What is mean piston speed? This parameter is sometimes used as an indication of how highly rated an engine is. However, although in principle a higher piston speed can imply a greater degree of stress and wear, in modern practice, the lubrication of piston rings and liner, as well as other rubbing surfaces, has become much more scientific. It no longer follows that a high piston speed is of itself more detrimental than a lower one in a well-designed engine.

Mean piston speed = l X n / 30

This is given in meter/sec where l- stroke length; n-number of revolution/min

141. Why LNG is the best fuel? Operation on natural gas results in very low emission. Methane the main constituent is the most efficient hydrocarbon fuel in terms of energy content per amount of carbon, containing the highest amount of hydrogen per unit of energy per fossil fuel. In gas operating mode the specific carbon dioxide emission is typically reduced by 20 %. Compared with heavy fuel oil or marine diesel oil. The corresponding reduction of nox is 85-90%. While sulphur oxide and particulate emission are almost eliminated. Further there is no visible smoke; no sludge deposits and no lead emissions and benzene emissions are also reduced by around 97%. Natural gas has very good combustion characteristic in an engine and because it is lighter than air and has a high ignition temperature is also a very safe fuel.

142. .Piston ring details-design wth reason n mtrl......(new developments) Different types of piston ring have different type of cross sections 1. Plain type is simple and inexpensive

2. Barrel face chrome plated cooling type. The barrel enables better and faster bedding in with liner profile. Chrome plating is a hard coating given for increased life. 3. Inlaid type where the inner laid material (molybdenum or electroplated chrome) provides scuff resistance, while the outer laid provides edge protection and oil control. 4. Tapper running face provides faster bedding in. 5. Stepped scrapper provides oil scraping and gas sealing. 6. Beveled undercut provides downward oil removal. 7. Slotted oil passage for oil scrapping. 8. Conformable oil scraper for consistent oil control. Wear resistance coatingPlasma coating (using a plasma spraying method where a gas mixture is directed through an electric arc generated between a tungsten electrode and a water cooled copper tube to create a plasma state at 10,000 to 15,000 deg c) this plasma state melts and fuses any metal, with gas molecules and atoms disassociating. Chrome plating is a hard galvanic chrome layer. Double chrome plating is done on both sides of the ring. This increases the wear and corrosion resistance. Tungsten carbide coating which gives better wear resisitance. Running in coating These are soft coating such as copper, graphite or phosphate which is meant to wear quickly and give the rings similar profile the liner. Controlled pressure relief (CPR) rings. In cpr rings the topmost ring has one double lap S seal and six controlled pressure relief grooves cut across the face. This ensures even pressure distribution and decrease thermal load to the second piston ring as well as the liner. Other piston ring have an Al-bronze coating and oblique cut.

143. anti polishing ring Its the ring which reduces the polished effect of liner wall, which is formed due to the hard deposits from combustion in contact with the liner. Polishing is unwanted as it does not allow oil film retention on the liner wall, and the oil passes over the ring pack portion to the combustion area where it is burnt and wasted. Polishing depends on the oil feed rate, excessive peak pressures,

ring and liner materials, and an increase combustion hard products at liner ring interface.

144. SIPWA (sulzer integrated piston wear analysis) It is a method using a continuous online feedback measurement of the piston ring wear condition. The piston ring has incorporated a wear band. As the wear down of the piston ring takes place , a corresponding wear down of copper wear band takes place . a sensor in the cylinder liner senses the wear of the copper wear band and transmits this signal to an online electronic unit, which record and prints any wear down, which can be used as pre warning.

145. Main engine turbocharger? Construction on the same stage mounted a single stage impulse reaction turbine and a centrifugal compressor. The turbine consist of a gas inlet casing with a nozzle ring a gas outlet casing, a turbine wheel forged integral with the shaft; blades that are fitted through side entry slots; and provision for water cooling. In the earlier design the casing was water cooled now design modern engines employ uncooled type turbocharger. The compressor consists of a volute casing which houses the impeller inducer and diffuser. The inducer guides the air inlet flow smoothly into the eye of the impeller. The impeller throws the air outwardly with the centrifugal force. The diffuser at the discharge end converts the kinetic energy into pressure energy, and leads the air into the volute casing. The volute shaped casing decreases the velocity further and increases the pressure energy. Bearing are of ball and roller type combination or journal sleeve type. Bearing are mounted in resilient type housings. These housings have laminar springs which provide axial and radial damping as they do not allow the bearing surface to chatter or flutter when stopped. Bearing lubrication is integral or separate. It also allows transfer of heat. Roller bearings have the advantages of less friction losses and more accurate alignment. The disadvantages are that they are more expensive; are prone to brinelling effects;and need higher grade lubrication and frequent changing.

Sleeve bearing can run at higher temperatures, running at low load create high friction. Seals- labyrinth seals are used prevent exhaust gas leaking into the air side and into the bearing housing. Sealing air from the air side is leaked off to cool and seal the shaft. Binding wire- A binding wire in small segments are closely passed through the holes of 4-6 blades. In order to fasten this binding wire, it is welded to the 1st blade of that segment. It works on the principle of centrifugal action, resulting in the loosely fitted wire touching the outside of the blade holes are at high speed. This alters the frequency of vibration and dampens it. In auxiliary diesel generator bindings are not necessary becoz they run at constant rpm. Fir-tree blade root- it provides better and more even distribution of stress at the root portion which is prone to failures. There is less stress concentration at the joint of the blade and root. Side entry fitting provides improved balance and easy replacement. Damping wires are required which passes through the blades. These dampen the low frequency blade vibration and a tab washer may be used to secure the blade in place.

146. how oblique cut in the plunger is determining the starting of injection in conventional VIT in B&W engines In earlier MAN B&W engines the VIT was arranged by means of a helx shape at the upper edge of the fuel pump plunger. This was in addition to the normal lower helix that terminates the injection by opening the spill port. As load was increased by turning the plunger by fuel rack, the upper helix would close the spill port earlier advancing the fuel injection begining. The above double helix determined a fixed relationship between the begining and the termination of injection for every fuel rack position and these could not be changed independently. This was considered a disadvantage as, for certain fuels or operating conditions, it is desirable to have independent adjustment possibility. This led to the improvement of the system by replacing the upper helix with an arrangement to adjust the fuel pump barrel height by a pneumatic

cylinder to alter the beginning of injection with change of load. In order to distinguish this from the old VIT, the new arrangement is called "Super VIT"