Topic Page No.

Operation Matter 2 to 20
Boiler & corrosion 21 to 30
Fire & Safety 31 to 51
Generators, prime-mover, 52 to 65
Electrical, Batteries
Laws 66 to 71
FO 72 to 78
Heat Exchanger 79
Pump 80 to 81
Fresh water Generator 82 to 84
Metallurgy & dry docking 85
IGG 86 to 88
LO system 89 to 90
Steering Gear 91 to 95
Refrigeration 96
Air Compressor 97 to 100
Purifier 101 to 102
Steam Turbine 103 to 110
Steam plant 111 to 114
Cooling System 115 to 117
Bilge 118 to 126
Motors

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 Operation Matter

Briefly describe the vessel that you sailed on before.

Explain the design of your previous vessel.
Give the particulars of the previous vessel.

LNG tanker, SS .PD,

IMO no:9030838
Length overall :274.3 m
Breadth :43.3m
Keel to highest point:63m
Main engine type :steam turbine with reduction geart UA360 kawasaki
Max power out put 26720KW 90rpm,(36330 HP)
MAX speed loaded 21 knots
Service speed 19.75 knots
Boilers:2x babcock ESD3, dual fuel, 65 t/h each
Cargo capacity:130299 m3

How the shipboard familiarization is carried out?

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  All newly appointed officers and ratings shall be required to undergo onBoard
familiarization upon joining a ship which a safety tour of the vessel within 24 hours .
The familiarization shall include the following as a minimum;
i. Fully understand duties and responsibilities;
ii. Location of firefighting equipment;
iii. Location of life saving equipment;
iv. Location of personnel life jacket and thermal protective aids (TPA);
v. Location of immersion suit;
vi. Location of muster stations;
vii. Emergency escape routes;
viii. Location of SOLAS training manual;
ix. Location of fire training manual;
x. Location of fire safety operational booklet

What are the procedures followed when you first sign on a ship.
-Report to master and present all necessary documentation and sign article.

-Report to chief engineer for duties and responsibilities as engineer.

-Inspect cabin; make sure all safety equipment and other necessary equipment are there.

-Undergo familiarization process within 24-hours.

What’s the responsibility of 4th engineer?

As the sms manual mentioned the following
 Essentially a watch-keeper engineer (WKE )
 Under studies the 3rd engineer’s duties and functions for eventual promotion.
 The safety of personnel working directly under him
 Specifically entrusted to maintain and ensure good working condition of the following
machinery;
A. Auxiliary boilers and economizer including all associated fittings and
safety trips and alarms
B. Purifiers for L.O F.O and D.O
C. All pumps related to the boiler systems including SW & FW pumps
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 D. Deck machinery, windlass , mooring winches , lifeboat winches , hatch
cover winches.
E. Fresh water generator and associated pumps.
F. Filters for FW FO LO DO and bilge lines.
G. Incinerator, sanitary system, domestic water system, FW cooling
system and lubrication system.
H. All control valves associated with F.O /D.O transfer/bunker lines for
settling & service tanks.
I. Keep up to date inventory of spare parts for above machinery.

 Supervise any repair work being carried out by shore repairs as directed by 2nd
engineer/chief engineer.
 Assist 2nd engineer/chief engineer in bunkering operations or fuel transfer operations.
 Report any undesired events, unsafe practices or near misses observed to the superior
officers and attempt to rectify them if safely possible.
 Assist in receiving engine stores, spares, chemicals, lubricating oil and gases .Anti-
ollution measures.
 Comply with principles and guidance for keeping safe and efficient engine room watch.

Talk through an engine room walk round on your last vessel?

Normally the duty engineer will start round and taking the logs from the following;

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 funnel
 Cold Room
 AHU Room
 Emergency Diesel Generator
 N2 ROOM
 CO2 Room
 Firing Platform entering from the engine room casing door
 3rd Platform
 2nd Platform
 1st Platform
 Bottom Plate
 Forward store (Take the reading for Forward Cathodic Protection unit.

 Funnel
Check the funnel emission .White smoke, black smoke, steam or sparks.

 AHU ROOM
1. Check belt
2. Check amps for Port and Starboard fan*
3. Exhaust fan
4. Galley EXHAUST damper
5. Check the condition of the evaporator (frosting, no leaking)

 EMERGENCY DIESEL GENERATOR(EDG)

1. Check for;
 earth fault
 deep stick (oil level)
 radiator cap( cooling water)
 exhaust fan (make sure run)
 check damper open
 make the EDG in auto mode
 check fuel level (make sure full)
 check battery (charging or not)

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 FIRING PLATFORM entering from the engine room casing door\

in the way down u have to check the following:

 Supply fan (damper)

 Make sure the soot blower master valve are shut
 Engine room damper fan(exhaust)
 Check economizer vent valve shut
 De-aerator level gauge glass
 Check exhaust fan
 Canopy fan and exhaust fan (damper)
 Check opacimeter
 Fire detection system
 Exhaust gas outlet temperature(130-170)if high means too much soot )
 De-aerator shell pressure,

In the firing platform check:

1. Make sure no steam leaking

2. Check gauge glass for both boilers
3. Check flame cell fan cooling for cell eye, scavenge for peep hole

4. Burner fire condition(bright red or golden)

5. Superheated temperature
6. Air heater(100c)
7. Fuel oil rail(temp .and pressure)120c)
8. Atomizing steam pressure(around 7 bar)

3rd PLATFORM

1. Steering flat
- grease tank reservoir
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- hydraulic oil level should be 85 %

- make sure the damper open and fan running
- no leaks at steering gear
- check the steering gear pump
- take the reading for aft cathodic protection*

Make sure all welding gas valve are shut(pop deck)

2. Force Drought Fan motor
- vibration and overheat

3. In the Boiler Technical Room (BTR),

- make sure the AC unit running
- check the burner cabinet (infrared and UV)
- take the vibration log*
- check the O2 reading in the exhaust gas analyzer

4. Check the level of Fresh water diesel generator make-up tank

- Top up if neccessary

5. Switch board room Port and Starboard

- check the AC unit running
- check the earth fault reading (511 m ohm normal reading)
- FD fan load(amps*)
- Excitation *

6. Fridge Compressor
- cooling water inlet temperature*
- cooling water outlet temperature*
- leaks
- motor vibration
- oil level*
- discharge pressure*
- suction pressure*
- oil pressure*
- amps*
- hour meter *

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7. Check AC compressor
- Motor vibration and overheat
- cooling water inlet temperature*
- cooling water outlet temperature*
- oil level*
- leaks
- Fan ampere*
- Suction & discharge pressure*
- Oil pressure*
- Suction temperature*
- AHU Outlet (No.1,2,3*)

8. Check for any leaks at LO storage tanks

9. Check incinerator room

- make sure fan running
- make sure damper are open

2ND PLATFORM

1. Check the starting air for diesel generator

- drain the water from the starting air receiver.
- Pressure( 26 bar)
- check the LO level
2. Check the Diesel Generator
- LO level
- Gas oil leakage tank
- Make sure the LO pump is running
- Bearing LO sight glass
- Make sure the switch in the ‘AUTO’ position
- Jacket cooling water temperature
- Rocker arm LO tank

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3. Low Pressure Heater

- make sure vent shut(open at high load)
- temperature*
- drain temperature*

4. Check the Observation Tank

- make sure no oil in the tank
- no leaks

5. Check the spare gear store

6. Turbo Alternator*
 Running unit
- sump level
- check the LO temperature inlet(around 38c)
- check the LO pressure(1.5 bar)
- air cooling outlet temperature( 30 c)
- fresh water cooling outlet temperature
- leaks
- max bearing temp (64c)
 Stand-by unit
- All above
- make sure LO pump running
- make sure shaft turn

7. Check the Electrical workshop

- make sure AC unit running supplied from electronic store

8. Hydrophore Tank
- level
- pump pressure
- UV lamp 95( %sterilizer(not less than 50)%
- Check the heater pump pressure
- Air pressure (5 bar)

9. Check the chemical store

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Leaking

10. Sewage treatment plant

- make sure the blower is running
- no leaks

11. Engine room hydrophore

- no leaks
- level
- air and pump pressure

12. Check the workshop

- make sure the AC unit is running
- check the lab and make sure all the valve is closed
- make sure the equipment in good working order

13. Check the attemperator spray

- Leak

14. Blow down valve make sure shut

15. Hydrazine tank

- Top up the tank with fresh water if required.

16. Open peep hole for boiler and check the fire condition
17. Deaerator outlet temperature
18. Superheated pressure(port and Stbd Boiler)

1st PLATFORM

1. Turbo Feed Pump

- LO temperature*
- Oil level
- Leaks
- Suction pressure (4 bar )
- Discharge pressure(80 bar)
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- Drain water from the LO sump.

2. Instrument & General Service Air Compressor
- drain water from the receiver
- check the oil level
- leaks
- check air pressure for instrument air(8bar)
- check air pressure for general service air(8bar)
- check air gauge
- check oil gauge
- check air temperature(around 70 C)
- check amps
- make sure the instrument crossover valve is shut

3. Check central cooling system

- Fresh water cooler outlet pressure( 4.2 bar)
- Fresh water cooler discharge temperature(30c*)
- check for leaks
- vibration of the motor
- heat

4. Fuel Oil Room

- check bilge well
- make sure no leaks
- make sure damper is open
- fan on
- check purifier water seal and LO level
- check the bunker tank temperature
- check the hot filter
- FO heater temperature(100 c)

5. Main engine platform

- check all the pressure gauge
- check for leak
- vibration
- hear the sound
- MP bleed pressure(2.4*)
- ME vacuum(*722 mmhg)
- Lever position *
- ME rpm*
- Gland steam pressure(0.2 bar)
- HP thrust temperature(*around 50 c)
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- LP thrust temperature*
- Main thrust temperature*
- LP exhaust temperature(50 c*)
- LP bleed pressure(*0.5 bar)
6. Top up chemical(Maxi-vap )for the evaporator
7. Air Ejector
- Pressure(17 bar)
- leak
- temperature(*320c)
8. Drain Cooler
- Leaks
9. Check the evaporator
- salinity condensate(not exceed 4 ppm)
- salinity distilled
- CC evap .outlet temperature(50 c*)
- motor pump (leak, vibration and heat)
- check the overboard valve (make sure no leaks and shut/open )
- check the catadyne
10. Ion Exchange Unit
- conductivity meter*
11. Check the heating steam line and drain for bunker
12. Take reading for chlorinator
- Voltage*
- Current*
- water flow*
- set point*

BOTTOM PLATFORM

1. Checking up all the bilge wells

 If the water level is high, it must be pump out bilge by using reciprocating bilge pump to the
Bilge Holding Tank (BHT.)
2. Check the level of the stern tube gravity tank
3. Top up the lub .oil for stern tube bearing(lubricates the outer lips of the sten tube fwd seal)
4. Check differential pressure of Duplex discharge filter( normally not more than 50)%
5. Check the shaft earthing device(around 100 mv depend upon the speed)
6. Make sure the OWS overboard valve is shut and locked.
7. Take the sounding for;
 Stern tube leakage tank
 ME LO Sump tank
 FO/LO Sludge tank
8. Check the condition(i.e vibration, overheat, cooling fan, suction and discharge pressure and
leak )of pump below;
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 Stern tube gravity tank pump

 Main circ .pumps(3)
 Ballast pumps(2- )check for Leak on ballast strainer.
 IMO spray pump
 Main Condensate pumps(3)
 Fire pump
 Centrifugal bile pump
 Fire/Bilge pump
 Sea water service pumps(2)
 Drain pumps(2)
 Evaporator Ejector pumps (CC and SW )– take note which one in used.
 Coaleser pump

9. The following are the others local reading which to be taken during morning round at the Bottom
Platform;

 Main engine bearing temperature

 aft shaft bearing
 fwd shaft bearing
 HP bleed pressure (7.0 – 9.8bar)
 Seawater temperature
 Control oil pressure(3.5 – 4.5 bar)
 Operating oil pressure(4.0 – 5.0 bar )
 Main engine spray pressure(1.2 – 1.5 bar)
 Main engine Lub .oil discharge pressure(4.0 – 5.0 bar)
 Main engine Lub .oil temperature (42 – 47ºC)
 Main condenser water box(inlet and outlet)
 Steam chest pressure(40 – 45)
 Check the main condenser level gauge glass(make sure there is a water drop for the
transmitter)
 ADT(atmospheric drain tank )temperature(70 – 80ºC)
 Check the ADT water level
 Seawater system pressure (2.4 – 2.7 bar)
 Condenser overboard temperature (depend of temp .of seawater and the efficiency of
main condenser max allowable temp is 45c)

10. Check the level of Stern tube LO gravity tank

11. Check flow through LO sight glass for main engine LO gravity tank
 make sure the oil is in overflow condition
12. Check the operating and trip oil filter
13. Check any leak around the pipe line and the filter for ME lub.oil system.
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14. Drain for FO room well to sludge tank.

15. LO Cooler check for leak and temperature.

After the round is completed, the duty engineer starts to fill out the Engine Log Book and the
Daily Log sheets with the reading taking during morning round.

The following are the Daily Log sheets which must to be completed during ER watch;

 Main Engine
 AC Compressor
 Turbine Vibration
 Air Handling Unit(Ag
 Turbo Alternator
 Cloropac and
 Main Condenser Water Box(cathodic)
 FWD & AFT CATHODIC PROTECTION
 CO2 room

Duty engineer also responsible for manage the water tank and check the level of the BHT and
sludge tank .If the weather and location permitted, and the level on both tank is getting higher, he will
start to decanted water from sludge tank to BHT and then from BHT to sea via OWS .During this
operation, I must follow the regulation of the water treatment and discharge it to overboard via OWS by
only 15ppm .After water in BHT decanted to overboard via OWS, Oil Record Book must be completed.

At noon, the duty engineer will be filling up the noon logs;

 FO counter
 Water log
 ME counter
 Ship power , thrust and torque
 Total bunker for that appointed day

Then, engine room will be vacated for lunch and the log book will be passed up to
Chief Engineer for any further calculation.

EVENING ROUND

For evening round, duty engineer will start evening round at 1530hrs and it almost the same like
morning round .For this round, only a few local reading need to be taken;
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1. FD fan load (in the switchboard room-port and Stbd)

2. FO rail temperature(port and stbd boiler)
3. ADT temperature
4. Deaerator shell pressure
5. Turbo Feed Pump LO temperature
6. LP Heater Drain temperature
7. Seawater service Discharge pressure
8. Some reading at Turbo Alternator like;
- Max .cooling water outlet temperature
- Air cooler outlet
- Excitation Amps.
- Exhaust temperature
These local readings are needed to be filling in the Engine Log Book .Either than those readings,
can take from the Distribution Control System (DCS.) As added up to the evening round, all the doors in
engine room will be lock up as a piracy precaution control .Then at 1700hrs, engine will be on
Unmanned Machinery Space (UMS )condition with the alarm has to be transferred to bridge as it can be
monitored by the watch keeping officer .If any alarm raise during this period, it will be raise at the duty
officer cabin, officer saloon and lounge, gymnasium and pantry.

The operation of all equipment must be satisfactory before the machinery space may be operated

unattended .Before running UMS system, make sure all the following checklist below have been

done;

The correct answered

1. the Bridge control system must be fully operational

2. the main alarm and trip must be operational
3. the fire detection and alarm system must be operational
4. an auxiliary/emergency diesel generator must be in auto start mode
5. all standby machinery must be ready to start automatically as required
6. all bilge alarm must be operational
7. the sequential restart system must be set to automatic operation

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1. Emergency generator auto normal

2. Workshop machines have been switch off
3. Provision, air condition plant normal
4. In use air compressor normal
5. Waste oil incinerator have been stopped
6. Boiler water level and firing normal
7. Steering gear system normal
8. FW generator running normal and tank being filled was corrected (Distil and Domestic tank)
9. Diesel generator oil level normal and on standby condition.
10. FO service tank level for diesel generator ready for UMS
11. Purifier and control system normal
12. Boiler FO tank level ready for UMS
13. Stern tube seal system normal
14. Propeller shafting bearings normal
15. Engine room bilge all clear and bilge high level alarm can operate normally
16. Dirty oil drain(SLUDGE) and overflow tanks not full.
17. FO transfer pumps on manual
18. Fire/bilge, IMO and ballast pump on standby position.
19. Main engine on Bridge control
20. UMS monitor and no blocked alarms
21. Alarm logger in use
22. Duty engineer selected is correct and tested duty engineer alarms at cabin and public spaces
for working normal.
23. Suppressed UMS alarms, if any approved by Chief Engineer
24. Checked with bridge all fire zones ON.
25. All standby units in auto and ready to run
26. All rubbish is empty
27. Fuel oil room doors are shut
28. All ER doors closed (and locked for pirates)
29. Oxygen /acetylene system shut down
30. CCR blinds closed
31. Reset Patrolman after testing alarms (unless duty engineer is still in ER.)
32. UMS entry and time made in ER Log Book
33. Bridge informed of UMS status in ON mode.
34. Confirmed no persons left in ER
35. Locked exit door on leaving UMS ER

According to Chief Engineer standing order, the duty engineer must make a night round
between 2100 and 2300hrs .The duty engineer usually make the night round at 2130hrs .During this
round, make sure that any fire hazard that maybe occurs must be secured and check for any leaks .Duty
engineer must be maintain low level at all the bilge wells to prevent from engine room floading .The

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temperature of bunker tank also must be manned .Adjust either bunker tank heating steam inlet or
outlet valve to get the required temperature.

NIGHT ROUND

During the night round, the Patrol Man system must be put on .This is for safety of the engineer
that entered engine room alone UMS condition .The Patrol Man system will be initiate after 15 minutes
and in three minutes after that, if it didn’t answered by the engineer, it then will initiate the engineers
call alarm, in that meaning something has happened to the engineer in the engine room .The Patrol Man
alarm also will rise at Bridge during the UMS condition.

The duty engineer has responsibility for any alarm received and it must be deal as soon as
possible .If any alarm occurs during the night, it must be answered by the duty engineer as he is
responsible for dealing with any alarm .If it a serious problem, sound the engineer alarm .If required
help or advice, call 2nd engineer .Don’t hesitate to call for help, because it may get worst .Refer to Chief
Engineer if 2nd Engineer agreed.

The duty will end at 0800hrs the next morning .Every detailed that has been changed and occurs in

the engine room will be brief to the duty engineer for that day, as a handover of the duty rotation .

Don’t forget to monitor the water tank quantity and fill it in water log for morning reading before

handover .It is because, to calculate the water quantity for morning reading is still under previous

duty engineer .The relieving duty engineer cannot take over the watch until he has examined the

engine room log and check that it is in accordance with his own observation.

During arrival or departure port, it is basically the same like the other days, but during the arrival
day, the duty engineer need to standby as per instruction by Chief Engineer or 2nd Engineer and monitor
the machinery at engine room during the cargo operation.

What document you check while you are on duty?

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When taking duty check the standing orders and special instructions of the chief engineer
relating to the operation of the ship’s systems and machinery

During the duty you have to check and fill the log book

Check and fill the check lists such as the following

1-Taking over watch at sea checklist

2 -Taking over watch at port checklist

3 -Arrival port checklist

4-depature port checklist

5-guide lines for port checklist

6 -Internal FO transfer checklist

7 -Duty engineer UMS checklist

8 -Duty engineer manned checklist

Oil record book should be checked

Explain the Watch keeping duties?

The Duty Engineer responsible for the safe and efficient operation of the plant for the
whole period of his duty .The duty period normally starts at 0800 hrs to 0800 hrs the next day .
On taking over the duty, the Duty Engineer is to make through round of the machinery spaces .
Duty Engineer is responsible for taking the various machinery logs and completing the Log Book
entries .A further through inspection of the machinery space is to be carried out towards end of
the working day .A short inspection of the machinery space is to be carried out in the between
2100 hrs and 2300 hrs .The duty engineer is also responsible to watch over the plant during
port operations alongside with the chief and second engineer.
At any time when the Duty Engineer is alone in the machinery space he must activate
the PATROLMAN system .And also inform Bridge or Cargo Control Room (if at port.)

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How do you prepare main engine when one hour notices?

How to prepare M/E during departure and arrival?
What preparation m/e at port?

U can also refer to the main engine starting and shutting down checklists

Departure one hour notice (main engine preparation)

At One Hour Notice, test Telegraph, synchronise clocks and record times in Movement Log.
Prepare and test Steering Gear .Record times in Movement Log.

If Chickasaws(manifold arms) are clear of Vessel, and after checking with the Bridge, the
warming through steam can be shut, Main Engine Turning Gear disengaged, and the Main
Engine Stop Valves open.

Main Engine tested astern and Ahead( manual blasting .)Entry made in Movement Log.
(Time permitting for the Main Engine should be manually blasted Ahead and Astern for as long
as possible to increase the Turbine steam inlet temperature to above the low temperature
alarm)

Inform Bridge that Main Engine is ready for Standby.

When requested or at Standby, changeover to Lever Control in C.C.R .and then to Bridge
Control ensuring that the telegraph lever is at the “Stop” position.

At Standby Engine the “S/B” button will be pressed by the Bridge and must be answered on the
C.C.R .telegraph.

Monitor Main Engine steam inlet temperature whilst waiting for the first movement and verify
that the Auto Blast system is functioning correctly

Record the Main Engine First movement time, in the Movement Log, then as per Bridge
Recorder.

Test to be carried out before departure – ME & machinery

Arrival and departure procedure – EOP(end of passage), FAOP(full away of passage) etc.
Refer to the arrival and departure checklists

When E.O.P .time known, enter Voyage Termination time for Performance Monitor.
Enter "Load Port "trim fwd .and aft values, found on the Loading Plan.
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At E.O.P .record F.O .Meter readings, Main Engine counter and Water Tank quantities.
Transfer to Port Log.

When F.A.O.P .time is known, enter "Terminate Voyage "time in Performance Monitor along
with the new voyage title and seagoing trim values f.wd and aft.

At F.A.O.P .record F.O .meters, water tank quantities and zero Main Engine counter.
Change over to Sea Log .

Duty engineer do before arriving port?

Refer to (arrival port checklist)
SMS manual

What is your action when you found out that the bilge level is increasing at a fast pace.
Procedure of Flooding in Engine Room.

1. Start Reciprocating Bilge Pump taking suction from bilge main and wells.
2. If the inflow water exceeds pump capacity, start the Bilge Pump taking suction of port
centre and discharge directly overboard.
3. If water inflow still increasing, start the Fire and Bilge Pump where suction from
starboard centre and discharge directly overboard.
4. If the problems still occur, start the aft Sea Water Pump getting suction from tank top
and discharge directly overboard.
5. Stop main engine and secure it.
6. Isolate equipment especially at the main switchboard.
7. Before the Sea Water Pump flooded, shut down boiler, TA and start the EDG
8. Secure other main equipment such as Feed Pump and DG.
9. Prepare to abandon ship.

Guidance in case of flooding (additional)

1. Control the rise of water level by pumping out or blocking inflow.

2. Isolate section of pipe work .The wrecked pipe should be wrapped with fibre rope
around it in order to reduce the flow and acts to support the pipe .If it is effectively
reduced, a cement box is build to seal the pipe .Usually baking powder is added to dry
the cement quickly but it can be brittle if excessively added.

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3. In case the main circulating pump damaged, main engine should be shut down while
turbo alternator exhaust are dump to auxiliary condenser.
4. Fire hose can be connected to port fresh water cooler to supply for cooling service
systems in emergency.
5. Instrument air could still remain in service using stern tube fresh water tank as a heat
sink for cooling.

What you’d do if the boiler tube is found leaking.

• Ensure that feed water supply to other boilers is maintained.
• Shut off fuel supply to burners, if low water level cutout already not active.
• Increase air supply to furnace.
• Partially close feed check valve, but keep sufficient level of water in drum to prevent
over heating while furnace is still hot.
• Shut steam stop valve.
• Lift superheated safety valve manually to reduce leakage of steam into engine room.

What’s your action if the jacket outlet temperature is higher than normal?
….

If the thermometer on the temperature jacket is not the same what do you do?
….

Scavenge fire – indications, action and prevention measures

INDICATIONS

• Loss in power and irregular running of the engine,

• High exhaust temperatures of corresponding units,
• High local temperature in scavenge trunk,
• Surging of turbocharger,
• Sparks and smoke emitted from scavenge drains .
 External indications will be given by a smoky exhaust and the discharge of sooty smuts
or carbon particles .
• If the scavenge trunk is oily the fire may spread back-from the space around or
adjacent to the cylinders where the fire started and will show itself as very hot
spots or areas of the scavenge trunk surfaces .
• In ships where the engine room is designed as UMS, temperature sensors are
fitted at critical points within the scavenge spaces .activation would cause
automatic slow down of the engine .

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ACTIONS

 In the event of scavenge fire the engine must be put to dead slow ahead as soon as
possible and the fuel must be taken off the cylinders affected by the fire or preferably
stopped .
 The turning gear should be put in and the engine continuously turned with increased
cylinder oil to prevent seizure (jam.)
 All scavenge drains must be shut to prevent the discharge of sparks and burning oil from
the drains into the engine room
 Air supply should be cut off by enclosing the turbocharger inlets, for mechanically
operated exhaust valves the gas side should also be operated, (hydraulically operated
exhaust valves will self close after a few minutes.)
 A minor fire may shortly burn out without damage, and conditions will gradually return
ok
to normal .The affected units should be run on reduced power until inspection of the
scavenge trunking and overhaul of the cylinder and piston can be carried out at the
earliest safe opportunity
 Once navigational circumstances allow it, the engine should be stopped and the whole
of the scavenge trunk examined and any oil residues found round other cylinders
removed .
 The actual cause of the initiation of the fire should be investigated
 If the scavenge fire is of a more major nature, if there is a risk of the fire extending or if
the scavenge trunk is adjacent to the crankcase with risk of a hot spot developing it
sometimes becomes necessary to stop the engine .
• Normal cooling is maintained, and the turning gear engaged and operated .Fire
extinguishing medium should be applied through fittings in the scavenge trunk :these
may inject carbon dioxide, dry powder or smothering steam
• The fire is then extinguished before it can spread to surfaces of the scavenge trunk
where it may cause the paint to start burning if special non inflammable paint has not
been used
• Boundary cooling of the scavenge trunk may be necessary .Keep clear of scavenge relief
valves, and do not open up for inspection until the engine has cooled down .

PREVENTION MEASURES

 Good maintenance and correct adjustment must be carried out

 Scavenge trunking must be periodically inspected and cleaned and any buildup of
contamination noted and remedied .
 The drain pockets should also be cleaned regularly to remove the thicker carbonized oil
sludges which do not drain down so easily and which are a common cause of choked
drain pipes .
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 Scavenge drains should be blown regularly and any passage of oil from them noted .
 The piston rings must be properly maintained and lubricated adequately so that ring
blow-by is prevented .
 At the same time one must guard against excess cylinder oil usage .
 With timed cylinder oil injection the timing should be periodically checked .
 Scavenge ports must be kept cleared
 The piston-rod packing rings and scraper rings should also be regularly adjusted so that
oil is prevented from entering the scavenge space because of butted ring segments .
 This may and does occur irrespective of the positive pressure difference between the
scavenge trunk and the crankcase space .
 Fuel injection equipment must be kept in good condition, timed correctly, and the mean
indicated pressure in each cylinder must also be carefully balanced so that individual
cylinders are not overloaded .
 If cylinder liner wear is up to maximum limits the possibility of scavenge fires will not be
materially reduced until the liners are renewed.

What should you do when crankcase explosion happen?

Crankcase explosion – action required?

 Should the oil mist detector activate an alarm condition, then personnel should take
steps to ascertain if the fault is real .
 They should initially assumed that it is, the bridge should be informed and the engines
slowed if the oil mist detector has not already done so .
 Should the bridge require manoeuvrability, and it is essential that the engine be
operated then consideration of evacuation of the engine room should be made.
 Otherwise the engine should be stopped and turned on gear until cooled .
 The Graviner Oil Mist detector indicates via markings on the rotary valve which sample
point has the high readings .
 By inspection of the graviner, and by viewing crankcase (or thrust, gear case )bearing
readings it is possible to ascertain whether a fault condition exists
 Under no circumstances should any aperture be opened until the engine has sufficiently
cooled, this is taken as normal operating temperatures as an explosion cannot occur
when no part has a temperature above 270'C (Cool flame temperature )
 Once cooled the engine can be opened and ventilated (the crankcase is an enclosed
space .)
 An inspection should be made to locate the hotspot, the engine should not be run until
the fault has been rectified.
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Boiler
General

Q .What type of boiler on board your ship?

Foster Wheeler ESD3 MODIFIED Water tube 2 drums marine tube boiler with dual firing
burners

Explain the type of boiler.

Q .Difference between water tube and smoke tube?

Water tube boiler is the boiler in which water flows through the tubes & fire is outside whereas
in the “Fire tube” boiler fire travels through the tubes & water flowing outside.

Fire tube boilers are usually low pressure, low temperature & low capacity boilers whereas the
water tube boilers are high pressure, high temperature & high capacity boilers.
Construction

Q .Different between mono-wall and membrane tube?

Ans .“Mono-wall tubes” are such tubes in which fins are integral part of tubes & are welded
together whereas “Membrane tubes” are such tubes in which “strips” are inserted & then they
are welded to the tubes.

Q .How many type of level controller for boiler steam drum?

2-element boiler water level controller

3-element boiler water level controller

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Our boiler is 3-element boiler water level controller( steam flow, feed water, water level)

Q .What type of burner used

Dual fuel steam assisted pressure jet burner (other types; pressure jet & rotary cup

Maker; HAMWORTHY

What is the function of fin on sunrod element or sunrod element itself?

-Increase the area of heated surface, thus increase heat transfer from exhaust to boiler water.
Gauge glass
How many gauge glass are there in a boiler?
-Gauge glass on port and starboard .

Are they in the same level?

-No

Give reason why are they not in the same .

-This is to show the true level or correct level of water inside the boiler especially due to
pitching and rolling .

Explain with sketches how to blow down a gauge glass.

-Close steam and water cock then open the drain .Nothing should then blow out of the gauge
is the steam and water cock are not leaking

-Open and close water cock to check that the water cock connection to the boiler is clear.

-Open and close steam to check the other cock connection to the boiler is clear.

-Close the drain - .Open the water cock .Water should then gradually rise up to the top of the
gauge glass.

-Open the steam cock and the water in the glass should fall to the level of water in the boiler

What is the purpose of blowing down the gauge glass?

-To make sure the true water level in the boiler.

-To make sure the gauge glass is working not choke.

What would prevent water rushing out of the boiler if the gauge glass were to break?
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A ball valve is fitted below the gauge glass tube to shut off the water.

If there was no water in gauge glass after blowing down?

Shut down the boiler immediately and use easing Gear to relieve boiler pressure.
Mountings

What is the Purpose of the Scum Valve on a Boiler?

It’s connected on the steam drum at the normal water level of the Boiler and enables the
Blowing Down or Removal of Scum and Impurities from the Water Surface.

What type of Valves are Boiler Feed Check Valves and Why?

Non-Return type and are fitted in pairs, to prevent Back Flow of Boiler Pressure down the Feed
Line.
Safety Valves

How many safety valves are there in the boiler and in your exhaust gas economizer?

-There are 2 safety valve with different setting fitted on the boiler steam drum(72.5,73
bar),one in superheater (65.1 bar )outlet and one at the economizer(80 bar) because in is the
minimum requirement.

Difference between relief and safety valve? (pop up, blow down setting, etc).

Safety v/v has a pop action means it opens 100 %when pressure reaches lifting pressure & it
reseats below working pressure as adjusted.

Relief vv opens gradually means it starts to open once pressure reaches lifting pressure & keeps
opening if the pressure rises thus it has a range of opening .It starts to close once pressure
starts reducing & fully shut @ the pressure just @ the lifting pressure.

Maintenance on safety v/v?

Already dismantle:

-Make sure do marking of the spring position.

-Dismantle the v/v check v/v seat, check v/v spindle, v/v disc.

-Box up the safety v/v.

-Do pressure test accordingly to the maker’s manual.

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-Then safety v/v connected back to the boiler.

-Do popping test accordingly.

-Now maintenance is done.

Safety valve attach on boiler:

-Maintenance on easing gear – no seize. Then Grease the safety v/v.

Types of safety v/v:

Refer to steam course note

1. -Ordinary spring loaded valve

2. High lift valve
a. High lift safety valve
b. Improved high lift safety valve
3. High capacity safety valve
a. Full bore safety vlave
b. Hylif safety valve
c. Consolidated type safety vlave

Boiler water test /treatment

Why carry out Boiler Feed Water Tests?

Boiler feed water tests are carried out to prevent and detect contamination of the feed water
i.e .a buildup of scale occurring, which could reduce boiler efficiency and can cause serious
overheating.

Also to prevent corrosion.

Prevent Carry Over -where soluble salts and suspended solids are carried over with Steam.

Purpose of boiler water treatment?

-To balance all chemical condition in the boiler

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 28

-To avoid corrosion.

-Avoid carryover

-Avoid loss of condensate

-Avoid contamination by salt water

What would you do if you had a High Chloride(TDS) Level in the Boiler?

To reduce the chloride level in the boiler, the boiler would be blown down, thus allowing fresh
feed to the boiler.

What type of Water Tests would you do on a Low Pressure Auxiliary Boiler /Economiser?

Chlorides test

PH-alkalinity test

Total dissolved solids test -using hydrometer

Phosphate reserve.

If scale happened what the effect?

-Overheating

-Reduce heat transfer

-Cause turbulence inside tube

Operation & System

Why Purge a Boiler Furnace?

A Boiler Furnace is purged before burner operations to ensure that there is no unburned fuel or
gases in the Furnace, which may cause a blowback .Purging should be carried out for at least
two minutes.

Why deaerator at higher place?

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Provide positive NPSH, water will not boil at 130 deg C.

To allow sufficient time for the o2 to be vent.

What is the range of uptake temperature?

160 ~ 180

State what is the inspection carried out at the boiler during operation

1. Boiler steam pressure

2. Boiler wtr level
3. Temp and pressure of fuel oil burner enter
4. Temp and pressure steam outlet
5. Flame combustion good(bright red color )>>>>>>>
6. Funnel smoke color haze brown .If blackish means less air but if colorless means more
air.

What action would you take if you spotted oil in the Gauge Glass of a Boiler?

The action to be taken would be to scum the boiler and blow down the gauge glass .Then the
source of contamination investigated and stopped.

Name procedure of doing soot blowing process.

- -Procedure step by step

a. Ask permission from bridge and adjust speed for sootblowing .
Normally at 80 rpm. And ask for wind direction.
b. Reduce superheated steam temperature to 500° C
c. Increase excess air by 0.3 percent( To provide extra draught).
d. Open sootblower steam mastervalve and shut drain.
e. Start sootblowing sequence
f. Monitor sootblowing and motor current.
g. After finish, shut sootblower mastervalve and open drain.
h. Inform bridge and adjust speed as necessary.
i. Bring superheat temp to 515° C back.
j. Put excess air back to normal.
- Why boilers load 40t/h?
At this load, the boiler draught is good to push soot out of the boiler

- Why reduced superheated steam temp to 500° C

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To compensate any fluctuate in the boiler .To supply colder steam to the
sootblower particularly the longstroke one in order to protect it especially in the
superheater region.

-To avoid over heating of the tubes and high steam temperature .

- Soot blower sequence .

With full sequence :Economiser from top to bottom

Superheater from bottom to top

Economiser from bottom to top

With partial sequence :Superheater from bottom to top

Economiser from bottom to top

- What you did if soot blower stuck?

Automatically, the sequence will change to manual leaving the drain valve shut
and steam valve fully open to protect the sootblower .Put the stuck sootblower
to local and try to retract it manually using the crank handle

- Soot fire, hydrogen fire.

Excessive heat in the economiser can cause hydrogen fire in the economizer
during sootblowing.????

What checks to be carried out in furnace?

Infringement of tube due to the flame, condition inside furnace, check brick refractory for any
defect,

Boiler check done?

Welding joint of the tube, crack/leak tube, refractory, membrane wall, combustion space and
any welded joint.

After hose down economizer what should be observe?

Check crack on tube, welded joint

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Reason for blow down:

-Blowing out deposit.

-Controlling chemical content in boiler water.

-Controlling high water level

-Emptying boiler for cleaning or inspection.

Safety Valve;

• Full bore, hylif, consolidated and similar types

• Important to open /shut smartly, not feather due to higher press, temp & capacity
(Feathering – cut on valve seat, undesirable loss of distilled water)

• Good SV – lift smartly at adjusted pressure & shut with equal smartness after relief
excess pressure – matter of design

• Achieved by allowing steam from initial lift to impinge on additional lifting surface in
guiding cylinder

Disadvantages of ordinary spring loaded SV

• Unable to fully relieve boiler pressure

• Valve chattering due to incomplete pressure relief

• Valve seat damage due to chattering – require frequent maintenance

Ordinary High Lift Improved high lift

Winged valve Winged valve Wingless valve

No waste piston Waste piston Waste piston

No floating ring Floating ring

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Opening Clearance should be at least D/4

What is the approx value of the chloride, alkaline, and pH value of the boiler feed water.

Chloride -max .30 ppm

Alkalinity -max .50~80 ppm

pH -9.6~10.3

hydrazine -0.05 ppm 0.1ppm

What’s corrosion?

It’s a chemical reaction in which material returns to its original form .The thickness of material
reduces & material becomes weaker & weaker & finally damaged.

What’s erosion?

It’s a mechanical reaction in which material is removed .It usually happens due to abrasive
particles( .pitting is the form of erosion.)

What’s the Scale?

It’s the formation of layer over the tubes which reduces the heat transfer & causes over heating
of tubes

Procedures
Procedure to enter the boiler.
 The burner flame shall be extinguished and fuel supply lines shut off and locked where
possible .Where oil is used, atomizers or oil gun assemblies should be removed from the
burner .Where gas is used, the supply lines shall be blanked off, or shutoff cocks closed
and locked.
 Care must be taken to ensure no fuel or fuel vapors can enter the boiler furnace while the
unit is shut down.
 Secure all inlet & outlet valves of the boiler
 Make sure boiler has been ventilated & depressurized
 Never enter the boiler until an adequate cool-off period has been observed and the
Owner's entry procedures have been completed.
 Open the manhole carefully & run portable blowers to ventilate.

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How to start the boiler from cold?

Need to be approved…

Why we need to purge the boiler? How it is carried out?

When to purge a boiler?
The furnace must be purge :
a )Before light-off
b )After failure of burners to ignite
c )After flame off
d )If there is any appreciable delay between the first purging and burner lighting

Purging is usually designed to supply the furnace with an air

volume which is 4 – 5 times the boilers’ total
combustion gas volume .For this purpose a minimum air
flow is necessary for a certain time

reasons
To remove combustible gases & vapors in order to avoid furnace blow back or explosion
during startup.

Procedures;
Open the dampers @least 80 %to ensure an adequate flow of air
Start FD fan & keep it running for about 5 to 10 min

How to do maintenance on FD fan?

Lubrication & cleaning of bearing & regular vibration checking
Checking of bearing temperature, air pressure & temperature, current

How to fill up the water at economiser? (Motor ship)

Inorder to warm up the economizer tubes before starting the main engine to avoid thermal
shock on the economizer tubes,
Circulating pp is used to fill up & then circulate from boiler to economizer to boiler again

How to shut down boiler

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Procedure of flashing up boiler .

-Make sure all safety precaution taken before commencing any work
-Check the boiler internally and externally
-All drain are closed
-All loose parts fastened
-Open air vent
-Open auxiliary feed check valve and fill boiler between the lowest and normal water level
-Purge the boiler
-Fire the boiler by using pilot burner
-Check flame condition
-Warm up boiler gradually
-Fire 5 minutes, stop 10 minutes
-Continue until steady whiff of steam come out from the air vent
-Close air vent
-Ease up boiler steam stop valve to avoid jamming
-Steadily and gradually increase the steam pressure
-Crack open the main steam stop valve to heat the FO before changing over from DO to FO
-Blow through the gauge glass
-Shut the auxiliary feed check valve and open the main feed check valve

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-Maintain water level and steam pressure before changing to automatic operation .

Explain how you blow down the boiler and why is it carried out?
-Take out the boiler of service .
-Allowed boiler pressure to fall about 3 bars .
st
-Check water level 1
-Should be done at light load
-Open ship side cock
-Open scum valve and scum boiler before blowing down and then close sum valve .
-Open blow down valve and continue to blow .
-Stop blow down when the noise level falls , pressure is observe is to be low and pipe next
to the blow down cock gets cold .Close the bottom blow down cock .
-Close the ship side cock .
-Wait till pressure in boiler is near atmospheric and open the air vent to prevent vacuum
formation inside the boiler .

How do you clean a DO service tank of a boiler?

-Shut the filling valve
-Then ventilate the tank by opening the cover for 10 minute .
-Scoop out all the left over diesel oil into a bucket .
-Then clean up the tank with rags .
-Now the tank is clean .
-Before shutting the tank, make sure no rags left behind .

Inspection and Maintenance

List down the maintenance required for boiler .
Why need to hose down the boiler?

After hose down economizer what should be observe?

Check crack on tube, welded joint, check brick refractory for any defect,

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Safety

Q .Describe the various fire protection systems fitted to your last vessel?

1- CO2 fire extinguishing system ER & some deck compartment (Cargo Machinary room,
motor room, paint store, EDG room
2- Dry chemical powder system cargo areas
3- Fire main (SW fire fighting system)
4- Potable fire extinguishers
5- IMO spray (Water curtain or fog for deck and accommodation front)
6- FW fire fighting system for accommodation.
7- Fire detection system for E/R and deck.

Q .Describe the procedure before release of the bulk fire fighting system into the machinery
space?

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 38

Q .Describe the location of general alarm push buttons in the engine room?

Total 5

3 hull part ; Bridge, forward store , EHQ & lift

1 ER; (1 ECR

Q .Describe the procedure following the activation of a smoke /fire detector – or general
alarm?

Or if u heard the fire alarm we have to muster to the designated muster station.

Please refer to the word document.

Describe the procedure following the activation of general alarm?

Muster @ your respective station upon hearing the announcement (abandon ship, security,
oil spill )

What kind of fixed firefighting system you have on board.

-Carbon dioxide, CO2 system & sea water (In engine room)

-Sprinkler system (Sea water, on deck & for accommodation )& Dry powder (For cargo spaces)

-Fixed fresh water fire-fighting Installation (In accommodatin.and sea water as well

How do you detect fire on board? In engine room and accommodation?

-smoke detector

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 39

-flame detector

-Heat detector

Q .What is the ship fire plan? Where it is located?

• To show clearly:

control stations, particulars of fire detection, fire alarm systems, sprinkler installation, fire-
extinguishing appliances, means of access to different compartments, deck,ventilation system -
particulars for the fan control positions, position of dampers and identification numbers of
ventilation fans serving each section

Location:

 We have four on deck .Two in the main deck near EHQ (P & S)
 Two near the accommodation ladder on main deck.
 We have the plan posted in accommodation, in 2nd deck and deck 5

Where is the muster station and embarkation station?

 We have two muster station on main deck port and starboard.
 Our secondary muster station will be near cargo mach room, in-case the access to the
above main muster stations is not applicable.
 Embarkation deck is deck 1 .

Q .What action to be taken when fire in engine room?

Find, Inform, Restrict, Extinguish

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 40

Fires are classified according to the types of material, which are acting as the source, what
are these Classifications?

Class A –(Solid Fire )wood, glass fiber, furniture and furnishings.

Class B -liquids Fire such as lubricating oil and fuels

Class C -gas Fire such as LNG

Class D -metals Fire such as magnesium and aluminum

Class E – any of the above with electrical .

Class F -cooking oil

What action would you take in the event of Fire breaking out in the Machinery Space?

If a Fire breaks out, the alarm should be raised and the Bridge informed immediately .If the Ship
is in Port, the Local Fire Authority should be called .If possible, an attempt should be made to
extinguish or limit the fire by any means possible (a Fire in its first few minutes can usually be
readily extinguished.)

Ventilation fans should be stopped (should stop automatically on activation of fire alarm .)
Openings to the space should be sealed to reduce the supply of air to the fire and to prevent it
spreading .Any fuel lines feeding the fire or threatened by it should be isolated .If practicable,
combustible materials adjacent to the Fire should be removed.

After the Fire has been extinguished, precautions should be taken against spontaneous re-
ignition.

Personnel, unless wearing breathing apparatus, should not re-enter a space in which a fire has
occurred before it has been fully ventilated.
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What is Boundary Cooling and the reasons for it?

Fire can be transmitted through bulkheads due to radiant heat, i.e .causing combustible
materials in adjacent compartments to catch Fire .Therefore, this radiant heat is prevented by
Boundary Cooling of all sides of the compartment on fire, using water spray hoses.

Fire is the combination of Three Factors, what are these?

1 .A substance that will burn

2 .Ignition Source

3 .A supply of oxygen, usually from air.

How do you handle fire?

F =find the fire

I =Inform

R =Restrict

E =extinguish the fire.

Q .Describe the dangers of having combination bilge /ballast /fire fighting

pumps?

For bilge in case of flooding to the engine room and the pump used to pump
over board the possibility of oil presence inside the pipe is there, so when used
for fighting the fire instead fighting the fire u will feed the fire.
What pumps in the Engine Room would supply the Fire Main?

Fire &Bilge pump, fire pump , Emergency fire p/p & IMO pump .

Sketch the fire main line on your vessel.

Sketch an Automatic Sprinkler System for the Ships Accommodation and explain.

Refer to the fire plan(Hull part) we don’t have)

What is a Water Fog based Fire-fighting Installation?

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Unlike conventional sprinkler systems utilising water under low pressure in heavy large
diameter pipes, the Water Fog Extinguishing System operates by using water under very high
pressure in small bore pipes .This reduces the weight and volume of the system and permits
easy installation on board.

The Water Fog System produces micro-droplets of water; thus a very large cooling surface is
created with only small quantities of water .With this system the amount of water required for
successful fire extinguishing is much less than conventional sprinkler systems .This allows for
the use of fresh water as the medium .Also with the Water Fog System, the Water Fog is
propelled into hidden spaces just like Halon or CO2, providing the most reliable Fire-
extinguishing.

State the capabilities of a Ships Main Fire Pump.

It must be capable of supplying water to, at least two hoses and nozzles in the Ship and they
must produce a good jet of water simultaneously.at least(180m3/h)

What is, and where would you find, the International Shore Connection?

This is a standard size Flange which is fitted with a suitable coupling suitable for the Ships Fire
Hoses .The Flange is slotted in order to fit any shore side Fire Main and enable water to be
brought on board Ship lying alongside .Usually located on the Bridge(containr ships( @
manifolds P & S.)

Shore Connection main dimensions

Description Dimension
Outside diameter 178 mm
Inside diameter 64 mm

EMERGENCY FIRE PUMP

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When emergency fire pump in use?

-When Engine Room can’t be enter.

-Main fire pump malfunction

-Engine Room fire main line destroyed during fire in engine room

How do you start emergency fire pump?

-Make sure suction and discharge valve is open.

-Check level of F.O & L.O.

-check the cooling water.

-Turn the shaft of pump by hand check whether stuck or not

-Now start the pump by push start button .Observe the ammeter until it stable(if motor is the
prime mover.)

-Check any leaking at the line and also at the gland packing.

From how many places we can start the emergency fire p/p?

-It can be started from three places.

1 .Bridge

2 .EHQ (Fire control station)

3 .Locally (There are two ways either by cracking manually or by battery)

Q .What’s the purpose of isolating v/v & how many on board ur ship?

Ans .Its purpose is to isolate engine room from deck or any defective part in the main line &
there were 11.

What is your emergency fire pump prime mover?

Ans .Its 4-stroke reciprocating Diesel engine.

Q .What checks & maintenance is carried out on the emergency fire pump?

Ans- .Check F.O & L.O .levels.

-Check Battery charging.

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 44

-Test the p/p every week.

Check the condition and working of the priming pump.operate the pump &check the pressure
of water running through the hoses.

Q .State the regulations regarding the Emergency Fire Pump.

Location; remote from the Machinery Space

Starting method; Independent Means of Power, which could be a diesel engine or from the
Emergency Switchboard.

Isolation of fuel tank in case of fire

Should have independent suction with NPSH of 4.5m at all conditions

Fuel should be enough to run the pump for 3hrs at full load continously and 15 hours with
engine room isolated capable to supply 2 nozzels with a water jet of 40 ft

Fire Extinguishers
What type of portable extinguisher would be used on ----fire (fill in the blank)

Type Of Fire Solid(class Liquid(class Gas(class Metal(class Electrical(class

A) B) C) D) E)
Extinguisher Water Foam, Dry Dry Water, Dry CO2 dry
Dry powder powder, powder powder powder
Inert gas &
steam

Describe the testing, refilling procedure for various portable firefighting devices.

Refer to prepared paper

Q .What are the Four Principle Types of Portable Fire Extinguishers found on board ships?

Water/Soda acid type extinguishers

Foam extinguishers
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 45

Dry powder type extinguishers

Carbon dioxide extinguishers.

Describe and sketch a Soda Acid Extinguisher .

The container of the Extinguisher holds a sodium bicarbonate solution .The screw on cap
contains a plunger mechanism covered by a safety guard .Below the plunger is a glass phial
containing sulphuric acid .When the plunger is struck, the glass phial is broken and the acid
and sodium bicarbonate mix .The resulting chemical reaction produces carbon dioxide gas,
which pressurizes the space above the liquid, forcing it out through the internal pipe to the
nozzle.

Q .On what type of Fire would you use a Soda Acid Extinguisher (Water)?

Ans .This type of Extinguisher would be used on Class A Fires :Fires burning wood, glass fibre,
upholstery and furnishings.
What testing and maintenance is done regarding Soda Acid and Foam Extinguishers?
The extinguisher containers are pressure vessels, therefore require testing .
Containers are initially tested to 25 bar every year for five years and thereafter at four
yearly intervals to 20 bar .
On Soda Type Extinguishers 20 %of contents should be discharged per year and replenished
with Foam Type 50 .%
Where practical the operating mechanism of portable extinguishers should be examined
every three months .
Where would you expect to find a Soda Acid Extinguisher (Water)?
Accommodation areas.

Q .What checks to be carried out on portable fire extinguishers?

-weigh the extinguisher.

-check the safety pin is in place

-Instructions are not removed

-Hose is not damaged or nozzle not chocked

-Container is not rusted .

-if dry powder u should shake it

Q .What does AFFF stand for and where would you use this type of Extinguisher?

Ans .AFFF stands for :Aqueous Film Forming Foam.

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This would be used on Class B Fires, fires burning liquids such as lubricating oils and fuels.

Q .With regards CO2 Extinguishers, what testing and maintenance is carried out?

Ans. It is sent shore to be tested to 207 bars.

Q .Where would you expect to find a CO2 Extinguisher?

A .Machinery spaces, particularly near electrical equipment, such as switchboards.

Q .On what type of Fire would you use a CO2 Extinguisher?=

.Class B and C Fires and Electrical Fires.

Where are CO2 Extinguishers not permitted?

CO2 Extinguishers are not permitted in the living quarters of the accommodation.

Note within the accommodation block, CO2 extinguishers are available in the Cargo Control
room, Bridge and Radio Room where dry powder could damage this apparatus.

Sketch and describe a Dry Powder Fire Extinguisher.

The outer container contains a sodium bicarbonate powder .A capsule of carbon dioxide gas is
located beneath a plunger mechanism in the central cap .On depressing the plunger the carbon
dioxide gas forces the powder up a discharge tube and out of the discharge nozzle.

Sketch and describe a CO2 Extinguishers.

A CO2 Extinguishers consists of a very strong container that is used to store liquid carbon
dioxide under pressure .A central tube provides the outlet passage for the carbon dioxide,
which is released either by a plunger-bursting disc or a valve operated trigger .The liquid
changes to a gas as it leaves the Extinguisher and passes through a swivel pipe or hose to a
discharge horn.

Why are CO2 Extinguishers not permitted in the accommodation?

Because if used in a confined space, it could be fatal.

Where would you expect to find a Foam Extinguisher?

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It would be located in the Engine Room, in the vicinity of Flammable Liquids, also Bunker
Stations( if motor ship.)

What is the duration and range of a 136L Trolley Foam Extinguisher?

The duration of a 136L Foam Trolley Extinguisher is 15 minutes approximately with a range of
around 18m.

How much foam is produced from a 9L Foam Extinguisher?

72 liters of Foam.

What is the duration of a 9L Foam Fire Extinguisher?

Approximate duration of around 50 seconds.

What is the range of a Foam Fire Extinguisher?

The range of a Foam Fire Extinguisher is roughly 7m.

On what type of Fires would you use a Foam Extinguisher?

Class B Fires :Fires burning liquids such as lubricating oil and fuels.
What is fitted in a Foam or Water Type Fire Extinguisher that ensures liquid, not gas comes out on discharge .

A dip tube or internal pipe is fitted in the Fire Extinguisher, which is connected to the extinguisher hose and travels
to the bottom of the extinguisher.

Sketch and describe the Chemical Foam type of Extinguisher.

The main container is filled with sodium bicarbonate solution and a long inner polythene
container is filled with aluminum sulphate .The inner container is sealed by a cap, held in place
by a plunger .When the plunger is unlocked by turning it, the cap is released .The extinguisher is
then inverted for the two liquids to mix .Carbon dioxide is produced by the reaction, which
pressurizes the container and forces out the foam.

Sketch and describe the Mechanical Foam type Fire Extinguisher.

The outer container is filled with water .The central container holds a carbon dioxide charge
and a foam solution .A plunger mechanism with a safety guard is located above the central
container .When the plunger is depressed, the carbon dioxide is released and the foam solution
and water mix .They are then forced out through a special nozzle, which creates the Mechanical
Foam .This Extinguisher has an internal pipe and is operated upright.

Sketch and describe a Dry Powder Fire Extinguisher.

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The outer container contains a sodium bicarbonate powder .A capsule of carbon dioxide gas is
located beneath a plunger mechanism in the central cap .On depressing the plunger the carbon
dioxide gas forces the powder up a discharge tube and out of the discharge nozzle.

On what type of Fire would you use a Dry Powder Fire Extinguisher?

The Dry Powder can be used on all classes of Fire, but it has no cooling effect.

What is a good practice before using a Dry Powder Extinguisher?

It is good practice to give a Dry Powder Extinguisher a shake before use, as the Extinguisher
could have been lying for a while causing the powder to clog up.
With regards Dry Powder Extinguishers, what testing and maintenance should be carried
out?

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Being a pressure vessel, the container is tested to 35 bar every four years .
Operating mechanism checked, where practical every three months.

CO2
Q .Describe the testing procedure of the bulk fixed fire fighting installation?
Please refer to the CO2 manual for PD

Releasing Pressure of CO2 relieve vv :126 bar (To Weather)

Q .Explain procedures prior to activating CO2?

Please refer to the word document.

Q .Explain what happens when the lever is pulled?

Refer to the CO2 manual .Plenty and detailed explanation is given there.

What are the alarms fitted to a Bulk CO2 System?

 CO2 release alarm

 Ventilation stop
 High Level Alarm (increase of contents over 98 %volumes )
 Low level Alarm (loss of 5 %volume )
 Leakage Alarm past Main Discharge Valve

What are the safety features fitted to a battery CO2 system?

A Stop Valve to stop discharge of CO2 to the Machinery Space .
A Safety Valve between the Starting Cylinders and Operating Piston .This is to prevent
operation of the System due to leaking Starting Bottles .
Pressure Alarm in discharge line to give an indication of an accidental escape or leaking CO2
bottle from the Battery .
What does the opening of the CO2 release cabinet do?
It sets off an Alarm in the Engine Room to warn personnel that the release of CO2 is imminent .
It also stops all ventilation .
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What are the requirements of a fixed CO2 Fire Fighting Installation?

The System must give 40 of the volume %saturation of the Compartment to be filled .
85 %of the CO2 charge must be discharged into the Compartment within the first two minutes .

What happens to the CO2 System in Dry dock?

In dry dock the CO2 System must be made inoperable & incase of fire occurs, shore supply
should be there.

What are the two types of CO2 Fixed Installations used on board ships for Fire Fighting?

The two types of systems are :Battery System(hp) and Bulk System( lp.)

What can be fitted over Relief Valve Vents on a bulk CO2 system to give an indication of
leakage?

Balloons.

On what type of vessel would you expect to find a Bulk CO2 System and what is normally
incorporated into these systems?
You would normally expect to find a Bulk CO2 System on a Cargo or Ro-Ro type vessel
where hold areas need Fire-Fighting Protection and the Cargo Space System is normally
arranged for smoke detection, alarm and CO2 flooding .
Small air sampling pipes from the individual cargo holds are led into a cabinet on the Bridge .
Air is drawn from each hold by a small fan and each pipe is identified for its particular hold .
If smoke is drawn into the cabinet from one of the holds it will set off an alarm .The smoke
is also passed into the Wheelhouse where it can be detected by personnel on watch .
The location of the fire can be identified in the cabinet and the hold distribution valve below
the cabinet is operated .This valve shuts off the sampling pipe from the cabinet and opens it
to the CO2 Main, leading to the Bulk CO2 discharge manifold .A chart indicating the amount
of time the release valve is to be opened for and this is done by first opening the main
discharge valve to the manifold, setting off CO2 alarms .

What is the purpose of the two sets of relief valves on a Bulk CO2 System .?
The purpose of the two sets of relief valves on a Bulk CO2 System is that one set being an L
P Set being set at 24.5 bar and designed to relieve excess pressure to atmosphere in the
event of over pressure .
The H P Set is at 27 bar and is required to discharge into the Compartment, i.e .in the
event of a Fire in the Bulk CO2 Compartment, this causes a rapid rise in pressure and in
theory CO2 will discharge into the compartment, extinguishing the fire.

What are the advantages of CO2 Systems compared to Halon Systems?

CO2 is more Environmentally Friendly also Halon Systems distroies the ozon layer are being
phased out.
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Why is an Alarm Sounded when CO2 is released into the Engine Room?

An Alarm is sounded to inform personnel in the Engine Room that the release of CO2 is
imminent .The type of Alarm will be visual and sound different from Engine Room Alarm
and General Alarm.

CO2 cannot support Life.

FOAM SYSTEM
How many types of Fire Fighting Foam are there?

AFFF -synthetic type

Protein based Foams (Ox's blood)

Which can be low expansion for use on decks etc for fire-fighting, or

High expansion, which can be used in Machinery Spaces

How does a Foam Nozzle work?

The foam nozzle works on the Venturi Principle where air is drawn into the nozzle aerating the
foam solution for good quality fire fighting foam
Sketch and explain a Foam Fire-fighting Installation .
Here an Automatic Foam Induction System is shown .The Automatic Inductor Unit ensures the
correct mixing of Water and Foam compound which is then pumped to hydrants, deck or
machinery space for use .The foam compound tank is sealed to protect the contents from
deterioration and has linked compound supply and air vent valves .To operate the system,
these two linked valves are opened and the Fire Pump started .Foam mixing is carefully
metered by the automatic inductor unit .The Fire Pump and compound tank must be located
outside the protected space .
Briefly explain how High Expansion Foam is produced .
High expansion foam is produced by means of a Foam Generator, where from Foam
Concentrate and Seawater, 1000 times quantity is achieved .The generator blows air through a
net sprayed with foam concentrate and water .The vastly expanded foam is then diverted away
to the space to be protected .The foam is an insulator and an absorber of radiant heat; it also
excludes oxygen from the fire .
Describe Halon Fire-fighting System, (CO2 )

In a Halon Fire-fighting system, Halon bottles are strategically placed around the Machinery
Space .The amount of Halon (1301 )required for Fire-fighting is very little .Each bottle has

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its own definition mechanism .This is operated from a remote location outside the
Machinery Space.

On opening the Halon release cabinet, this will sound the Halon Alarm in the Engine Room,
which will let personnel know that the release of Halon is imminent and that

the Space should be evacuated .Ventilation to the space should then be stopped and space
sealed .Before release of Halon, all personnel should first be accounted for.

What is the Re-entry Procedure once a Machinery Space has been Flooded with CO2 or
Halon?

(Cool down > re-entry ‘with BA set’ to check hot spots or possibilities of re-ignition >
ventilate).

Once CO2 or Halon Flooding has taken place, the Space should be continued to be Boundary
Cooled.

Only when the Extinguished Fire has been left long enough to cool down, can the Space be
re-entered .Note :early re-entry can lead to re-ignition.

Re-entry should be done by personnel wearing breathing apparatus, taking water spray
hoses with them to cool down any hot surfaces .Note :Re-entry should also take place from
the lowest point remote from the seat of the Fire, if possible.

Cooling and smoke dispersal are the first priorities to provide an atmosphere in which
others can operate and gradually bring machinery back into service.

Where the Machinery Space Fire involves electrical equipment then only Dry Powder of
Carbon Dioxide Extinguishers can be used until the equipment is isolated.

What are the advantages of Halon Systems over CO2 Systems?

Less Halon is needed to extinguish a Fire than CO2 therefore less storage space is required.

Also the atmosphere in a Holon flooded Space is not toxic, although does contain some
highly irritant gases when extinguishing.

What /%Ratio Halon is required to extinguish a Fire in a Compartment?

5%

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Fire detecting system

Q .What daily checks are carried out on the fire and smoke detection
equipment?
• AUDIBLE FIRE ALARM & ZONE INDICATING LIGHT IS WORKING PROPERLY.

• EXTENSIVE SIMULATION TEST FOR DETECTORS.

• AUDIBLE ALARM INDICATING LIGHT FOR SYSTEM FAILURE IS WORKING

INCLUDING CCT BREAK & EARTH LEAKAGE MONITORING.

• EMERGENCY BATTIERS SUCCESSFULLY CUT IN WHEN POWER LOSS

OCCUR.

Q .Describe the location of fire and smoke detection heads?

Please refer to the PD fire control plan.

Q .Describe the different types of smoke and fire detection equipment fitted to
your last vessel?

Q .Describe the workings of certain types of detectors?

Please refer to the presentation about detection system attached with this file.

You can also refer to MEP book named “Fire Fighting Equipment”

What fire detecting system you have on board .How do they function?

a )Smoke detector (Photo-electric cell)

-When smoke detected, light scattered around the barrier on to the photo-cell and an
alarm is triggered.

b )Flame Detector (infra Red)

-Flickering radiation from flame reach the detector lens/filter unit, which allow infra-red ray
to pass and focused upon the cell and then trigger the alarm.

c )Heat Detector (Bi-metal coil)

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-When 2 metal strip bent forward the contact point that caused by different kind of metal
used in the strip when react to heat.

What is the Principle Operation of a Flame Detector?

As Flame has a characteristic Flicker Frequency of 25Hz, use is made of this fact to trigger an
alarm .Flickering radiation from flames reaching the detector lens/filter unit, which only
allows infra-red rays to pass and be focused upon the cell .The signal from the cell goes into
the selective amplifier, which is tuned to 25Hz, then to a time delay unit (to minimise
incidence of False Alarms )then to an alarm circuit.

What is the Principle Operation of a Heat Detector?

This type of Heat Detector uses two bi-metallic strips/coils attached to a vertical support
bracket .When temperature is present, the bi-metallic strips will start to move, at a fixed
temperature the first strip will hit a stop, the second strip continuing to move, thus the
contact is made and triggers the alarm.

Once a Fire Detector has detected or sensed a fire, what happens?

Associated with Fire Detectors is a Circuit connected to an Alarm Panel, which is usually
situated on the Bridge, where the Alarm is accepted, usually there is a Repeater Panel in the
Engine Control Room .The Panel giving an indication on which Deck and Zone the Detector
was activated .Someone will then be sent to investigate and verify if it is a Fire or a False
Alarm.

Where would you find Heat Detectors and why?

Heat type Fire Detectors would be used in places such as the Galley, where other types of
Detectors would give false alarms.

What is the Principle Operation of a Smoke Detector?

The above detector, of the light scatter type uses a photo cell separated by a barrier from a
semi-conductor intermittently flashing light source housed in an enclosure whose
containment allows smoke but not light inside .When smoke is present in the enclosure,
light is scattered around the barrier on the photocell and an alarm is triggered.

What type of Detector should be fitted in conjunction with an Infra-Red type Fire Detector?

It should be used in conjunction with a Smoke Detector, to give an early warning of fire.

Where are Infra-Red type(flame ) Fire Detectors best situated?

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They are best situated in machinery spaces and boiler rooms ‘firing plate form’ & above DG
where there is a high risk of fire

BREATHING APPARATUS SET

Describe a Self-Contained Breathing Apparatus Set.

 1 or 2 cylinders of compressed air kept in a harness, which is carried on the back .

 200-240 bar .reducing valve and then to a demand valve.
 demand valve setting;
1) positive pressure mode, that will supply a constant demand of air
2) demand mode, which will only supply air as the wearer demands
 A non-return valve permits breathing out to atmosphere not back to the cylinder
 Whistle for air LP
 20-25 minutes operation, but this will also depend on a few factors, such as
workload of wearer.

How do you carry out a Face Seal Check on a Breathing Apparatus Set?

Don Face Mask, tighten straps properly and turn air supply on .Then switch air supply off
and breath in, the mask should stick to face .Note, pressure gauge should not drop
rapidly either .Switch air supply back on.

What checks should be carried out on a Breathing Apparatus Set before entering a
smoke filled compartment?

The following checks should be carried out:

Ensure the bottle is full,( pressure)

Check operation of low pressure whistle, and

Face seal check should be carried out.

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Q .What should be used with Breathing Apparatus Sets when entering a Space or
Compartment?

A time in/time out board or Paper should be used .This board will normally have a built
in clock .On this board the time the wearer enters a space is noted, plus bottle number
and pressure, the time the wearer is due out is calculated as the time the low-pressure
whistle operates at .This gives the wearer time to exit.

Q .Why is a Hydrostatic Release fitted to a Life raft?

In the event of the Vessel sinking, the hydrostatic release operates at a predetermined
water depth(around 4.5 m), releasing the Life raft lashings, allowing the Life raft to float
free and inflate.

How is a Life raft launched?

A Life raft is simply launched by releasing it from its lashings, a painter is secured to the
Ship and the Life raft container is thrown over the side .Inflation takes place
automatically, the container bursting open and the Life raft floats clear .A pressurized
cylinder of CO2 is used to inflate the raft .Life rafts must normally be boarded from
water level, dry if possible.

What survival equipment would you expect to find in a Lifeboat?

Survival equipment would include oars, a boathook, a compass, distress rockets, first aid
equipment, rations and fresh water,hylicopter mirror.

What must the capability of Gravity Davits be with regards heel of ship?

The Davits must be able to lower the Lifeboats when the Ship is heeled to 15° on either
side.

What Speed does the Centrifugal Brake on a Lifeboat Winch limit the Speed of Fall of
the Lifeboat to?

The Centrifugal Brake on a Lifeboat will not allow the Lifeboat to fall faster than
36m/min.

Explain the procedure for lowering a Lifeboat with Gravity Davits.

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Refer to MSCR BOOK.

What are the two Brakes on a Lifeboat Winch?

The two brakes on a Lifeboat are a centrifugal brake and a weighted brake known as
a "Dead-Man's Brake "i.e .once you let go of the braking lever, the brake will come
into action stopping the fall of the Lifeboat.

What is done to ensure that a Lifeboat Engine will start when needed?

once a week the Lifeboat Engine should be run for around 3 to 5 minutes, all Fuel and
Oil Levels checked and the gearbox should be operated i.e .Engine run astern and ahead
to check Operation.

Most Engines are air cooled, but some are a combination of air and water, in which case
water level checked and if operating in cold climates anti-freeze levels also.

Larger Lifeboat Engines will be battery started, therefore condition of battery must be
checked i.e .S G(specific gravity) of electrolyte and that electrolyte is covering cell plates.

Procedure

Q .Explain why we need the hot work permit?

Hot work permit is issued so that ensuring the personnel carrying out the
work is fully understood the correct procedures for doing the hot work job

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Q .Who will issue the hot work permit onboard?

Q .How long the hot work permit will last?

Q .Is there any limitation to the hot work permit?

Please refer to the word document regarding “Hot Work Permit” .Detailed information is
given

Q .If you are required to work by using welding equipment on a hydraulic

system inside an empty ballast tank, what permit you should apply?
Hot work permit

Enclosed space entry permit

Q .List down the procedure towards safety at work?

You may better refer to the “Code of safe working practices”

Q .Procedures and precautions before entering an enclosed space?

Please refer to SMS manual for details.

Refer to the word document for the checklist attached with this file.

What oxygen levels would you regard as safe to enter an enclosed space?
20 %or above.
What is regarded as an enclosed space?
An enclosed space is a space that cannot be assumed to contain oxygen and may
contain flammable gases.
These are spaces such as a duct keel, a double bottom tank, a cofferdam, boiler,
etc.
Would you enter an enclosed space if the oxygen levels were recorded as 19 %
or below?
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No

What is the procedure for entering an enclosed space?

An enclosed space entry permit is required which can only be obtained with the
permission of a responsible officer .This permit will list the conditions to be met
before entry.
The space should be well ventilated before entry takes place; before entry,
oxygen levels must be checked using an O2 Meter.

Procedure to enter confined space.

Apply enclosed space entry permit from chief officer.

Delegate work to all personnel covering from operational level, support level and em’cy level
for duties and nature of work

Prepare all tools for commencing work e.g .blower, intrinsically safe bulb, air trunk, B.A .set,
stretcher, first aid kit, fire extinguisher, walkie-talkie

Open the manhole and force ventilate for a period at least 24 hours

Confirm the condition with chief officer for permit approval (oxygen level, hazardous gases)

Prepare the space with adequate lighting provided by intrinsically safe bulb

Enter the enclosed space carefully taking into account all the safety precaution

Make sure to station one personnel at the entrance during work

Ensure constant communication between the person inside the enclosed space and the person
standing outside

While working, if the condition doesn’t permit further work to be done, immediately leave the
space

Another person should remain at the entrance while the person is in the space, to summon
assistance if necessary and there should also be means of communications arranged between
the person within the space and the attendant.

Lifelines and harnesses should be available at the entrance to the space.

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If the occupant appears to be in danger, the attendant should first raise the alarm, but should
not enter the space unless equipped with breathing apparatus.

What advantage do Inert Gas producing units used for Fire Fighting Installations have over
CO2 and Halon Systems?

Inert Gas Producing Units have the advantage of being able to continuously produce Inert Gas .
A bottle storage system, such as CO2 or Halon Flooding is a "one shot "Fire Extinguisher which
leaves a ship unprotected until further gas supplies can be found.

Generators;
Describe the power generation plant fitted to your last vessel..
Ans .2 T/As driven by 60b steam @ a speed of 1800rpm with a rating of;

440V, 60 Hz, 3 Phase, p.f 0.8

Maximum loading of 2900 KW

 T/A

Turbine :Horizontal rateau 9 stage condensing type, Shinko RG 92

Generator; Brushless AC, Taiyo

 D/G; Daihatsu

Generator; Brushless AC, Taiyo

 EDG; Yanmar,

Generator; Brushless AC, Taiyo,

440V, 60 Hz, 3 Phase, p.f 0.8

maximum loading of 300 KW

Q .Describe how a Self Excited AC Generator would work

Components;

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Main Generator & Exciter Generator (mounted on same shaft)

 Main Generator has revolving magnetic field ‘magnet or iron +windings’ & static
windings
 Exciter Generator has stationary electro-magnetic stator & Rotor having
windings
 Rectifier ‘Diodes’

Operation;

 P.M starts, shaft revolves, and the generator shaft is moving .This turns the exciter
armature, the main field, and the rotating rectifier.
 The exciter initiates an EMF .The rotating exciter armature cuts the residual magnetic
field left over in the stator
 Exciter AC is rectified to DC by Diodes Rectifier & sent to main field winding mounted on
the rotor
 As the rotor shaft turns the main field, the alternating polarities induce an EMF of
alternating potentials in the main armature windings
 Initially, only a small three-phase EMF is produced.
 Voltage control takes over .The voltage regulator senses an under-voltage condition and
diverts the current flow back to the stationary exciter field, thus exciter field is further
magnetized.
 The increased exciter armature current is rectified by the rectifier and directed again to
the rotating main field .
 The increased magnetic field, of the rotating main field, cuts the windings in the
stationary main armature.
 This produces a greater three-phase EMF.

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What is done to ensure the Emergency Generator is Always Available and Will Start?

The System should be checked regularly and operated weekly to ensure its availability if
required .Fuel tanks should be kept full, ample cooling water in radiator cooling system
and starting equipment should be functional, i.e .batteries should be fully charged or air
receivers full. Always check the stand by lamp is light up which indicates EDG is on
standby mode

Q .What Conditions are Necessary to Parallel two Generators?

Ans .The Speed of both Machines must be the same i.e .the Frequency and the Voltages
must be the Same and in Phase.

Q .What is meant by Preference Tripping?

Preference Tripping is the tripping of non-essential loads when an overload condition

occurs on a Generator( .Aircon, ventilation)

If a Generator Overload develops the Preference Trip Relay operates an Alarm and acts
to trip selected non-essential loads .These loads may trip at set intervals depending on
how essential the load is, i.e .1st trip 5 seconds, 2nd trip 10 seconds.

Q What is Load Sharing?

Load Sharing is the equal balance of loads between Generators irrespective of Load
Changes.

Q .What is the purpose of the Under Voltage Trip?

An Under Voltage Trip is fitted to all Generator Breakers .Its main function is to Trip the
Breaker when severe Voltage Dip (around 50 )%occurs .The Under Voltage Trip on a
Generator Circuit Breaker also prevents it being closed when the Generator Voltage is
very low or absent.

Q .Where on the ship is the Emergency Generator Located?

The Emergency Generator is located remotely from the Engine Room, usually on the
Accommodation Deck or at Weather Deck Level or above.

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Q .What are the Essentials supplied by the Emergency Switchboard?

Essentials are :Emergency Lighting, Alarms, Communications, Watertight Doors and

other services necessary to maintain safety and to permit safe evacuation of the Ship by
Lifeboats .Also you will find that a Steering Gear Motor, Emergency Air Start Compressor
and Emergency Fire Pump Motor are supplied from the Emergency Switchboard.

Q .Describe how Synchronizing Lamps are used to parallel a Generator.

This is normally used as a back-up or alternative way to the synchroscope, the Lamps
are connected between the Incoming Generator and the Bus-bars .The" Sequence
Method "is the preferred one as it displays a rotation of Lamp Brightness, which
indicates, whether the incoming machine is running fast (clockwise )or slow (anti
clockwise .)As with the Synchroscope, the Lamp Sequence must appear to rotate slowly
clockwise .Correct synchronization occurs when the top or "Key "lamp is dark and the
two bottom lamps are equally bright.

Q .Name the Trips found on a Generator Circuit Breaker.

Over Current

Under Voltage

Reverse Power.

What is Sequential Starting?

Sequential Starting is the automatic starting of essential equipment when power is

returned after a total power failure, i.e .equipment such as Steering Gear.

What Loads are considered Non-essential?

Loads considered as Non-essential are :Air Conditioning and Ventilation, Laundry,

Galley, Refrigeration and Deck Equipment.

Explain what would happen if you were to lose a Generator.

First the Standby Generator set would start up and automatically put itself on the Board .
If this did not happen, the Ship would "Black Out "and after a time delay, usually 30
seconds, the Emergency Generator would start up and supply the Emergency
Switchboard, which supplies essential equipment( .EDG starting requirement is within
45 secs).

What is Reverse Power Protection for?

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Generators intended to operate in Parallel must have a Reverse Power Protection Trip .
A Reverse Power Relay monitors the direction of power flowing between the Generator
and the Switchboard.

If a Prime Mover Failure occurred the Generator would act as a Motor .The Reverse
Power Relay detects this fault and acts to trip the Generator Circuit Breaker.

What is the Function of the AVR?

It tries to maintain the voltage of generator by regulating current to exciter .Comparing

the output voltage with the set value.

What is meant by Protection Discrimination?

This is the ability of a Protection System to disconnect only Faulty Circuits and to
maintain the Electrical Supplies to Healthy ones.

Discrimination is achieved by coordinating the Current Ratings and the Time Settings of
the Fuses and Over-current Relays used between the Generator and the Load.

i.e .a Motor Fault on a Centrifugal Pump would not cause the Generator Breaker to Trip.

Q .Explain how the Emergency Generator starts up in the Event of Total Power Failure.

The Start-up of the Emergency Generator is initiated by an Electrical Relay, which

monitors the normal Mains Power Supply .Falling Mains Frequency or Voltage causes
the "start-up "relay to operate the Generator Starting Equipment .The Prime Mover
may be electrically cranked from it's own 24V battery and starter motor or air started
from it's own air reservoir fitted local to the Generator Engine .A manual start-up may
also be initiated by push buttons in the Main Control Room and in the Emergency
Generator Room.

Also when power loss occurs, the Breaker feeding the Emergency Switchboard from the
Main Switchboard opens .This Breaker is interlocked with the Emergency Generator
Breaker, which is normally open under normal circumstances, but in the event of Total
Power Failure, this breaker will close when the Breaker feeding the Emergency Board
from the Main Board opens .Thus the Emergency Generator will feed the Emergency
Switchboard

Describe the method of synchronizing a generator on to a live board

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Synchroscope method
or Sequence method, 3 lamps
Top lamp (key lamp )is connected in one phase (R to R), 2 lamps (bottom )are phase cross
connected (Y to B & B to Y)
Mounted in triangle formation & once the incoming generator is running & ready to be
synchronized, the synchroscope switch to be on & lamps will start rotating clockwise (fast )or
anticlockwise (slow)
The moment to synchronize is when the key lamp is dark & the other two are equally bright
Ideally; the key lamp should not light up because there is no a potential difference due to its
connected to the same phase & the bottom lamps should always light up due to their
connection in different phases which will create a potential difference between the 2 ends of
the lamp.
However, during synchrozing, when the frequency of the incoming generator is either higher or
lower than the bus bar frequency, the lamps will keep rotating clockwise or anticlockwise
respectively

What are the effects of putting a generator having different frequency or voltage on to a live
board, what is the protection against this?
This may lead to a motorizing effect happens to the incoming generator (If it’s lower )or the
running one (if the incoming is higher)
A reverse power relay is fitted to prevent this.

Describe the protection devices fitted on the main bus bars and distribution circuits
Over current
Under voltage
Revesre power relay
Preferential trip

What provision is there for electrical supply following failure of the main generation plant?
EDG.

Where are the locations of emergency 24v lighting?

1. Enable persons to make their way to the open deck; (escape routes)
2. Illuminate survival craft launching and embarkation; (boat stations)
3. Illuminate man-overboard rescue equipment and rescue areas
4. Permit work on essential machinery(.steering gear compartment & EDG)
How the manual load sharing is achieved?

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By adjusting the knobs of both governors of the incoming (Raise )& running generator
(Lower )& observing the various parameters
Explain how you test the EDG for on load.
Announcement shall be made to the whole ship crew through PA to avoid losing any
information or work done on computers or such machinery supplied by ESB
Opening the breaker responsible of feeding the ESB from MSB, this will stop the supply
to ESB cutting the current going to machinery supplied from ESB, simulating a blackout
condition that will let the EDG start & come on load automatically (within 45s)

Briefly explain the emergency distribution board system.

ESB is supplied by the MSB in normal condition
It can also be supplied by running EDG.
It supplies 440v (steering gear)
220v (Lightings)
24v (Radio equipment)
ESB supplies to the critical equipment e.g., , emergency fire p/p, Navigational equipment.

Electrical
Q What minimum current can be regarded as Fatal?

A shock current as low as 15mA ac or dc can be fatal.

Q .What is the Function of a Fuse?

The function of a Fuse is to give Short-circuit Protection and also Overload Protection and
operates in milliseconds

Q .What would you consider a minimum IR reading?

IR must be kept above at least 1MΩ, the higher the IR the better .Companies have their own
regulations, but most companies only allow readings above 5MΩ.

Q .Give reasons why protection equipment is essential in an electrical distribution system..

 To disconnect and isolate faulty equipment in order to maintain the power supply to the
remaining healthy circuits in the system.

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 To prevent damage to equipment from the thermal and magnetic forces that occur
during short circuit and overload faults.
 To protect personnel from electric shock.

Q .What is the Normal Reading on and Insulation Test Meter?

Infinity is a normal reading, but readings should be kept above 5 MΩ.

What is meant by the Term, Type Ex'i'?

Ex'i' =Intrinsically Safe.

Equipment with circuits that do not generate enough heat to ignite a gas .This generally means
limiting circuits to less than 30V, 50mA. E.g .torch lights

What is meant by the Term, Type Ex'd'?

Ex'd' =Flame Proof Enclosure .
This is an enclosure that will withstand an Internal Explosion of Flammable Gas within itself and
dissipate heat from that explosion before reaching outside atmosphere, which could ignite the
gas in surrounding atmosphere, i.e .a Ship's Battery Locker could be classed as Ex'd'.

What is meant by the Term, Type Ex'e'?

Ex'e' =Increased Safety Equipment.

This type of protection is applied to electrical apparatus that doesn’t produce arcs or sparks in
normal operation e.g .squirrel cage induction motor.
Increased Safety Equipment is based primarily on the elimination of “open or outside sparking",
i.e .equipment that does not have contacts

What is meant by the Term, Type Ex'p'?

Ex'p' =Pressurisation.
Pressurized equipment consists of separately ventilated enclosures & so the equipment cannot
energized till the enclosure has been purged e.g .some deck lights on tankers.
This is where Equipment is Pressurised to prevent any gases entering the equipment.
The Circuit Breaker is an Isolating Switch that also acts as a Fuse .It has two designed ratings;
one of normal safe working current, and the other against overload, which may also have a
time delay.

Q .What type of Clutch is used on an Electric Windlass?

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The type of Clutch used is a Dog Clutch.

Q .What control the speed of a generator?

Governor

Q .Prepare start and synchronize generator?

Prepare> Run auxiliary LO pump> Engage & start Turning Gear> Gland Steam Exhaust, Inlet &
Outlet Valves are to open

 Liaise with E.C.R.

 Open Drain Valves fitted on Main Stop Valve pipeline until dry steam comes out
 Open casing drain valves .Keep draining until steam dry .Then leave it in crack open position
 Open slowly the Turbine Main Exhaust Bypass Valve to raise vacuum slowly inside Turbine
Casing .Monitor Main Condenser vacuum locally or from D.C.S (920 mmHg.)
 Once Turbine Main Exhaust Bypass Valve is fully open and Main Condenser vacuum is
steady, slowly open Turbine Main Exhaust Valve to Main Condenser, whilst monitoring the
Main Condenser vacuum at the same time .Then shut Turbine Main Exhaust Bypass Valve
 Stop and disengage Turning Gear .
 Open slightly the Main Steam Supply Valve just to create 60 bar inside casing.
 Full open the Main Steam Supply Valve
 Press ‘RESET’ button on Local Control Panel that will reset Trip Valve
 after few seconds shut casing drain valves.
 Open slightly the Quick Closing Valve to allow the Turbine to start rotating and increase the
speed to 500 R.P.M ..Maintain Turbine rotating at this speed for ½ an hour for warning up .
Observe for any abnormalities and monitor common parameters are in normal operating
condition.
 After warming up time elapse, increase Turbine speed to rated speed of 1800 R.P.M .within
10 minutes .During speed increase, pass through ‘Turbine Critical R.P.M.’ (approx .1130
R.P.M ).as quickly as possible, when passes from 900 to 1000 rpm, make sure Auxiliary
pump stops.
 Confirm that Turbine Governor takes over speed control
 Couple Incoming T/Alt .to Main Swbd .either from D.C.S .or Main Swbd .Panel locally

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Q .Synchronizing TA…

DCS OK

MSB; 2 types;

Make sure Voltage, frequency & phase are same, If incoming TA is no.1 then go to MSB no.1
Change control switch from DCS to MSB1

Now 2 options are there;

1) Power control auto
a. Select power control auto & check the light
b. Put select switch to TG1
c. Adjust the governor then press Auto synchronizing push button & synchronizing
will take place automatically (breaker will close automatically.)

2) Manual synchronizing;
1) Select power control manual & check the light
2) Put select switch to TG1
3) Adjust the governor & keep monitoring the synchroscope
4) Once steady rotation (clockwise & slow), close the breaker@ 11 O’clock

What are the protection devices fitted

Over speed 2000 rpm
High exhaust pressure -670
Low LO pressure 0.5b
Rotor axial movement 0.7 mm
Rotor vibration 140 micro meter

Daily checks on TA;

Supply steam pressure
Exhaust steam pressure
LO pressure & temperature
Cooling water temperature
Bearing temperature
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L.O .filter differential pressure

Q .How does Generator Lub Oil cope with Blow By?

Generator Lub Oil copes with Blow By, by having a TBN of 20-30 (Total Base Number which is an
indication of the quantity of Alkali, i.e .base, which is available to neutralize acids from blow
by .)

Q .What Trips are there on a Generator?

Lub Oil Low Pressure Shut Down,
Jacket Water High Temperature
Overspeed Shut Down .
Excessive Vibration
…

How do you Start Up, and Parallel a Generator? DG

 First check Engine Oil Levels, such as Lub Oil Sump, T/C Oil Level, Governor Oil Level,
Rocker Arm Bank Oil Level (if fitted .)
 Check Jacket Water Header Tank Level
 Ensure Indicator Cocks are Open, Start Lub Oil Priming Pump then (ensure Turning Bar is
removed .)
 Kick Engine on Air .Close Indicator Cocks .
 Start the Engine .
 Check all Parameters are correct :Lub Oil Pressure/Temperature, Jacket Water
temperature/Pressure, Check Sea Water Cooling Pressure and Rocker Arm Lub Oil
Pressure .
 Allow Engine to warm up and when satisfied that everything is okay.
paralleled as follows :
 Ensure the Voltage of the Machine to be paralleled is the same as the Bus-bar Voltage .
Ensure the Frequencies of both Machines are the same (the Frequency of the Incoming
Machine can be adjusted using the Speed Control .)
 Select the Machine to be paralleled on the Synchroscope Selector .
 The Synchroscope should then start to rotate, it should be rotating in a clockwise
direction slowly .If it is rotating in an anti-clockwise direction, this means the speed of
the Incoming Machine is too slow or if it is rotating Fast Clockwise, the speed of the
Incoming Machine is too fast, this is adjusted using the Speed Control .
 When the Needle of the Synchroscope is Rotating in the clockwise direction slowly, the
breaker of the incoming machine should be closed .When the needle of the
synchroscope is at the 5 to 12 position, this will allow the incoming machine to take a
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slight amount of load when coming on the switchboard and also prevent the machine
tripping on reverse power .
 The load is then shared equally between both machines.

Q .Explain ship earthing system.

Unlike the shore earth system onboard what is in use is an insulted neutral system that
provides the priority of the continuous running of the essential machinery such as steering gear
motors
If a single earth fault happens, machinery will continue to run, but if another 1 safety devices
like fuses will blow up & machinery will be isolated.

Q .Explain the procedure how would you isolate the running electrical motor?
Stop the motor, close the breaker, take out the fuse & put the warning notice, open the
terminal, check for residual voltage, marking of phases, disconnect.

Working on switch board.

 Do inform duty engineer before shutting down any equipment for maintenance
 Approved rubber mating placed in front of switchboard
 Rubber gloves –
 Portable hand lamps – fully insulated
 Isolate and lock off the apparatus, remove fuses if any
 Verify the dead apparatus by live line tester
 Conduct test between phases & between phase and earth( megger tester)
 Post proper warning notice /sign on the apparatus
 Lashed area if required
 Don’t touch live conductors under any pretext
 Don’t touch rotating parts
 Don’t leave wires or rotating parts exposed
 Don’t overload equipment or wiring
 Don’t neglect or abuse the equipment

Short Circuit;
When 2 cables By-passing the load, so too much current is passing through the cable that
the cable can’t withstand, that’s why fuses are fitted to blow up & stop the current flow in
order to protect the cable & machinery .

Earth fault
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When insulation fails, the conductor touches the body, current flows

Can we megger the electronic components? Why?

No, because high voltage is injected that may damage the component

How to measure the voltage .

What’s your action when blackout .

Batteries
What are the two main types of battery commonly used on board ships?
Lead Acid and Alkaline.

What are the advantages and disadvantages of alkaline batteries?

Advantages - they can retain charge on open circuit and even if discharged, it can be left for
long periods without adverse effect .
Disadvantages – require greater number of cells to produce a particular voltage, more
expensive than lead acid batteries .

What are batteries used for onboard ships?

They are used for supplying essential power to :Radio Equipment, Telephone Exchange, Fire
Detection, General Alarm Circuits, ACC & BMS etc( Uninterruptable power supply UPS :giving
continuous supply to DCS, BMS, ACC regardless of blackout .)These Systems are often supplied
from two sets of batteries worked on a regular charge/discharge cycle .
They are also used as Emergency Supplies, i.e .for Emergency Generator Start-up and
Emergency Lighting .Being used in this case in a "stand-by "role to give power when Main
Supplies fail.

Q .How do you ensure that batteries are always in good working order?

Where Lead Acid Batteries are used, they require a constant trickle charge, but for both types
of Battery a regular charge up is necessary.

Check state of Battery using a Hydrometer; Lead Acid -SG 1270~1285 Alkaline is 1190
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but SG for Alkaline Batteries does not change much during charge or discharge.

Ensure cells are fully immersed in electrolyte, if not, top up with distilled water.

Keep batteries dry and clean.

Terminals should be smeared with Petroleum Jelly.

When working on batteries, what precautions should be taken?

Ensure the space is well ventilated, do not smoke or use naked lights and also wear protective
clothing such as apron, gloves and face shield.

What Gas is given off by Batteries while Charging?

Hydrogen.

What are the Disadvantages and Advantages of a Lead Acid Battery?

The Advantages of a Lead Acid Battery are; they require fewer cells to achieve particular
voltage and are reasonably priced.

The Disadvantages are that they require regular attention to keep fully charged, always require
a trickle charge and they discharge on open circuit.

Q .What was rating of batteries used on ur ship?

Ans .Output :22-35 volt D.C, 150 Amp.D.C .

How to add 12V batteries into 24V consumers? What connection takes place? How? Sketch.

Connect 2 batteries of 12V in series

Q .A ship's battery locker is fitted with a flameproof luminaire marked Exd IIc T4 .Is this
luminaire certified for use in the battery room?
ANSWER
Yes -The hazard is hydrogen gas from the batteries which requires apparatus designed for
use in apparatus gas group IIc .The ignition temperature of hydrogen is 560"C and the
temperature classification of the luminaire is T4 .This means that it's surface temperature will
not exceed 135'C, so the temperature classification is OK.

What is the maintenance required on lead acid battery?

Battery maintenance includes keeping the cell tops clean & dry, checking the tightness of
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terminal nuts and applying a smear of petroleum jelly to such connections to prevent
corrosion .Be most careful when handling the battery electrolyte (e.g .when using a
hydrometer
to check its specific gravity .)Use protective rubber gloves and eye goggles when
handling electrolyte .Insulated spanners should be available for use on cell connections to
prevent accidental short-circuiting of battery terminals .Such a short-circuit across the
terminals of just one cell of a battery will cause a blinding flash with the probability of the cell
being seriously damaged

TITLE :INTERNAL BATTERY EXPLOSION

Incident
1 .The E/Eng was performing the weekly routine testing of lifeboat engine .Prior to starting the
lifeboat engine the E/Eng had checked the battery voltage, hydrometer indicator and terminal
connections .All were reported to be in a satisfactory condition.
2 .When the E/Eng started the lifeboat engine, the battery exploded.
3 .Battery Details:
(a )Type :12V Lead Acid Heavy Duty Maintenance Free Battery
(b )Maker :ACDelco
4 .Both the batteries had been put into service in Jan-2007 .Battery No .1
was replaced in Nov-07, while Battery No .2 exploded in Feb-08.
Consequences
1 .The battery casing was damaged beyond repair and had to be replaced .2 .No personnel
injury was reported as the explosion was contained/restricted to the battery box.
Lessons to Remember
1 .The most probable cause of internal explosions can be attributed to
the following:
(a )The plates may not be covered with electrolyte.
(i )Depletion of electrolyte can be caused by battery overcharging (non-automatic-manual
battery charger .)If the battery is left connected to the charger for an extended period of time,
it results in loss of water and creation of hydrogen gas.
(b )Presence of trapped hydrogen gas within the battery .
(i )Vent holes on the battery may be blocked due to the ingress
of dirt and dust, which allows hydrogen gas to become trapped in the top of the battery.
2 .During starting, when current flows in the battery (with low electrolyte levels )a spark occurs
between the plates and ignites the hydrogen in one or more of the cells, which causes the
battery to explode.
Recommendations
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1 .To minimize the risk of battery explosions, the E/Eng or Officer/Engineer directly incharge
battery maintenance
should ensure the following:
(a )The battery is not being overcharged, to prevent the build up of hydrogen gas .Verify if the
battery is being charged as per maker’s recommendations.
(b )Check the electrolyte level if it has fluid fill caps .If there are no fill caps, refer to the maker’s
instructions on how to check the battery electrolyte levels.
(c )Verify that the battery plates are covered with electrolyte at all times.
(d )Verify that the battery vent holes, if any, are not blocked.
(e )Ensure that the lifeboat and battery box have been properly ventilated to release any
explosive gases that may be present.

How much is the car battery voltage?

24V

Laws
Marpol Annexes;

Regulation for the prevention of pollution by OIL

Regulation for the control of pollution by noxious liquid substances in bulk

Regulation for the prevention of pollution by Harmful Substances carried by sea in packaged
form

Regulation for the prevention of pollution by Sewage from ships

Regulation for the prevention of pollution by Garbage from ships

Regulation for the prevention of AIR pollution from ships

What are special areas? Why is it so important?

Definition of the term “Special Area”?

 Special area means a sea area where for recognized technical reasons in relation to its
oceanographical and ecological condition and to the particular character of its traffic the
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adoption of special mandatory methods for the prevention of sea pollution by oil is
required.
 The special areas are :

1) the Mediterranean Sea area

2) the Baltic Sea area
3) the Black Sea area
4) the Red Sea area
5) the Gulfs area
6) the Gulf of Aden area
7) the Antarctic area
8) the North West European waters
9) the Oman area of the Arabian Sea
10) the Southern South African waters

Q .List down the activities onboard ship which involving the MARPOL requirement.

Following are the activities which require the involvement of MARPOL;

 Discharge of Bilges
 Discharge of sewage
 Disposal of Garbage
 Disposal of noxious liquid (e.g….
 Disposal of harmful substances (e.g .Plastics)

Q .State the ISM code,

The International Management Code for the Safe Operation of Ships and for Pollution
Prevention (International Safety Management( ISM )Code )was adopted by the Organization
by resolution & entry into force on 1 July 1998 of SOLAS chapter IX on Management for the Safe
Operation of Ships .The ISM Code provides an international standard for the safe management
and operation of ships and for pollution prevention.

ISM Code:
 The purpose of this Code is to provide an international standard for the safe management
and operation of ships and for pollution prevention.

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Objectives:
 The objectives of the Code are to ensure safety at sea, prevention of human injury or loss
of life, and avoidance of damage to the environment, in particular, to the marine
environment, and to property .

Safety management objectives of the Company should :

 Provide for safe practices in ship operation and a safe working environment;
 Establish safeguards against all identified risks; and
 Continuously improve safety management skills of personnel ashore and aboard ships,
including preparing for emergencies related both to safety and environmental protection .

The safety and management system should ensure :

 Compliance with mandatory rules and regulations; and

 That applicable codes, guidelines and standards recommended by the Organization,
Administrations, classification societies and maritime industry organizations are taken
into account .

Functional requirements for a Safety Management System (SMS :)

Every company should develop, implement and maintain a Safety Management System
(SMS )which includes the following functional requirements :

 A safety and environmental protection policy

 Instructions and procedures to ensure safe operation of ships and protection of the
environment in compliance with relevant international and flag State legislation;
 Defined levels of authority and lines of communication between, and amongst, shore and
shipboard personnel;
 Procedures for reporting accidents and non-conformities with the provisions of this
Code;
 Procedures to prepare for and respond to emergency situations; and
 Procedures for internal audits and management reviews .

State Ism code ( SMS)

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1 .GENERAL

2 .SAFETY AND ENVIROMENTTAL PROTECTION POLICY

3 .COMPANY RESPONSIBILITIES AND AUTHORITY

4 .DESIGNATED PERSON(S)

5 .MASTER’S RESPONSIBILITY AND AUTHORITY

6 .RESOURCES AND PERSONEL

7 .DEVELOPMENT OF PLANS FOR SHIPBOARD OPERATIONS

8 .EMERGENCY PREPARENESS

9 .REPORT AND ANALYSIS OF NON-CONFORMITIES, ACCIDENTS AND HAZARDOUS

OCCURANCES.

10 .MAINTENANCE OF THE SHIP AND EQUIPMENT

11 .DOCUMENTATION

12 .COMPANY VERIFICATON

13 .CERTIFICATION AND VERIFICATION

Q .How the ISM is implemented onboard?

By carrying out drills of safety such as abandon ship, firefighting, sopep, first aid & keeping a
record

Refer to the answers of the first question on ISM (Details are given.)

Q .what is SMS?

Safety Management System (SMS)

Functional requirements for a Safety Management System (SMS :)

Every company should develop, implement and maintain a Safety Management System
(SMS )which includes the following functional requirements :

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 A safety and environmental protection policy

 Instructions and procedures to ensure safe operation of ships and protection of the
environment in compliance with relevant international and flag State legislation;
 Defined levels of authority and lines of communication between, and amongst, shore and
shipboard personnel;
 Procedures for reporting accidents and non-conformities with the provisions of this
Code;
 Procedures to prepare for and respond to emergency situations; and
 Procedures for internal audits and management reviews .

SOLAS (12 chapters)

International Convention for the Safety of Life at Sea .It deals with the maritime safety .1st
version was adopted in 1914 following the Sinking of Titanic, the version which currently in
force was adopted in 1974

Q .Where On Board a Ship would you find Information on the Carriage of Hazardous
Substances?

Information on the Carriage of Hazardous Substances would be found in the IMDG

(International Maritime Dangerous Goods Code), which would normally be found on the
Bridge.

SOLAS Chapters

Chapter I -General provisions

Chapter II-1 -Construction -Structure, subdivision and stability, machinery and electrical
installations
Chapter II-2 -Construction -Fire protection, fire detection and fire extinction

Chapter III -Life-saving appliances and arrangements

Chapter IV – Radiocommunications

Chapter V -Safety of navigation

Chapter VI -Carriage of cargoes

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Chapter VII -Carriage of dangerous goods

Chapter VIII -Nuclear ships

Chapter IX -Management for the safe operation of ships
Chapter X -Safety measures for high-speed craft
Chapter XI-1 -Special measures to enhance maritime safety
Chapter XI-2 -Special measures to enhance maritime security
Chapter XII -Additional safety measures for bulk carriers

Q .What is DPA, its function and authority?

“Designated Person(s )or person ashore”

To ensure the safe operation of each ship and to provide a link between the company and
those on board, every company, as appropriate, should designate a person or persons ashore
having direct access to the highest level of management .The responsibility and authority of
the designated person or persons should include monitoring the safety and pollution
prevention aspects of the operation of each ship and to ensure that adequate resources and
shore based support are applied, as required.

Q .What do you understand by ISPS? Where to find its reference?

This part of (the International Code for the Security of Ships and Port Facilities )contains
mandatory provisions to which reference is made in chapter XI-2 of the International
Convention for the Safety of Life at Sea, 1974 as amended.
Q .What ships are covered by this code based on tonnage, length, type?
This Code applies to following types of ships engaged on international voyages :
.1 .passenger ships, including high-speed passenger craft;
.2 .cargo ships, including high-speed craft, of 500 gross tonnage and upwards; and
.3 .mobile offshore drilling units; and
.2 .port facilities serving such ships engaged on international voyages.
Note :This Code does not apply to warships, naval auxiliaries or other ships owned or operated
by a Contracting Government and used only on Government non-commercial service.

Q .What’s the objective of “ISPS” code?

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Ans .It’s function is to establish a co-operation between “Government, Shipping & port
authorities” to detect the security threats & take preventive measures & also “To ensure the
early & efficient collection &exchange of security related information”.

Q .How many security levels are there & describe them?

Security level 1:

1) Ensuring the performance of all ship security duties;

2 )Controlling access & embarkation to the ship;
3 )Monitoring restricted areas to ensure that only authorized persons have access
4 )Monitoring of deck areas and areas surrounding the ship
5 )Supervising the handling of cargo and ship’s stores
6 )Ensuring that security communication is readily available.
Security level 2:

The additional protective measures, specified in the ship security plan, shall be implemented
for each activity detailed in section 7.2, taking into account the guidance given in part B of this
Code.
Security level 3:

Further specific protective measures, specified in the ship security plan

Q .What is objective of these laws?

Safety at sea,

Prevention of human injury or loss of life,

Avoidance of damage to the environment, in particular, to the marine environment, and to

property

What is the Importance of "M "Notices?

"M "Notices are important as they convey very useful information such as :
1 )Merchant Shipping Notices (MSNs :)which will only be used to convey mandatory
information, which must be complied with under British Legislation .
2 )Merchant Guidance Notes (MG6Ns :)which will provide advice and guidance to relevant
parties in order to improve the Safety of Shipping and of Life at Sea .
3 )Marine Information Notes (MINs :)which will provide information to a more limited
audience such as Training Establishments or Equipment Manufacturers?

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F.O:
Flash point;
This is the minimum temperature @ which oil gives flammable vapors
DO, 95 C
HFO, 100 C
LO, 230C

Oil for propulsion onboard should have a minimum closed flash point of 66C & in storage tank
should not be above 52C

Oils with FP < 22C are dangerous (highly flammable )e.g .Gasoline, Benzene etc
Oil with Fp > 66C are safe for marine purposes e.g .Gas, DO & FO

Calorific Value;
The amount of energy released by complete combustion of 1kg of fuel
Coal 34 MJ/kg
FO 42, DO 45, Pure Hydrocarbon 50MJ/kg

Dew point;
When air temperature falls below saturation temperature, due to which condensation of vapor
occurs.

Pour point;
The lowest temperature @ which oil can flow.

Why are High and Low Suctions fitted on Fuel Oil Service Tanks?

They are Safety Features to prevent inverting Shut down of Boilers due to Water Contamination
of the Fuel .Normally the High Suction is kept in use .If any Water should find its way into the
Fuel and Service Tank, it will gradually separate towards the Tank Bottom .When it becomes
apparent Water is present by finding it at the Tank Drains.

Give an example of the density of Heavy Oil, Lub Oil and Diesel Oil .
Heavy Fuel Oil :950kg/m3
Lub Oil :870kg/m3
Diesel Oil :880kg/m3

Why are Weighted Cocks fitted to Sounding Pipes of Fuel Oil Tanks?
Prevent Fuel Oil spills from overflows & vapors escaping from Tanks .
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What are the Impurities in Heavy Fuel Oil?

Solids :dirt, rust and sand

Liquids :water and sludge .

What are the Pipes, used for Pumping Fuel around the Ship, Protected by?
Quick Closing Valves :which can be operated remotely? In most cases from the Bridge or a
remote location from the Engine Room (EHQ)

What is the Purpose of the Fuel Oil Settling Tank?

To allow any water to separate from the Fuel Oil due to its higher density .Heating Coils in the
Tank aid this and the water is then drained from the tank using Sludge Cocks/Drains .

At what Temperature does the Department of Trade and Industry state that Fuels must be
kept in Storage Tanks?
@ least 14°C under their Flash Point.

What Limit does the Department of Trade and Industry state that the lower limit of Flash
Point of Fuels used on board Ship should be?

65°C

Why are Quick Closing Valves fitted in a Fuel System and how can they fail to operate?

So that in the event of a Fire in the vicinity of these Systems or

Fracture or Break in these Lines, the System can be shut down rapidly and remotely.

They may fail to operate if not maintained or tested regularly.

Q .Describe the effects of water contamination, what are the likely sources, how would you
rectify the problem?

A .Effects:

Water reduces the heat of combustion of fuel .This means fuel containing water will burn less
efficiently.

Presence of water also reduces the calorific value of fuel.

Water causes corrosion of vital fuel system components :fuel pumps, injector pumps, fuel lines,
etc.

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Water accelerates the growth of microbe colonies, which can plug up a fuel system .Biodiesel
users who have heated fuel tanks therefore face a year-round microbe problem .

Additionally, water can cause pitting in the pistons on a diesel engine .

Sources:

Leaky heat exchangers or coolers .

Steam leaks in to the Oil if heating coils are damaged.

Poorly operated centrifuges.

Rectification:

Drain water from F.O .tanks daily.

Oil should be purified.

Q .What problems would be cause by over/under heating of the fuel (Heavy or marine fuel oil
only)?

A .Overheating:

If overheated specially if above its “Flash point” starts to release flammable vapors which when
exposed to source of ignition can cause explosion.

Under heating :

Due to under heating high viscosity which causes poor atomization becoz of which poor
combustion.

Q .Describe the procedure for changing over form Heavy to Diesel and vice versa

In terms of DG We need to change over normally after starting & before stopping

 Main target is to avoid mixing of HFO in DO lines & tanks

 DO in HFO lines & tanks No problem

 While changing over keep an eye on the fuel line pressure as it may vary & lead to ME
trip due to too low FO pressure

HFO to DO;

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Initial Condition
• HFO In & Out are open
• DO In & Out are close
• HFO pp run, DO pp stop
Start Changing;
• Start DO pp & fast open DO In
• Close FO In
• Open DO Out
• Close FO Out
DO to HFO;
Initial Condition
• DO In & Out are Open
• HFO In & Out are Close
• DO pp, HFO pp stop
Start Changing;
• Open HFO Out
• Close DO out
• Start HFO pp & fast open HFO In
• Close DO In
• Stop DO pp

What safety devices, alarms and shut downs are fitted in FO?

Safety devices;

- Quick closing valve which can be operated from outside the machinery space they are
fitted to all tanks (in a motor ship fitted to the main engine inlet as well .)
- Remote cut out for the pumps for use in emergency of HFO transfer pump.
- Remote Cut in of FO Burning pump in case of running pump failure or drop in discharge
pressure.
- Drip trays and save-alls place to prevent the possibility of hot oil spraying onto heated
surfaces.
- Oil contained in tanks with open drains should not normally excess a temperature of
50C or if lower may not exceed a temperature of 20C below the flash point of the fuel.
- Vents and overflow from all tanks led to overflow tanks situated above the bunker
tanks.

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Q .What Safety Equipment should there be at a Bunker Station?

 A Foam Fire Extinguisher,

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 SOPEP Gear such as Spill Absorbent

 Communications between manifold area & OOW.
 Regular rounds to check the pipings & Line Pressure

Bunkering Operation;

Prior;

A bunker meeting should be conducted by the CE & all involved crew are aware of their duties
& bunker plan to be discussed.

Chief Officer to be informed about the quantity & Place of Bunker

Soundings should be taken

Ensure vessel is securely moored

Scuppers are plugged
Communication between both parties
No smoking signs placed
Naked Light regulations are being observed Ex’I’ intrinsically safe
No hot work is taking place in the vicinity
SOPEP gear is available
Correct valves are opened for bunkering
The overflow tank is empty

Check list should be singed from all parties

An effective watch on board the barge /at the terminal

All external doors and ports in the accommodation are closed.

Firefighting equipment should be in place

During :Commence @ minimum pumping rate

Ullages to be taken during operation

Samples of Fuel Bunkered to be taken throughout Bunkering for Analysis.

Pressure should be always monitored & pipe line to be checked.

AFTER;

Confirm with port that pumping stop,

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Purging of lines to be done

Secure lines, Record timing & quantity in ORB

Samples of Fuel Bunkered to be exchanged with port facilities

Restore deck scuppers & check sounding caps are in place.

Q .Correct procedure to transfer from double bottom tank to settling tank.

C/E informed, tanks & quantity identified & sounded

Inform deck officer for the stability measures

Sufficient temperatue & empty savalls

Oil spill equipment to be ready & overflow tank to empty

Communication tested

Set the line & respective valves

Start the pump & check the pressure or any leakages

Keep monitoring oil level in tanks

Record to be made in ORB

How /procedure to clean FO/LO tank.

 Shut the filling valve

 Drain all the tank
 Open manhole & ventilate well & then check with O2 & Hydrogen sulphide content
meter
 Remove all the remaining sludge into empty drums
 Clean either mechanically with rags or chemically with chemicals

In the occurrence of an Oil Spill, what do you do?

raise the alarm Stop the flow of oil .If possible contain the spill on Deck and start clean up
procedure using appropriate oil spill equipment and .There will be a set Drill for Oil Spill
Procedure .
If the oil has spilt into the Sea, if in Port, the Port Authorities must be informed, if at Sea, the
Coastguard must be informed .

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The time, place or position, type of oil and approximate quantity must be recorded in the
Engine Room Log, Bridge Log and Oil Record Book .Circumstances of spill must also be
recorded.

What do you intend to bunker first, FO or DO? Why?

If same line, DO first so line not contaminated

If different lines, any 1

Heat Exchanger:
Q .What is heat exchanger?

Equipment used to transfer heat from one medium to another.

Q .what are the types of heat exchanger?

Shell and Plate type Coolers

Shell being where a Tube Stack is used and Fitted into a Shell and closed at either end with end
covers .

Plate type being made up of a number of pressed plates surrounded by seals and held together
in a Frame .
Heat Exchanger Tubes .

Q .Where & why cupro-nickel is used onboard?

It has good corrosive qualities and very good heat transfer qualities .
What do you understand by the word

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. Pump .
Explain types of pump

What is cavitation.
the formation and subsequent collapse of vapor bubbles in a pump

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What need to be inspected before starting the pump?

Suction & discharge valves
Cocks to pressure gauges
Power panel on
…………

What are the uses of Centrifugal Pumps, Positive Displacement Pumps and Gear Pumps on
board a Ship?

Centrifugal Pumps :Seawater Cooling Pumps, Ballast, Fire & gs, feed

Positive Displacement Pumps :Reciprocating Bilge Pumps, Steering Gear Pumps.

Gear type Pumps :Fuel Oil transfer, Engine Lub Oil Pumps

Give a Shipboard use for Grey Cast Iron and the Properties that make it suitable for this use .
Freshwater Pump Casings .It has fairly good machining qualities and is also inexpensive .

Why is a Gear type Pump used for pumping Oil, while a Centrifugal Pump is used for pumping
Water?
A Gear Pump is used for pumping Oil as it has a high suction lift, is self-priming, able to produce
the discharge pressure required by the System and can handle large amounts of Vapor or
Entrained Gases .It is also able to pump High Viscous Fluids .

A Centrifugal Pump is used for pumping Water, as it is unable to pump High Viscous Fluids such
as Oil, the Centrifugal Pump is not Self-Priming .

What would happen to the amps of a Centrifugal Pump if it were run with the discharge valve
shut?
The amps would drop, as there would be no load on the pump .

What is the correct method of Starting and Stopping a Centrifugal Pump?

The correct way to Start and Stop a Centrifugal Pump is with the Discharge Valve from the
Pump closed, i.e .less load on the Motor when Starting and Stopping .

What does a Positive Displacement Pump require that a Centrifugal Pump does not?
A Relief Valve.

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What is a Shipboard use of Stainless Steel and the Properties that make it appropriate?

Stainless Steel could be used for Seawater Pump Shafts .It has good anti-corrosive properties
and also it’s good to resist wear .

Give a Shipboard use of Aluminium Bronze and the Properties that make it suitable for this
use .

Pump Impeller. It is good to resist wear, fatigue and it has anti-corrosive properties.

Why does a Centrifugal Cargo Pump have a Relief Valve?

A Centrifugal Cargo Pump requires a Relief Valve as the Working Pressure of the Pump has to
tie in with the Working Pressure of the Cargo Pipework .

How the survey on the pump is carried out?

Pump for inspection

 Make sure all safety precaution taken before any work commence

 Prepare all tools

 Isolate the pump from usage/take the pump out of service

 Open breaker and take out its fuse

 Inform all personnel by hanging warning notice on the MSB

 Disconnect the motor and cover the terminal from any contact

 Separate the motor from the pump by disconnect the connecting shaft

 Before dismantling make sure to make marking on all connection and body of the pump

 Dismantle the pump and place all the component accordingly on a clean area

 Now the pump is ready for inspection

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Fresh water Generator :

What is the Regulation regarding use of Evaporators Inshore?

Evaporators should not be used within 20 miles from Shore, due to risk of pollutants being
taken into the Freshwater System.

Fresh Water supplied for Drinking and Culinary purposes must meet Specified Purity
Standards .How is this achieved?

These Standards are met by passing through Silver ion sterilizer (Katadyn), Injecting minerals
by the mineral injection unit & an Ultra Violet Steriliser.

Another Method a Hypochlorinator where the Water is Sterilised by an excess dose of Chlorine
provided as Hypochloride Tablets .It is then de-chlorinated in a Bed of Activated Carbon to

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remove excess Chlorine .Any Colour, Taste and Odour, which was present in the Water, will also
be removed by the Carbon

Reasons for weak vacuum in FWG. Or Why FWG can lose its vacuum.

-No suction at ejector p/p (check pump)

-Ejector unit/line blockage

-Gasket leakage

-Vacuum breaker plug leakage/not tighten properly

Q .How do you start a Fresh Water Generator?

 CC EVAPOTATOR START UP OPERATING PROCEDURE

 1 .Open suction and discharge valve of the ejector pump & Open the overboard valve
after the air/brine ejector outlet.
 Reset the stop button on the ejector pump.
 Open sea water inlet and outlet valves of the brine ejector.
 Open condensate inlet and outlet valves and shut the bypass valve . Ensure that the
vacuum breaker, vent and drain below the evaporator are shut .
 On the main steam line, ensure that the steam trap primary and secondary valve to ADT
are fully open.
 Reset any alarms visible on the control panel, when all alarms are clear start the ejector
pump from the control panel.
 Establish a vacuum to a minimum of 90 %in the separator and steam line.
 Confirm that the pressure at the inlet of the brine ejector at a minimum of 3.5 bar and a
back pressure of 0.6 at the ejector outlet
 Open the drain to remove all the condensate from the steam line.
 Open manual steam valve, ensure that the drain before and after the valve are shut and
there is control air supplied to the heating steam pressure control valve .Open the
condensate spray inlet valve after the pressure control valve.
 Slowly open the pressure control valve by adjusting the pressure controller on the
control panel step wise 0.1 bar up to the specified steam pressure.
 When the production of condensate can be seen, start the condensate pump and
quickly drain all the water until the salinity decreases to 0.5 ppm or maintain below the
alarm limit .
 Open the outlet valve from condensate pump to ADT and shut the drain.
 When the production of fresh water can be seen, open the valve to the water tanks.
Start the distillate pump and drain the water until the salinity drops until 0.5 ppm.
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 Fill the chemical injection tank until full and add 300-400ml of maxi -vap plus, adjust the
flow rate to specified rate.
 Enable the alarms for fresh water and drains salinity and the alarm response on the
control panel.

Q SHUTTING DOWN PROCEDURE FOR CC EVAPORATOR

 Firstly, disable alarm on the control panel, fresh water salinity and drains salinity panel.
 Then reduce the set point for the pressure control valve slowly by adjusting the pressure
controller .Make sure not reducing the pressure fastly for prevents any damage.
 After that, monitor the pressure decrease slowly .If there are no visible sign of
condensate produce, the condensate pump can be stopped .Then shut outlet valve of
the pump to ADT.
 Until there is no more production of fresh water, stop the distilled pump and shut valve
to the water tank.
 Then decrease the steam pressure further more until pressure control valve is fully shut.
 After that, shut the condensate spray valve and then shut inlet condensate valve and
outlet valve & open the bypass
 Shut the secondary drain valve at the steam trap to ADT.
 After all procedure was finished, just leave the Ejector Pump for a minimum 30 minutes
 Stop ejector pump and then shut inlet valve, outlet valve and overboard valve.
 Open the vacuum breaker & switch off starter panel

Q .What chemical used for sea water treatment inside fresh water generator?

Maxi Evap plus

Metallurgy is a domain of materials science that studies the physical and chemical
behavior of metallic elements, their intermetallic compounds, and their mixtures, which are
called alloys .It is also the technology of metals :the way in which science is applied to their
practical use.

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What is dry-docking procedure?

-Every 2 years the ship has to go for dry docking
-Dry docking plan have to be prepare before the ship come in and to be confirm from both side
i.e .shore and ship.

Lightweight; displacement of ship in tonnes without (cargo, Fuels, waters, crew)…

Deadweight; difference of displacement between Loaded & lightweight ship

IGG;
Dew Point; When the moisture in air starts to condense
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Saturation Temp; When the water starts boiling

Inert conditions :This is where a space has oxygen content equal to or less than 8 %

Explain IGG Process?

Combustion takes place in the combustion chamber because of which 85 %N2 & 15 %CO2 are
produced & also combustible gases contain sulphur & unburned carbon

Sulphur oxides are removed by the SW shower in the scrubber tower

Then it goes to the refrigerant unit where it is further cooled

Then IG moves to Dryer where the water droplets are removed by the Desiccant

Finally IG is sent to either tanks 4 inerting or vented to atmosphere 4 testing purposes.

Starting procedures;

IG PLANT OPERATION

1. If the IG plant needs to be run on test, then first remove the blank from the IG line
At deck & open the outlet manual valve
2. Ensure the instrument air supply to the plant is open.
3. Check overboard valve on DCS opened .IG jacket cooling water overboard valve is open
on bottom platform stbd aft .
4. Open up slowly the main steam supply for the dryer /combustion chamber .
5. Open fresh water cooling inlet and outlet valves for the dryer and the condenser .
6. Set the starboard ballast pump by opening the suction valves Open the IGG seawater
inlet manual valve bypass 035VPJ fully to start filling the seawater line to IGG .Select the pump
mode switch to IG mode to
activate the ballast valve interlock system .Open pump discharge valve
100 %and over board valve 024VPJ .
7. Start stbd ballast pump .Seawater pump running indicator light should lit on the starter
then open IGG seawater inlet valve.
8 .Sea water supply to IG generator should be more than 1.5 bar and this can be
achieved by closing valve 013VPJ from DCS to 0 .%Therefore, the pressure obtained
should be around 2.4 bar .The water pump running indicating light lit on the local
panel 2 .
9 . Put the steam on the heaters and atomising steam to burner online and ready to use
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after thoroughly draining the lines .Ensure all the supply valves and steam trap valves
are opened
10 .Line up gas oil line
11 .Run the dryer fan will run first and the dryer sequence and timer will be ON.
12 .Set up Refrigeration plant
13 .After about 3 minutes the first blower will run one after the other and later the gas oil
pump .After sometimes then the burner will start sequence and light up .
14 .Allow about half an hour for plant to settle down .Check the Oxygen content and dew
point value .Adjust the Oxygen to maintain between 0.5 %to 1.0 %by opening or
closing more the air purge valve 2052 .This measure only to be taken when the
desired oxygen content cannot be achieved.
15 .2 hours after the generator stopped, rinse the combustion jacket for about 1 hour via
valve 2313 on the jacket with about 3m3 of fresh water .The jacket will drains
automatically via the water seal in about 2 hours then shut the rinsing valve .
16. Rinse the scrubber section for 1 hour with about 3 m3 fresh water used via valve
2310 located on the scrubber tower .Close the rinsing valve.

17. Rinse the inert gas cooler for about 40 minutes and around 2m 3 of fresh water used
via valve 4401 on the inert gas supply line and drain via the drain valves 4108 and
4119 .Check drain valve 4113 beneath the demister vessel .Close the rinsing and
drain valves.

Cooling on IG takes place;

1) Combustion chamber by jacket sea water cooling
2) In the scrubber tower
3) Refrigeration plant to abt 5 C

What are the various cut-outs and alarms in a Funnel Inert Gas System?

 Cooling sea water temp .high

 Cooling water pressure low
 Combustion air pressure low
 Control air pressure low
 Fuel oil pressure low
 Flame eye failure

Q .What is IG?

IG (Inert gas )is an odorless( fragrance-free) & colorless containing very low amount of oxygen
thus dangerous for life.

Use of IGG in LNG?

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To inert the tk before aerating ,We can’t aerate the tk directly bcz of flammable vapors inside
that can lead to explosion

Therefore by inerting removing of these vapor is done then only tk is aerated (by switching
from IG mode to O2 mode )for the purpose of entering the tank.

Q .What is the safety of IGG system?

Emergency stop push buttons are provided @ local control panel, cooler control panel, dryer
control panel

What is the purpose of the Deck Seal on an Inert Gas System?

The purpose of the Deck Seal is to act as a non-return valve and prevent the back flow of gases,
i.e .hazardous to non-hazardous.

What is the gas analysis after the Scrubber Tower on an Inert Gas System.

Oxygen :0-1( %Alarm at 5)%

Carbon-monoxide :0

Carbon Dioxide :14-15%

Nitrogen :85%

What are the various cut-outs and alarms in a Funnel Inert Gas System?

High oxygen level (above 5)%

Loss of sea-water pressure/flow

Fan/blower failure

High gas temperature alarm.

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LO System
Function LO –

Lubrication, cooling and control hydraulic oil

What would be your first indication that there was water in the Sump?
Your first indication would be from your Lub Oil Purifier .
Or even possibly from water in Lub Oil Tests, if done regularly.

Explain a Main Engine Lub Oil System

We have a ME sump tank & gear driven main LO pump & 2 auxuliary pumps, 2 LO coolers, 2
strainers.

How would you check that there was excess water in the Sump?
By using Water Finding Paste on the sounding rod or tape or by the results from maritec

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How is Lub Oil Temperature Controlled?

By means of a Thermostatically Controlled Valve, which will allow Lub Oil to by-pass the Cooler
when too cold and divert Lub Oil through the Cooler when too Hot .

What would happen if the Lub Oil Pressure just dropped to Zero?
The Engine would Shut Down on the Low Lub Oil Pressure Trip .

What are the Alarms and Trips on a Lub Oil System for the Main Engine?

High Lub Oil Temperature Alarm

Low Lub Oil Pressure Alarm
High Lub Oil Filter Differential Alarm
Low Lub Oil Sump Level Alarm
Low Lub Oil Pressure Shut Down Alarm
Stand By Lub Oil Pump Cut In Alarm .

What would you do if Lub Oil Temperature started to fall?

Reduce Sea Water Cooling Flow through the Lub Oil Cooler by throttling the Sea Water
Discharge Valve from the Cooler.

What would cause the Level of the Lub Oil Sump or Drain Tank to Rise?

Water entering the oil, or fuel or even a Lub Oil Filling Valve passing.

What is the cause of water in the m/e sump tank?

Due to interface, distortion of `A` frame and bilges flooding the engine room space.

LO service system?

Sump tank > main L.O .pump > strainer> L.O .cooler > Auto backwash filter > 1 )Back to main
engine 2 )To camshaft booster pump > camshaft.

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Steering Gear;
Q .Describe the steering gear fitted to your last vessel -for electro hydraulic plant he may be
interested in the power supply

4cylinder, 4ram Electro hydraulic

2 supply pumps electrically driven

2 Servo controlled variable stroke pumps (Mitsubishi Janney pump)

Maximum Working Pressure 216 b

Design Pressure( Safety valve setting )270 b

Auxiliary 14b

Q .Describe the daily checks you make on the steering gear

Visual inspection around the steering gear .Check for any leaks, sufficient hydraulic oil in port
and stbd tanks, grease is sufficient in the grease pump, motor and pump running satisfactory.

Check the temperature of the oil tank, check if any unusual vibration or noise.

Describe the steering gear tests before leaving port

Upon receiving one hour notice by the bridge, the telegraph is tested and the steering gear is
tested immediately after it’s complete.

1) Establish communication’s between bridge and steering gear room.

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2) Test 3 types of phones.

 I.S sound powered telephone 15 stations, self-handle generator
 2 )VHF RADIO TELEPHONE
 3 )AUTO EXCHANGE TELEPHONE
3) Visual inspection around the steering gear .Check for any leaks, sufficient hydraulic oil
in port and stbd tanks, grease is sufficient in the grease pump, motor and pump running
satisfactory.
4) OOW will commence the test by running a single motor and then both motor from hard
port to 30 stbd & vice-versa .The engineer officer below will take the timing (should be
within 28 secs )put down in the steering gear log.
5) When the bridge complete testing the rudder,
6) Trips and alarms are tested in the steering gear room .Low level float for port and stbd
tanks.
7) On the running steering gear motor, shut the valve at the level transmitter and drain the
oil till you get low low level alarm, this will allow the “Automatic Isolation sytem” to
operate.
8) Shut the drain and open the valve from the tank to the level transmitter and reset alarm
from DCS.
9) Upon completion, visual checks should be made and make sure all valves are open and
everything is in order.
10) Check & compare the Gyro readings provided & the steering compartment with the one
at the bridge
11) Inform bridge that steering gear test is complete.
12) Enter the timing taken in the steering gear log .

Q .How is the Signal from the Bridge when the Helm is Moved Transmitted to the Hydraulic
Rams in Steering Flat? OR
Q .Operation of the steering gear.

Small electrical signal is given from bridge through the helm (1 to 5 V OR 4 to 20 mA )to the
TELEMOTOR TRANSMETER (Amplifier )located at the bridge

The amplifier enlarges the signal in order to be easily transmitted to the TELEMOTOR RECIEVER
(Pilot valve OR Servo Controller )located at the steering room which controls the stroke
(suction & discharge) of the JANNEY Pump (main pump)

The JANNEY pump will send the oil through the TRANSFER valve & the Transfer valve will direct
the oil the respective cylinder

Transfer valve is a hydraulic operated spring loaded return, that either open or close (will be
held in open position if there is a pressure, If no pressure the spring loaded will shut the flow )
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(that’s why when the pump is off, there is no oil going in or out from the cylinders means
rudder doesn’t move)

Due to the hydraulic pressure inside the cylinder, piston is pushed moving the ram which is
connected to the tiller

The tiller connected to the rudder stoke which moves the rudder.

Q .Describe the emergency steering procedure on you last vessel

 If there is oil leak to the hydraulic pipelines with No.2 pump in service and No.1 pump
on standby ( as seen in figure 2), the oil level in No.2 oil tanks will fall.
 This will activate the low level switch and alarm sounded.
 As the low level switch activated, No.1 pump will cut in for the parallel operation with
the No.2 pump to top up the oil lost in the system.
 If the No.2 oil tanks keep dropping, it will activate the Low Low level switch and cause
the motor for No.2 pump trip.
 At the same time solenoid valve for No.1 compartment will energize and causing the
isolation valve switch from "A "position to "B" position in order to isolate the hydraulic
oil to the tripped lines.
 With No.1 pump running, the oil will supply to the No.1 and No.2 cylinder.

 Same case as above, where No.1 pump trip and No.2 pump take over.
 The No.2 solenoid valve will energise and the isolation valve will switch from "C "to "D "
position.
 The No.2 running pump will operate the No.3 and No.4 cylinder .

How the pump works when no leak is detected

(on , off)

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Describe the effects of air in the steering gear (if you have hydraulic telemotors system -the
effects of air in this)

AIR LOCKED IN THE HYDRAULIC SYSTEM

Air locked in the hydraulic system will reduce the efficiency of the steering gear .Air in the
hydraulic system must be avoided because the air being compressed and give incorrect balance
between units, time lags, and irregular operation .The rudder response to wheel movement will
be sluggish or slow .So, the air venting has to be undertaken .If, after long service air venting
does not remove sluggishness, it may be necessary to recharge the system with new fluid .
Procedures to remove the air locked are as follow:

Procedures for purging air from the hydraulic system

1) Observe the level of oil in the oil expansion tank and it has to be in normal level .Top up
as necessary.
2) Open vent screws when pump running
3) Close the vent screws when the oil escapes .It indicates the absence of air in the system.
4) Move the rudder to check either air locked still remain in the system.

How steering gear pump works?

Steering gear pump equipped with solid cam (hunting gear )that regulates the oil discharge
which is controlled by the servo controller (pilot valve )

Q .How often is the Emergency Steering Tested?

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At least once every 3 months .

Q .Explain Regulations regarding Power Supplies for Steering Gears .

The Electrical Power Supply must be from two widely separate supplies i.e .one from the Main
Switchboard and the other from the Emergency Board .
Electrical leads and fuses are to allow 100 %overload, giving only short circuit protection .
If failure does occur on one system, the stand-by system will cut in within 45 seconds .The
Steering Motors will have sequential starting.

Q .Remaining Regulations regarding Steering Gear.

The mian steering gear shall be

Capable of putting the rudder over from 35° on one side to 35° on the other side with the ship
at its deepest seagoing draught and running ahead at maximum ahead service speed and,
under the same conditions, from 35° on either side to 30° on the other side in not more than
28s

The auxiliary steering gear shall be :

Capable of putting the rudder over from 15° on one side to 15° on the other side in not more
than 60 s, If failure does occur on one system, the stand-by system will cut in within 45
seconds .

Differences between FU, NFU, Auto mode?

Follow Up ‘FU’; using hand wheel,

Where the amount of rudder angle depends upon the amount of hand wheel movement
If 0 to 15 then hold It will remain 15
If 0 to 15 then leave, It will return to 0
Non follow up ‘NFU’; Using Lever (Joystick)
Where the steering gear will move as long as the control lever is held in an actuating position
(either port or stbd), & will stop only when it’s moved back to an Off position.
Auto Mode:
SG circuits are controlled by the signals received from master compass, so that the ship is
automatically held on to a selected course.

Q .Describe the workings of the steering gear hunting gear -including protection for heavy sea
effects on the rudder.

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It controls the stroke of the pump i.e .suction & discharge of the pump after receiving the signal
from tele-motor transmitter.

& buffer spring is provided to reduce the excessive movement in heavy seas.

More infos refer to MEP book SG.

What is special about the overload protection for the steering gear motors?
Short Circuit protection
Instead of overcurrent protection an Overload alarm is fitted set to operate more than twice
normal running current

Refrigeration System;
Q .What is the Primary Function of the Expansion Valve in a Refrigeration System?
To regulate the Flow of Refrigerant from the H P side to the L P side of the System .

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The pressure drop causes the Saturation Temperature to drop, enabling it to boil off at the Low
Temperature of the Evaporator .

Q .What would cause an Excessive High Pressure in a Refrigeration System?

High Pressure could be caused by lack of Cooling or a Fouled Condenser or even Overcharge,
but this is usually unlikely .
How would you know a Refrigeration System was undercharged?
Undercharge will show as a Low Compressor Pressure and large bubbles in the Liquid Line Sight
Glass .

Q .What is the Function of an Evaporator in a Refrigeration System?

The Function of the Evaporator is to boil off the liquid Refrigerant, at the same time cooling the
air .The design of the System and Evaporator should be such that all Liquid Refrigerant is boiled
off and the gas slightly superheated before returning to the Compressor .

Q .What is the Function of the Condenser in a Refrigeration System?

The function of a Condenser in a Refrigeration System is to condense and sub cools the
refrigerant below Saturation Temperature.

Air Compressor
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What are the Safety Devices fitted to an Air Compressor?

Low Lub Oil Pressure Shut Down
High Air Temperature Shut Down
1st Stage Relief Valve or bursting disc
2nd Stage Relief Valve or bursting disc
A Fusible Plug is fitted after the 2nd Stage Cooler, Set at 120°C
If Water Cooled, a Jacket Water Safety Valve is fitted .

Why is a Jacket Water Safety Valve fitted on Air Compressors?

It is fitted to relieve excess pressure in the Cooling System should a Cooler Tube burst and
Compressed Air escape

What is the Maximum Compressed Air Temperature that should leave an Air Compressor?
93°C

What is the Purpose of a Fusible Plug on an Air Receiver and at what Temperature is it
Designed to Melt?
The purpose of the Fusible Plug is to act as a Safety Feature to Release Compressed Air from the
Receiver in the event of a Fire in the Vicinity .The Fusible Plug is designed to melt at 150°C .

Explain how you would start an Air Compressor and Stop It (after overhaul )
Refer to 59 of 85 screw air comp manual
 Check Oil Level in Crankcase .
 Then ensure all drains are open, i.e .Intercooler Drains and also Unloaders .
 Check Air Intake Filter is clean .
 Ensure Oil Pressure Gauge is Open and that Air Pressure Gauges i.e .1st and 2nd Stage,
are Partially Open to stop Gauge Fluctuation .
 If Water cooled, check Valves are open and Cooling is supplied .Also check Header Tank .
 Bar Machine Over by hand to see if it is Free to Turn .
 Start the Machine, check there are no unusual Noises or Vibrations and Oil pressure is
Correct .
 Then close Drains and Unloader .
 If all seem okay, run for 30 minutes, after which, it can be stopped, covers removed and
bearings checked .If okay, machine can be started and run on automatic mode .
 To stop the machine, always make sure the machine is unloaded and drains opened
before stopping, unless automatic drains and unloaders are fitted .

What are the dangers of excessive lubrication in Starting Air Compressors?

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Could lead to explosions in Air Start Lines/Manifolds .

Excessive lubrication can lead to carry over with compressed air, being deposited in the
Receiver then transferred to the Air Start Manifold, where a leaking Air Start Valve may allow
hot gases from combustion into the Air Start Manifold, ignite the oil vapour, causing an
explosion .

What checks/inspections are required on air compressors?

 Lubrication: Compressor oil pressure should be visually checked daily, and the oil filter
changed monthly.

 Air Filters: The inlet air filter can easily become clogged, particularly in dusty
environments .Filters should be checked and replaced regularly.

 Condensate Traps: Many systems have condensate traps to gather and (for those traps
fitted with a float operated valve )flush condensate from the system .Manual traps
should be periodically opened and reclosed to drain any accumulated fluid; automatic
traps should be checked to verify they aren't leaking compressed air.

 Air Dryers: Drying air is energy-intensive .For refrigerated dryers, inspect and replace
pre-filters regularly as these dryers often have small internal passages that can become
plugged with contaminants .Regenerative dryers require an effective oil-removal filter
on their inlet, as they will not function well if lubricating oil from the compressor coats
the desiccant .The temperature of deliquescent dryers should be kept below 100°F to
avoid increased consumption of the desiccant material, which should be replenished
every 3-4 months depending on the rate of depletion.

 Compressor Controls: Air compressors become inefficient when they are operated at
significantly below their rated output .To avoid running extra air compressors when they
are not needed, a controller can be installed to automatically turn compressors on and
off, based on demand .Also, if the pressure of the compressed air system is kept as low
as possible, efficiency improves and air leaks are reduced.

 Check the cooling system for operation .Check the inlet and outlet temperatures.

 Check oil pressure is high enough, usually 5 bar.

 Check for abnormal noise or vibration, for leak of oil or air piping.

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 Check the unloader is functioning correctly.

 Check the oil level in the crankcase should be more than half.

Explain an air starting explosion? Cause, effect, procedure etc .

How to detect if any potential of explosion in the starting line?

causes
• ME leaky starting air valve jamming or at open position

• Compressor Excessive sump oil level or excessive cylinder lubrication or defective oil
scrapper rings or the oil vapours inhaled from the oily engine room atmosphere.

How

With defects starting air valve, hot gases or flame may enter the starting air manifold, vapourize
the oil and set fire to the oil mists

Effect

• In such event an explosion may occur

Prevention

Fitting of oil wetted filters on the suction air compressors

Regular draining of the intercoolers, after coolers, air receivers and starting air system

starting air valve should be removed & inspected

Detection of a leaky cylinder starting air valve

• While engine in operation by local overheating of the pipe adjacent to the valve (inlet .)
If this occurred the engine should be stopped and replaced the valve.

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• While in port the leakage can be detected by shutting the isolating valve to the air pilot
distributor and applying air to the starting air manifold .Escape of air through open
indicator cocks will detect a leaking starting air valve

Explain interlock on the starting air system .

From the figure above (Starting air system), an interlock is shown in the remote operating valve
(starting air valve )line which stops the valve from opening when the engine turning gear is
engaged.

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Purifier
Starting a Purifier!...
 Start the motor of purifier .Wait until the motor ampere is constant, start transfer pump
of purifier.
 Then crack open the heater valve and maintain it at (90-95’c.)
 Then supply closing water to raise the bowl.
 Next supply sealing water until overflow at sight glass, then stop sealing water.
 Then supply the fuel by opening the valve or (purification pushbutton.)
 The purifier is operated.

Manually sludging

 Shut the fuel valve

 Supply some more fucking sealing water
 Then supply opening water so uncover the sludge port for ejecting the sludge.
 Next supply closing water to raise the bowl to cover the sludge port.
 Then supply sealing water until overflow you can see at sight glass.
 Supply fuel by opening the valve.
 Now the purifier is operational.

Checks after starting the purifier during regular watches:

1 .Adjust the throughput, back pressure, temperature of feed inlet if necessary

2 .Gear case oil level, motor amps, general leakages, vibration have to be monitored

3 .De-sludge every 2 hours for heavy oil purifiers & every 4 hours for lubricating oil purifiers .
(Refer manual or chief engineer instructions)

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Purpose of Gravity Disc:

Is to form an interface between oil & water in the bowl

What’s your action when purifier overflows?

 Immediately press the emergency stop push button.

 Investigate the cause of this overflow.
 Do manual sludging and start again.
 If same problem continues stop purifier, prepare for overhaul and
inspection( .Check the gravity disc for the correct size—possible reason.)

ON what principle a purifier works?

Centrifugal force & different in densities

How do you purify HFO?

Heavy Fuel Oil is purified using a Centrifugal Separator, which operates by the principle of
Centrifugal Force separating two liquids, in this case Fuel Oil and Water by means of a
Cylindrical Interface between the two .The positioning of this Interface being very important for
the correct operation .

What is the Difference between a Clarifier and a Purifier?

A Purifier removes Water as where a Clarifier removes Solid Impurities .
In some cases, both are used for separation purposes, firstly the Oil is purified, then clarified .

After Stripping and Cleaning a Purifier, what do you have to make sure of on re-assembly?
You have to make sure that the Mark on the Bowl Lock Ring lines up with the Mark on the Bowl .
Also if Vertical Shaft has been removed, that height of Shaft is correct .

How are HFO Impurities Removed?

Impurities in Heavy Fuel Oils are removed by centrifugal separators i.e .purifiers and clarifiers .
Liquids and Sludge being removed by purifiers, solids by clarifiers.

The purifier can become clarifier by removing the gravity disc, but clarifier cannot be purifier

What is partial & total sludging

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Total; shut the closing

Partial; no need to close the closing water

How to achieve better purification

Reduce viscosity by increasing temperature

Reduce throughput (output )to 25%, so oil will stay more time in purifier

Q .Routine checks required during normal purifier operation.

During normal operation, check regularly lub .oil inlet temperature, Purifier gear oil level,
sound, vibrations, load and front panel information of the control unit.

Steam Turbine

Q .Describe the safety devices fitted?

 Number of safety devices is fitted to a steam turbine to PREVENT DAMAGE TO THE
TURBINE BLADES and BEARINGS.
 The devices are connected in parallel and operate hydraulically, obtain their oil supply
from the LO system.
 Activation of any one of these devices results to trip the steam turbine by cutting
(shutting off )the steam supply through the main steam valve (nozzle valve.)
The safety cut-outs are:

1) Over-speed Trip:

 In the event of a sudden loss of load, a steam turbine would speed up very rapidly, and
large forces generated (centripetal )would soon cause destruction.
 To avoid this, an overspeed trip is fitted to the turbine which comes into effect at 10% over
maximum design speed and immediately causes the steam supply to the turbine to be shut off.

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@ 97.9 rpm MT will trip

2) Lubricating Oil Failure Trip :@ 0.5b

 In the event of loss of lub oil supply (due to oil pump failure )should the turbine
continue to rotate under load the bearings would overheat and subsequently melt .
This would cause great damage to the rotor and would at least necessitate the renewal
of the bearing material which is an expensive laborious task.
 To prevent this damage, a device is fitted, which should the lub oil pressure fall below a
certain pre-set level, causes the main steam valve to close immediately, in turn causing the
turbine to stop.
 LO Gravity will keep supplying for almost 30 min after the turbine trips to avoid such
damages.

3) Axial Movement Trip:

 The clearances (axial )between successive rotor and fixed blades are often very
small .If the rotor moves axially (usually due to heat expansion )more than a certain
amount then the clearance may close up completely causing blade damage.
 To prevent this from occurring an axial movement trip is provided which, when the axial
movement of the rotor relative to the casing reaches a pre-set level, causes the turbine
main steam valve to close.

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4) Loss of Vacuum Trip:

 In order to improve the efficiency of the turbine, the condenser and hence the turbine
exhaust is under a very high vacuum (about 730mm Hg .)This means that the saturation
temperature of the steam is about 50ºC .Ideally, a turbine should be designed so that at the
exhaust the steam is dry saturated( .880~960 mmHg normal & 44C)

 Should the condenser pressure suddenly rise i.e .the vacuum falls then since the heat
content of the steam is the same and the exhaust steam temperature has risen to the new
saturation temperature, steam will be wet .Thus the exhaust conditions have changed, since
instead of dry saturated steam at about 50ºC we have wet steam at a temperature in excess
of this i.e .100ºC.

 This change in condition will cause sudden overheating of the last few rows of blades, the
resulting expansion causing blade running .Further to this, there will also be very rapid
erosion as high speed LP blades strike the water particles.

 To prevent this from occurring a vacuum trip is fitted which closes off the turbine steam
supply should the vacuum fall to a pre-set level( .Usually 50 %vacuum.)
ALARM slowdown trip.

5) Emergency Shut-off Device:

 Under any emergency (fire, flooding, hp steam pipe bursting, …), this device can be
operated not allowing any operation on the turbine.
 When the trips operate they cause the oil to flow directly to the drain or sump (which is
under atmospheric pressure .)Thus if any of the emergency trips operates, the oil pressure
at the emergency shut off relay falls to atmospheric .This would also occur if the lub oil
pressure itself falls.
 When the oil pressure at the relay drops it causes the turbine emergency self-closing
valve to close thus cutting the supply and thus stopping the turbine .

 Any turbine supervisory system must have at least these major alarm and trip
facilities:
1 .Turbine overspeed
2 .Low lubricating oil pressure
3 .High condenser pressure
4 .High condensate level

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 In addition, a cross-compound turbine unit should monitor the following, and

incorporate them into the turbine trip system:
(Excessive vibration)
1 .H.P .turbine rotor eccentricity or rotor vibration
2 .L.P .turbine rotor eccentricity or rotor vibration
3 .H.P .turbine thrust wear
4 .L.P .turbine thrust wear
5 .H.P .turbine differential expansion
6 .L.P .turbine differential expansion
7 .Main thrust wear

 Specific trip functions and their set point onboard PFS:

Item Set
Manual emergency trip switch Off – On

(Ahead and astern)

Overspeed trip HP rpm :6,477 rpm

LP rpm :3,749 rpm

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(110 %MCR rpm)

LO low pressure trip (Ahead and astern) 0.5 bar (G)

Control oil low pressure trip 0.5 bar (G)

HP turbine thrust bearing excess axial Aft side 0.5 mm

displacement

LP turbine thrust bearing excess axial Fore side 0.5mm

displacement

HP and LP turbine rotors excess vibration 125 microns

Main condenser level high trip +450 mm

Both boiler trip

Boiler drum level high high

Main reduction gear excess vibration trip 500 microns

(HP 1P & LP 1P)

Inlet steam temp very high trip 530 degree

Inlet steam temp very low trip 390 degree

Inlet steam pressure very high trip 67 bar (G)

Inlet steam pressure very low trip 43 bar (G)

Q .Describe the routine checks carried out?

 The routine checks carried out in main engine are:
1 – Check all trips and alarm for the main engine are in operation.

2 -Check all pressure and temperature parameter.

3 – Check main condenser vacuum.

4 – Check lubricating oil level for sump tank and gravity tank .
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5 – Check cathode protection for main condenser.

6 – Check shaft milli volt erosion.

(For avoid spark erosion in the main shaft and bearing created by the effect of static electricity
coming through the shaft into the shaft to the bearings.)

7 – Check oil condition spray through the sight glass.

8 -Check gland steam.

Normally in the main engine, we check :Please note that these readings are taken from Puteri
class ships .For PFS need to find out the correct readings.

Main engine Units reading

Lever position % 82
1st stage steam press. Bar 24.3
Steam inlet temperature °c 370
1st bleed belt press Bar 7.5
2 nd bleed belt press Bar 0.1
Lp turbine inlet press. Bar 3.1
Lp turbine exhaust temp. °c 50
Gland seal press. Bar 0.45
Condenser vacuum mmhg 718
Condenser overboard temps. °c 32
Sea temp °c 28

Lubricating Units reading

Pump discharge press. Bar 5.0
Control oil pressure Bar 4.1
Spray rail press. Bar 1.6
Lo supply temperature °c 46
Hp thrust bearing temp. °c 50
lp thrust bearing temp. °c 50
Main thrust bearing temp. °c 45
Main lo sump level M³ 20.6

Q .Describe the procedures for preparing and shutting down engine prior to
and after sailing?
Please refer to the procedure (word document.)
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Q .Explain the need for warming through?

1 )The main objective of warming through is to ensure straightness of the rotor.

-To do this, a negligible temperature gradient must exist throughout the rotor.

-There is a tendency for the rotor to hog where steam is introduced (that is to say the rotor bends
due to temperature gradient rather than sagging under gravitational forces.)

2 )To prevent distortion of the casing.

-Rotation of the rotor churns up the steam and provides adequate mixing.

3 )To prevent thermal stresses caused by temperature gradient in thick materials.

4 )In case of the ship @ port, W/T is needed to keep the turbine ready for next call.

Q .Describe the need for turning the engine when on stand-by?

 Turning of rotors is intended to correct the distortion of the rotor and to prevent vibration
due to the distortion during normal operation condition.
 To ensure that the heat is evenly distributed while warming through and that the turbine
rotors do not sag due to vacuum in the main condenser.
 To aid in gearbox inspections, shaft bearings.

Q .Describe the effects of insufficient/too much gland steam supply?

 If too low :Leakage of air to the turbine will continue if turbine is stop .However if
running, main steam may leak to atmosphere.
 If too much :Bearing temperature will go high because steam temperature of gland let’s
say at 1 bar will have high temperature 100 degree and will damage the bearing.

Purpose:

 To stop /restrict steam outflow from turbine casing to atmosphere when turbine running
 To stop ingress of air from outside during warming through operations
 Used to prevent steam leakage from or air to casing where rotor extends through casing
 If glands consisted labyrinth packing or carbon rings only, some steam would leak out if
casing pressure above atmospheric, regardless how many rows of packing /rings are
installed
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 Steam leakage result to loss of water, engine room steaming & possible injury to
operator
 Entrance of air -necessary to enlarge capacity of air removing equipment - keep
oxygen content down
 When turbines low power (maneuvering, standby etc )steam supplied to glands – prevent
entry of air
 Steam taken from auxiliary source & supplied to gland steam reservoir
 As power input increased & pressure rise in casings, glands become self supplied with
steam flowing outward to atmosphere along shaft
 When full power approached, steam need to bled from glands via gland steam reservoir
to gland steam condenser
 Yet, steam is still required for LP astern gland -supplied from gland steam reservoir
 Pressure control in gland steam reservoir – by control valve which inter related between
gland steam condenser, reservoir & external supply
 In conjunction, steam can be leaked from /supplied to reservoir
 Gland steam pressure system 3.45kN/m²

Q .Describe the effects of loss of condenser vacuum?

 can lead to rise in the exhaust temperature of the turbine.
 Producing thermal stresses in the turbine.
 Can create a back pressure on to the LP turbine, and possibly cause the rotor hog.
 Can cause the last rows of blades to overheat rapidly due to steam flow will be restricted
of going to condenser and therefore can get damaged.
 Can lead to a loss of plant efficiency and eventual loss of power.

Q .Describe the effects of salt water leakage into the condenser?

 Will cause a great amount of feed water contamination with sea water.
 Will destroy vacuum( air will enter into the system.)
 Condenser level will rise very high and possibly can reach to turbine outlet and cause
damage.

Action:
 When an excessive amount of salt is found in the condenser, stop the turbine
immediately if possible .Check all points from which sea water is suspected to enter the
system, for example, breakage of the cooling tube, the fitted position of the tube plate and
the cooling tube, etc .
 Try to inject sawdust .If no response, stop turbine .The tubes will need to be plugged.

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Q .Describe the effects of operating the vessel with a partially shut throttling
valve?
Need to find out.

Q .Explain the reasons and effects of boiler carryover?

Please refer to the word document.

Q .Describe the consequences for operating the plant with too much high /low
superheat temperature?

 Too high steam temperature it will lead to tube overheating and main engine (turbine )
will trip due to lost vacuum in the main condenser .Also temperature-creep rupture
will be observed in some stages which will cause complete lifting of the blade shroud
bands.
 Too low steam temperature it will lead to water hammering due to condensation in the
pips and specially in the turbine blades.

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Steam plant
De-aerator -construction, why at the top?

Functions:

 To remove dissolved oxygen

 As a feed heater – increase thermal efficiency

 Storage tank to feed pump

 Provide positive suction head (NPSH)pressure to feed pump

Why placed at the top:

 Positive suction head (NPSH)for feed pump( p=ρgh)

 Prevent gassing problem to feed pump( cavitation)

 Eliminate the needs for booster pump

 Allow sufficient time for dissolved oxygen to be driven away( Hydrazine to react with
water)

Construction:

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Purpose of Ion Exchanger?

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Main condenser – sketch, how non-condensable gases are removed, how regenerative is
achieved?

 The construction is such that a direct passage is left down center of the
condenser.
 Exhaust steam can pass directly on to the feed water lying condensed in a large
well at the condenser bottom.
 The level of water in the well being maintained and controlled by the closed feed
controller.
 The central path allows direct contact between the exhaust steam and
condensate so giving regenerative heating.
 The condensate is then maintained at the same temperature as the exhaust
steam.

 This means negligible undercooling and only latent heat extraction during
condensation which is the ideal thermal principle.

 Air vapors are driven ahead of the steam and subject to maximum cooling
surface before being drawn up and extracted under the air baffles to the air
ejector with minimum volume.

 To avoid large degrees of undercooling, provision is made to control over the

flow of cooling water either by quantity or recirculation so that the condenser
operates at design conditions at all times .

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Purpose of vacuum?

 To let steam be condensed in main condenser, not in turbine.

 Creating vacuum assists the flow of exhaust steam.
 Allows low saturation temperature and hence increasing recoverable heat energy from
the steam.
 Allows the steam to condense with the minimum drop in temp

What is "Water Hammer "and its danger?

When steam lines are shut down it is possible from various causes for them to fill with water .If
steam is allowed to enter a line with water, the steam starts to move the water down the line .
The steam in contact with the water eventually condenses and a vacuum is formed causing the
water to be pulled back to the valve which has just been opened and striking it with a heavy
blow, often fracturing the valve .If the valve fractures, it may end disastrously with risk of loss
of life.

How is "Water Hammer "prevented?

In order to prevent water hammer it is necessary to open up drains on steam lines being
brought into use .The water must be completely drained so it leaves the line clear .The steam
valve is then cracked open so the line is heated and brought up to near working temperature .

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Any condensate found during this process drains out of the line via the drains previously
opened .The valve may then be opened and drains closed .

Why have turbine astern spray?

To avoid thermal shock to the 2-stage astern turbine

How main condenser create vacuum from cold?

Fill up to the normal working level by gravity from the distelle water tank
Start running air ejector & then slowly by condensation of the steam vacuum will be created

Why condensate level low at condenser (load )

Why have recirc?
This recirc is fitted @ the suction of pump to recirc gases to condenser

How air ejector works without condensate water

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Cooling System
What safety devices, alarms and shut downs are fitted .

Standby SW cooling pp will cut in if the pressure of running pp falls due to pp failure or
strainer

Describe the cooling water treatment, testing, expected results, effects of under/over
treatment?

Usually we test fresh water cooling system to check the following:

1) PH\Alkalinity to check the water alkalinity, slightly alkalinity condition is preferred

Tested by immersing ph (litmus )paper into a sample
2) CL\Chloride to check if there is sea water content.
Using cl meter
3) NITRITES to suppress copper corrosion .
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Cooling water test (:Nitrites Test )

 Add some water to the sample.

 Add 4 drops of MN1 and you will notice that the colour will be orange and then you
must SHAKE it
 Continue dropping of MN2 until the colour become blue .Then stop.
 According to how many drops you have added to make the colour blue, you will come to
know how much chemical that you have to add

Under treatment:

Scale deposits and corrosion will form and it will reduce the heat transfer.

Over treatment:

Too much erosion will be there

What temperature regulation was fitted on the fresh water system, what are the effects of
under/over cooling on the plant?

The Temperature is controlled by means of a Thermostatic Valve, normally known as an

"Amot "Valve .This operates by diverting Jacket Water through the Cooler when too hot
or by-passing the Cooler when cold .The Amot Valves normally use Wax Elements or air
to operate the Valve.

Under cooling the plant( :less cooling)

Under cooling the plant will cause thermal stress and will lead to engine overheating.
The effects of engine overheating will be:
- CYLINDER HEAD AND BLOCK CAN CRACK OR WARP
- RINGS AND VALVES MAY SEIZE OR STICK DUE TO GUMS, LAC QUERS, AND VARNISHES
FORMING FROM OVERHEATED OIL AND CARBON FORMATION
- BEARINGS MAY BE DAMAGED CAUSING EXCESSIVE WEAR

Over cooling the plant:

Overcooling the plant will cause mechanical stress and will lead to overcool the engine.
The effects of overcooling will be:
 INCREASED ENGINE WEAR
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 IMPROPER LUBRICATION
 INCREASED FUEL CONSUMPTION
 INCREASED SLUDGE FORMATION
 INCREASED ENGINE CORROSION
 MOISTURE CONDENSES IF BELOW 140 DEGREES IN THE ENGINE CRANKCASE

Describe different types of Cooling Systems i.e .Seawater Cooling System and Central Cooling
System .
A SW cooling system is an arrangement that uses individual coolers for LO, JCW and the piston
cooling system .Each cooler being circulated by SW .
Modern ships use a Central Cooling System with only one large SW circulated cooler .This cools
a supply of FW which then circulates to the other individual coolers .With less equipment in
contact with SW, the corrosion problems are much reduced in this system.

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Bilge
Describe the restrictions (regulation )for pumping bilge water with respect to you last vessel (be
aware of latest M-Notices)?

List down the regulation which involved with pumping out bilges.?

Annex 1

Oily water separators are required on ships to comply with MARPOL Annex 1 regulations .

For ships greater than 400 grt, and all tankers, in order to discharge bilge water:

 the ship must be en route,

 the oil content must be below 15ppm,
 there must be an oil content monitor,
 the bilge water can not originate from a cargo pump room,
 bilge pumping operations must be recorded in the oil record book..
 if the separator is to be used in a special area then the monitor must have an automatic
stopping device,

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Special areas with regard to oily water separators are:

Special Areas under MARPOL

In Annexes I Prevention of pollution by oil, II Control of pollution by noxious liquid substances and V Prevention of
pollution by garbage from ships, MARPOL defines certain sea areas as "special areas "in which, for technical reasons
relating to their oceanographical and ecological condition and to their sea traffic, the adoption of special mandatory
methods for the prevention of sea pollution is required .Under the Convention, these special areas are provided with a
higher level of protection than other areas of the sea .

Annex VI Regulations for the Prevention of Air Pollution from Ships establishes certain sulphur oxide
(SOx )Emission Control Areas with more stringent controls on sulphur emissions.

Special areas under MARPOL are as follows:

Adoption, entry into force & date of taking effect of Special Areas

Date of Entry into

Special Areas Adopted # Force
In Effect From

Annex I :Oil

Mediterranean Sea 2 Nov 1973 2 Oct 1983 2 Oct 1983

Baltic Sea 2 Nov 1973 2 Oct 1983 2 Oct 1983

Black Sea 2 Nov 1973 2 Oct 1983 2 Oct 1983

Red Sea 2 Nov 1973 2 Oct 1983 *

"Gulfs "area 2 Nov 1973 2 Oct 1983 1 Aug 2008

Gulf of Aden 1 Dec 1987 1 Apr 1989 *

Antarctic area 16 Nov 1990 17 Mar 1992 17 Mar 1992

North West European

25 Sept 1997 1 Feb 1999 1 Aug 1999
Waters

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Oman area of the Arabian

Sea
15 Oct 2004 1 Jan 2007 *

Southern South African

13 Oct 2006 1 Mar 2008 1 Aug 2008
waters

Annex II :Noxious Liquid Substances

Antarctic area 30 Oct 1992 1 Jul 1994 1 Jul 1994

Annex V :Garbage

Mediterranean Sea 2 Nov 1973 31 Dec 1988 1 May 2009

Baltic Sea 2 Nov 1973 31 Dec 1988 1 Oct 1989

Black Sea 2 Nov 1973 31 Dec 1988 *

Red Sea 2 Nov 1973 31 Dec 1988 *

"Gulfs "area 2 Nov 1973 31 Dec 1988 1 Aug 2008

North Sea 17 Oct 1989 18 Feb 1991 18 Feb 1991

Antarctic area (south of

16 Nov 1990 17 Mar 1992 17 Mar 1992
latitude 60 degrees south )

Wider Caribbean region

including the Gulf of
4 July 1991 4 Apr 1993 1 May 2011
Mexico and the Caribbean
Sea

Annex VI :Prevention of air pollution by ships (SOx Emission Control Areas)

Baltic Sea 26 Sept 1997 19 May 2005 19 May 2006

North Sea 22 July 2005 22 Nov 2006 22 Nov 2007

# Status of multilateral conventions and instruments in respect of which the international maritime organization or its
secretary general perform depositary or other functions as at 31 December 2002

*The Special Area requirements for these areas have not taken effect because of lack of notifications from MARPOL Parties
whose coastlines border the relevant special areas on the existence of adequate reception facilities (regulations 38.6 of
MARPOL Annex I and 5(4 )of MARPOL Annex V.)

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1) Red sea.
2) Mediterranean sea.
3) Baltic sea.
4) Black sea.
5) Gulfs area.
6) Gulf of Aden.
7) Antarctica.
8) North west European waters .

If working on the North American coast then certain signs have to be displayed at the Oily
Water Separator.

Oil record book.

An oil record book is an official document which is required to be kept on board all vessels .
Certain pumping operations are recorded in this book, these are:

Bunkering (internal or from shore), bilges, LO sludge, Waste Oil transfer

What checks are made on the operation of the bilge separator?

Check the oil content in the oil monitoring device.

Check for leakage in the pipe lines.
Check the pressure inside the OWS compartments
Check the BHT level.

Describe the procedure for pumping bilges (over board)?

Starting procedure:

1. Permission is asked from the bridge .The bridge will confirm

that the ship is away from land and will be for the expected
time of the bilge pumping operation.
2. Note the time and ship’s position in the oil record book.
3. The sludge tank and bilge holding tank levels were recorded in
the oil record book.
4. The ship’s side overboard valve to open.
5. Open the fresh water supply to the oily water separator.

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6. Open the priming valve to the OWS and the vent .The
separator to be filled with water .When the water appears at
the vent cock, indicating that the OWS is full of water, the
priming valve and vent cock are to closed.
7. The fresh water supplying to the analyser is opened, and the
analyser is cleaned .A reading of 0 ppm should be indicated as
fresh water is passing through .The fresh water supply to the
analyser then shut closed.
8. If needed (The heating coil outlet to bilge was opened and the
heating coil steam is crack open .When clear condensate
water is seen at the outlet, the heating steam supply is fully
open .The heating steam will lower the viscosity of the oil,
making it easier to separate.)
9. The sample line from the pump discharge to the analyser is
open to ensure a flow of sample to the analyser is maintained .
The separator pump was then switch on .The analyser and
chart recorder were monitored and were make sure to be
giving the correct indication.
10. The 3 way Dump valve for the treated outlet is checked .It’ll
dump the water back to the holding tank in the event of the
reading exceeding the designated limit; in this case over than
15 p.p.m.
11. Pumping of bilges has now commence.
12. Regular check on the discharged water at the sampling cock .
Monitor and take local sounding for the bilge holding tank
until the desired quantity has been pumped out.

On completion:

1. Stop the pump

2. Flush the analyser
3. The OWS was filled with fresh water.
4. shut the fresh water supply..
5. The ship’s side overboard discharge valve were closed.
6. The bridge was then informed of the completion of
pumping bilges overboard.
7. Note the time of the operation and the ship’s current
position
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8. Record all the full details of the operation in the Oil Record
Book (as highlighted in attachment 1.)

What alarms and shutdowns are fitted?

 15ppm equipment detects discharge with oil content over 15ppm it shuts the unit down
and activates and alarm.
 High level alarm bilge well.
 BHT high level alarm.
 High oil level in the OWS pump will stop and oil outlet valve will open supply to the
sludge tank.
 Should the oil interface reach the alarm and shut down probe and alarm is activated and
the unit shut down.

What special provision is made for evacuating the bilges i.e emergency suctions/pumps?
Including cargo areas?
The main line bilge system consists of two pumps which are fire/bilge pump and the bilge
pump .These pumps are normally used when flooding in engine room occurred and when the
other method had failed to overcome the situation. Direct bilge valve is use during emergency
case (flooding in engine room.)

If engine room flooding, and the reciprocating pump already pumping but the level still raising
that shows the inflow of water is exceeding the capacity of the pump .Then the bilges pump will
be used.

If the levels of sea water still rising open the discharge overboard valve for fire and bilge pump,
open the direct suction and start the fire /bilge pump.

Aft sea water service pump will use if the sea water level still raising .The suction is taken from
tank top by opening Emergency Bilge suction vv or (extended spindle valve Puteri Class.)

The extended spindle is located at platform 1 whilst the valve itself located at bottom platform .
Therefore the valve can be easily operated and accessible.

The extended spindle well highlighted, red color and there is a notice posted, emergency bilge
suction valve.

Give likely causes to poor pumping performance of the bilge system?

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Blocked strum box(.very high vacuum on the gauge)

Hole in suction line(.zero or very low vacuum on the gauge)
Priming pump not functioning if working in series with centrifugal pump.
A Valve may be left open from an Empty Bilge.

How to discharge bilges in the special area?

A .Discharges outside special areas

2 .Any discharge into the sea of oil or oily mixtures from ships of 400 gross tonnage and above shall be prohibited
except when all the following conditions are satisfied :

.1 .the ship is proceeding en route;

.2 .the oily mixture is processed through an oil filtering equipment meeting the requirements of regulation 14 of this
Annex;

.3 .the oil content of the effluent without dilution does not exceed 15 parts per million;

.4 .the oily mixture does not originate from cargo pump room bilges on oil tankers; and

.5 .the oily mixture, in case of oil tankers, is not mixed with oil cargo residues .

7.1.1 B .Discharges in special areas

3 .Any discharge into the sea of oil or oily mixtures from ships of 400 gross tonnage and above
shall be prohibited except when all of the following conditions are satisfied :

.1 .the ship is proceeding en route;

.2 .the oily mixture is processed through an oil filtering equipment meeting the requirements of
regulation 14.7 of this Annex;

.3 .the oil content of the effluent without dilution does not exceed 15 parts per million;

.4 .the oily mixture does not originate from cargo pump room bilges on oil tankers; and

.5 .the oily mixture, in case of oil tankers, is not mixed with oil cargo residues .

4 .In respect of the Antarctic area, any discharge into the sea of oil or oily mixtures from any
ship shall be prohibited .
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5 .Nothing in this regulation shall prohibit a ship on a voyage only part of which is in a special
area from discharging outside a special area in accordance with paragraphs 2 of this regulation.

How to discharge bilges in Malacca strait?

.!!!!!!!!!!!!!!!!!!!!!!!!!!!!
What is OWS? What is its purposes?
Oily water separator
Oily water separator (OWS )is a device that used on board ship to ensure that the ship does
not discharge oil during pumping bilges overboard .Using gravity separator as working
principle which the lowest density, oil will rise and collected upward in OWS while the
mixture water and bilge that has highest density will go downward in OWS .

Sketch the bilge system (complete piping system)?

Refer to your last vessel diagram

Explain the working principle of OWS.

Principle of Oily Water Separator

All the bilge water that collected in bilge well pumps to the Bilge Hold Tank (BHT )using
reciprocating bilge pump .However the BHT cannot hold the bilge water for big amount so that
the bilge water must be discharge overboard by using oily water separator .

, TURBULO COMPACT SEPARATOR TCS-HD is using gravity separator as working principle which
the lowest density, oil will rise and collected upward in OWS while the mixture water and bilge
that has highest density will go downward in OWS .The pump is screw type that has rate 5 m3/h
will draw out bilge water in OWS to overboard.

OWS is fitted with oil monitoring device (OMD )that will monitor only water that contain less
than 15ppm discharge overboard .PPM is part per million is used to show the ratio between
water and oil .If we have 1 million of bucket; 15 bucket is fill with oil and the rest is fill with
water .That is what means by 15 ppm.

Water that contains more than 15 ppm will go back to BHT .This is done by 3 ways valve
pneumatic operated .The 3 way valve is connected with line to discharge overboard and line to
discharge back to BHT .When the OMD detect that bilge water discharge overboard is more
than 15 ppm, it will send signal to the 3 way valve that will shut discharge overboard and open
discharge to BHT.

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The oil that collected in OWS is discharge to the sludge tank .On the top of the OWS, there is an
oil detector .The oil detector will detect oil that collected in OWS and operate the oil out valve
which means open the outlet for oil discharge to sludge tank .During this time, pump will stop
and the inlet valve for fresh water oil outlet will open. The purpose of this fresh water is to
force the oil that collect in OWS out of it .This done because oil and water will not mix together.

After the oil detector detects no oil, the oil outlet will shut and same thing also occur to the
valve for fresh water oil outlet .After that the pump will start automatically and continue
pumping bilges overboard.

Heating steam may used to decrease the viscosity of the oil and improve its flow properties .
This will make the oil and water efficiently separate .Before use the heating steam, the OWS
must be completely filled.

Explain the procedure to pump out the bilges via OWS?

Explain the Bilge System from Bilge Wells to Overboard?

Description of the Service Line of Bilge System

For the service line, the bilge water from the bilge wells is normally emptied through the
reciprocating bilge pump .The reciprocating bilge pump will take suction from the wells and
discharge them to the bile holding tank (BHT .)To emptying the BHT, the oily water separator
(OWS )will be used to discharge the water overboard .All the service line are fitted with strainer
which is will trap particle and solid waste to avoid them passing the line that can cause bung in
the pipe line .After that, the bilge water will pass the non-return valve that will permit the flow
only one direction which is to the reciprocating bilge pump and not to return back to the well .
This will cause the pipe line always priming condition .All the bilges well are fitted with manual
valve which is butterfly type valve except for the both forward bilge wells .Emptying process
needs to be done manually by opening the suction valve of the required well and start the
pump.

For the forward port and starboard bilge wells, their service lines are fitted with pneumatic
control valve to operate the valve .They are provided with an automatic bilge pumping .The
wells are provided with a level switch. When the reciprocating bilge pump is set at remote, the
pump will cut in when the level switch indicates the level of bilge water is high. Once the level
switch detects the high level in the well, it will open the discharge valve and the pump will start
pumping .

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For the steering gear well, which is port and stbd side, they are drained to the aft bilge well by
operate the self-closing test cock

Explain the Bilge System from Bilge Wells to Overboard .

The Bilge Pump (Positive Displacement Pump )takes Suction from the Bilge Well via a Strum
Box, then via a Strainer before entering the Pump where it is then discharged to the Bilge
Holding Tank .
From the Bilge Tank the Oily Water Separator takes Suction, Bilge Water passes through the
Separator before being discharged overboard via 15ppm Monitoring Unit, which will
automatically stop the Oily Water Separator Pump and give an Alarm if the Oily Water Mixture
exceeds 15ppm .

What types of pumps are used for Pumping Bilges in an Emergency?

These Pumps are normally High Capacity Centrifugal Pumps( .fitted with a self-priming device
to enable the suction from the tank top

How is 15ppm reached in an Oily Water Separator?

15ppm is achieved in an Oily Water Separator by normally passing through a Two Stage
Separator where in the first stage Oil/Water is passed into the coarse separating compartment .
Here some oil will rise to the top of the Compartment due to its lower density, Heating Coils
may aid this .The remaining Oil/Water will flow down into the Fine separating Compartment
and moves slowly between Catch Plates .More Oil will separate out onto the underside of these
Plates and travel outwards until free to rise to the oil collecting space .The almost Oil Free
Water (usually being at 100ppm at this stage )will then pass to the second stage of the
separator, which is a Filter Unit comprising membrane cartridge .The first Filter Stage removes
Physical Impurities present and promotes some Fine Separation .The second Stage Filter uses
Coalescer Inserts to achieve the final De-oiling, Oil/Water Mixture leaving this Stage at less than
15ppm .

How many PPM can be Pumped in Marpol Restricted Areas?

15ppm .

How many pumps are there in the Engine Room that you can pump Bilges with?
A Bilge Pump which is normally Positive Displacement .
The others may vary from Ship to Ship, but can be the Ballast Pump, General Service Pump and
Main Sea Water Cooling Pump .These Pumps are only used for Pumping Bilges in the event of
an emergency and have an Emergency Bilge Suction/Injection Valve connected to them .

What is the Bilge Injection Valve?

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The Bilge Injection is a valve that enables the Engine Room Bilges to be pumped out directly
overboard in the event of an emergency such as flooding .The valve is normally fitted to the
end of a branch connection with the main sea-water suction line .This enables large main sea-
water cooling pumps to be used as a bilge pump in an emergency .

Regarding the Emergency Bilge Injection Valve, what is its relevant size compared to the Main
Sea Water Injection Valve?
The valve size of the Emergency Bilge Injection Valve must not be less than 2/3 the size of the
Main Sea-water Injection Valve .

How is the Bilge Injection Valve brought into Operation?

To bring the Bilge Injection Valve into operation during an Emergency, the Valve is opened fully
and the Sea Injection or Suction Valve is fully closed .After it is established the Bilge Injection
Valve is capable of lowering the water level in the Engine Room, the Sea-water Injection Valve
or Suction Valve may be opened slowly .This should be done in stages so that the Tank Tops are
not pumped dry, as this would cause the sea water pump to loose suction

Start from cold ship up to full away

 Start Emergency Air Compressor to fill air bottle to 25 bar & put system online
 Line up FO LO & CW for EDG
 Start EDG & supply to ESB

 Online CCS (SW & FW )& supply cooling water to different machinery
 Prepare DG (FO LO CW & starting air)
 Start DG & put on-load (ensure running machinery are supplied from MSB)
 Stop & secure EDG & connect MSB to supply ESB
 Start up all miscellaneous machinery (Air compressors, ventilation)

Start boiler preparation

 Ensure furnace clear & manholes are secured properly

 Fill up ADT (from distillate tank), Deaerator (from ADT pumps )& Main Condenser (from tank )

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 Ensure control air is available

 Check gauge glass valves are setup
 Ensure vents of steam drum & super heater are open & all blow down valves are shut
 Setup cold start feed pump to fill up economizer & boiler to normal levels (40= %2/5 )
 Setup DO, Atomizing air
 Run sealing air fan
 Reset all alarm trips
 Start FD fan @ low speed to purge the furnace manually
 C/O control from DCS to BGB (local control )in-order to put FO low temp switch to bypass
 Light-up 1 burner & check flame (golden OK, if orange means less air, if yellow indicates FO
temp high )& smoke (brown OK, if white there is excess air, if black less air )
 When steam is 1 bar, close steam drum vent
 Repeat firing on & off for few times to avoid thermal stress on boiler
 @ 10 bar warm up & start supplying to auxiliary steam lines e.g .FO tanks
 Line up FO to Change over from DO
 Bottle up your boiler Stop firing in order to change over from atomizing air to atomizing steam &
from DO to FO
 Change over FO temp from by-pass to normal & BGB to DCS
 Fire up with FO
 Adjust firing rate to meet the maker’s instruction
 @ 20 bar warm up Feed pump & online air ejector
 @ 25 bar start Feed pump & secure cold start feed pump
 & 60 bar warm up & start T/A & secure DG
 Warm up Main Turbine; (start T/G, supply warming steam )@ least 8 hours
 Steering gear to be tested
 When order given by bridge prepare MT

a) stop warming through,

b) stop & disengage T/G,
c) open ME boiler stop valves, ahead stop valve, un-jack astern guardian valve
d) give manual blasting to check ahead & astern movement
e) transfer the control to bridge & monitor the auto-spinning

keep monitoring the movement orders given by bridge & record in the movement book

Procedure to enter the boiler.

 The burner flame shall be extinguished and fuel supply lines shut off and locked where
feasible .Where oil is used, atomizers or oil gun assemblies should be removed from the
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burner .Where gas is used, the supply lines shall be blanked off, or shutoff cocks closed
and locked.
 Care must be taken to ensure no fuel or fuel vapors can enter the boiler furnace while the
unit is shut down.
 Secure all inlet & outlet valves of the boiler
 Make sure boiler has been ventilated & depressurized
 Never enter the boiler until an adequate cool-off period has been observed and the
Owner's entry procedures have been completed.
 Open the manhole carefully & run portable blowers to ventilate.

How to start the boiler from cold?

Need to be approved…

Why we need to purge the boiler? How it is carried out?

When to purge a boiler?
The furnace must be purge :
a )Before light-off
b )After failure of burners to ignite
c )After flame off
d )If there is any appreciable delay between the first
purging and burner lighting

Purging is usually designed to supply the furnace with an air

volume which is 4 – 5 times the boilers’ total
combustion gas volume .For this purpose a minimum air
flow is necessary for a certain time
reasons
To remove combustible gases & vapors in order to avoid furnace blow back or explosion
during startup.

Procedures;
Open the dampers @least 80 %to ensure an adequate flow of air
Start FD fan & keep it running for about 5 to 10 min

How to do maintenance on FD fan?

Lubrication & cleaning of bearing & regular vibration checking

Checking of bearing temperature, air pressure & temperature & current
How to shut down boiler

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How to fill up the water at economiser?

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