RESTRICTED

DOCKET FOR
ERA-IV ‘Q’ COURSE
DOCKYARD SPECIAL ENTRY SAILORS

TRADE: SHIP OUTFITTING( PLUMBING & PIPE

FITTING)
SUB: PRACTICAL IN WORKSHOP-I

RESTRICTED
 RESTRICTED

CONTENT

Sub: Practical in workshop

Chapter Topic Period Page

1 Propeller and Shafting System:Visiting dock ship for 15 1
effective training, Defects of shafting and its bearing.
How to remove of a ‘P’ bracket and stern tube and
bush. Alignment of shafting system.
2 Pump & Compressor. Maintenance and inspection of 15 5
Fresh water, Sea water and Lube oil pump,
overhauling, Maintenance and routine check of HP
and LP air compressor.
3 Thread cutting, turning, facing,slotting, boring, drilling, 15 9
machine operating procedure etc. Work as group
member of pump machining team, safety in.
4 Pipe fabrication, bending, measuring, joining, pickling, 15 21
testing. Valves Overhauling & testing. Rudder &
associated parts measuring & maintenance. Capstan
overhauling. Pneumatic & hydraulic control
equipment.
5 Operation and maintenance of Lathe Machine. 10 41
6 Operation and maintenance of Overhead Crane. 10 49
7 Operation and maintenance of Drill Machine. 10 51
8 Operation and maintenance of Grinding Machine. 10 55
9 Procedure of shaft trueness checking, Load Ring and 20 57
Piano Wire method.
10. Procedure of Pump Test Bench. 20 59
11. Revision and Examination. 10

ii
RESTRICTED
 RESTRICTED

CHAPTER-1

Name of Experiment- Visiting dock ship for effective training, Defects of

shafting and its bearing. How to remove of a ‘P’ bracket and stern tube and
bush. Alignment of shafting system.

0101. Aim of Experiment-

1. To acquire knowledge about Propeller and Shafting system.

2. To enhance the technical skill.

0102. Theory- If we want to gain our knowledge, we should improve knowledge

on
Propeller and shafting servicing and alignment work and it is very important in
practical work.

0103. Propeller and Shafting System- To learn about propeller and shafting
shafting system we have to visit dock ship for effective training. Defects of shafting
and its bearing must be found out. We can learn there how to remove stern tube
and bush and alignment of shafting system.

0104. Instrument-

i. Hammer
ii. Chisel
iii. Screw driver
iv. Open spanner
v. Ring spanner
vi. Combined spanner
vii. Socket spanner
viii. T-Handle
ix. Vernier scale
x. Circlip plier

0105. Procedure-

Visiting dock ship:

To learn about propeller amd shafting system we must visit dock ship.
We must inspect the propeller and shaft.
We must keep a note to write down the inspection result.
We must keep concentrate how the repair work is done.
Defects of shafting and bearing:
ii
RESTRICTED
 RESTRICTED
Check if the shaft is worn out in any where.
Check if the GRP coating is drooped.
Check if the bearing is distorted.
Check if the bearing is drooped.

Removing of stern tube and bush: Need to remove the prop, shaft (to shorten &
true the coupling) and replace the cutless.The shaft won’t clear the rudder and the
rudder top bearing/seal design won’t allow it to tilt enough, even after removing the
bottom rudder shoe. Bad access to top of the rudder stuffing box precludes its
removal. The stern tube goes about an inch into the keel and once pulled out,
looks like the 1 ½” shaft can shift laterally more than ½”, which should be enough.

Alignment of shafting system:

1. Loosen the hose clamps and remove the rubber boot from the front end of the
shaft log.

2. Slide it and the packing gland ahead on the shaft.

3. Disconnect the two coupling halves connecting the shaft to the transmission by
removing the four bolts holding them together. Slide the shaft back a bit, perhaps
1/2 inch.

4. Slip four pieces of carefully milled hardwood or square steel rod back a couple
inches into the shaft log around the shaft, one each on the top and the bottom and
one each on the sides. This centers the shaft in the shaft log and gets rid of the
wiggle, assuming your cutless bearing was recently replaced. For instance, if the
inner diameter of the shaft log is 1.5 inches and you have a 1.0 inch shaft, the
square rods (whatever they’re made of) will have to measure 1/4 inch by 1/4 inch
by whatever length is convenient. Now the shaft is stabilized.

5. Carefully wrap duct tape around the exposed rods so they stay in position on the
shaft and keep it centered.

6. Slide the shaft forward (the rods will have to slip back and forth on the shaft or in
and out of the shaft log a bit) until the shaft flange butts up against the transmission
flange loosely.

7. Note the variations in the gap between the two halves. Slide the shaft back
again 1/2 inch.

8. Using the adjustment nuts on your engine mounts, move the engine so it’ll take
up the slack. Like this: If the coupling halves clicked together at the bottom but had
a small gap at the top, the front of your engine probably has to go up some. This
can also involve some port-starboard adjustment if there’s a sideways gap. Do
whatever it takes. Any reputable engine mount offers the ability to make vertical
and lateral adjustments.

9. Slide the shaft forward again so the two flanges click together loosely.

10. See how you did in adjusting the engine’s position so that the two flanges fit
together snugly all the way around.
ii
RESTRICTED
 RESTRICTED
11. Check the gap using a feeler gauge. If the gap is more than 0.004 inch on any
side, adjust the gap again.

12. Keep repeating Steps 6 through 10 until you get it right. The less gap the
better. Ideally, the coupling halves should slide together easily and butt up to each
other with no gap. This process of repetitive adjustments may take a few hours. If
you get burned out, go home and come back. Having your most mechanically
astute friend helping you will relieve the stress a lot.

13. When everything looks good, tighten down your engine-mount nuts, do a final
check, then bolt the two flanges back together. Tighten all nuts a little, then go
around again and do the final tightening. Check the set bolt that holds the coupler
onto the shaft for tightness. Make sure it has a keeper wire around the coupling
and through the hole in the square bolt head.

14. Finally, remove the rods centering the shaft in the shaft long, slide the boot and
packing gland back so the boot is back to where it was, and cinch down both hose
clamps. If you put the transmission in neutral and slowly rotate the prop shaft by
turning the coupler around, you should see essentially little or no wiggle in the
packing gland and the flexible boot behind it. If you start your engine and let it run
at idle, everything will be jiggling and wiggling some as it’s supposed to. That’s why
engines have a flexible boot between the packing gland and the shaft log and four
flexible mounts. As the engine approaches operating speed, around 2500 to 3000
rpm, under load on the water, the jiggle should go away, and there should be no
gross movements, only an engine and shaft humming away in a steady state. The
transmission and cutlass bearing should now be able to enjoy extended lifetimes.
If you plan to go cruising very far from home, this is a skill you should have. Doing
an alignment requires great care and patience.

0106. Results-

ii
RESTRICTED
 RESTRICTED

Fig: Propeller and Shafting System

0107. Discussion- Above this procedure we can learn about propeller and
shafting system.

0108. Precautions-

i. Always wear eye protection or safety goggles.

ii. Wear leather aprons to protect chest and lap when standing or sitting.
iii. Always wear safety gloves.
iv. When we work with cutting tools, it should be taken highly safety so that
there is no injury.
v. If any injury occurred, take first aid immediately and inform your concern
authority.

ii
RESTRICTED
 RESTRICTED
CHAPTER-2

Name of Experiment- Maintenance and inspection of Fresh water, Sea water

and Lube oil pump, overhauling, Maintenance and routine check of HP and
LP air compressor.

0201. Aim of Experiment-

1. To acquire knowledge about pump and compressor maintenance and

overhauling.
2. To enhance the technical skill.

0202. Theory- If we want to gain our knowledge, we should improve knowledge

on
Pump and compressor maintenance and overhauling work and it is very important
in practical work.

0203. Sea and Fresh water pump and HP& LP air compressor miantenance
and overhauling- Pump is fitted with the engine as fresh and sea water pump.
HP & LP air compressor is fitted in the engine room. We should do maintenance
them regularly and when they get problems, we need to overhaul the them.

0204. Instrument-

i. Hammer
ii. Chisel
iii. Screw driver
iv. Open spanner
v. Ring spanner
vi. Combined spanner
vii. Socket spanner
viii. T-Handle
ix. Vernier scale
x. Circlip plier

0205. Overhauling Procedureof pump-

i. Close suction and discharge valve.

ii. Remove suction and discharge pipe flange bolt & nut.
iii. Remove pump foundation bolts from engine.
iv. Remove impeller lock & nut & take out the impeller
v. Remove mechanical seal.
vi. Remove bearing cover from other side & take out shaft with ball bearing
vii. Renew mechanical seal and bearings if required.
viii. Clean and inspect all parts and assemble.
ii
RESTRICTED
 RESTRICTED
0206. Maintenance and inspection Procedure of pump-
i. Check if impeller worn out or broken.
ii. Check if wear rings worn out or torn.
iii. Check if neck bush worn out.
iv. Check if ball bearing worn out or jammed.
v. Check if shaft worn out.
vi. Check if mechanical seal worn out.

0207. Overhauling Procedure of Compressor-

i. The compressor to be isolated both electrically and mechanically and

locked out.
ii. ‘MEN AT WORK’ notices are posted.
iii. The oil and cooling water is drained.
iv. Compressor is stripped down removing cylinder head and valves,
piston and connecting rod.
v. The circlips, gudgeon pin and top end bearing are removed from the piston
using proper tools.
vi. The piston rings are removed.
vii. The parts to be cleaned for survey, but no evidence of wear or damage is
removed.
viii. The parts are gauged (ring grooves, piston pin diameter, bearing
clearances) and the readings are recorded. Safety devices are
checked.
ix. Hydraulic tester can be used to test the opening pressure of relief valves.

0208. Maintenance and running check of compressor-

i. Check Pump Oil Level

ii. Oil Leak Inspection
iii. Drain water in tank
iv. Check for weird noise and vibration
v. Inspect all air leaks
vi. Inspect belts
vii. Check air filters, clean or replace
viii. Check safety relief valve
ix. Check belts if necessary
x. Check and tighten all bolts
xi. Check connections for leaks

ii
RESTRICTED
 RESTRICTED

0209. Results-

Fig: Compressor overhauling Fig: Pump overhauling.

0210. Discussion- Above this procedure we can overhaul a pump and

compressor.

0211. Precautions-

i. Always wear eye protection or safety goggles.

ii
RESTRICTED
 RESTRICTED
ii. Wear leather aprons to protect chest and lap when standing or sitting.
iii. Always wear safety gloves.
iv. When we work with cutting tools, it should be taken highly safety so that
there is no injury.
v. If any injury occurred, take first aid immediately and inform your concern
authority.

ii
RESTRICTED
 RESTRICTED
CHAPTER-3

Name Of Experiment : Thread cutting procedure

Thread cutting : A thread is a uniform helical groove cut inside of a cylindrical

work piece, or on the outside of a tube or shaft. A screw thread is a ridge of uniform
section in the form of helix cut around the circumference of a cylinder and
advancing along the axis is called thread.

Figure: Thread Cutting

Types of thread : Thread is mainly two types. such as

a. Metric thread (mm)

b. British thread (inch)

Another way there is many types of thread. Such as.

a. British standard with worm thread (BSW)
b. British standard fine thread (BSF)
c. British standard Pipe thread (BSP)
d. British association standard thread (BSA/BA)
e. American national standard ‘V’ thread
f. Acme thread
g. Metric thread
h. Buttress thread
i. Square thread
j. Knuckle thread
k. Worm thread
l. Sharp ‘V’ thread
m. Round thread

ii
RESTRICTED
 RESTRICTED

Single Stud Thread : A single thread is a thread that has a lead equal to the pitch.

Figure: Single Stud Thread

Multi Stud Thread : Multiple threads are the thread in which the lead is an integral
multiple of the pitch. A multiple thread having two starts or separate threads is
called double threads. One having three starts is called triple thread.

Figure: Multi Stud Thread

Thread Cutting Procedure : Thread Cutting. thread cutting is to produce a helical

groove on a cylindrical surface by feeding the tool longitudinally. The job is
revolved between centers or by a chuck. The longitudinal feed should be equal to
the pitch of the thread to be cut per revolution of the work piece. The advantage of
this method is that long tapers can be machined. As power feed can be employed,
the work is completed at a shorter time. The disadvantage of this method is that
internal tapers cannot be machined.

ii
RESTRICTED
 RESTRICTED
a. The job is revolved between centers or by a chuck. The longitudinal
feed should be equal to the pitch of the thread to be cut per revolution of the
work piece. The advantage of this method is that long tapers can be
machined. As power feed can be employed, the work is completed at a
shorter time. The disadvantage of this method is that internal tapers cannot
be machined. Taper turning by taper attachment method is illustrated in Fig.

b. The carriage should be moved longitudinally obtaining feed through

the leads crew of the lathe.

c. A definite ratio between the longitudinal feed and rotation of the

headstock spindle should be found out. Suitable gears with required number
of teeth should be mounted on the spindle and the lead screw.

d. A proper thread cutting tool is selected according to the shape of the

thread. It is mounted on the tool post with its cutting edge at the lathe axis
and perpendicular to the axis of the work.

e. The position of the tumbler gears are adjusted according to the type
of the thread (right hand or left hand).

f. Suitable spindle speed is selected and it is obtained through back

gears.

g. Half nut lever is engaged at the right point as indicated by the thread
chasing dial.

h. Depth of cut is set suitably to allow the tool to make a light cut on the
work.

j. When the cut is made for the required length, the half nut lever is
disengaged. The carriage is brought back to its original position and the
above procedure is repeated until the required depth of the thread is
achieved.

k. After the process of thread cutting is over, the thread is checked by

suitable gauges

ii
RESTRICTED
 RESTRICTED

Figure: Thread Cutting Procedure

Turning : Turning is a form of machining, a material removal process, which is

used to create rotational parts by cutting away unwanted material. The turning
process requires a turning machine or lathe, work piece, fixture, and cutting tool.

Figure: Turning

Types of Turning : There are two types of turning. Such as,

a. Plain Turning
b. Taper Turning.

Plain Turning. Plain or Straight Turning. Plain turning originated in the watch
industry and is used to manufacture long, slim parts from rod stock or wire. On the
plain lathe the rod material is clamped in a chuck and pushed through a guide
sleeve.

ii
RESTRICTED
 RESTRICTED

Figure: Plain Turning

Taper Turning. When the diameter of a piece changes uniformly from one end to
the other, the piece is said to be tapered. Taper turning as a machining operation is
the gradual reduction in diameter from one part of a cylindrical work piece to
another part. Tapers can be either external or internal.

Figure: Taper Turning

Facing : Facing is machining the ends and shoulders of a piece of stock smooth.
flat, and perpendicular to the lathe axis. Facing is used to cut work to the desired
length and to produce a surface from which accurate measurements may be taken.

ii
RESTRICTED
 RESTRICTED

Figure: Facing

Boring: In machining, boring is the process of enlarging a hole that has already
been drilled (or cast) by means of a single-point cutting tool (or of a boring head
containing several such tools), such as in boring a gun barrel or an engine cylinder.

Figure: Boring

Drilling : The tailstock of a lathe can be used for drilling, with the aid of a drill
chuck attachment. The drill chuck has a mores taper shaft which can be push into
the shaft of the tailstock, locking it in position. The usual starting point for drilling
with a centre lathe is to use a countersink bit.

ii
RESTRICTED
 RESTRICTED

Figure: Drilling

Knurling : Knurling is a process of impressing a diamond shaped or straight line

pattern into the surface of a work piece by using specially shaped hardened metal
wheels to improve its appearance and to provide a better gripping surface.

Figure : Knurling

Reaming : Reamers are used to finish drilled holes or bores quickly and accurately
to a specified diameter. The work piece is mounted in a chuck at the headstock
spindle and the reamer is supported by the tailstock in one of the methods
described for holding a twist drill in the tailstock.

ii
RESTRICTED
 RESTRICTED

Figure: Reaming

Grooving : Groove cutting on CNC lathes is a multi step machining operation. The
term grooving usually applies to a process of forming a narrow cavity of a certain
depth, on a cylinder, cone, or a face of the part. The groove shape, or at least a
significant part of it, will be in the shape of the cutting tool.

Figure: Grooving

Parting : Parting uses a blade-like cutting tool plunged directly into the work piece
to cut off the work piece at a specific length. It is normally used to remove the
finished end of a work piece from the bar stock that is clamped in the chuck.

ii
RESTRICTED
 RESTRICTED

Figure: Parting

Chamfering : Chamfering removes the burrs and sharp edges, and thus makes
the handling safe. Chamfering can be done by a form tool having angle equal to
chamfer which is generally kept at 45°.

Figure: Chamfering

Machine operating procedure :

a) Always know where the power off button is located in case of

emergency.

b) Always disconnect the machine from the power source before making
any repair, adjustment, or when installing or removing tooling.

c) Do not wear gloves, loose sleeves, jewelry, or unrestrained hair

styles as they could get caught in the rotating elements of the machine.

d) Wear long hair in a bun so it is not caught in the rotating elements of

the machine.

e) Wear safety glasses to protect the eyes from chips.

ii
RESTRICTED
 RESTRICTED

f) Always keep the belt assembly enclosed when running, to prevent in-
running nip points from causing injury.

g) Always secure work to mill table. Never mill loose work. Never secure
the work with hands.

h) Always check validate spindle speed with the end mill size and type
of material before beginning the milling process.

j) Do not operate while under the influence of drugs or alcohol

Experimental Procedures.

k) Put on all safety equipment and tieback loose hair or clothing before
operating machine.
l) Check to make sure all parts of machine are working and functioning
properly.

m) Double check all measurements for operating machine on work

piece.

n) If spindle speed needs to be changed.

Experimental procedure : Disconnect the machine from the power source.

a) Loosen the motor mount lock lever, and pull motor toward head
casting to release tension on the v-belts.

b) Release belt cover latches and slide the pulley guard open.

c) Arrange the v-belts on the pulleys for the desired spindle speed.

d) Look at the speed chart on the front face of the machine for the
correct pulley and v-belt configuration.

e) Push motor away from head casting and lock motor mount lock lever.

f. Note: For best results, all milling operations should be done with the
spindle as close to the head assembly as possible.

g) Lock spindle and table in place before operating.

h) Position work piece as desired and clamp to table.

j) Make sure all safety equipment is on correctly and put safety guards
into position.

k) Start machine by pressing the on button.

l) Use machine to mill work piece as desired.

m) When finished, turn off milling machine right away.

ii
RESTRICTED
 RESTRICTED

n) Wait until spindle has completely stopped before unclamping work

piece.

P) Clean machine after use and dispose of debris.

Work as group member of pump machining team :

a) Isolate pump electrical circuit breaker on main switch board and

attach a warning notice. (Do Not Operate-Men at Work).

b) Switch off and lock pump supply at its local supply panel. Attach a
warning notice to pump local supply panel.

c) Close suction and discharge valves, chain and lock hand wheels.

d) Open pump suction and discharge pipe drain valves to bilge and
when water ceases to flow; crack open the pipes / pump flange joints
carefully to ensure that pump has drained off and is safe for opening.

e) Fix a shackle to lifting pad eye above pump and hang chain block;
ensuring SWL of block, slings and shackles are satisfactory.

f) Use a center-punch to match/mark coupling and casing, then remove

the coupling bolts.

g) Disconnect, fix i/d tag and remove motor supply cables; taping over
bare ends with insulating tape.

h) Connect shackle and sling to motor eyebolt and lift motor clear of
pump using overhead chain block. Lay motor on its side out of harm’s way,
protecting machined surfaces on both pump and motor coupling halves
against damage. (Cardboard and masking tape is quick and efficient
method.)

j) Disconnect all external fittings from pump casing e.g. cooling pipe,
pressure gauge, oil reservoirs and air cock.

k) Remove bolting from top cover and remove cover. Scrape off old
gasket and check mating surfaces, and renew gasket on assembly. (Light
smear of grease on gasket / faces)

l) The pump shaft with impeller can be lifted out of casing.

m) Dismantle the impeller, and remove the wear ring.

n) Remove the gland packing and disregard; replacing it on rebuild.

Remember to cut ends of packing at 45° and stagger joints when repacking
gland.

ii
RESTRICTED
 RESTRICTED

Safety in machining operation :

a) Ensure that the guards are in position and in good working condition
before operating.

b) Know the location of emergency stop switch.

c) Do not wear loose clothing or jewelry that can be caught in the

rotating parts.

d) Confine long hair. The keys and adjusting wrenches must be

removed from
e) the machine before operating it. Stop the machine before measuring,
cleaning or making any adjustments.

f) Do not handle metal turnings by hand as they can cause injury. Use
brush or rake to remove turnings.

g) Keep hands away from the cutting head and all moving parts.

h) Cutting tools and blades must be clean and sharp, so that they can
be used without force. Avoid awkward operations and hand positions. A
sudden slip could cause the hand to move into the cutting tool or blade.

j) Keep work area clean. Floors must be level and have a non-slip
surface.

k) There must be enough space around the machine to do the job

safely. Safety precautions while working with machinery

l) The person working with the machine must not be distracted.

m) Machines must not be left unattended. Switch off the machine before
leaving.

n) Rotating parts of machines must not be stopped with hands after

switching off

p) Compressed air must not be used to clean machines, as this can

force small particles to fly off and can cause injury.

ii
RESTRICTED
 RESTRICTED
CHAPTER-4

Name of Experiment : Pipe fabrication ,bending ,measuring ,joining , pickling

and testing.
Aim of experiment.
a) To acquire knowledge about skill in chipping ,machining.
b) 3.To enhance the technical skill.
c) To knowledge about the banding pipe different size.
d) To knowledge about pressure testing as the dimension.

Required items:
a) Hammer
b) pipe
c) Tem plate
d) Wooden plug
e) Dry sand
f) Banding disk
g) Prevot,etc

Pipe bending procedure in hydraulic pipe bending machine:

a. At first collect the actual size pipe which is to be bent.

b. Then set the machine vice according to the dia of the pipe.
c. After that we will ensure the Electrical supply is on in the machine.
d. Then we can start the hydraulic pipe bending machine.
e. After that we can start the hydraulic motor.
f. Then we must set the necessary data to the machine monitor. Set the
necessary angle how much we need.
g. Then open the machine vice and set the pipe to the vice properly. After
that we should close the machine vice.
h. Then press the Forward button until the pipe is fully bent. After that again
press return button.
i. Then open the machine vice and remove the pipe from the machine vice.

As this way we can bend a pipe easily in the Hydraulic Pipe Bending Machine.

ii
RESTRICTED
 RESTRICTED
Example: Calculate the total length of pipe required to bend a pipe through 90° to a
radius of 50mm. To carry out this calculation we must find the length of the
circumference and divide it by 4:
If, R = 50
D = 100mm
Then, C = π D
Therefore: C = 3.142 X 100mm C = 314.2mm
Length of pipe required = 314 ÷ 4
=78.5 Which can be written as 79mm.

Pipe renewal procedure:

a. At first identify the fault of the pipe.

b. If the pipe condition is very poor it should be renewed.
c. Make a template of the damage pipe.
d. Then collect all necessary tools to repair this job.
e. Collect a new pipe. New pipe should also same Dia and Length as size
as damaged pipe.
f. set the pipe in bending machine with proper size of disk
g. Bend the pipe according to the template.
h. Then new pipe set to the working place.
i. Then tight all necessary Nuts & Bolts properly.
j. At last check the pipe joint for any leakage.
k. If there is no leakage it is completed to use.

safety precaution for pipe bending/renewal :

The following are some of the important safety measures that should be followed
while using
a. Check the pipe bender thoroughly. Check for any damage or defect. Make
sure to do this check every time while using the pipe.
b. Make sure that the roller shafts are properly pinned, prior to using the pipe.
Also, ensure that the bending die is properly seated, so that there is no
mishap.
c. The pipe should be cleaned regularly, so that its performance is not lowered.
d. Always remember to keep your hands away from the die and rollers while
you are bending the pipe.
e. It is always recommended to consult a professional when it comes to
maintaining and lubricating the hydraulic unit.
f. Always use the right hydraulic oil during the maintenance.
g. You should only use hydraulic oil. Avoid using brake fluid.
h. If you find the pipe bender in a damaged state, you should not use it.
i. You should never exceed the rated capacity of the hydraulic units.
j. Use the hydraulic pipe bender only for the purpose it is meant for, and not
for any other purpose.
k. You should not change the valve settings of pressure control.
l. Always make sure that you store the hydraulic pipe in a cool and dry place
when it is not in use. This prevents moisture and formation of moss on the
pipe.
m.Read and understand the instruction manual before using the pipe bender.
n. In order to ensure performance, make sure that all the shafts are fitted
correctly and the pip rollers are in the right holes.

ii
RESTRICTED
 RESTRICTED
o. For achieving the right degree of bend, you should ensure that the pump
and valve handle are in the correct position
p. It is always recommended to replace the hydraulic oil every year.
q. While using the high pressure hose, you should make sure that both the
ends are clean otherwise the pipe bender will not operate properly.
r. Do not take off the nameplates and labels because they include important
safety instructions.
The hydraulic pipes come in different shapes and sizes. Thus, it is required to
take the actual equipment into account while following the aforementioned
safety.

Pipe Bending of hydraulic bending machine :

Figure : Hydroulic pipe bending machine

Pipe bending procedure in hydraulic pipe bending machine:

a) At first collect the actual size pipe which is to be bent.
b) Then set the machine vice according to the dia of the pipe.
c) After that we will ensure the Electrical supply is on in the machine.
d) Then we can start the hydraulic pipe bending machine.
e) After that we can start the hydraulic motor.
f) Then we must set the necessary data to the machine monitor. Set the
necessary angle how much we need.
g) Then open the machine vice and set the pipe to the vice properly. After
that we should close the machine vice.
h) Then press the Forward button until the pipe is fully bent. After that again
press return button.
i) Then open the machine vice and remove the pipe from the machine vice.

As this way we can bend a pipe easily in the Hydraulic Pipe Bending Machine.

Example: Calculate the total length of pipe required to bend a pipe through 90° to a
radius of 50mm. To carry out this calculation we must find the length of the
circumference and divide it by 4:
If, R = 50
D = 100mm
Then, C = π D
Therefore: C = 3.142 X 100mm C = 314.2mm
Length of pipe required = 314 ÷ 4
=78.5 Which can be written as 79mm.

ii
RESTRICTED
 RESTRICTED

Pipe renewal procedure:

a) At first identify the fault of the pipe.
b) If the pipe condition is very poor it should be renewed.
c) Make a template of the damage pipe.
d) Then collect all necessary tools to repair this job.
e) Collect a new pipe. New pipe should also same Dia and Length as size
as damaged pipe.
f) set the pipe in bending machine with proper size of disk
g) Bend the pipe according to the template.
h) Then new pipe set to the working place.
i) Then tight all necessary Nuts & Bolts properly.
j) At last check the pipe joint for any leakage.
k) If there is no leakage it is completed to use.

safety precaution for pipe bending/renewal :

The following are some of the important safety measures that should be followed
while using
a) Check the pipe bender thoroughly. Check for any damage or defect. Make
sure to do this check every time while using the pipe.
b) Make sure that the roller shafts are properly pinned, prior to using the pipe.
Also, ensure that the bending die is properly seated, so that there is no
mishap.
c) The pipe should be cleaned regularly, so that its performance is not lowered.
d) Always remember to keep your hands away from the die and rollers while
you are bending the pipe.
e) It is always recommended to consult a professional when it comes to
maintaining and lubricating the hydraulic unit.
f) Always use the right hydraulic oil during the maintenance.
g) You should only use hydraulic oil. Avoid using brake fluid.
h) If you find the pipe bender in a damaged state, you should not use it.
i) You should never exceed the rated capacity of the hydraulic units.
j) Use the hydraulic pipe bender only for the purpose it is meant for, and not
for any other purpose.
k) You should not change the valve settings of pressure control.
l) Always make sure that you store the hydraulic pipe in a cool and dry place
when it is not in use. This prevents moisture and formation of moss on the
pipe.
m) Read and understand the instruction manual before using the pipe bender.
n) In order to ensure performance, make sure that all the shafts are fitted
correctly and the pip rollers are in the right holes.
o) For achieving the right degree of bend, you should ensure that the pump
and valve handle are in the correct position
p) It is always recommended to replace the hydraulic oil every year.
q) While using the high pressure hose, you should make sure that both the
ends are clean otherwise the pipe bender will not operate properly.
r) Do not take off the nameplates and labels because they include important
safety instructions.
s) The hydraulic pipes come in different shapes and sizes. Thus, it is required
to take the actual equipment into account while following the
aforementioned safety measures.

ii
RESTRICTED
 RESTRICTED

Pipe joints : In plumbing system it is require to joint pipe. To joint in following

ways:
a) Flange system
b) Threading system.
c) Hose system.
d) Welding system
e) Brazing system
f) Coupling system

Use of pipe on board ship :

1. Fresh water, Oil line ………………… Copper/GI pipe.

2. Sea water ……………………………. Copper/Nickel, Ferrous.
3. HP air ………………………..………. Copper-Nickel pipe.
4. Steam, LP air ………………..………. Seamless carbon steel pipe.
5. Steam, medium pressure ……………………….. Carbon steel pipe.
6. HP hydraulic ………………………………. Seamless steel pipe.
7. Drain line …………………………………… MS

Composition of Metal :

1) Brass= Copper- 70%

Tin- 01%
Zinc- 29%
2) Bronze= Copper- 90%
Tin- 09%
Lead- 01%
3) Gun Metal= Copper- 88%
Tin- 10%
Zinc- 02%
4) White Metal= Copper- 06%
Tin- 78%
Lead- 04%
Antimony- 12%
5) Mild Steel= Iron- 98.9%
Phosphors- 0.5%
Suppler- 0.6%
6) Stainless Steel = Iron- 74%
Chromium- 16%
Nickel- 08%
Carbon- 02%
7) Cast Iron= Iron- 98%
Carbon-02%civil
8) Bell Metal= Copper-80%
Tin-20%

ii
RESTRICTED
 RESTRICTED
Purpose of valve test : The purpose of these procedures is to ensure that
pressure tests are conducted safely and effectively. They cover pressure testing of
new and existing pressure systems or components at a test pressure more than 0
psig. They apply to mechanics, supervisors, inspectors, custodians, and
subcontractors responsible for pressure tests.

Procedures : Pressure tests are performed to ensure the safety, reliability, and
leak tightness of pressure systems. A pressure test is required for a new pressure
system before use or an existing pressure system after repair or alteration. There
are two methods for pressure tests: hydrostatic and pneumatic. A hydrostatic test is
performed by using water as the test medium, whereas a pneumatic test uses air,
nitrogen, or any non-flammable and nontoxic gas. At SLAC pressure tests must be
hydrostatic unless pneumatic tests can be justified. Pressure tests must always be
performed under controlled conditions, following an approved test plan, and
documented in a test record. A single approved test plan may be used for several
similar tests, but a separate test record is required for each.

Pneumatic pressure Test Procedure : Pneumatic tests are potentially more

dangerous than hydrostatic because of the higher level of potential energy.
Pneumatic tests may be performed only when at least one of the following
conditions exists: When pressure systems are so designed that they cannot be
filled with water. When pressure systems are to be used in services where traces
of the testing medium cannot be tolerated. Using a pneumatic test instead of
hydrostatic requires approval by the pressure systems program manager. In
addition to a justification, a piping schematic for pneumatic pressure test is
required. A recommended typical piping schematic for pneumatic test is shown in
Figure 1. Important Installation of a pressure relief valve is required for a pneumatic
test.

ii
RESTRICTED
 RESTRICTED

Figure : Pneumatic pressure Testing

Name of Experiment: valve overhauling

Aim of experiment.
a) To acquire knowledge about skill in valve overhauling.
b) 3.To enhance the technical skill.
c) To knowledge about pressure testing as the dimension.

Required Items:
a) Hammer.
b) Chisel.
c) screw driver.
d) spanner( open, ring, adjustable ,as per size).
e) Hydraulic packing / towing.
f) Packing removal bar.
g) Grassed.
h) Joint and grinding paste ,etc.

ii
RESTRICTED
 RESTRICTED

Testing of the Valves :

The testing of the valves can be done in a similar way as the globe valves. In brief the valve
should be filled up with water and then air should be given from the other side. The
presence of air bubbles would indicate bad sealing and must be rectified. Remain that
pressure test minimum 5 to 10 bar.

Precaution:

a) Always wear eye protection or safety goggles.

b) Wear leather aprons to protect chest and lap when standing or sitting.
c) Always wear safety gloves.
d) If any injury occurred, take first aid immediately and inform your concern
authority

Valve Testing :
Valve Leakage Tests Explained: All valves are inspected and tested by the
manufacturer to ensure that they conform to the required valve leakage standards.
In addition, optional testing can be requested by the purchaser, and regular testing
is critical for ongoing valve maintenance and safety. In many cases it is
recommended that valves are tested at an interval of no longer than 12
months. However, the specific interval may vary based on the valve condition, the
service condition, and the desired level of performance

Valve leakage is tested using either a hydrostatic test (i.e., the test medium is a
liquid, such as water or kerosene) or a pneumatic test (the test medium is a gas,
such as air or nitrogen). Zero leakage is rarely if ever possible, so the standards
define the maximum allowable leakage (MAL) for valves under the specified testing
conditions.

ii
RESTRICTED
 RESTRICTED
For both hydrostatic and pneumatic tests, the MAL is usually defined by valve size
—a small amount of leakage through a valve with a small effective orifice poses
much more risk than would the same amount of leakage through a valve with a
large effective orifice. MAL may also be a function of the valve class and pressure
category.

Valve leakage test results can vary based on the technique of the tester, so it’s
essential to have your valves tested by trained, highly qualified technical

Valve testing procedure : A typical hydrostatic valve test follows these basic
steps:

a. The valve body is filled with the testing fluid at the specified temperature.
b. The specified pressure is applied for the specified length of time (usually
at least 1 minute).
c. Leakage is measured across the valve element of interest (e.g., stem,
seat, closure mechanism) using both measuring instruments and visual
examination. Most valve standards specify that no visually detectable
leakage is allowed.
d. A visual inspection is performed to ensure the valve has not been
damaged during the testing procedure.

Types of valve leakage tests : The tests that must be conducted depend on the
type of valve and, therefore, the valve elements. Below are some of the most
commonly performed tests of valve leakage.
a. Valve seat leakage tests are required for pressure relief valves.
b. Backseat tests are required for valves with a backseat element,
including gate and globe valves.
c. Closure tests are required to test the closure mechanism of several
types of valves, including gate, globe, plug, check, and ball valves.
d. Shell leakage tests are required for valves that are used in “full open”
and “full closed” service, such as check, stop, and isolation valves.

Name Of Experiment: Rudder Maintenance :

Rudder : The rudder is used to steer the ship. The turning action is largely
dependent on the area of the rudder. The required area of the rudder varies with
different type of vessels since desired maneuvering ability differs considerably and
the general ship design may imposed restriction.

ii
RESTRICTED
 RESTRICTED

Figure: Rudder

Types of Rudder: By the function there are three types of rudder generally used in
vessels. such as:
1. Unbalanced Rudder

2. Balanced Rudder

3. Semi balanced Rudder

Area of Rudder : There are regulations for the area of rudder but at has been
found in practice that an area between one sixtithe and one seventith of the
produce of the length and drought of the ship provides ample maneuverability for
deep sea vessels.
a. For slow ship rudder area= 1/70 x L x D

b. For fast ship rudder area= 1/60 x L x D

c. And the area of the rudder is= 1/16 of immerser suction area

Constructions of Rudders:
The rudder frame may be of forged cast steel or it may be built of Wes
plates welded together.
The plating is usually welded to the frame slot weld of continuous butt weld
are commonly used for the purpose. When plate frames are used flat bars are
welded to their edges to take the slot welds.
Common damage found the Rudder parts:
a) Large clearance between rudder pitch and gudgeous

b) Corrosion build on the rudder head stock.

c) Cracking, bending, or fractureto the rudder journal.

d) Increasing the bush clearance.

ii
RESTRICTED
 RESTRICTED
e) Misalignment occurs the pentle hole.

f) Bending, cracking of the rudder blade due to wave action.

g) corrosion attack in the rudder blade.

Parts of rudder :
a) Rudder stock
b) Rudder blade
c) Roller bearing
d) Ball bearing
e) Bush bearing
f) Tiller
g) Key
h) Stuffing box
i) Thrust washer
j) Connecting rod
k) Packing
l) Seal rubber.

Rudder operating system :

a. Manual system.
b. Hydraulic system.
c. Electro hydraulic system
d. Electric system.

Common defect of rudder :

a. Rudder stock bent.
b. Rudder stock perforated/pitted/cracked in places.
c. Stock broken
d. Rudder blade perforated/pitted/cracked in places.
e. Rudder bush bearing wear down
f. Excessive clearance between bush and stock.
g. Packing torn out.
h. Tiller bend
j. Stock key damaged.
k. Flange coupling bolt & nut broken.
l. Thrust washer worn out.
m. Bearing damaged.
Rudder removal procedure:
a. Firstly, ‘I- hook’ to be fitted at rudder blades and bottom portion of the
ship as required.
b. Proper capacity chain block fitted with the rudder and blades.
c. Removal the out fittings of rudder.
d. Removed the connecting rods.
e. Removed the tiller
f. Removed the key.
g. Removed the gland of the stuffing box.
h. Removed the packing/seal.
j. Removed the bearing cover and bearing.
k. Removed the thrust washer/ring.
l. Removed the rudder blades.
ii
RESTRICTED
 RESTRICTED

Rudder refitting procedure :

a. Firstly, ‘I- hook’ to be fitted at rudder blades and bottom portion of the ship
as required.
b. Proper capacity chain block fitted with the rudder and blades.
c. Rudder stock refitted.
d. Rudder blades refitted.
e. Bearing and bearing cover refitted.
f. Rudder gland replaced.
g. Thrust washer/ring refitted.
h. Key refitted.
j. Tiller refitted.
k. Connecting rod refitted.
l. Gland repacked with new packing.
m. Out fittings refitted.
n. Test & trial to be carried out.

Measuring clearances of rudder bearing and bush material

Rudder Clearance:

Pads are welded to the hull and rudder. A clearance is given ( sometimes referred
to as the jumping clearance). As the carrier wears this clearance will increase.

The jumping clearance is required to prevent damage to the steering gear,

regardless of rudder type. Therefore the maximum jumping clearance should
always be less than the clearance between tiller and steering gear. An increasing
jumping clearance can indicate that the bearing wear is excessive.

Steering gear Clearance :

Direct measurement can be taken from the steering gear assembly. Shown below
is one example, here the clearance will be seen to reduce as the carrier wears and
impact his has on the system can be directly judged.

Rudder clearances :

Rudder and steering gear arrangements may have different wear criteria
depending on the manufacturer. These calibration and running clearance limits
should be checked (normally indicated on drawings).

Some points to consider:

ii
RESTRICTED
 RESTRICTED
Dimension (2) should be sufficient to cater for wear in carrier bearing and
substantially greater than riding washer clearance (5).

Usually (1) and (2) are of the order 20 mm/25 mm on a small/medium size vessel.

If the riding washer clearance has reduced then the carrier bearing is wearing or
the skeg is set up. Check for reduction in steering gear crosshead dimension (2) to
verify downward displacement.

These limits do not only take into consideration the functioning of the bearing but
also the effects of “hammering” and damage to the rudder itself as clearances
increase. See manufacturer’s recommendations for special rudder designs or the
use of synthetic bearing materials. To avoid jamming and premature failure
renewed bearings should have adequate clearance. Special care is required with
those synthetic materials which swell. Rudder should always be swung in dock
when possible after repair to check free movement.

Rudder bush materials:

a. Gun metal
b. Rubber
c. Wooden
d. Bronze

Capstan:
A capstan is a type of device used on ships to wound the cables and ropes during
anchoring. Capstans are to old wooden ships what windlasses are to modern
ships. Read this article to find out the difference between a capstan and a
windlass.

Capstan Vs Windlass:

As time passed, capstans were completely made from iron and steel. Gears were
used at the head of the capstan to provide a mechanical advantage when the bars
were pushed anti-clockwise. Even though things improved, capstans still used to
be driven by human power, making their usage stressing and difficult.

However, in the modern ships, the traditional capstans are replaced by

hydraulically or pneumatically operated windlass. A windlass is a complex device
meant for the same purpose as that of capstan, but comprised of different parts,
which together make the anchorage process smoother and easier. A capstan
differs from a windlass only in the matter of the axis on which the rope or cable is
wound (for a capstan it’s vertical axis, whereas for a windlass it’s horizontal)

ii
RESTRICTED
 RESTRICTED

Overhauling Procedure of Capstan :

a) At first Capstan should be removed.

b) Separate Gearbox from motor.
c) Open side cover.
d) Remove all seal.
e) Open main cover.
f) Remove bearing to open serclip.
g) Then sequencely dismantle shaft, Gear worm & wheel.
h) All parts to be clean & examined.
i) To repair/replace/renewal damage/defected parts, if required.
j) At last assemble/refitting all parts in sequencly.
k) Re-fitting G/box on board ship & should be carried out test trial.

Renewal procedure of brake liner as bellow :

a) Generally Brake ‘shoe’ Attach to liner with riveting system, for that brake
‘shoe’ remove from brake liner by hammer chisel.

b) Clean brake ‘shoe’ properly.

c) Select same dimension brake liner which liner was defected if brake liner
measurement is not correct the brake will not correct. The brake will not
work properly.

d) Brake ‘shoe’ Attach tightly with the liner by hand vice.

e) Then Drilling operation cashed out on brake liner by electric hand drill
machine.

f) Counter holes on the holes should be done so that the head of the revet is
inside the line.

g) With a table vice to the same size of the rivet head.

ii
RESTRICTED
 RESTRICTED
h) Then gradually riveting work will be done by hamming and brake line fitted
with brake shoe

i) Finally brake shoe refitting on board ship carried out test trial.

Name of Experiment : pneumatic and hydraulic system

Examples of Hydraulic & Pneumatic Systems :

The brakes on your car are hydraulically operated; the garbage truck that passes
weekly by your house uses hydraulic power to compact trash. Your mechanic uses
a hydraulic lift when working on the underside of your car.
Pneumatic systems are equally widespread. Trucks and buses use air-actuated
brakes. Spray painters use compressed air to spread paint. Ever been irritated in
the morning by the sound of a jackhammer? That's a pneumatic machine hard at
work using compressed air .

Definition of Hydraulic System :

In 1647, French mathematician Blaise Pascal developed a principle of fluid
mechanics known as Pascal's law. It states that when pressure is applied at any
point in a confined fluid, the pressure will increase equally at every point in the
container. As convoluted as this principle may sound, it's the basis for the
operation of a hydraulic system.
Suppose you have a hollow cylinder that has a piston with an area of 2 square
inches and it receives an input force of 100 pounds. This results in a pressure of 50
pounds per square inch (100 pounds/2 square inches).
This pressure gets passed by the hydraulic transmission system to another
cylinder, known as an actuator, which has a piston with an area of 6 square inches.
At 50 psi, this cylinder now has an output force of 300 pounds (50 psi X 6 square
inches).

Pascal's Law Applied to a Hydraulic System :

Pascal's Law gives hydraulic systems their advantage. A minimal input to a small
device can result in a larger force output in a bigger actuator. It's a simple way of
multiplying the output force sufficient to handle heavy workloads.
Since hydraulic systems can operate at pressures up to several thousand psi, the
output force at the actuator can be huge. With this higher force output, the
mechanical actuator now has the power to perform heavy lifting, pushing and
moving tasks, such as earthmoving.

ii
RESTRICTED
 RESTRICTED

Working Procedure of Hydraulic System :

A hydraulic system uses a transmission network to carry a pressurized fluid that
drives hydraulic actuators. The hydraulic fluid gets its pressure from a pump driven
by a prime mover, such as an electric motor or a gas/diesel engine. The
pressurized oil is filtered, measured and pushed out through the transmission
system to an actuator to perform some action. Afterward, the fluid returns under
low pressure to a reservoir where it's cleaned and filtered before returning to the
pump.
Hydraulic systems are used in manufacturing and production plants, such as the
steel and automobile industries, to operate all types of mechanical equipment.
They're used to move, push and lift materials in industries like mining, earthmoving
and construction.
Basic Components of a Hydraulic System :
Hydraulic oil : Hydraulic fluids are non-compressible and have low flash points.
A reservoir : The reservoir holds the fluid for the system. It has space for fluid
expansion, lets air entrained in the liquid escape and helps the liquid to cool. Fluid
flows from the reservoir to the pump, which forces it out through a piping network
and, ultimately, back to the reservoir.
Filtering devices : Small metal particles and other foreign matter usually find their
way into the fluid. The hydraulic system uses several filters and strainers to remove
these foreign particles. Fluid contamination is one of the most common sources of
problems in a hydraulic system.
A prime mover : Electric motors or gas-powered diesel engines are used to drive
the fluid pump.
A pump : The pump draws the fluid from the reservoir and forces it through a
pressure-regulating valve and out the transmission network to the actuators.
Connectors : A network consisting of pipes, tubing and flexible hoses transports
the fluid to the mechanical actuators.
Valves : Various valves control the amount of fluid flow, its pressure and
direction.
Actuators : Actuators are the devices that perform work motions. They can be
rotary, such as a hydraulic motor, or linear, like a cylinder

Advantages of a Hydraulic System :

A hydraulic system has numerous advantages over pneumatic and other types of
mechanical drive systems because it:
a) Uses small components to transfer large forces with consistent power
output.
b) Has actuators that are capable of precise positioning.
c) Is able to start up under heavy initial loads.
ii
RESTRICTED
 RESTRICTED
d) Produces even and smooth movements under varying loads since the fluids
aren't compressible and flow rates can be accurately controlled with valves.
e) Delivers consistent power at moderate speeds compared to pneumatic
systems.
f) Is easy to control and regulate with pressure, directional and flow control
valves.
g) Dissipates heat easily and quickly.
h) Performs well in hot environments.

Disadvantages of Hydraulic Systems :

a) Pumps, valves, transmission networks and actuators are expensive.
b) They can pollute the workplace with leaks, which may cause accidents or
fires.
c) They're not suitable for cycling at high speeds.
d) Hydraulic fluids are sensitive to dirt contamination and must be tested
regularly.
e) Ruptures of high-pressure lines can cause injuries.
f) Performance of hydraulic fluids is a function of changes in temperature,
which can cause changes in viscosity.

Kinds of Hydraulic Fluids : The most common hydraulic fluids are based on
mineral oils, polyalphaolefins and phosphate esters because of their low
compressibility. Water isn't suitable because it can freeze in cold temperatures and
boil in high-temperature environments. Water can also cause corrosion and rusting.

Hydraulic Fluids Purposes :

a) Transmit power and force through conductor lines to actuators to perform a
work motion.
b) Lubricate the components, devices, valves and actuators in the circuit.
c) Act as a coolant by transferring heat away from any hot spots in the system.
d) Seal clearances between moving parts to increase efficiency and lessen the
heat from excess leakages.

Properties of a Hydraulic Fluid :

Some of the properties and characteristics of a hydraulic fluid are as follows:
Viscosity : Viscosity is the internal resistance of a fluid to flow. It increases as the
temperature goes up. An acceptable hydraulic fluid must be able to provide a good
seal at piston, valves and pumps but not be so thick that it impedes liquid flow.
Fluids with high viscosities can lead to power loss and higher operating
temperatures. A fluid that's too thin can cause excessive wear of any moving parts.
Chemical stability : A hydraulic fluid must be chemically stable. It has to resist
oxidation and be stable under severe operating conditions, such as high
temperatures. Operating for long periods of time at high temperatures can shorten
the useful life of the fluid.

ii
RESTRICTED
 RESTRICTED
Flash point : A flash point is the temperature when a fluid turns into a vapor in a
sufficient volume to ignite or flash in contact with a flame. Hydraulic fluids need a
high flash point to resist combustion and exhibit a low degree of evaporation at
normal temperatures.
Fire point : Fire point is the temperature where a fluid vaporizes in a sufficient
volume to ignite when exposed to a flame and continue to burn. As with the flash
point, an acceptable hydraulic fluid must have a high fire point.

Definition of Pneumatic System :

Pneumatic systems are like hydraulic systems, but they use compressed air
instead of a fluid to transmit power. They rely on a constant source of compressed
air to control energy and actuate motion devices.
Manufacturing plants use compressed air to drive pneumatic drills and presses and
to lift objects and move materials. Fabrication shops use a pneumatic machine to
hold unfinished products for welding, brazing and forming operations.

Components of a Pneumatic System :

Air compressor : The air compressor draws air from the atmosphere, pressurizes
it and stores the compressed air in a tank for release to the transmission system.
Prime driver : A prime driver, such as an electric motor or a gas-powered engine,
provides the power to an air compressor.
Control devices : Valves regulate the pressure and control flow and direction.
Air tank : A tank holds compressed air for delivery to mechanical devices.
Actuators : These are devices that take the energy from compressed air and
convert it into mechanical movements.
Transmission system : A network of pipes and tubing transports the compressed
air to actuators.

Advantages of Pneumatic Systems :

Efficiency : The supply of air is free and unlimited. Compressed air is easy to
store, transport and can be released to the environment without costly treatments.
Simple Design : The configuration and components of a pneumatic system have a
simple design and are easy to maintain. They're more durable and aren't easily
damaged.
The ability to operate at higher speeds : Pneumatic systems can operate
actuators at more rapid cycles, such as in packaging production lines. Linear and
oscillating movements are easy to adjust by using a pressure-regulating valve to
control flow rate and pressure.
Cleanliness : No risk of leaking hydraulic fluids that pollute the environment.
Pneumatic systems are preferred in workplaces that need high levels of
cleanliness. Exhaust air devices clean up the air being released back into the
atmosphere.
ii
RESTRICTED
 RESTRICTED
Less Costly : Pneumatic components are less expensive, and compressed air is
widely available in manufacturing areas. Maintenance costs are lower compared to
hydraulic systems.
Safer to operate : Pneumatic systems are safe to use in inflammable
environments without dangers from fire or explosions. Pneumatic components
don't overheat or catch on fire when overloaded.
Able to function in harsh environments : Dust, high temperatures and corrosive
environments have less effect on pneumatic systems compared to hydraulics.

Advantages of Pneumatic Systems :

a) Light weight equipment.
b) No return lines for the used fluid .
c) Infinite control of speed and pressure .
d) Faster speeds possible .
e) Instant stopping starting and change of direction .
f) Transmission of large forces .
g) Easy installation of lines at any desired angle .
h) Cheaper system as air is free .
i) Storage facilities required only for compressed air .
j) No environment impact and safe to use in explosion prone
areas .
k) No effect due to temperature variations up to 120 deg C .
Disadvantages of Pneumatic Systems :
Reduced power : Pneumatic systems typically operate at less than 150 psi and
provide less total force at actuators. Pneumatic cylinders are usually small and
don't have the power to handle heavy loads.
Noisy : Air compressors generate more noise, and compressed air is noisy when
it's released from the actuators.
Rough movement : Because air is compressible, the motion of pneumatic
actuators can be rough, which reduces the accuracy of the movements of the
system. Piston speeds are uneven. Hydraulics movements are smoother.
Need pre-treatment of air : Before use, air needs processing to remove water and
dust particles. If this isn't done, the increased friction between the control devices
and moving components will wear out the part and require premature repair or
replacement.
Hydraulic Systems versus Pneumatic Systems :
Hydraulic actuators are more suitable for operations that need high force. They're
rugged and can produce forces up to 25 times greater than a pneumatic actuator
with the same size piston. Hydraulic systems can also operate up to 4,000 psi.
Pneumatic actuators are usually less than 150 psi.
The compressibility of air and pressure losses reduce the efficiency of pneumatic
systems. The compressor must run continuously to maintain pressure in the lines
even when the actuators aren't moving; hydraulic systems can hold constant
pressure without the pump running.

ii
RESTRICTED
 RESTRICTED
CHAPTER-5

Operation and maintenance of Lathe Machine.

Lathe Machine: Lathe is a power driven. General purpose machine tool used for
producing cylindrical work pieces. Both inside and outside surface can be
machined on a lathe. By using attachment and accessories other operation. Such
as drilling, reaming, boring, taper and angle turning, screw thread cutting, form
turning, milling, knurling, grinding and polishing may be performed.

As the work pieces to be machined is rotated in the lathe while single point cutting
tool removes the material by traversing in a direction parallel to the axis of rotation.

Figure: Lathe Machine

Types of lathe Machine : There are various types of lathe. Such as ;

a. Engine lathe
b. Center Lathe
c. Precision lathe
d. Watch makers lathe
e. Surfacing & Boring Lathe
f. Turret Lathe
g. Capstan Lathe

Main Parts Of Lathe Machine :

a. Head stock
b. Tail Stock
c. Bed
d. Carriage
e. Saddle
f. Tool Rest
g. Lead Screw
h. Feed Rod
i. Power Feed & Thread Cutting Mechanism
ii
RESTRICTED
 RESTRICTED
j. Cross Slide
k. Compound Rest
l. Follower Rest
m. Steady Rest
n. Gap Bed

Operation of Heavy Duty Universal Lathe Machine : The lathe is a machine tool
used principally for shaping pieces of metal (and sometimes wood or other
materials) by causing the work piece to be held and rotated by the lathe while a
tool bit is advanced into the work causing the cutting action.

a. Facing Operation.
b. Group Cutting.
c. Turning Operation.
d. Thread Cutting.
e. Taper Turning.
f. Radius Cutting.
g. Boring Operation.
h. Shaft Alignment Checking.
j. Drilling
k. Knurling
l. Reaming
a. Grooving
b. Parting Chamfering

Work holding device of lathe machine : The work piece is held by various types
of work holding devices depending on its shape, length, diameter and weight of the
work piece and the location of turning on the work. Chucks are efficient and
accurate devices for holding the work on the lathe during the operation.

a. Three Jaw chuck

b. Four Jaw chuck
c. Magnetic chuck
d. Collect chuck
e. Mendel
f. Face plate
g. Angle Plate
h. Steady Rest
i. Follower Rest

a. Three Jaw Chuck : A Three Jaw Chuck is a specialized type of clamp used to
hold an object with radial symmetry, especially a cylinder. It has three jaws. In drills
and mills it holds the rotating tool where as in lathes it holds the rotating work
piece. On a lathe the chuck is mounted on the spindle which rotates within the
headstock.

ii
RESTRICTED
 RESTRICTED

Figure: Three Jaw Chuck

b. Four Jaw Chuck : A Four Jaw Chuck is a specialized type of clamp used to
hold an object with radial symmetry, especially a cylinder. It has four jaws. In drills
and mills it holds the rotating tool where as in lathes it holds the rotating work
piece. On a lathe the chuck is mounted on the spindle which rotates within the
headstock.

Figure: Four Jaw Chuck

c. Magnetic Chuck : Concentric pole magnetic chucks are round chucks that are
used when the work piece needs to be rotated during machining. They have
magnetic poles that run concentric to each other throughout the diameter of the
chuck, and are separated from each other by a steel section.

ii
RESTRICTED
 RESTRICTED

Figure: Magnetic Chuck

d. Colet chuck : This type of chuck is versatile enough to be used in a wide range
of turning applications. However, it's not the best chuck for all jobs. The collet
chuck is an alternate work holding device that, like the jaw chuck, also uses
mechanical force to hold the part being turned.

Figure: Collet Chuck

e. Face Plate : A lathe faceplate is a basic work holding accessory for a wood or
metal turning lathe. It is a circular metal plate which fixes to the end of the lathe
spindle. The work piece is then clamped to the faceplate, typically using t-nuts in
slots in the faceplate, or less commonly threaded holes in the faceplate itself.

Figure: Face Plate

ii
RESTRICTED
 RESTRICTED

f. Angle Plate : An angle plate is a work holding device used as a fixture in

metalworking. The angle plate is made from high quality material that has been
stabilized to prevent further movement or distortion.

Figure-Angle Plate

g. Lathe Dog : A lathe dog, also known as a lathe carrier, is a device that clamps
around the work piece and allows the rotary motion of the machine's spindle to be
transmitted to the work piece. A carrier is most often used when turning between
centers on a lathe, but it may be used on dividing heads or any similar situation.

Figure: Lathe Dog

h. Steady Rest : Steady rest in a lathe or grinding machine in which long round
pieces of work may rotate but without eccentric movement. Steady Rest called also
center rest.

ii
RESTRICTED
 RESTRICTED

Figure: Steady Rest

i. Follower Rest : A tool rest that travels with the slide rest of a lathe. A rest that is
fixed as to position relative to a grinding wheel and used for supporting cylindrical
work etc.

Figure: Follower Rest

Centre use of Lathe machine : There are commonly two types of center use in
lathe machine.
a. Death centre
b. Live centre/ Ball bearing centre

a. Dead Centre : Dead centre is in the tail stock which is not revolving or rotating
where as live centre is in the head stock and this is revolving or rotating.

ii
RESTRICTED
 RESTRICTED

Figure: Death Center

b. Live centre/ Ball bearing centre : A revolving center, also known as a live
center in some countries, is constructed so that the 60° center runs in its own
bearings and is used at the non-driven or tailstock end of a machine. It allows
higher turning speeds without the need for separate lubrication, and also greater
clamping pressures.

Figure: Live Center/Ball Bearing Center

Maintenance of Heavy duty universal Lathe Machine:

a. Cleaning the Machine.

b. Maintenance Lube Oil Unit.
c. Maintenance Coolant Unit.
d. Maintenance carriage.
e. Maintenance headstock.
f. Maintenance tailstock.
g. Maintenance Electrical unit.
h. Maintain User Manual Properly.

ii
RESTRICTED
 RESTRICTED
CHAPTER-6

Operation and maintenance of Overhead Crane

Operation of Overhead Crane : Some of the most popular reasons for using an
overhead crane include:
a) Loading or unloading materials from a truck.
b) Moving materials around a facility more efficiently than a tow motor or
manpower can.
c) Flipping or pulling dies in and out of stamping machines at a
manufacturing facility.
d) Feeding raw material into a machine at a manufacturing facility
e) Moving pieces or parts down an assembly line in a controlled fashion
f) Moving containers around a shipyard or rail yard.
g) Lifting & Shifting the Job.
h) Shifting the Job Left, Right, Front & Back Accurately.
j) Maintain Low Speed & High Speed Properly.

Figure: Overhead Crane

Safety Precaution of Overhead Crane : Another advantage of installing an

overhead crane in a manufacturing, assembly, or warehousing facility. Cranes can
be used to lift and move materials in extreme environments and can handle
corrosive or dangerous materials like hot metals, chemicals, and heavy loads. A
workstation or jib crane can be put in place to help workers move heavy objects in
a controlled manner and help cut down on repetitive motion injuries and muscle
strains.

Maintenance of Overhead Crane.

a) Inspect all wearable items for signs of excessive deterioration or fatigue.
b) Inspect load chains and/or wire ropes.
c) Check all components requiring lubrication.
d) Check gear-boxes for proper oil levels.
e) Check control stations for safe operation.
ii
RESTRICTED
 RESTRICTED
f) Inspect all structures and supports for safe operation.
g) Test brakes for proper operation and adjust as needed.
h) Confirm the proper operation of all limit switches and safety devices.
i) Inspect all contactors and replace tips as needed.
j) Inspect and lube load hooks and other lifting devices.
k) Maintain a permanent maintenance record as required by OSHA.
l) Cleaning the Overhead Crane.
m) Oiling All Oiling Point.
n) Check Electrical Unit & Maintenance.
p) Cleaning the Rail & Check Alignment.
q) Maintain Load Test Every 01 Year.
r) Maintain User Manual Properly

ii
RESTRICTED
 RESTRICTED
CHAPTER-7

Operation and maintenance of Drill Machine

Drill Machine : machine in which the drilling head is mounted to slide along a
radial arm which can be rotated, raised, or lowered on a vertical mast to adjust the
position of the drill above the work piece.

Figure: Drill Machine

Operation of Drill Machine :

a. Drilling
b. Reaming
c. Boring
d. Counter boring
e. Counter sinking
f. Spot facing
g. Tapping
h. Trepanning

Operating Procedure:
a) On main switch.
b) On control panel switch.
c) Set drill bit & lower at the centre of hole to be made.
d) Set speed for drill.
e) Set gear for as per drill bit.
f) Start main motor for drill.
g) On pump motor for cooking fluid.

ii
RESTRICTED
 RESTRICTED

Stopping Procedure: a) Stop main motor switch.

b) Off main motor switch.
c) Off main switch.

Drilling Process :

Figure: Drilling Process

Reaming Process :

Figure. Reaming Process

ii
RESTRICTED
 RESTRICTED

Center Drilling Process :

Figure: Center Drilling Process

Drill Bit : Drill bits are cutting tools used to remove material to create holes, almost
always of circular cross-section. Drill bits come in many sizes and shapes and can
create different kinds of holes in many different materials.

Figure: Drill bit

Drill Bit Material :

a. High Speed Steel

b. Diamond Tool Steel
c. Carbon tool Steel

Cutting Angle Of Drill Bit : Cutting angle of drill bit is - 59 degree

Point angle of drill bit is - 118 degree.
Safety Precautions Of Drill Machine : Safety Precautions When Using Your Drill
Machine;

ii
RESTRICTED
 RESTRICTED
a. Wear Work Gloves. Power drills give off intense vibrations, especially on
high torque.
b. Wear Safety Goggles.
c. Wear Protective Clothing.
d. Turn Off the Drill before Changing Drill Bits.
e. Ensure that the Chuck is Tight before Using the Drill.
f. Use the Correct Drill Bit for Every Job.
g. Avoid Clogging or Binding of the Drill Bit.

Maintenance Of Drill Machine :

a. Cleaning the Machine.

b. Maintenance Lube Oil Unit.
c. Maintenance Coolant Unit.
d. Maintenance headstock.
e. Maintenance Electrical unit.
g. Maintain User Manual Properly.

ii
RESTRICTED
 RESTRICTED
CHAPTER-8

Operation and maintenance of Surface Grinding Machine.

Surface grinding Machine : Surface grinding is used to produce a smooth finish

on flat surfaces. It is a widely used abrasive machining process in which a spinning
wheel covered in rough particles (grinding wheel) cuts chips of metallic or
nonmetallic substance from a work piece, making a face of it flat or smooth.

Figure: Surface grinding Machine

Operation of Surface grinding Machine :

a. Surface grinding
b. Cylindrical grinding.
c. Center less grinding.
d. Form and profile grinding.
e. plunge cut grinding
f. Snagging
g. Off-hand.

Maintenance of Surface grinding Machine :

a. Cleaning the Machine.

b. Maintenance Lube Oil Unit.
c. Maintenance Coolant Unit.
d. Grinding Wheel dressing.
e. Maintenance Electrical unit.
f. Maintain User Manual Properly.

ii
RESTRICTED
 RESTRICTED

CHAPTER-9

Operation and maintenance of Tool Sharpening Machine :

Tool Sharpening Machine : Sharpening is the process of creating or refining a

sharp edge of appropriate shape on a tool or implement designed for cutting.
Sharpening is done by grinding away material on the implement with an abrasive
substance harder than the material of the implement, followed sometimes by
processes to polish the sharp surface to increase smoothness and to correct small
mechanical deformations without regrinding.

Figure: Tool Sharpening Machine

Tool Sharpening Machine :

a. Various size of Tool Sharpening.

Maintenance of Tool Sharpening Machine :

a. Cleaning the Machine.

b. Maintenance Lube Oil Unit.
c. Maintenance Coolant Unit.
d Grinding Wheel dressing.
e. Maintenance Electrical unit.
f. Maintain User Manual Properly.
g. Maintenance job clamping equipment

ii
RESTRICTED
 RESTRICTED
CHAPTER-10

Name of Experiment- Procedure of shaft trueness checking, Load Ring and

Piano Wire method.

0901. Aim of Experiment-

1. To acquire knowledge about shaft trueness checking, Load Ring and Piano Wire
method.
2. To enhance the technical skill.

0902. Theory- If we want to gain our knowledge, we should improve knowledge

on
Shaft trueness checking work and it is very important in practical work.

0903. Shaft trueness checking- To repair propeller shaft Shaft trueness checking
is a must. without shaft trueness checking we cannot be ensure of a perfect shaft.

0904. Instrument-

i. Hammer
ii. Chisel
iii. Screw driver
iv. Open spanner
v. Ring spanner
vi. Combined spanner
vii. Socket spanner
viii. T-Handle
ix. Vernier scale
x. Circlip plier
0905. Shaft Trueness Checking- The first practical difficulty lies in determining
where the shaft is bent since, when supported on steadies at each end, the whole
shaft sags by an amount which may be many times the actual deflection from truth.
To find the true shape of the shaft, the longitudinal plane in which the bend lies
must first be determined followed by the shape of the shaft when the apex of the
bend is in the highest and lowest positions. When the shaft is rotated
measurements are taken at the highest and lowest positions attained then for any
selected point along the shaft half the difference between the deflections observed
will be the true deflection from a straight line at that part of the shaft. When the high
spot has been found, the crest should be arranged at the top of the shaft, the
steadies being set approximately equidistant on either side and as far apart as
possible.

ii
RESTRICTED
 RESTRICTED

0906. Piano Wire method of Shaft alignment -

Fig: Piano wire method

Piano wire method: Produces fairly accurate results. Used where we can’t use
sophisticated methods like method of Flexible wire having uniform weight over its
length (piano wire) is used as a Reference line. Wire is tensioned to a standard
amount by fixing at one end and having a weight over pulley at the other end.

Items required :

A length of piano wire, Ball bearing pulley, anchoring or support clamp & weights.
Distance from wire to bearing are then measured either electronically or using
micrometer. Allowance being made for sagging of the wire. Maximum sag will
occur at the centre of the span if the pulley and support are horizontal. Flexible
wire having uniform weight over its length, when it ends are supported ----- curved
formed is a catenary which has certain mathematical property.

0907. Results-

Fig: Shaft trueness checking

ii
RESTRICTED
 RESTRICTED

0908. Discussion- Above this procedure we can check shaft trueness.

0909. Precautions-

i. Always wear eye protection or safety goggles.

ii. Wear leather aprons to protect chest and lap when standing or sitting.
iii. Always wear safety gloves.
iv. When we work with cutting tools, it should be taken highly safety so that
there is no injury.
v. If any injury occurred, take first aid immediately and inform your concern
authority.

ii
RESTRICTED
 RESTRICTED
CHAPTER-11

Name of Experiment- Procedure of pump test bench.

1001. Aim of Experiment-

1. To acquire knowledge about pump test bench.

2. To enhance the technical skill.

1002. Theory- If we want to gain our knowledge, we should improve knowledge

on
various pump test work and it is very important in practical work.

1003. Procedure of pump test bench- Pump is one of the most important
auxiliary machinery of main engine. When it gets problems we need to servicing
pump. After servicing we need to test the pump at the test bench.

1004. Instrument-

xi. Hammer
xii. Chisel
xiii. Screw driver
xiv. Open spanner
xv. Ring spanner
xvi. Combined spanner
xvii. Socket spanner
xviii. T-Handle
xix. Vernier scale
xx. Circlip plier

1005. Pump test procedure- Put the pump to the test bench. Following the
starting procedure, start the pump in engineeing workshop and observe if there is
any abnormal sound or symptoms from the pump. Check the input and discharge
pressure from the guage.

1006. Results-

ii
RESTRICTED
 RESTRICTED

Fig: Pump test bench.

1007. Discussion- Above this procedure we can test pump atthe test bench

1008. Precautions-

vi. Always wear eye protection or safety goggles.

vii. Wear leather aprons to protect chest and lap when standing or sitting.
viii. Always wear safety gloves.
ix. When we work with cutting tools, it should be taken highly safety so that
there is no injury.
x. If any injury occurred, take first aid immediately and inform your concern
authority.

ii
RESTRICTED