Lg Ecsu Ekg 170413

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ECSU (M & S)/Function 1 EKG/Vers No.1/April 2013 1

To Be A World Class Maritime Academy

LEARNING GUIDE

Name of Course : Combined Chief and Second

Engineer Unlimited Voyage

For 3000 kW or more

Course Code : ECSU

Module : Function 1 (EKM & EKG)

Subject : Marine Engineering (EKM/EKS & EKG)

Instructional Hours Lecture : 180 hours

Practical : 0

Total Contact Hours : 180 hours

Self Learning : 300

Total Hours : 480 hours

Entry requirements : Watchkeeping Engineer 750

kW or more

Subject Aims :

The course is designed to provide the students with the knowledge and

understanding necessary to prepare him/her for the Chief and Second Engineer

Officer (Motor/Steam) Certificate of Competency for Unlimited Voyages.

Teaching MethodThe course shall be conducted in a combination of classroom lectures, and self-

learning exercises.

Self learning topics are identified in italics.

Assessment MethodLecturers’ Class Assessment : 20%

Mid Course Test : 30%

Final Exam : 50%

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Recommended Texts

1.

Leslie Jackson and Thomas D Morton (2003), General Engineering

Knowledge for Marine Engineers, Adlard Coles Nautical.

2.

Dr J Cowley (1992), The Running and Maintenance of Marine

Machinery, Marine Management (Holdings) Ltd for The Institute of

Marine Engineers.

3.

Leslie Jackson (1992), Instrumentation and Control Systems, Thomas

Reed Publications Limited.

4.

MARPOL 73/78 Consolidated Edition (2002), International Maritime

Organization.

5. Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine Engineering,

Science and Technology.

6. http://www.imo.org

7.

http://www.dnv.com 8.

http://www.imarest.org

9.

http://marineengineering.org.uk

10.

http://www.engineersedge.com/pumps/pump_menu.shtml

11.

http://www.navis.gr/safety/occupatl/safety_m.htm

http://www.imo.org/

http://www.imo.org/

http://www.dnv.com/

http://www.dnv.com/

http://www.imarest.org/


http://marineengineering.org.uk/







http://www.dnv.com/

http://www.imo.org/

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Note 1: The letters K, U, A and I in the table of specifications

denote the K nowledge, Understanding (Comprehension),

A pplication and Integration (Higher than Application) levels

of Bloom’s taxonomy in the cognitive domain.

Note 2: In the following detailed syllabus, all objectives

should be understood to be prefixed by the words “At the endof the lecture, the learner should be able to…”. In the second

column, L : SL denotes the number of instructional hours

devoted to lecture and self learning respectively.

Main Objectives

Fundamentals of Instrumentation, Automation and Control SystemsAt the end of the course, the learner should be able to:

1. Describe the function of a transmitter or transducer

2. Describe the flapper and nozzle arrangement

3. Describe the conditions which may dictate the need for a positioner

4. Describe the principal features of a positioner

Table of Specifications

TopicsWeightage%

Total K U A I

A. Propeller and Shafting, ShaftFittings, Thrust Block and

Bearing

1 11 0 0 12

B. Pumps 1 6 1 0 8

C. Steering System 1 5 0 0 6

D. Hydraulic Gear 0 1 0 0 1

E.Refrigeration, Air Conditioning

and Ventilation 1 6 1 0 8

F.Heat Exchangers, Evaporators

and Domestic Water Supply0 4 0 0 4

G. MARPOL 73/78 1 7 0 0 8

H.Chemistry of Fire and

Extinguishing Agent 2 9 2 2 15

I.Fundamentals of Instrumentation,

Automation and Control Systems 0 14 1 0 15

J.Physical and Chemical Properties

of Bunkered Fuels and Lubricants 1 13 1 0 15

K. Technology of Materials 0 8 0 0 8

Total 8 84 6 2 100

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5. Sketch a graph illustrating control by a two-step controller

6. Make a single line sketch of a self-operating liquid level controller and

explain its proportional control action

2.

Explain the meaning of proportional band

3. Explain that the object of integral control is to reduce offset to zero

4.

Sketch a P & I control loop for controlling liquid level

5. Explain that the object of derivative control is to give quicker response

to a large change of load and to supplement inadequate proportional

damping of control

6.

Sketch a (P + D + I) control loop for controlling liquid level

7.

Describe applications of split-range control

8. Describe the cascade control of the outlet temperature of diesel engine

jacket cooling water with varying engine load and varying supply of

cooling water

9. Describe the lighting-up sequence of an automatic combustion system

for an auxiliary boiler

Study GuideStudents are advised to pay particular attention to following reference material

listed under “Recommended Texts” over and above the notes that will be

provided during lectures.

1.



2. Leslie Jackson (1992), Instrumentation and Control Systems, Thomas

Reed Publications Limited.

Students are advised to study the relevant Chapters in the above mentioned

books and ensure the following aspects are understood:

Fundamentals of Instrumentation, Automation and Control Systems

1. Telemetering, Chapter 11, Page 452-457

Study signal transmitters and transducers.

2. Terminology, Chapter 11, Page 457-458

Be familiar with control terminology.

3.

Control Actions, Chapter 11, Page 458-463

Study the three basic control actions: proportional, integral andderivative.

4.

Control Systems, Chapter 11, Page 463-470

Study typical control systems such as fluid temperature control,

automatic boiler control, and bridge control.

5.

Final Control Elements, Chapter 8, Page 115-126

Refer to the operation of control valves, valve positioners and

servo-motors. 6. Process Control Theory, Chapter 9, Page 127-155

Further reference to terminology, and proportional, integral and

derivative control actions.

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7.

Pneumatic Control Principles, Chapter 10, Page 157-169

Study pneumatic two step control, and pneumatic proportional, integral

and derivative controls.

8.

Electronic Control Principles, Chapter 11, Page 171-183

Understand electronic two step control, and electronic proportional,

integral and derivative controls.

9. Actual Controller Types, Chapter 12, Page 185-202

Refer to actual types of controllers used in practice such as

mechanical-hydraulic controller, electro-pneumatic controller,

electronic P.I.D. controller, pneumatic controller for fuel-air ratio and

pneumatic controller for viscosity.

10. Typical Control Circuits, Chapter 13, Page 203-237

Study typical control circuits such as sootblower control, steam

temperature control, jacket temperature control, bridge control and

refrigeration control.

Key Questions1.

Give a reasoned explanation of how Wheatstone Bridge networks are

employed in circuits of electrical resistance thermometers.

2.

Sketch and describe an explosive gas sampling device illustrating the

function of the Wheatstone Bridge.

3.

Sketch and describe a remote boiler water level indicator explaining its

principle of operation.

4. Illustrate how a Venturi tube or orifice plate can be used to generate a

pressure drop for fluid flow through a pipe. Express Bernoulli’s

equation in terms of kinetic and potential energy, and deduce therelationship between mass flow rate and differential pressure.

5.

Illustrate how a Bourdon tube can be used to convert a pressure

variable into an electric signal for pressure indication.

6.

With reference to control system, explain with the aid of simple

graphs, the difference between:

a. deviation and offset,

b. proportional without integral action and proportional with integral action,

c.

integral action and derivative action.

7. Sketch and describe a pneumatic flapper nozzle mechanism in which accuracy

is of importance but speed of action is insignificant.8. Explain what is meant by the following terms:

a.

Fail Safe

b. Ratio Control

c. Hysteresis Loop

d. Proportional Band

9. Explain briefly what is meant by the following terms:

a.

Cascade control system

b.

Split-range control system

c. Valve positioner

10. Sketch an auxiliary boiler automatic combustion control system.a.

Explain how it operates.

b.

Specify typical safeguards and interlocks provided.

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Additional Questions

1.

Explain the principle of operation of an oxygen analyser.

2.

Explain the difference between level type and comparator type of oil

mist detectors.

3.

Explain the principle of operation of a viscosity controller.

4.

Illustrate how a square root extractor may be used to eliminate the non-

linear relationship between flow and differential pressure.

5. Describe the requirements for UMS operation.

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Main Objectives

Heat Exchangers, Evaporators & Domestic supplyAt the end of the course, the learner should be able to:

1.

Understand how heat exchange is effected using various types of heat

exchangers.

2. Explain the constructional features of regularly used heat exchangers

such as shell & tube design, plate type and extended surface types.

3.

Explain what types of exchangers are best suited for cooling duties,

heating duties as also depending on the fluids involved.

4. Explain normal maintenance of heat exchangers such as mechanical

cleaning and chemical cleaning.

5. Explain operational problems such as tube leaks and methods of fixing

them.

6.

Understand methods of producing fresh water on board.7.

Explain the working of a typical, low pressure fresh water generator

employed on board.

8.

Explain normal maintenance such as SAF acid cleaning and chemical

dosing.

9.

Explain operational problems such as loss vacuum and methods to

overcome.

10. Understand that water used for human consumption needs to be treated

and the methods employed on board such as carbon bed filtering, silver

ion sterilizing and UV.




1. Leslie Jackson and Thomas D Morton, General Engineering

Knowledge for Marine Engineers, (2003), Adlard Coles Nautical

2. McGeorge H D, Marine Auxiliary Machinery, (2002), ISBN 0 7506

4398 6, Butterworth Heinemann



Heat Exchangers, Evaporators & Domestic supply1. Students must understand the various expansion arrangements

provided in the heat exchangers.

2.

Students must be able to explain the construction and function of

regenerative condensers.

3.

Students must be able to explain the relative advantages anddisadvantages between shell & tube design and plate type of heat

exchangers.

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4.

Students should be able to estimate the normal fresh water

requirements for personnel as well as machineries.

5.

Students should be able to explain the limitation of fresh water

generator operation close to coast line.

6. Students should understand and explain the use of eductors in air and

water side of the shell as also the importance of maintaining the brine

density.

7. Students must be able to explain the harm of excessive Chlorine dosage

in fresh water treatment

Key Questions

Heat Exchangers, Evaporators & Domestic supply1. Sketch & label a shell and tube heat exchanger. Show the provision for

expansion as also protection for corrosion.2.

Plate type of heat exchangers are limited in their application.

Discuss how the limitations are being overcome by way of design.

3.

Explain the principle of reverse osmosis. Sketch a simple RO plant

circuit, labeling the relevant parameters.


Heat Exchangers, Evaporators & Domestic supply

1. Illustrate the following flow patterns used in heat exchangers with

sketches:

a. Parallel b. counter c. cross d. mixed2. Tabulate the materials and components commonly used in heat exchangers.

3. Describe a central cooling system, explaining how coolant temperatures are

maintained.

4. Explain the purpose of: the demister, eductor, salinometer and a relief valve

in an evaporator.

5. Explain how the density is controlled in a two stage flash evaporation plant

6. Briefly explain with sketches how automatic fresh water and sanitary water

systems work

7. Explain how additives in diesel engine cooling water and seawater

inhibitors could be harmful to drinking water.

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Main Objectives

MARPOL 73/781. Summarize the implications of MARPOL 73/78 with respect to the

various annexes in relation to marine engineering processes

2. Describe, in principle, how bilge and ballast water are discharged

3. Describe the requirements for oily-water separators

4. Explain the purpose of the oil record book and how it is used

5. Describe a sewage retention system

6.

Explain why vacuum transportation systems are used

7. Describe the processes in a biological treatment plant

8. Describe the operation of chemical treatment plants

9. Explain how liquid and solid waste are prepared for combustion in an

incinerator




1.



2. MARPOL 73/78 Consolidated Edition (2002), International Maritime

Organization.

Students are advised to study the relevant Chapters in the above mentioned books and ensure the following aspects are understood:

MARPOL 73/781.

Oily Water Separator, Chapter 10, Page 381-388

Study the IMO requirements for oily water separators.

Study the operation of automatic valve operation combined with alarm

and protection circuits.

2.

Sewage and Sludge, Chapter 9, Page 390-393

Study the various types of sewage treatment plants.

What are the advantages of chemical treatment plants?3.

Regulations for the Prevention of Pollution by Oil, Annex I, Chapter I

– General, Page 45-50

Refer to Regulations 1 and 2 on definitions and application for Annex I

4. Requirements for Control of Operational Pollution, Annex I, Chapter

II, Page 58-95

Study Regulations 9 to 20 on the control of discharge of oil outside of

and within special areas, exceptions, reception facilities, segregated

ballast tanks, dedicated clean ballast tanks and crude oil washing,

segregation of oil and water ballast and carriage of oil in forepeak

tanks, retention of oil on board, oil discharge monitoring and controlsystem and oil filtering equipment, tanks for oil residues, pumping,

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piping and discharge arrangements of oil tankers, standard discharge

connection, and oil record book.

5.

Regulations for the Control of Noxious Liquid Substances, Annex II,

Page 243-253

Understand Regulations 1 to 5 on definitions, application,

categorization and listing of noxious liquid substances, and the

discharge of noxious liquid substances.

6. Regulations for the Prevention of Pollution by Harmful Substances

Carried by Sea in Packaged Form, Annex III, Page 363-366

Understand Regulations 1 to 8 on application, packing, marking and

labeling, documentation, stowage, quantity limitations, exceptions, and

port state control on operational requirements.

7. Regulations for the Prevention of Pollution by Sewage from ships,

Annex IV, Page 373-379

Study Regulations 1 to 11 on definitions, application, surveys, issue,

form and duration of certificate, discharge of sewage, exceptions,reception facilities, and standard discharge connections.

8.

Regulations for the Prevention of Pollution by Garbage from Ships,

Annex V, Page 385-392

Understand Regulations 1 to 9 on definitions, application, disposal of

garbage outside special areas, special requirements for disposal of

garbage, disposal of garbage within special areas, exceptions, reception

facilities, port state control on operational requirements, and placards,

garbage management plans and garbage record- keeping.

9. Regulations for the Prevention of Air Pollution from Ships, Annex VI,

Chapter I – General, Page 399-401Refer to Regulations 1 to 4 on application, definitions, general

exceptions, and equivalents.

10.

Regulations for Control of Emissions from Ships, Annex VI, Chapter

III, Page 408-416

Study Regulations 12 to 18 on ozone-depleting substances, nitrogen

oxides, sulphur oxides, volatile organic compounds, shipboard

incineration, reception facilities, and fuel oil quality.11. Amendments/Changes in Calendar Year

Key Questions1. With respect to Annex I of MAROL 73/78, identify the special areas?

2. In accordance with Annex I of MARPOL 73/78 concerning special areas, what

restrictions apply with respect to the discharge into the sea within such areas of

oil or oily mixture other than processed bilge water from a ship of less than 400

tons gross tonnage other than an oil tanker?

3. With reference to Annex I of MARPOL 73/78:

What are the conditions as per regulation 9 which need to be satisfied before an

oil tanker could discharge oil or oily mixtures into the sea?

4. With reference to Annex I of MARPOL 73/78:

State the “Exceptions” to the control of operational discharge of oil such that

uncontrolled discharge may be justified.

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5.

What are the conditions which need to be satisfied with respect to Annex I of

MARPOL 73/78 concerning special areas before discharging processed bilge

water from machinery spaces into such areas?

6. What is the role of Port State control on operational requirements as specified in

Annex I of MARPOL 73/78?

7. What type of oil filtering equipment is needed to satisfy the requirements of

Annex I of MARPOL 73/78?

8. List out the machinery space operations which would require entry into the

ship’s Oil Record Book Part I.

9. With reference to Annex IV of MARPOL 73/78, explain the regulations

governing the discharge of sewage waste from a ship into the sea areas outside

special areas.

10. In accordance with Annex VI of MARPOL 73/78, state the global limit for the

sulphur content of any fuel used onboard ships, and the sulphur content limit

within a SECA.

Additional Questions1.

What is the specific restriction with regard to the discharge into the sea of oil or

oily mixtures within the Antarctic area as stated in Annex I of MARPOL 73/78?

2.

Which authority has the right to inspect the Oil Record Book Part I, and

subsequent to such inspection, what other actions may be taken by such

authority with regard to this book?

3.

What are the various annexes specified under MARPOL 73/78?

4.

Which are the annexes of MARPOL 73/78 to which Malaysia is a party to?

5.

Sketch and fully label a biological treatment plant that can satisfy the

regulations of Annex IV of the MARPOL Convention.

6. List five problems that may arise during the operation of a ship’s biological

sewage treatment plant which may cause the effluent to be unsuitable to be

discharged overboard.

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Main Objectives

Propeller and Shafting, Shaft Fittings, Thrust Block & BearingAt the end of the course, the learner should be able to:

1.

Describe in principle how shafting is lined up at the initial stage

2. Explain how the propeller is secured to the tail shaft

3. Sketch a coupling arrangement which would allow outward removal of

the tail shaft

4.

Given a drawing of a water-lubricated stern tube as fitted in a ship with

its tail shaft and propeller, name and explain the function of all of the

components and their features

5. Given a drawing of an oil-lubricated stern tube, name and explain the

function of all components and their features

6. Describe the typical seals used at each end of the tail shaft

7.

Describe the arrangement of a withdrawable stern gear.8.

Given a diagrammatic arrangement, explain how the pitch of a

propeller is controlled

9.

Explain the principles of a torsion meter

10.

Explain how the propeller thrust is transmitted to the ship’s structure




1.

Leslie Jackson and Thomas D Morton, General Engineering

Knowledge for Marine Engineers, (2003), Adlard Coles Nautical

2.

Dr J Cowley, The Running and Maintenance of Marine Machinery,

(1992), Marine Management (Holdings) Ltd for The Institute of

Marine Engineers

3. Christensen Stanley G , Lamb’s Questions and Answers on Diesel

Engines (2000),ISBN 0 852 643071, Arnold, Hodder headline Group

4. McGeorge H D, Marine Auxiliary Machinery, (2002), ISBN 0 7506

4398 6, Butterworth Heinemann



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Propeller and Shafting, Shaft Fittings, Thrust Block & Bearing

1.

Shafting: Alignment,

Older alignment methods used piano wires and micrometers and feelers

between coupling faces, whereas modern methods utilize optical

telescopes/lasers and targets giving accuracies of 2m per 1 m

length. To fully describe the methods it will be assumed that the

shafting and engine are first lined up by the older method, being

checked at each stage by the modern method. Students should

understand the alignment concept and the adjustments made in the

stern tube by slope boring.

2. Shafting: Bearings, Couplings and Bolts

The concept of fair curve alignment must be studied and Students

should be able to demonstrate how load-Deflection curves are

generated in dry-docks. Students should be able to explain the concept

of Poisson’s ratio and how it relates to bolts as also how this problemis overcome by designs employing hydraulics.

3.

The Propeller Shaft and Stern tube:

Water lubricated stern bearings are being employed with better

sophistication in design and materials to mitigate the problem of oil

pollution. Study the water lubricated type and the oil lubricated type of

propeller shaft and stern tube, and their sealing arrangements. Students

should be able to explain the concept of a withdraw able stern gear

system and the alternative stern gear with shaft withdrawal aft or

inboard. Students should comprehend the function of inflatable seal

and advantages of such arrangements and also the importance ofachieving nil leakage if the seal gives way.

4. Propeller Mounting & Removal:

Students should be able to describe the various methods of fitting the

propellers and removal procedures adopted.

5. Controllable Pitch Propeller:

Students should be able to cite reasons for using controllable-pitch

propellers. Students should be able to describe the mechanism for

changing the pitch as also the emergency arrangements in case of

hydraulic system failure.

6. The Thrust BlockStudents should be able to explain how the concurrence in the thrust

surfaces help in forming the wedge and the hydrodynamic lubrication

film.

Key Questions

Propeller and Shafting, Shaft Fittings, Thrust Block & Bearing 1. Sketch and describe a Pilgrim nut for a propeller. Explain how it is

used when fitting the propeller on to the shaft taper. State two

advantages this type of nut has over a conventional propeller nut.

2. What is the purpose of putting a thrust bearing between the mainengine and the propeller? How is the thrust bearing cooled?

3. Sketch and label a lip seal arrangement employed in a stern tubes.

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4. With sketches, explain the advantages of a radial shaft seal fitted on tail

shafts.

5. Sketch and list down the procedure for tightening and releasing a muff

hydraulic coupling

6. Explain how following clearances are taken:

a. Propeller drop or Stern bearing wear down

b. Thrust pads

7. Explain actions taken if: a. Stern tube tank levels are dropping b. stern

tube tank levels are increasing.

8. List the advantages and disadvantages of a Controllable Pitch

Propeller.



1.

Sketch and write brief notes on different types of bolts used inshafting.

2.

Sketch and label a self-aligning type of line shaft bearing (axial)

and briefly describe its construction and working.

3.

Sketch and label a tilting pad type of line shaft bearing (radial) and

briefly describe its construction and working.

4.

Sketch and label a roller type of line shaft bearing and briefly

describe its construction and working. Point out how minimal

misalignments are accommodated in this type of bearing.

5. Draw the line sketch of a conventional stern tube oil lubrication

system. Discuss how leakages are noticed and how they may bedealt with.

6.

Sketch the hub detail of a controllable pitch propeller. Explain, in

steps with simple sketches how the pitch variation is

accomplished.

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Main Objectives

Physical and Chemical Properties of Bunkered Fuels and Lubricants1. Name the three types of crude petroleum and state the characteristics

constituent of their residues after distillation. Name the four main

series of hydrocarbons that are in petroleum.

2.

Define Viscosity- kinematics viscosity and dynamic viscosity. Explain

“viscosity index”.

3. Explain fire point, flash point, pour point, carbon residue, CCAI,

cetane number. Explain the ignition quality of a fuel. Explain how

‘knocking’ occurs. Explain that the higher the cetane number the better

the ignition quality. Describe the common relationship between

density, viscosity, flash point and calorific value of common marine

fuels.

4. Describe oil filtration methods. Explain the principles of an oil and

water centrifuge. Explain the factors which govern the limiting particle

size in a large bowl centrifuge. Describe the operation of a self-cleaning purifier.

5.

Explain the parts played by the oiliness and viscosity of a lubricant.

Describe boundary lubrication and where it occurs. Describe

hydrodynamic lubrication and the type of bearing where it can exist.

6.

Sketch a graph indicating the effect of viscosity, speed and pressure on

the lubrication of a bearing. Explain the effect of viscosity, surface

speed, bearing clearance and pressure on the lubrication of a bearing.

Describe the generation of oil films in both a journal and a Michell-

type bearing.

7.

Explain the meaning, causes, effects and remedies of: scuffing, pitting,emulsifying, oxidation, lacquering.

8.

Describe how to test lube oil for: viscosity, alkalinity, dispersiveness,

contamination, water.

9.

Explain the factors which contribute towards the formation of tin

oxides in white metal bearings, describe the effect of tin oxides present

in bearings. Explain what can be used to prevent or alleviate the

problem of tin oxides in bearings.

10.

Describe the means by which microbial degradation may be prevented

or remedied.




1. Leslie Jackson and Thomas D Morton (2003), General Engineering

Knowledge for Marine Engineers, Adlard Coles Nautical

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Physical and Chemical Properties of Bunkered Fuels and Lubricantsa. Liquid Fuels, Chapter 2, Page 47-50

Crude petroleum is taken under distillation processes at various pressure and

temperatures and the valuable distillates like gas oil, kerosene , lub oil extracted .

Residual fuel tapped off from the bottom of the distillation tower. As a result

Residual Fuel will carry the Asphalt and other unwanted presence of water,

aluminium and silica. Student will learn the composition of fuel oil and realize

the importance of handling residual fuel with care to prevent damage of engine

and equipments by presence of harmful objects.

b. Testing of liquid fuel and oils, Chapter 2, Page 51-65

To ensure compatible quality of fuel for the engines, certain test of fuel

properties and quantitative test of certain harmful constituent is very important.

From this chapter student will understand terms such as viscosity, viscosity

index, flash point, fire point, pour point, “carbon residue”, knocking, ignitionquality, cetane number and calorific value. And understand the common

relationship between density, viscosity, flash point and calorific value of

common marine fuels.

c.

Combustion of Sulphur, Chapter 2, Page 67-68

Presence of sulphur in fuel may finally causes corrosion on the engine

components and on the exhaust system. Student will understand the mechanism

of corrosion and how to prevent this acid corrosion.

d. Filters, Chapter 10, Page 406-412 Minute particles while penetrating to the surface like- between fuel pump barrel

and plunger, damage the components severely. To protect the machinery from

such damage filtration is of prime importance. In present days particles of 5 – 10

µm is claimed to be separated by filter technology. Students will be able to

understand the construction and operation of different type of filters.

e.

Centrifuges, Chapter 10, Page 416-425

Separation of minute particles in residual fuel and other fuel and lubrication oil

finally occurs inside the centrifuge. Students will understand the principal of

separation, operational procedure. Operational and design parameters that willaffect the limit size of particles, will be well understood. Student will be able to

distinguish a purifier from a clarifier. Student will understand the self cleaning

mechanism of a purifier.

f.

Bearing Lubrication, Chapter 10, Page 425 – 431

Oiliness and viscosity are the two most significant properties of lubricants,

contributes in boundary and hydrodynamic lubrication. Student will understand

the mechanism of both boundary and Hydrodynamic lubrication. Students will

also understand the other factors related to hydrodynamic lubrication. Student

will be able to realize that hydrodynamic lubrication exists in journal bearing andMichell bearing.

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h. Definitions, Chapter 10, Page 431-432

Student will understand terms such as scuffing, extreme pressure lubricant,

pitting, emulsion, oxidation, and lacquering, and know as how to combat the

phenomena by using quality lub oil and by maintaining the qualities of

lubricating oil.

i. Lubricating oil Tests, inspection for Microbial degradation and corrosion in

white metal bearing Chapter 10, Page 432-435

Test for TBN, Viscosity, presence of water would give early indication of failure.

Students will know as how to test for these parameters. Student will learn the

way of detecting Microbial degradation and as to the preventive and remedial

actions of Microbial degradation. In the presence of electrolytic corrosion (sea

water contamination), tin of white metal may form hard tin oxide. In this pages

student will learn the mechanism of formation fo tin oxide, appearance of tin

oxide, harmful affect of tin oxide and actions to be take to prevent formation of

tin oxide.

Key Questions

1. How was fuel used to be ordered in the old days? Explain why ordering based on

viscosity is not practiced nowadays. How is fuel specified in the present days while

placing order to the bunker traders?

2. It is necessary to define the fuel-quality over a range of parameters to which the

engine plant is sensitive. State the important parameters of marine residual fuels.

3. Proper Bunker Calculation can save a good amount of money for the company.

Explain how you will convert the volume of sounding to the volume at 15oC and

how you convert the density at vacuum to the density in air.

4. With regard to bunker, what is a representative sample? How long the sample to be

kept on board. Briefly describe the procedure of sampling in modern practice.

5. What is Bunker Delivery Note (BDN)? What parameters are to be laid down in

BDN in compliance with MARPOL Annex-VI?

6. With regard to lubricating oil properties define oiliness and viscosity. Describes

how viscosity and oiliness achieves hydrodynamic and boundary lubrication

respectively.

7. Define each of the following terms in relation to lubricating oil: pour point, flash

point, auto-ignition point, State, with reasons, when will each of these

characteristics be of primary importance.

8. Give the approximate composition , and the properties of the following metals:

manganese bronze, cupro-nickel, Babbitts metal. In each case give two examples ofthe metals in use on board ship, and explain why the metal is chosen for the

applications you mention.

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Acknowledgement



2. Dr J Cowley (1992), The Running and Maintenance of Marine


Marine Engineers

3.


Reed Publications Limited

4. MARPOL 73/78 Consolidated Edition (2002), International Maritime

Organization

5. Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine Engineering,

Science and Technology

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Main Objectives

Propeller and Shafting, Shaft Fittings, Thrust Block & BearingAt the end of the course, the learner should be able to:

1.

Describe in principle how shafting is lined up at the initial stage

2. Explain how the propeller is secured to the tailshaft

3. Sketch a coupling arrangement which would allow outward removal of

the tailshaft

4.

Given a drawing of a water-lubricated stern tube as fitted in a ship with

its tailshaft and propeller, name and explain the function of all of the

components and their features

5. Given a drawing of an oil-lubricated stern tube, name and explain the

function of all components and their features

6. Describe the typical seals used at each end of the tailshaft

7.

Describe the arrangement of a withdrawable stern gear8.

Given a diagrammatic arrangement, explain how the pitch of a

propeller is controlled

9.

Explain the principles of a torsion meter

10.

Explain how the propeller thrust is transmitted to the ship’s structure

Pumps1. Name the two basic types of pump

2. List the factors which influence the selection of a pump

3. Explain how characteristics curves are obtained

Steering System

1.

Describe the basic control system for a steering gear

2.

Describe the principle of operation of an electrical telemotor

3.

Explain how a ship is steered if there is a failure in the telemotor

system

4.

Explain how, in a Hele-Shaw pump, the volume and direction of oil

discharge are controlled

5. Explain how, in a swash plate pump, the volume and direction of oil

discharge are controlled6.

Sketch a diagrammatic arrangement of a four-ram steering gear,

illustrating:

a.

connections from two hydraulic oil power units

b.

emergency hand pump connection

c.

rudder-shock relief valves

d. all isolating or bypass valves for emergency operation

7. Describe a rotary vane unit

8. Explain that both the main and auxiliary steering gears, which could be

identical units, must be kept operative and maintained in proper

working order and that both need to be in operation at the same time in

some situations

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9. Explain that control of the steering gear must be available both on the

navigating bridge and in the steering compartment

Hydraulic Gear 1. Describe the common uses of hydraulic power on ships

2.

Describe the type of pump, fittings and equipment used in hydraulic

systems

Refrigeration, Air Conditioning & Ventilation1. State the function of each of the components, and briefly describe their

operation

2. Describe the controls used to operate the plant automatically

3.

Describe the symptoms of the following:a.

undercharge of refrigerant

b.

overcharge of refrigerant

c.

oil in the system

d.

presence of air in the refrigerant

e.

a partial blockage at the regulator

f.

leakage of refrigerant

4. Explain what is meant by:

a. direct expansion

b. secondary coolant

c.

grid coolingd.

battery cooling

5. Describe a simple air-conditioning system suitable for supplying a

living space with conditioned air and using recirculation

6.

Describe the areas in a psychrometric chart which is known as the

‘comfort zone’ , being the air condition necessary for personal comfort

in living spaces

Heat Exchangers, Evaporators and Domestic Water Supply1. Describe the following flow patterns as used in heat exchangers:

a.

parallel b.

counter

c.

cross

d. mixed

2. Explain the factors which decide whether flow is streamline or

turbulent

3. Explain how the differential expansion and contraction is allowed for

in heat exchangers

4.

Describe the materials commonly used in heat exchangers

5.

Describe the attention required to maintain the efficiency of a heat

exchanger with reference to:a.

corrosion

b. erosion

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c.

fouling

d.

leakage

6.

Describe a central cooling system, Explaining how steady coolant

temperatures are maintained

7. Explain why central cooling systems are installed

8.

Describe the scales which are deposited in evaporators

9. Describe the principal methods used to reduce scale deposits in

evaporators, i.e.

a.

low pressure, including high vacuum

b.

magnetic treatment

c.

flexible elements

d. continuous chemical treatment

10. Explain the safeguards necessary to ensure that the water produced is

safe to drink

11. Describe how automatic fresh water and sanitary water systems work

12.

Explain the requirements for drinking water13.

Describe a system which is capable of supplying satisfactory drinking

water

MARPOL 73/781. Summarize the implications of MARPOL 73/78 with respect to the

various annexes in relation to marine engineering processes

2. Describe, in principle, how bilge and ballast water are discharged

3. Describe the requirements for oily-water separators

4. Explain the purpose of the oil record book and how it is used

5. Describe a sewage retention system6. Explain why vacuum transportation systems are used

7. Describe the processes in a biological treatment plant

8. Describe the operation of chemical treatment plants

9. Explain how liquid and solid waste are prepared for combustion in an

incinerator

Chemistry of Fire & Extinguishing Agent1. Explain the conditions required for fire to occur as:

b.

the presence of materials (gas, liquid or powder) which acts as a

fuelc.

a source of ignition, e.g. chemical, biological or physical

d.

the presence of oxygen, as air or from oxidizing agents

2. Describe the use of water as a fire-fighting medium

3. Describe the use of carbon dioxide as a fire-fighting medium

4. Describe the use of foam as a fire-fighting medium

5. Describe the use of chemical powder as a fire-fighting medium

6.

Describe methods of detection, and determine the suitability or

effectiveness of:

a. smoke detectors

b. high-temperature probesc. rate-of-rise-of-temperature probes

e. patrols

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7. Describe fire fighting systems, appliances and equipment, and identify

the best possible approach or action in combating fire using:

a.

fixed systems, e.g. water, foam and carbon dioxide

b.

portable appliances, e.g. water, foam, carbon dioxide and powder

c. mobile equipment, e.g. foam, carbon dioxide and powder

8. Explain how fire alarm tests are carried out to ensure alarms are in

working condition

9. Explain how fire detector tests are carried out to ensure detectors are in

working order

Fundamentals of Instrumentation, Automation and Control Systems 1. Describe the function of a transmitter or transducer

2. Describe the flapper and nozzle arrangement

3. Describe the conditions which may dictate the need for a positioner

4. Describe the principal features of a positioner

5. Sketch a graph illustrating control by a two-step controller6. Make a single line sketch of a self-operating liquid level controller and

explain its proportional control action

7.

Explain the meaning of proportional band

8.

Explain that the object of integral control is to reduce offset to zero

9.

Sketch a P & I control loop for controlling liquid level

10.

Explain that the object of derivative control is to give quicker response

to a large change of load and to supplement inadequate proportional

damping of control

11. Sketch a (P + D + I) control loop for controlling liquid level

12.

Describe applications of split-range control13.

Describe the cascade control of the outlet temperature of diesel engine

jacket cooling water with varying engine load and varying supply of

cooling water

14.

Describe the lighting-up sequence of an automatic combustion system

for an auxiliary boiler

Physical and Chemical Properties of Bunkered Fuels and Lubricants1. Name the three types of crude petroleum and state the characteristics

constituent of their residues after distillation

2. Name the four main series of hydrocarbons that are in petroleum3.

Define viscosity in simple terms

4. Explain “viscosity index”

5. Explain what is meant by the fire point of an oil and relate this to the

flash point

6. Explain the importance of the pour point

7. Explain “carbon residue”

8.

Explain how ‘knocking’ occurs

9.

Explain the ignition quality of a fuel

10.

Explain that the higher the cetane number the better the ignition quality

11.

Describe the common relationship between density, viscosity, flash point and calorific value of common marine fuels

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12.

Describe the harmful effects of sulphur trioxide in the products of

combustion

13.

Explain that fuel sample analysis may reveal:

a.

low flash point

b. high sulphur content

c.

high water content

d. high vanadium content

e. high aluminium content

f.

instability and incompatibility

14. Explain the actions to be taken to overcome the problems encountered

as stated in objective 13.

15. Describe oil filtration methods

16. Explain the principles of an oil and water centrifuge

17. Explain the factors which govern the limiting particle size in a large

bowl centrifuge

18.

Describe the operation of a self-cleaning purifier19.

Explain the parts played by the oiliness and viscosity of a lubricant

20.

Describe boundary lubrication and where it occurs

21.

Describe hydrodynamic lubrication and the type of bearing where it

can exist

22.

Sketch a graph indicating the effect of viscosity, speed and pressure on

the lubrication of a bearing

23. Explain the effect of viscosity, surface speed, bearing clearance and

pressure on the lubrication of a bearing

24. Describe the generation of oil films in both a journal and a Michell-

type bearing25.

Explain the meaning, causes, effects and remedies of:

a.

scuffing

b.

pitting

c.

emulsifying

d. oxidation

e. lacquering

26. Describe how alkalinity can be checked for lubricating oil

27.

Describe how to test lube oil for:

a.

dispersiveness

b.

contaminationc.

water

28.

Describe how viscosity can be checked for lubricating oil

29. Explain the factors which contribute towards the formation of tin

oxides in white metal bearings

30. Describe the effect of tin oxides present in bearings

31. Explain what can be used to prevent or alleviate the problem of tin

oxides in bearings

32.

Describe the means by which microbial degradation may be prevented

or remedied

33.

Relate typical test analyses to sources of problems on board ship34.

Determine the action to be taken to overcome the problems

encountered in objective 34

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Technology of Materials 1. Relate the approximate carbon content and use of:

a. mild steel

b.

medium carbon steel

c. high carbon steel

d. cast iron

2. Sketch a load - extension diagram for mild steel in tension

3. Describe how proof stress is obtained and why it is sometimes

necessary

4. Describe the principles of hardness testing

5. Explain the purpose of an impact test

6. Relate results from impact tests on common materials to their use in

marine engineering

7. Explain the meaning of brittle fracture8. Describe the factors which affect the tendency to brittle fracture

9. Explain briefly what is meant by creep

10. Describe metal failure due to fatigue

11. Explain what is meant by fatigue limit

12. Describe the factors which affect the fatigue limit

13. Describe the bend test

14. Describe the following methods of non-destructive examination of

surfaces for cracks:

a. visual

b.

oil and whitewashc.

fluorescent penetrant

d.

red dye penetrant

e.

magnetic detection

15. Explain the principles of non-destructive examination for defects

within a metal, using the following methods:

a. hammer

b. radiography

c.

ultrasonic

16. Describe the process and the effect on a medium-carbon steel of

hardening and tempering17. Explain the purpose of annealing

18. Describe the process of annealing

19. Describe examples where annealing might be necessary

20. Explain the difference between annealing and normalizing and their

applications

21. Describe conditions in marine applications where work hardening

occurs

22. Explain the measures taken to rectify or reduce the effect of work

hardening

23. Explain that the welding process involves heating, melting and coolingmetals, which affects the structure and properties of the resulting

materials

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24. Explain the principal reasons for adding the following elements:

a.

cobalt

b.

nickel

c.

chromium

d. molybdenum

e.

vanadium

f. tungsten

g. copper

h.

manganese

i.

silicon

j.

titanium

25. Give examples of marine applications of the above

26. Explain the reasons for adding the following elements to bronze:

a. manganese

b. phosphorus

c.

aluminumd.

zinc

27. Describe in general terms the range of copper-nickel alloys and their

applications in marine Engineering

28. Compare the approximate analyses of both tin and lead based white

metals and the use for which they are suited

29. Describe the applications of and the reason for using the following

materials:

a. nitrile rubber

b. neoprene

c.

P.T.F.Ed.

epoxy resin

e.

rubber

f.

asbestos

g.

cotton

h. silicon nitride

i. glass reinforced plastics


listed under “Recommended Texts” over and above the notes that will be provided during lectures.




a.

Shafting Alignment, Chapter 6, Page 211-224

Older alignment methods used piano wires and micrometers

and feelers between coupling faces, whereas modern methodsutilize optical telescopes and targets giving accuracies of

2m per 1 m length. To fully describe the methods it will be

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assumed that the shafting and engine are first lined up by the

older method, being checked at each stage by the modern

method.

b. The Propeller Shaft and Sterntube, Chapter 6, Page 231-236

Study the water lubricated type and the oil lubricated type of

propeller shaft and sterntube, and their sealing arrangements.

Be familiar with the withdrawable stern gear system and the

alternative stern gear with shaft withdrawal aft or inboard.

c. Controllable Pitch Propeller, Chapter 6, Page 237-238

What are the reasons for using controllable-pitch propellers?

d. The Torsionmeter Chapter 6, Page 238-241

Why the electrical torsion meter is used in preference to

others?

e. The Thrust Block Chapter 6, Page 241-243

What is the Michell principle?

Pumps a.

Types of Pumps: Classification, Chapter 9, Page 350-351

What is the difference between the two basic types of pumps?

b.

Selection of Pumps, Chapter 9, Page 350-361

What are the criteria for the selection of a particular type of

pump?

c. Characteristic Curves, Chapter 9, Page 357-360

Careful study of characteristic curves would assist the reader to

answer some of the questions.

Steering Systema. Steering Gears, Chapter 5, Page 175-200

Study the various types of steering gears available on board.

The two main types are electro-hydraulic and all electric.

Reader should pay attention to emergency operation.

b. Some Rules Appertaining to Steering Gears, Chapter 5, Page

200-201

Be familiar with rules governing the operation of steering

gears. Rules are subject to change and one must be wary of the

latest development.

Hydraulic Geara. Hydraulic System, Chapter 9, Page 379-380

What are the main advantages of a centralised hydraulic

system? Items that can be operated by such system include

pumps, which are submersible or line-shaft driven from deck

motors, and deck machinery such as winches, windlass, cranes,

derricks, hatch covers, ramps, water tight doors and bow

thruster.

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Refrigeration, Air Conditioning and Ventilationa. Common Faults and Simple Detection, Chapter 7, Page 264-

265

Familiarization with these faults would help one to

troubleshoot problems encountered.

b. Direct Expansion Units, Chapter 7, Page 276-281

The control automation required is start, stop, superheat

control, emergency cut out, cooling air or water circulation,

and oil separation.

c.

Brine Circuits, Chapter 7, Page 283-284

The colder the brine circuit, the greater would be the density

required of brine in circulation to avoid any freeze up.

d. Air Conditioning Circuit, Chapter 7, Page 289-291

When heating is required, the cooling unit would be shut

down, and the air would pass over heating elements, andhumidity is regulated by controlled water spray.

e.

Psychrometric Chart, Chapter 7, Page 288-289

The chart gives a quick performance check on the air entering

and leaving the cooling coil.

Heat Exchangers, Evaporators and Domestic Water Supplya. Heat Exchanger, Chapter 9, Page 370-376

What is the flow pattern used in most heat exchangers?

Study the difference between streamline and turbulent flow.

Study the difference between shell and tube type and plate typeheat exchangers.

b.

Evaporators, Chapter 3, Page 129-131

What is the consequence of scale formation?

c.

Drinking Water, Chapter 3, Page 137

Study the safeguards necessary to ensure that the water

produced is safe to drink

d. Automatic Domestic Water Supply Systems, Chapter 9, Page

377-378

Study the automated control system common for either

sanitary or fresh water supply.e.

Water Purification, Chapter 9, Page 378-379

For domestic purposes the water used must be slightly alkaline,

sterilised, clear and pleasant tasting.

MARPOL 73/781. Oily Water Separator, Chapter 10, Page 381-388

Study the IMO requirements for oily water separators.

Study the operation of automatic valve operation combined

with alarm and protection circuits.

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2.

Sewage and Sludge, Chapter 9, Page 390-393

Study the various types of sewage treatment plants.

What are the advantages of chemical treatment plants?

Chemistry of Fire and Extinguishing Agent

a.

Principle of Fire, Chapter 8, Page 301

Understand the conditions required for the occurrence of fire.

b.

Fire Prevention and Precautions, Chapter 8, Page 301-302

Cleanliness, vigilance and common sense are the principal

weapons with which to prevent fire.

c. Types of Fires and Methods of Extinguishing, Chapter 8, Page

302-303

Be familiar with oil fires, coal fires, material fires and

electrical fires, and how they can be extinguished.

d. Fire Detection Methods, Chapter 8, Page 303-310Study the various methods of fire detection.

e. Critical Analysis of Fire Extinguishing Mediums, Chapter 8,

Page 310-312

Study the characteristics of various fire extinguishing mediums

for fighting various fires. The use of halon has now been

phased out.

f. Fire Extinguishers and Fixed Fire Fighting Installations,

Chapter 8, Page 313-340

Study the operation, maintenance and testing of fire

extinguishers and fixed fire fighting installations.g. Merchant Shipping (Fire Appliances) Rules

Be familiar with rules with regards to fire fighting equipment

such as international shore connection, water pipes, hydrants

and fire hoses, firemen’s outfits, breathing apparatus, and

emergency fire pump.

Fundamentals of Instrumentation, Automation and Control Systemsa. Telemetering, Chapter 11, Page 452-457

Study signal transmitters and transducers.

b. Terminology, Chapter 11, Page 457-458Be familiar with control terminology.

c. Control Actions, Chapter 11, Page 458-463

Study the three basic control actions: proportional, integral and

derivative.

d. Control Systems, Chapter 11, Page 463-470

Study typical control systems such as fluid temperature

control, automatic boiler control, and bridge control.

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Physical and Chemical Properties of Bunkered Fuels and Lubricantsa. Liquid Fuels, Chapter 2, Page 47-48

Understand that crude petroleum is classified into three main

types. Understand that hydrocarbons are divided into four

main series

b. Testing of liquid fuel and oils, Chapter 2, Page 51-65

Understand terms such as viscosity, viscosity index, flash

point, fire point, pour point, “carbon residue”, knocking,

ignition quality, cetane number and calorific value. Understand

the common relationship between density, viscosity, flash

point and calorific value of common marine fuels.

c. Combustion of Sulphur, Chapter 2, Page 67-68

Understand the harmful effects of sulphur trioxide in the

products of combustion.

d. Filters, Chapter 10, Page 406-412Study the different filtration methods.

e. Centrifuges, Chapter 10, Page 416-425

Understand the factors affecting the limit size particle path.

Understand operation of the centrifuge either as a purifier or a

clarifier. Study the operation of a self-cleaning purifier. Study

the variation of throughput rate against the quantity of

impurities in the system.

f. Bearing Lubrication, Chapter 10, Page 428

The two most important properties of a lubricant would be

oiliness and viscosity. What are boundary friction andhydrodynamic lubrication?

g. Factors Affecting Hydrodynamic Lubrication, Chapter 10,

Page 429-430

Understand that factors include viscosity of the lubricant,

relative speed of surfaces, bearing clearance, and pressure.

h. Journal Bearings, Chapter 10, Page 430-431

What kind of lubrication exists in journal bearings?

i. Michell Bearings, Chapter 10, Page 430-431

What kind of lubrication exists in Michell bearings?

j. Definitions, Chapter 10, Page 431-432Understand terms such as scuffing, extreme pressure lubricant,

pitting, emulsion, oxidation, and lacquering.

k. Shipboard Lubricating oil Tests, Chapter 10, Page 432-434

Be familiar with qualitative oil tests carried out on board ship.

Tests for alkalinity, dispersiveness, contamination, water and

viscosity are usual.

l. Corrosion of White Metal Bearings, Chapter 10, Page 434

Study the factors which contribute towards the formation of tin

oxides.

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m. Microbial Degradation of Lubricating Oil, Chapter 10, Page

434-435

State the remedy and prevention for bacterial attack of diesel

engine lubricating oils, crankcase and cylinder.

Technology of Materials

a. Simple Metallurgy of Steel and Cast Iron, Chapter 1, Page 5-9

Refer to diagram on microstructure variation with increasing

carbon content for examples of applications of mild steel,

medium carbon steel, high carbon steel and cast iron.

b. Testing of Materials, Chapter 1, Page 9-23

Understand the stress-strain diagram, and the significance of proof stress. Understand destructive tests such as tensile,

hardness, impact, creep, fatigue and bend tests, and non-

destructive tests such as visual inspection, penetrant test,

magnetic crack detection, hammer test, radiography and

ultrasonics.

c. Treatment of Metals, Chapter 1, Page 23-28

Understand the different heat treatment processes such as

hardening and tempering, annealing and normalizing and work

hardening, and the applications of these processes.

d. Welding, Chapter 1, Page 35-43

Understand that welding processes can change the

microstructure and mechanical properties of the base metal.

Understand that welding of metals may cause imperfections on

the surface or internally to the weld and adjacent metal such as

overlap, undercut, spatter, blowhole, porosity, inclusion,

incomplete root penetration and lack of fusion.

e. Elements in Irons and Steels, Chapter 1, Page 30-32Study the effect of alloying irons and steels with elements such

as manganese, silicon, sulphur, phosphorus, nickel, chromium,

molybdenum and vanadium.

f. Non-ferrous Metals, Chapter 1, Page 32-34

Study the properties and uses in marine applications of non-

ferrous metals such as copper, brass, bronze, aluminium,

copper-nickel alloys, white metals and titanium.

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g. Non-metallic materials, Chapter 1, Page 34-35

Study the properties and uses of non-metallic materials such as

plastics, nitrile, P.T.F.E., Epoxy resin, rubber, asbestos, cotton

and silicon nitride.



Marine Engineers

Pumpsa. Pumps, Chapter 10, Page 333-338

Refer to the various types of pumps.

b. Common Uses of the Various Types of Pumps, Chapter 10,

Page 338-340

Study typical applications of the different types of pumps.

Refrigeration, Air Conditioning and Ventilationa. Marine Refrigerating Plant, Chapter 8, Page 270-276

Refer to system components such as oil separators, condensers,

evaporators, air cooler batteries and filter driers, and controls

such as defrosting and refrigerant flow controls.

Physical and Chemical Properties of Bunkered Fuels and Lubricants a. Marine Fuel Oil characteristics, Chapter 4, Page 160-177

Further reference on terminology such as viscosity, flash point,

pour point, “carbon residue” and ignition quality.What are the actions required to overcome problems

encountered due to low flash point; high sulphur content; high

water content; high vanadium content; high aluminium

content; instability and incompatibility?

3. Leslie Jackson (1992), Instrumentation and Control Systems, Thomas


Fundamentals of Instrumentation, Automation and Control Systems

a. Final Control Elements, Chapter 8, Page 115-126Refer to the operation of control valves, valve positioners

and servo-motors. b. Process Control Theory, Chapter 9, Page 127-155

Further reference to terminology, and proportional, integral

and derivative control actions.

c. Pneumatic Control Principles, Chapter 10, Page 157-169

Study pneumatic two step control, and pneumatic proportional,

integral and derivative controls.

d. Electronic Control Principles, Chapter 11, Page 171-183

Understand electronic two step control, and electronic proportional, integral and derivative controls.

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e. Actual Controller Types, Chapter 12, Page 185-202

Refer to actual types of controllers used in practice such as

mechanical-hydraulic controller, electro-pneumatic controller,

electronic P.I.D. controller, pneumatic controller for fuel-air

ratio and pneumatic controller for viscosity.

f. Typical Control Circuits, Chapter 13, Page 203-237

Study typical control circuits such as sootblower control,

steam temperature control, jacket temperature control, bridge

control and refrigeration control.

4. MARPOL 73/78 Consolidated Edition (2002), International

Maritime Organization

MARPOL 73/78

a.

Regulations for the Prevention of Pollution by Oil, Annex I,Chapter I – General, Page 45-50

Refer to Regulations 1 and 2 on definitions and application for

Annex I

b. Requirements for Control of Operational Pollution, Annex I,

Chapter II, Page 58-95

Study Regulations 9 to 20 on the control of discharge of oil

outside of and within special areas, exceptions, reception

facilities, segregated ballast tanks, dedicated clean ballast

tanks and crude oil washing, segregation of oil and water

ballast and carriage of oil in forepeak tanks, retention of oil on board, oil discharge monitoring and control system and oil

filtering equipment, tanks for oil residues, pumping, piping

and discharge arrangements of oil tankers, standard discharge

connection, and oil record book.

c. Regulations for the Control of Noxious Liquid Substances,

Annex II, Page 243-253


categorization and listing of noxious liquid substances, and the

discharge of noxious liquid substances.

d. Regulations for the Prevention of Pollution by HarmfulSubstances Carried by Sea in Packaged Form, Annex III, Page

363-366

Understand Regulations 1 to 8 on application, packing,

marking and labeling, documentation, stowage, quantity

limitations, exceptions, and port state control on operational

requirements.

e. Regulations for the Prevention of Pollution by Sewage from

ships, Annex IV, Page 373-379

Study Regulations 1 to 11 on definitions, application, surveys,

issue, form and duration of certificate, discharge of sewage,exceptions, reception facilities, and standard discharge

connections.

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f. Regulations for the Prevention of Pollution by Garbage from

Ships, Annex V, Page 385-392


disposal of garbage outside special areas, special requirements

for disposal of garbage, disposal of garbage within special

areas, exceptions, reception facilities, port state control on

operational requirements, and placards, garbage management

plans and garbage record- keeping.

g. Regulations for the Prevention of Air Pollution from Ships,

Annex VI, Chapter I – General, Page 399-401

Refer to Regulations 1 to 4 on application, definitions, general

exceptions, and equivalents.

h. Regulations for Control of Emissions from Ships, Annex VI,

Chapter III, Page 408-416

Study Regulations 12 to 18 on ozone-depleting substances,

nitrogen oxides, sulphur oxides, volatile organic compounds,shipboard incineration, reception facilities, and fuel oil quality.

5. Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine

Engineering, Science and Technology

Chemistry of Fire and Extinguishing Agent

a. Fire Extinguishing and Extinguishing Media, Section 3, Page

25-42

Further reference on methods of extinguishing fires and properties of extinguishing media.

b. Fire Extinguishing Equipment, Section 4, Page 44-65

Further reference on fire extinguisher performance, portable

extinguishers, foam-making equipment, fire hoses and nozzles,

fire-fighter’s outfit and breathing apparatus.

c. Fire-fighting Arrangements, Section 5.8, Page 78-89

Further reference on operation and maintenance of fixed

installations, and operational requirements of fire pumps.

d. Automatic Sprinkler Systems and Fire Detection, Section 10,

Page 147-171Further reference to the operation of sprinkler systems and

types of fire detectors.

Key Questions

1. Sketch and describe a Pilgrim nut for a propeller. Explain how it is used

when fitting the propeller on to the shaft taper. State two advantages this

type of nut has over a conventional propeller nut.

2. What is the purpose of putting a thrust bearing between the main engineand the propeller? How is the thrust bearing cooled?

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3. Describe with sketches a super-cavitating pump. State the purpose of

such a pump and gives an instance of current shipboard application.

4. Describe with sketches an axial flow pump. Explain its principle of

operation. State what important advantage and serious disadvantage it

possesses compared to other pumps. Explain the effects of throttling

either the suction or discharge valve.

5. Describe a simple test to ensure that steering gear hydraulic telemotor

systems are ‘air free’.

a. Define two ways whereby air enters such systems.

b. Give reasons why it is essential that such systems be ‘air free’.

6. With reference to electro hydraulic steering gears explain how the ship

can be steered in each of the following circumstances:

a. Destruction by fire of primary supply cables

b. Destruction by fire of telemotor lines

c.

Bearing failure in running pump7. Sketch and describe a centralised hydraulic system. What are the

equipment which can be operated by such a system?

8. Briefly describe how in main refrigeration plants:

a.

sea temperature can restrict plant operation

b.

the limitations in (a) are overcome

c.

short cycling occurs

d. short cycling is avoided

9. With respect to heat exchangers,

b. What is the difference between streamline flow and turbulent

flow?c.

What are the principal advantages of the plate type heat

exchanger?

10. With respect to Annex I of MAROL 73/78,

a.

What are the special areas?

b. What are the restrictions with respect to the discharge of processed

bilge water from machinery space into the waters of these areas?

11. Differentiate between fixed temperature and rate of rise types of fire

detector. Sketch and describe a fire detector of the rate of rise type and

explain how a gradual rise of ambient temperature is accommodated.

12. Sketch diagrammatically an auxiliary boiler automatic combustioncontrol system. Explain how it operates. Specify how ‘fail safe’

conditions are ensured.

13. Define each of the following terms in relation to lubricating oil:

a. pour point

b. flash point

c. auto-ignition point

State, with reasons, when will each of these characteristics be of primary

importance.

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14. Give the approximate composition , and the properties of the following

metals:

a.

manganese bronze

b.

cupro-nickel

c. Babbitts metal

In each case give two examples of the metals in use on board ship, and

explain why the metal is chosen for the applications you mention.

Acknowledgement




Machinery, Marine Management (Holdings) Ltd for The Institute ofMarine Engineers

3.



4.

MARPOL 73/78 Consolidated Edition (2002), International Maritime

Organization

5.

Dr J Cowley (2002), Fire Safety at Sea, Institute of Marine Engineering,

Science and Technology

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Main Objectives

Technology of Materials

At the end of the course, the learner should be able to:

1.

Describe the properties of steel and the steel making process.

2. Describe the material testing (destructive) and the properties being

tested.

3.

Describe the Non-destructive testing (NDT) and their principles.

4.

Explain the heat treatment process of metal

5.

Explain the reason for adding alloying elements in steel.

6. Describe the application of non metallic materials.


listed under “Recommended Texts” over and above the notes that will be provided during lectures.

1.



Technology of Materialsa. Simple Metallurgy of Steel and Cast Iron, Chapter 1, Page 5-9

Refer to diagram on microstructure variation with increasing

carbon content for examples of applications of mild steel,

medium carbon steel, high carbon steel and cast iron.Understand the properties of steel and steel making process.

b. Testing of Materials, Chapter 1, Page 9-23

Understand the stress-strain diagram, and the significance of

proof stress. Understand destructive tests such as tensile,

hardness, impact, and fatigue tests, and non-destructive tests

such as penetrant test, magnetic crack detection, hammer test,

radiography and ultrasonics. Understand the differences

between the destructive tests and non-destructive tests.

c. Treatment of Metals, Chapter 1, Page 23-28

Understand the different heat treatment processes such ashardening and tempering, annealing and normalizing and work

hardening, and the applications of these processes.

d. Welding, Chapter 1, Page 35-43

Understand that welding processes can change the

microstructure and mechanical properties of the base metal.

e. Elements in Irons and Steels, Chapter 1, Page 30-32

Study the effect of alloying irons and steels with elements such

as manganese, silicon, sulphur, phosphorus, nickel, chromium,

molybdenum and vanadium.

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f. Non-ferrous Metals, Chapter 1, Page 32-34

Study the properties and uses in marine applications of non-

ferrous metals such as copper, brass, bronze, aluminium,

copper-nickel alloys, white metals and titanium.

g. Non-metallic materials, Chapter 1, Page 34-35

Study the properties and uses of non-metallic materials such as

plastics, nitrile, P.T.F.E., Epoxy resin, rubber, asbestos, cotton

and silicon nitride.

Key Questions1. Give the approximate composition , and the properties of the following

metals:

a. mild steel

b. medium carbon steel

c.

high carbon steelIn each case give two examples of the metals in use on board ship, and

explain why the metal is chosen for the applications you mention.

2.

Define ‘mechanical property’ of an engineering material. State any six

mechanical properties and give their definitions.

3.

State the alloying elements added to steel to get alloy steels and the effect

they produce. Give at least one example of each.

4. Briefly explain the differences between destructive testing and non-

destructive testing (NDT).

5. Explain the following heat treatment processes:

Normalising Hardening

Tempering

Additional Questions1.

Describe the classification of materials for engineering use.

2. List the most commonly used engineering materials and state at least one

important property and one application of each.

3.

Define the following properties of a material:

Ductility

Toughness

Hardness

4.

Discuss the effects of nickel, chromium and manganese on steel.

5.

Explain the determination of the fatigue resistance of a material.

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Main Objectives

Refrigeration, Air Conditioning & VentilationAt the end of the course, the learner should be able to:

1. State the function of each of the components, and briefly describe their

operation

2. Describe the controls used to operate the plant automatically

3. Describe the symptoms of the following:

a.

undercharge of refrigerant

b.

overcharge of refrigerant

c.

oil in the system

d. presence of air in the refrigerant

e. a partial blockage at the regulator

f. leakage of refrigerant

4. Explain what is meant by:

a.

direct expansion b.

secondary coolant

c.

grid cooling

d.

battery cooling

5. Describe a simple air-conditioning system suitable for supplying a

living space with conditioned air and using recirculation

7.

Describe the areas in a psychrometric chart which is known as the

‘comfort zone’ , being the air condition necessary for personal comfort

in living spaces






2. Dr J Cowley (1992), The Running and Maintenance of Marine Machinery,

Marine Management (Holdings) Ltd for The Institute of Marine Engineers.

Students are advised to study the relevant Chapters in the above mentioned books and ensure the following aspects are understood:

Refrigeration, Air Conditioning & Ventilation1. Common Faults and Simple Detection, Chapter 7, Page 264-265

Familiarization with these faults would help one to troubleshoot

problems encountered.

2.

Direct Expansion Units, Chapter 7, Page 276-281

The control automation required is start, stop, superheat control,

emergency cut out, cooling air or water circulation, and oil separation.

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3.

Brine Circuits, Chapter 7, Page 283-284

The colder the brine circuit, the greater would be the density required

of brine in circulation to avoid any freeze up.

4. Air Conditioning Circuit, Chapter 7, Page 289-291

When heating is required, the cooling unit would be shut down, and

the air would pass over heating elements, and humidity is regulated by

controlled water spray.

5.

Psychrometric Chart, Chapter 7, Page 288-289

The chart gives a quick performance check on the air entering and

leaving the cooling coil.

6. Marine Refrigerating Plant, Chapter 8, Page 270-276

Refer to system components such as oil separators, condensers,

evaporators, air cooler batteries and filter driers, and controls such asdefrosting and refrigerant flow controls.

Key Questions1. Briefly describe how in main refrigeration plants:

a.

sea temperature can restrict plant operation

b.

the limitations in (a) are overcome

2. Briefly describe how in main refrigeration plants:

a. short cycling occurs

b. short cycling is avoided

3. With reference to refrigeration system, what are the causes of the followingfaults?

a.

Loss of lubrication oil

b.

Knocking

4. With reference to refrigeration system, what are the causes of the following

faults?

a. Suction pressure too high

b. Compressor cut-out

5. Explain the purpose of the heating element of an oil separator

incorporated in a refrigeration system.

6.

With respect to refrigeration system, explain how icing on evaporator coil mayor may not be detrimental to the operation of the system.

7.

With respect to refrigeration system, explain how you would charge up the

system with refrigerant from zero charge to full charge.

8. With reference to the psychrometric chart, explain the significance of the dry

and wet bulb temperatures.

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1.

Explain how a refrigeration compressor could short cycle due to loss of

refrigerant.

2. Explain how a refrigeration compressor could short cycle due to a

heavily frosted evaporator coil.

3. What are the factors which could cause a refrigeration compressor to run

continuously?

4. With reference to refrigeration system, what is the function of the oil separator?

5. Explain how the air in an air-conditioned room becomes dehumidified.

Acknowledgement

International Maritime Organisation (IMO), IMO Model Course (3.09), (7.02),

(7.04) (2001)

DNV Seaskills Learning Guide

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Lg Ecsu Ekg 170413