Republic of the Philippines Philippine Merchant Marine Academy

San Narciso, Zambales

BSMar-E SEA PROJECT/ Function 1-4

Second Class Year/ 3rd Year

RP DEPARTMENT OF TRANSPORTATION AND COMMUNICATION

MARITIME INDUSTRY

AUTHORITY Republic of the Philippines

PHILIPPINE MERCHANT MARINE ACADEMY

San Narciso, Zambales

FOREWORD

In June 1998, The Commission on Higher Education ( CHED ) implemented a new structure as well as ne curricular for education towards Bachelor of Science in Marine Engineering. These changes were made to comply with the ammendments made to the International Convention on Standards of Training and Watchkeeping for Seafarers of 1978 ( STCW 98 ) and adopted by the International Maritime Organization ( IMO ) in July 1995. The goal of this sea project book is to guide, monitor and provide the knowledge to every cadet/cadette needed to meet the requirements stated in CHEDs syllabus for the subject. Every reasonable effort has been made to ensure that the information provided is relevant and presented in logical way. Bear in mind that the technical and socio-economical developments entail to the new equipment and systems will constantly be introduced and implemented in the shipping industry. This development and its consequences must also be reflected and use in teaching aids. Any comments, revision of this sea project book for improvement and updates of knowledge from officers on board therefore highly appreciated.

Engr. Felix G Bermas Engine Training Officer Dept. of Shipboard Training PMMA Class 2003

ENGINEERING SEA PROJECT ENGINE MIDSHIPMEN, SECOND CLASS

TABLE OF CONTENTS

Section 1. PMMA Shipboard Training Program 2. Sea Project Receipt 3. Sea Project Report 4. Helpful Hints from SBT 5. Booklist 6. Instructions 7. Function 1 (Marine Engineering System) 8. Function 2 (Electronic Control Engineering) 9. Function 3 (Maintenance and Repair) 10. Function 4 (Ship Operation and Safety) 11. Tool Fabrication ( replacement) 12. List of Graduates Sailed On Board with

Abbreviation PSTP SPR SPRC HH BL I F1 F2 F3 F4 TF LGSBW

Philippine Merchant Marine Academy San Narciso, Zambales

Republic of the Philippines

CERTIFICATION

I certify that this sea project is my own work. I did not use reports prepared by other students in any form, in its preparation. I also certify that all textbooks, technical manuals and other references used in the preparation of this report are all listed in the report. I understand that failure to comply with these requirements is an honor violation and can result in my dismissal from the Academy.

Signature ______________________ Print Name 2CL GUALBERTO, IVAN A

(This certification must be included infront of each quarterly sea project report)

HELPFUL HINTS FOR SUCCESSFULLY COMPLETING THIS SEA PROJECT

1. Probably the most important aspect of these Sea Project is the only record of your accomplishments during the sea year. When answering questions in the project, use your observations and what you have learned to demonstrate your competence. 2. Read your Sea Project thoroughly understood the instructions and questions being ask during the scheduled sea project lectures. 3. All work on some parts of your project start from day 1. Identify these portions of your project and commence accordingly. 4. Carry a small pocket notebook at all times and make frequent notes of your observations and research throughout the workday. 5. Ships officers are an excellent source of information but are employed to operate the vessel and are not obliged to teach cadets. However, if the cadet shows motivation, worthiness, and selects proper time to ask questions they will generally be wiling to pass on their knowledge. 6. Typewritten projects are easy to read and preferable since clarity and neatness enhance your work, handwritten project are not acceptable anymore. 7. All computational work on Navigational/ Engineering problems is to be submitted and each problem is to be properly labeled whether acceptable triangle is attained or not. 8. Do not leave out any questions unanswered. Answer all to the best of your knowledge. 9. Photographs are fine and enhance the clarity of your project, but a brief explanation of subject matter is necessary to assist the grader in identifying the photo. 10. Diagrams are most helpful and should be used when possible. 11. Do not stow your sea project in your Luggage. Carry it in your hand baggage to prevent possible loss. Remember if you do loss it will require considerable remedial work. 12. Do not copy other cadet sea projects. Copied material is soon forgotten. Your independent work will be remembered when needed most during licensing time. 13. A passing grade in al aspects of your sea project is a graduation requirement. 14. Do not forget to submit your quarterly sea project to the office of shipboard training in the Academy.

PMMA SHIPBOARD TRAINING PROGRAM

As part of the professional training, each cadet participates in a cooperative educational program consisting of a sea year of two phases of ten months plus two months aboard commercially operated merchant ships. The first shall be a period of orientation followed by the first phase, second phase and the last month for review and polishing up. Each cadet generally trains on one vessel with the exception of certain companies. They thereby become familiar with the performance and the operating characteristics of various classes of ships and with the diverse operating requirements with different trade routes while at the same time gaining available practical experience in the performance of shipboard duties. Shipboard duties consist of 8-hour shipwork and 2-4 hour watches daily, that ratings normally performed. In short they are primarily crew member first and third year BSMar-E students second. After their duties, cadets who pursue a BSMar-E correspondence course for at least 2 hours daily. The shipboard training program provides all cadets with the opportunity to use a ship as a sea going laboratory. Engine cadets are given a study guide called Sea Project and are required to complete written assignments which are submitted to the Academy for evaluation and grading. The assignments are carefully designed to ensure that, while aboard ship, cadet midshipmen apply the knowledge and skills learned in the Academy classrooms. But what is most important is for cadets to acquire a firm foundation for advanced study upon their return to PMMA. Written Assignments cover the following areas:

Function 1- Marine Engineering Systems Function 2- Electrical, Electronic Control System Function 3- Maintenance and Repair Function 4- Engine Operations and Care for Person on Board Note: Both Functions are covered for Sea Phase (phase 1 and phase 2)

Aboardship, BSMar-E cadets are assigned to the Engine Department or General Purpose crew duties. Sea project assignments concentrate on subject matter appropriate to the cadet specialty. However, during the first phase of training, Engine cadets are required to complete assignment in the opposite departments to ensure the basic familiarity with all aspects of ship operation. Through counseling, the office of Shipboard Training can ensure the cadets assignments that will provide maximum exposure in the desired area of specialization during this cooperative program. PMMA Training Representatives at New York, Los Angeles, New Orleans, Hamburg, Rotterdam, Yokohama, Singapore and from PMMA will board the cadets respective ships to monitor, guide cadets in their progress, conduct midterm and final examinations, maintain liaison and even board cadets if necessary. The sea year is concluded with a de-briefing upon arrival to respective companies and another de-briefing from the office shipboard training at PMMA including sea year evaluation before enrolling as fourth year cadet. Each cadet is required to complete and submit following documents; Sea service in PRC form, SIRB, Sea project bookbinded, De-briefing form to be given a enrollment flowsheet for final evaluation at the Office of Shipboard Training through Engine Training Officer.

RECEIPT ENGINEERING SEA PROJECT: SECOND CLASS

Received from Midshipman 2cl Gualberto, Ivan A. the following sea project units as indicated below:

class of 2014___

Date of Submission: ________________________________ Sea Year Split ______ FUNCTIONS Function 1 UNITS 5 REMARKS Collector Signature

Function 2 Function 3

5 5

Function 4

NOTE TO ALL MIDSHIPMEN SUBMITTING SEA PROJECTS FOR GRADING:

1. 2. 3. 4.

This is your receipt for your sea project.

Make certain receipt is acknowledged and signed by your collector at the turn-in. Original receipt will be retained by the Department of Shipboard Training. Copies of the receipt can be obtained upon request from the Department of Shipboard Training.

Philippine Merchant Marine Academy

San Narciso, Zambales
SEA PROJECT REPORT College of Marine Engineering Subject Marine Engineering System Assignment # 2

Republic of the Philippines

Sea Phase 1st Semester

Vessel (s) Assigned (Name) MV EVER PRIMA Date Assigned June 16, 2012 Date discharged ____________________________ days on board ____________ Type of Vessel (s) Cargo Routes Travelled Taiwan Japan Singapore Malaysia Hong Kong

Graders Initial _________________

Midshipman 2cl Gualberto, Ivan A. Engine Cadet Class 2014

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ENGINEERING SEA PROJECT MIDSHIPMEN- SECOND CLASS

GENERAL INSTRUCTIONS

The Engineering Sea project is to be completed by you during your first sailing period or first phase. It is made up of several assignments covering various aspects of the engineering plant of ships which you have been assigned. Each assignment consists of a written report in which you describe a particular area, system, component, or operation. When writing each assignment, utilized your ship as a laboratory and make the necessary observations yourself. Your report will be a record of your own personal observations and the reports are to be in your own words based on practices of your assigned vessel. Do not copy instructions verbatim. Before starting a work read the entire Marine Engineering assignment. You must take the initiative in this work. No one will assign this work to you or allot the time for it to be done. You will be completely on your own to complete this work as your responsibility. Take your time wisely. From time to time you may need assistance in doing some parts. Properly approached, the ships engineers will often be helpful in clarifying engineering principles which may not be so easily understood. Remember, however, that these officers have their own work to perform and should usually be consulted only after you exhaust other sources of information. Also, each ship usually has a complete set of instruction books that may be available to you. Take every opportunity to get accurate information, but report it in your own words. In each case where you obtain material from some source other than your own observations, note and credit the source by an endnote. Do not copy from instructional manuals, but make each section as original as you can. The attitude with which you approach these assignments will have a marked effect on your performance in your whole second class year and specially your first class year. You will be regularly called upon to answer questions upon your sea experience and sea project. You will be held directly responsible for each and every reading assignment you are given. You must comply with the directions outlined in the paragraph of each assignment. The clarity, neatness, accuracy, and completeness of your presentation will all be reflected in your grade.

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SPECIFIC INSTRUCTIONS

1. SKETCHES: ALL Final ready for submission required system schematics must be
accompanied by the original rough tracing that you performed in the engine room, on location. The rough sketch is to be placed directly behind (i.e., immediately following) the final. Good clean schematic.

2. You are encouraged to use simple sketches, wherever you desire to clarify the
written material. Such sketches may be inserted and need not be put on the standard sheets. However, these small sketches do not take the place of required sketches.

3. No duplicated material is to be submitted. The only exceptions to the above are

sketches or graphs submitted in addition to those required by the assignment.

4. All references must be listed at the end of each assignment. Endnotes must be
included where necessary. References may include, in addition to the required textbooks, the following: a. Ships engineers and crew b. Personal observations c. Ships literature and manuals d. Textbooks other than required textbooks

5. Assignment sheets indicating project requirements must be removed from this

booklet and included in the submitted project. They are to be placed up from as the first set of pages.

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6. Photographs greatly enhance the quality of your sea project. You are encouraged to
use them where you desire. A brief explanation must be provided to assist the reader in identifying the subject matter.

DEPARTMENT OF TRANSPORTATION AND COMMUNICATION

MARITIME INDUSTRY AUTHORITY

BSMAR-E SEA PROJECT/ ENGINE

FUNCTION I MARINE ENGINEERING SYSTEMS

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PHILIPPINE MERCHANT MARINE ACADEMY PMMA COMPLEX, SAN NARCISO, ZAMBALES

MARINE ENGINEERING SYSTEMS MAIN PROPULSION SYSTEM

The sea training period you are now undertaking will present you with challenges and opportunities unique to your engineering education. It is important to take advantage of these opportunities in order to get the most out of them as possible. The primary goal of the sea year is to expose the cadet to the practical aspects of Marine Engineering as they relate to operating and maintaining marine equipment and systems. It is also the major component in your preparation for the licensure examination to be taken in their first class year.

1. Whenever anything is going on in the engine room, regardless of the time of day,
be there! This includes maneuvering, repair work, shipyard overhauls, etc.

2. Take this as an opportunity to study the textbooks references in the

assignments. You will not have time during your first class year to prepare for licensure examination.

3. You have to complete one of the two assignments in this section depending on
what ship you were assigned. You are required to complete the appropriate complementary assignment.

Assignment 1 is required to be completed by those cadets who are assigned to a steam propulsion vessel for more than 30 days.

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Assignment 2 is required to be completed by those cadets who are assigned to a diesel propulsion vessel for more than 30 days. However, if a midshipman is assigned for both ships during his/her sea period, the cadet may select to complete either assignment 1 or assignment 2. The cadet is required to complete the designated complementary assignments in Marine Engineering systems as directed in its instructions.

MARINE ENGINEERING SYSTEMS PROPULSION PLANT/SYSTEM

A. OPERATIONS 1. Prepare a detailed description and steps required to prepare your ships
propulsion plant for getting the ship underway. Consider sequence, precautions, and timing and personnel assignments. Assume the ship is in a state of cold iron or cold start.

2. Prepare a detailed description of the steps required to secure your ships

propulsion plant for an extended period at lay up berth/port. Consider sequence, precautions, and timing.

3. Prepare a description of the steps required to perform each of the operations

listed on the Performance Verification check- off list next to this page. When written procedures are prepared, proceed with obtaining signatures for accomplishing the operations, procedure and verification sheets should be signed and approved by ships engineer.

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4. Include a copy of completed page from the engine room log book. Including set
of readings from both sea watch and port watch.

5. Complete two copies of pertinent data sheet for which vessel you are assigned
and to be placed in front of the report/ sea project.

PERFORMANCE VERIFICATION

Demonstrate to the satisfaction of the licensed Engineer the ability to accomplish the listed operations below. In some instances, ships requirements may only allow simulated or dry run demonstrations. But with advanced planning, these circumstances should be minimized. While completing this portion of your sea project, remember that ships engineer/officers have extensive responsibilities of their own to look after and should not be approached for your demonstration until you are confident of your understanding to the system involved. Do not attempt any of the operations listed without the permission of the Chief Engineer or First Engineer.

Operation

Date procedure approved

Date Signature of accomplished ships Engineer

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1. Light off boiler cut in burner 2. Operate sootblower 3. Take water samples and conduct boiler water chemical analysis 4. Switch and clean a fuel or lube oil strainer 5. Transfer fuel oil from storage tank to settling tank 6. Start up, parallel and secure service generators 7. Start a feed pump 8. Take on fuel for sample after bunkering 9. Bunker loading/discharging watch MARINE ENGINEERING ASSIGNMENT NO.1 B. PROCEDURES Explain in detail procedures indicating possible causes, problems and steps to be taken to determine the actual cause, and plant operating procedures to be followed in following plant emergencies. a. Loss of fires in one boiler while steaming b. Loss of fires in both boilers while steaming c. Loss of main condenser vacuum d. Loss of feedwater supply e. Low and high D.C heater water level

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f. Excessive use of make-up feedwater g. Water level out of sight in boiler gauge glass h. High stack temperature i. Excessive black smoke from stack j. Excessive white smoke from stack k. High salinity at condensate pump discharge l. Fresh water generator trips due to high salinity m. Fresh water generator not working at capacity

MARINE ENGINEERING Assignment no.2

Note: This assignment must be completed if assigned to a Diesel Propulsion Ship. I. Shipboard Systems Prepare Schematic Diagrams of the systems listed below as the system exists in the vessel to which you are assigned. Use standard symbols. Do not use colors, use the proper drawing tools. Show flow direction with arrowheads on the piping runs. Accompany each schematic with a brief written discussion of the system. Label your diagram fully and the discussion must include the following:

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a. The purpose of the system b. The major components of the system c. How the major components contribute to the purpose of the system d. Include nameplate data for major components e. Know the basic principle of the system In your diagram, include the following: a. All pressures and temperatures b. Flow arrows/directions c. All components labeled Systems to be studied are: 1. Engine starting air system 2. Fuel oil service system 3. Fuel oil transfer system that includes purification 4. Fresh water cooling system 5. Circulating water system 6. Sea water cooling system 7. Lube oil system 8. Lube oil purification and transfer system 9. Exhaust system 10. Fuel injection system 11. Steering gear system 12. Incinerator system (if available in your vessel)
MARINE ENGINEERING SYSTEMS PROPULSION PLANT/SYSTEM

C. OPERATIONS 1. Prepare a detailed description and steps required to prepare your ships
propulsion plant for getting the ship underway. Consider sequence, precautions, and timing and personnel assignments. Assume the ship is in a state of cold iron or cold start.

2. Prepare a detailed description of the steps required to secure your ships

propulsion plant for an extended period at lay up berth/port. Consider sequence, precautions, and timing.

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3. Prepare a description of the steps required to perform each of the operations

listed on the Performance Verification check- off list next to this page. When written procedures are prepared, proceed with obtaining signatures for accomplishing the operations, procedure and verification sheets should be signed and approved by ships engineer.

4. Include a copy of completed page from the engine room log book. Including set
of readings from both sea watch and port watch.

5. Complete two copies of pertinent data sheet for which vessel you are assigned
and to be placed in front of the report/ sea project.

D. Casualty Operation/Procedures Explain in detail procedures indicating possible causes, problems and steps to be taken to determine the actual cause, and plant operating procedures to be followed in following plant emergencies. a. Loss of fire in auxiliary boiler b. Water in fuel c. Plugged fuel filters d. Loss of feedwater supply to auxiliary boiler e. Excessive use of make-up feedwater to various expansion tanks f. Water level out of sight in auxiliary boiler gauge glass g. Serious oil leak in machinery space h. Loss of lube oil from main pump i. Fresh water generator not working at capacity j. High stack temperature

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k. Black smoke from the stack l. Turbocharger surging m. High engine bearing oil temperature n. Exhaust temperature from one cylinder is high o. One cylinder cut out p. Crankcase explosion q. Smoke detection at the crankcase r. Engine run-away s. Low pressure from air bottles t. Scavenging fire PERFORMANCE VERIFICATION

Demonstrate to the satisfaction of the licensed Engineer the ability to accomplish the listed operations below. In some instances, ships requirements may only allow simulated or dry run demonstrations. But with advanced planning, these circumstances should be minimized. While completing this portion of your sea project, remember that ships engineer/officers have extensive responsibilities of their own to look after and should not be approached for your demonstration until you are confident of your understanding to the system involved. Do not attempt any of the operations listed without the permission of the Chief Engineer or First Engineer.

Operation

Date procedure

Date accomplishe

Signature of ships Engineer

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approved 1. Remove fuel injector from main engine and replaced with conditioned one 2. Test fuel injector 3. Start ship service generator 4. Secure centrifuge, clean and put back in service 5. Test water in engine fresh water cooling system 6. Start Main Engine 7. Operate maneuvering station for main engine, arrival or departure 8. Operate emergency steering 9. Take crankshaft deflection readings for at least one cylinder

PERTINENT DATA SHEET MARINE ENGINEERING Instructions: Two complete sets of pertinent data form are inserted in the engineering sea project that should be removed and inserted in your final sea project. This form shall start within one month after assignment to the engineering department of each vessel and completed prior to detachment from the assigned vessel. The information is to be obtained during normal sea operation, unless otherwise noted. Midshipmen _______________________________________ Date _____________ Class of _________________ SS ____________________________ Shipping Company ____________________

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Type and class of Ship _________________________________________________ Gross tonnage _________________________ Design Speed __________________ Builder ________________________________ Year Built ___________________ Dates Assigned: From ______________________ to _______________________ Main Propulsion Engine Maker _________________________ Model # _____________ Cycle __________ Type of Turbo charging System ________________________________________ BHP (give KW equivalent) ______________________ Prop Shaft RPM _______ Method of Reversing _________________________ SHP ___________________ Type of Fuel used ____________________________________________________ Fuel Oil Consumption Average Per day in metric tons _____________________ Reduction gear Manufacturer (if any) ___________________________________

GENERATORS Maker ______________________________________________________________ Cycles ______________________________________________________________ Type of Turbo charging System _________________________________________ HP (also include KW equivalent) ________________________________________ RPM ________________________ Number of Cylinders (including firing order) _____________________________ Fuel Used _______________________________

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Fresh Water Generator Number ______________________ Type ________________________________________________________________ Manufacturer ________________________________________________________ Rated Capacity _______________________________________________________

Purifiers Number __________________ Type ________________________________________________________________ Manufacturer ________________________________________________________

DEPARTMENT OF TRANSPORTATION AND COMMUNICATION

MARITIME INDUSTRY AUTHORITY

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BSMAR-E SEA PROJECT/ ENGINE

FUNCTION I MARINE ENGINEERING SYSTEMS

Auxiliary Systems

MARINE ENGINEERING
AUXILIARY SYSTEMS

The sea year training period will present you with challenges and opportunities unique to your engineering education. It is important to take advantages of the opportunities in order to get the most out of them as possible. The primary goal of the sea year expose to every cadet to the practical aspects of Marine Engineering in relation for operating, maintaining marine equipment and systems. It is also the major component in preparation for licensure examination.

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1. Whenever anything is going on in the engine room, regardless of the time of day,
be there! This includes maneuvering, repair work, shipyard overhauls, etc.

2. Take this as an opportunity to study the textbooks references in the

assignments. You will not have time during your first class year to prepare for licensure examination.

3. Note that the Midshipman is required to complete assignments in Auxiliary

Diesel Systems or Diesel Propulsion Plant

This assignment must be completed regardless to which ship you are assigned with either steamship or diesel propulsion plant.

ASSIGNMENT

A. B. C. D.

The purpose of the system Major components of the system How the major component contribute to the purpose of the system Data of the components

Schematic diagram:

a. All pressures and temperatures b. Flow arrows c. All components labeled

Systems to be studied and labeled are:

1. 2. 3. 4. 5. 6.

Engine starting air system Fuel oil service Fuel oil transfer including Purification Fuel injection system Lube oil service, transfer and Purification Exhaust system

Since these systems are being traced externally to the engine and it should not be elaborated as to the Main Engine. Therefore tour schematic diagram must include internal features regarding circulation and arrangements.

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OPERATIONS

1. Explain in detail the procedures that should be followed for the emergencies that
may arise concerning auxiliary machineries. Causes and problems be included in Function 4 of this sea project in meantime answer the following and write the steps to be taken to determine the actual or possible cause.

a. b. c. d. e. f. g. h. i. j.

Water in fuel Plugged fuel filters Serious oil leak Excessive loss of lube oil from pump High exhaust temperature Excessive black smoke from the stack Surging turbochargers High engine bearing oil temperature High hydrocarbon vapor content Operation without one cylinder firing

BOILER:

a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u. v. w.

Loss of fire Loss of feedwater supply Low and high DC heater water level Excessive use of make-up feedwater Water level out of sight in boiler gauge glass Serious oil leak in auxiliary boiler High stack temperature Excessive black smoke from the stack Panting in watertube boiler Tube failure Excessive oil temperature Safety valve hang-up Safety valve chatter, simmer and leakage Unstable main flame No ignition/failure of ignition flame Incomplete combustion Internal waterside corrosion including forms of corrosion Formation of scale in boiler Procedures in boiler water treatment Survey and maintenance of boilers Boiler operation and safety Procedure of circulation and steam raising Emergency operation due to fire

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AIR CONDITIONING AND REFRIGERATION A. B. C. D. E. F. G. H. What is refrigeration? What is refrigerant? What is air conditioning? Characteristics of a good refrigerant? Principle of Mechanical refrigeration? Types? Advantages? Difference between Direct and Indirect System ( Draw ) Four processes of Mechanical Refrigeration Cycle Definition of technical terms: 1. absolute pressure 2. ambient temperature 3. calorimeter 4. chiller 5. compression ratio 6. critical pressure and temperature 7. cryogenic 8. enthalphy 9. latent heat 10. psychrometer

FRESH WATER DISTILLER/GENERATOR a. b. c. d. e. Principles of operation Schematic diagram Main components and their specific functions Relation with HT and LT Starting procedures

AIR COMPRESSOR a. operating principle including design and safety b. schematic diagram c. starting and stopping procedures PURIFIER a. principle of centrifugal separation b. draw vertical section of separator bowl including parts c. Definition General Terms 1. Purification 2. Clarification 3. Viscosity

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4. Centrifugal separation 5. separation by gravity 6. throughput 7. Back pressure 8. Displacement water 9. Conditioning water 10. Density Difference

DEPARTMENT OF TRANSPORTATION AND COMMUNICATION

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MARITIME INDUSTRY AUTHORITY

BSMAR-E SEA PROJECT/ ENGINE

FUNCTION 2 ELECTRICAL, ELECTRONIC CONTROL SYSTEM

PHILIPPINE MERCHANT MARINE ACADEMY PMMA COMPLEX, SAN NARCISO, ZAMBALES

ELECTRICAL ENGINEERING

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The electrical course during second class/3rd year, are component parts of an integrated program in electrical power for marine engineers. The function of this Electrical Section is to expand further your knowledge in electrical machinery and control apparatus aboard ship, and to familiarize with maintenance procedures and operating techniques included in this license oriented sea project. For assistance refer to licensed engineers and electricians aboard your ship.

ASSIGNMENTS 1. Definition of Terms a. Electricity b. Alternating Current c. Ampere turns d. Armature winding e. Balancer set f. Commutator g. Counter emf h. DC generator i. DC motor j. Dead band k. Ground lights l. Growler m. Impedance n. Horsepower o. Rheostat p. Slip ring q. Synchroscope r. Thermocouple s. Transducers 2. 3. 4. 5. 6. What are the sources of energy that electricity can be produced? What are the causes of failures of a DC generator to build up? Causes of sparking at the brushes? Causes of too low generator speed? Reasons why a self-excited DC generator might fail to come up to its rated voltage when starting up? 7. A generator is vibrating, what checks should be made before changing any balance weights? 8. Give at least four factors that affect resistance on a wire?

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9. What condition must exist in order that two AC generator will operate in parallel? 10. What protective devices are installed in an electric drive system? 11. Give the method of synchronizing by the use of bright and dark lamp method? 12. Name the major parts of an AC and DC generator including kinds? 13. Characteristics and applications of types of DC motor? 14. Two different types of induction motors and its applications? 15. Characteristics and applications of types of DC generator? TESTING AND EVALUATING ELECTRICAL INSULATION 1. What factor is the principal determinant of insulation life? What rule of thumb applies for insulation life expectancy vs. operating temperature? Name some possible causes for a machine found to be operating above its permissible temperature rise. 2. What instruments are available aboard your ship for measuring the insulation resistance? State manufacturer, model number, voltage rating, and megohm ranges. Briefly describe how this equipment functions and is constructed. 3. State in detail, the procedure used aboard your ship for measuring the insulation resistance of the ships service generators and compare it with the recommended procedure. 4. What was the most recent insulation resistance determination for the ships service generator? What was the reading and at what temperature it was taken? 5. Determine from the ships engineers and electrician if any unusually low megger readings were experienced on your ship and if experienced, what were the cause and what corrective action was taken?

CLEANING, DRYING AND REVARNISHING INSULATION

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1. What are some causes of insulation breakdown? How often generators and motors thoroughly cleaned in your ship? What was the basis for establishing the frequency of cleaning? 2. Under what conditions are solvents used for cleaning electrical insulation? What type of solvent is used aboard ship? What damage can occur from excessive use of solvents? 3. What damage can occur to electrical apparatus during periods of inactivity? How is idle electrical equipment protected during inactivity aboard your ship? 4. How ships engineers and electricians aboard your ship recondition an electrical machine that was submerged in saltwater. Describe in detail? 5. What restrictions should be placed on the use of reconditioned flooded equipment?

TRANSFORMERS: 1. Copy the nameplate, date of ships lighting transformers. How many transformers are there on your ship and how they connected? Neatly sketch the circuit. 2. What maintenance is performed on the transformer aboard your ship and how often is it performed? 3. What was the most recent insulation resistance reading for the ships service lighting transformers and at what temperature was it taken? What conclusion can you form concerning the condition of the insulation?

MOTOR CONTROLLERS

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1. Describe some of the electrical trouble shooting repair work done on the motor controllers aboard your ship? 2. What are the damaging effects that may result from an inadequate controller maintenance program aboard your ship? 3. Using on board textbooks as a guide, apply the analytical troubleshooting techniques to the circuit diagram of an electrically operated auxiliary, such as capstan, cargo winch, anchor windlass on your ship. Assuming a fault condition allows the motor to operate in only one direction, determine the possible faulty components.

COMMUTATORS SLIP RINGS AND BRUSHES This section does not only apply to those on board with commutator or slip ring type machinery. If any not installed aboard ship, it is required to answer following questions for additional knowledge. 1. How are commutators and/or slip rings cleaned aboard your ship? 2. How are commutators and/or slip rings resurfaced aboard your ship? 3. Describe the entire procedure in proper sequence that is used or will be used for installing and seating new brushes on machinery aboard your ship. 4. Where any d-c machines aboard your ship troubled with sparking? What was done to remedy it?

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Republic of the Philippines Philippine Merchant Marine Academy

San Narciso, Zambales

BSMar-E SEA PROJECT/ Function 3-4

Second Class Year/ 3rd Year

RP DEPARTMENT OF TRANSPORTATION AND COMMUNICATION

MARITIME INDUSTRY AUTHORITY DEPARTMENT OF TRANSPORTATION

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AND COMMUNICATION

MARITIME INDUSTRY AUTHORITY

BSMAR-E SEA PROJECT/ ENGINE

FUNCTION 3 MAINTENANCE

and

REPAIR

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PHILIPPINE MERCHANT MARINE ACADEMY PMMA COMPLEX, SAN NARCISO, ZAMBALES

MAINTENANCE AND REPAIR

In this Function, cadets must be familiar with all equipments regarding machineries during maintenance program aboard ship and having knowledge how to repair said machinery. The primary goal of this section is to expose cadet in practical aspects of Marine Engineering as to relate in operating and maintaining marine equipment and systems. In this assignment take every opportunity to take some pictures, drawings, sketches, et al. and procedures to be taken. Xerox copied from manuals is accepted but make sure it is a clear copy and attached here on your assignment. ASSIGNMENTS: Procedures: 1. Assembly and disassembly of Piston (pulling out) 2. Disassemble and assembly of Main Engine FO pump 3. Overhauling of FO injection Valve 4. Overhauling of Main Engine Exhaust Valve 5. Checking Crankshaft Deflection 6. Checking of Piston Rings 7. Inspection and measuring of Cylinder liner 8. Checking of crosshead and crankpin bearing clearances 9. Emergency procedures in putting cylinders out of action 10. Inspection through scavenge ports: piston and liner 11. Turbocharger water washing, maintenance and inspection 12. Procedures in taking Engine Indicator Diagram MAIN PROPULSION/ MAIN ENGINE

13. Inspection of camshaft 14. Emergency maneuvering engine side procedure 15. Inspection of Main bearing

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Troubleshooting: 1. 2. 3. 4. 5. 6. 7. Reasons and causes of wear from cylinder liner Symptoms and causes of turbocharger surging Engine RPM drops and engine stops while at full speed Engine does not turn when starting air applied Engine does not ignite or firing Engine knocks Abnormal exhaust gas: high exhaust gas from one cylinder, low exhaust gas from one cylinder, high exhaust temperature in all cylinders, black exhaust gas, bluish exhaust gas, and white smoke exhaust gas. 8. Lube oil pressure drops: Main system, valve gear system 9. Overheated bearings 10. Insufficient cooling in one and all cylinders 11. Scavenging Fire alarms 12. Oil Mist detector failed alarms

AUXILIARY ENGINES GENERATORS: Procedures: 1. How to couple Generator from incoming to running DG ( manual ) 2. Changing of fuel pumps 3. Changing LO Filters and FO filters 4. Changing over from FO- DO 5. Changing auto backflush filter 6. Crankshaft Deflection 7. Overhauling fuel injection valve 8. Overhauling fuel injection pump 9. Required test for injection valve 10. Cylinder head replacement Troubleshooting: 1. 2. 3. 4. 5. Running Generator shut down Standby Generator did not start upon shutdown of running DG Emergency Generator failed to start Synchronization failure Generator too much vibration

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6. One cylinder fail to fire 7. Low level Sump tank 8. DG overflow tank low level alarm 9. Starting air failure 10. Genarator too high exhaust temperature on all cylinders

BOILERS: Maintenance: a. b. c. d. e. f. g. h. i. j. k. l. m. treatment of water ( external and internal ) frequency of surveys scope of surveys arrangement before surveys survey route procedures weekly, monthly and yearly maintenance for rotary cup burner safety valves sootblowers economizers furnace How would you make an Hydrostatic test on a boiler? Procedure in lay-up the boiler Procedures for adjustment of safety valves

Troubleshooting: 1. water level gauge glass low/high 2. flame failure 3. DO/FO low temp 4. Tube failure 5. air and scab bubble pitting 6. primary air low 7. Main flame failure during ignition 8. Black Smoke or Incomplete Combustion 9. boiler chatters, simmer, leakage and hang-up 10. panting in watertube boiler 11. excessive oil temperature 12. feedwater pump seal broken

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PUMPS: 1. Disassembling and assembling: a. removal of volute cover b. removal of rotating element c. removal of impeller and sleeve d. removal of mechanical seal e. removal of coupling f. removal of ball bearing 2. Clearance and Limit Use of Suction Piping And Alignment of Coupling 3. Checking of Alignment- Rotary Pumps 4. Cautions during operation 5. Troubleshooting: a. pump cannot discharge b. insufficient discharge c. prime mover overload d. overheating of bearing e. abnormal noise in ball bearing f. vibration in pump g. leakage in mechanical seal h. cavitation in pumps

AIR COMPRESSOR: Weekly, Monthly and Annually checks

REFRIGERATION AND AIR- CONDITIONING: 1. Maintenance: a. starting procedure b. freon charging c. purging procedure d. charging oil to crankcase e. method in defrosting 2. Troubleshooting: a. Compressor will not start b. Compressor starts and stops frequently c. Compressor starts but stops immediately afterwards d. Compressor runs continuously e. Insufficient compressor capacity f. Excessive discharge pressure g. Excessive suction pressure h. Excessive discharge pipe temperature

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i. j. k. l. m. n. o.

Oil temperature too high Oil level in crakcase falls Sweating or frozen crankcase Bubbles in the liquid sight glass Low refrigerant level in the receiver Capacity regulator hunting Liquid hammer in the compressor during start up

PURIFIERS: 1. Maintenance: a. Dismantling procedure b. Assembling procedure c. Major Overhaul d. Motor Dismantling e. Starting and stopping procedure 2. Troubleshooting: a. Water in worm gear housing b. Speed too high/ low c. Run up time too long d. Bowl fails to open for sludge discharge e. Separator vibrates f. Unsatisfactory separation result g. Unsatisfactory sludge discharge h. Bowl opens unintentionally during operation i. Liquid flows out through bowl casing drain/ or sludge outlet j. Indicating pressure ( in water outlet ) too high k. Discharge pressure low l. Steam pressure too high m. Feed pump failure OTHER ESSENTIAL MACHINERIES or SYSTEMS: Starting and stopping procedure of Fresh Water Generator Inert Gas System for Cadet/Cadette assigned on Tanker vessels LT and HT filter maintenance procedure Cleaning on FWG plates ( condenser and evaporator sides) Maintenance on airhorn machinery Maintenance procedure for winches and capstans. Anchor and Windlass checks Steering gear weekly, monthly and annually checks/maintenance Provision Crane and other crane maintenance program

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DEPARTMENT OF TRANSPORTATION AND COMMUNICATION

MARITIME INDUSTRY AUTHORITY

BSMAR-E SEA PROJECT/ ENGINE

FUNCTION 4 Engine Operations and Care for Persons On Board

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PHILIPPINE MERCHANT MARINE ACADEMY PMMA COMPLEX, SAN NARCISO, ZAMBALES

DEPARTMENT OF TRANSPORTATION AND COMMUNICATION

MARITIME INDUSTRY AUTHORITY

BSMar-E

SEA PROJECT
Sea Phase Periods/ 2nd Class year
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Republic of the Philippines

PHILIPPINE MERCHANT MARINE ACADEMY

San Narciso, Zambales

Engine Operations, & Care for persons on board

In this section, each cadet/cadette should be familiar with regards to safety equipments on board and should have learned and completed task on board regarding operations from engine and how safety implemented on board their vessels. In Maritime safety: . We must always prioritize our own safety what ever jobs we have. . We must always protect our own life and the lives of others. . We must always remember that we have one life to live. . We must show respect so that we earned others respect. . We must be cooperative, so each task we do on board be easy. . Lastly, remember that our family and love ones are depending and waiting for us. ALWAYS THINK SAFETY FIRST ! Our Life Depends on Our Own Hands

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Know your ship: Duty and obligation to know and study the following: 1. Type of the vessel 2. Muster Station 3. Duties and Responsibilities at emergencies 4. location of; a. fire fighting equipment b. saving equipments c. nearest fire alarm d. fire escape e. lifejacket in cabin f. first aid boxes, medicine and medical equipments g. lifebouys h. main switch of cabin Modern ships are designed with safety in mind but modern equipments demands that new techniques have to be learned. Majority of accident are caused by lack of awareness amongst personnel and very seldom by faulty equipments. Whole concept of function 4 is to know Maritime Safety regarding Prevention of Major Disasters and Minor Disasters,start your research on the causes of said disasters.

Task to do: Procedures to launch lifeboats from ship until boats are finally away. Procedures to start and secure lifeboat engines both in water and stowed position. Procedures to launch and board the liferafts on your ship, how will raft be released in the event that the ship sinks with the raft in secured/stowed position. Procedures for taking soundings, frequency, by whom and what is done with this information. Show calculation from ullage or actual soundings? Refer to ships manual bunker calculation. Procedures for taking arrival with respect to bridge personnel. Start research from time bridge notifies engine room of arrival plans and follow through until finished with engine.

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What are the external and internal means of communication systems on board including emergency communications, flags, flashing light, whistles, engine order telegraph, radios, telephones, PA systems and so on. Who is tasked with operating these pieces of equipment. Procedures for Anchoring the vessel and for weighing anchor. Be familiar with the actions on the foredeck as well as in the wheelhouse. If the vessel does not anchor during your assigned stay, find out information regarding this matter from deck officers. What firefighting systems are used aboard your ship. Where is it located. Who is responsible for the fire pumps during fire drill. How are the fire pumps activated? Who comprises the emergency crew. What type of firefighting suits available aboard your ship. What are accommodation and pilot ladders used for. How are they stowed and who is responsible in getting the pilot aboard and away. How often safety meeting conducted aboard your vessel. Who runs the meeting and persons attended the meeting. What transpires at the meeting and what logbook are made concerning the meeting? Responsibilities of deck officer with respect to the care of cargo at sea and preparation of vessel for next cargo? Logbook entries? Procedures in taking bunker? What are the safety precautions to be made and what plans should be taken before taking bunker? What are to be check during safety checks on board your vessel. List all. What is ISPS code? Who is the ship safety officer on board your vessel? What are his responsibilities? When it was implemented regarding on this matter, include dates. Emergengy drill and Emergency Procedures that includes signal alarms. Purpose of Emergency Drill, On Board Training and Drills, 5Fire Control plans, and other important drills? What are the Personal Protective Equipments? Their Safety Guidelines? What is SCBA? Safety measures in taking care of a SCBA? It is very important to understand and study B.A set of the ship. Every ship have different types of B.A sets. Safety Equipments in the lifeboat, lifejackets, fire hoses and nozzles, lifebouys/ring? Research regarding on board distress signals and explain the importance? Location of EEBD in engine room? What is EEBD? Purpose and uses of EEBD?

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What are IMO Safety Signs and Symbols? Location of each Signs and symbols? Draw/picture each signs and symbols?

What is SAFIR? What should be reported? Suggestion for Improvement? Elements of SAFIR? Role of DPA or Designated Person Ashore? Role of the Company? Motivation? Methods of Investigation? Importance and uses of Accident Report? Documentation? Liability for personal injury? How can you Help with this SAFIR?

In addition as for Safety and care for persons on board, cadet/cadette should have the knowledge regarding SECURITY THREATS for incidents and to be reported to IMB piracy reporting center. 1. 2. 3. 4. How big is the problem? The methods used? What is the real Intentions? How to handle the problem

Each cadet/cadette should study and learn the following: Elements of Preventing Attacks Piracy Prone Areas and Warnings Actions to take when Entering hostile waters Actions to take if ship is boarded by pirates or terrorists Reprting of Incidents Principles of Security Measures Examples Of Security Measures Searches and Inspection

Engine Operation Regarding Safety Below simplified questions each cadet should have the knowledge to answer following itemized questions. Explain/Enumerate on the topic that will be ask below items. You may ask engineers help

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or any other officers on board how fire will be prevented/eliminated with a minimum effort. 1. Basic ways of preventing fire? 2. Elements of effective Fire Prevention Programme in: a. Training b. Maintenance and use of portable extinguishers c. Good house keeping d. Elimination and control of ignition sources e. Safeworking procedures 1. working in confined spaces 2. performing hotwork 3. working on oil pipes 4. working on machines 5. working on propulsion engine and propeller shaft 6. working on boilers, steam machinery and steam pipes 7. working on refrigeration system 8. working at heights 9. on completion of work f. Periodic inspections g. Preventive maintenance and repair h. Cargo Operation i. Transfer of fuel 3. Conditions for entry into enclosed spaces, pumprooms, Non Gas free and suspect compartments 4. Sample of Fire Station Bill and Lifeboats Station that includes duties and reponsibilities. 5. General Safety Precautions in Machine Shop? 6. Safety Operations of: a. Drilling Machine b. Shaper c. Planer d. Milling Machine e. Grinding Machine f. Boring Mill g. Lathe Machine

TOOL FABRICATION As replacement from former sea project tool fabrication it is recommended to draw following tools and stating its uses and importance including parts of Machinery in the Machine Shop. In this 48

section be familiar with the machinery and the tools uses, you may use the opportunity to handle things for the reason that all of the things you may encounter at the machine shop will be included to your licensure examination as Officer-in-Charge of an Engineering Watch. Task to do: Draw and label importance of its Draw and label importance of its Draw and label importance of its Lathe Machine Include uses, definition and parts. Milling Machine Include uses, definition and parts. Shaper Machine Include uses, definition and parts.

Draw, Define and State Uses Of the following: 1. Depth Rule 2. Combination Caliper Rule 3. Steel Squares And Combination Set 4. File 5. Shapes of Files 6. Center Gage 7. Hammer ( ballpeen and Chipping ) 8. Different types of Punches 9. Twist Drill Shanks 10. Pliers 11. Wrenches ( Adjustable, Monkey, Stillson, Box, Socket ) 12. Clamps 13. Drill Vise 14. Bolt ( Hole ) Punch 15. Taper tap and Tap Wrenches 16. Flaring tool 17. Packing tools 18. Open- end wrenches 19. Different Kinds of Puller 20. Tube Cutter 21. Chisel 22. Hand Drill 23. Allen wrench and set screw 24. spanner wrenches 25. Stock and adjustable Die 26. Split or Adjustable Die 27. Thread Counter 28. Portable Drill 29. Vernier Caliper 49

30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.

Plastic Hammer Micrometers Reamer Screw Drivers Divider Thickness Gage Scriber with Double Ends Bolt Cutter Markings for Identification of Piping System Basic Welding Symbols Methods And Positions of Welding

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The Philippine Merchant Marine Academy would like to have following information about any graduate employed on the vessels to which you have been assigned with. Print all data neatly and clearly. Name: 2003 Home Address : License : Company : ____________ Kahano, Neil Ian P. 2nd Engineer Cargo Safeway Inc. Class : Vessel : ______________ Signature :

Name: 2007 Home Address : License : _______________ Company : ____________

Degay, Steve B. 3rd Engineer Cargo Safeway Inc.

Class : Vessel : Signature :

Name: Home Address : License _______________ Company : ____________

Lopez, Froilan C. 3 rd Engineer Cargo Safeway Inc.

Class : 2006 Vessel : Signature :

Name: Home Address : License : _______________ Company : ____________

Calingan, Jimmy B. 2nd Officer Cargo Safeway Inc.

Class : 2003 Vessel : Signature :

Name: Home Address :

Florendo, Victor

Class : 2001

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License Prima Company : ____________

2nd Engineer Cargo Safeway Inc.

Vessel : MV Ever Signature :

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