AKRAMANUJAN.

ORG
26TH DECEMBER 2019
BLOG232
ramanujan1933@gmail.com
FUNCTION 4 AND 6

CHENNAI ORALS.

QUESTIONS CONTRIBUTED BY MR VISHNU SHANKAR

71 As 2/E what to check on AE cylinder head

Answer:- question needs more elaboration.

72Engine not starting on air. Reasons.

Answer:- The reasons are:

 Main air start valve drain valve blocked for

some reason preventing opening of the valve.
 Turning gear interlock faulty though the T/G is
disengaged.
 Main air distributor leaking heavily from the
seals.
 More than three air start valves leaking in a six
cylinder engine.
 Wrong direction interlock fault
73ME Rpm not increasing above 60rpm, reasons

* The tacho generator driven by main engine not building

voltage.

* The fuel control rheostat faulty or discontinuous or

earthed.

* the fuel control motor faulty and not able to move the
control lever to the required position.
 74 How to test boiler low water level trip

Answer:- High and Low water level cut out:- The steam
and water cocks/valves of the sensor are to kept shut and
boiler may be in operational mode, so that normal functions of
the boiler are not stopped. Drain the water in the sensor by
opening the sensor drain cock or valve. When the water level
reaches the low level the alarm will sound first and further
reduction of the level will put the flame off.
To test the high level alarm and cut off, shut the sensor drain.
Open the sensor lid and fill water in the sensor till level reaches
the high mark, when the high level alarm will sound. Further
filling of the sensor will cause the flame to extinguish when the
level reaches the set level.

75 Reasons for firing water tube boiler 7 minutes and for smoke
tube boiler 15minutes?
Answer:- When conducting the accumulation pressure test
of the boiler a lot of water is consumed and the
water level reduces. A water tube boiler water capacity
is small and if the test is prolonged for fifteen minutes
the level of water in the boiler will go down below
the safety level. hence this instruction.

76 How crankcase door of ME and AE checked for proper

operation

Answer:- The opening pressure of the crank case relief

door is very low l, less than 0.5 kg /cm 2. The valve
should spring open by hitting thr valve lid by the r
hammer handle.
 77 Where is thrust pad located in AE? How it looks
Answer:- The aux engine driving a generator does not
need a thrust pad or block , since there is no end
thrust. However a small collar is provided on the
crankshaft close to the coupling which bears against the
last main bearing flange which is whitemetal lined . This
takes any residual thrust caused by slight mis alignment.
This is in Daihatsu engine and is called a thrust washer.

78 Explain Nitriding, Annealing, Creep, Brinelling with examples

Answer;- ing

Nitriding is a surface hardening treatment, where nitrogen is

added to the surface of steel parts either using a gaseous
process where dissociated ammonia as the source or an ion or
plasma process where nitrogen ions diffuse into the surface of
components. Gas nitriding develops a very hard case in a part
at relatively low temperature, without the need for quenching.
The process has the advantage of being able to penetrate blind
holes, and also allows for the masking of parts to keep areas
which may need further machining soft. Also parts of different
sizes and shapes may be nitrided in the same cycle, allowing
for versatility

of the process. Ion nitriding, on the other hand, is a more

restrictive process. For uniform case depths in a load, parts
must be of similar size and geometry. Also, masking is difficult,
and penetration of blind or through holes is not possible.

Annealing, treatment of a metal or alloy by heating to a

predetermined temperature, holding for a certain time, and then
cooling to room temperature to improve ductility and reduce
brittleness.
 CREEP:-

In materials science, creep(sometimes called cold flow)

is the tendency of a solid material to move slowly or
deform permanently under the influence of
mechanical stresses. It can occur as a result of long-
term exposure to high levels of stress that are still below
the yield strength of the material. Creep is more severe
in materials that are subjected to heat for long periods,
and generally increases as they near their melting point.
The rate of deformation is a function of the material's
properties, exposure time, exposure temperature and
the applied structural load. Depending on the magnitude
of the applied stress and its duration, the deformation
may become so large that a component can no longer
perform its function — for example creep of a turbine
blade will cause the blade to contact the casing,
resulting in the failure of the blade. Creep is usually of
concern to engineers and metallurgists when evaluating
components that operate under high stresses or high
temperatures.
Brinelling is a material surface failure caused by Hertz contact
stress that exceeds the material limit. It usually occurs in
situations where a significant load force is distributed over a
relatively small surface area.
79 Globe valve overhauling. Survey points?
Answer:- The scope of survey consists in exhibiting the
valve in dismantled state . the various checks are:
 Checking the casing and cover for cracks.
 Check of valve lid and valve seat for proper
bearing condition.
  Check spindle for bends or deformity. Try the
spindle threads on its bridge countr part for
easy yet non – play movement
 Inspection of gland and gland box and the
studs of the gland.

80

How propeller weight is taken when tail shaft is removed?

(1) Answer:- Propeller blades position adjusted and

weight of propeller supported by slings and chain
blocks which are suspended from bridles(harness)
properly rigged from poop bollards. (Fig3)
 FUNCTION 3
QUESTIONS ON DECK MACHINERY COMPOSED BY AKR
CARGO GEAR
10 describe the various regulatory tests on lifting gear and
what are the lifting gear which are tested

Answer:- As per the code of safe working practice all

ships should have a valid load test certificate issued by
regulatory bodies such as classification societies and
cargo Bureaus who are authorised to issue these
certificates on behalf of the administration.
Without this certificate the port authorities
will not allow the ship to load or discharge cargo using
the ship’s gear.This certificate has a validity for five
years and is harmonised with the other certificates.
The certifying Authorities utilise the
services of licensed service/testing workshops who
bring their equipment to test the cargo gear.
Before testing the cargo gear is
superficially Inspected for any defects . Ships over 15
years old will have their hook blocks and jib head
blocks dismantled and inspected. Worn out bushes and
pins along with worn pulleys will be renewed or
suitably repaired.
The procedure of the test is as follows:
(a) Derricks and Winches:-For derricks including
winches,
The test can be carried out using a calibrated
dynamometer measuring in tons. The winch is
rigged up with one derrick properly stayed and
the runner wire is connected by a shackle to a
 strongly welded pad-eye on the deck with the
dynamometer positioned and connected between
pad –eye and the runner wire end. The winch is
started and wire hauled in till the dynamometer
registers the safe working load. The load is
maintained for 30 minutes with power switched
off.
During this period the derrick and its fittings as
well as blocks examined to see if any deformity or
crack have occurred. The load measured is also
observed.Any drop in the measured load indicates
that the auto-braking devise needs adjustment,
which has to be carried out.
(b) Cranes :- In the case of cranes a dynamo meter
cannot be used since the cranes functions of
hoisting, luffing ,and slewing must be observed
with the safe load on hook and jib positioned at
the angle prescribed. The Procedure is as follows:
The safe load is made up by filling a
canvas sack spherical in shape filled with water
and reinforced with suitable wire ropes . A heavy
scale measuring in tons is connected between
load hook and sack to measure the water loaded
in the sack. Water is filled in till it registers the
required load. The test steps are as follows:
 (1) Hoisting:- The test load is lifted and jib
adjusted to the correct angle as declared in
the cargo register.
The power is shut off for about 10 minutes. During
this period if any drop in the load hook is
observed it is noted. If there is a drop the auto –
braking device needs adjustment.
The upper limit switch should be tested for
correct operation. If defective it should be
corrected.
Luffing:-The jib is luffed up and down till it
engages the limit switches at both limits and
causes power shut off with brake engagement. Any
slip of auto brake of the jib is noted and has to
be adjusted.
Slewing:- The jib is kept at the correct declared angle
and the slewing carried out in both directions . During
stopping violent jolting indicates that the dynamic
braking device needs adjustment. This should be carried out.
If any limit switches are fitted especially if the crane is the
aft most crane, the limit switches should be tried out and
noted for its working or deficiency.
The load test is to be carried out once every five
years for the following equipment apart from the
cargo gear mentioned above. These include:
 (1) Provision crane or derrick.
(2) Hose derricks for tankers.
(3) Engine room crane
(4) Passenger lift (if provided.)
The passenger lift and the provision crane are tested by
simulating the operation utilising filled sand bags of known or
measured weight forming the declared load. The tanker hose
derricks are tested using a calibrated dynamometer.
Engine room crane;- The engine room crane test is to be
simulated using weights. An old piston along with some other
heavy used/ condemned components may be used to form
the declared safe load if the water sack is inconvenient. The
test should simulate hoisting/lowering with auto brake
function test. Any adjustment of auto-brake should be carried
out as recommended.
The traverse longitudinal and transverse should
be simulated with the load on and its easiness and
smoothness noted. If traverses are electrical their limit
switches should be tried out.
(c) Additional documentation and requirements for
geared ships:- Geared cargo vessels using cranes
and / or derricks with winches are provided with a
cargo gear register. This register is to be filled in
by the Captain and C/O for the following
activities:
 (1) When topping lift or runner wires are
renewed due to suspected defects in
the wires especially if individual
strands are frayed.
(2) When half yearly and annual
inspections are carried out.
(3) Any special accessories such as clamps
and special attachments used in grab
operation or container loading/
discharging have been changed or
repaired and tested.
As per the cargo Bureau requirements geared cargo ships
should carry one set of runner wire and topping lift wire as
minimum spares on board at all times.

11 Describe the rocking test carried out on cranes.

Answer:- Over the years the slewing bearing will have some wear,
and to be able to know if there is a need for changing the slewing
bearing it is needed to keep a record of the wear.

The measurements should be taken regularly, every 6 months.

Measurements can be sent to the Maker for evaluation.

Measuring the gear ring play or rocking test

The measurements has to be taken when the ship have as little

list/trim as possible.
Not any load or cargo handling equipment (e.g. grab) should be on the
crane hook.

By using a venire caliper instead of dial indicator the result would be

wrong. With the dial indicator the measurement is more accurately.

Procedure

On the cranes bottom plate two reference point need to be marked.

The reference points have to be always used for the future measuring.
The marked surfaces should be on the front and rear bottom plate of
the crane.

It is important to use about the same position for all further

measurements to be able to compare the measurements.

The dial indicator should be positioned between the rotating and

nonrotating bearing races and crane jib must be raised maximum up
and maximum down.

Measurements shall be taken on four positions of the slewing bearing.

With the jib pointing: forward, starboard, aft, port side.
Set the indicator at zero then raise the crane jib at maximum up and
record the value. The indicator of dial indicator should return to zero
when the crane jib is lowered back to its original position.