- ~ BoleR- . SCAVENGING A SUPERCHARDE CA BOILER ~ be (1) What is boiler mounting/ what are they? 36 (2) Where are the air vent cock located and its purpose? 36 (3) Boiler safety devices. 3¢ (4) Why need to blow down the gauge glass? 8¢ (Boiler gauge glass blows down procedure. 3% (6) Why need to blow down the boiler water? 37 (7) Why do scum blow down and bottom blow down? 37 (8) Purpose of boiler water test. 32 (9)Enumerate the boiler water test. 37 (10) Purpose of individual boiler water test. 33 (11) Purpose of boiler water treatment. 3 (12) How many kinds of boiler water treatment? 3¢ (13) What is foaming? How to prevent it? 39 (14) What is priming? How to prevent it? 34 (15) Boiler blows down (cool down) procedure. 39 (16) Boiler fresh up procedure from cool condition. 34 (17) If no water in the gauge glass what will you do. 40 (18) Disadvantage of frequent boiler blow down. 40 (19) Low.water level. 40 (20) What is caustic enbrittlement? How will you prevent it? 41 (21) What will you do for prevention of oxygen? 41 (22) If chloride is found too much in boiler water how will you do. 41 (23) What is boiler? 41 (24) What is composite/ alternative/ economizer? 41 (25) What is accumulation pressure? 42 (26) Purpose of accumulation pressure test. 42. (27) Procedure for accumulation pressure test. 42 (28) Safety valve setting under steam pressure. 42 (29) How do you take action if one of the passages of gauge glass choked? 43 (30). Cause of furnace blow back. 43 (31) Boiler not in service. 43 (32) Boiler water treatment chemical. 44 (33) Difference between safety valve and relief valve. 44 (34) Marking on safety valve. 44 (35) Type of boiler by pressure. 44 (36) What is the water hammer? How do you prevent it? 44 (37) How to make boiler test on your ship? 45 (38) How do you take boiler water sample? 45 (39) How to know scum valve open or not? 45, (40) Where manhole door is fitted? Why fitted? 45 (41) What is salinometer? 45° (42) Effect of foaming and priming? 45 (43) What is blow back? 45 34(44) (45) (46) (47) (48) (49) Procedure of boiler hydraulic pressure test? 45. What is liquid coagulant? 46 How to renew the boiler water gauge glass? 46 Burner maintenance? 46 When boiler safety valves setting are made? 46 Why shipped blow down is opened first and closed last?. 46 35(1) What is boiler mounting? What are they? It is directly fitted to the boiler shell, is called boiler mounting. They are, (1) safety valve (2) main steam stop valve (3) air vent cock (4) two gauge glass level indicator (5) fuel check valve (6) scum blow down valve (7) bottom blow down valve (8) salinity cock or test cock (9) manhole (10) mud doors (11) pressure gauge connection (2) Where are the air vent cock located and its purpose? Air vent cock is fitted at the top of the steam space of the boiler. Their purposes aré, (1)To release air from the boiler either filling the boiler water or raising the steam. (2)To allow air to enter in the event of boiler cooling down or blowing down to prevent vacuum effect. . (3) Boiler safety devices? (1)2 safety valve (2)high watet level alarm (3) low water level alarm (4)too low water level alarm and shut down (5)water level indicator gauge glass (6)pressure gauge (7)F.0 low pressure alarm and shut down (8)F.O low temperature alarm and shut down (9)F.O high temperature alarm (10) flame failure alarm (11) smoke density alarm (12) air vent valve (13) force draft fan stop alarm and shut down (4) Why need to blow down the gauge glass? Gauge glass blow down is made to know gauge glass to connection is clear or not and to get the exact water level in the boiler and to detect the leakage from the cocks. :(5) Boiler gauge glass blows down procedure? (1)Shutsteam and water cock then open the-drain cock. After draining the water from the sight glass, there is nothing in coming out both steam and water cocks are good in order. (2)Open the steam side cock; blow out the steam, Close the steam sides cock; the steam connection is clear. (3) Open the waterside cock; blow out the water. Close the waterside cock the water connection is clear. (4) Close the drain cock. (5) Open the water cock, water should then gradually rise up to the level of the water in the boiler. © Working position All cock handles are in down ward position. (© Why need to blow down the boiler water? (1) Boiler is made to remove the dissolved and suspended solids also the residual sludge, floating solid, impurities from the boiler system. (2)If they are not removed from the boiler water system foaming, priming, corrosion will occur in the boiler steam and feed water system. (7) Why do scum blow down and bottom blow down? Scum blow down (surface blow down) To remove the accumulated, suspended and floating solids and also removed high dissolved solid concentration. They hinder the formation of steam. Bottom blow down To remove suspended solids and residual sludge that have settled out of the water. If these contaminates are not removed regularly, they will build up until they hinder the circulation patterns. (8) Purpose of boiler water test? To know the condition of water. . (1)To ensure that proper chemical treatment are maintained at all the time. (2)To keep the boiler water in harmless condition. (3)To detect the present of contaminants in the water that may be injurious to boiler and system. . (9) Enumerate the boiler water test? (1)Phenolphthalein (p) alkalinity test? (2)Total (T) alkalinity test (3) Chloride test (4) Condense pH test (5) Amerzine test (Hydrogen test) (6)Excess phosphate test (7)conduetivity test 37(10) Purpose of phenolphthalein (p) alkalinity test? (1) This test is carried out to prevent acidic corrosion. To detect the amount of CaCO; level in the boiler water. (2) Total (T) alkalinity test To determine the amount of hydroxide alkalinity in the water. (3) Chloride test To minimize chloride level and to adjust blow down. To know the amount of salt in boiler water. ° (4) Condensate pH test To conirol condensate pH value within a limit. To minimize corrosion in steam and condensate system. (5) Amerizine test (Hydrazine test) To minimize oxygen corrosion in boiler, steam and condensate system. (6) Excess phosphate test (Hardness test) To control the scale formation due to hardness. (7) Conductivity test To remove dissolved and suspended solid by blowing down. (11) Purpose of boiler water treatment. (1)To prevent the scale formation in the boiler and feed system. (2)To prevent the corrosion in boiler and feed system. (3)To control the sludge formation and prevention of carry over with steam. (4)To maintain the boiler water in alkaline condition and to be free from dissolved gases. (5) To prevent of entry into the boiler of foreign matter. Such as oil, waste, mill scale, FeO, Cu, Send, etc. (12) How many kind of boiler water treatment? (1)GC ™ (concentrated alkaline liquid treatment) (2) Adjunct-B (phosphate boiler water treatment) (3) Amerzine (oxygen corrosion inhibitor treatment) (oxygen scavenger) (4)SLCCA (condensate corrosion inhibitor treatment) (5) Liquid Coagulant (Boiler sludge conditioner) (6)Blow down (13) What is foaming in boiler and how to prevent it? (1)Itis the formation of thick layer of steam bubbles on the top of the water ~~~ surface inside the boiler due to high concentration of floating impurities and increase in level of dissolved and suspended solids. (2)Foaming is usually caused by the animal or vegetable fats in feed water carry over from the oil heaters. (3)To prevent foaming, surface or scum blow down should be done frequently to expel any floating impurities from the boiler and no L.O should be allowed to enter the boiler. 8(14) What is boiler priming and how to prevent it? (i)It is a condition in which large amount of water are carried along with the steam into the steam line. (2)It is caused by 1) excessive foaming 2) improper amount of steam space or 3) by a sudden rush of steam. (3)To prevent priming never keeps the water level to high and open the steam stop valves slowly. (15) Boiler blows down procedure (cool down). (1)Change the fuel oil burning system from H.O to D.O and then shut down the burning system. (2)Stop feed pump and close feed check valve. (Drain down the boiler after allowing it to cool down. If there is no sufficient time to do this) (3) Lower the boiler pressure down to 3 to 4 bars. (4)Shut the main steam stop valve. (5)Open the ship side valves then open the blow down valve. (6)Banging noise will appear when the boiler is empty. (Close the blow down valve and ship side valve) (7) Then release the steam pressure through safety valve by means of easing gear. (8) When the pressure is off, open the air vent and allow the boiler to cool down. (16) Describe boiler fresh up procedure from cool condition? (1) Check the boiler blow down valve in close position. Shut the main steam stop valve. Open the air vent cocks. (2)Open the feed checks valve and pumping up to % of the gauge glass level. (3) Start the force draft fan with dampers, opened correctly to purge the furnace and combustion spaces off any foul gases. Also checking must be made of to ensure that there are no deposits of oil in furnace. (4) The air register steers may be operated to reduce the airflow to a minimum at the start so that a flame can be established which is adjusted to give a Smokeless combustion. Light the burner after closing the re-circulating valve. (5)Normally allow the fire to burn for 5 min and stop the fire for 30 min. When steam coming out from the air vent, close the air vent. (6)Raise up to working pressure step by step slowly allows the fire to bur for 30 min and stop the fire for 10 min. (7) When the steam reached to working pressure draining the lines sufficiently to avoid water hammering, The main steam stop valve is opened slowly.“(17) Ef no water in the gauge glass, what do you do? If there are two-gauge glass and one is showing low or no water level. The other gauge glass should then be approached to find the reason of its malfunction. If botli gauge glass are showing no level of water, (1) The fire must be immediately stopped. (2)The main steam stop valve must be closed. (3)Blow down the boiler and cooling down it. (4)Enter the boiler after it has cooled and examined it for possible damage. (5) Located the cause of trouble and make necessary repair. (6)If no damage occurred inject water slowly into the boiler and restore it to operation. The possible reason for low water level. (1) One of the gauge glasses is defective. (2)A tube in the boiler burst. (3)Feed regulator jammed. (4) Defective feed pump. (5) Steam utilization from boiler increased too much. (18) Disadvantage of frequent boiler blow down? (1) Loss of heat from the boiler and increase fuel consumption. (2) Loss of chemical and increase F.W consumption. (3) Large amount of cold feed water may cause tube bulking and distortion. “ (19) Lows water level? If water level has not yet dropped completely out of the sight glass, water may be put into the boiler. If water drops completely out of the sight glass do not add water until the boiler is cool enough to prevent any possible damage due to rapid cooling of over heat plate. (1) The fire must be immediately stopped. (2) The main steam stopped valve must be closed. (3) Located the cause of trouble and make necessary repair. (4) Blow down and cool down the boiler. (5)Enter the boiler after it has cooled and examined it for possible damage. (6)If no damage occurred inject the water slowly into the boiler and restore it to operation. ‘40(20) What is caustic embrittlement? How to prevent it? (1)Itis an inter crystalline fracture, High concentration of caustic soda NeOH. and the material under stress cause it. The stress corrosion eracks follow the grain or crystal boundaries of the material and failure. (2)Sodium sulphate or sodium nitrate is used for the prevention of caustic embrittlement. (3)Itis can be found in high stress area in boiler tube and tube plate connection, riveted head, seam and boiler mountings. (21) What do you do for prevention of oxygen? (1) The oxygen scavenging chemical is used for de-aeration the water are usually sodium sulfate or hydrazine. 2Na,SO3+ Oz = 2Na,S0, (precipitate) NH, + O2 = 2H,0 + Nz (2) Exercise dosage of hydrazine could lead to steam and condense line corrosion due to ammonia being produced as the excess hydrazine de- composed. (3)In high pressure boiler by using the sodium sulfate the sulfite can break down to give hydrogen sulfite (H,S) and possibly sulfur dioxide (S0;) can attack steel brass and copper. (22) Jf chloride is found too much in your boiler water what will you do? (1)1 will make blow down frequently. (2)Reduce the boiler load to minimum. (3)If highly contaminate shut down completely and wash out. (4) Trace anid find out the fault and remedies. (23) What is the meaning of boiler? It is a pressure vessel in which the water is heated to evaporate and generate the steam and the unit is so arranged the generated steam accumulated in it. The two main types are water type and fire tube. (24) What do you understand composite, alternative and economizer boiler? Composite boiler (1) If the exhaust gas and oil fired can be used at the same time, it is termed the composed boiler. (2)In this type, a separate nest of tube for exhaust gas is provided, situated above the return tubes from the oil fired furnace uptake from the tube nests are separated, ‘ Alternative boiler (1) If the exhaust gas and the oil fire are arranged to be used only one at a time, the exhaust gas boiler is termed as the alternative boiler. (2)This unit can be oil fire or heated by the exhaust gases alternatively, (3)It requires only one uptake. AlEconomizer (1)In this system a separate exhaust gas economizer is connected to oil fired auxiliary boiler or an accumulator by means of piping and a set of circulating pumps. (2) Exhaust gas is used as heating medium and it has no steam space. (25) What is meant of accumulation pressure? Accumulation of pressure is the rise in boiler pressure, which take place when the spring-loaded safety valve lift due to the increased loading caused by further compression of the spring. (26) Purpose of accumulation pressure test? To detect the safety valve is suitable for this boiler or not. (27) Accumulation pressure test? (Procedure) This test is carried out on new boiler or new safety valve. (1) Shut off feed water. (2)Close main steam stops valve. (3) Arrange the boiler fire rate to a maximum. (4)Safety valve will be lifting during the test. (5) The test is carried out as long as the water permit in the boiler. Duration of the test is 15 minutes for a tank boiler and 7 minutes for water tube boiler. (6) Accumulation pressure must not exceed 10% of the working pressure. (28) Safety valve setting under steam pressure? (1) Take the standard pressure gauge, which is being accurate and approved by surveyor. (2)Shut off steam stop and feed check valve. (3) Ensure that the valves have been already correctly assembled with compression on the spring less than previous setting and no hood and easing gear. (4) Raise the steam pressure up to the desired blow off pressure. (The safety valve will be lifting.) (5) Screw down the compression nut until the valve stop lifting. (Keep the boiler at desired pressure.) (6)Screw backs the compression nut slowly until the valve lift. (7)Then screw down the compression nut slowly, while taping the valve spindle lightly. until the valve returns to its seat and remain closed. (8)Measure the gap between the compression nut and spring casing cover. The compression ring is the machined to require size and fitted to its place. (9) The spindle of the safety valve, which already set to the gagged to prevent opening, whiles the other one being set. (10) Retest after inserting compression rings and sees both valves lift and close together. : (11) Finally cap, cotter and easing gear to be refitted. Cap and cotter are pad locked to prevent the altering of the setting. 420 (12) Check easing gear performance: All safety valves must be above the working pressure not greater than 3% above the approved pressure. (29) How do you take action if one of the passages of gauge glass is choked? Steam and water cocks passages in the gauge can be cleaned while the boiler is still steaming. (1)To do this shut the steam and cocks and open the drain. (2)Remove the cleaning plug opposite the obstruction. Screw in this plug with small holes about 5-mm diameter, drilled through it in place of the cleaning plug. (3) Insert into this hole a rod of such a size that held by a gloved hand it can be moved easily without being stack. (4) Then open the choked cock and push the rod through to clear the blockage. When clear the open drain will prevent a build up of pressure and only a small amount of steam will blow past the rod; the glove protecting the operator from injury. (5) Then close the cock and replace the normal cleaning plug. The gauge glass can now be tested and if satisfactory retum to service. (6)Do not carry out this operation on a plate type glass on a high-pressure boiler. (30) Caused of furnace blow back? Itis caused by (Insufficient oil temperature. (2)Collection (accumulation) of oil in furnace. (leak from burners) (3) Too little air (4)Boiler tubes and uptake full of soot’s. (5) Air registers control not operating for the high flame mode. (31) Boiler not in service? With fire tube boilers out of service for short periods, the boiler must be completely filled with alkaline water. The boiler must be topped up periodically and any air in the system must be got rid off. Regularly test the boiler water and keep the alkalinity to phenolphthalein in a range of recommended value. If the boiler is to be taken out of service for long periods, (1)It should be drained completely and open up. (2) Dried out by means of heater units. (3) Then trays of quicklime should be placed intemally in suitable positions: (4) Blanks should be fitted to the pipe connections in the event of steam being maintained in other boiler and also the blow down line. (5)The quick lime should be renewed at least once every two months. 43u (32) Boiler water treatment chemicals, (1)To prevent scale formation - Tri-sodium phosphates is used. (2)To remove traces of oxygen — Sodium sulphide Na2SO3 or hydrazine (N2H4) is used, . (3)To give alkalinity and minimize corrosion — Sodium Hydroxide (NaOH) or Sodium Carbonate (Na2CO3) is used. (4)To reduce tisk of caustic cracking (caustic embrittlement) sqdium sulphate or sodium nitrate is used. (33) Different between safety valve and relief valve? Safety valve (1)Directly to design lift at set pressure. (2)Can open manually by easing gear. (3) Setting pressure is just above the working pressure and not more than 3% above the approved working pressure. Relief valve (1) Setting pressure is 10% above working pressure. (2) Open at set pressure. (3) Opening is proportion to the increase in pressure. (4)Can not be opened manually. (34) Marking on safety valve? (1) Manufacture name (2)Serial number (3) Inlet diameter (4) Operating pressure (5)Discharge capacity (6) Safe working pressure (7)Blow off pressure (35) Types of boiler by pressure? (1) Low pressure boiler up to 10 ke/em2. (2)Medium pressure boiler 10 to 25 kg/cm2. (3) High-pressure boiler over 25 kg/em2. (36) What is water hammer? How will you prevent it? - impact of moving water in steam line. When.the steam is allowed to a line with condensate water. (2)The steam will condenses and partial vacuum occurred and moves draw back the water along the pipe with very high velocity, (3)The water will strike at the vent or valves. To prevent the water hammer. (1)Install the water hammer. (2)Open the drains first before allowing steam into the line, (3) Crack open of steam valve first. 442 (37) How to make boiler water test on your ship? The boiler water test is carried out as follows. (1) First - I take the Boiler water sample from salinometer cock or'test cock and cool down. (2) The test is carried out by using maker’s supply test kit chemical instrument and instruction supplied from using chemical company. ~ (38) How do you take boilér water sample? (1) Slowly open salinometer cock until clean hot water coming dut. (2)Take the small amount with copper jar to wash out about two or three times. (3) Then collect the boiler sample with copper jar. * (39) How to know scum valve open or not? (1)It can be checked by opening of ship side blow down valve. If banging noise will appear, scum blow down valve is in open position. (2)Can detect, over heating of the scum blow down pipe. (40) Where manhole door is fitted? (1) It is fitted at one on steam side and other one for waterside. (2) Function, To enter the boiler for cleaning inspection and repairing purpose. (41) What is salinometer? ‘An instrument which measure and indicate the amount of salt in the boiler water. 7 (42) Effect of foaming and priming? (1)Can occur water hammer. (2)Can cause contamination and scaling. (3)Can cause fluctuation of working water level. (43) What is blow back? (Back fire) It occurs when lighting up with explosive gas inside the furnace without pre purging sufficiently. The ignition results in a large flue gas inside the furnace and gas blows out at increased pressure through the furnace opening. (44). Procedure for boiler hydraulic pressure test? —» Hydraulic pressure test is 1.25 times working pressure. 10 minute maintain. Close all opening. (1) Opening air cock. (2)Fill up boiler water fully. (3)Close the air vent cock. (4) Placed hydraulic jet to feed water line. (5) Fit standard pressure gauge. (6) Applied hydraulic pressure 1.25 times of working pressure and maintains 10 minutes. 45(45) What is liquid coagulant? It is a more molecular cut color less solution. Such as sodium aluminate; starch; torn; resin. Once being dose into the boiler water floating solid. Particles and suspended solid are settle down to the bottom of the boiler and easily remove by blowing down. . (46) How to renew the boiler water gauge glass? (1) Shut steam and water cock and open drain cock. (2)Check any leakage from the respective cock. (3)Slack the gland auts. (4) Open the cap and remove old gauge glass. (Fit new glass tube correct size and length into its place. Give the expansion allowance 1/8 inch vertical clearances: I use new packing.) (5) Close the cap. (after fitting warm the glass by steam) (6) Tighten the gland nut. (7) Then steam and water passage should be tested whether they are fairs and clear. (8)Close the drain and open water and steam side cock. (9) Thoroughly check the leakage all are satisfactory and put back into operation. (47) Burner maintenance? (1)Clean the rotating cup. (2) Check and adjust the belt tension between motor and rotating shaft. (3)Clean pilot burner nozzle and filter. (4)Clean carbon deposited'on electrode igniter ‘and adjust the gap. (5)Check fuel valve and air register. (linkage and joints) (6)Check and clean the flame eye cover glass. (7)Check and clean inspection peep hole glass cover. (8) Adjust the fuel and air ratio. Clean the fuel oil filter. (9) Check the fuel oil pressure. (48) Where the boiler safety valve setting is made? (1) Every boiler survey. (2) After safety valve overhaul. (49) Why ship side blow down valve is opened first and closed last? To prevent pressure builds up in blow down line. If pipe burst it may injurious to watch keeper. 46a “= SCAVENGING AND: SUPERCHARGING 1. What is scavenging? 21 : 2, Scavenging efficiency? 21 3. How many types of scavenging? Which one is the best? Why? 2 4, How do you understand the ‘3? kinds of scavenging? 91 5, What is supercharging? 21 6. What is turbocharger? 21 7. What do you understand constant pressure and pulse system. 21 8. What is T/C surging? 92 9. Causes of T/C surging? 22 10.Advantages and disadvantage of ‘pulse system’? 22 11-Advantages and disadvantage of constant pressure system? 22 12.What is exhaust turning? 23 13.What is the main purpose of T/C water washing? 23 14.Disadvantage of T/C water washing to turbine side? 23 15.Advantage of solid (crystal) cleaning? 23, 16.Effect of inters cooling the charged air? 23 17.Types of T/C LO system? 23 18.Function of labyrinth seal? 24 19.Defect of labyrinth seal? 24 20.How will you know T/C air filter choke? Defect? 24 21.Function of nozzle ring? 24 22.Pulse system? 24 23.Buchi system? 25° 24,What is the labyrinth seal? 25 25.Purpose of inducer? 25 26.What is ‘K’ value and purpose? 25 27.Procedure for cutting of T/C? 25° 28.Procedure for G/E T/C overhaul? 25 29.What part will you check when G/E T/C overhaul? 26 30.How will you carried out T/C turbine and blower side water washing? 26 31.When G/E TIC overhaul, what measurement do you take? 26 32. Advantages of loop scavenging? 27 33.Major requirement for the loop system? 27 34,Disadvantages of cross and loop scavenging? 27 38. How many types of T/C system? 27 26~~ 1 {1) What is scavenging? Scavenging is the process of removing the bunt gas in the engine cylinder by means of incoming charge air. (2) Scavenging efficiency? Scavenging efficiency = weight of air enter into cylinder Weight of air for stroke volume (3) Howimany types of scavenging? Which one is the best and why? There are three types of scavenging. 1. Cross-scavengiig. 2. Loop scavenging, 3. Uniflow scavenging. Uniflow scavenging is the best because of high scavenging efficiency. The air inlet and’exhaiist do not change in air direction. (In passing through the cylinder) The possibility of short circuiting or excessive mixing is therefore reduced, (4) How do you understand the 3 kind of scavenging? Cross scavenging : The air inlet in exhaust parts are arrange at the same end of the cylinder liner and they are placed opposite to each other. Scavenging efficiency 0.75 to 0.8. Loop scavenging The air inlet and exhaust parts arranged at the same end of cylinder liner but the exhaust parts are on the top of the inlet parts. Scavenging efficiency 0.8 to 0.9. Uniflow scavenging The air inlet parts and exhaust parts or value are arranged on the opposite ends of the cylinder liner. Scavenging efficiency more than 0.9. (5) What is supercharging? Itis the process of the increasing of the weight of the charged air by increasing the density of the charge. (6) What is turbocharging? It is one kind of supercharging by using exhaust gas turbocharger. In which the energy in the exhaust gas expelled from the engine cylinder is utilised for driving a gas turbine, which is connected, to centrifugal air blower. Which air is supplied to scavenge air trunk? ~*~ : (7) What do you understand constant pressure and pulse system? Constant pressure system , In this system. the exhaust gas are discharged from all cylinders into a common large manifold where the pulse energy is largely dissipated. The exhaust gas flow will be steady rather than intermitted and at a constant pressure t T/C turbine inlet. va): 3 Pulse svstem -** a This system makes full use of the higher pressure and temperaturé of the exhaust gas during the blow down period. And rapidly opening the exhaust valve. The exhaust gases leave the cylinder at high viscosity as pressure energy is converted into kinetic energy to create the pressure wave or pulse inthe exhaust lead to the turbocharger. (8) What is turbocharger surging? It is excess aerodynamie pulsation in air stream. When the discharge volute pressure exceed the pressure build up in the diffuser and impeller. It produces a back flow of air trom discharge to suction and itis characterised by noise and variation of turbocharger speed. (9) Causes of turbocharger surging? Tris caused by, . Scavenging space fire. . Exhaust trunking fire. . Poor power balance. . Dirty nozzle and blades . Individual cylinder misfire. . Choked scavenging exhaust parts. . Suddenly load change by heavy sea . Incorrect matching of turbocharger to engine. Srna FENe (10) Advantages and disadvantages of pulse system? Advantage. ‘At low level. it is more efficient. No need assistance of scavenge air pump or auxiliary blower. Ithas highly response to change engine condition giving good performance of. all speed ranges sadvant ~The exhaust grouping is complicated, Different size of exhaust pipes are need for spare. High-pressure exhaust from one cylinder would pass back into another cylinder during the low-pressure scavenging period thus adversely effecting the combustion efficiency. 2. 3. (11) Advantages and disadvantages for constant pressure system? lve gs ' . Good performance at high load. . More suitable for high out put engine. . There is no need to group the cylinder exhaust into multiple of three, (Simple exhaust piping system.) High turbine efficiency due to steady flow. 5. The work transfer at the turbine wheel is smooth. ee >Disadvantage “4 1. The major disadvantage of this system is that when running at reduced speed and especially starting up, low available energy at turbine. Thus it supplies ‘inadequate air quantity of the scavenge pressure necessary for efficient scavenging and combustion. It required scavenges assistance. 2. Poor response to changing load. i (12) What is exhaust euning? Exhaust tuning means by arranging the exhaust pipes with suitable léngth and suitable value timing to exhaust into the same pipe Without distance, (13) What is the main purpose of T/C water washing? 1, The main purpose is to ensure efficient functioning of turbocharger. 2. Itis essential to protect the compressor and turbine from contamination. (The pressure energy available at the turbine iniet is insufficient to drive it to supply the quantity of air atthe scavenge pressure necessary for efficient scavenging and combustion. Additional source of air compressor must be made such as scavenge air pump or under piston compression in series with T/C.) (14) Disadvantage of T/C water washing to turbine side? Engine speed has to lower. Thermal stress and corrosion usually occurred. Longer cleaning time. Very fine hard deposits and combustion residues can not be removed easily with water washing. BEL (15) Advantage of solid (crystal) cleaning? 1. Not required to reduce engine RPM. 2, No use of water. no corrosion and thermal stress. 3, Cleaning time is short. (not wear turbine blade) 4, Effectively removed combustion residues and hard particles. (16) . Effect of inters cooling the charged air? Advantages 1. The effect of cooling reduces the scavenging air temperature and increase the density of air delivered to the cylinders, thus increasing the power out put delivered by the engine. It can increase thie output by about 10%. 2. Cooled scaveiize air reduces cylinder and exhaust gas temperatures at a given power level and these temperatures thus remain within the acceptable limits. (17) Types of turbocharger LO system? For ball tvpe bearing (rolling type! Used T/C LO is supplied from the sumps on both air and exhaust sides on to the bearing by means attached rotor driven gear type pumps.5 For sleeve type bearing LO is supplied from external LO supply system. a. By gravity independent header tank situated about six-meter above the bearing. » The tank capacity;must supply for about 15 minutes after the engine is stopped. b. From a main LO pump lead to the bearing-with a separate LO pipe line. It has also gravity tank in case of failure of oil supply. (Under main engine LO system.) (18) Function of labyrinth seals? . 1. The bearing are separated from the blower and turbine by labyrinthiseals, These seals are sealed by air supply from the discharge of blower to prevent oil entering to the blower. 2. To prevent contamination of the oil by the exhaust gas. (19) Defect of labyrinth seals? At blower side 1, Oil is leaked into the air system; the cooling surface is covered with oil, which are insulators and the cooling efficiency will be reduced. 2. Also there will be deposits on the blower and the blower efficiency will be reduced. At turbine side 1. Ifoil is leaked into the exhaust side, there will be carbon deposits on the nozzles and turbine blades. 2. Reduce blower efficiency and fire in the exhaust piping. It will cause turbocharger-surging. 3. Oil will contaminate with exhaust gas. (20) How will you know T/C air filter choke? It can be know by comparing the manometer difference. If manometer different is greater than normal T/C air filter may choke. It can cause, 1. Scavenge air pressure will reduce. 2. Reduce engine power. 3. Black smoke will emit from the funnel due to incomplete combustion. (21) Function of nozzle ring? To change pressure energy to velocity energy. (Kinetic energy) (22) Pulse system? . This system makes full uses of higher pressure and temperature of the exhaust gas during blow down period and rapidly opening of exhaust valve or ports. The gases leave the cylinder at high velocity as pressure energy is effectively converted into kinetic energy to create a pressure wave or pulse in the exhaust pipe lead to T/C. 2. This pipe so constructed in small diameter is quickly pressurised and boosted up to form a pressure pulse. 24i ‘ 3. The pulsating pressure waves reach up to the turbine nozzles and further _ expansion takes place. eos (23) Buchi system? One type of ‘pulse system’ used in 4-stroke engine. (24) What is labyrinth seal? * Itis a sealing ring, which is sealed by air supply from the discharge of blower. Functions, To prevent oil entering the blower. To prevent the contamination of the oil by the exhaust gas. (25) Purpose of inducer. To feed the shock less air flow to the impeller. (26) What is K-value? 1. It is a distance between the rotor shaft end and the flange of bearing cover measure at blower side. 2. (Purpose of K-value?) To ensure that rotating impeller does not touch the stationary blower casing cover. (27) Procedure for cutting of turbocharger? 1. Remove the nozzle ring. 2. Lock off the rotor shaft. 3. Blank off the blower discharge. 28) Procedure for G/E T/C overhaul? | . Lock off the engine starting mechanism. oi manos Weve aa 3. Drain off the oil from the both drain plugs. 4, Remove the bearing covers from both sides, UG 5., Remove the locking wire. 6. Unscrew the hexagon serews and remove oil suction pipe. 7. 8. 9. I . Tighten again the hexagon screws of bearing boxes. . Check the deflection of the divergent nozzle by pick tester and magnet-stand. . Remove the divergent nozzle by screwdriver. 0.Measure the K value at the’ blower side by using depth micrometer or calliper and straight edge. 11.Extract the lubrication disc. 12.Extract the both bearing by bearing extractor. 13.The various parts should be wrapped in waxed paper to protect them against dirt and moisture. 25. 7 (29) What parts will you check when G/E T/C overhauled? » Check the deflection of divergent nozzle. .» Measure the K value.at blower side. ' . Change the bearing on both sides with new one. Because bearing service life is _same as T/C overhauling time. Clean blower and turbine side with chemical and inspect carefully. . Check the labyrinth seal. . Made clear the labyrinth seal airline, wre aun (30) How will you carried out T/C turbine and blower side water washing? Blower side water washing. 1. It can be done when M/E on full load. 2. Open the hopper cover and fill up the warin fresh water to hopper and close the cover. 3. Open the valve and allow water will flow into the blower casing and mechanically attach the blower blade and cleaned the deposit. - 4. Close the valve, open the hopper cover and check cleaning water must be empty. Turbine side water washing procedure. Turbine side water washing can be made with hot fresh water. Turbine side water washing can be made as follows. . Inform to the bridge. . Reduce M/E rpm to slow and exhaust temperature will be low. Maintain at recommended T/C rpm about 2000 rpm. Check the water washing injection nozzle and fitted at its place. (Directly aim to the exhaust grids before entering to the T/C.) Open TIC drain. . Open the water supply about 1 bar to turbine side. . Water washing must bé made until the clean water coming out. . Close the water supply and remove the nozzle. 9. Exhaust side drain can be closed after all water drained out and dried. 10.Inform to the bridge and increase the M/E rpm gradually to sea speed. ¢ The turbine side water washing is usually done at the departure after manoeuvring time. + For usual practice cleaning is done at every 500 running hours depending onthe cleanliness of the T/C, FeNne eI aH oo) When G/E TIC overhaul, what measurement does you taken? . K value. It is & distance between the rotor shaft end and the flange of bearing cover measure at blower side axial clearance with depth micrometer and straight edge. Check radial ciearance at plain bearing by placing clock gauge on the shaft from top and clamp by screwdriver from bottom record the clearance. v 268 (32) Advantage of loops scavenging? {thas no exhaust valve and it’s driving mechanism. It saves the energy losses to drive the exhaust valves. (33) Major requirement for the loop system? 1. The inet airports are angled to give rotary swirling effect to the incoming air. 2. Italso required long piston skirt or exhaust timing valve to prevent air leak into the exhaust while the piston is top of its stroke, (34) Disadvantages of cross and loop scavenging? 1. The air inlet and exhaust ports are arranged at the same end of the cylinder, 2. The air and exhaust gas changes direction in passing through the cylinder. Short circuiting or excessive mixing may occur. Thus reduce the scavenging efficiency. 3. It required long piston skirt or exhaust timing valve is necessary to prevent scavenging air leak into the exhaust while the piston is at top of its stroke. 4. Ithas thermal stress between scavenge and exhaust ports, (35) How many types of T/C system? Constant and pulse. 07Lo 1, Funetion of a lubricant? 2% 2. Effect of lubrication? 2% . Properties of crankcase LO? 29 What is viscosity? 29, What is viscosity index? 29, ‘What is power point? 24 . What is flash point? 25 . What are TAN and TBN? 29. . What type of engine is using high TBN? Why? 29 10.What is detergency / dispersancy? $0 11. Explain the LO sampling procedure to send for LO test? 30 12.Essential factors affecting the establishment of hydrodynamic lubrication, 20 13. Where do locate ME LO sump tank and its fitting? 30 14.Why magnetic filter is fitted on LO system? Where fitted? 30 15.Contaminants in the LO? 3! 16. Water contamination in LO? 31 17.Fuel dilution in LO? 4} 18.How do you make batch purification? 31 19.When periodic batch purification makes? 31 20.What is grease? 3 21.What is solid lubrication? 1 22.Properties of cylinder oil. (Requirement) 32 23.Requirement of cylinder lubricator, 32 24.At what point oil will feed to piston? $2 25.Effect of excess lubrication and lack of lubrication? 32 26.Why flash point is important? 32 27.What will happen when temperature is lower than power point? 33 28.Why viscosity is important? 33, Sen auEe (1) Funetion of lubricant? a, Separate entirely the working surface, thus reducing the static and dynamic friction to minimum and preventing wear. b. Remove heat, generated either within the bearing or from an outside source. c. Protect against corrosion. d, Flush away contaminants. ' e. Dampen noise. £ Insome case, act as a sealant. (2) Effect of lubrication? 1. Hydrodynamic - Full fluid film lubrication. 2. Boundary - Thin film lubrication. 3. Hydrostatic - Thick film or Force lubrication 4, Elastohydrodynamic'— Thin film or squeeze film lubrication. 28(3) Properties of crankcase LO? 1. Viscosity (suitable), 2. Viscosity index (high), 3. Pour point (low), 4. Flash point (high), 5. Oxidation stability, 6, Carbon residues (low), 7. Total acid number (TAN), 8. Total base number.(TBN), 9. Detergency, 10. Dispersancy a (4) What is viscosity? Ifis a property of liquid, which is a measure of its internal resigtance to flow. Viscosity of oil changes with temberature, falling when temperature rises and vice-versa, Crankcase LO 130 to 240 seconds, redwood No. | at 60°C. (5) What is viscosity index? The rate of change of viscosity of oil in relation to change of temperature is indicated by its viscosity index: Low VI- higher viscosity change with changing temperature. High VI- lower viscosity change with changing temperature. © Good crankcase oi VI scale is 75 to 85°C. (6) What is pour point? It is the lowest temperature at, which an oil will barely flow. Pour point of engine crankcase should be ~ 18°C. (7) What is flash point? It is lowest temperature at which an oil will give off a sufficient inflammable vapour to produce a flash when a small flame is brought onto the surface of oil. Flash point for a crankease LO is around 220 °C. (8) What are TAN and TBN? Itis the neutralisation value of used engine LO. The ability of an oil to react with a base reagent which indicates the “acidity” expressed as TAN. TBN- The ability of an oil to react with ari acidic reagent, which indicates the “alkalinity” expressed interns of milligrams of mg KOH. Potassium hydroxide required neutralising one gram of sample oil for both TAN and TBN. “TBN for oil used for cross head type diesel engine. Crankcase is 8 mg KOHV/gram of oil. For trunk piston engine using heavy oil is 30 mg KOH per gram of oil.’ (9) What type of engine are using high TBN and why? At trunk type engine using heavy fuel oil. 1. If blow pass occurs in trunk type engine incomplete combustion products reaches directly into the crankcasé and may cause the contamination with acid easily. 292. Thus in this types of engine to combated the acid contamination must be used high TBN gil. (10) What is detergency / dispersancy? \ Itis a chemical compound which has property of preventing the deposition of i carbonaceous deposits and wash away with the LO. Dispersant, additive addition is made to divide the larger size deposits into ! tiny particles tobe carried in a colloidal suspension evenly though the bulk ' of the oil. | (11) Explain the LO sampling procedure to send for LO test? 1. the sample should be drawn with oil circulating in'the system such as a i test cock on the discharge side of the LO pump. i 2. Before taken the sample oil, sufficient amount af oil should be drained out to clear the line. { 3. The sample is filled into a chemically cleaned container after itis rinsed with sample oil and immediately closed. 4. The container should be attach with a label indicating. (a) engine type. (b) engine running hour, (c) LO running hour (d) fue! used (e) draw of p and (f) date. (12) Essential factor affecting the establishment of hydrodynamic lubrication? * Viscosity of oil + Load acting on the bearing * Surface smoothness * Speed of rotating Continuous LO supply { «Bearing clearance, bearing length and pin diameter. ‘There must be convergence between fixed and moving surface. + Essential requirements Formation of lubricants wedges between surfaces. 3) Where do locate WE LO sump and its fittings? . Ttis located under the engine in the ship double bottom and surrounded by : cofferdams. j 2. It consists of (a) level gauge (b) manholes (c) air vent pipe (d) sounding pipe - (e) healing steam coil (f) suetion pipes and valves. Valves for LO pump and purifier. (14) Why magnetic filter is fitted on LO system? Where fitted? 1. To prevent pump damage due to ferrous metal particles. i 2. Screw pump (used in LO system) is working in very fine clearance thus to prevent entering the small ferrous metal particles into the pump, magnetic filter is fitted prior to the main circulation LO pump. 301 OY (15) Contaminants in the LO. (a) Water (b) fuel dilution (c) Oxidation product (d) product of fuel combustion (e) foreign mineral matters (f) biological contamination. (16) Water contamination in LO? 1, Condensation of water vapour within the crankcase. 2. Leakage from the cooling water system for cylinder or piston. 3. Leakage from the sump tank heating steam coils. D Effects 1. Reduce cooling efficiency due to emulsion, 2. Increase the acidie formation in trunk piston engine. (17) Fuel dilution in LO? Poor atomisation of a fuel injector and back leak through the fuel injection pump plunger and barrel. Effects, Fuel dilution usually diesel oil lower viscosity and lower flash point. Lower viscosity LO reduces their properties. E.g. load carrying capacity. Lower flash point will cause crankcase explosion. (18) How do you make batch purification? 1. Firstly, I take the immobilisation permit from the port authority. 2. The entire oi] charge should be pumped by the purifier by the main circulating pump into the renovating tank. 3. It should be allowed to settle for at least 24 hours with heating about 60°C. 4. Water and sludge should be drained of periodically. 5. Cleaned the interior of the sump tank and carefully examined. 6. The oil should then be passed through the purifier at its optimum efficiency and then pump back into the sump tank. (19) When periodic batch purification makes? 1, It is made if the oil is suspected from containing strong acids, high insoluble content due to poor combustion or water due to leak cooling system. 2. Itis also made at least once a year when cleaned and examined for sump tank. (20) What is grease? 1. Itis a semisolid lubricant consisting of high viscosity mineral oil and metallic soap with filler. 2. Metallic soaps are compound of Ca Na Al. 3. Filler are lead, zinc, graphite and molybdenum. (21) What is solid lubricating? Itis grease lubricating. 3(22) Properties of cylinder oil requirements, » ~ . It must reduce sliding friction between piston rings and cylinder to a minimum. 2. It must process adequate viscosity at high working temperature and still be sufficient fluid to spread rapidly over the entire working surfaces to form a good absorb oil film. 3. It must form an effective seal in conjunction with piston rings. Preventing gas blow by, burning away of the oil-film and lack of compression. 4. It must be burn cleanly, leaving as little and as soft deposit as possible. . It must effectively prevent the “deposition built up” in the piston ring zones and exhaust parts. . It must effectively neutralise the “corrosive effect” on the mineral acids formed during combustion of the fuel. w a (23) Requirement cylinder lubricator? 1. Must deliver regularly every stroke against moderate pressure. 2. Must have a wide rang of adjustment. 3. Oil feed amount per stroke should be clearly visible. 4. Can be operated by hand. (24) At what point oil will feed to the piston? 1. The cylinder oil is feed the piston at the time when the top two piston rings pass the lubricating holes in the cylinder during the piston up stroke. 2. Itis timed lubrication. (25) Effect of excess lubrication and lack of lubrication? Excess lubricating, . Fouling of rings grooves and resulting rings zone deposits, 2. Can cause ring sticking, loss of gas sealing effect and blow by followed. Leading to breakage of piston rings. 3. Fouling has scavenged air space and scavenges fire follows. Also effective the combustion process. 4, Fouling of exhaust system and turbocharger. Increase consumption and uneconomic. Lack of lubricant. 1. Increase wears rate of liner and rings. 2: Overheating of local area resulting microseizure due to lack of boundary lubrication. 3. Consequently major damage to piston and cylinder. (26) Why flash point is important? FO- It is important, fuel oil flash is fairly high because if they were low, there would be a possibility of fire of fire in storage. LO- Engine crankcase oil flash point should be as high es possible to prevent crankcase explosion. 32i : (27) What will happen when temperature is lower than flash point? The oil can not freely flow thus effect the pumping system, lubrication system. (28) Why viscosity is important? FO- Low viscosity is required for fuel in order to obtain good atomisation at the fuel valve. LO- LO must be chosen which has suitable viscosity for the working temperature for efficient lubrication. 33