Seamanship Marine Engineering and Human Relations Part 1

Seamanship, Marine Entineerint
and Buman Relations ; ~1i::2~~~ion
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Revised Edition - 2014
Seamanship, Marine Engineering and
Human Relations
Part 1
Section 1 - Personal Development and Basic Ship Knowledge
Section 2 - Marine Engineering
ISBN-978-81-908022-5-3
A Collaborative Unit of
Institute of Marine Engineers India
and
The Company of Master Mariners of India
Published and Distributed by:

Board of Examinations for Seafarers Trust
303, Mayuresh Chamber, ISBN 978-81-908022-5-3
Plot No.60, Sector 11,
Opp. Raheja Arcade,
CBD Belapur (W),
Navi Mumbai, Maharashtra, " I
India, Pin Code: 400 614

Phone: +91-22-67935170
Email: bestexam@bestrust.in
Website: www.seafarers.edu.in 9 788190 802253 >
© Board of Examinations for Seafarers Trust
Printed in India by - Siddhi Offse t, Prabhadevi, Mumbai

Seamanship, Marine Engineering and Human Relations
Part 1
Section 1 - Personal Development and Basic Ship Knowledge
Section 2 - Marine Engineering
Foreword
This is in continuation of our effort in facilitating training of seafarers . Though this is a
revised version of our earlier book "Seamanship , Marine Engineering and Human
Relations " published in June 2011 .
This part of the book has two sections as given above. Contents have been improved as
per STCW 2010 and feedback from the end users.
A comprehensive Question Bank has been included at the end of each section.
Part 2 of this series contains chapters on General Ship Knowledge
Board of Examination for Seafarers Trust has been striving for excellence. It has been pos-
sible because of the feedback and comments we receive from training institutes, examin-
ers and from the shipping industry.
All readers are urged to send their comments to the Board of Examinations for Seafarers
Trust at bestexam@bestrust.in. Please do visit our website: www.seafarers.edu.in.
The Board of Examinations of Seafarers Trust (BES) was established at the invitation of
the Directorate General of Shipping (DGS) to conduct All India Exit Examination for
Ratings passing training institutes across the nation.
-BES is registered under the Societies Registration Act, 1860 formed through the collabo-
ration of the Institute of Marine Engineers India (IMEi) and the Company of Master
Mariners of India (CMMI).
The Institute of Marine Engineers (India) [IMEI] is a professional body established in 1980
and is a Charitable Organisation under Bombay Public Trust Act 1950 (Registration No.F-
7589 of 31 May 1982.
The Company of Master Mariners of India [CMMI] is a professional body registered under
the Companies Act, 1956 (Registration No. 10924 of 1957-58).
Aim of BES is 'Enhancement in Quality of Maritime Education and Training in India'.
On behalf of the Board of Examinations for Seafarers Trust
Capt. Subrato Mukherjee

Chief Operating Officer
August, 2014
(i)
Acknowledgements
-------
We are grateful to the Directorate General of S~ipp~ng for a_uth~rising us (~oard o!Examinations
for Seafarers Trust - BES) to_ condu ct _All India Exi~ E~am~nat10n for R~tings; t~lS. has_ lead to a
very healthy interaction with th e Dir~ctorate, sh~p ping _in~u stry, umon~, train~ng institutes,
trainees, trainers, and examiners, and it h as contrib u ted in improvement in quality of training
of ratings in India.
Preparation of this b ook h as b een possible due _to the m oral sup~~rt and fee_dback from the
training institutes. This version of the book contains much of the onginal material sent by train-
ing institutes and extracted from several text books. However, team of authors at BES has bee
continuously editing and improving text and diagrams and adding information. n
Acceptance of the book by the training institutes has made it simpler and economical to pro-
duce it.
This project continues to receive the blessings and guidance of past and present Trustees of
BES.
We wish to acknowledge technical contribution of the following training institutes in prepara-
tion in one way or the other: (Not in any specific order)
Original material and feedback received from the following institutes:
• Training Ship Rahaman, Mumbai
• Sriram Institute of Maritime Studies , New Delhi
• Cosmopolitan Technology of Maritime, Chennai
• Indus Seafarers Training Academy, Chennai
• Commander Ali's Academy of Merchant Navy, Hyderabad
• Southern Academy of Maritime Studies Pvt. Ltd., Chennai
• Baba Marine, Mumbai
• Hindustan Institute of Maritime Training, Chennai
• NUSI Maritime Academy, Goa
• Maritime Foundation, Chennai
• Euro-Tech Maritime Academy, Kochi
Pictures, text, and suggestions from:
• Fleet Management Training Center, Mumbai
• Anglo Eastern Training Center, Mumbai
• Several websites
Creation, editing, and compilation of text by:
Capt. Rajender P Menrai, Capt. Terrance A. Rodrigues; Capt. Pratap S. Mehta,
Capt. Augustin J. Parackal, Capt. S. Mukherjee, Mr. Amitabh Babar,
Mr. Naresh Nanda, Ms. Ritu Goswami, Mr. Pooran P. Chugani and Mr. Sunil Gupta.
Technical support and advice from the members of the Core Committee of BES: .
Mr. GSK Mohan Rao, Capt. PS Barve, Capt. Jung Bahadur Singh, and Capt. Suresh B. Kuutlargi
The outcome has bee1;1- possible because of the hard work put in by the BES staff: .
Mr. Chandan Pardeshi, Mr. Sanjay Parab, Mr. Vinod Kanade; Ms. Akshtha Mathapathi,
Ms. Shakuntala Matri, Mr. Shyam Kumar, Mr. Rajendra Kachale & Ms. Darshana Gadge
Reference Material:
• ILO - Learning elements
• D.J: House; Seaman ship Techniques
• Heinemann Newnes ; Shipboard Practice Vol. 1
• Admiralty Manual of Seamanship HMSO
(ii)
.....
~ ~ /Government of India
lffil~ ~ /Mtntsuy of Shipping
I
~ 'ltllf.l~;jll(',4 / ~ General of Shipping
\~ ~ . ~ ~ / I X Floor. Beta Building
~ -fficfi tcAT ~ / I-Think Techno campus
~~ ~ 11fq ~ / Kanjur VIiiage Road
~ 1"1f (1ff} / Kanjur Marg (East)
• d •·•·•·
~'!11r.ta;,t;~ffl~•.w~ ~ / Mumbai - 400 042.
GAUTAM CHATTERJEE I.A.I
DndOr General rA Shlppino &
M-Of11c1o AdM>"'II.Secre181Y to Govt. of India
Date: 22 nd September, 2014.
MESSAGE
I compliment the Board of Examinations for Seafarers Trust fer this

wonderful effart in compiling this exhaustive set of informative learning
material for guiding the young aspirants of Merchant Navy.
This revised edition has taken into consideration the STCW 2010 ancd
has also incorporated the various ~ggestions of !he end users.
I am sure, the boaklets will help the candidates, Teachers.and Institutes

alike.
.
I congratulate the Board ef Examinations for · Seafarers Trust for this
valuable contribution towards making our "Ratings" more knewledgeable and
professional.
(iii)
.....
'lffiijmc6TT
Government of India
~~~ '
Ministry of Shipping ,
~ 'lEtlH~ ⇒ IIM~
~'Gpffl Directorate General of Shipping,
mft~. ~~. ~ ~ l { f l f.
~ i\tt' 'ITT, u. -«, VI Floor,Jaha_z Bhavan,Walchand Hirachand Marg,
~ ~ 'l~lf.l& ⇒ rch ~ / Mumbai - 400 001.
Deepak Shetty, rRs,
Joint Director General of Shipping it.3TT.~ -~./ D.O.F. No. Jt.DG/DS/2011
MESSAGE
I am delighted to learn that the Board of Examinations for Seafarers Trust

(BEST) is releasing, shortly, a book/publication designed to match the
General Purpose Rating Course entitled 'Seamanship, Marine
Engineering and Human Relation', after a few revisions and re-
formatting, coupled with incremental chapters and material. I
understand that it comprises simple and easily intelligible diagrams,
pictures of parts & equipments on board vessels and adequate texts.
The underlying simplicity and clarity of the material therein is
appriciable.
2. The Indian maritime sector is poised to take on the emerging
challenges of a globalised world which is characterized as the new and
skill-based economy. Acquisition of advanced, competiitve &
technology-oriented skill sets by the Indian seafarers is of paramount
significance in equipping them to deal with the paradigms emerging
there-from. Towards this end, meaningful capacity-building is the
way forward.
3. In this direction, the publication of this book is a welcome
step. I have reason to believe that the trainees will find this publication
useful, relevant and contemporary.
4. I compliment the BEST in its constant & purposive endeavors,
inclusive ofthis one.
~ I
(Deepak Shetty
Joint Director General, Shipping
(iv)
~mcoTT.
Government of India,
™~~.
Ministry of Shipping,
~ •H?IP!~:!ll(')<l,
Directorate General of Shipping,
~-3fl «<cfiH, ·,u.u.ir. \ cfT ll™, cTTcT ~ . 3TT{-m 2cRT lffuR,
,Jq¼~ql\'1 l{(qf.l~~jcf, I IX Floor. BETA Building , i-Think Techno Campus,
~ lfrf (~) / Kanjur Marg (East),
MAHOA SARKAR, J.R.S.
Dy. -Director Gcncn1l of Shipping ~/ Mumbai - 400 042. '!lffif/lndia.
22 nd September, 2014
MESSAGE
I am happy to note that the Board of Examinations for Seafarers Trust

(BEST) has revised the books "Seamanship, Marine Engineering and Human
Relations11 as per STCW 2010 and as per the requirement of the trade.
All Training Institutes for GP Ratings and even otherwise, are using these
books published by BEST and finding it very useful for candidates getting
acquainted with the terms used in Shipping for the first time . I am certain that
the trainees will find these publications· beneficial and relevant. BEST has well
understood the need of training and is thus enabling ·raising the standards of the
Indian Ratings in the global shipping sector.
I wish all the best to the Board of Examinations for Seafarers Trust (BEST),
the Trainees, the Trainers and the Maritime Training Institutes.
(MAHUA SARKAR}
(v)
◄
'J{R(f~
I--:nit
Government of India
l!ra~.~~$~ ·
Ministry of Shipping, Road Transport & H ~
(qra~~) '911-.ways
(Department of Shlppirig)
<fi'Gfr,f~.~.W'ft' ~ 'ii!IPl~tl icil<I

Directorate General of Shipping
'lfffifffllfjR$~~
CAPT. M. M, SAGGI ~1l<R'.~~iil'f
'Jahaz Bhavan', Walchand Hlrachand'M
Nautical Adviser to Govt. of India. ~/ Mumbai - 400 001 . arg,
No.NA/ Notes/ 2011-12 June 15, 2011
1 am very pleased to see the efforts of the Board of Examinations for S~afarers Trust (BES) in
continuous improvements in the quality and contents of the text now coming out under a new title
"Seamanship, Marine EngineeringAnd Human Relations".
Perhaps, BES is the only examination body that has gone beyond the role of conducting
examinations towards producing teaching learning aids, and advising the Directorate on issues
related to training and employment of ratings.
I would to recommend this book for all other training programmes as this the minimum knowledge
every seafarer should posses irrespective of their role on Deck or in the Engine Room.
~1/be&wish:
Capt. M. M. Saggi,
Extra Master
Nautical Advisor to the Government of India
~fflff, ' l { f f i f ~ 'l:!Tffl~.trnf~.

~~~~IRT~
A.BANERJEE
Chief Surveyor with the Govt. of India
& Chief Examiner of Engineers I ~~atR~~.
(trnf~~)
~ '161~~1'ili:il4,
~ ~ im, ~ · 400 001 .
GOVERNMENT OF INDIA
'~ffl',
Ministry of Shipping, Road Tranaport & HlghWIY'

(Department of Shipping)
DIRECTORATE GENERAL OF SHIPPING
'Jahaz Bhavan', w. H. Marg, Mumbai· 400 001.
SUB: SEAMANSHIP, MARINE ENGINEERING AND HUMAN RELATIONS-REG
I am rather impressed with the efforts made by the Board of Examination for Seafarers Trust in
bringing out the two volumes of "Seamanship, marine Engineering and Human Relations·. we are
aware that seafaring is rewarding profession as long as the various funtions requied to be carried out on
bard are discharges safely and deftly, under arduous conditions. The sheer variety of the shipboard
duties and the multidimensional skills they elicit, make rather diffcult for any attempt to harness such
knowledge under a single roof. These volumes seem to have dealt with this difficulty in large measur~.
I trust that the seafarers who have the opportunity to read these editions will certainly add to their
knowledge in the years to come. '
(vi)
d
From Capt. S. M. Halbe 13-09-2014
Chairman and Director, MASSA
My heartiest congratulations to Board of Examination of Seafarers Trust for coming

out with a revised edition of "Seamanship, Marine Engineering and Human
Relations".
The book is very well laid out and can, infact, be used by a primer by all ranks! The
language and illustrations are simple and easy to understand, and convey the mean-
ing effectively.
This book will certainly contribute towards the Industry's goal of creating a
'Competent Seafarer in a limited period of time, without diluting standards'. After all,
basic knowledge is the bedrock of Competency!
I wish the Staff and Trustees of BES the very best in their future endeavors.
With Best Wishes,

Capt. S. M. Halbe
***********
From Capt. V. N. Aindley Date: 19-09-2014

Master CMMI and Chairman Board of Examinations for Seafarers Trust
I remember having sent a message when the first edition of this book for ratings was
published in June, 2011. I reiterate that the book in two volumes is of utmost impor-
tance not only for Indian ratings but also for those of foreign origin.
I am glad to know that the revised edition, which will be published soon, would
include the provisions under STCW 2010 and also latest practices developed in the
recent past.
In my opinion copies of these two volumes on board would prove to be a valuable

asset to the ratings as a ready reference.
The first chapter on personal development is very relevant for the Indian ratings. The
budding ratings of India should learn the importance of being a professional Seaman.
I highly appreciate the efforts of the whole team of the Board of Examinations for
Seafarers Trust (BES) for continual improvement.
With Best Wishes,

Capt. V. N. Aindley
***********
(vii)
Date: 11-09-2014
From C. V. Subba Rao
President, Institute of Marine Engineers India &
Co-Chairman, Board of Examinations for Seafarers TruS t
·t t f M ·ne Engineers India I offer the warmest felicitations
0 n b eh alf of t h e Ins t i u e o an . . . ' 0 amendments
on the launch of your Revised Edition, m lme with STCW ZOl ·
r h t t th t BES has once again taken the lead in putting together a text
th:~ is ~~~~is~,~~l:va:t and most importantly, simple and easy to follow.
Such simplicity is what we require to run ships efficiently and safely.
I wish BES great success as it continues to invest in uplifting the career of a seafarer.
Yours sincerely,
C. V. Subba Rao
***********
From: Sanjeev S. Vakil

Managing Director, HIMT
We congratulate you on having the vision to have authored and compiled an exhaus-
tive volume of information for the use of Faculty and trainees during the tenure of the
GP Rating Training course and thank you for the same. This book provides a level
platform of knowledge that all trainees are expected to achieve.
The section on Marine Engineering knowledge is comprehensive though condensed

in some areas and too detailed in others. The acceptable median can be achieved
mainly through repeated reviews and revisions which are being done by you.
I would like to suggest that the pictures of engineering equipment be depicted in

colour. In keeping the larger picture in view, I must appreciate the research and labour
that has been expended to achieve this compilation. I take this opportunity to congrat-
ulate you for this fine effort and pray that the Almighty will, in his unbounded wis-
dom, deem fit to endow you with the strength to achieve even better results. Please
feel free to call upon us at any time, for any assistance that we can render in this proj-
ect.
With all good wishes, I remain

Sanjeev S. Vakil
***********
From: Uday Mitra
Principal, Sri Chakra Maritime College, Puducherry
Since all, the. stud~nts ~ave not sailed on board Ships, way of working / living on
board CDs with ammat10n effects of various operations/ Engine room & Deck will be
of great help in imparting training to the GP students.
Uday Mitra
***********
(viii)
From Mr. A. Banerjee
(now Chief Surveyor and Principal Officer - MMD Kolkata)
It is indeed commendable of the Board of Examinations for Seafarers Trust to have

brought out the two Learning Guides", for (i) G.P. Ratings , & (ii) Certificate Course in
Maritime Catering. India, with full support and direct involvement of the
Government & private enterprises has always been in the forefront of maritime train-
ing. This has been the cornerstone oflndian seafarers having made a veritable contri-
bution to international shipping.
As I see both the Learning Guides, it is evident that no effort has been spared in mak-
ing them comprehensive, lucid and effective.
I have no dearth of trust in envisaging the great extent to which these books shall h elp
in "guiding" the ratings community, in pursuit of their "learning" how to serve suc-
cessfully on board ships.
A. Banerjee
*** ** *** * * *
From Dr. P Misra

Principal Officer - Mercantile Marine Department, Chennai
I am pleased to see the effort in compiling basic level learning material for Seafarers.
The book is very well formulated and covers practically every area of competence that
would be necessary for a beginner. It is observed that a number of management relat-
ed issues and personal. development matters are also included. It is an excellent book
and I would recommend it for necessary applications.
With Best Wishes ,

Dr. P. Misra
** ***** *** *
From Capt. P.S. Barve

Nautical Advisor, Government of India (Retired),
This is the best educational material available for the ratings; not only to be used dur-
ing their training period but also during their sea service leading to watch keeping cer-
tificates.
The volumes are indeed well compiled and edited so that they are easy to refer to and
provide a wealth of information through the very well illustrated diagrams and fig-
ures.
I wish all those who use these volumes best of learning and a very prosperous career
in the maritime fiel d. Hope to see more such material in the future.
With Best Wishes,

Capt P S Barve
***********
(ix)
From Capt. R. D. Kohli,
Past Master, Company of Master Mariners, India
Religion was the name given to rituals which humans deemed fit to perform with the
aim to propitiate the mysterious power that is believed to be behind the 'Universe' and
its going on.
The evolution of religion is today called spirituality. This has no link to any _religion
or it applies to all religions. Spirituality refers to human values and behav10ur. By
now humans have come to well comprehend the science, technology and their intri-
cacies to enjoy the passing comforts and conveniences however they are far from real-
izing the characteristics of spirituality which alone can give permanent peace and joy
through understanding concentration, contemplation and meditation.
Understanding the need for sense control, mind control and practice of spirituality,
these form a foundation for superstructure of spirituality. The 'Learning Guide' which
is being renamed as 'Basics of Seamanship, Marine engineering and Human Relations
for Seafarers.' is the foundation for each who will take to it, understand its content
practice_ it when on the ship or otherwise, and thus find this book to be the strongest
foundation on which to build fearlessly to any heights he may desire.
Rondev Kohli
**** *******
Message from Capt. N. Hiranandani,

P!st Master - Company of Master Mariners of India;
Director and Former Chairman - MASSA,
As a result of a surplus ratings training in India was stopped in 1981 till 1992, and it
was restarted for two reasons.
1. To meet future demand resulting from retirements

2. To reduce the age profile and image of Indian ratings.
~~rentl~ there _are 5000 ratings being trained and though this creates a surplus the
m us try 1s lookmg_ out for efficient, competent, willing and physicall ft ' f
. employment on ships of today. ' y I persons or
In the past trainee ratings hailed from traditional family sea£ · dh d1

entry s tan d ar d s, d ue t owh'1ch th eir
• trammg
. . received littl ttarmg· areasdan a · ·ow
institutes were paying little attenti'on t o improvements
• Inea
trod ent10n
f an
f Allthe
I trammg
d. E .
Examination for r_atings w~s much needed intervention. from ~c rnn o n ia x1t
say that the quality of ratmgs coming out of tra· . . . e DGS. I am pleased to
steadily. mmg mshtutes has been improving
My congratulation to the Board of Examinations £

excellent book for trainees and thus makin 1 °~?eafarers Trust for creating an
the standards. I must say that BES has one~ a va u~ e contributi~n towards raising
nd
ings will gain from it throughout their gcare eyo its mandate to fill the gap and rat-
er.
With best wishes
N and Hiranandani
******** * **
(x)
Sea.II1ansh i p, Marine Engineering
and Human Relations
Part 1
Section 1
Personal Development and Basic Ship Knowledge
Reading Writing Speaking
Published by
Revised Edition
August 2014
◄
Contents
Part 1 - Section 1
Personal Development and Basic Ship Knowledge
Chapters Page No.

1. Personal Development 1
2. Basic Ship Knowledge 32
3. General Ship board Safety and Health 66
4. Hand Tools and Measuring Instruments 96
Contents
1 Learning
a. Meaning
b. Importance
c. How do we learn?
d. Learning Mind Map
2 How to improve own English?

a. Tips for improving English Reading
b. Tips for Spellings
c. Tips for Writing
d. Tips for Speaking
e. Tips for Listening Skills
3. How to Study?
a. Tips for studying in class
b. Studying for Exams
c. Studying on the day of Exam
4. The Whole Person

a. Meaning of the concept of Whole Person
b. Knowledge
c. Skills
d. Attitude
e. Values
5. How to succeed in life

a. Mind map of factors influencing success of a person
6. How to be presentable?
a. Grooming tips for men
b. Grooming tips for Women
7. Communication Skills
a. Mind map of Communication
b. Importance of Communication
c. Meaning of communication
d. Need for communication
e. Barriers in Communication
f. Modes of Communication
g. Exercises
h. Listening Skills
i. Basic Approach to reading

Part 1 Section 1
1 o eveloprnent
Chapter 1 - Persona
2
8. Time Management
a. Meaning
b. Tips for Time Management t
c. Benefits of Time Managemen
9. Stress Management
a. Meaning
b . Signs and symptoms of stress
c. Reasons of Stress
d . Tips for removing stress
10. Team Work

a. Meaning of team
b. Elements of a team
c. Need for teamwork
d. Steps in creating a team
Advantages of team work
:.· Key factors in the development of team
11. 'Leadership
a. Meaning
b. Qualities of a good leader
12. Ethics
a. Meaning
b. Tips for maintaining ethics at workplace
13. Gender Sensitisation
14.
A Short Course in Human Relations
a. A short course in Human Relations
b. Serenity Prayer
c. Ten Commandments of Success
15. Computers
a. Introduction
b. Parts of a computer
c. M icrosoft office- brief introduction
d . Microsoft Word (MS Word) - Usage
e. Internet - how to use it?
Introduction
s ess·
The intention of this chapter is to guide you to develop your skills to become a uccl ad
. . d · d to e
ful seafarer and a canng human bemg. In fact the entire book has been esigne . you
you to become a very successful person in your life beyond your present imagination- JllB
will get out of this book much more than what you put in. Use this opportunity to beco
a proud Seafarer, one who cares for self, others , and the environment.
Seamanship , Marine Engineering and Human Relations

Part 1 Section 1 Chapter 1 - Personal Development 3
1 Learning
Specific Learning Objectives:- Trainee will be able to explain basic concept of learning.
Let's find out what is learning? Learning does not mean studying for qualifications. We are con-
tinuously learning and not even realizing. But when we learn with purpose, it develops new
knowledge, updates or builds on current skills. Learning is a "Permanent change in behavior".
Why is learning important in life? Learning is the key to our
► Success You learn something every .d ay

► Happiness if you pay attention.
► Confidence -Ray LeBlond
► Communication
► New opportunities and
► Motivation
People generally People are able to ...

remember... (learning outcomes)
(learning activities)
10% of what they read Define List

Describe Explain
20% of what they hear
30% of what they see

Passive Demonstrate
Apply
30% of what
they see and
Learning Practice
hear
70% of what they

say and write Active Analyze
Define
90% of what Learning Create
Evaluate
they do
How do we learn?
► Learning is influenced by the number of questions that come to our mind. The more, the
better.
e What? Where? Why? Who? When? How? . .
► Learning depends upon the use of our senses. (Sight, touch, smell, taste, hstenmg)
► Learning also depends upon our vocabulary. (The number of words we know)
► Learning becomes permanent by practice. Practice makes one perfect.

Chapter 1 _ Personal Development Part 1 Sect·10
4 11
There is no age barrier to learning ..... We need to learn all th e time to keep pace with chang 1.
this highly competitive world. es
Expressions
Symbols.__ Reading
\ ,-----1
I Smell I Imaging
Sound I_
Memory Shapes
~ .__s_u--e-ild-in_g____.
Touch
Senses Techniques
Taste
~ Meanings
IShort Term j
Jvocabularvl------l Learning 1----- Memory
IPermanent I
Thinking
Receiving Problem
Solving
IConcentration I
Use of 5 W's
and 1 H
What?
Why?
Who?
When?
Where?
How?
Seamanship ' Mari ne Engmeermg

. . and Human Relations
2 How to improve own English?
Reading Writing Speaking
Specific Learning Objectives:- Trainee will able to describe methods for improving own skills
for reading, writing and speaking English.
Whether it is English or any other skill it is the "Practice that makes one perfect". The following
tips are based upon personal experience in an attempt to improve language. The difference in
progress depends upon dedication and technique. Hard work can produce some results but more
important is technique and regular practice (discipline)
Here are some tips: Reading is to the mind what

exercise is to the body.
Reading ~ Joseph Addison
• Set a goal for yourself in terms of the speed of reading
• Buy a medium size dictionary
• Buy old books - Primary School English
• Read what interests you
• Choose a paragraph and read aloud
• Mark the words that you find difficult to pronounce
• Check those words in the dictionary
• Choose some nursery rhymes to practice
• Read a short paragraph to a friend and let him do the same. Compare the differences
• Read jokes and tell them to your friends
• If you have difficulty in reading, then listen first (on recorded tapes)
For spellings
• Use a dictionary
• Make a separate notebook and write the spellings of the words that you find difficult
• Keep trying new words
• Break the words and then make spellings
• Play word games. A very good site for playing word games is
http://www.manythings.org/c/hm-clothes.cgi
Writing
• Be Simple, Clear, Concise(short), Complete and Honest
• Read what you have written and listen to your writing
• Check spellings
• If possible, choose a friend and get his feedback
• Buy a handwriting book to improve your handwriting

6 Chapter 1 - Personal Development Part 1 Section. 1
Speaking .
• t Of those who speak English well and try to copy them
Ob serve th e mou th movemen s
• Use the dictionary for checking the pronunciation
• Make a list of w ords that you find difficult to pronounce a nd ask someone who speaks the
l an guage well to pronounce t h em for you. If Poss ible search on the computer
• Read aloud in En glish fo r 15-20 minutes everyday
• Record your own voice and listen to the pronunciation mistakes
• Listen to and sing En glish songs
• Don't sp eak too fast or too slow
Listening
• Pay attention
• Accept the fact that you are not going to understand everything
• Keep cool when you do not understand
• Do not interrupt
• Listen to how something is said
• Face those you are talking with and maintain eye contact
• Don't talk too much
Start right now with the following exercise:

A) Read this page again but note the time it takes you to read. Keep a record for compar-
ing it next time. Now read it aloud and see how your words flow and time it again
B) Underline the words you do not know at this stage. Make a separate list and write
their meaning in simple English by looking at an English to English dictionary.
C) Close this page and write as many points as you can recall about learning English, or,
speak to some one about the contents of this page.
Keep a record and repeat the above exercise after three days and see the difference.
Practice, practice , practice!!!!!!
Keep practicing and find ways to improve your technique. Remember, where there is a Will
there is Way. Smile, and world will smile with you; frown and you will be
left alone to brood. Choose © © ©
Seamanship , Marine Engineering an d Human Relations

3 How to Study?
Specific Learning Objectives:- Trainee will be able to suggest methods for self study and for
preparing for examination.
The most common barrier to success is the lack of techniques for studying and preparation for
exams
Important skills:
a. Reading The noblest exercise of the
b. Listening mind within doors, and most
befitting a person of quality, is
c. Writing, Grammar, Spelling
d. Vocabulary
study"
Here are some tips for studying:

• Studying in class
a. Take good notes
b. Pay attention in the class
c. Review (see what have you written) your notes everyday
d. Read your textbook thoroughly (understand)
e. Finish your class work and home work on time
• Exams
a. Do not wait for the last day before e~am to study
b. Highlight the main topics in your note book
c. Do not try to memorize (learn) the notes from beginning Exams are on my head; how
till the end. Its not the words that are important; do I study??? So less time so
much to do ....... .. .. .
it's the idea
d. For learning, make charts, lists
e. Manage your time and stress
f. Sleep well
• On the day of exam

a. Be physically prepared
b. Bring necessary writing materials
c. Go to the bathroom before exam
d. Never miss an exam
e. Do not cheat or use unfair means
f. Reach the center of exam 30 minutes before the scheduled time
g. Read the instructions carefully before starting to write
h. Read the questions carefully
i. Write clearly. Time your paper and then start answering
For more information on tips for studying visit the websites given below;
http://www.cod.edu/people/faculty/fancher/STUDY.HTM
http:/ /www.studytips.org/
http:/ /www.studygs.net/

8 Chapter 1 _ Personal Development
The Whole Person

4
Spec1·fic Learnmg
• ob·Jeet'1ves:- Trai·nee will be able to state describe the concept of a ,Whole
person'.
What is the definition of a whole person? There is no definition but it is a concept.

A whole person is one who has K-S-A-V.
Knowledge
Values Skills
Attitude
Values are of the highest importance because they influence development of Knowledge, Skills,
and Attitude.
Knowledge: It's not hard to make decisions

• Knowing things, names, numbers etc. when you know what your val-
• Understanding principles ues are.
• Solving problems ~ Roy Disney
• Ability to see the difference between things
Skills:
•• Ability to do something by practice or learning
Imitating/ Copying
•• Performing
Expertise (to be an expert)
Attitude:
•• Behavior representing feeling
Receiving well/ Being attentive
•••
Responding well
Cooperation
Takes initiative/ Leads others
Values:
•• The principles or moral standards (honesty, integrity, punctuality)
Team Spirit
•••
Supporting others
Discipline
Safety of self and others
••
Protection of environment
Non-violence, etc .

Part 1 Section 1 Chapter 1 - Personal Development g
5 How to Succeed in Life?

Specific Learning Objectives:- Trainee w ill be able to identify the factors that contribute to
success.
Factors that in fluence su ccess of a person are summarised below :
Improve English Manage

• Handwriting • Set Goals
• Speaking • Plan
• Grammar
"- / •. Organize
• Develop
"-r---- - - -- - ----< Prepare
Vocabulary
How to Succeed • Achieve
In Life
Socialize
Communicate
Learn • Team Work
• Read better
• Make Notes • Help others
• Write well
• Write Assignments • Cultural
• Oraw well Activities
• Listen Effectively • Write Lab reports
• Sports Activities
• Non-Verbal • Through sharing
• Make friends
Communication • Understanding
Concepts
Study the above diagram; discuss it with your friends, parents, and teachers.
You will realize that one needs to learn a lot, and work hard to succeed. The good news is that
any level of success is within your reach. What you need is to set high goals for yourself and
st&rt working in small steps. Remember "a journey of thousand miles starts with first step" - a
Chinese Proverb. Imagine you were to climb Mount Everest - where will you start and what
preparations will you need.
"The secret of success in life is

for a man to be ready for his
opportunity when it comes."
~ Benjamin Disraeli

1
Chapter 1 - Personal Develop men t Part 1 Se .
10 ct1on 1
6 How to be presentable? .
. . be able to appreciate the importance of b .
Specific Learning Objectives:- Tramee wt11 e1 g
11
presentable.
Here are some tips to be presentable

• Tips for men:
• Brush your teeth and carry breath mints
• Shower before going to work
• Shampoo your hair every two or
three days as needed
• Have your hair cut and trimmed at
regular intervals
• Be clean shaved
• Dry and style your hair neatly
• Clean and trim nails ·
• Use deodorant or talcum powder
• Clean and iron your uniform
• Polish your shoes
• Don't wear jewellery
Tips for women (at work)

• Nails should be short and trimmed
• Do not wear nail polish
• Hairstyling should be tied up properly
• Hair color should not be used
• No make up
• No jewellery
• Wear clean and ironed uniform
• Wear uniform with good fitting
Women can wear light jewellery and make
up with informal clothing. Clothes should
not be revealing.
Note - Some of the tips for men apply for

women as well and are not being repeated
A General Principle while talking to people r - - - -- ,:-------do not

• Maintain eye contact while talking Clothes and manners .
1
• Stand straight but comfortably make the man; but, when heh.:
· rove 1
made, they greatIY imp
• When shaking hands , hold the hand firmly; not tightly
• Do not go too close to the person's face while talking appearance. her
• Do not touch the other person ~ Henry Ward Beec
These tips will not only make you presentable at work, but the will boost up your confidence
and add a charm to your personality y

7 Communication Skills
Specific Learning Objectives:-
Trainee will be able to You can have brilliant ideas,
1. State the importance of communication skills but if you can't get them
2. Describe the components of a 'communication process' across, your ideas won't get
3. Identify the barriers in communication you anywhere.
4. Read Verbal and Non-Verbal messages ~ Lee Iacocca
•• .J
5. Improve his knowledge about communication
7 .1 Importance of Communication Skills
Poor communication has been recognized as a cause of many accidents on boa.rel. Minimum com-
petence (qualification) in English is necessary for safety of life, ships and the environment.
Communication increases efficiency and human relationships on board. Success of a person is

dependent on Communication Skills.
Are you interested in succeeding in life?

Can you succeed without putting in effort?
Questions to bear in mind:

Before you proceed further spend some time with the questions posed here
a) What is the meaning of Communication?

b) Why do we communicate?
c) How do we communicate?
d) What dof;}S 'Process of Communication' mean?
e) What are the factors that influence the effectiveness of communication?
f) Who is responsible for the effectiveness of communication - Sender or Receiver?
g) What do 'Barriers to Communication' mean?
h) What is meant by 'Communication Skills'?
i) What are the different modes of communication?
j) How to assess the level of our own communication skills?
k) How to improve the effectiveness of our own communication?
In the text that follows, you will find answers to the above questions.
7 .2 Meaning of Communication
Gommunication is the base of our entire life and to understand it in depth would mean a study
of a very vast subject. Therefore, for the time being, we shall confine our thoughts to the 'Process
of Communication' and related factors.
Communication includes sending and receiving words and ideas

In its simplest form, it is "An act and process of transmitting and receiving messages in any
form." The words - process, transmitting, receiving and form in this context means the following:

12 Chapter 1 - Personal Development Part 1 Section 1
► Process - a series of actions, changes, or functions that bring about an end or result
► Transmit - convey (speak, write, signal, act, demonstrate) verbally or non-verbally
► Receive - to take in or contain (read, see, observe, think, accept)
► Form - a mode, style, code, complete in ways and means of achieving a change (ver-
bal or non-verbal)
The diagram gives an overview of important aspects of communication. You will be able to use
these concepts and continue improving your communication skills
Social
I Send and get information I r ISelf- Expression /

~-~
Need
Problem in
channel
Distarce
Noise
1 Distractim
External Time Sender Message
Barriers ...____. Communication--- Process

....__ __,._ _.....,1
Channel
Ego.- Internal Emotions Receiver
Language Lack of Modes

confidence
Speaking-- Verbal Non-Verbal Gestures
Pictures
Reading
Writing Symbols

The process of communication can be well appreciated with the h elp of diagram given below
r - - - - - - - - - - - - - - - - - - -.
: Thoughts, idea, :
: symbol, picture COMMUNICATION
: (Concept)
I __ __ _ _ _ !__________} PROCESS
(8 = barriers)
SENDER selects one
or a combination of ~ Transmission ) RECEIVER,
modes to convey it to I) through selected Interpretation
the Receiver mode
I
I
B B
I
- --- --- ---- --- -
• Verbal and Non- Verbal ideas are thought by the sender;

(Verbal= using words, Non-verbal= other than words e.g. picture, symbol)
• Sender decides to convey the same to another person or persons;
• Sender selects a mode or, a combination of modes (speech, written, symbol, action, picture,
sound) to transmit (convey) the concept; and transmits
• Receiver may or may not receive the transmitted idea due to various reasons;
• On receiving the message, the receiver will interpret according to his/her understanding or
feelings
• The received concepts may or may not be the same as intended by the Sender;
• Receiver may or, may not respond (carry out) as intended by the Sender.
Communication Model
1. Message sent 4. Reaction
2. Message Receoved
3. Interpretation

These pictures are examples of Non-Verbal aspects of Communication
Eye contact
Facial Expressions
If you want to learn more - buy two books 1) "How to read a person l i kP.- a book", and 2) "Body I
Language".
The best way to learn is by observing others - remember you were doing it when you were very
small but may have lost the habit while growing up.
7 .3 Need for Communication

• Send and get information
• Express your,,feelings to others
• Impress others
• To become confident
Barrier in this case is any factor which affects the quality of concept/idea as it passes through dif-
ferent stages in the process of communication
Ineffective communication (poor communication) will have a vast difference between the con-
cepts of the Sender and that of the Receiver
Exercise A. Identify two incidents when your message was not received the way you intended
(choose one written and one spoken message)
Exercise B. Identify two incidents of what you received was not the same as intended by the
sender. (Choose one written and one oral form of communication)
Assess each of the incidents by:
What went wrong, and where, and why, and when?

Exercise C.
I. What can go wrong between the sender and the receiver of a message? Discuss these fac-
tors with your colleagues and modify your list of factors. Can there be barriers at any other
place as well?
II. Categorize the identified barriers as
a) 'Physical conditions, e.g. noise, distance, heat, etc. ('external factors')

b) 'Mental conditions', e.g. emotions , prejudice, fear, etc. ('internal factors ')
III. Who is responsible for the effectiveness of communication: Sender or Receiver?
IV. What should the Sender do to ensure that the Receiver receives the intended concept with
minimum of distortion?
V. What should the Receiver do if the incoming message is not clear?
7 .4 Barriers in communication
Barriers - things that block or effect quality of Communication
Barriers in communication can be categorized as:
► Internal Barriers (these are present in the Sender or Receiver)

► External Barriers (barriers present in the environment)
Internal Barriers Better understanding in absence of Noise
• Lack of Con fi rl . a
HI hear? 4 Hi
• Emotions
•
e Ego
Language
External Barriers
I
I . .►
I
------...1
;._ _
Hello
X
~
!!'
!_
Can you hear?
. __/
#' -
~
: ~:~il:: in the channel or medium QT> Q)'
•••
I can not understand j I can understand who says what!
Lack of privacy _w_h_os_a_s_wh_ai_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
L___
· ___J
Distraction (your attention is somewhere else)

Time
7.5 Modes of Communication
Questions to bear in mind?
1. What are different means (called modes) of communication?

2. Difference between verbal and non-verbal modes?
3. Which is easier a) being a Sender; orb) being a Receiver?
4. Difference between, a) Poor communications; b) Lack of communication?

◄
You will realise that:

Effectiveness of a sender depends on his /her:
a) Knowledge and clear perception of a concept;
b) Language and vocabulary;
c) Understanding of different kinds of Barriers that may be present;
d) Ability to speak/write/act/draw/sounds;
e) Availability of different modes (means) for transmission to one or more persons at a time
even at a great distance from the Sender. '
Effectiveness of a receiver depends on his/her:

a) Knowledge and perception (including vocabulary)
b) Reading capability
c) Listening capability
d) Observation
e) Ability to think
f) Interest and attitude
7 .6 Key to successful communication

RECEIVE WELL Read carefully and try to understand clearly
Listen carefully
Observe everything during communication
ANALYSE Think rationally (not emotionally) (Why?)
PLAN Decide action (What, when, where, how, to whom?)
SEND As necessary: Write, Speak, Act, and Draw, do nothing
Always think with the help of your best and most faithful friends:
Why? What? When? Where?
How? Who? Whom? Which?
7. 7 Effective Listening
Learn to observe & understand non-verbal messages
1. Facial expressions
2. Body language
3. Intent of words (Speaker's thoughts, questions, goals, or objectives)
4. Avoid misunderstanding
5. Searching for the meaning of words
6. Listening for the real meaning
7. Evaluating how vs. what is said . .
8. Source of information, experience, observat10ns, and standmg of the speaker
9. Speaker's assumptions if any
10. Facts vs. opinions of the speakers . . .
11.
Para hrasing (Repeat in own words exactly what 1s bemg said)
Avoi~ing wishful listening (What is being said as against what you want to hear)
12.
13. Refrain from immediate value judgment
14.
Refrain (avoid) mental argument with the speaker

Patt 1 Section 1 Chapter 1 - Personal Development 17
Exercise D Carry out self analysis using the table given below:
Judge the strengths and weaknesses of your own communication . You wish to verify your self-
assessment by asking some one with better skills , one willing to assess you.
7.8 Exercise for assessment of own skills (Communication):

Communication Skills elements Very Good OK Not
(with respect to English language) good good
enough
Listening
Speaking (Confidence, clarity, volume, tone)
Writing (Technical)
Writing (General)
Reading capability (Comprehension)
Vocabulary
Drawing
Acting
All of the skills listed above are useful and need to be developed to become more effective - the
sooner the better.
a) Identify the areas that need improvement in your own case?

b) Set priority (A. immediately needed, B. good to have , C. can wait)
c) It would be beneficial if you make a specific pledge to yourself for improving at-least two
of the above listed aspects of communication.
d) Think of various ways you can honor your pledge.
e) Make a plan for the next six months.
7.9 Basic Approach to Reading (A reminder)

You have been reading since your very early age and will continue
to do so more and more. Your success in life depends upon how well
you read.
Vocabulary (number of words you know) is the main factor in read-

ing skills of a person. If you want to improve your reading skills,
build your vocabulary. Vocabulary plays a very important role in
other skills such as listening, speaking, and writing.
Communication skills are directly proportional to your vocabulary.

By strengthening your vocabulary you will strengthen your commu- c _ __ _ __ _ __ _ __ _
nication skills and performance in all aspects of your life.

1
8. Time Management
Trainee will be able to state the benefits of Time Management.
How many times have you given up doing something even before you gave yourself a chance of
doing it? Why? Is it because you have a fear of failure?
To be successful in life and to develop your personality, you need the following skills
► Time Management
► Energy Management
► Stress Management
► Personal Resources Management
At this stage, we will address only two skills: Time and Stress Management
To "Manage" means to have the situation under control; to handle
Time Management - It means to manage the time. Doing more work in less time.
Tips for Time Management
1. Set goals
2. Plan your actions
3. Differentiate between urgent, important and not important
4. Schedule time for your tasks on the basis of importance (make time-table)
5. Monitor how you use your time
6. Learn more about Time Management
Benefits of Time Management

Better:
• Control on situations in life
•• Sense of satisfaction
Achievement in less time
The key is in not spending
time, but in investing it.
•• Results; less worry

Confidence
~ Stephen R. Covey
• Efficiency in meeting goals

• Motivation
• Planning

9 Stress Management
Trainee will be able to
1. Define stress
2. List the mental and physical symptoms of stress
3. Identify the reasons for stress and means for eliminating stress
"Stress is nothing more than a

socially acceptable form of
mental illness"
~ Richard Carlson
/ Mental IFeelings I ___

!Response!
~..-F-in-a-nc----'ia--,1 Health 1----- Stability
Proper use of
IValues I
Money
What is stress? Stress is the emotional strain caused by our response to the pressure from the out-
side world. Stress is important for success but it needs to be within limits - neither too little - nor
too much. Each one of us has a capability to mapage stress by learning to deal with it - mentally,
physically, and emotionally. Mental health, physical health and emotional health can be achieved
by right thoughts, exercise, yoga, and good _feeling about self and all others around us.
What are the signs of stress?
Stress can cause both mental and physical symptoms. The results of stress are different for differ-
ent people.

I
The mental symptoms of stress include:

• Tension
• Irritability (one gets irritated)
• Inability to concentrate
• Feeling very tired
• Trouble sleeping
The physical symptoms of stress include:

• Dry mouth
• Difficulty breathing
• Stomach upset
• Too much urination
• Sweating hands
• Tight muscles that may cause pain and trembling
Reasons of Stress
We think that only bad events bring stress but even success can be a cause of stress
• Fear of failure
• Lack of confidence
• Negative thinking
• Poor health
• Lack of planning
• Wrong habits
Tips for removing stress

• Schedule your work in advance
• Sleep well. Maintain proper routine
• Eat well. Watch your diet
• If highly stressed, find a quiet place and relax
• Exercise and Yoga
• Discuss your problems with your friends and your family
• Have a hobby
• Do some yoga or meditation
• If stressed with some work, leave it for some time (Take a break)
• Refrain from smoking, drinking or drugs of any kind
• Too much tea or coffee is also harmful
A very old saying: "Early to bed, early to rise, keeps a man - Healthy, Wealthy and Wise".. .

10. Team Work

Trainee will be able to state
1. Understand the basic concept of team work
2. Learn the advantage of team work
3. Explain how to build up and develope a team
4. Important factors in team development
The concept of teamwork is very important for any organization. What is a team? Why is team-
work important? The answers to these questions are given below.
Team -A team is a group of people contributing their individual knowledge and skills but work-
ing together to achieve a common goal.
TEAM- Together Everyone Achieves More
Basic elements of a team:

• Each goal is the responsibility of all team members
• Team goals are as important as individual goals
• Individual competitiveness (the feeling of competition between individuals) is reduced on
a winning team
• Communication is increased among team members
• Mutual understanding, respect and co-operation exist among team members
• The winning team leader concentrates on leading the team and refuses to manage on a one-
to-one basis
• Winning teams are highly productive
• Willingness to sacrifice and make commitment.
Why Teamwork?
Because it improves
• Quality
e Flexibility
• Coordination
• Satisfaction and Development
• Productivity/Cost
Steps in creating a team

• Defining the mission (a mission is the team's ultimate purpose)
• Communicating the vision and making goals (a vision is something one wishes in future)
• Developing a Code of Ethics - How are we going to behave towards one another? Which are
the team's values?
• Giving roles to different people
• Blending (mixing) individual styles (by utilizing strengths, weaknesses)
• Making the success criteria
• Celebrating success-recognition
• Action-planning

---r- - ---r::::: · .-:r:::::s::z=;::::c:r
r
/1\ f777T ) ~ - ~
-
d:n~ ~ --n'
u
--,-r:::r:r
A\ r=r-~-.; r:~ ~ -f
.: ~tt·-1
I'
Advantages of Team Work

"Individually, we are one drop.
• Improvement in work methods
Together, we are an ocean."
• Promotes creativity
~ Ryunosuke Satoro
• Reduces tensions and conflicts
• Helps both large corporations and small groups
• Service and product quality increases
• Staffing flexibility increases
• Supervision can be reduced
• Output improves
• Decision making improves
Key Factors in team development:

• Commitment
• Trust
• Purpose
• Communication
• Involvement
• Process to achieve the goal
Team Work has its own fun and rewards .. .involve yourself in teamwork and see the differ-
ence ........... ©©©

Part 1 Section 1 Chapt er 1 - Personal Development 23
11. Leadership

Trainee will be able to identify the qualities of a good leader
Everyone can n ot become a leader. Successful leadersh ip dep en ds on the following qualities :
Positive Inspiring
Honest
Listening
Sight
I Rewarding I
Awareness Equal
Decisive
L Listening Skills
E Enthusiasm (Spirit to do a work)
A Awareness
D Decisive (able to make decisions)
E Equal (doing equal behavior with everyone)
R Reward (giving rewards)
S Sight ( to see future goals)
H Honest
I Inspiring
P Positive Communication
Some of the qualities of a leader: If your actions inspire others to

1. Takes challenge / Initiative dream more, learn more, do
2. Builds teams more and become more, you
3. Self-awareness are a leader."
4. Optimistic (positive thinking) ~ Adams
5. Dedicated
6. Believes in self-improvement
7. Sense of humor
8. Competent (well qualified)
9. Forward-looking
10. Enabling others to act.

24 Chapter 1 - Personal Developm ent Part 1 Section
1
12 Ethics
Specific Learning Objectives:- Trainee will be able to state the importance of workplace ethics
The word ethics is defined as moral rules or code of conduct

of an individual. Ethics is doing right or moral thing when
no one is looking.
Work Ethics includes how one feels about his job, career and
his/her responsibilities.
Here are some important tips that will help you to maintain
ethics at work place:
• Self-discipline
• Follow the rules of your work place.
• Accept responsibility for your behavior.
• Do not use company equipment, supplies or facilities
for personal use.
• Set and complete goals.
• Do what you say; finish what you start
• Ignore conflicts (here meaning difference in opinion) with your co-workers.
• Keep the information of the workplace confidential
• Speak the truth
If a team has no ethical values:

• It will be in the danger of failing "A man without ethics is a wild
• It will have no rules and regulations beast loosed upon this world. "
• Everyone will work according to his own ideas ~ Ralph Waldo Emerson
• People will start exploiting each other
Ethics are important set of values for peace and harmony in life.
For more information on "Ethics", visit the site - http://www.hrhero.com/sample/trial-ethics.pdf

13. Gender Sensitisation
Specific Learning Objectives:

The Trainee will be able to understand the need to prevent discrimination against women on
board ships.
Equal Rights Dignity
MEN AND WOMEN

IN EQUALITY;
ENDOWED WITH
THE SAME DIGNITY
1. Women in Shipping:
• Though women make up only around 2% of world's maritime work force they are the least
protected in their jobs at sea.
• Importance of this issue has been highlighted by International Maritime Organization in its
STCW Convention.
2. STCW Convention, as amended in 2010:

• Resolution 14 states " ....... HIGHLY DESIRABLE that both men and women have equal
access opportunities to maritime training and to employment on board ship ....... "
3. Purpose and Objectives:

• To understand the need for positive actions to prevent discrimination against women on
board ships.
• Behavioral change is necessary as male seafarers have to:
a) Work with them
b) Take orders from them
c) Adjust with them
4. Challenges faced by the women seafarers:

• Women can never equal men in physical strength.
• They have to keep proving themselves.
• Acceptance by other members of the crew.
• Cultural difficulties.
5. All persons on board are expected to: 6. To be a professional:

• Do the job regardless of their gender • Develop a personal value system
• Work together as effective and safe team • Maintain high ethical standards
• Avoid inappropriate behavior • Be a good human being.
• Respect others and follow appropriate
dress code
• Avoid arrogance and rudeness
• Behave professionally

I
Ch ap ter 1 - Personal Development Part 1 Section 1

26
.
Specific Learning Objectives:- Tramee w1•11 be abl e tO u tilise tips for improving interpersonal
relationships
14 A SHORT COURSE IN HUMAN RELATIO~S ,,

. mos t.1mport an t words·. "/ admit I made a mistake
Th e S1x . ,, .
The five most important words: "You did a good Job ·
. . ?"
The four most important words: "What is your opinion.
The three most important words: "If you please".
The two most important words: "thank you".
The one most important word: "We"
The least important word: "I"
SERENITY PRAYER
God grant me the serenity to accept the things I cannot change,
courage to change the things I can, and wisdom to know
the difference.
The Ten Commandments of Success

1. Speak to people: There is nothing as nice as cheerful greeting
2. Smile: It takes 72 muscles to frown, only 14 to smile
3. Call people by name: Everyone is pleased when you remember their
name.
4. Be friendly & helpful: and others will respond in like manner
5. Speak & act as if everything you do were a genuine pleasure
6. Be genuinely interested in people
7. Be generous with praise - caution with criticism
8. Be considerate with the feelings of others , it will be appreciated
9. Be thoughtful of the opinions of others; there are 3 sides to any contro-
versy - yours, the other persons & the right one?
10. Be willing to give; what counts most in life is what we do for others.

15 Computer
1. Identify the external parts of a computer
2. State the basic functions of MS word
3. Access the internet
The Computer is a group of pieces of hardware put together to get a job done faster.
It includes a central Processing Unit CPU (its brain), a viewing screen called Monitor, a Keyboard
for typing and a Mouse for making it easy to select, move, etc.
The computer CPU is a rectangular box that sits on your desk (called a "Desktop Case") or under
the desk. The CPU is an electronic machine.
t :•:•· ........,•,•· · ······· ·,'·· ········ ,·.·•, ............,•, ... .
·'
l
i
--===--
I
- -' I I
Monitor
The Monitor - It is like a TV. Monitors range in
CPU sizes of14", 15", 17", 19", etc.
\
\
!
Mouse
It is used to point objects on the monitor to
select as needed. By using the mouse and key-
A Key Board board together, we can work easily and fast.
It is like a typewriter that communicates with computer.

Peripherals -They are any electronic objects that can be hooked -up (put/ connected) to the corn.
puter.
These objects include Speakers, Microphones, Printers, Scanners, Digital Cameras, etc
The Floppy Diskette Drive - Floppy diskettes are used as a The CD-ROM Drive. Data can be written and
storage container for computer data. rewritten on the CD.
Microsoft Office
Microsoft Office is a software that has different applications that complete different activities.
• Microsoft Word - It has powerful tools for creating (making) word professional documents.
• Microsoft Excel - It is used to make spreadsheets and calculations.
• Microsoft PowerPoint - It has tools for making very good presentations.
• Microsoft Access - It is used to share your data with co-workers over a network, find infor-
mation and quickly make database.

• Microsoft Publisher - It help s you to easily make and publish materials like newsletters,
brochures etc.
For more information visit the site:
http :// www.bcsch ools.net/ staff/microsoftoffice.htm
Out of all the programs, Microsoft Word is th e m ost important for you as a beginner.
Microsoft Word - Microsoft Word is a powerful tool to m ake professional documents. It does
many important fun ctions like;
• Preparin g (Creating) a document - MS Word is used to open a file (known as d ocument) .

After the document is created, one can save the matter in the document. He can see that
matter later on also. Using the m enu (menu is always shown on the top of a w ord docu-
m ent).
• Using different styles of writing - One can use different styles of writing a document. For
e.g. italics (Ship), Bold (Ship) etc.
• Page Set Up - One can control the settings of his entire document e.g. Margins, Paper Size,
etc
• Placing and Sizing Graphics (they include photographs, clip art, pictures , Digital photos ,
etc) - One can place these graphics in the document if needed and their size can also be
changed.
• Changing the document in HTML (hyper text mark up language) - It is very easy to convert
a document to web page (html) by using MS Word.
• Sorting (to separate) - This is a very easy function. It sorts the paragraphs that are selected,
places them in alphabetical, reverse alphabetical or numerical order.
• Drawing - By using the drawing tool bar, one can draw pictures and shapes in the document.
• Spell Check- One of the best functions of MS Word is that it checks the spelling mistakes
automatically.
Non-printing
characters
Undo
Print Hyperlink
_,
' I
I
'V'
Left, centre,
Italic right and justify
Current font Font size Numbering

Style
Bold Underline
Bullets

30 Chapter 1 - Personal Developm ent Part 1 Section 1
There are many other comman ds that you can learn after going to the site written above .. .
Text Area
For more information visit the site - It has much guidance and information.
http:/ /www. ed. uri. edu/homepage/ agenda/mop/word/word_beg.html
Command Function
1. New Opens a new Word document
2. Insert Table Inserts a table into the document
3. Open Opens an existing file
4. Insert Excel Worksheet Inserts an Excel Document
5. Save Quick -save files
6. Columns Format text into two or more columns
7. Print Quick- Print Files
8. Draw Draw objects into the document
9. Print Preview Shows a preview of files before they print
10. Spell Grammar Spelling and Grammar Check
11. Paragraph/ Tabs View paragraphs, tabs, spaces, etc
12. Cut Cuts files into the clipboard
13. Zoom Zoom in and out
14. Copy Copies files into the clipboard
15 Paste Pastes copied or cut files into the document
16 Bulleted List Auto format bulleted lists

Chapter 1 - Personal Development 31
Part 1 Section 1
17 Undo Undoes previous actions

18 Redo Redoes "Undo" actions
19 Insert Hyperlink Inserts links into th e document
20 Draw Table Draws a table into the document
21 Font Color Changes the color of the text
22 Bold Changes the typed letters into bold
23 Italics Changes the typed letters into italics
24 Underline Underlines the letters in the document
25 Font Size Increases or Decreases the font size
26 Style Shows the style of the written document
27 Current Font Shows the current font of the document
28 Left, Center, Right justify Does the alignment of the document
29 Numbering Writes numbered bullets
30 Non-printing characters Shows the Non-printing characters in the document
Internet
Internet is a worldwide series of interconnected computer networks.
Its uses:
• Send and receive messages using E-Mail, chatting, blogs.
• View different Websites for information and other needs
• Have own website
• Share information
• Reach out to a vast number of people in the world
• Entertainment - play games , down load music, news, etc.
• Marketing of products
Man is still the most extraordi-
How to use Internet nary computer of all
Steps (an example) ~John F. Kennedy
a. Start your computer;
b. Double click internet explorer icon;
c. Type google in the blank provided and press control+ 'enter';
d. Google site will open;
e. Then type -whatever you want to search in the blank and press 'enter'
For more information, visit the site http://en.wikipedia.org/wiki/Internet # Common uses of the
Internet

Chapter 2 - Basic Ship Knowledge
General Aspects of Shipping

1. Im portance of Ship ping in th e National and International Trade
2. In ternation al Routes
3. Typ es of Ships and Cargoes
4. Shipboard Organization
5. Nautical
Specific Learning Objectives
1 Importance of Shipping in the National and International Trade
The trainee will be able to:

State the role of shipping in the National and International trade.
2 International Routes
The trainee will be able to:
I Use a World-Map (without labelsJ, or Globe, name and identify location of continents'.
and oceans. ·
II State International Sea routes for ships
3 Types of Ships and Cargoes:

Trainee will be able to:
• Differentiate between Types of Merchant Vessels as mentioned below:
• State the use of each Type
• State the Type of Cargo carried by each Type of Vessel.
4 Shipboard Organization
Trainee will be able to state that:
• There are two Distinct Departments on the Ship
• These Departments are Nautical Department and Engin.e ering Department.
• Nautical Department is responsible for Cargo Operations, Navigation of the vessel and
General Maintenance of the Ship and Administration y
• Engineering Department is responsible for the upkeep and maintenance of all

Machinery onboard ship and the propulsion system
• Each Department consists of Officers and ratings
• Nautical Department consists of Master, Chief Officer, 2/0 , 3/0, Cadet or Apprentices
and Able Seafarers (Deck), Watch-keeping, deck ratings or GP ratings
• Engineering Department consists of Chief Engineer, 2/E, 3/E, 4/E, Electro.-Technical
Officer, Electrical Officer, Electro-Technical Rating, Electricians or Fitter and Able
Seafarers (Engine), Watch-keeping, Engine ratings or GP ratings.
• Master is overall in charge of the ship.
• Catering Department includes Catering Officer, Chief Cook & General Steward (G.S)
who are responsible for cooking food for Officers and Crew and general cleanliness in
accommodation.

Part 1 Section 1 Chapter 2 - Basic Ship Knowledge 33
5 Nautical Terms - Parts of the Ship

5.1 Hull
5.2 Ships Decks
5.3 Fore Castle
5.4 Poop Deck
5 .5 Accommodation: - (Teaching Aid: Video)
5.6 Bridge: - (Teaching Aid: Video)
5. 7 Monkey Island
5.8 Cargo Spaces (Cargo Holds, Tanks)
5.9 Cargo Handling Gear (Derricks, Cranes, Grabs, Pumps)
5.10 Machinery Space
Trainee will be able to Name/ Identify a part of the Ship given in the following sketches and state
its purpose:-
5.1 Hull:
Shipside, Name of the Ship, Port of Registry, IMO number, Stern, Propeller, Rudder, Draft marks,
Load~line Marks, Stem, Forecastle, Anchor, Hawse Pipe, Poop Deck
5.2 Ships Deck:

Forward, Aft, Amidships, Portside, Starboard Side, Forecastle, Poop Deck, Derricks, Cargo
Winches, Cranes, Cargo Holds, Hatches, Bulwarks, Railings, Sounding Pipes, Air Pipes, Filling
Pipes, Bollards, Main Mast, Fore Mast, After Mast, Hold Ventilators, Gangway, Pilot Ladder,
Scuppers, Tank domes, Manhole & Covers, Cargo & Ballast lines, Manifold
5.3 Fore Castle:

Windlass, Brake Handle, Warping Drum, Spurling Pipe, Hawse Pipe, Bow Stopper, Devil's Claw,
Chain Stopper, Rope Stopper, Heaving Line, Mooring Hawsers, Mooring Wires, Headline,
Back-Spring, Breast Rope, Fair Leads, Panama Lead, Forepeak stores, Rat guards, Jack staff,
Ship's Bell, Anchor Ball, Anchor, Anchor Shackle, Joining Shackle, Chain-locker, Walkie-talkie,
Tow wire, Fire Wire, Towing bracket (Tankers)
5.4 Poop Deck:

Mooring Winch, Stern Line, After Back Spring, Breast Rope, Chain Stopper, Rope Stopper,
Mooring hawser, Mooring Wires, After Peak, Steering Flat, and Accommodation, Walky-Talky.
5.5 Accommodation: - (Teaching Aid: Video)

Bridge Front Bulkhead, Port holes, Alleyways, Officer's cabins, Passenger's cabins, Crew cabins,
Dinning Rooms, Smoke rooms, Washrooms, Toilets, Pantry, Galley, Laundry, Lounge Storeroom,
Cold storage, water-tight doors, Boat deck, Lifeboats, Life raft, Railing, Ship's funnel.
5.6 Bridge: - (Teaching Aid: Video)

Steering Wheel, Gyro Compass, Magnetic Compass, Radar, V.H.F, Engine Room Telegraph,
Rudder Angle Indicator, Anemometer, Whirling-Psychrometer, Flags, R.P.M Indicator, Ship
Whistle/Siren, Light Sentinel, Man Overboard Marker, Chart Room, Side Lights, Clear-Vi m .
Screen, General Alarm, P.A. System (Public Address), GMDSS - Equipment, EPIRB, AIS, Voyage
Data Recorder, Immersion Suit, Life Buoy, Life Jacket, Extinguishers.
Seamanship, Marine Engineering 'and Human Relations

34
Chapter 2 - Basic Ship Knowledge Part 1 Section 1
5.7 Monkey Island

Magnetic Compass, RADAR Scanner, Flag Mast, Halyards, Funnel, Ship's Whistle / Siren or
Whistle.
5.8 Cargo Spaces:

Cargo Holds, Hatch Coamings, Hatch Openings, Hatch Covers, Hatch Boards, Hatch Beams,
Tween Decks, Hold Bilges, Tank Top, Double-bottom Tanks, Manhole Covers , Cargo Tanks.
5. 9 Cargo Handling Gear:

Derrick, Cargo Winch, Cranes, Grabs, Gantries, Cargo Pumps
5.10 Machinery Spaces (Engine Room, Pump Room)

Location of Engine Room: Existence of Entrance doors, Emergency escape routes. Location of
steering gear. Location of pump room on tankers, Emergency Fire Pump & Generator. CO 2 Room,
Foam Room, Foam Line, Foam Monitors.

1 General Aspects of Shipping

• Importan ce of Shipping in the National an d International Trade
• International Routes
• Types of Ships and Cargoes
• Parts of ships
• Shipboard Organ ization
1 .1 Importance of Shipping and Types of Ships

A ship is a floating vessel used for transporting cargo across the oceans and through rivers. Ships
come in different sizes and arrangements to carry different types of cargo. Ships h ave served
mankind since pre historic times. Modern ships made of steel, equipped with very powerful
engines, very large, operate at different speeds though much slower than trucks, trains , and
planes.
Importance of the role of shipping and ships can be appreciated from the fact that ships transport
about 95% of world's cargo (including that by road, rail, air, and other means). The economy of
the world depends upon shipping. All attempts are made to make ships suitable and economical
for carrying different types of cargo
Ships can be categorised as follows:
There are two major categories (not counting the ships for defense - Navy) - namely Cargo Ships ·
and Passenger Ships. Cargo Ships are further subdivided into Dry Cargoes and Wet Cargoes as
given in the chart below. There are other types that can be placed under 'special category'
Basically 2 types of Ships exist namely Passenger & Cargo. Cargo Ships are further subdivided
intb Dry Cargoes and Wet Cargoes as per Table below:
Types of Ships / Types of Cargo
Cargo Ships Passenger Ships
Dry Cargo Ships Liquid Cargo Ships (Tankers) Cruise Liner
General Cargo General Cargo (eg:) Oil Tankers Crude oil, refined Ferries
Boxes, Machinery, oils, and petroleum
etc products
Container Containers Chemicals Chemicals in bulk

Vessel Carriers
Bulk Carriers Bulk Cargoes, Gas Carriers Liquefied Gases
(Ore, Grain, Coal, (LNG, LPG, and other
Cement, etc) gases in liquid state)
Roll On -Roll Trucks, trailers,
Off Vessel cars & other
vehicles
Other ships: Tug Boats, Offshore supply vessels, Cable laying ships , Survey ships , Oil plat-
forms , etc .
Small floating vessels u sed for different purposes are called boats

36 Chapter 2 - Basic Ship Knowledge Part 1 Section
1
1.2 Types of Ships
• General Cargo Ships: Are used for carrying different types of dry cargo in different sizes
and shapes. This type is the earliest of cargo ships. First change was in the size of ships
then in method of packaging cargo, several other factors made the ships more and more spe~
cialized and thus different categories.
A container ship is one such advance version of general cargo ship providing options for
different sizes of containers and a very speedy loading and discharging of cargo.
• Roll-on/roll-off (RORO or RO-RO) is yet another version of a 'General Cargo ship' designed
to carry wheeled cargo such as automobiles, trailers or railroad cars. RORO vessels have
built-in ramps which allow the cargo to be efficiently "rolled on" and "rolled off" the ves-
sel when in port. Car/fruck Carriers are distinctive looking ships with a box-like super-
structure running the entire length and breadth of the hull , fully enclosing and protecting
the cargo. They typically have a stern ramp and a side ramp for dual loading of many thou-
sands of vehicles, as well as extensive automatic fire control systems
• Bulk Carrier. A bulk carrier, bulk freighter, or bulker is a merchant ship used to transport
unpackaged bulk cargo such as grain, coal, ore, cement and other similar cargoes.
• Tanker is a ship designed to transport liquids in bulk. Petroleum tankers are a particular
brand of tanker. A wide range of products are carried by tankers, including:
► Crude oil, refined oils, and many other liquids
► Chemical carrier is yet a specialised version of a tanker
► Yet another specialised version of a tanker is liquefied gas carriers - liquefied petrole-
um gas (LPG), liquefied natural gas (LNG), and other gases in liquid state
• Passenger / Cruise Liners. A passenger ship is a ship whose primary function is to carry
passengers. The category does not include cargo vessels which have accommodations for
limited numbers of passengers
• Offshore Supply Vessel (OSV). OSV is a ship specially designed to supply offshore oil plat-
forms. These ships range from 25 m to 100 min length and accomplish a variety of tasks.
The primary function for most of these vessels is transportation of goods and personnel to
and from the offshore exploration activities.
• Tugboat, or tug, is a boat, with a high-powered engine, used to manoeuvre, primarily by

towing or pushing, other vessels in harbors, over the open sea or through rivers and canals.
They are also used to tow barges, disabled ships, or other equipment like towboats.
• Reefer is a type of ship typically used to transport perishable commodities which require
temperature-controlled transportation, mostly fruits, meat, fish, vegetables, dairy products
and other foodstuffs.

2 Major Parts of a Ship
This is an overview of major parts of a ship. You will learn more in Part 2 & Part 3 of this book.
Cargo Control Galley
Sto res - - Super Structure 1-- Accommodation
Radio Navigation
Communication Bridge
Deck -I•---• Parts of a ship 1---.i Engine Room
Wings Tank Holds/Tanks
Hatch
Ballast Tanks Cargo Spaces Cover
DB Tanks Aft Side ---- Poop Deck
Mid-Ship
Mooring
Winches
Fore Peak
Anchor
I Windlass I
Collision
Bulk Head

38
Chapter 2 - Basic Ship Knowledge Part 1 Sectio
n1
In each of the pictures shown below identify the parts and terms listed above. First learn to id
tify different types of ships, and most common parts. en.
A simple meaning of terms is given in the glossary of terms at the end of this chapter. You Will
learn more details in other chapters in this book.
The best way to remember these terms is to read them aloud and repeat them once a
week. Practicing to write will make it better and improve your spelling.
On each of the picture, write the name of the part indicated by arrows.
A very large Bulk Carrier (Cape Size) (gear less, side opening hatches)
Type of ship -

Chapter 2 - Basic Ship Knowledge 39
Part 1 Section 1
.._____....
.,..,. ..
,
' • .
I/ , .. , .
Ii- • ' . . .•
. '-:....,_' :
.:.~.i.~ .....:_~ . . L'

• • I
A geared Bulk Carrier (side opening hatched)
Type of ship -

l
40
Chapter 2 - Basic Ship Kno w ledge Part 1 Sec;t·
ion 1
Type of ship -
Type of ship -

~---····-'~:._·,..·~-fi:,:.,,.., .. - .
. :--::-- -
Jt~t-- ~-,;
--
.:.
-- J
.··-~
.. -
- - •-..
i~J~/~i~t~: :;;~~:- -~,

;.:.. ..;.~··-- :.,,:,. .·-_ -- .. ., .. .
A Container ship
A fully Loaded Container Ship

I
Chapter 2 - Basic Ship Knowledge Part 1 Secti'
42 on 1
crude Oil Carrier
An Oil Tanker (Crude carrier)

Other ships in this category are 'Product Carrier ' that carries refined oil products such as fuel
oil, lubricating oils, etc. A 'Chemical Carrier' is an advanced type of Product Carrier designed
to carry chemicals
Type of ship .

Liquefied Natural Gas Carrier (Other ships in this category are LPG Carrier)
~-
~··'
,
~-
:..-~ :.-
.!';..
-Z,· .
·l ~v:..
. . ··,
''lj ,·»,, ' ::: >' ; .~ :; ,
' ~ '!:.,
.... - .,. ~- (
' I
LPG Carrier

1
44 Chapter 2 - Basic Ship Knowledge Part J. Section
1
A Cruise Liner (Passenger Ship)

Identify the parts shown by arrows (This ship is in a dry dock)
This ship is in a dry dock

Find the function of each of the items shown in this picture and previous pictures.

3 International Sea Routes

International Sea routes: Identify names of oceans, continents,
major countries, and major sea routes.
--~- ....
~
-~
~- 4
.-~
.,,,~~~-'....
'
\· '
- -·. ...
IF
t,~ .
\ ..~
·' ,
'
Recognise names of oceans, continents, major countries, and major ports. Draw sea routes.
A R C T 1 (' 0 C F A N N
WORLD MAJOR SEAPORT A
G.OJ'.t •l1" t
0 '"'" ',;
....
Murmansk J, A!khangerslc
8 J,
J, efl)en .J,St. Petersburg
AndlorageJ. Reykjav1l
lmeilll ,.,. EUROPE
G1i1iJt."" 1 ~
London u J,Hamburg
Al.i," • NORTH Quebec
x o I{ -n-1 Victoria .i. No RT H Rotterdam •Vanino
Totonll> ,t, Porto Mars~llle ~Venice . {' .1.-... VradiYOstok ; c-paro
PAC1PIC J.. AMERICA ,t, lloston ATLAN,IC J, J, ,I, 51~,t;;,• 1 .J, "'I'
o c I' ,1 N Portland Nel'iYolk.i,.t Barcelona J.'-·, .tistanbul • A S A Dalian .s,Tokyo
Rabat"' BizertE -,.,,.,,_ J; .i,Port
()CU/'I
)';.Ji TH
Qingdao ±Busan (Mb
I.Gs Angeles Charleston J, Norfolk
J. NewOrll!il~ J, AJ,iandrla Said Kuwait Shanghai J,,:, J, P,tl ll'lt
J, Miami ·"dah .• "',1, ICarachi .:..Tai-pei OCEAN
J"" .,, Dubii -t- Mumbai li\lllgkong
, ----, -ramf)kt ---- .ar,r,:.....
i:~l,~l~ -
j, _,..-- Dakar Port Smlilll Salalah ••• f J. Kol•au .t ,.t, Kaohsrung
AapukoJ, Ver;iCIIJ; J,<artagena J, A F R I c A\ Aden J, ·'Panaji J, r ;..i ~oulmein
Col~n .LMontetia ' Kodll J. Chennal J. Ba ~ k
Abidjan"' J. l..agM folombo .i, .:, "' o
J,PortGentll J. Mombara Port Klang .!.Singapore
lalibettadJ.
Re<ife ..1, Boma .i, Par es Salum Jahrlll J. DI&
Callao,:, SOUTH J. N.aula . J, J,
AMERICA .tsatvador .t Toamasina Dan.In l illt
Nazea J, .L.Ja _. WalvlsBayJ. B,ira .!, J. J, twflSY
,otrr1-1 Santos J.Rlo "" n~,rv J, M,apu~ A U S T R. A LI A BlisbMe

Antofagasta .t J,
PACif/C .i.9uenosAirus S<WTH CapeTown.i, J. J.Dwbin Ptnti.i, Adela:' .J..J. Auckllnd
Yalpuliso ,1,
OCSAN ,!,Montevideo .ATL.A!vTlc
J,a.hta8tanc.a OO:,J.N
PortElzabeth I N 1" · 'c E " N °
Mellaun1u. s,daeJ .r.
HobutJ. lhlllllin
J.
~ i. a e·N O Mao not to s~ale S O tr T H I JI N 0 C lJ A
~)OI St"!"'n .J, CoP'frlOhlll2012 •1

International Routes:
To learn about the ocean routes, you need to look at the world map and connect different parts of
the world th ough sea. You need to locate the follow ing oceans
There are man-made routes (canals) to r educe the distance ships wou ld otherwise travel between
ports. Canal: Panama Canal, Suez Canal
Learn the following by looking at a world map , and a globe.
Oceans: Atlantic ocean, Pacific ocean, Indian ocean
Seas: Arabian Sea, Black Sea, Mediterranean sea, Straits of Malacca, Bay of Bengal, China sea,
Alaskan sea, Great lakes , West Asia (Persian Gulf)
4 Shipboard Organisation
'Organisation' in simple words means - a group of people that perform tasks necessary for achiev-
ing results. In case of a ship, organization means people necessary to operate and maintain a ship.
Tasks involved in moving a ship from one port to the other are:
• Maintain and control the direction of ship across the sea (Navigate the ship)
• Operation and control machinery needed to move the ship, and for different services
• Serve all other needs of people living on board
• Other important needs are safety and security of personnel, cargo and the ship. Loading and
discharging cargo efficiently, maintaining the ship and machinery in good condition for effi-
cient and economical performance.
There are two Distinct Departments on the Ship , namely the Nautical (Deck) Department and
Engine Department.
Nautical Department is responsible for cargo operations, navigation of the vessel, general main-
tenance of the ship, and administration.
The Engineering Department is responsible for upkeep and maintenance of all machinery on the
ship, and the propulsion system.
Each Department consists of Officers and ratings.
Nautical Department consists of Master, Chief Officer, 2/0, 3/0, Cadet or Apprentices and Able
Seafarers (Deck), Watch-keeping, Deck Ratings or GP Ratings.
Engineering Department consists of Chief Engineer, 2/E, 3/E, 4/E, Electro-Technical Officer,
Electrical Officer, Electro-Technical Rating, Electricians or Fitter and Able Seafarers (Engine),
Watch-keeping, Engine ratings or GP ratings.

I
Chapter 2 - Basic Ship Knowledge Part 1 Secu

011 1
48
Master is overall in charge of the ship .

. . ff cer Chief Cook & Gen eral Steward (G.S) who
Catering Departmen~ m cludes Catef: m g O ~ C , w and gen eral cleanliness in accommodationare
responsible for cookmg food for Of 1cers an re .
Master
~ ~
(Captain)
Engineering
Navigation
(Engine Department)
(Deck Department)
• Chief Officer • Chief Engineer
• 2nd. Officer, • 2nd. Engineer,
• 3rd Officer • 3rd Engineer
• Deck Cadet • 4th Engineer
• Deck Ratings • Junior Engineer
(Bosun, Able • Engine Ratings
Seamen, Quarter (Oiler,
Master, Seaman, fitter, wiper)
Trainee Seaman)
Catering and House

Keeping Department
• Chief Cook
• 2nd. Cook,
• Stewad
The above organisation structure is for cargo ships.Passenger

ships have additional departments and a large crew. The number
of crew on a ship depends upon the size of the ship, type of the ship,
the extent of automation of machinery, international regulations, national
regulations and other needs.
5 Duties of Ships Crew
Duties of a General Purpose Rating (GP Rating)
GP Rating candidates are those who have been trained in both Deck and Engine- Room duties,
Such ratings may be employed in either department according to the needs and requirement of
the company.

After going on th e ship, these candidates are able to work in all seamanship activities on board
with deck-side and other w ork at engine side .
Duties of the Deck- Crew:

• General u pkeep an d cleaning of deck area, h olds and tanks
• Carry out orders from Bosun, Ship Officers and Master
• Chipping and painting of the parts of ship
• Keep lookout on Bridge, Gangway and Security watch
• Steer ship under the direction of the officer on watch
• Operate and maintain deck equipment such as winches, cranes, derricks and hatch covers,
valves, gangways, anti pollution equipment, LSA, FFA
• Handle mooring lines, splice and repair ropes , wire cables and cordage
• Mooring and Anchoring
Duties of the Engine-Crew:

• Assist ship engineer officers in performing routine maintenance work and repair to ship's
engine, machinery and equipments
• Monitor engine , machinery and equipment indicators and report abnormalities to ship engi-
neer officer on watch
• Lubricate moving parts of engines, machinery and equipments
• Operate and maintain off-loading liquid pumps and valves
• Clean engine parts and engine room
Career Progression
Joining 6 months GP Rating Course
•.....
After passing CDC is issued by the DG Shipping which is required for employment
.
Eligible to ioin as either Deck Crew (or) Engine Crew
Promoted as AB Seaman, Bosun in Deck side (or) promoted in engine side
•.
Rating forming part of Navigation watch and Engineering watch
There are possibilities of changing from a 'Rating' to a qualified officer on Coastal

Ships or Foreign Going ships and a committed person can rise to the levels of a
Captain of a ship or a Chief Engineer moving one step at a time.
At the end of this chapter we have included, duties of other personnel in Deck and Engine
Departments.

Chapter 2 - Basic Ship Knowledge Part 1 Secti·
50 on l
Steering the Ship
Windlass
Manifold Crane on Tanker
j
6 Glossary of Nautical Terms (Abridged)

This is a limited list of nautical terms expected to be learnt by a good seamen, and in this case,
by a General Purpose Rating. These terms have been placed in alphabetical order. Most of these
terms are explained or used within this learning guide under different chapters . In fact, you will
find many other terms not listed here but described in this guide . Do create additional list and
send it to the Board of Examinations for Seafarers Trust at best1@mtnl.net.in or
bestexam@gmail.com and h elp us improve this list. This list h as been compiled from different
sources and edited to suit the need.
Term Description
1. Abaft the beam Area of horizon between 90 degree and 180 degree from ahead on each
side.
2. Accommodation Space containing officers and crews cabins, mess room, crew's toilets,
sanitary and laundry spaces.
3. Accommodation Aluminum portable ladder with railings attached to a platform at ship's
ladder side, providing certified access to ship from water or shore.
4. Aft Toward aft, or near the stern. Behind, or near the stern of the ship.
5. After A phrase applied to any object in the rear part of the ship, as after
hatchway or aft mast.
6. After peak The compartment in the stern, abaft the aftermost watertight bulkhead.
7. Aground The situation of a ship when her bottom, or any part of it, rests on the
ground. A dangerous situation of a ship as it can break or gets ruptured.
8. Ahead In front of the ship.
9. Along side Side by side, or joined to a ship, wharf; etc.
10. Amidships A helm order to indicate the rudder is to be put on the centerline.
11. Anchor Equipment lowered down by a chain to the seabed, which renders the
ship stationary.
12. Anchorage Place where ships anchor.
13. Ashore On the shore.
14. Astern Any distance behind a ship , as opposed to ahead.
15. Athwarship Across the ship, at right angles to the fore-and- aft centerline.
16. Anchor Aweigh When the anchor is drawn out of the ground and sighted above water
level.
17. Ballast Weight added in a ship.
18. Bearing Angle between north and direction of an object or between ahead and
direction of an object.
19. Bitter-end Inner end of the anchor cable.
20. Bollard Large and firmly secured post of circular section for securing hawsers
and mooring ropes. Often fitted in pairs on same base plate.
21. Booby hatch An access hatch in a deck to a compartment.
22. Boottop or boot- The surface of the outside plating between light and load waterlines.
topping
23. Bow The forward end of a ship
24. Bow stopper A metal bar used across the anchor chain to ease the strain on the
windlass
25. Breakwater Inclined bulwark like structure on the weather deck which minimizes
the impact of the sea breaking on it.

1
Chapter 2 - Basic Ship Knowledge Part 1 Sect·
52 lo~ l
Stone wall structure at the harbor entrance to dampen the sea and
26. Breakwater
C the ship for navigation and maneuvering.
27. Bridge ontro1 room on
Protruding bow below waterline which helps increase speed.
28. Bulbous bow
Specialized ship with large cargo hold volume for bulk cargoes such as
29. Bulk carrier
coal, grain, bauxite and sugar . .
Vertical partition which subdivides ship m to co~partments.
30. Bulkhead
The foremost transverse watertight bulkhead designe d to keep water
31. Bulkhead colli-
out of the forward hold in case of bow collision damage.
sion
The sides of a ship above the decks. (Vertical plating at ship to reduce
32. Bulwark
quantity of water breaking into deck.)
A floating conical or cylindrical tank with or without a top mark, -------
33. Buoy
anchored on the sea or river bed, to mark the entrance to the channel,
danger or for any other specific purpose.
When two materials rub against each other causing wear and tear. -
34. Chafing
Rounded plate designed to minimize chafing of ropes. -
35.
36.
Chafing plate
Chain locker A compartment for the stowage of anchor chain. -
37. Chart room Room where charts are kept in as well as other navigating equipment
such as sextants; situated on navigating bridge/wheelhouse.
38. Cleat A fitting having two arms or horns around which ropes may be made
fast.
39. Coaming, hatch The vertical plating bounding a hatch for the purpose of stiffening the
edges of the opening, trackway for the hatchcover and resisting entry of
water below.
40. Cofferdam Narrow void space between two compartments that prevents leakages
between the adjoining compartments.
41 . Collision (See bulkhead, collision)
bulkhead
42. Cowl A hood-shaped top or end of a natural ventilation trunk that may be
rotated in direction to cause wind to blow air into or out of the trunk.
43 . Davit A metal arm for handling life boats , bunker hose pipes etc.
44. Dead weight The carrying capacity of a ship at any draft and water density. Includes
weight of cargo, fuel, lubricating oil, fresh water in tanks, stores, pas-
sengers and baggage, crew and their effects.
45. Deck A platform in a ship corresponding to a floor in a building. ~
46. Deck Mast An enclosed space on or above the weather deck that does not extend
house from side to side of the ship.
47. Deck, freeboard Deck to which freeboard is measured; the uppermost continuous deck
-
having permanent means of closing all weather openings. ___
48. Double bottom Compartments at the bottom of a ship between inner bottom and the
49. Draft
shell plating, used for ballast water, fresh water, fuel oil, etc.
The depth of the ship below the waterline measured vertically to the --
50. Draft marks
lowest part of the hull.
The numbers on each side of a ship at the bow, stern, and amidships, to
indicate the distance from the draft mark at the water level to the bot-
---
tom of the keel.

51. Drift The angle or distance through which the ship is -pushed due to wind or
tide.
52 . Dunnage Cushioning material placed under or between cargoes to prevent cargo
motion, prevents th e goods from being damaged and to allow drainage
of moisture.
53. Even keel A ship is said to be on an even keel when the ship is floating at the
same draft, fore and aft.
54. Fair-way The channel of a narrow bay, river, or haven , in which ships usually
advan ce in their passage up and down.
55 . Fathom A measure of length, equivalent to 6 linear fe et.
56. Fender Floating, fixed or portable devices such as rubber tyres , to prevent dam-
age to ship side through rubbing or chafing against other ships or piers.
57. Flange The part of a plate or shape bent at right angles to the main part; to
bend over to form an angle.
58. Fore-and-aft Throughout the whole ship's length from bow to stern.
59. Forecastle A superstructure fitted at the extreme forward end of the upper deck.
60. Forepeak The watertight compartment and store at the extreme forward end.
61. Forward .Towards the fore part of a ship.
62. Free board The distance from the waterline to the upper surface of the freeboard
deck at side.
63. Gangway A ladder used for boarding a ship.
64. Gantry crane A lifting device , traveling on rails , located either on the ship or on the
wharf having the lifting hook which is movable horizontally
athwartship direction.
65. Halyards The ropes by which the flags are hoisted.
66. Harbor A secure place for a ship to berth.
67. Hatch (hatch- An opening in a deck through which cargo and stores are loaded or
way) unloaded.
68. Hatch coaming (See coaming, hatch)
69. Hawsepipe Pipe through which anchor chain is led overboard from the windlass on
deck through the ship's side ..
70. Head-sea When the waves meet the head of a ship in her course, they are called a
head sea. It is likewise applied to a large -single wave coming in that
direction.
71. Head-way The motion of advancing, used in opposition to sternway.
72. Heel The inclination of a ship sideways due to an external force such as
wind or sea.
73. Helm The wheel by which the ship is steered.
74. Holds The large spaces below deck for the stowage of cargo.
75. Hull The structural body of a ship, including shell plating, framing , decks ,
bulkheads , etc.
76. Keel The principal fore-and-aft component of a ship's framing, located along
the centerline of the bottom and connected to the stem and stern
77. Knot A unit of speed, equaling one nautical mile p er hour; the international
n autical mile is 1852m (6076 .1.ft.)

I
Part 1 Section 1 Chapter Z - Basic Ship Kn owledge
78. Knot (rope) Mean s of tying two ropes together, or a rope to an object.
79 . Lash To bind. Lashing cargo together.
A rope with a lead weight attached to measur~ th ~ depth of water. The
-------
80. Lead line
rop e h as coloured markers along its length to md1cate depth.
78. Knot (rope) Mean s of tying two ropes together, or a rop e to an object.
To bind. Lashing cargo together.
----
-----
79. Lash
80. Lead line A rope w ith a lead weight attached to measure the depth of water. Tfie
rope h as coloured m arkers along its length to indicate d epth.
81. Lee That part of the hemisphere to which th e win d is directed, to distin- --
guish it from the other part which is called to windward.
82. Lee-side That half of a ship , lengthwise, which lies between a line drawn -
through the middle of her length and the side which is farthest from
the point of wind.
83. Lee-way The lateral movement of a ship to leeward of her course; or the angle
which the line of her way makes with a line in the direction of h er keel
84. Life boat A boat carried by a ship for use in emergency.
85. Life raft A very buoyant raft, usually of inflatable material, designed to h old
people abandoning ship.
86. Life-lines Ropes for holding onto in life boats when it is lowered or hoisted.
87. List The inclination of a ship from the horizontal by an internal forc e such
as uneven distribution of weights.
88. Look-out A watchful attention for signals , other ships, for land, and floating
objects etc.
89. Marline Small line used for securing the pilot ladder steps etc.
90. Marline-spike An instrument to assist in splicing etc.
91. Mast A tall vertical or raked structure , usually of circular section, located on
the centerline of a ship and used to carry navigation lights , radio anten-
nae and usually, cargo booms.
92. Midships See Amidships.
93. Mooring The term used for securing a ship to a berth, buoy or to the seabed.
94. Muster To assemble.
95. Oars Wooden paddles used to row the boat.
96. On board Within the ship.
97. On the beam Any distance from the ship on a line with the beams , or at right angles
with the keel. -
98. On the bow An arc of the horizon within 90 degree from the direction on each side
the ship's head. Thus, they say, the ship in sight bears 30 degrees on the
starboard bow. ~
99. On the quarter An arc of the horizon within 90 degree from the direction on each side
of the ship's stern.
100. Over-board Out of the ship ; as , h e fell overboard, meaning h e fell out of, or from ,
----
the ship
----
101. Painter
102. Palm
A rop e attach ed to the bows of a b oat, u sed to make her fast.
A piece of steel when mounted acts as a thimble for sewing canvass. ____ --
103. Parting Breaking of th e cable or rop e.
Seaman ship , Marine Engineering and Human Relations
I
104. Pendant A long narrow flag used in Intercode .

105. Pitching The movement of a ship, by which she plunges her head and after-part
alternately into the waves .
106. Platform (See Deck)
107. Poop Aftermost part of the main deck.
108. Port The left side of ship also a harbour or haven
109. Porthole Small opening on the side with a glass (within the cabin or otherwise)
110. Propeller A revolving fan like device that drives the ship through the water, con-
sisting of two or more blades ; sometimes called a screw or wheel.
111. Purchase Rope reeved through a set of blocks and rigged to raise or lower
112. Reef Rocks lying near the surface of the water.
113. Rolling The motion by which a ship rocks from side to side like a cradle.
114. Rudder The machine by which the ship is steered.
115. Rudder stock A vertical shaft that connects the rudder to the steering engine.
116. Samson post Vertical posts on deck to which mast head blocks, derrick heel or flood
lights are supported.
117. Scraper A steel instrument to scrape with.
118. Scuppers Drains from decks to carry off accumulation of water, condensation or
seawater overboard.
119. Shell plating The plates forming the hull.
120. Shore A general name for the sea-coast of any country.
121. Slack-water The interval between the ebb and flood of the tide.
122. Slings Devices to lift cargo, stores etc.
123. Sounding To find the depth of water.
124. Sounding tube A pipe leading to the bottom of a bilge, double bottom, deep tank,
or Sounding drainwell, hold or other compartment, used to guide a sounding line,
Pipe tape or rod to determine the depth and nature of any liquid.
125. Splice To make two ends of ropes fast together by untwisting them, and then
putting the strands of one piece with the strands of the other.
126. Spray The sprinkling of a sea, driven occasionally from the top of a wave.
127. Spring-tides Are the tides at new and full moon, which flow highest and ebb lowest.
128. Squall A sudden violent blast of wind.
129. Stanchion Vertical column supporting decks, flats , girder, etc; also called a pillar.
Rail stanchions are vertical metal columns on which fence like rails are
mounted.
130. Starboard side The right hand side of a ship when looking forward. Opposite to port.
131. Stays Wire ropes coming from the mast heads.
132. Steady The order to the helmsman to keep the ship in the direction she is
going at that instant.
133. Steering The art of directing the ship's way by the movement of the helm.
134. Steering Gear Equipment provided for controlling the rudder of a ship. It is located at
the after part of the ship in a compartment termed as 'steering room'.
135. Stem The fore-part of the vessel.
136. Stern post Sometimes the vertical part of the stern frame to which the rudder is
attached.

56 Chapter 2 - Basic Ship Knowledge Part 1 Section 1
13 7. Stoppers Rope or chain used to temporarily take the weight on mooring hawsers
or wires .
13 8. Strand Part of a rope or wire. (ropes are made of more than one strand).
13 9 . Stranded When a vessel is aground on some rocks, and filled with water.
14 0. Superstructure A decked structure above the upper deck.
14 1. Swell The fluctu ating m otion of th e sea when the wind blows across th e sea
over a period of time .
-.!
142. Tank, wing Tanks located well outb oard adjacent to the side shell plating, often I
I
consisting of a continuati on of the d ouble bottom up the sides to a deck
or flat.
143. Tarpaulin A water proof cloth of canvas us ed for covering h atches or other open-
ing to m ake it w ater-proof.
144. Telegraph An apparatus for transmitting engine speed orders , from a ship 's bridge
to the engine room.
145. Telemotor A device for operating the steering engine from the bridge, either by
fluid pressure or by electricity.
146. Tiller An arm, attached to rudder stock, which turns the rudder.
147. To anchor To let the anchor fall into the ground .
148. To clear the Is to get the cables and ropes off the flukes ready for dropping.
149. To coil the rope To lay it round in a ring, one turn inside another
150. To deballast To discharge the ballast water out of a ship.
151. To drag the To trail it along the bottom, after it is loosened from the ground.
152. To drop anchor Used synonymously with 'To Anchor'
153. To heave to In bad weather to keep the ship as nearly head on to the wind and sea
with minimum steerage way.
154. To hoist To lift.
155. To leeward Towards that part of the horizon to which the wind blows.
156. To lower To ease down gradually
157. To pay away or To slacken a cable or other rope, so as to let it run out for some particu-
pay out lar purpose.
158. To row To move a boat with oars.
159. To slip the cable To let it run quite out when there is no time to weigh the anchor.
160. To stem the tide When a ship is sailing against the tide at such a rate as enables her to
overcome its power, she is said to STEM THE TIDE.
161. To stow To arrange a ship's cargo.
1 62. To trim the hold Spread the cargo evenly in the hold.
16 3. To weigh To heave up an anchor from the bottom.
16 4. Topping lift A wire rope or tackle extending from the head of a boom, to a m ast or
to the ship's structure for the purpose of supporting the w eight of the
boom and its load and permitting the boom to be raised or lowered.
16 5. Topside Tank A tank u su ally used for ballast in bulk carriers, formed by the deck out-
board of the hatches and the upper shell plating and a longitudinal
b ulkhead sloping around 45 degrees. -
16 6 . Trim Th e differen ce between the draft forwar d and the draft aft. If the draft
fo rward is the greater, the vessel is said to "trim by the h ead" if the aft
dr aft is the greater, she is "trimming by the stern ".
Seam an ship, Marine Engineering an d Human Relati on s

Part 1 Section 1 Chapter 2 - Basic Ship Know ledge 57
167. VLCC Very large crude carrier

168. Waterline The line of the w ater's edge when the ship is afloat.
169. Water-tight Th e state of a ship , or any compartment in which w ater cannot enter.
(Free of leak/h ole/cracks) .
170. Weigh To h aul up; as , weigh the anchor.
171. Well (bilge) Space in the bottom of a ship to which bilge w ater drains so that it may
be pumped overboard.
172 . Whipping To bind twine round the ends of ropes to prevent strands opening up .
173. Winch An electric or electro hydraulically operated machine, used for hoisting
and lowering wires or mooring ropes.
I
174. Windlass The machine used to hoist and lower anchors.
7 Draught, Loadline and Tonnage Measurement
Draft: This is measured on the shipside, as the vertical distance between the Keel and the water-
line
Freeboard: This is measured on the shipside, as the vertical distance between the Main Deck and
the waterline.
Shipside Markings:
The Ship's name her Port of Registry are marked in bold letters on both bows, and on the stern of
the Vessel. IMO number is marked on the stern or on the hull amidships
Draft Marks:
MAIN DECK
_l:EEBOARD
-----
WATER LINE
4
. -- r-
3
3 DRAFT
2 2
1 1
OM
KEEL
How does a ship change direction/ man oeuvre?

The wheel of a ship is the modern method of adjusting the angle of the rudder, in turn chang-
ing the direction of the boat or ship. It is also called the helm, together with the rest of the steer-
ing mechanism.
The steering wheel (helm) is typically connected to a mechanical, hydraulic or an electronic

system. In some modern ships the wheel is replaced with a simple joystick that remotely con-
trols an electro-mechanical or electro-hydraulic drive for the rudder, with a rudder position
indicator presenting feedback to the helmsperson.

8 Glossary of Engineering Terms (Abridged)
This is a limited list of engineering terms expected to be learnt b y a good seamen, and in this case,
by a General Purpose Rating. These terms have been p laced in alp habetical order. Most of these
terms are explained or used within this learning guide under different ch apters. In fac t , you will
find many other terms not listed here but described in this guide . Do create additional list and
send it to the Board of Examinations for Seafarers Trust at best1@mtnl.net .in and help us improve
this list. This list has been compiled from different sources and edited to suit the need .
Term Description
1. Abrasion When used with reference to gearing is the action of scraping scoring of
the gearing teeth, caused by solid particles in the lubricating oil and the
sliding effect of one tooth over another.
2. Abrasives Used mainly in grinding, honing and polishing. Classified as: (1) natu-
rals sandstone, quartz, emery, corundum, natural diamonds (2) synthet-
ic silicon carbide, aluminum oxide, diamonds .
3. Accumulator (1) Electric storage battery (2) Accumulator can be used to store liquid
and gases at constant pressure, acting as a reservoir.
4. Air cooler Consists of battery of finned tubes material depending on the cooling
medium. When warm humid air is exposed to the chilled surfaces of
the cooler and comes into contact with the tubes or fins it is cooled to a
mean surface temperature. If this is below its dew point, moisture is
deposited.
5. Air ejector/ Air Used to extract (remove) air or gases from a vessel, space or a compart-
Eductor ment (e.g. condenser, ballast line , or a cargo tank.)
6. Anode (sacrifi- In a system of cathodic protection, sacrificial anodes corrode faster than
cial) steel/iron and thus prevent corrosion of steel or other metals in that
area. Sacrificial anodes mounted on the hull of a ship are made of zinc
or aluminum alloys.
7. Assemble To fit together small parts, in making a large section or part.
- - - ~ - - -- -+-,----;-;---c:--:---------=---=-- -----,,----- --=-~- -- - -- - - -- - - -----t
8. Auxiliary All machinery other than that required for main propulsion
machinery
9. Back pressure Pressure in the reverse direction of the flow of air or exhaust of an
engine or system. The output or efficiency of the system will be
reduced if the back pressure exceeds the design value.
10. Ballast Any solid or liquid weight placed in a ship to increase the draft, to
change the trim, or to regulate the stability
11. Ballast line Piping system used to fill and empty ballast tanks.
12. Ballast tank Watertight compartment to hold water ballast.
13. Bearings Bearings are an essential part of all machines. A journal bearing sup-
ports a rotating shaft and a thrust bearing is designed to withstand force
along the axis of a shaft. Special bearings include ball or universal
joints. _
14. Berth Where a ship is docked or tied up; a place to sleep abroad; a bunk or bed
15. Bilge Intersection of bottom and side. May be rounded or angular as in a
chine from hull. The lower parts of holds, tanks and machinery spaces
where bilge water may accumulate.

16. Bilge (1) Curved portion, often circular, between bottom and side shell plat-
ing. (2) Drainage space within the ship .
17. Bilge and bal- A system of piping generally located in the holds or lower compart-
last system ments of a ship and conn ected to pumps. This system is used fo r pump-
ing over board accumulation of water in holds and compartments, and
also for filling ballast tank.
18. Blower, soot Unit using steam jet for externally cleaning boiler tubes when steaming.
Retractable when located in or close to the boiler furnace to avoid heat
damage when not in use.
19. Boiler water Provided to reduce corrosion and scale formation in boilers. Boilers
treatment water must be maintained in slightly alkaline condition by carefully
controlled additions of chemicals.
20. Bunk A berth or bed usually built in.
21. Butt The end joint between two plated or other members which meet end to
end.
22. Camshaft Shaft carrying the cam(s) which operate valves. Camshafts for automobile
engines and industrial engines are mostly made in high duty cast iron.
23. Cathodic protec- Protection of a ship's hull against corrosion by superimposing on the
tion hull an impressed current provided by a remote power through a small
number of inert anodes. Also accomplished by fitting aluminum, mag-
nesium or zinc anodes in tanks or the underwater portion of a ship
which waste away by galvanic action.
24. Check valve Non return valves which regulates flow of fluids to boilers, in piping
systems and machinery.
25. Chock One of several pieces of metal precisely fitted between machinery units
and their foundations to assure alignment, also made by pouring plastic
material in place. A small piece of plate fitted to in side of a plated
structure opposite the landing of a structural member on the other side.
26. Circuit breaker Mechanical switching device capable of making, carrying and breaking
currents under normal circuit conditions and also making, carrying for
a specified time, and breaking currents under specified abnormal circuit
conditions, such as, short circuit. A safety device.
27. Circulating Centrifugal or axial flow type pump that draws water from sea or tanks to
pump supply cooling water to condensers and coolers for different purposes.
28. Combustion Act of burning. Chemical action accompanied by heat.
29. Combustion (1) Space bounded by piston crown, cylinder cover or upper piston
chamber crown and cylinder wall in direct injection diesel engine , in which com-
bustion takes place at or near top dead centre (2) Chamber formed in
cylinder to main cylinder by relatively narrow passage to promote turbu-
lence (3) Space adjacent to burner in which combustion takes place in
30. Condenser (1) Chamber in which exhaust steam is led to condense into water. (2)
Electrical condenser. See Capacitor.
31. Corrosion Deterioration of a metal by the natural process which reverts the metal
to a state of lower free energy, such as an oxide.

32 . Cotter pin Pin, usually tap ered or sp lit, inserted through a shaft an d engaging With
h oles or castellation in a nut or collar so as to preven t accidental turning,
particularly slackening. As a m ethod of locking n u ts this application is
now becoming less common b ecause of th e introduction of lockashers oj
various types and adhesive chemical p reparations such as 'Loctite'.
33. Expansion tank A tank within the cooling water circulating system of an engine. Its -
main function is to allow expansion or contraction of cooling water. In
addition it compensates the water loss due evaporation or leaks.
Expansion tanks are located at heights to allow for flow of water
through gravity. They are fitted with a sight glass, a vent , filling valve,
drain valve, outlet valve and an overflow connection. It is fitte d with a
'low level' alarm to warn if the level has become abnormally low.
34. Fabricate To process h u ll material in the shops prior to assembly or erection. In
hull work, fabrication consists of shearing, shaping, punching, drilling,
countersinking, scarfing, rabbeting, beveling and welding.
35. Flange The part of a plate or shape bent at right angles to the main part; to
ben d over to form an angle.
3 6. Foundation The structural supports for the boilers, main engines or turbines and
reduction gears are called main fo u ndation. Supports for machinery
space auxiliary machinery are called auxiliary foundations. Deck
machinery supports are called for example, steering engine foundation,
which foundation , etc.
37. Galley A kitchen on a ship.
38. Gasket Flexible material used to pack joints in machinery, piping, doors , hatch-
es, etc, to prevent leakage of liquids or gases.
39. Sea chest An enclosure attached to the inside of the underwater shell and open to
the sea, fitted with a portable strainer plate. A sea valve and piping con-
nected to the sea chest passes sea water into the ship for cooling fire, or
sanitary purposes. Compressed air or steam connections may be provid-
ed to remove ice or other obstructions
40. Shaft tunnel, A watertight enclosure for the propeller shaft in large enough to walk
shaft alley in, extending aft from the engine room to provide access and protection
to the shafting in a way of holds .
41 . Sky light A framework fitted over a deck opening and having covers with glass
inserted for the admission of light and air to the compartment below.
42. Steering gear A term applied to the steering wheels, leads , steering engine and fitting
by which the rudder is turned. Usually applied to the steering engine.
43. Stern tube The watertight tube enclosing and supporting the tail-shaft. It consists
of a cast-iron or cast steel cylinder fitted with bearing surface within
which the tailshaft, enclosed in a sleeve, rotates.
44. Stiffener An angle, T-bar, channel, built-up section, etc . used to stiffen plating oC
a bulkhead etc.
45. Tailshaft The aftermost section of the propulsion shafting in the stern tube in sin:
gle screw ships and in the struts of multiple screw ships to which the
propeller is fitted. Also called 'propeller shaft'.

46. Tank settling Fuel oil tanks used for separating entrained water from oil. Th e oil is
allowed to stand for a few hours until the water has settled to the bot-
tom, when the latter is draine d or pumped off.
47. Uptake A casin g connecting a boiler or gas turbine combustion product outlet
w ith the base of the inner casing of th e smoke stack.
How does a Ship move?

The primary fun ction of any marin e engineering plant is to convert th e chemical en ergy of the
fuel into u seful work and to use that work in the propulsion of the ship.
• A propulsion unit consists of the machinery, equipment, and controls that are m echan ical-
ly, electrically, or hydraulically connected to a propulsion shaft. The most common typ e
of propulsion plant has diesel engines. Steam plant is installed on many of the passenger
ships, very large crude oil carriers, and LNG ships.
• A ship moves through the water due to the thrust created by the rotating propeller.
• The main shaft extends from the main engine to the propeller.
• Turning of the ship is achieved by a 'rudder' (not shown in this diagram) placed at the end
of the propeller. Rudder is turned by means of machinery called 'steering gear'.
9 Role and responsibilities of persons on Board

Captain / Master
The Captain or Master is the ship's highest ranked responsible officer, acting on behalf of the
ship's owner and representing overall administrative in charge of the vessel.
Deck Department
Chief Officer / Chief Mate
The Chief Officer (often called the Chief Mate) is the
a. First NWKO (Navigation Watch Keeping Officer) and the executive Head of the deck
department, and g/enerally a cargo officer.
b. Safety Officer and Second-in-command after the ship's Master.
The Chief Mate's primary duties are:
c. The Navigational Watch i.e.: 0400-0800hrs, 1600-2000hrs.
d. Vessel's Cargo Operations and Ballasting Operations, including Stability and the Safety of
the Ship influenced by these operations. .
e. Assigning / Supervising the Deck Crew for Deck I Hull Mamtenance.
f. Assigning of Crew and the monitoring of Deck and Bridge Watches.
g. Safety and Security of the ship.
h. Plan and prepare ship for stationary and other surveys.
i. Maintenance/Corrosion Control of the ship's hull, cargo gears, accommodations,
j. Training the Crew and Cadets on various aspe cts like Safety, Firefighting, and various other
contingencies.

l
Second Officer / Second Mate

The Second Officer or Second Mate is the
a. Second Navigation Watch Keeping Officer of a merchant vessel and is usually the
Navigating Officer of the Ship.
b. The Navigating Officer is responsible for maintaining the Ship's navigational publications
& equipment, on the bridge, and prepares voyage plan under the guidance of the Master.
C. The Second Mate typically stands the 1200-1600, 0000-0400hrs Navigation watch at Sea,
and the Cargo watches in Port as directed by chief officer/master.
d. The Second Mate is also in charge of the Ship's Medical Locker.
e. The other duties of this position often depend upon the type of ship worked aboard. The
Second Officer usually provides the Chief Mate with assistance in Cargo Operations,
Third Officer / Third Mate
The Third Officer or Third Mate is the

a. Third Navigation watch keeping officer and Asst Safety Officer (responsible for LSA &
FFA), under the guidance of the Chief Officer.
b. The Third Mate typically stands the 0800-1200, 2000-2400hrs Navigation watch at Sea,
and the Cargo watch in Port as directed by the Chief Mate and Master.
c. The Third Mate is also in charge of the Flag Locker, All Meteorological Equipment on
board, and the procedures of Weather Reporting to Land Stations where assigned.
d. The other duties of this position often depend upon the type of ship worked aboard. The
Third Officer also provides the Chief Mate with assistance in Cargo Operations
Deck Cadet
a. A Deck Cadet (Trainee Navigating Officer) may be a Nautical School Graduate, or having
attended a Pre-Sea training programme of shorter duration (one year).
b. The Cadet is required to undergo training on board ships, as prescribed by the
Administration, executing the tasks of a Navigation Watch Keeping Officer under the
supervision of senior Officers, where after he may take the necessary examinations to
obtain the License of a Navigation Watch Keeping Officer.
Boatswain / Deck Serang
A Boatswain (also called Serang in India), is in charge of ALL the Crew on board a Ship, in
respect of their welfare and admin requirements, and is especially in charge of the Deck Crew
in respect of the Maintenance of the entire ship, excluding the Engine Room, the Machinery
Spaces, and Machineries, wherever they may be located .. The Boatswain may be considered as
the Foreman of the Ship's Crew.
Able Seaman / Helmsman / Lookout / General Purpose Rating
In the modern merchant marine, an able seaman (AB) is a member of the deck department and
must possess a merchant mariner's document, certifying him competent enough to form part of
Navigation, Engine room watch in a Support Category. An AB will work in a ship's deck depart-
ment as either -

• a watch keeper,
• a day worker, or
• a combination of these roles
At sea an AB watch keeper's duties include keeping watch
• Acts as a h elmsm an an d when required as a lookout man. A helmsman is required to
maintain a steady course, properly execute all rudder orders and to communicate, utiliz-
ing navigational terms relating to heading and steering.
• While the ship is not underway, a watch keeper may be called up on to stand security-relat-
ed watches, such as a gangway watch or anchor watch.
Day worker
• A day worker performs general maintenance, repair, sanitation / plumbing and upkeep of
material, equipment, and areas. in the deck department.
• This can include maintenance of the ship's metal structures such as chipping, scraping,
cleaning, priming, and painting.
• Areas frequently in need of such maintenance include the hull, decks , superstructure, and
cargo gear, maintenance of life boat, rescue boat, life raft and damage control gear.
Engineering department
Chief Engineer
The Chief Engineer on a merchant vessel is the official title of person qualified to oversee the
engine department. The Chief Engineer is responsible for:
• All operations and maintenance that have to do with all engineering equipment through-
out the ship
• The Chief Engineer is in-charge of the E/Room during maneuvering operations, and during
emergency situations.
Second Engineer
The Second Engineer is the Officer responsible for supervising the daily maintenance and oper-
ation of the engine department. He reports directly to the Chief Engineer.
a. The Second Engineer is the Marine Engineer second in command of the engine depart-
ment, after the ship's Chief Engineer.
b. Operational duties include responsibility for the refrigeration systems, main engines
(steam/gas turbine, diesel), and any other equipment not assigned to the Third Engineer.
c. This officer is usually a "day worker" from 0630-1830. At sea the duty hours are 0400-0800
& 1600-2000 hrs.
Third Engineer
a. The Third Engineer is usually in charge of boilers, fuel , auxiliary engines , condensate, and
feed systems.
b. The Third Engineer of the ship is usually responsible for electrical, sewage treatment, lube
oil, bilge, and oily water separation systems . At sea the duty hours are 0000-0400 & 1200-
1600 hrs.

Fourth Engineer
a. He performs a variety of tasks connected with the maintenan ce an d repair of engine roorn,
machine shop , reefer room , and steering-engine room equipment. At sea the duty hours are
0800-1200 & 2000-2400 hrs.
b. He inspects equipment such as pumps, turbines, distilling plants, and condensers, and
prepares record of condition.
c. He lubricates and maintains machinery and equipment such as gen erators, steering sys-
tems, lifeboats, and sewage disposal systems, and also cleans an d restores tools and equip-
ment.
d. The Fourth Engineer assists the Third Mate in maintaining LSA & FFA equipment as relat-
ed to the Engine Room.
e. The Fourth Engineer is also typically in charge of fuelling or bunkering, under the guid-
ance and authority of the Chief Engineer.
Junior Engineer/Engineering Cadet

a. An Engineering Cadet may be a Marine Engineering School Graduate, or sometimes a
Marine Workshop Apprentice, having some Pre-Sea Training.
b. The Cadet is required to carry out training on board ships, as prescribed by the
Administration, executing the tasks of a Engine Room Watch Keeping Officer (EWKO)
under the supervision of Senior Engineer Officers, where after he may take the necessary
examinations to obtain the License of an EWKO.
Electrical Officer
He is responsible for maintaining the Electrical Machinery and Systems on board a Ship.
Fitter
A Fitter is a Petty Officer in the Engine Department, ranked between Enigineer Officers and
Engine Ratings.
Oiler
An Oiler is one of the Senior Crew members in the Engine Room of a ship, equating in rank
to an AB in the Deck Department. An Oiler's role consists mainly of keeping machinery
lubricated.
Wiper
A Wiper is the Juniormost Crew member in the Engine Room of a ship. A Wiper's role consists
of wiping down machinery and generally keeping all machineries clean.
Catering Department
Chief Steward / Catering Manager
The Chief Steward is the Petty Officer in charge of the Catering department of a ship. The Chief
Steward directs, instructs, and assigns personnel performing such functions as:
a. Preparing and serving meals
b. Cleaning and maintaining Officers' quarters\
c. Cleaning and maintaining the Catering department areas including the cold storage rooms,
Provisions Stores, and the Housekeeping Equipment Stores.

d. Receiving, issuing, and inventorying Stores (Provisions and Housekeeping Equipment

Stores)
The Chief Steward also:

a. Plans daily menu.
b. Compiles Supplies, and Cost Control records under the supervision of Master.
Chief Cook
The Chief Cook is a Senior Crew member working in the Catering department of a ship. The
Chief Cook directs and participates in the preparation and serving of
a. Meals
b. Determines timing and sequence of operations required to meet serving times
c. Maintains the cleanliness of the galley and its equipment, also the preparation of food.
d. The Cook may plan, or assist in planning meals, and taking inventory of stores and equip-
ment
e. Additional duties may include baking bread, rolls, cakes, pies, and pastries
f. Requisitions or purchases Stores and Housekeeping equipment
General Steward / Trainee

A General Steward/ Trainee is an entry level Crew Member in the Catering department of a ship.
This position is also referred to as Mess man, and this Crew Member's tasks are mainly:
a. Cleaning and assisting cooks with the preparation of meals.
b. Keeping the mess decks clean by sweeping and scrubbing. he disposal of trash and
garbage, and the keeping of garbage cans clean.
d. Other tasks could include defrosting and cleansing refrigerators, and reefer rooms

Chapter 3 - General Shipboard Safety and Health
General Shipboard Safety and Health

1. Personal Protection and Personal Protection Equipment
2. Safe working practices for merchant seaman (including permit to work system, and fire ~re-
vention aspects, Safety Precautions when working aloft, Safety Precautrnns when workmg
over side)
3. Risk Assessment (Basics)
4. Emergencies
5. Safe Access to the Ship
6. Safe Working Practices during Berthing / Unberthing, and Anchoring
Learning Objectives
1 Personal Protection Equipment (PPE)
Trainee will be able to list the different items of PPE as:-
Equipment Protection of
Safety Shoes Feet
Safety Helmet Head
Safety Goggles Eyes
Hand Gloves Hands
Ear Muffs Ears
Boiler Suit Body
Safety Harness Working Aloft/Over Side
Face Mask Nose & mouth, Face

• Give examples, when & where to use each of the above equipment.
• Maintain the above equipment in clean, good, working condition ready for immediate use.
• State that safety of the ship and its crew would be his first priority.
• List the precautions necessary before lifting any heavy loads manually
• Safe working procedures, Tools & instruments
2 Safe working practices (general)

• State causes of accidents as 'negligence' and 'ignorance'.
• List at least 15 different situations leading to accidents on board
• Appreciate importance of safe working practices on board
• Adopt safe working practices related to personal safety, safety of others, and safety of the
ship and the environment.
3 Risk Assessment (Basic)

• Describe the concept of 'risk assessment' and basic approach to work keeping in mind the
risks involved.
4 Permit to Work System

• State purpose of 'Work Permit', and types of work permits.

p
Patt 1 Section 1 Chapter 3 - General Shipboard Safety and Health 67
Name various types of 'Permit to Work' as

• Hot Work Permit
e Tank Entry permit
• Enclosed Space Entry Permit
• Working Aloft / Overside Permit
5 Work-Permits
Trainee will be able to state that 'Work Permits' are required prior doing any of the following jobs
on the ship :-
• 'Man entry 'into tanks.
• 'Hot work' , any where on the ship.
• 'Enclosed space entry'
• 'Working aloft'
• 'Working Over the side'
The following sections will be described in Part 2 of the Book - Seamanship
Emergencies
• Define an emergency
• Enumerate different types of emergencies he may encounter on a ship
• State the emergency signal to be made to inform the ship's crew about the emergency
• State the action to be talGen by a crew member on hearing an emergency signal
• Explain, what is 'Mustet list' and what it is used for?
• State that immediately after joining the ship , he will get himself familiarized with the Ship,
and understand the location of LSA & FFA equipment onboard the ship, muster stations and
duty
• State that he will always follow the 'Safe Working Practices' onboard.
Safe Access to the Ship

Trainee will be able to state that
• Access to the ship will be either from a shore gangway or from the ship 's gangway (also
called Accommodation ladder)
•• The gangway will be well secured on the ship
A safety net will be fixed below the gangway to protect some one falling accidentally
•• Gangway will be lowered / hoisted during the rising / falling tide
A lifebuoy and a Heaving-line will be kept ready near the gangway for emergency use
•• Gangway will have railing and taut ropes on the sides
There will be a platform at the bottom end of the ship's gangway

Part 1 Section 1
68 Chapter 3 - General Shipboard Safety and Health
Safe Working Practices during Berthing / Unberthing, and Anchoring
Trainee will be able to state that

• All crew should be properly dressed up in suitable clothes, depending upon the weather
• All crew should be w earing Safety helmet, Safety shoes, Hand gloves, Safety goggles (when
anchoring)
• Crew should not stand in the bights of mooring ropes or wires .
• Crew should be careful not to stand too close to fairleads, to avoid the back-lash of partmg
mooring ropes.
Safety Precautions, when working aloft

Trainee will be able to list the following safety precautions For working aloft,
• Take permission from Master, for working aloft
• Be properly clad in Boiler suit, safety Helmet, Safety Harness, Safety shoes, Hand gloves etc
• Have necessary equipment for working aloft (e.g. Chipping hammers, Scrapers, Paint
Brushes , Paint, etc. to have lanyard to be put around wrists to prevent slipping from land
• Have a Person standing by on deck for any assistance or emergency
• Before starting work aloft, fix the safety harness in position.
Safety Precautions, when working over side

Trainee will be able to list the following safety precautions when working over side
• Take permission from the Master, for working over the side
• Be properly clad in Boiler suit, Safety Helmet, Life-Jacket, Safety shoes, Hand gloves, Safety
harness etc.
• Have a 'stage' rigged up on the shipside, where work has to be carried out
• Have a rope ladder fixed up securely close to the stage
• Have necessary equipment for working over the side (e.g. Chipping hammers, scrapers,
paints to have lanyard to be put around wrists to prevent slipping from hand.)
• Have a Person with Walky Talky standing by on deck for any assistance or emergency.

part 1 Section 1 Chapter 3 - General Sh' b
ip oard Safety and Health 69
1 Safety
Personal
• Safety Shoes An overview of

• Boiler Suit
• Aprons Safety Aspects on
• Ear Board
Defenders
• Goggles
• Gloves
Emergency Escape
LSA
• TPA
Safety • Life Jackets
• Firrst Aid
• Life Buoys
Box
• Life Boats/Rafts
EEBD
• Rescue Boats
• ABC
Technique
• Immersion Suits
Non-Portable Extinguisher
• CO 2
Fixed Equipment • Foam
• Dry Powder
• Pumps
• Extinguisher ( CO 2' Water, Portable Extinguisher
Foam, Dry powder)
• Hoses/Nozzles • CO 2
• Fire line & Hydrants • Water
• Fixed System( Dry Powder, • Foam
Foam, CO 2 • Dry Powder
Fire Man's
Outfit
• BA Sets
• Fire Suit
• Safety Boots
• Life Line
• Helmet
• Gloves
• Fire Axe
• Torch Light

70 Chapter 3 - General Shipboard Safety and Health Part 1 Section 1
.1 Introduction
• Safety of Life refers to our own safety and of those around us. It includes prevention of all
incidents that may lead to minor injuries, severe injuries, disabilities and death.
Safety is a matter of attitude, whereas Accident is an outcome of

negligence , or a habit.
• Safety of property includes prevention of damage to all physical objects around us and in
our charge - accommodation, machinery and equipment, and cargo. In fact, damage to
property has many other losses linked with it, e.g., loss of time, reputation, feelings , etc.
• Safety of environment is prevention of pollution of sea, air, and the space from any source
(oil, chemical, gases, exhaust, sound, sewage, garbage, etc.) .
The most important factor in safety is use of our senses - sight, touch, hearing, smell, and taste,
whereas the 'sixth sense' is indeed of great help in predicting before other senses can identify
abnormal or dangerous situations. Our efficiency in every respect depends upon sharpness of our
senses, and the good news is that we can continue to sharpen our senses if we only try. When in
doubt , always ask for advice.
• Sight - See the danger, visual signals, lights, etc.

• Touch - Finding abnormality (temperature, vibration, softness, hardness , etc.)
• Hearing - Abnormal sounds of operating machinery, squeaks, alarms, etc.
• Smell - Abnormal smells of gases, burning, etc.
• Taste - Abnormal food
• Sixth Sense - Gut feeling,
.2 Safety of self and others

Incidents leading to injuries happen due to the following:
• Impacts
e Slips
• Falls
• Entanglement
• Burns (heat, chemical, radiation)
• Electric shocks
• Cuts
• Foreign particles in eyes, or lungs, or ingestion (through mouth)
• Inhalation of toxic vapour, or lack of breathable air
• Sprains and other physical injuries
To be safe is our inner instinct but we tend to be negligent due to several other reasons. The unde-
sirable incidents and their consequences depend upon the level of negligence of an individual,
or a group of people. To prevent accidents, all we need is basic 'common sense' and its applica-
tion, because, we already possess much of the knowledge for prevention of accidents.
An accident is an unplanned, undesirable, uncontrollable event leading to

injuries, loss of life , and or damage to the property and the environment".
All harmful events are undesirable , and sometimes uncontrollable , but almost all accidents are
avoidable. If an event is avoidable but we let it occur, then it cannot be called an unplanned, and

part 1 Section 1 Chapter 3 - General Shipboard Safety and Health
71
thus it is not an accident as per the definition given above Th d , 'd , . h h

' . d w ord · e war acci ent is , per aps, t e
most misuse ·
It has been an est ablished fact th at 'huma~ error element' is responsible for almost 80% of acci-
dents. Human error occurs du e to tw o maJor factors:
• Ignorance
• Negligence
'Ignora~ce'. plays o~ly a minor role as compared to 'Negligence'; so much that 'one is negligent
to remam ignorant .
.3 Safe Working Practices

The fo~low~ng list w_ill gi_ve you an idea of the extent of precautions to be taken while working on
board m different situat10ns. You will find specific precautions while learning different topics
and during the practical training.
Preventive measures for accidents and injuries include:

• Using personal protective gear and equipment (helmet, gloves , boiler suit, safety shoes, ear
muffs, goggles, safety harness, etc.)
• Using appropriate hand tools correctly.
• Checking tools and equipment before using
• Putting covers on openings or barricading the area
• Replacing hand rails and guards, or barricading spaces without rails and guards
• Taking precautions while working on decks and open spaces
• Using protective gear while handling dangerous substances
• Using protective gear while welding
• Using appropriate tools while welding
• Taking extra precautions while using power tools
• Taking care while working near operating machinery
• Taking care before opening machinery items which may have internal pressure
• Taking care before opening machinery items which may have fluids
• Taking care before working on machinery with electrical motors, or connections
• Taking precautions while working in fridge rooms (entry, protective clothing, etc.)
• Taking 'permit to enter' before entry in enclosed spaces, making proper checks, being extra
careful, maintaining communication, etc.
• Using safety harness and taking care while working at heights, working aloft.
• Taking care while working in narrow spaces
• Safe movement of heavy equipment, using appropriate lifting devices and accessories, tak-
ing proper position before using manual force
• Taking precautions while working in pump rooms (entering, moving around, working)
• Taking precautions while working in store rooms (entering, shifting, lifting, storing items)
• Taking precautions while working on items with remote controls (like cranes, winches, etc.)
• Good housekeeping (well arranged, clean, lighting, secured, etc.)
Pay attention to symbols and notices, and check your habits towards safety.
The following exercise is meant to increase your awareness of possible dangers, consequences
and precautions to be taken.

'-l
Exercise - Fill in the chart to the best of your ability. See what your class mates have written. Find the correct answers from your N
lecturer.
Caused due to: How and where it can occur? Type of injuries Safety precautions to be taken to prevent
them from happening
1. Impacts
(hitting some
r.f.J thing while
co
p, moving
s
p, around, or n
~ ::,--
CJ)
p"'
being hit) ~
"d
,s· ,-+
CD
....,
w
C')
CD
::i
CD
....,
e.
2. Slips U'l
::,--
,-,.
"d
o"'
0
e;
0..
U'l
~
co'
,-+
'<
~
3. Falls ::i
0..
::r:
CD
e:.
,-+
::,--
4. Entanglement
of clothes,
-0
hair, tools, ~
....,
,-+
gloves i-a
U'l
CD
,t
(")
,-+
::i
i-a
Caused due to: How and where it can occur? Type of injuries Safety precautions to be taken to prevent
them from happening ,....
en
5. Heat burns CD
,.....
C"l
5·
\:l
,....
6. Chemical
burns n
::r
P:l
'"d
,.....
Cl)
>-j
0
Cl)
\:l
CD
>-j
7. Burns due to e:..

U)
radiation ::r
,;·
O"'
0
e;
O-
U)
P:l
CT!'
,.....
'-<
ti
0-
8. Electric shock :::r::
Cl)
P:l
§'.
9. Cuts
-...J
w
-...J
Caused due to: How and where it can occur? Type of injuries Safety precautions to be tn~~en to prevent >+"
them from happening
10. Particles in
eyes
11. Particles in
lungs n
l:;'
p:,
"d
,-+
co
►1
w
~
e; c;;
5· co
::;l
co co
►1
trj 12. Particles in p:,
,-.....
:::::i
00 body Cf)
5· l:;'
......
co "d
co cr'
'"-:I 0
5· e;
00 P-
p, C/)
:::::i p:,
P- cb'
,-+
::c
~
'-<
p:,
s
p,
13. Ingestion of
::;l
P-
:::::i ::i::
co
:,::l harmful p:,
,-.....
co
...... ,-+
a substances l:;'
.....
0
:::::i
C/l
14. Inhalation of
toxic vapor
I-'
C/)
co
C')
.....
,-+
0
::;l
I-'
r /Caused due to: How and where it can occur? Type of injuries Safety precaution s to be tak en to prevent
them from happening ......
15. Lack of
breathable air
in the space
Cf:;
co
s
§
16. Sprains and
other physical n
:::r
C/)
::r- injuries PJ
..... "'d
,......
(l)
'Cl ""1
w
~
e; C')
s·co (l)
~
(l)
""1
tr:l 17. Other causes e:...
::;
00 en
5· :::r
co
co
..a·
cr'
..,; 0
5· e;
00 p_,
PJ en
::; PJ
p_. ~
,......
::r:: '-<
PJ
~
s
PJ
~
p_,
::; ::I:
(l)
~ e:...
,......
co
,-...
PJ
:::r
.....
,-+
0
::;
C/)
--.:i
CJl
r
2 Health and Hygiene

a. Everyone must take care of own health because falling sick on board is not the same as
falling sick at home. There are no doctors, specialists or nurses on board to treat serious ail-
ments and injuries. The best way is not to fall sick or get injured.
b. High standards of personal cleanliness and hygiene should be maintained.
c. Good health depends on balance of work, rest, recreation and on sensible and regular meals,
on adequate sleep and an avoidance of excesses of rich food, alcohol and tobacco.
Physical Health Mental Health Spiritual Health

Positive Aspects
• Balance of work • Positive Thoughts, • Believing that all is fine ,
• Sufficient rest/sleep feeling good about self and accepting life as it comes,
Recreation others, respecting others, prayers
• Sensible and Regular • Knowledge of work and of any kind, meditation,
• meals skills ,
• Being friendly and helpful
• Willing to learn
Negative aspects
• Excessive work load • Fear • Being closed minded
• Lack of sleep/rest e Ego • Disrespect for others
• Alcohol, tobacco, drugs • Unfriendly
j Feelings j .-------.
Response
,i-----ei Stability
Proper use of
I Values I
Money
Physical
Hygiene and Cleanliness on Board:

Hygiene and Cleanliness on board is very important.
As per MLC 2006 and also MARPOL, a ship may be penalised if Hygiene and Cleanliness on
board is not satisfactory.
a. On board ship , simple infections can easily spread from one person to others. Thus preven-
tive measures and effective treatment are essential.
b. Cuts and bruises should be cleaned at once and given first aid treatment to prevent infec-
tion.
c. Working clothes should be washed regularly. Oil-soaked rags should be disposed off prop-
erly.

Chapter 3 - General Shipboard Safety and Health 77
Part 1 Section 1
Rats and other rodents are carriers of infection and should never be handled with bare
d.
hands.
Contact with toxic chemicals or harmful substances should be reported immediately and
e.
proper first ~id applied. . .
High humidity and heat can lead to heat exhaustion and heat stroke. Drmk at least 8 glass-
f.
es of cool water daily, small quantities at frequent intervals. Take salt tablets or a teaspoon-
ful of table salt in plenty of water as advised by the medical officer.
g. In tropical areas especially, exposure to the sun during the hottest part of the day should be
avoided as far as possible. While working in very strong sunlight, body should be well cov-
ered.
h. Where it is required to work in exceptionally hot and/or humid conditions or when wear-
ing respiratory equipment, short breaks in the fresh air or in the shade may be necessary.
i. Alcohol or drugs affects fitness for duty and harm health. The immediate after-effects may
increase liability to accidents.
j. Fresh fruit and salad should be thoroughly washed in fresh water before eating.
k. Crew members are advised to wash their hands with soap, before handling food items .
1. The mess room should be kept clean at all times.
m. No soiled plates or utensils should be left dumped in the pantry wash basin. This should
be always cleaned out.
n. Cleanliness of cabins is important; this includes regular cleaning of the decks, with disin-
fectant. Cabin inspections by Master and chief officer are carried out at regular intervals in
this regard to ensure required standards are met.
0. Proper Disposal of cabin waste and cleanliness of the attached toilets. Shower heads should
be disinfected on a regular basis.
p. Changing the bed linen and towels at regular intervals is a priority.
q. Disposal of garbage should be done as per the prescribed norms.
r. Alleyways and decks to be kept clean and no garbage to be stored anywhere, especially in
the accommodation areas. Care must be taken that the exits from the accommodation are
not blocked by garbage etc.
s. Clothes must not be hanged in the alleyways. Clothes are to be dried in drying room only.
t. Oil spillage/traces of oil anywhere onboard (including discarded cooking oil from galley)
has to be handled as per regulations.
3. Working Clothes
Personal protective clothing and equipment can be classified as follows:
A. Head protection Bump caps, safety helmets, hair protection

B. Hearing protection Ear plugs, and ear muffs
C. Face and eye protection Goggles and spectacles, facial shields
D. Respiratory protective equipment Mask, respirators, breathing apparatus, EEBD
E. Hand and foot protection Gloves of different kinds, safety boots and
shoes of different kinds for different situations
F. Body protection & Protection from falls Boiler suits, safety suits, safety belts, harnesses,
aprons
G. Protection against drowning & Life jackets, buoyancy aids and Lifebuoys ,
Hypothermia Immersion Suit.

r
Chapter 3 - General Shipboard Safety and Health Part 1 Section 1
78
Clothes should be chosen to minimise risks during work.

Working clothes should be close fitting with no loose flaps. Serious injuries occur when clothing
get caught by moving parts of machinery, or on obstructions or projections.
One should cover the body properly while working in galleys to avoid injuries due contact burns
or hot liquids. Clothes should be of low flammability such as cotton or terry-cot.
Long sleeved shirts and overalls provide better protection. Sleeves should not be rolled up.
Scarves, sweat rags and other neck wear, loose clothing, finger rings and jewelry can be hazards
when working. Long hair should be covered. ·
Appropriate non-skid safety shoes must be worn while working. Sandals and soft shoes are dan-
gerous and should not be worn.
Gloves should be used when handling sharp or hot objects. Gloves should be well fitting, clean
and dry.

p
Part 1 Section 1 Chapter 3 - General Shipboard Safety and Health 79
Personal protective gear
Accidents may happen at any time in any part of the ship. Keeping fit and working with proper
precautions can prevent many accidents.
Risks:
• Protruding nails and screws
• Slippery Deck (Ice)
• Loose fittings and handles
• Uneven and damaged flooring
• Rough and splintered edges to woodwork
• Jamming doors
Any of ~e above may cause cuts , bruises or trips and falls.

They should be put right (fixed) as soon as they are noticed.

Other items to be taken care of: ·
• Flickering lights fused light bulbs should be replaced as soon as possible. .

• Instruction plates, notices and operating indicators should be kept clean and legible.
• Heavy objects, particularly if at a height above deck level, should be secured against move-
ment during rough weather. Similarly, furniture should be properly secured.
• Doors whether open or closed, should be properly secured; they should not be left swinging.
• Waste material is always a fire risk or cause accident.
• Working spaces should be well lit, clean and tidy.
Risk Assessment
• Before starting any task, hazards and risks should be considered; for example, if while
washing the decks water falling in galley can lead to serious fire.
• Dangerous articles such as razor blades and lighted cigarette ends should be disposed of
safely.
• Aerosols have volatile and inflammable contents - They should never be used or placed
near naked flames or other heat source even when 'empty'. Empty canisters should be land-
ed ashore.
• Chemical fumes can be harmful to health and fire risk. Smoking can very dangerous in oil
or paint spray area.
5. Substances Hazardous to Health
Many substances on ships can be injurious to health. Hazard-warning labels on containers must
not be ignored.
Consumption of substances (drugs) hazardous to health is a crime.
6. Signs, Notices and Colour Codes
Every ship has signs for information and warnings displayed at places of risks. Safety signs and
notices must confirm in shape and colour with the International standards. These normally fall
under three categories
• Prohibition
• Precautions/Warning
• Information/Directions/Location
•
LIFEBOAT~+
L___ -- -

►
STOP
1-\-ohib.'iio,n .;gu
,..., ""''-r:
• \ '1•J nust ,..
..J r.,_•~•-1'
l h...,......,
-·--
~~-~
----,
OBEY
•
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7. Means of Access & Safe movement on board
One must get familiar with all spaces on the ship as soon as possible. Passages, entrances, exits
and escapes within the accommodation, engine room and outside the ship must be understood.
8. Permit to Work
There are many operations on board ship where the risk of accidents is high and dangerous. A
series of action steps need to be taken to ensure the safety of all persons , cargo , and the ship.
Irrespective of the protection provided through equipment, signs and warnings, it is essential to
follow proper procedures.
Oral instructions, if misheard or misinterpreted or not fully remembered, may lead to accidents.
The use of written instructions and checklist provide greater safety. In situations of work with
greater risk, a 'permit to work' system is used and required.

►
part 1 Section 1 Chapter 3 - General Shipboard Safety and Health 83
'Permit to work' is essentially a document that sets out the work to be don e, and precaution s to
be taken while working. It consists of adopting predefined safety procedure. It forms a recor d of
precautions taken. A 'permit to work' does not make the job safe, but it is a guide for those
involved in th e job.
9. Entering Enclosed Spaces
The atmosphere of any enclosed or confin ed space may put at risk the h ealth or life of any p er-
son entering it. It may b e deficient in oxygen and/or contain flammable or toxic fume s, gases , an d
vapors .
Enclosed spaces:
a. Cargo Holds & Cargo Tanks
b. Double Bottom, Ballast Tanks , Fuel Tanks, or any other tank ducts
c. Sewage Tanks,
d. Coffer Dams , Void Spaces , Duct Keels, Inter-barrier Spaces, Cable Trunks, Pipe
Tunnel, Sewage Tanks
e. Machinery Spaces (Engine Room, Pump Rooms , Compressor Room, etc.)
f. Pressure vessels (Boilers, air bottles, etc.)
g. Battery Rooms
h. Chain Lockers
i. Paint Stores
j. Inert Gas Scrubber
k. Storage Spaces
1. Gas Cylinder Rooms
m. Space for fixed type of Fire Extinguishing Equipment (CO2 , Halon, Foam)
Should there be any unexpected reduction in, or loss of the means of ventilation of those spaces
that are usually continuously or adequately ventilated then such spaces should also be dealt with
as dangerous spaces.
Instructions on the following will be through lectures and safety film during the course and short
courses. Pay attention to all that is shown in the films. Do not hesitate to ask questions.
•• Precautions on Entering Dangerous Spaces

Duties and Responsibility of a competent Person and of Responsible Officer
••
Identifying Potential Hazards
Oxygen Deficiency
► Toxicity of Oil Cargoes
► Toxicity of other substances
► Flammability
► Other Hazards
•• Preparing and Securing the Space for Entry
Testing the atmosphere of Space
•• Testing for Oxygen Deficiency
Testing for Flammable Gases or Vapors
• • Testing for Toxic Gases

Use of Permit to work System

84 Chapter 3 - General Sh i ph0rml Safety and Health Part 1 Section 1
• Procedures and arrangements Before entry

• Procedures and Arrangements During Entry
• Drills and Rescue Procedures .
10. Manual Lifting and Carrying
Many people have sustained serious back and other injuries during manual lifting or carrying
operations as a result of accidents , poor organisation or unsatisfactory working methods on board
ship.
Before any person is instructed to lift or carry by hand, risks to health and safety must be evalu-
ated and due account should be taken to prevent any accident or injury.
When assessing the risks and considering adequate protection full account should be taken not
only of the characteristics of the load and the physical effort required but also of the working
environment (ship movement, confined space, high or low temperature, physical obstacles such
as steps or gangways, etc) and any other relevant factors (e.g. the age and health of the person, the
frequency and duration of the work, etc).
Manual Lifting and Carrying
When lifting loads without the use of lifting devices, care must be taken to avoid injury to
the spinal column and the stomach and back muscles. By using the "kinetic method" of man-
ual handling, injuries to the back can be avoided.
1. The kinetic method is based on two

principles:
i. Using the strong muscles of the
legs for lifting, rather than the
much weaker muscles of the back;
ii. Using the momentum of the
weight of the body to start hori-
zontal movement.
These two motions are combined in smooth continuous movements by correct positioning of
the feet, maintaining a straight back and flexing and extending the knees.
2. In practice, this requires: correct posi-

tioning of the feet, a straight back, arms
close to the body when lifting or carry-
ing, the correct hold, keeping the chin
tucked in and using the body weight.
The correct procedures for certain
types of handling are described in the
next pages.

►
Part 1 Section 1 Chapter 3 - General Shipboard Safety and H ealth 85
Correct Position of Feet

3. Injury to the back muscles is often caused by
loss of balance, due to working with the feet
too close together wh en lifting, pushing or
pulling. Th e feet should be positioned with
one placed in the proposed direction of
movement and the other where it can push
the body. This draw ing shows this where the
movement is upwards and forwards.
4. This drawing shows correct positioning of
the feet when moving a load in a sideways
direction to avoid twisting the trunk.
NOTE: It is recommended that the feet are
placed about 50cm apart. This distance is
suitable for a person having a height of
about 175cm.
5. During manual handling, at no time should

the feet be close together on the ground.
Straight Back
6. A straight back is not necessarily a vertical
back. When lifting loads, particularly from
the ground, the back is often inclined but
the inclination should be from the hips, so
that the normal curvature is not altered.
This normal curve is called a "straight
back".
7. Never lift with a bent back, as shown here.

This would overload the back muscles and
the spine and could cause serious injury.

Part 1 Section 1
86 Ch apter 3 - General Shipboard Safety and Health
8. When a weight is being lifted from the

ground the back is straight but inclined
forwards. The lift takes place by extending
the knees an d the back then returns to the
vertical position.
9. The p osition of the feet and the flexing of

the knees are the key factors in maintaining
a straight back.
Arms Close to the Body

10. When lifting and carrying loads , the arms
should be kept close to the body and as
straight as possible. This will avoid unnec-
essary strain on the upper arm muscles and
the chest. Also, if the load has to be carried
a long distance, the weight can rest on the
thi hs, as shown here.
Correct Hold
11. An insecure grip may be due to taking the
load on the fingertips. This drawing shows
a poor grip caused by a badly designed han-
dle. Greasy surfaces often prevent a secure
hold.
12. Wherever possible, use a full palm grip.

This gives a stronger hold and decreases the .
possibility of the load slipping.
Chin In
13. When lifting a load, the chin should be
tucked in. This will automatically raise the
chest and thus prepares the shoulders for
more efficient arm movements.

>
Lifting Loads from the Floor

14, Now, applying t e principles described, a
load should be lifted from the floor as fol-
lows.
15. Bend the knees keeping the back straight
and the chin tucked in.
16. Grasp the load firmly, keeping the arms

close to the body, and then straighten up by
flexing the knees.
Lif:\ing a Load from a Bench

17. Keep your back straight, extend your arms
in front of you and bend your knees slight-
ly, until you can grasp the load firmly.
18. Pull the load towards you, straighten up

and lean back slightly.
Handling a Large Drum

19. Here is the correct position for the feet and
hands when preparing to upend a large
drum.

20. The arm is lifted by pushing with the back

foot and extending the legs , and at the same
time p ositioning the hands on opposite sides
of the rim. To allow the drum to settle on its
base, the bodyweight is used as a counterbal-
ance by straightening the back leg.
21. When a large drum is standing upright and

has to be moved a short distance, a good
method of doing this is to push onto the
edge, as shown here.
22. And then the arm is moved as shown here,

with the worker walking and rolling the
drum ahead of him.
11 Tools & Materials
11.1 Hand tools
a. A tool is designed for one particular function and no other. It should be treated with
respect. The material of which it is made is appropriate to the intended purpose but usu-
ally not to others. Files are hard but brittle; screwdriver shanks bend where levers do not,
and pliers may slip on nuts.
b. For every job, the proper tools in the right size should be available and used. Tools used for
a purpo_se for which they were not designed may cause injury to the user and damage to the
work piece and the tools.
c. Damaged or worn tools should not be used. Handles of hammers, screwdrivers and chisels
should be secure; wooden handles should be straight-gained, smooth and without splinters.
Punches and cold chisels with jagged heads should not be used. Cutting edges should be
kept sharp and clean. Faces of hammers, punches and spanners should be true. A compe-
tent person should carry out repair and dressing of tools.
d. When not in use, they should be stowed tidily in a suitable tool rack, box or carrier, with
cutting edges protected.
e. Wherever practicable, a tool in use should be directed away from the body to avoid injury
should the tool or work piece slip.
f. Both hands should Utl kept behind the cutting edge of a wood chisel.
g. A cold chisel is best held between thumb and base of index finger with thumb and fingers
straight, palm of hand facing towards the hammer blow.
h. A saw should not be forced; it should be pushed with a right even movement.

►
part 1 Section 1 Chapter 3 - General Shipboard Safety and Health 89
11 .z Portable electric, pneumatic and hydraulic tools and appliance
Power operated tools m ay be dangerous unless properly maintained, handled and used .
11.3 Workshop and bench m achines (fixed installations)

a. No one_s~ould operate a_ ~ach~n e _unless auth orised to do so. The operator should be com-
petent m its use and fam iliar with its control. He should not attempt t o use it if he has band-
aged hands .
b. All dangerous p arts of machines should be provided with efficient guards that should be
properly secured before the machine is put into operation. Self-adjusting guards are prefer-
ably wh ere. the po_s ition of the guard has to relate to the work piece. Grinding machines
should be fitted w ith eye screens that need to be renewed from time to time.
c. Guards should b e made preferably in solid material. Where they are perforated metal, m esh
or bars, the openings should not be large enough to allow a finger to be inserted to reach a
dangerous part.
d. Control of machines and switches for supplementary lighting, where this is provided,
should not be so placed that the operator has to lean over the machine to reach them.
e. A machine should be checked every time before use. It should not be operated when a guard
or safety device is missing, incorrectly adjusted or defective or when it is itself in any way
faulty.
f. If defective in any respect, the machine should be isolated from its source of power pend-
ing adjustment or repair. Only a competent person should attempt repairs. Unskilled inter-
ference with electrical equipment in particular is highly dangerous.
g. Workbenches should be well lit and some machines may require individual supplementary
lights.
h. Working areas should be kept uncluttered and, as far as practicable, free of litter and spilled
oil. Loose gear, tools and equipment not required for immediate use should be cleared away
and properly stowed.
i. Swarf (metal turnings, filings and the like) should not be allowed to pile up around a
machine. The machine should be stopped for its removal. A rake of similar device should
be used for the purpose, never the bare hand.
j. A heavy item of equipment brought into a workshop for repair should be made secure
against accidental movement.
k. Appropriate eye and face protection should be worn during chipping, scaling; wire brush-
. ing, grinding and similar work where particles may fly; this is a special risk in turning brass.
1. Where sanding or other processes generate a lot of dust in the air, dust masks, or respirators
should be worn.
m. Other people working in the area may need the protection indicated in either of the two pre-
ceding paragraphs.
n. Before a lathe or drill is started, the chuck key should be removed and the operator should
make sure that other people are clear of the machine.
o. A machine should be stopped when not in use, even if it is to be left unattended for a few
moments only. The machine should be rechecked on every occasion before being started up
again in case controls, guards, etc have been altered or moved while the machine has been
left unattended.
p. Where a machine is driven by a V-belt in conjunction with a stepped pulley, and alterations
in spindle speed require a change in the position,_ means sho~l?- be provided if practicable
for the belt tension to be eased during that operat10n: the posit10n of the belt should never
be changed while the machine is running.

Part 1 Section 1
q. Work pieces for drilling or milling should be at all times securely held by a machine vice
or clamp. d
r. Material projecting beyond the headstock of a lathe should be securely fence ·
11.4 Abrasive wheels (Grinders) .

a. Abrasive wheels should be selected, mounted and used only by competent persons and m
accordance with manufacturer's instructions.
b. Abrasive wheels are relatively fragile and should be stored and handled with care.
C. The guard should enclose as much of the wheel as possible. .
d. Where a work rest is provided, it should be properly secured to the machme and should be
adjusted as close as practicable to the wheel, the gap normally being not more than 1.5 mm.
e. The side of a wheel should not be used for grinding: it is particularly dangerous when the
wheel is appreciably worn.
f. The work piece should never be held in a cloth or pliers.
g. When dry grinding operations are being carried on or when an abrasive wheel is being trued
or dressed, suitable transparent screens should be fitted in front of the exposed part of the
wheel or operators should wear properly fitting eye protectors.
11.5 Compressed air
When compressed air is used, the pressure should be kept no higher than is necessary to under~
take the work satisfactorily.
Compressed air should not be used to clean the working place.
In no circumstances should compressed air be directed at any part of a person's body.
11.6 Compressed gas cylinders
Compressed gas cylinders should always be handled with care, whether full or empty. They
should be properly secured and kept upright. The arrangements for securing the cylinders should
be capable of quick and easy release so that they may be readily removed in, say, the case of fire.
If available, cylinder trolleys should be used to transport cylinders from one place to another.
The protective caps over the valve should be screwed in place when the cylinders are not in use
or are being moved. Valves should be closed when the cylinder is empty.
Where two or more cylinders of either oxygen or a fuel gas (such as acetylene) are carried the oxy-
gen and the fuel gas should be stowed in separate, well-ventilated compartments that are not sub-
ject to extremes of temperature. The space in which acetylene or other fuel gas cylinders are
stowed should have no electrical fitting~ or other sources of ignition and prominent and perma~
nent 'NO SMOKING' signs should be displayed at the entrance and within the space. Empty
cylinders should be segregated from full ones and so marked.
Special precautions as follows need to be taken in the case of cylinders of oxygen and acetylene
or other fuel gases:
a. Cylinder valves, controls and associated. fitti1_1gs should be kept free from oil, grease and
paint. Controls should not be operated with mly hands;

--
Part 1 Section 1 Ch t
ap er 3 - General Shipboard Safety and Health 91
b. Gas should not be taken from such . d

has been attacked to the cylinde cytl1m ers unless the correct pressure reducing regulator
. d r ou et valve·
c. Cy1m ers found to have leaks th at cannot be stopp
'
taken to the open deck away fr ed bY c1osmg
· t h e outlet valve should be
th e atmosphere. om any sources of heat or ignition and slowly discharged to
d. Identifying markings on cylinders.
11.7 Chemical agents
A chemical from an unlabelled contain h ld

itively established. er s ou never be used unless its identity has been pos-
Chemicals should always be handl d · h h

from accidental exposure or contac: wit t e utmost care. Eyes and skin should be protected
Manufacturer. or supplier's advic e on th e correct use of the chemicals

• should always be followed .
Some c1eanmg agents
. , even though use d d · 11
omeshca y, for example caustic soda and bleaches
may b urn th e skm. ' '
Chemicals should not be mixed unless it is known that dangerous reactions will not be caused.
12. Fire Precautions (Fire Safety)
Questions to bear in mind:
1. What are the common causes of fires in the Engine Room? Distinguish combustible sub-
stances and sources of ignition in Engine Room.
2. What are the common causes of fires in the Accommodation of a ship? Distinguish com-
bustible substances and sources of ignition in Accommodation.
3. What are the causes of fires on oil tankers cargo area? Distinguish combustible substances
and sources of ignition in cargo spaces.
4. What are the causes of fires in cargo spaces of Bulk carriers? Distinguish combustible sub-
stances and sources of ignition in cargo spaces.
5. What are the causes of fires in cargo spaces of a container ship? Distinguish combustible
substances and sources of ignition in containers.
6. What types of fire extinguishing agents are available on board?
7. What are different types of fire extinguishing equipment on board ships?
8. What are different types of fire detectors available for use on board?
9. What are different methods of restricting the spread of fire on board? Identify the equipment
available for restricting Engine Room fires.
10. What are the 'emergency escapes'?
11. What is meant by 'Fire Door'? Identify fire doors on your ship?
12. What maintenance is required for each of the fire extinguishing equipment?
13. What arrangements are provided in the Engine Room and Accommodation for prevention
of fire , minimising its effect, and its sp~ead? . . .
14. What are the items in Fire Man's Outfit on board? What is the mimmum number of fire-
man's outfit required on board cargo ship? What additional equipment is required on board
tankers?
15. What does EEBD mean and where is it kept?

92 Chapter 3 - Gen eral Shipboard Safety and Health rj I SAr:tion 1
16 • What is the difference between EEBD & SCBA?
T~e only sure way to avoid the disastrous consequences of a fire at sea is not to ~ave one at all.
It 1_s a moral responsibility of everyone on board to take all th e n ecessary precautwns to prevent
a f1re from occurring.
Although safe working practices have been d etailed below it is basically a common sense, and a
sense of resp onsibility (attitude) that matters eventually.
Good h ou sekeeping is the prime requirement for prevention of fires.
12.1 Smoking
Fires are often caused by careless disposal of burning cigarette ends and matches , or smoking at
p rohibited places. Ashtrays and suitable containers must be provided and used w h ere smoking
is p ermitted. Care must be taken to ensure that matches are fully extinguished, and that the cig-
arette ends are properly stubbed out. They must not be thrown overboard since these may be
blown back on board.
Conspicuous warning notices should be displayed in any part of the ship where smoking is for-
bidden. Disciplinary action must be taken against the persons not obeying such instructions.
It is dangerous to smoke in bed.
12.2 Electrical Appliances and Other Fittings
a. Unauthorised persons must not interfere with electrical fittings. Permission should be
sought from the ship's electrical officer or the responsible engineer officer before using and
connecting personal electrical appliances.
b. Notices should be displayed on the notice boards and in accommodation spaces to this
effect.
c. Appliances and fittings must be tested and maintained as per Rules and Regulations of
national and classification authorities.
d. Precautionary measures must be adhered to before commencing, during and after any of the
electrical item or distribution system is being attended to for repair or maintenance.
e. Use of a faulty appliance, machinery, fitting or wiring should be stopped immediately and
brought to the attention of responsible officer.
f. All electrical appliances must be firmly secured and served by permanent connections
wherever possible.
g. Make shift plugs , sockets and fuses should not be used.
h. Overloading of circuits must be avoided at all times to prevent damage to the fittings and
insulation.
i. All portable appliances , lights etc. must be isolated from the mains after use.
j. Fixed heaters and similar appliances must be fitted with appropriate guards and main-
tained. Practice of drying clothes over the heaters must be avoided.
k. Use of portable heaters must be avoided at all times. However, only under special circum-
stances in ports, such appliances may be used with appropriate precautionary measures of
preventing contact or proximity with combustible materials such as furniture, carpets,
floors , etc .

►
12.3 Laundry Spaces
a. Hand_pressing irons must be switched off after use, and secured on suitable stand.
b. Clothmg should be left_to dry ~nly in designated places. Drying of clothes in machinery
spaces, or close to he~tmg appliances, radiators, etc. must be prohibited.
c. ~ontact of clothes with steam pipes, electrical appliances , etc. must be prevented at all
times .
12.4 Spontaneous Combustion
Dirty w~ste, ~oiled laun~ry, linen, rags, sawdust and other rubbish - particularly if it is contami-
nated with ml or damp is susceptible to spontaneous combustion if left on its own in a closed
space or a container. Risk of fire increases in proximity with paints and other volatile liquids.
12.5 Decks, Stores, and Machinery Spaces
a. Good housekeeping entails cleanliness, prevention of oil leaks, proper storage of com-
bustible materials, maintaining guards, and similar practices.
b. Suitable metal containers should be provided for storage and disposal of cotton waste or
rags. Such containers must be emptied at frequent intervals and contents disposed off in
safe manner.
c. . Wood, paints, spirits, oils, greases and similar substances must be kept away from hot
spaces like boiler rooms , generator platforms, purifier spaces, etc.
d. Engine room bilges and tank tops should be kept clean and free of oil and rags. Proper light-
ing would help inspection and indication of leaks etc.
e. Particular care must be taken in carrying out maintenance work on lubricating, hydraulic,
and fuel oil equipment and system to avoid accidental release of oils under pressure.
f. Possibility of oil drips on hot surfaces (exhaust trunking, steam pipes, heaters) must be
eliminated through repositioning oil lines or providing appropriates guards as far as possi-
ble.
g. Welding and gas cutting work must be carried out with great care at all times. Similarly
grinding and metal cutting work needs to be carried out with appropriate precautions
against occurrence of fire.
h. Particular care must be taken when filling a tank that has its sounding pipe in the machin-
ery spaces; ensure that the weighted cock on the sounding pipe is closed all the time.
Similarly, transfer of oils and bunkering operation where there is a possibility of overflow
within the machinery spaces must be carried out with utmost care.
i. Where potable lights are needed to provide adequa~e illumination, they should be clamped
or otherwise secured in position, not hand-held with leads kept clear of the working area
and protected from chaffing.
12.6 Hot Work
a. Welding and flame cutting elsewhere than in the workshop should generally be subject of
a 'permit to work'.
b. Only competent persons should be allowed to carry out welding and hot work. Equipment
must be checked carefully before use.
C. Welding and flame cutting must be properly supervised at all times. Suitable fire extin-
guishers must be kept nearby for any emergency.

Part 1 Section 1
d. Before comm encing any kind of hot work, check must be made to ensure that th~re . is n o
combustible material (solid, liquid or gas) at, below or adjacent to area of work. Similarly,
when w orking on bulkheads, ceilings and similar locations one must ~nsure t~at th~ other
side is clear of combustible materials, cables, pipelines and other services which might be
affected by heat.
e. Utmost care m u st be taken wh ile working in tanks, pump rooms and ~nclosed spaces .
f. Suitable screens/nets must be erected to prevent falling of h ot metal m open tanks, hatch -
es, etc.
12.7 Galleys
a. Fire in galleys and pantries occur due to spills of oil and fat on hot surfaces , or oil leaks
from pipes and container. .
b. Electrical equipment with loose/faulty connections, switches, broken insulation and simi-
lar defe cts must not be used until the fault has been rectified.
c. An oven, burners , hot plates should be shut off when cooking is finished.
d. Oil pans should never be left within ovens.
e. Only recommended frying pans and appliances must be used.
f. Fire blankets and extinguishers must be kept readily accessible at all times.
12.8 Ships under repair are under far greater risk than other times. Responsibility of fire precau-
tions and fire fighting must be clearly established between the ship and shore personnel.
Sufficient alternative arrangements must be made with regards to fire fighting appliances,
properly marls,ed escape routes, communication and alarms.
Most fires start in a small way and can be extinguished by using the proper portable equipment.
Failure at this early stage to extinguish a fire could have disastrous consequences.
13. General Advice to Seafarers

Seafarers are reminded to take care as they move about the ship and to do so in a seaman-like
fashion. In particular, the following points, though obvious, are too often overlooked:
a. The possibility of an unusual lurch or heavy roll of the ship should always be borne in
mind;
b. Suitable footwear should be worn which will protect toes against accidental stubbing and
falling loads and will afford a good hold on deck and give firm support when using ladders;
extra care should be taken when using ladders whilst wearing sea boots or gloves;
c. It is dangerous to swing on or vault over stair rails, guardrails or pipes;
d. Injuries often happen due to jumping from heights, etc or by stumbling over doorsills or
other obstacles.
A seafarer who finds any defects in equipment, or a condition he
believes to be a hazard or unsafe, should immediately report it to a
responsible person, who should take appropriate action.
This is only the beginning - it will ne: er be enough t~ le~n about _safety. All your life you will
learn more about dangers and precaut10ns to be taken m different situation ..
Your interest in your own protection will determine how seriously you learn this chapter and put
the learning in practice.

Part 1 Section 1
Chapter 3 - General Shipboard Safety and Health 95
j The safe way to work J Start

. + I Risk Assessment J
Think about the dangers
Consider Job Hazards Consider Environmental Hazards
Decide on precautions to be taken
Prepare
i
lPut on appropriate safety clothing I
i
, i,
+ ,,
Assemble Remove any loose Position
correct tools Position danger
equipment f(om area equipment and
and equipment warning
which might cause a route electric
inspect for notices, safety
hazard. Erect safety pneumatic or
serviceability barriers as
equipment as hydraulic cables
required
required (i.e. chip in safest possible
guard, protective wey
screen
, ,,
+ •
I Carry out
+
task
i
Work to a logical Always use correct
Wear appropriate
sequence tools. Never
safety clothing
improvise on tools
,, J Clear up on completion J
i
•
Return equipment
~ Ji'
Remove notices
--------.. Secure
Collect tools &
store in respective to store or bay safety barriers and any loose
panels or boxes safety equipment equipment
i +
I Finish I

Chapter 4 - Hand Tools and Measuring Instruments
Specific Learning Objective:

Trainee w ill b e able to identify and state the u se of common hand tools and measu ring instru~
m ents u sed on board sh ips.
1 Introduction
As a new person on board, you will be assisting others in maintenance work, operations and
watch keeping.
The foremost of any maintenance work, n ext to concepts of safety, is the knowledge of all kin ds
of tools, their proper use, and upkeep. Many a times your superior will ask you to p ass on or bring
a particular tool from the workshop , and you are expected to do it promptly.
The quality of discipline and maintenance on a ship can actually be judged by the w ay tools have
been stored, and their condition. You will experience that much harm to the machinery by using
improper or by poor conditions of tools. Similarly, much damage is done by application of exces-
sive force in dismantling or assembling components .
We appreciate that you are not in a position to change objectionable habits of others around you;
however, the least you can do is to develop proper habits for self, and not be influenced by wrong
habits of others.
We are not in a position to give exact instructions on maintenance work that you will be asked to
carry out, but we assume that you have learned much of it during your pre-sea training. However,
we advise you to be very honest with your superiors to let them know the extent of your knowl-
edge and ability to perform the tasks given to you. It is better to be safe than sorry. ·
2 Tools on Board Ships
Familiarize yourself with location of common tools in the engine room. Get familiar with all other
special tools kept near specific machinery such as centrifugal separators, generator platforms,
steering flat and main engine (refer ch.3.3). A list of most of the common tools to be found on
board is given below for your convenience. Make sure you can recognize all of the listed items .
.1 Hammers: (Ball pein, Cross pein, Sledge, Chipping hammer, Mallet, Soft)
These are tools which are used to strike, shape, adjust, assemble and remove workpiece,
tools, parts and components .
.2 Chisels: (Flat, Side cutting, Diamond point, Cross cut, Round nose)
These are tools used for cutting and chipping away pieces of metal.
.3 Screw Drivers: [standard tips to suit screw slots ( - ) or Phillips ( +),Insulated, special type
with tips to suit recessed head screws (slots of different shapes)].
These are tools used to tighten or loosen screws .
.4 Bench vice: These are work holding devices which are mounted onto the tops of work
benches. They are used to hold wok pieces whilst carrying out operations like filing, saw-
ing, bending or chiseling etc.

>
Part 1 Section 1 Chapter 4 - Hand 'T' 1s an d Measurmg
. Instruments
.100 97
,5 Files: (Flat - Bastard, Second t F ·

files) cu , me cut; Half round, Round, Triangular, Square, needle
These are tools which are u d t O • . ·

. d f t se remove material m the form of small chips from work-
piece ma e o me a1, p 1astic or wood .
.6 Hacksaw: (Hand, ~ower, Pipe cutters, Hole saw)

These are d which are used t O cut b ars, ro d s, sect10ns,
th tools · ·
pipes, · tubes, an d cabl es
condmts,
1
to eng , an to cut parts and work pieces to rough shapes .
.8 Punches: (Hole, Number, Letter, Centre) .

These are tools used in a bench work for marking out, locating centres, etc. in a more per-
manent manner.
.9 Spanners & Wrenches (What is the difference between the two?)

Spanners come in specific sizes so as to open .
► Open ended - single or double ended
► Tubular box spanner and tommy bar
► S?cket spanner, fitting sockets, extension pieces, adapters, universal joints, drive, ratchet,
► Rmg spanner- double ended, normal, flat, special duty,
► Open ended, and ring combination type,
► Adjustable Spanner; - Hook spanner;
► Heavy duty spanners (open ended, ring);- Striking spanners;
► Wrenches - Stilson pipe wrench, footprint pipe wrench, monkey wrench;
► Hexagonal socket wrench (Allen keys); - Torque wrench .
.10 Pliers: (Common or Combination, Round nose, Flat nose, Snipe nose, Multi Grip, Slip joint,
Circlip pliers, Insulated)
These are tools which are used for:

► Holding, gripping, pulling and turning small parts and components,
► Shaping and bending light sheet metal parts,
► Forming, bending, twisting and cutting small diameter wires .
.11 Lifting Tackle: (Eye bolts, Shackles, Slings, Chains, Ropes, Hooks, Pulley blocks, Chain
blocks, Ratchets block, staging, cranes, crow bars)
These are the tools used to lift and move heavy objects or machinery.
.12 Die Nuts, Die Sets: (Die nuts, Die sets, Taps, Reamers, Screw extractors)
Taps Reamers: (Machine threads/ Pipe Threads)
Dies are used to cut threads on a round bar of metal, such as the threads on the bolts. These can
cut external threads on steel pipes and steel bars, extend existing threads and cut slightly dam-
aged threads.
Cutting inside threads is called tapping. After the hole has been drilled, it is ready for tapping .
.13 Miscellaneous: Measuring and marking too~s, Calipers, V~rnier calipers, Micrometer,
Feeler gauge, depth gauges, tri-squ~es, Bearmg ~uller~, Dnlls, Clamps, Vice, Riveting
machine, Jacks, Welding tools, Machme tools and bits, Brass bars.)

98 Chapter 4 - Hand Tools and Measuring Instruments Part 1 Section 1
Diagrams given below are of the common hand tools. You will need to learn
their names and use them during practical training and on board ship
H£V'CO...:,.
t
@
Part 1 Section 1
Chapter 4 - Hand Tools and Measuring Instruments 99
Sledge Hammer
1 - Pein
2- Flat Face
Claw
• • ••
• • • • •• • • • • ••••
• •• • • • • •
• • • • •• • •• • • •• •
•


>
Part 1 Section 1 Chapter 4 - Hand Tools and Measuring Instruments 101

J ;.~
250-300mm
,. ¾)
(+· -+j
+·
Part 1 Section 1 Chapter 4 - Hand Tools a nd MeaSurmg
. Instruments 103
½"


-
part 1 Section 1 Chapter 4 - Hand Tools and Measuring Instruments 105
►
Chapter 4 - Hand Tools and Measuring Instruments Part 1 Section 1
106
ig
qJ 81
wtm:rz ae1·7

II
part 1 Section 1 Chapter 4 - Hand Tools and Measuring Instruments 107
Spanners
►
l
Check
Controls
Chain Block
Swivel Hook Eye Bolt Hook Pully Block
-- . . -- ---- - --- -~-- - - - -

f(t;e-· ~~· XDH·xxir;.,~-~"t..lH -« · tr , i\r;,;·-:J~. ,. .,'' · .
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Part 1 Section 1 Chapter 4 - Hand Tools and Measuring Instruments 111
Joint
Legs

Part 1 Section 1 Question Bank 113
. . Chapter 1- Personality Development

Each quest10n has four opt10ns of which only one is correct
1. Learning becomes permanent only by: 9. Non- Verbal modes of communication
A) Practice are
B) Reading A) Symbols
C) Use of Senses BJ Words
D) Asking questions C) Channel
2. What is important for stu dying? D) Speech
A) Good teacher 10. One of th e m ost important practice
B) Proper techniques for stu dying while talking to a person is to
C) Reading speed A) Maintain eye contact
D) Self - Discipline B) Stand very close to the person
3. On the day of exam, one should reach C) Hold hands
the ex am center___ before exam D) Speak politely
A) 30 minutes 11. We communicate to
B) 15 minutes A) Receive information
C) 5 minutes B) Send information
D) 1 hour C) Send and receive information
4. Before starting writing in the exam, one D) Please others
should 12. One of the internal barriers to communi-
A) Read the instructions properly cation is
B) Just start writing A) Ego
C) Ask question to invigilator B) Noise
D) Write the name and roll no. in answer C) Time
sheet D) Distraction
5. K-S-A-V stands for 13. Barriers to communication
A) Knowledge, Skills, Attitude, Values A) Create problems in communication
B) Knowledge, Style, Attitude, Values B) Make the communication better
C) Knowledge, Skills, Aptitude, Values C) Do not influence communication
D) Knowledge, Seamanship, Altitude, D) Are essential for communication
Values 14. Sending information is the opposite of
6. While studying for examination, one A) Action
should B) Transmitting information
A) Highlight the main points in the book C) Receiving information
B) Read very carefully D) Encoding message
C) Try to understand the matter 15. Communication can be done
D) Memorise everything A) Verbally
7. Skill is an ability gained by B) Non Verbally
A) Practicing or learning C) Both verbally and non- verbally
B) Responding well D) By self - expression
C) Dominating others 16. Showing anger through fa cial expres-
D) Cooperating with others sions is an example of
8. The ability to learn by practice is called A) Verbal Communication
A) Skill B) Non - Verbal Communication
B) Knowledge C) Mode of communication
C) Attitude D) Receiving communication
D) Values
~

.,
Question Bank Part 1 Section 1
114
26. Which of the following is required for -

17. Telephone is an example of
A) Sender success of a project?
B) Channel of communication A) Personal gain
C) Receiver B) Politics
D) Barrier in communication C) Lots of money
18. Who is more important in communica- D) Purp ose and Goal
tion process? 27. Which of th e following is a NOT a
A) Sender quality of a good leader:
B) Receiver A) Dedication
C) People B) Inspiring
D) Self C) Demanding
19. Which of the following is NOT a com- D) Forward looking
munication skill? 28. Which of the follo wing is unethical?
A) Writing Being:
B) Teaming A) Honest
C) Reading B) Cooperative
D) Speaking C) Arrogant
20. To manage means to deal with D) Punctual
A) Situations properly 29. Being ethical is important for
B) Situations A) Office life
C) Bad situations B) Personal life
D) All situations happily C) Both office and personal life
21. While doing work, priority D) Avoiding conflict
should be to 30. For good relationship with others:
A) Most urgent work A) The two most important words:
B) Most important and urgent work Thank you
C) Most important work B) The one most important word: You
D) Needs of others C) The least important word: We
22. Stress is a ____ strain D) The best words are: You are wrong.
A) Physical 31. CPU stands for
B) Emotional A) Central processing unit
C) Mental B) Central process unit
D) Social C) Computer processing unit
23. The PHYSICAL symptom of stress is D) Computer programme unit
A) Tension 32. Which of the following works like a
B) Sweating hands brain of a computer:
C) Trouble sleeping A) Key Board
D) Inability to concentrate B) Monitor
24. If stressed with some work, one should C) CPU
A) Give up D) Optical Mouse
B) Leave it for some time 33. Printer is a
C) Keep doing it till it is complete A) Peripheral
D) Tell someone else to do it B) CD-ROM Drive
25. In a team, to achieve a goal is the C) Monitor
responsibility of D) Memory
A) An individual
You will be expected to identify compo-
B) The leader
nents of a desk top computer and its periph-
C) All team members
erals from the given diagrams.
D) Management

►
part 1 Section 1 Question Bank 115
Match the Column Questions.

Match the items from Column I to tho se m · c o1umn II. Items m • column II could be used once,
more than once or not at all.
34. Column I Column II 37. Column I Column II
Command Action
Commands Action
a) Save 1. Zoom in and Zoom out a) New 1 . Spelling and Grammar
check
b) Zoom 2. Undoes previous actions b) Open 2 . Changes the color of the
c) Undo 3. Quick save files text
d) Cut 4. Opens a new word docu- c) Bold 3. Opens an existing file
ment d) Print 4. Writes numbered bullets
e) Numbering 5. Cuts files into the clip- preview
board e) Spell 5 . Open a new word docu-
DRedo 6. Redoes previous actions Grammar ment
7. Writes numbered bullets f) Paste 6. Changes the Type into
8. Shows a preview of files 7. Shows a preview of files
before they print Before they print
8 . Paste copied or cut files
35. Column I Column II
into the document.
Terms Meaning
a) Verbal 1. Lack of Confidence Short answer questions
Communication 38. Write any 4 values that should be pos-
b) Non - verbal 2. Noise sessed by a good leader
Communication 39. Write any 4 points needed to achieve
c) External Barrier 3. Computer success
d) Mode of 4. Facial Expression 40 . Write any 4 points for being presentable
communication at work
41. Write any 4 points for effective listening
e) Internal 5. Self-Expression
42. Write 4 points for time management
barrier
43 . State any 4 benefits of Time
DNeed for 6. Speaking
Management
Communication
44. Write any 4 reasons of stress
7. Feedback
45. Write any 4 points for removing stress at
8. Receiver
work
36. Column I Column II 46. What does the word "TEAM" stand for?
Items Function 47. Write any 4 advantages of teamwork
a) CPU 1. Like a T.V. 48. Write any 4 qualities of a good leader
b) CD-ROM 2. Peripheral to the computer 49. Write any 4 commandments of success
Drive 50. Write any 4 uses of MS Word
c) Keyboard 3. Used to point objects on the 51 . Write any 4 uses of internet
monitor 52 . Write any 4 senses of our body
d) Mouse 4. Data can be written and 53. Write the 5 WS and 1 H concept in
rewritten on the CD learning
e) Printer 5. Like a type-writer ; commu- 54. What challenges are faced by a woman
nicates with computer seafarer?
fl Monitor 6. The brain of the computer 55. Write 3 points where male seafarers are
7. Getting music required to adopt behavioural change
8. Sending messages for working with female.

116 QLl(is lion Bank Part 1 Section 1
Chapter 2 - Basic Ship Knowledge

Identify type of the ship, parts shown by arrows, and their purpose. There can be multiple type
questions using these pictures.
/7 1
6~.
S'ji·. • -
2 4 ,. A
1'
•
-,·
-
• •• • ·I! "
/
.
'
. t I
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j ,,
, \..
•
Q '
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.,....:~., 7!: .
?-'.-- - - . , ...,
---- ~
... :-... · -4
1
;..
- ,_
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·-
.....____..,,,.,..--"="
6 5

Part 1 Section 1 Question Ban k 117
. '
,-· .. : . l
·:[-=-:- ,_, ...__ ,
~ I I
~ § 51..::.:'--r~
111 ,::-ti"!:ij:'.l.;,11 ~
:.
- ~...-:::
""-,.,~~ II II tt ,. t.J ~
II II II II 11
jl U II
u u r,
Q1. Select the name for Part 1 from

the following:
A) Crane Jib
B) Mast
C) Foremast
D) Crane Cabin
Q2. Identify the name for part 2 from

the following:
A) Crane Jib
B) Bridge Wing
C) Accommodation
D) Bridge

Part 1 Section 1
Question Bank
118
Identify the types of ships, and their parts in pictures given below.

--
Identify item shown by arr ow. Wh ere is the Ship?
International Sea routes - Identify names of oceans, continents, major countries,

and draw major sea routs.
I WORLD MAJOR SEAPORT!_. .,--. - '
.
,.
N
,~,: . ~--·~ :~: f~--~ ~ -·

·, '.;;...
f..QffU!AUO .;:
~--.._=:.-~
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, .. <
~--,.,-·.:·.·;··· ···-/ 'S,
. .
'· .. )
'u ll. Jv., n J
.IJ~J' .
Abidjan . .,, Lagos

J,
.tPort G~ntll
Lt lktad.i. Bt~nF
.i; Boma
.t Re<if!
e.a11ao.;,
J.salvador :
Nazt.1 .1, . Watvis8ay
Rio de Janeiro J,
Antofaga_sta .i. San Ifn.1,.t
Bu~Airus
Vatpiraiso~ , .i. J. Montnidea
/ ',J,BahiaBlallGl
J.. '
C: LUEN O I Map _no110 Scare \L-.
• I

l
120 Question Bank Part 1 Section 1
Chapter 3 - General Shipboard Safety and Health
1. Personal Protection and Personal Protection Equipment

2. Safe working practices for merchant seam an (including p ermit to work system and fire pre-
vention aspects , Safety Precautions when working aloft, Safety Precautions when working
over side)
3. Risk Assessment (Basics)
4. Emergencies
5. Safe Access to the Ship
6. Safe Working Practices during Berthing/ Unberthing and Anchoring
I. Match the items from Column A to those in Column B:

Q.1 Q. 2
Column A Column B Column A Column B
Couse of accident Possible outcome Injuries Caused due to
a) Sharp tools 1. Head injury a) Cuts 1. Fall
b) Heights 2 . Cuts b) Chemical Burns 2. Lack of oxygen
c) Falling objects 3.Falls c) Particle in eye 3 . Too much noise
d) Hot work 4. Sprain d) Fracture of limbs 4. Flying dust
e) Oily surface 5. Burns e) Suffocation 5. Electrical
f) Enclosed Spaces 6. Suffocation equipment
7 . Head f) Redness in eyes 6. Acids and alkalis
8. Eyes 7. Sharp objects
8. Welding
Q. 3
Column A Column B
Equipment Protection of
a) Safety Shoes 1. Hands
b) Safety Helmet 2. Feet
c) Safety Goggles 3. Nose & mouth, Face
d) Hand Gloves 4.Body
e) Ear Muffs 5. Ears
f) Boiler Suit 6. Working Aloft/
over side
7. Head
8. Eyes

---
II What do the following types of signs mean in general?
/::i venow
2
Red Blue
4
Green Red
III What is meant by each of the following signs?
1 2 3 4 5
IV Identify the items shown below
2 3
5 6
4
7 8 9
►
V. Short Answer Questions
1. List any six items of the Fire man's outfit

2. List any four 'Permits to Work' used on board
3. List four of the precautions necessary before lifting any heavy item
4. List any four of the lifting devices used in the engine room
5. List four of the mechanical items that will be used for lifting a cylinder head
6. List eight ways a person can get injured on deck & E/R
7. List any six items to be used for personal safety
8. Give six steps to be taken before commencing maintenance work from the aspects of pre-
vention of accidents
9. List six different preventive measures for accidents and injuries
10. List three of the positive and three of the negative aspects that affect physical health of a
person when on board
11. List three of the positive and three of the negative aspects that affect mental health of a per-
son
12. List four of the spaces on the ship that would come under 'Enclosed Space'
13. State three of the precautions to be taken for manual lifting of a load.
14. What happens when a ship is not maintained clean and hygienic as per requirements of
MLC and Marpol?
15. List injuries that can be caused during the following:
Work Possible injuries

Painting
Welding
Working on deck
Enclosed spaces

p
Chapter 4 - Hand Tools
Be able to identify the names of tools and state their use.
1 2
3 4
5 6
7 8
11
12 13

◄
124
14
15 16
17 18
·..•:-:. .·.:: . .....

. . .......
;
· :..
19 20
21 22
23 24

a
25 26
27 28
:ntffie ·e-n
29 30
31

Part 1 Section 1
Question Bank
126
33
32
34 35
36 37
38 39
40

p
41 42 43
44 45
I
•
A
47 48 49 50
46
2. For lifting a heavy load, you will use

1. ABOLT has
a) Hydraulic jack
a) Double pitch threads
b) Chain block
b) Thread at both ends
Threads at one end with a slot at the c) Air cylinder
c)
d) Eye bolt
other end
d) Hexagonal head at one end and threads
at the other end
3. A STUD has
a) Double pitch threads

b) Thread at both ends
c) Threads at one end with a slot at the
other end
d) Hexagonal head and thread at the other
end

Seamanship, Marine Engineering
and Human Relations
Part 1
Section 2
Marine Engineering
Published by
Revised Edition
August 2014
Contents
Part 1 - Section 2
Marine Engineering
Chapters Page No.

1. Familiarisation with Engine ·R oom Machinery and Duties 131
2. Instruments in the Engine Room 139
3. Maintenance Work & Workshop Practice 146
4. Auxiliary Machinery 165
5. Diesel Engines 198

6. Watch Keeping in the Engine Room 213
7. Working with Machines 217
8. Welding 235
9. Lubrication 255
10. Level Measuring Devices 264
11. Lagging and Insulation 268
12. Electrical Tools and Fittings 271
13. Chemicals on Board 277
14. Steering Gear 279
15. Storage Tanks 281
16. Emergencies in the Engine Room 283
17. Fire Extinguishing Equipment in the Engine Room 286
_j
p
Chapter 1 - Familiarisation with Engine Room Machinery and Duties

1 Duties of a Trainee Rating

.1 States duties of a rating in the Engine room for assisting in maintenance and watch keeping
.2 State the person to report to while working in the Engine room

• As_si~t ship enginee_r officers in performing routine maintenance work and repair to
ships engme, machmery, and equipments.
• Lubricate moving parts of engines, machinery and equipments as instructed
• Operate and maintain pumps and valves under the guidance of ship's engineers.
• Clean engine parts and engine room.
• Look after ER stores and spares
• Paint engine room
• Assist watch keeping in the engine room
• Monitor engine, machinery and equipment indicators and report abnormalities to ship
engineer office on watch.
2 Engine Room Machinery

State major items of machinery and their purpose (Main Engine, Shafting, Auxiliary Engines,
Auxiliaries, Boilers)
Study the diagram on the next page to understand all of the major items of machinery in the Engine
Room. Note that Deck Machinery is outside the engine room but gets the power supply from the
engine room. Similarly, power supply for the whole ship is produced in the engine room.
Word 'Machinery' can be used as singular, or plural application.
'Machinery Space' - a space or a compartment containing a group of machinery. Some machin-

ery spaces have specific names e.g., engine room, boiler room, purifier room, pump room, battery
room, steering flat, cargo machinery units, etc. Some of the machinery spaces have extensions
for remote operations e.g., cargo control room, engine control room, etc.
'Machinery Item' can be used for one machinery component, or an assembly e.g. pump, valve,
etc., or a group of items forming a complete unit e.g., main engine, boiler, alternator engines, etc.
'System' - a group of items that support operation of the ship, or other machinery e.g. lubrication
oil system, cooling water system, bilge and ballast system, etc.
'Propulsion Machinery' items meant for moving the ship (main engine, shafting, and propeller).
'Main Engine' complete unit meant for providing power for propulsion of the ship.
'Generators' (engine and alternator) for production of electric power for all purposes.
'Auxiliary Machinery' support other machinery or systems e.g., boilers, air compressors, dis-
tillers, etc.
You will learn more about machinery and systems in this book as we go on.
1:he size of the engine room depends ~pon the size of th~ ship and typ~ of th~ ship. Similarly,
size of almost all machinery changes with the power reqmrements of mam engme.

Deck Machinery
► Cargo Handling Gear
► Steering Gear
(cranes, winches, hatch np-'
► Manoeuvring Aids
cover operating DJ
C/"J (Thruster, Controllable Ventilation & air Emergency Equipment ""d
Ct)
machinery) r-+-
..,
► E. Generator
p., (l)
Pitch Propeller) Conditioning
8 ► Mooring Machinery r--'
p.,
► ER Ventilation ► E. Fire Pump I
::J (windlass, capstan,
v:,
► ECR Air conditioning ► E. Air Compressor 'Tj
p-' winches) DJ
'"d. ► Remote controls ► Fire extinguishing
► Provision Winch
s,_.. . .
Main Engine ► Fire Detection .. .
~ ► Gang Way lifting M/C e;. . .
e; ► LO. System ► Oil Spill Control en
► F.W. Cooling System ► Life Boat Machinery DJ
5· .0. .
r-+-
Ct)
trj
► Fuel System I :::1
::J ► Air Starting System Boilers & Steam § .
00
.......
::J ► Supercharging Engine Room Distribution System
r-+-
p-'
trj
Ct)
Ct) ► Control System I ► Oil Fired Boiler :::1
>-; (JQ
5· ► S. W. Cooling Auxiliary Machinery ► Exhaust Gas Boiler s·
(l)
00
► Air Starting System ► W aste heat recovery
p., ► Air Compressors ~
::J ► Safety System ► Feed System
0
p.. ► Pumps 0
~ ► Incinerator Domestic Services ► Fuel System s

~
► Air supply system ~
► Domestic Fresh
s ► Sewage System
water system ► Soot Blowing
DJ
('")
p-'
§ ► Oily water Separator s·
Auxiliary Engine ► Galley Equipment ► Steam distribution
► Fresh Water ..,
(l)
~
......, ► Generator Engines
► Air conditioning '-<
Generator
~ ► Cargo Pump Engines DJ
.......
► Bilge System ► Domestic fridge :::1
p_.
0
::J
v:, ► Ballast System ► Stores & spares Stores t:J
~
► Fuel Storage & ► Workshop .....
r-+-
(l)
transfer ► Repair & maintenance en
► Lube storage & equipment

transfer
>
Part 1 Section 2 Chapter 1 - Famil iarisation with Engine Room Machinery and Duties 133
3 Engine Room Space
Describe engine room spaces - platforms (levels)- boiler - main engine - generator - bottom, fun-
nel trunking, tank top , pipe tunnel, emergency escapes, steering flat, workshop , ventilation, and
engine control room
Machinery items, systems, and their layout in the engine room depen ds up on the following
factors :
Type of ship (container ship , oil tanker, bulk carrier, RO/RO , passenger, reefer, supply vessel, etc.)
• Type of main propulsion plant (diesel, steam, gas turbine, electric)
• Type of engine (slow speed, medium speed, etc.)
• Type of main engine control (bridge, UMS , ER)
• Number of power units (one or more main engine)
• Type of drive (direct or indirect) , (single or twin propeller)
• And various other factors depending upon the overall combination of above aspects .
Difference in the size of the ship or the engine room can be well appreciated by the differen ce
between a small three wheeler to a 24 wheel lorry and trailer though some of the basic needs
remain the same.
Size of the machinery in the engine room can be appreciated by pictures given below:
. . . .H d I
Mam Engme Cylmde1 ea P a
;for:
1~ t;~th level from the double bottom tank in the E. R)
. Marine Engineering and Human Relations

Seamans h 1p,
134 Chapter 1 _ Familiarisation w ith Engin e Room Mach in ery and Duties Part 1 Section 2
..
_r e
elief Valves
ri Main Engine
ii
This is the lowest platform in the engine room called floor plate level (above the double bottom tank). The double bottom tank top
and can be 2 to 3 meters below the floor plates. (Crankcase pressure relief valve on main engine prominent in this picture)
A generator engine - as big as the main engine of a large tug boat

(Crankcase pressure relief valves on generator engine prominent in this picture)

>
Part 1 Section 2 Chapter 1 - Familiarisation with E .
ngme Room Machinery and Duties 135
View of a generator engine from free end. (alternator is attached to the other end)
4 Auxiliary Machinery
Learning objective:
Describe purpose and importance of auxiliary machinery items. (Pumps, valves, fresh water gen-
erator, oil separators - purifiers, hydrophores, air compressors.
A simple meaning of 'auxiliary', as given in the Oxford Dictionary is 'Helpful; giving support;
Subsidiary, additional, ancillary'.
I Pumps
I Air Compressors
AUXILIARY
I
Evaporator
MACHINERY
I Purifiers
Boiler
Heat Exchangers

' ·1111 : I)·-tHJJ II Mi1c :l1 i 11r :r.v illl(I l)11l ios
Chapter 1- Famil iarisc1tion wi llI I•,11g l'ill'I 'I Snc:lio11 'J
136 l.,
- -.
Oil Purifier (Centrifugal Separator) J\ir Compressor
Water Coolt!r (Heat Exchang1!r) Oil Filh!r
Seamanship, Marinn Engineering and 1:-lunrnn Reh1tinns

..
part 1 Section 2 Chapter 1 - Familiarisation with Engine Room Machinery and Duties 137
Difference between the term 'Engine', 'Machinery' and 'Equipment'
Engine is a comple,te set of items to move a vehicle (ship, car, truck) , but it is also used for other
machines such as generator engine', 'diesel engine', 'steam engine' which may indirectly con-
tribute in moving a vehicle .
Machine is a group of components (parts) put together to achieve mechanical output (tum a shaft,
move a substance, etc.), thus a 'pump', 'purifier' drill machine, lathe, etc.).
The term machinery is plural of machine and thus it can be applied in wider context as 'engine
room machinery', 'deck machinery', etc.
Equipment is an engineering component used for a purpose to achieve the desired result, for
example, e.g. a valve, a filter, etc.
Difference between the terms 'main' and 'auxiliary'.
Main purpose of the merchant ship is to move cargo from one place to the other. Machinery that
achieves movement of the ship is thus termed as 'main engine'. However, we require other
machinery such as pumps, purifiers, etc, to be able to operate main engine. These other machin-
ery necessary for the function of the main are called 'auxiliary'.
Difference between 'equipment' and 'system'
System is a set of machines and equipment put together to achieve the desired outcome. By itself,
a valve is only equipment and is not useful without other items such as a pipeline, tank and a
pump. Thus a combination of machinery and equipment goes to make a system, e.g., 'cooling
water system', 'lubricating oil system', etc.
Some more examples are given below:

System Main component
Propulsion system Main Engine
Compressed air system Air compressor
Oil purification system Purifier
Ballast system Centrifugal Pump
Steam generation and distribution system Boiler
Another way to distinguish one from the other is given in the table below:
Engine Machinery Equipment Tools Instruments System Components
• Diesel • Compressors • Valve • Hammers • Gauges • L.O. • Gears
• Steam • Purifiers • Filter • Files • Thermometers • Fuel • Bearings
Turbine • Turbo • Pipe • Chisels • Callipers • F.W. • Shafts
• Gas turbine • Charger • Pulley • Pliers, • Micrometer • S.W. • Impellers
• Electric • Pumps, • Crane etc. etc. etc. etc.
~ Drive, etc. etc. Jack, etc.
I~terestingly, by itself, Boiler is a steam generating plant. Engine Room is a place where you can
find all of the above.

138 Chapter 1 - Familiarisation with En gine Room Machinery and Duties Part 1 Section
2
5 Symbols used in the engine room
Identify different signs and symbols commonly found in the engine room (danger, no smoking,
emergency escape, electrical safety, no entry)
Symbol Meaning Examples
~m
~~
Warning ..
Danger
.. ( ~ C• •
••
JVlandatory -
Must do· .·· . . ' .
c■
Emergency Escape,
First Aid and Safe
Condition-
Thesafeway
mm PY4
(i)
•
& Dinger
high vo1taa11

Chapter 2 - Instruments in the Engine Room
Instruments
1 Identify and n ame the instruments in the engine room: pressure gauges, thermome-
ters , pyrometers , level gauges
2 Read different type of instruments in the engine room: pressure gauges, thermometers,
pyrometers, level gauges
Introduction
Though it will be hard to believe and accept, there is very little difference between operation of
our body and that of a machine. The following comparison is worthy of understanding:
An example
Perhaps you will be able to add more similarities.
Need Human System Diesel Engine

1. Structure Body / bones/ flesh/ organs/ Bed plate, frames, cylinder
stomach, nervous system, etc head, crank mechanism, piping
system, combustion system,
·control system, etc
2. Clean air needed Yes Yes
3. Proper food (fuel) Yes Yes
4. Cooling System/ temperature Yes Yes
control
5. Lubrication Yes Yes
6. Maintenance/ Rest Yes Yes
7. Rest Yes Yes
8. Filters Lungs, kidneys, liver, etc Air filter, lube oil filter, fuel fil-
ter, etc
9. Temperamental Yes (Gets upset if not treated Yes (Gets upset if not looked
properly) feels good when after properly) operates well
looked after when looked after.
10. Speaks/complaints/ Cries, gets angry, makes faces, Noise changes, gives alarm,
falls sick, withdraws, etc. temperature goes up or down,
breaks down, etc
11. Life span Yes Yes
12. Break Down Medication, Surgery, replace- Repair, Replacement n eeded
ment needed

S eamans h 1p,
14 0 Chapter 2 - Instruments in the Engine Room Part 1 Section 2
The only logical difference between a human and diesel engine is th e method of creation - some-
what natural versus man made.
A similar comparison can be created between the humans and the ship, and with different
machinery. Basics will not change.
Keeping the above comparison in mind you will be able to appreciate the need of every compo-
nent of a ship, and importance of care and maintenance.
In our body, we have natural control mechanisms for maintaining body temperature, blood pres-
sure, speed, etc. Our body has built in thermometers , pressure gauges, and speedometer, etc. Our
brain is a control center.
On the ship, we have several instruments, alarms, control mechanism and auto shut down. A
ship needs internal as well as external communication system.
As an operator and care taker of machinery and the ship, we need to learn to use, understand how
it works, and how to communicate with it.
Modern ships have very sophisticated automation systems, but there is still a human who has to
operate, monitor, set it, repair it when required, and control it.
To start with you will need to learn at least the following:
1. Read pressure gauges

2. Read thermometers
3. Read level gauges
4. Find level of fluids in a tank
Learn to recognise each of the above because you will be required to read them and report differ-
ent temperatures and pressures and safe operating range.
Most of these items will be in the workshop of your institute.
The instruments on board ship are marked (calibrated) in metric system of units:
1. Pressure kg/cm 2 or Bar
2. Temperature °C (Celsius)
3. Level Meters and Centimeters (m, cm, mm)
4. Tank contents Cubic meters or Liters (m3, 1, tonnes)
5. Weight kg
6. Distance Nautical mile
7. Ship's speed Knot
8. Current A (Ampere)
9. Voltage V (Volt)
10. Power W, kW (Watt or kilo Watt)
11. Frequency Hz (Hertz)
12. Revolutions RPM (revolutions per minute)

part 1 Section 2 Chapter 2 - Instruments in the Engine Room 141
F ~ ..... ~
Variety of pressure gauges and thermometers.
M Pressure gauge in Bar & PSI (lb/in2) Upto 7 Bar - (general service pump,
ax. Pressure 1 Bar (Generator engine turbo-charger air outlet) or similar duties)

.
Chapter z - Instruments in the Engine Room Part 1 Section 2
142
On the left side a pressure gauge for over 150 Bar system Pressure regulator and pressure gauge on gas bottles.
(Hydraulic machinery such as remote operating valves, etc)
..,I..,
-~-is ,J ~
<: ~::~J·O iitllg

.' '
Pressure Gauge on Refrigeration Compressor Vacuum Gauge
I
V 400
\
500
' A .,,,;.::❖\
:-~,·. ~so'· ~l lW
300
.-,;:-:' 200,l
\
.... ' l.
200 158 ~r:
/-... 1fl0 ·-·1 ll
-100
•
_£ 50
• ~
1,._- a
\I ,,.,,., ·L .
Voltmeter Ammeter Power in kW

Part 1 Section 2 Ch apter 2 - Instruments in the Engine Room 143
---<llllt---VENT
PROCESS PLUG
CONNECTION
INDICATOR
·;;t1111t-1-+--FLOAT
[
~
'•."'-!~ ~
Ra.-- INDICATOR -Lev.~ .g·
TUBE
SCALE
Level Gauge arrangement
Bicolor type water

Tubular type water/ Reflection type Transparent type Bicolor type water level guage
liquid level guage water level guage water level guage level guage (multi-port type)
Variety of level gauges
>
144 Chapter 2 - Instruments in the Engine Room Part 1 Section 2
Red line
Oil guage
Sight glass for oil levels in gear case of purifiers, crankcase of air compressors, and similar small machines
.\
· .../·_
'~ :;f;}lf
Oil level sight glass on a purifier gear case

---
Part 1 Section 2 Chapter 2 - Instruments in the Engine Room 145
Thermometers for Cooling water and L.O. Temperatures Thermometer for Engine room temperature, or on the bridge
Infrared Remote Temperature Sensor

Chapter 3 - Maintenance Work & Workshop Practice
1 Basic Maintenance Requirements

.1 Common Maintenance Tasks
2 Assembly items
.1 Common Fasteners
.2 Common Bolts, Nuts and screws
.3 Common Tools and their applications
1 Introduction
On board, you will be assisting others in maintenance work, operations and watch keeping.
The foremost of any maintenance work, next to concepts of safety, is the knowledge of all kinds
of tools, their proper use, and upkeep. Many a times your superior will ask you to pass on or bring
a particular tool from the workshop, and you are expected to do it promptly.
The quality of discipline and maintenance on a ship can actually be judged by the way tools have
been stored, and their condition. You will experience that much harm to the machinery is caused
by using improper tools. Similarly, much damage is done by application of excessive force in dis-
mantling or assembling components.
You can develop proper habits for self, and not be influenced by wrong habits of others.
We are not in a position to give exact instructions on maintenance work that you will be asked to
carry out, but you will learn much during the practical sessions in the workshop.
Although Chief Engineer is overall in charge of the operation and maintenance of machinery, the
work load is distributed among all engineers. Some of the responsibilities of maintenance of
equipment on deck come under Deck Department as well.
• Generally, Second Engineer (or First Assistant Engineer) is the person who executes main-
tenance plans under the instructions of Chief Engineer. Similarly, the entire workload is
shared with other engineers who carry responsibility for specific items under the supervi-
sion of the Second Engineer.
Most common maintenance tasks have been listed below. You will be learning some of these tasks
during your training at the workshop as per the Pracdcal Training Record Book that provides the
minimum requirements. You can learn much more by own interest.

part 1 Section 2 Chapter 3 - Maintenance & Workshop Practice 147
pumps and valves

a) Overhaul globe valve.
b) Overhaul sluice valve or a butterfly valve in place
c) Complete overhaul (including inspection) of centrifugal pumps
d) Overhaul gear pump
e) Overhaul screw pump
Heat exchangers (Inspection, Cleaning, and Pressure Testing)

a) Air Cooler
b) 1.0 . Cooler
c) F.W. Cooler
d) Stearn Condenser
e) Fridge Condenser
f) Oil heaters
Filters (Inspection and Cleaning)

a) Cleaning Fuel filters for A/E, M/E, Boilers, purifiers , and oil transfer pumps
b) Cleaning of L.O. filters for A/E , M/E , and hydraulic systems
c) Air filters on air compressors and for turbo-chargers of ME/ and A/E.
Air Compressors
a) Inspection and overhauling suction and delivery valves;
b) Crankcase inspection, oil change, and cleaning of oil filter.
Purifiers
a) Changing centrifugal clutch pads;
b) Inspection of gear case;
c) Overhauling manual/auto de-sludge system;
d) Cleaning of bowl and discs.
Oil fired boiler/Exhaust gas economiser

a) Overhauling a gauge glass
b) Overhauling oil burner
c) Rectifying faults with operating system
d) Overhauling a feed water regulator
e) Overhauling fittings on steam line
fJ Renewing gland packing and joints
g) Repairing leaky pipes
h) External inspection
i) Internal cleaning and inspection of water and steam drums
j) Inspection and cleaning of furnace and cleaning of smoke tubes
Maintenance work on Diesel Generator Engine

a) Crankcase inspection;
b) Inspection of bearings and taking bearing clearances;
c) Taking crankshaft deflection ;
d) Overhauling cylinder head and mountings;
b
l
148 Chapter 3 - Maintenance & Workshop Practice Part 1 Section 2
e) Checking cylinder and its bore during major overhaul;

f) Inspecting piston and connecting rod;
g) Overhauling fuel injector;
h) Overhauling fuel pumps;
i) Inspection and cleaning of scavenge and exhaust manifolds;
j) Ovehauling of turbo charger;
k) Cleaning and pressure testing of scavenge air cooler;
1) Cleaning and pressure testing of jacket water and lube oil cooler.
Main Engine
a) Overhauling and pressure testing of fuel injectors
b) Overhauling cylinder head valves
c) Overhauling exhaust valves
d) Routine maintenance of turbo-chargers
e) Preparation before commencing major overhaul of a unit.
Control system and equipment

a) Testing controls for air compressor
b) Routine maintenance on hydraulic system
c) Tracing & rectifying faults in the pneumatically controlled devices
d) Tracing and rectifying faults in electronic control system
e) Testing boiler burner control system and rectifying faults.
Electrical system & equipment

a) Tracing faults on accommodation lighting
b) Tracing faults on deck machinery items
c) Detecting and rectifying earth fault
d) Routine maintenance on alternator
e) Overhauling an electric motor
f) Routine maintenance on batteries
g) Routine maintenance on starters
h) Routine maintenance on main switch board
Deck Machinery
a) Routine inspection and maintenance of Windlass/Mooring winches;
b) Routine maintenance on deck crane or winches;
c) Routine inspection and maintenance of life boat davit gear;
***************************************

part 1 Section 2 Chapter 3 - Maintenance & Workshop Practice 149
3 Assembly items
Almost since the ?-awn of civiliz~tion, man has used fasteners to hold together th e things he
makes. Probably fu st came rope-like vines or reeds, leather thongs and simple wooden pegs.
Gradually, as the need ~ose, he_ developed other more sophisticated fasten ers until now there is
a host of them - some simple like buttons , safety pins , zippers , paper clips, nails; oth ers more
complicated or developed for a special need such as high strength bolts, lock n uts, and keys .
®Button
© m()m
Bolt and Nut
§::
~ 2)
Paper Clip Copper Pin
~ s;.-
L j]~
Nail
Keys
Why are fasteners used?
Fasteners are used today in manufactured products for a number of very important reasons:
Many components and assemblies cannot be made in one piece; they must be made of two or
more parts assembled and held together by fasteners.
Fasteners also simplify the jobs of maintenance and repair; by removing the fasteners, an assem-
bly can be separated into the individual parts for inspection, repair or replacement.
Many fasteners also serve as safety devices. Such items as lock washers, cotter pins, lock wire,
jam nuts assure that an assembly, once put together, will stay that way with little possibility of
its coming apart.
Common fasteners
Fasteners must have many qualities
Fasteners must be carefully made out of high quality materials. They must be strong enough to
hold the components together and yet easy to remove or install, and capable of being used over
and over.
Many fasteners ;must stand vibrations without loosening, must be unaffected by extremes in tem-
perature, must be corrosion resistant, and must last as long as the parts they join.
Because the right fastener is so important, a good mechanic will make sure that the ones he uses
are of the right type, size and quality - and he will remove and install them in the correct man-
ner, using proper tools. He will read and follow all available service information provided by the
manufacturer in shop and technical manual.

150 Chapter 3 - Maintenance & Workshop Practice Part 1 Secti·
on 2
Common bolt and screws
Bolts are usually used in plain holes drilled Head

Threads
through the parts being fastened. The bolt is
held in place with a mating nut. In contrast,
screws are normally used in threaded holes,
without a nut.
A bolt or screw is a length of metal rod with a
head and a body. The head is usually round,
D- Body
SQUARE HEAD BOLT

square or hexagonal. The body of a bolt has
external helical ribs , called threads" as shown
in the diagram. The top of the rib is called the Head
Threads
crest, or thread tip. The bottom of the groove
is called the thread root. Threads are made by
cutting or by forming with a die. Die-formed
or rolled threads are stronger than cut threads.
(Because of cold forming)
Body
HEXAGON HEAD BOLT
Root
Crest
I
How to measure screws and bolts?
Bolt length
♦
Bolt
Size
t
Flat Head
The size of a bolt is determined by the diameter of the crest of the threads. The length of a com-
mon bolt is determined by measuring from the bottom of the head to the end of the threads.
Some bolts (like flat headed countersunk bolts) are measured slightly differently.
A bolt head is measured across flats. Head size determines what size of wrench or socket must be
used to turn or hold the bolt.
For example, a 13mm wrench is needed to turn an 8-mm hex bolt.

part 1 Section 2 Ch apter 3 _ M · t
am enance & Workshop Practice 151
Thread
Guage
I ~
■i~i_l__,,~
Threads on metric threaded fasteners are measured by the distance between threads (pitch) in
millimeters. (Imperial: counting the number per inch). Also, thread gauges are available that
match the bolt thread against those on the gauge. There is a separate gauge for each size.
Some threads are coarse with deep grooves and are used for most applications. Other threads
are finer, with shallower grooves. Bolts with finer threads are used only under special condi-
tjons where coarse-threaded bolts are not suitable. For example, when the parts being fastened
have thin walls.
-
-I l-1.2s mm
Common Bolts and Screws
Bolts and screws normally have right-hand

threads; that is, they are turned to the right in
a clockwise manner when they are threaded
into a nut or threaded body part.
In a few cases bolts screws and nuts with

left-hand threads are ~eeded. A turnbuckle is
one example of right~and left -hand thread in
use.
Right Left
Hand Hand
Threads Threads
. •ng and Human Relations

. Marine Engmeen
Seamans h 1p,
Part 1 Section 2
Chapter 3 - Maintenance & Workshop Practice
152
Left-hand bolts and nuts are also used when

rotary motion may tend to spin them loose.
The spindle and nut of a sanding attachment
for an electric drill is an example.
The general definition of a bolt is an external-

ly threaded fastener that is inserted thr?ugh
holes in an assembly and tightened with a Left Hand
Threads
nut. A screw is an externally threaded fasten-
er that is inserted into a threaded hole and
tightened or released by turning its head.
Should an assembly fail, it is better that the

screw break than to have the internal thread
stripped from the hole. It is generally easier to
remove a broken screw than to drill and tap
for a larger screw size.
Diameter
Combined thread a ~ n d
Stud bolts
Stud bolts have threads on both ends. They rs---l Grip length
I• C
are used where one end is semi-permanently
screwed into a threaded hole.
Coarse
nmnm~mmn~1
Stud Nut
End End
w w
Oval head
Flat slotted
~Clutch
Head
~ Pan head
~
Cross recessed
flat head
~
Hex slotted
head
Cap screws
Capscrews are made with a variety of different head shapes. They are manufactured with
coarse, fine or special threads. The strength of the screws depends mainly on the kind of mate-
rial used. (Aluminium, Brass, Steel, etc.)

Chapter 3
- M amtenance
• & Wor k sh op Practice
part 1 Section 2
153
CoJ111IlOll tools and their application

Open end spanner Allen
Screw Crossed recessed
Key Driver Screw Driver
0
External Hexagon
Head
@ CID
Internal Hex
Recess Head
Slotted
Head
~
Cross-Recessed
Head (Phillips)
I II
~~
Hex-Head Bolt Hex Socket Slotted Head Pan Head Screw

Heat Cap Countersunk
Screw Screw
Hex and square nuts
Themot
int s common nuts are made of steel and are hexagon or square. They have coarse or fine
ga:r:~l thr~ads that correspond to those of the bolt. Threads can be determined with a thread
chg t)US t like bolts or screws, as long as the nut is not too small. The corners of some nuts are
do~ ered (beveled) on one side, others on both sides, so they can be installed with either side
insi~ ~uts have three important dimensions. The thi~kness,_ the_ d_istance across flats, and the
diameter, which is the same as that of the bolt with which it is to be used.

-,
Jam or thin nuts (locking nut)

Jam Nut
One way to lock a threaded part in place is
with a jam nut. Usually a jam nut is thinner
than a full nut. The "full nut" is designed to
take the load while "Jam nut" is used for lock-
ing. A common application of jam nuts is on
control linkage, such as the steering tie rod on
a car. Once the adjustment is made, the jam
nut is tightened against the rod end to lock the
adjustment.
Castellated and slotted nuts
There are many applications where it is nec-

essary to secure a nut in place so it can't pos-
sibly come loose. For this purpose castellated
Castle Nut Slotted Nut
and slotted nuts are available. As you can see
from the illustration, the top part of the castle
nut is smaller in diameter than the body of the
~
nut. A slotted nut is simply a hex nut with
slots.
Pinbeing
Both nuts are used with bolts having a hole inserted
Pin being
drilled through the end. When the nut is tight- secured
ened onto, the bolt, a cotter pin is inserted

through the slots and hole to hold the nut '
firmly in place.
Castle and slotted nuts are identified by thick-

ness and width across flats as well as by the
thread diameter.
Self - locking nuts
Some nuts, once tightened, stay firmly in

place because of the way they're made.
There are many types of these lock nuts, uti-

lizing many ingenious means of staying tight.
The ones that are most commonly called pre- Prevailing Torque Lock Nut
vailing - torque and plastic-insert nuts.
A prevailing - torque nut is, by definition, one that is frictionally resistant to rotation due to a
self contained prevailing-torque feature. This simply means that they grip the mating threads.
There are many ways of doing this. One popular prevailing - torque nut resembles a castle nut,
but the top is split into sectors bent inward. When the nut is threaded onto a bolt, the sectors
are forced outward and grip the bolt tightly. Prevailing - torque nuts can be reused over and
over.

section 2 Chapter 3 - Maintenance & Workshop Practice 1 55
part 1
Lock Nuts
Nylon
Plastic insert nuts Insert
These nuts, wh ich are actually _a special type

f prevailing-torqu e nut, contam a relatively
~oft collar of unthreaded material built into
the head. The collar m ay consist of or a plas-
tic such as nylon. This nuts are also called
NYLOCK nuts.
Plastic Insert
When the nut is threaded onto a bolt the Lock Nut
threads are impressed into the collar. Being
elastic, the collar has the tendency to return to
its original shape when removed so this nut
can be reused many times.
Removing stubborn nuts and bolts
Sometimes, due to rust, dirt, or other corrosion, nuts become very difficult to remove. Some
workshops have a power impact wrench or impact driver that can be used to loosen these hard-
to-remove nuts and bolts. If you don't have an impact wrench or driver, and the location of the
n~t permits, try a striking wrench. Sometimes hard-to-get-to nuts and bolts can be loosened
with penetrating oil or special liquids made for this purpose.
Heat can also be used. However, heat can destroy heat treatment of a hardened bolt or nut, as
Well as that in the surrounding area, so gas torches should be used judiciously.
If all else fails, a sharp chisel or a hacksaw can be used, if care is taken not to damage other
Parts.
Hacksaw----1

Washers
Plain Washers
- A plain washer is simply a steel disk with a

hole through the center. Though simple parts , Bolt O.D. Actual
washers are very important in many applica- 0 .D.
tions .
When used under the head of a bolt, or under

l
a nut, a plain washer distributes the load over
an area larger than the head of the bolt or nut,
thus reducing the stresses in the fastened
parts that would otherwise exist. Washers also
protect the surfaces of fastened parts from
damage that might occur without them when
a bolt is tightened.
Plain
Plain washers are identified by their outside Washer
diameter and diameter of the bolt size rather
than the actual diameter of the a little oversize
(0.4 to 3 mm) so the washer will slide easily
over the body of the bolt.
Usually washer thickness is given in millime-

ters. Sometimes inch-size washer thickness is
specified by the gauge of the steel from which
it is stamped. The larger the gauge number, the
thinner the washer. Some typical metric wash-
er thicknesses in mm are 0.6 , 1, 1.2, 1.6, 2, 2.5.
Helical Spring Washers
A frequently used method of keeping nuts and

bolts tight, especially when they are subject to
machine vibration, is the use of helical spring
washers. Lock
These washers are made of tough, spring steel. Washer
Loose Tight
At one point they are split and one end of the (Washer Grips)
split is bent up.
Usually lock washers are placed under a nut but they can also be used under a bolt head.
When the nut or bolt is tightened, the section of the washer that is bent up grips the nut or bolt
head and prevents it from turning back.
Like plain washers, the inside diameter of lock washers is expressed by screw diameter, rather
than the washer inside diameter which is slightly larger so the washer will slide easily over the
bolt.
Metric lock washers are identified by nominal screw (thread) diameter in millimeters.

-
part 1 s ection 2 Ch apter 3 - Maintenance & Workshop Practice 157
External Internal External &

lntrnal
Toothed Lock Washers
When special holding power is required, a toothed lock washer is often used becaus e it has
many sharp, heat-treated teeth to dig into the surfaces pressing against it, preventing the nut
from becoming slack.
These washers (often known by their trade name, "Shakeproof' may have external (outside)
teeth or internal (inside) teeth. Some have both internal and external teeth for extra holding
ability.
({ m
Dowel Pin
~
c-----rn
Pin
Taper
Spring Locking
Pin
Pin
Pins
Few manufacturers of machines and similar products could get along without pins of one kind
or another. In their many forms , pins are convenient fasteners, utilized in many ways.
Clevis or headed pins

The simplest pin, perhaps, is a headed pin,
sometimes called a clevis pin because it is
used to attach a part to a U-shaped yoke 4---~
known as a clevis.
Headed pins are usually drilled on the end

opposite the head for insertion of a cotter pin
?r one of several types of special "conven-
ience' pins.

Part 1 Section 2
158
Pin
Governor
Weight
nch
\ \\
Pivot Pins
Some pins serve as small axles on which parts may pivot. Pivot pins are usually headless and
are drilled or grooved for cotter pins or snap rings.
These pins require exact fitting and are often tight in their holes. Their diameters may be
expressed in hundredths of a millimeter instead of fractions.
When tight-fitting pins are to be removed, they must be driven out with a hammer and pin
punch that is nearly the size of the pin.
Pins are often staked in place so they won't fallout. A small center punch is used for this pur-
pose. Striking the punch with a hammer "upsets" the pin and causes it to swell slightly, press-
ing it firmly against the sides of the bore.
Taper Pins
Parts that must fit tightly are often fastened wii;,
<:).#'
together with a taper pin. The taper helps to
line up the holes in the parts being assembled. ·~'
~Li~
o~rS'
--
~~~
The pin is driven into a specially reamed hole 0
until it is fully seated. Standard inch-size

taper pins taper at the rate of 1 :48 and are des- i
ignated by overall length and the diameter of
the large end. Standard metric pins taper at a
rate of 1:50 and are designated by overall
length (mm) and diameter of small end (in
~'<
Nominal Diameter
mm). of Metric Pin
Taper pins are driven out with a hammer and

a punch held against the small end of the pin.

·----
part 1 Section 2
159
Dowel Pins
Dowel pins are frequently used to assure that
fastened parts align exactly as they are sup-
posed to, and to make parts alignment easier,
during reassembling after overhaul.
A dowel pin is a tiny bit larger in diameter

than the hole into which it is to go, so it must
be pressed or driven in. Once in place the
press fit assures that the pin will not come
out.
The outer end of a dowel pin projects above
the surface of the part into which it is pressed,
and mates with other holes in the parts to be
assembled.
The nominal diameter of a metric dowel pin is

the size of the hole the pin is designed to fit.
The actual diameter is slightly oversized to
assure a press fit. Metric diameters range from
3 mm to 100 mm.
Dowel pins are usually permanently installed

and need not be replaced unless they are dam-
aged.
Spring Pins
Spring pins, often called rollpins, give manu-
facturers a quick, convenient, inexpensive
means of fastening parts where loads are not
un-duly great.
Slotted spring pins are hollow cylinders of

spring steel. They are split lengthwise and
chamfered on both ends for easier "starts".
Metric slotted spring pins may be chamfered
on only one end. Coiled springs are rolled up
spring steel chamfered on both ends.
These pins are made slightly oversize so when they are driven or pressed into place they are
compressed and their attempts to expand hold the parts firmly in place.
To remove a spring pin, drive it out of its hole with a punch just a little smaller in diameter
than the hole.

.
Chapter 3 - Maintenance & Workshop Practice Part 1 Sect·
160
ion 2
Spring Locking Pins
~
~. Spring
~Length ~I Spring Locking
Pins Locking
Pin
These simple pins, which come in various shapes and sizes, are useful when parts must be sep-
arated for operating adjustments, or when attachments are installed and then removed when
they are no longer needed
Usually a spring locking pin is inserted into a hole drilled through a clevis pin after the clevis
pin has been installed to hold parts together.
Spring locking pins are measured by the size of wire from which they are made, and by the dis-
tance from the center of the top loop to the end of the point.
Cotter Pins or Split Pins

These simple pins are used to hold a nut and Nut
bolt tightly together and to keep the nut from
coming off.
The cotter pin is slipped between the nut slots

and through a hole in the end of the bolt.
Cotter pins are made of soft metal so the Cotter Pin

prongs can be bent around the nut. or Split pin
When used with a castle nut the prongs are

usually bent back against the rounded nut top.
Correct
When a cotter pin is used with a slotted nut Bend Prongs
(on an engine connecting rod, for instance),
one prong is usually bent up and over the end
of the bolt.
If the hole in the bolt does not line up with the

nut slots when the nut is tightened, the nut
must be tightened just enough more so the pin Slotted Nut
can be inserted.

Part 1 Section 2 Chapter 3 - Mainten ance & Workshop Practice 161
Lockwires
Sometimes lock or safety wire can be used to
anchor bolts in place. The bolts for this pur-
pose have holes drilled through their heads.
The lockwire is pushed through the boltholes
and twisted in such a way that the wire will
tighten if the bolt loosens.
Occasionally it is important to prevent unau-

thorized tampering with critical mechanisms
or adjustments. In such a case a seal is
attached to the lockwire as it is twisted; the
seal must be broken before the lockwire can
be removed.
Flat metal locks
Another way of locking bolts or nuts to keep

them from turning is with flat metal locks.
These are usually made of soft metal,
although some are hardened. Some have spe-
cial shapes for specific applications.
One common usage for metal locks is for lock-

ing flywheel bolts; the locks are placed under
the bolt heads.
Locks have ears that are bent up against one of

the bolt head flats with a cold chisel or punch.
Some locks are placed on the corners of metal

parts; these require that an ear be bent down-
ward, too, against a flat edge - not a rounded
corner, as shown.
Seam anship, Marine Engineering and Human Relations

162 Chapter 3 - Maintenance & Workshop Practice Part 1 Section
2
Lock Rings / Snap Rings
There are many applications where there is a

need for a removable shoulder to accurately
locate, retain, or lock components on shafts
and in bores and housings. A good example is
the wrist pin that connects the connecting rod
to the piston in an internal combustion
engine.
Snap
The wrist pin is kept from slipping out of its Ring
bore by a spring steel snap ring at each end.
The snap ring fits into a circular groove in the
wrist pin hole in the piston wall near the end
of the pin.
Because these rings keep parts in place, they

are often called retaining rings or lock rings.
There are two basic styles of snap rings: inter-

nal and external.
External snap rings
External snap rings are installed around the

shaft, rather than in a groove around a hole.
Many bearings are located on and locked to
their shafts this way.
Most external rings are removed and installed
by means of a special plier. The jaws on these
pliers open up when the handles are squeezed
instead of closing as do the jaws on regular
pliers.
Small shafts are often locked in place with an

external "E" snap ring, usually removed or
installed with ordinary pliers.
Snap rings can be formed out of wire or can be

punched from flat material. They are general-
ly reusable unless damaged or broken.

p
Part 1 Section 2 Chap ter 3 - Main tenance & Workshop Practice 163
000~
Internal Prong
Type
Internal
Hole Type
External
Hole Type
External
"E"Type
Internal snap rings

Internal snap rings, like the wrist pin retainer, fit inside a hole an d so are called "internal".
The pro~g - typ~ i_s re~oved o~ installed by grasping the two prongs with pliers and compress-
ing the rmg until it slips from its groove. To install the ring, it is compressed and inserted into
its groove. When released, it will spring outward and firmly seat itself in the groove.
Keys
Square or rectangular key
One very common way of holding a gear, pul-
ley or other part to a shaft is by means of a key.
In some ways the name is misleading because
these fasteners do not look like keys in the
usual sense. Most are simple lengths of steel
cut from square or rectangular stock, or round
stock cut in half.
The gear or other part, and the shaft have a

groove cut into them. These grooves are called
keyways.
The square or rectangular key is driven into
· the keyway when both grooves are matched.
When driving a key in place care must be
taken to avoid "upsetting" the end of the key
(that is, causing a bulge) . It is always best to
~
Key
drive keys in place with a "soft" of plastic
hammer.
Straight
Slot
~Woodruff Key
Key lnstalle~
Between
Mating
Parts
Semicircular
Slot
Woodruff Keys
A semicircular key made from round stock cut i~ half (lik~ ~ half moon) is ca_lled a Woodruff
key. This key is used to lock the shaft and gear m one posit10n, rather than simply to anchor
the gear onto the shaft.
When a Woodruff key is to be used, a semicircul_ar keyway is cut in the shaft. The gear to be
mated to the shaft has a straight slot cut through it.

Ch apter 3 - Maintenance & Workshop Practice Part 1 Section
2
164
Bearing Pullers
Bearing Puller (three legged)

Bearing Puller (two legged)
Stud Extractor
The most common extractor, which has
become known as an "Ezy-Out" is a hardened,
tapered rod with coarse, sharp, left-handed
spirals, resembling threads. A "flat" on top is
provided so the tool can be turned with a
wrench.
Stud
To use the extractor a hole is drilled in the Extractor
exact center of the broken stud or bolt. This
must be done carefully; most studs are hard
and difficult to drill. Extractor kits are avail-
able with guides that center the drill in the
hole and keep it straight.
The extractor is inserted into the hole where it

securely bites into the stud and allows it to be
unscrewed.
Extractor sets contain extractors in several

sizes, guides in several sizes to center the
drill , and other useful items.
NOTE:
Although these tools are commonly called
stud removers, they can also be used to
remove broken bolts and cap screws.

Chapter 4 - Auxiliary Machinery
Auxiliary Machinery & Equipment & mai'nt
·1· . enance work
1. Auxi iary Equipment
2. Valves
3. Pumps and Pumping Systems
4. Joints and Gland Packing
5. Filters
6. Centrifugal separators
7. Other Auxiliaries
8. Boiler and Steam System
1 Auxiliary Equipment
.1 Identify a~d state function of strainers , filters , heat exchangers - coolers and heaters .
. 2 Name ma1or parts of strainers, filters, heat exchangers - coolers and heaters
2 Valves
.1 Identify common types of valves and cocks used on board (globe, sluice or gate , but-
terfly, spring loaded, non return globe, float valve, taper cock, and ball cocks .
. 2 Identify major components of each type of valve and cock.
.3 State procedures for opening and closing of valves for operation (globe valves, gate
valve, butterfly valve, using a wheel spanner)
.4 State function of drain valves and drain cocks for air bottles, oil fuel tanks , expansion
tanks and level gauges.
3 Pumps and Pumping Systems

.1 Identify common types of pumps in the Engine Room (centrifugal, reciprocating, gear,
screw pump)
.2 State the pumps that come under the category of 'positive displacement pump' and
their peculiarity.
.3 State precautions necessary before starting a pump
.4 List major pumping systems in the engine room (Bilge, ballast, deck wash and fire
supply, domestic fresh water, domestic sea water, jacket cooling water system, boiler
feed water system, compressed air system)
.5 State the purpose of each of the pumping _system mention_ed in .4 above
.6 State observations to be made on a operating pump and au compressor
4 Joints and gland packing: . . . .

.1 Identify types of joints used for pipe line and equipment having water, 011, au, steam,
exhaust gases, and hot water. .
.2 Identify type of packing material used for packmg glands of vales or pumps for sea
water, steam, and oil.
.3 Joints of rubber or of stiff material suited for round or sq1:are flanges.
s for cutting packing and for packmg a gland.
.4 Demons t ra t e proce dure . k · 1·
• t b t ken before commencing repau wor on a pipe me or compo-
.5 State precaut10ns o e a
nents in situ.
. M . Engineering and Human Relations

Seamans h i p , anne
Chapter 4 - Auxiliary Machinery Part 1 Section
166 2
.6 Iden tify soft metal join ts and 'O' rings and state care to be taken on th ese du ring main-
tenance . b 'l l'
.7 Carry out temp orary repair to a leaky pipe using clamps or JU 1 ee c 1P ·
5 Filters
.1 Identify name of oil filters , and air filters u sed on board .
.2 Identify parts of a bucket type filter and a duplex type filter
.3 States risks involve d in cleaning filters on a running machinery .
.4 Lists precautions to be taken before opening a filter on a stand by machine .
. 5 States checks to be made on a filter during cleaning and re-assembly .
. 6 State precautions to be taken while working on a hot filter.
6 Centrifugal separators
.1 Identify and state purpose of a centrifugal separator
.2 Assist in opening up purifiers and cleaning disc stack.
7 Other Auxiliaries:
.1 State functions of other auxiliaries and services such as sewage system, incinerators,
refrigeration and air conditioning,
8 Boiler and Steam System

.1 State uses of steam on board .
.2 State major mountings on the water and steam side (Main steam stop valve, gauge
glasses , safety valves, feed valve, blow down valve, air vent, pr gauge connection)
.3 State basic operation of boiler (fuel supply, air supply, feed water supply, water level
regulators, fuel control and cut outs)
.4 State observations to be made on an operating boiler
.5 State risks involved in operating an oil fired boiler
.6 State the meaning of 'back fire', 'over pressure', 'low low water level'
9 Protection and preservation: (also covered in Part 2)

.1 Use chipping hammers , wire brushes, and power tools in removing rust .
.2 Prepare surface for painting - cleaning and degreasing .
.3 Paint surfaces using paint brushes, roller
.4 Identify components and function of air spray machine
.5 Explains advantages of using air spray machines
.6 States risks involved in using air spray machines.
10 Compressed air for auxiliary purposes

.1 State different uses of compressed air for auxiliary purposes. (cleaning components
and portable machines)
.2 State risks involved in working with compressed air for auxiliary purposes .
.3 Demonstrates use of compressed in cleaning filters and other components
.4 State the fitti ng provided for draining the water from the air bottle

part 1 Section 2 Chapter 4 A ·1·
- ux1 1ary Machinery 167
Maintenanc_e of equipment to be learnt during

practicle session at the workshop
Introduction
The word 'auxiliary' m ean s giving assistance or support; aiding; h elping. It also means sub-
sidiary, supplementary, and additional. All systems and machinery aiding the main engine or
main propulsion gear to perform its function could be grouped together as "Auxiliaries". Thus ,
the term 'Au xiliary Machinery' has a very wide application on board. It can refer to just one p iece
of machinery e.g., bilge pump, filter, or a group of items forming a system (interacting, inter-relat -
ed, or interdependent elements or components forming a whole) e.g. fresh water gen erator, boil-
er, etc. There are several machinery items which functions for ships crew, passengers, naviga-
tion, and for cargo operations. We will draw your attention to at least the following:
1. Valves and Pumps

2. Oil Purification Equipment
3. Boiler.
4. Air compressors
5. Fresh Water Generator
6. Domestic Fresh Water Supply (Hydrophore)
7. Domestic Sea Water Supply (Hydrophore)
8. Sewage treatment plant
9. Engine Room Ventilation
10. Domestic Fridge
11. Air Conditioning
12 . Deck Machinery & Cargo Handling Gear
13. Generator Prime Movers
Let us first look at the some of the most comman 'Auxiliary Machinery'
I
Air Compressors
I Pumps
I
AUXILIARY
Evaporator
MACHINERY
I Purifiers
Boiler
Heat Exchangers

. Marine Engmeenng
Seamans h 1p,
Part 1 Section
Chapter 4 _ Auxiliary Machinery 2
168
Valves and Cocks used on board
1. Introduction - Valves on board
Valves & cocks are the most used and the most important items on board · They come in variety
of sizes, shapes, and operating mechanism to serve the required purpose.
Valves are the most important and common in any system that has to deal_ with flo': of fluids_ Oiq-
uids or gases). Basic requirement in a system is to control the flow to achieve re~mred functions.
Valves are designed and incorporated in a system to achieve one or more functwns that are list-
ed below.
2. Functions:
a. Stop or allow flow;
b. Vary the amount of flow;
c. Allow flow only in one direction;
d. Direct flow in desired directions;
e. Relieve pressure hence preventing damage or failure or;
f. With other devices maintain pressure or level, or temperature.
Flow control or interruption is done in cocks by rotating the plug, and in valves by lowering rais-
ing or rotating a disc in relation to a seating surface or by controlling the movement of a ball.
These fittings have bodies furnished with flanged or screwed ends (or ends prepared by welding)
for connection to the joining pipes.
Valves & cocks used on board
3. Types of Valves and their Applications
Types of Valves and their Applications

Type Application Remarks
1. Globe To vary flow accurate- Most common type of valve in the engine
ly _a nd where positive room, accommodation, and on the deck for
shut off is required general applications of all fluids (oil, water,
steam, air). Screwed down type stop valve or
screw down non-return arrangement)
2. Gate To allow or stop flow When full open, it allows free flow with least
resistance. Rarely for varying flow because
accurate control of flow is not possible. When
partly open, high velocity of flow and vibra-
tion can cause erosion and breakage of discs
and seats. Commonly used for ballast lines,
cargo lines on oil tankers, S.W. line valves in
E.R, bunker lines. -
3. Cock (tapered As above where quick Not suitable for varying flow. Used for steam,
or ball type) shut off is required water, oil and gas. Widely used cargo or line
cargo lines of chemical carriers and liquefied
gas carriers.

part 1 Section 2 Chapter 4 - A uxi•i·iary Machinery 169
st~o~p;,~o~r::--v~a~r=y:--r,N
4,7 1BB:Uutttttleurf.flGyr -- - ~Tf<oJaaJlllco~w--;;,~ ~ o-w----,b_e_c_o_m i_n_g_a_ c_o_m_m
_ o_11_t_y_p_e_ o--=f-v-a--.lv
--- -e o-n-
flow usually involving
board for almost any application in the
low pressure
engine room as well as on deck for oil
cargo. Compact and reliable.
Check To prevent backflow Such valves must be mounted in exactly
a) Lift (allows flow in one vertical. Commonly used on bilge lines,
b) Swing direction only _ non- discharge side of pumps to prevent back
c) Ball return type)
flow, overboard discharge, feed check valve
on boiler, etc.
Flap or swing checks must always be able
to close freely and positively by gravity.
Commonly used for overboard drains from
the decks and accommodation (scuppers) .
6. Spring loaded Relieve pressure or Pressure relief valves on cylinder heads of
vacuum, remote shut main engine - compressors - crank case
off or open doors - pump discharges etc., safety valves
on boilers, air bottles. Pneumatically or
hydraulically operated valves, quick clos-
ing or quick opening valves on fuel tanks,
pressure reducing valves on air or steam
lines.
There other types of valves you could learn about.
7. Diaphragm To allow, stop , or vary Working parts of valve are isolated from
flow fluid . Simple to maintain. For corrosive,
viscous fluids. slurries, beverages, water,
gases and compressed air.
8. Pilot To direct flow Automatic sequential control applications
using pneumatics and hydraulics. For start-
ing system of main engine, turbines, cargo
handling equipment, etc.
9. Solenoid valve Electrically operated Commonly used for automatic control sys-
remote shut off or tern for pneumatic - hydraulic - refrigerant
open. - oil or water lines in the ER, steering &
deck machinery.
4. Actuation of Valves
4.1 Handwheel Operated (Most common)
4.2 Lever Operated (Butterfly valve, Cocks)
4.3 Mechanically operated using springs, and cams
4.3.1 Using Springs (Safety Valve)
4.3.2 Using Cams (Inlet and exhaust valve of diesel engine)
4.4 Float Operated (Boiler water level control valv_e)
4.5 Temperature Sensitive (Control valves on coolmg system)
4.6 Electric Operated using Solenoid or Motors
4.6.1 Using Solenoids (Shut off valve on refrigeration system, control system)
4.6.1 Using Motor & Gear (Remote operation) .
4.7 Pneumatic or Hydraulically Operated (Remote operatwn)
4.8 Mechanically operated by cable/wire

S eamans h 1p,
Part 1 Section 2
170
5 Globe Valves (Screwed down stop valves or non-return valves)
The Figure shows cross-sectional view of a typical globe valve. You should recognise it immedi-
ately, as it is the most commonly used valve on board, and as a 'taps' in your cabin or at home.
A valve (circular disc) is lifted or lowered against a valve seat to allow or restrict the flow of fluid
from one side to the other. Valve body is of a shape of a globe with provision of flanges for attach-
ment to the pipes in the system. Valve disc is actuated by means of spindle which can be operat-
ed by turning the hand wheel or a remote control device.
This valve is very efficient in stopping flow completely i. e. w ithout leaks.
".alves and seats ~an wear due to erosion, corrosion or due to mechanical damage during opera-
trnn. However, discs an d seats can be reground or re-machined or replaced easily in the same
body of valve.
,,; ~ Handwheel
Handwheel
Yoke Bush
Yoke Bush Yoke
Yoke
Stem (Spindle)
Spindle (Stem)
Gland
Gland
Bonnet (Cover)
Bonnet
Gland Packing Gland Packing
Bonnet Gasket Bonnet Gasl<et
Back Seat Bush

Guide
Disk Stem Nut
Weld
Disk (valve) Disk (valve)
Body Seat Ring Body Seat Ring
Flange Flange
Body Body
Screwed down stop valves Screwed down non-return valves

Identify the difference between the two J

Part 1 Section 2
171
6 Gate Valves or Sluice Valve
The Figure shows the side view of a typical

'gate valve'. Another commonly used name of
this valve is 'sluice valve'. In this case the disc
is raised or lowered like in case of a globe
Valve Stem valve by the handwheel at the threaded part of
Spindle the spindle. It has advantage over the globe
valve for straight flow characteristic. Fluid
Valve can flow through the valve with little obstruc-
Casing tions, no change in direction and hence little
loss in pressure energy "pressure drop".
Valve
Seat

Seamans h 1p,
>
Chapter 4 - Auxiliary Machinery t'art 1 Section
2
172
7 Cock or Plug
Cocks have the advantage of being able to turn 'on' or turn 'off' or change connections for the flo
quickly (90", 180", 270"). Flow is permitted or prevented by rotating the plug within a close;
enveloping body. The plug may be cylindrical, .spherical or conical. Conical plugs being morey
common. The most common example of a cock 1s a tap.
Example of a three way cock
From D.O. From D.H.

Servoce Tank Servoce Tank
To Main Engine
Lubricant Screw
All sides shut
A Conical Plug (Cock)
A four way cock
A Ball valve
Seamanshi p, Marme
· Engineering and H
uman Relations
>
part 1 Section 2 Chapter 4 - Auxiliary Machinery 173
Butterfly Valves
8
Figure shows the side view of a butterfly valve. It is as simple as the cock and has the advan-
The
tage over the gate in
ft being able to allow full flow in ¼ turn of the "butterfly" which is only a disc
rnou n ted on a sha .
. usually intended to handle large flows like the gate valve is used in liquid cargo, ballast and
Jtis I t d' d . d
cooling piping system. ts ou stan mg a vantage is its compactness in terms of space occupie
in the pipeline.
Operating Mechanism (Gearbox or Wench)
Two Butterfly valve on a deck line
Valve
discharge
Shaft
. Manne
Seamanship, . Eng ineering and Human Relations
1
174 Chapter 4 - Auxiliary Machinery Part 1 Section 2
Identify each of the above items
9 Check Valves
Check valves allow flow in one direction only and close automatically on reversal of flow-hence
the other commonly used name, "non-return valves".
From the sketches, you can see that they all work on gravity.
Non-Return valves are fitted on the bilge line and ship side discharge to prevent water from acci-
dentally flowing back to the bilges.
In steam system, feed water is supplied to the boilers by a feed pump, to prevent water flowing
back from the boiler to the pump; a check valve is always fitted. To double check the returned
flow, a screwed down stop valve is also fitted in the boiler feed line, which can be operated man-
ually, if the check valve starts leacking.

Chapter 4 - Auxiliary Machinery 175
part 1 Section 2
Check Valve (Globe Type)
Cover Nuts
Cover
Cover Gasket
Check Valve (non-return) Globe Type
Cover - - - - - - - - - -
Cover Gasket- - - - - - - -
Cover Boit - - - - -
Hinge Pin
Body Seat
Ring - - -t-----1""""
Swing valve with shut off arrangement
Body_ _~~..;f,..;JE..S..'4~~~~~
(Storm Valve - Overboard Discharge from
Accommodation)
Ball Type Check Valve

176 Chapter 4 - Auxiliary Machinery Part 1 Sect·
ion 2
1 Introduction: Pumps on Board
Definition: A pump is a device that transfers energy to a fluid passing through it.
In practice, pumps change both the velocity and the pressure of the fluid passing through it h
ratio of these energy changes depends upon the type and the speed of the pump in use. 't e
2. Types of Pumps
Type of pump What it looks like On board

application
Reciprocating Bilge pump

(small), electric
drive
Centrifugal
pump S.W & F.W circu-
lating pumps for
main engine and
Auxiliary engine,
Fridge-A/C cool-
ing, Fire-General
Service-Bilge-
Ballast pumps,
Cargo Pumps on
tankers, Boiler
feed pump & cir-
culating pumps,
Domestic water
supply, (on some
ships as ME L.0.
pump).
Seamanship Mar· E . .
' me ngmeenng and Human Relations
Gear Pump Fuel oil and L.O.

purposes.
Transfer pumps,
Generator engines
pumps, Purifiers,
ME Fuel booster
pump, Stern tube
lubrication,
Hydraulic Drive,
etc.
Screw Pump ME lubricating

oil, (can be used
for F.O. transfer
purposes as well),
sludge pump (sin-
gle screw)
Eductors Vaccum Chamber For stripping of

ballast tanks, cre-
Water Supply ► Discharge ating vacuum in
fresh water gener-
ators, etc.
f
Inlet
. M an·ne Engineering and Human Relations

S eamans h 1p,
Chapter 4 - Auxiliary Machinery Part 1 Sect·
178 lOtq
Discharge
Bearing
and seal
-"4r-lnlet
Centrifugal Pump (horizontal)
Motor
Half Coupling
Top Cover
Casing
Wear ring
Centrifugal Pump (vertical)

>
part 1 Section 2 Chapter 4 - Auxiliary Machin ery 179
Dischar e
Suction Port
Drive Gear
Mounting Flange
Pressu re Port
Bush ings
Idler Gear
Suction
Gear Pump
Semi Rotary Pump (Reciprocating Type)
A similar pump is fitted on generator engines

for priming lube oil system before starting the
engine.
.
S eamans h 1p,
M ar1•ne Engineering and Human Relations
Chapter 4 - Auxiliary Machinery Part 1 Section 2
180
Air Compressor
.. - - - - - -- - - Suction filter
Water safety valve ----..
_ _ _ Cylinder head
Instrument panel
_ _ _ _ _ Safety valve (1st stage)
Breather cap
(oil port) - - - Cooler cover (1st stage)
Drain separator (1st stage)
Cooling water pump -....._ Air temperature switch
Magnetic Valve.. ----1:. - - - - - Pressure switch

Oil level guage _ _..,
- - - - - Drain Valve
Oil screen - - - - -
' - - - - - - Side cover
Oil filler element _ _ __,,
' - - - - - - - Auto Drain Trap
Oil drain plug _ _ _ ___,
~ - - - - - - - - Drain Valve
Oil safety valve - - - - - - . /
Oil release valve -----.J

- -- - - - Water checker
- - - - - Safety valve (2nd stage)
Delivery pipe
Motor-------
Cooler cover (2nd stage)
Drain Valve
' - - - - - - Side cover
' - - - - - - - - - Flywheel cover

part 1 Section 2 .
Chapter 4 - Auxi.1iary Machinery 181
/ Suction Filter
Cylinder Head
Instrumental Panel '
Safety Valve ( 1st Stage)
Cooler Cover (1st stage)
Water Safety Valve Drain Separator (1st stage
Air Temperature Switch
Cooling Water Pump
Pressure Switch
Tanabe Air Compressor
Protective
Cowl
Metal
Guaze
Air In
Compressor
Air Filter

Part 1 Sect·10112
182
Joints, Gaskets and Packings

Joints of soft material are used between two parts to ensure proper sealing e.g. pipe flanges, val
cover and valve body, cylinder head and cylinder etc. !oints need to _w ithsta~d.the operating le~'
peratures, pressures and fluid (Water, oil, steam, air, chemicals, etc) within the equipme
Different material and methods are used to make the joint suited for the purpose. nt.
Ring Type Joint Gasket
Ring Ty~e Join~s are commonly used on valve, pipe work assemblies and with some integrit
vessel JOmts. Rmg type are used to seal flanged connections subject to high pressures and te~
peratures.
Some of the material used are

• Rubber
• Compressed sheet
• Cork
e Felt
• Sponge
• Plastics
• Thermal materials
Variety of ready made joints for different purposes

packing
Soft packing is used _to preven_t leakage between the casing and rotating shafts of a pump, valves,
and machines. Packing matenal needs to withstand different conditions of pressures, tempera-
tures and quality of fluids.
Packing is placed in a stuffing box and retained in place by a gland. The packing gets worn and
gland needs to be tightened a bit to achieve the seal.
Modern pumps and rotating machinery have a ready m ade 'Mechanical Seal' made of carbon or
ceramic rings, springs, 0 rings, etc. Th ese seals are long lasting and self adjusting type.
Top View of Packing Ring Joints Bearing Puller (three legged)
Gland
Sleeve
/Gland Packing
Suction Side
Note:
To allow for expansion due to compression cut the
packing rings such as to leave a gap of about 1/4 of
thickness of packing
Soft packing
Seamansh1. p, M arme
. Engineering and Human Relations
Part 1 Section
184
Uses of Oils on Board:
Th e d"iagram below gives most common uses of oils on board a ship.

As Lubricants ----
As Fuel (ME, AE, compressors,
Diesel Oil and Heavy Oil purifiers , etc. )
-
Uses of Oils on Board:
-
For Power transmission
As heating medium (cranes, mooring
(In special application)
equipment, etc)
Fuel Oil
The fuel oil used in diesel engines on board is of very low quality and i~ ca~led H~~vy ~uel Oil
(HFO). ·It requires continuous heating to maintain its viscosity_- It con_tan1:s 1mpunhes like ash,
sediments, etc. and some water, which are harmful for the engme. This ml needs to be cleaned
before use in the engine.
Diesel oil used on board is of much inferior quality than that used in cars and generators ashore.
The common name for the diesel for ships is 'Marine Diesel Oil'.
Lubricating Oil (Lube Oil)
Lube Oil prevents wear and tear of machinery parts, and in the process continuously deteriorates.
Hence it has to be purified or renewed. The machinery used to purify lube oil is called Lube Oil
Purifier.
Oil cleaning and purification equipment
Strainers and Filters: Used for removing solid particles. They come in different designs,
size, and fineness of the filtering element.
Strainer is name given to the equipment that separates large particles such as sand and other solid
particles. These are fitted on the suction side of pumps.
Modern filters can remove very fine particles and are fitted on discharge side of pumps that sup-
ply heated oil to the diesel engine.
Centrifugal sepa~a~ors: com~only known as 'purifiers', are used for cleaning oils on board.
These ar~ ve~y ef~1c1ent machmes for removing water and solid suspended articles from fuel oils
and lubncatmg mls. p

part 1 Section 2 Chapter 4 - A uxiliary
. . Machinery 185
Bolt
Gut (Dog)
Upper Element Ring ,

Screen
Punching Plate
Body
Lower Element Ring
Drain Plug
Strainer and its parts
G-Spacing/Distance
Pieces
F-Filter Plates
-Filter
A-Filter Housing Plate
J..=1~
Small Fixed Plate . Spacing/
Distance Piece
B-Filter Element
J-Bottom Plug
Components of an Auto clean filter

Part 1 Section
186
Auto Clean Filter
Special air nozzle for cleaning filters with compressed air

part 1 Section 2 Chapter 4 - A u x1hary
.. Mach mery
' 187
~----~--
, '
----------~ t
A Centrifugal Separator (Oil purifier)
Bowl
Frame Cover
Frame
Motor
Horizongal
Shaft
Major components of a Centrifugal separator

Chapter 4 - Auxiliary Mach inery Part 1 Section 2
188
Set of Centrifugal separators in the engine room (Fuel oil, Diesel oil and Lube oil)
Fresh Water Generator (FWG)
Advantages of producing water on board:

• Ship can carry more cargo in place of water.
• Saving in cost of water when purchased from suppliers in port.
• Availability of high quality of water for use for boiler feed, and as coolant where required.
• When used for sanitary system it saves the cost of installation and maintenance of a sepa-
rate sea water supply system.
• Availability of high quality of water for cooking and drinking purposes.
• No risk of running out of water as long as the water can be produced on board.
Hence we have machinery on board called Fresh Water Generator which makes fresh water from
sea water.

[)
I
I
'
( l· .:~
' ,'
,
'
~
-~
@
1
i;J' I ~'.'".,~,.""
----- :.:c.i. / ' r;:,- ~~-~-
1 /
, ,,
;r~ (I
/M ' ~ ti!
I · :"
.,: -~t,t,
®
® ,)'
Fresh water generator on board
Domestic Fresh Water Supply
Fresh water supply is commonly arranged with a

Hydrophore system that consists of a pressure tank
and pressure switches for starting and stopping a
multistage pump. Pressure is maintained due to air
cushion above the water surface while the water
outlet is always submerged in water to prevent air
from escaping. Pressure in the system drops as the
~-~
-
.;·•,~~ a_.;:_-~
~ = "'-:':
water goes out, and at a set point, the pump starts
automatically to fill the tank. Pressure increases
with the rising level of water till another pressure
-~ , "5'
switch cuts off the pump at a set point. This process
works automatically requiring least attention.
For supply of hot water, separate connections to

different parts of the ship are provided with water
passing through a heater which usually operates
with steam, but is provided with electric heating
coils as an option. Temperature of water is con-
trolled through thermostatic control of steam sup-
ply valves or a thermostatically operated switch for
electric heater.
Quality of heating depends upon the condition of

heating coils, pressure of steam, rate of flow, and
response of the thermostat.

Part 1 Secti' orq
190
Domestic Sea Water Supply

. 'milar to that of the fresh water syste
t' purposes is si . f . Ill
Arrangement for seawater for d omes ic h Seawater is used mam 1Y or samtary sy
. tly from t e sea. h' s-
except that the pump gets water d uec . d 1·er more and mores ips are using fresh
A ment10ne ear i '
tern and for washing decks or spaces. s . lt deposits and marine growth.
water in place of seawater to minimize corroswn' sa '
Engine Room Ventilation

. •t circulation, exhaust and control. You need
Ventilation covers all aspects of supply of fresh au, i s . s locations within the engine roon-.
·
to appreciate ·
the importance of proper vent'lation
i . at vanou »1,
and action to be taken in case of fire in the engme room.

. . N aturaI Draft ' and Forced Draft.
. categories.
Ventilation falls under two maJor
Domestic Fridge
· food items
For carrying and stormg · to b e use d for crew, 1arge rooms are provided. Since different
·
food items · different
reqmre · temperatures for st orage, se parate rooms are for vegetables, meats ,
fish and dry items.
Air Conditioning
Air conditioning is an arrangement that controls the quality of air within a space, ~ither by c~ol-
ing or by heating as required. Ships have a central air circulation system for cooling or heatmg
similar to large spaces such as shopping malls and theaters.
On board ships, air is supplied by means oflarge axial flow fans, one each for Port and Starboard
side of accommodations. Air ducts from each side spread to different levels, and spaces. Each
branch (duct) is provided with flaps and dampers to control the flow.
For re-circulation, air is drawn back to the fans through strategically positioned openings, usual-
ly at the end of corridors. Amount of re-circulation is controlled by means of adjustable flaps.
Boiler (Steam Generator)
Boilers are pressure vessels in which steam is produced. On a diesel ship, steam is used for heat-
ing fuel oil for main engine, heating fuel storage tanks, for purification of oils, heating accommo-
dation air and water for domestic use. In Oil Tanker ships, high capacity boilers are fitted to heat
the cargo as required.
Water in the boiler is heated by burning fuel oil in a combustion chamber. Oil fuel is injected in
the form of fine spray and air is supplied through a fan and the mixture burns in the combustion
chamber through a bu_rner. Heat ~ets transferred to the water through steel tubes and water
becomes steam. Steam is collected m a steam space. Each boiler is designed to operate within the
maximum designed pressure. Steam is released through the steam stop valve and distributed
where needed. Steam condenses and returns back to the feed water tank for reuse.

part 1 Section 2 Chapter 4 - Auxiliary M ac h'mery 191
Steam is
produced and Steam
collected in the Distribution
boiler at a
pressure
A simple
steam
Water is pumped Goes to heaters
back to boiler cycle and tanks
Returns back as
water and
Lost water
collected in hot
Supplemented
well tank
from feed
water tank ►
Boiler Mountings:
Boiler Mountings are equipment mounted on the steam and water side boiler shell. The follow-
ing mountings are a must on a boiler
1) Steam stop valve: The function of this valve is to stop or allow the flow of steam
from the boiler to the steam distribution pipe, for distribution to the operating
systems including supply to turbines.
2) Two safety valves: The function of these valves is release steam to the atmos-
phere when the pressure within boiler reaches the maximum design pressure.
3) Two water level indicators (Gauge glasses): Its function is to show the level of
water in the boiler.
4) Feed check valves (one way): Allow the feed water under pressure to pass into
the boiler and to prevent any water escaping back.
5) Pressure gauge: Its function is to indicate the steam pressure of the boiler.
6) Blow off cock: Its function is to
a) to remove sediments( mud, impurities) collected at the bottom of the boiler
b) to empty the boiler when it has to be cl~aned.
c) to low er water level, if it becomes too high.
7) Man hole: Manhole is to provide an opening through which a m an can enter a
boiler fo r cleaning and inspection purposes.

Chapter 4 _ Auxiliary Machinery Part 1 Secti·01q
192
Safety cut outs: . 11 th b ner to p rev t d

· The boiler is fitted w ith safety cut outs which automatica Y st0 P e ur ' en a111age
to the b oiler.
The safety cut outs are:
• Low-low water level
• Fuel oil temp erature high or low
• Flame failure (loss of flame or p oor combustion then the bu rner cuts out)
Observations to be made on a running boiler:
When boiler is running the watch keeper has to check the following poi?"t~: .
• 1
Water level in the gauge glass (water level indicators). If the level it ~ becomrng low and
not coming up, inform the duty engineer immediately and start checking the hot well and
the operation of the feed pump.
• Quality of flame when viewed from the inspection window. It should be steady, bright,
golden yellow colour, not too long and not too short.
• The steam pressure gauge. When boiler is oil fired, the steam pressure is self-regulated;
however, when exhaust gas economiser (exhaust boiler) is connected, the pressure will fluc-
tuate and depend upon the main engine load and steam consumption.
• Fuel oil temperature and pressure
• Feed pump operation - pressure , vibration, leakage from the gland, and abnormal noise
• External signs of leakage of water or steam from pipes and boiler mounting.
Risks involved in operating an oil fired boiler:
• Though modern boilers are designed and provided with all necessary safety features, and
have very efficient control system, accidents have occurred due to negligence and poor
maintenance.
• The highest level of risk is due to manipulation with safety devices and automation.
• The o.ther major cause of serious accidents is due to leaky or dripping oil burner. The drip-
ping oil collects in the combustion chamber and it gets ignited during the startup operation
and leads to explosion and fire in the engine room. Such an explosion has been the cause
of severe injuries to the operators and can be fatal.
• It is important to follow the given procedures and warning signs

part 1 Section 2
Chapter 4 - Au x11ary
·1· M h'
--------------~ ac mery 193
Fireproof
Material
Cove
Outer Casing
Inner Casing
Heat
Insulator
Water Tube
Lower Drum
Inspection
Hole
Vertical Boiler (Water tube type) (Water in tubes)

Pressure stats
on/off & override Safety Valve
Water level guage
Boiler Shell
Cf)
CD
p:,
s
p:,
:::::i
Cl)
p-'
>5·
~ Mowbrey
e; dual control Smoke box
5·
CD Smoke box
t:r:l Lower water
:::::i cut-out
00
I-'•
:::::i Tubes Division Plates
CD
CD Pressure Guage - - - - Cumbustopm
>-j
Cumbustic
5· chamber
backplate The 'middles'
Chambe r
00
§ Sight Hole
0.. Feed Check
::r:: Valve
· Fue l Pipe
~
s
p:,
:::::i
Furnace
~
CD
.......
p:,
,-+-
Mui hole
I-' •
0 contained
:::::i
Cl)
'bottom belt'
Boiler Control
Panel Feed Pump
'7j
...,
0)
,.....
Aux iliary Boiler (vertical smoke tu be / low pressure)

, Section 2 Chapter 4 - Auxiliary Machinery 1 95
part 1
LayoU t of Pipelines
It takes time to ~ear~ layout of pipelines on board, but it is very important to learn as m uch as
n about p1pelmes.
one Ca
y 0 u must know th e position a~d function of valves and other compon ents such as fi lters, pres-
sure-relief arrangements , etc., 1n the pip eline system s.
It is of equal imp~rta~ce to k~o~ the fluid in a pipeline and its purpose. Pipelines should be
clearly marked to indicate fl uid it carries , direction of flow, temperature and pressure at essen -
tial position s
None of the pipes should be dismantled without permission and without due precautions to pre-
vent leakage of fluid and accidents.
Allowing flu id to enter a pipeline must be done in a careful and controlled manner. This is high-
ly important for steam systems where 'warming through' and drainage of water (condensate)
must be carried out to avoid 'water hammer'.
Waste material that gets generated during maintenance work is categorised below:
Waste Material Recommended and safe approach for disposal

Dirt and carbon particles from parts Collect it and land it ashore.
being cleaned
Waste oil or greases Collect and incinerate or land it ashore
Broken parts, rejected parts, metal
shavings, etc Collect and land them ashore
Rubber rings, joints, insulation material,
plastics, and plastic coated packing material Collect and land them ashore
Oily rags, oil soaked waste, Collect and land ashore or incinerate if
permitted
Dirty water Can be discharged overboard at sea
Chemical used for cleaning Collect and land them ashore
Wood, Saw dust, paper packing material Incinerate
. • · g and Human Relations

Seam anship , M anne Engineenn
196 Ch apter 4 - Auxiliary Machinery Part 1 Section
2
Air Compressors and Compressed Air System

-
Control System Air
Starting of Diesel Engines (for main engine, instruments, remote
Clean & Dry air operating devices like valves & pumps)
(20-30 bar) (very dry & clean air ranging 1-7 bar)
I I
Compressed Air
I I
Operation of hand tools & Cleaning of parts (7 bar)
Machines (7 bar) I I
(pneumatic hammers, chipping
machine, life boat winch, gang
way lifting motor, hatch cover Charging of Breathing
operation, pneumatically operated Apparatus bottles
pumps, etc.) (around 220 bar)
On board, compressed air is used: starting of m ain and auxiliary engines, operation of the ship's
whistle and for control equipment and instrumentation. Many tools such as and lifting gear,
impact and torque wrenches, drill machines, grinders, etc. are operated by machines using com-
pressed air.
Air in its natural state cannot do any of the above mentioned tasks , unless it is compressed (work
done on air). On compression temperature and pressure increases while volume decreases.
Air Compressor runs by electric motor to do the work of adding energy to the air.
Ships are fitted with at least two air compressors and compressed air is stored in "Air Bottles".
A/E Air Outlet Valve Air To Whistle Valve
M/E Air Outlet Valve \ Service Air Valve

Control Air Valve
Main Air Inlet~\ \ \
mospheric Air Release v/v
;
/; To Outside
t \ / Reliefv/v
Dogs Holding
Man Hole
Door~
r__________ L
_ o_n ~g~it_u_din a1 Seam
Circumferential Fusible Plug

Seam Drain Valve
.
To Outside E/R
Drain Valve

part 1 Section 2 Chapter 4 - Auxiliary Machinery
197
Common fittings on Air Bottle:

1. Filling valve
2. Su pply fo r Main Engine
Starting
- 3. Supply for Generator
. ... ~
4. Supply for Auxiliary servic-

: ,., \~: ',./;i: es through a pressure reduc-
ing valve
5. Drain valve
6. Supply to deck.
7. Pressure Gauge
8. Inspection door
9. Safety Valve
Operating Procedures for Air Compressor
Given b~lo~ is a che~kl_ist from a ship given for starting, stopping, and running a compressor.
Your ship will have similar checklist as applicable to the type of compressor and arrangements.
Procedures for Starting & Stopping Air Compressors

Checks before starting
1. Check lube oil level in the compressor crank case is normal.
2. Check that the filling valve for the air bottle is open.
3. Check that the compressor air discharge valve is open
4. Check that the compressor cooling water inlet and outlet valves are open and the drain
valve shut.
5. Check that the L.P. and H.P. drain valves leading to the unloader are open.
6. Bar the compressor by hand and ensure that the compressor is turning freely.
7. Switch on the power for the compressor.
8. After the compressor starts, shut the drain valve for the L.P. stage first and then shut the
drain valve for the H.P. stage. Now the compressor is on load and discharging air to the
air bottle.
9. When the air bottle is filled, unload the compressor by first opening the drain valve for
the H.P. stage first and then the drain valve for the L.P. stage.
lO. Stop the compressor by pressing the stop switch.
Checks during running , . , , ,
1. Ensure that the lube oil level is between the high and low mark on the level gauge.
2. Check the L.P. and H.P. stage pressure gauges f~r c~rr_ect pressure.
3· Check that the lube oil pressure is correct and m limits.
4· Check the compressor and motor for any noise I vibrations .
5· Check that the compressor is drawing normal amps. . .
6· th
Check that the unloader operates for draining as per e timer settmg.
7
· Check for water and air leaks. . 1
8. Check that the temp for cooling water and discharge au are norma .
. · and Human Relations
Seamanship, Marine Engmeenng
Chapter 5 - Diesel Engines
Identify components of diesel engines listed below:

1 Generator Engines . . .
.1 Identify and state function of major components of an auxiliary (generator) diesel
engine
.2 State important systems needed for operation of a auxiliary diesel engine
(Lubrication, fuel , cooling water, starting, air charging and exhaust, safety system,
speed control system/governor)
.3 List safety devices on an auxiliary diesel engine
.4 Describe preparation needed for starting a auxiliary diesel engine
5 State instruments fitted on an auxiliary diesel engine for monitoring its operating
parameters .
.6 State checks to be made on an operating auxiliary engine.
2 Main Engine:
.1 Identify major components of Main Engine (Cylinder head, exhaust valves, indica-
tor valve, fuel injectors, fuel pump, piston, piston rod, connecting rod, cross head
and guide, main bearing, cam shaft, crank shaft, crank case, crankcase relief valve.)
.2 State important systems necessary of operation of a Main Engine (Lubrication, fuel,
cooling water, starting, air charging and exhaust, safety system)
**********
1 Introduction
There is very little difference between mechanism and operating principles of Auxiliary diesel
engines and main engines on board. There can be several configurations depending upon the type
of ship, size and speed. It can be summed up that Auxiliary Engines are smaller, medium speed
engines and used for electrical power generation where as Main Engine is reversible, slow speed,
large in size and used to propel the ship, although there are medium speed main engines.
All diesel engines are on board fall in the category of Internal Combustion Engine (ICE). Internal
Combustion Engines are of mainly two types i.e. Spark Ignition (petrol) and Compression
Ignition. All diesel engines on board ship are Compression Ignition type. There is further divi-
sion in types of compression ignition engines - Two Stroke or Four Stroke. Two stroke engines
are Cross-Head Type and four stroke engines are Trunk Piston Type on the basis of their construc-
tion. You will learn more about different types of engines in this chapter and by looking at actu-
al engines.
2 Operating principle of Compression Ignition Engines (Diesel Engines)
An engine is a device that converts heat energy into mechanical energy to perform work. An inter-
nal combustion engine is any engine in which fuel is burned within its cylinder. The combustion
that occurs within the cylinders produces energy. This energy moves the parts of the engine that
drives the equipment.

-
Chapter 5 - Diesel Engines 199
part 1 Section 2
Chemical Energy Combustion Heat Energy is

-
in fuel within cylinder released
- 1
~
1f
Fuel & Air ignited under Mechanical energy Drives a machine

--
controlled condition \<vork / power / propeller
n
A B
D
Piston
Piston
Pin
Connecting
Rod
Crankpin
C ra nkshaft
An engine uses b oth reciproca ti ng motion an d

rotary motion to transmit energy. Four main
parts of th e engine work together to convert
reciprocatin g motion into rotary motion .
These four parts are as follows: a cylinder
Exhaust
(including cover), a piston, a connecting rod, Valve
and a crankshaft.
Piston
The piston and cylinder are matched parts, Intake
Valve
fitted closely to allow the piston to glide easi- Connecting _ __.o;,~ - 111
ly with little clearance at the sides within the Rod
cylinder. The top of the cylinder is closed and
has a space for the combustion chamber. The
connecting rod transmits the up-and-down
motion of the piston to the crankshaft. The
crankshaft has a section offset from the center C rankshaft
line of the shaft so that it "cranks" when the
shaft is turned
Seamanship , Marine En gineerin g and Human Relations

Part 1 Section 2
200 Chapter 5 - Diesel Engines
3 Diesel Engine Cycle

J1 f~:d
When the piston is at the highest point in the cylinder, it is in a posit~~n c~lledlf
0
C~nter
(TDC). When the piston is at its lowest point in the cylinder, the positwn is ca e th
O
omk had
Center (BDC). As the piston moves from top to bottom or from bottom to top, e cran s aft
rotates exactly one half of a revolution (180°).
Each movement of the piston from top to bottom or from bottom to to!? is called a stroke; there-
fore, the piston completes two strokes for every full crankshaft revolutwn.
For a 4 stroke petrol engine to operate, the following sequence of events must occur: (Two Stroke
Cycle simple description)
1 Intake: Air enters into the cylinder as the piston moves from TDC towards BDC.
2. Compression: Air is compressed as the piston moves from BDC towards TDC and
its temperature rises.
3. Ignition and Power: Just before the TDC, Fuel is injected at high p~essure and it
ignites. Pressure and temperature increases further and pushes the piston.
4. Scavenge and Exhaust: Fresh air starts entering and the burnt gases are removed
from the cylinder.
The engine repeats this sequence of events over and over again to produce sustained power. One
complete series of these events in an engine is called a cycle. Engines have either a four-stroke
cycle or a two-stroke cycle; almost all Auxiliary engines on ship operate on the four-stroke cycle.
Two-stroke engine is most common for main engine (for propelling the ship), however, four-
stroke engines are also used as main propulsion on some ships
Four-Stroke Cycle - there are four strokes of the piston in each cycle: two up and two down. The
four strokes of a cycle are as follows: intake, compression, power, and exhaust. A cycle occurs
during two revolutions of the crankshaft.
Four Stroke Cycle (simple description)
Intake Stroke. - The intake stroke begins at
top dead center, and as the piston moves
down, the intake valve opens. The downward
movement of the piston creates a vacuum in D
the cylinder, causing air to be drawn through D
the intake port into the combustion chamber.
As the piston reaches bottom dead center, the
inlet valve closes.
Compression Stroke.- The compression stroke

begins with the piston at bottom dead center
and rising up to compress the fuel and air
mixture. Since both the intake and exhaust
valves are closed, there is no escape for the air
and it gets compressed to a fraction of its orig-
inal volume. Pressure and temperature rises.
il D
At this point, the fuel is injected and it ignit-
ed immediately as it mixes with hot air. By
this time the crank has turned over and the
piston is in a poistion to move down. C Power Stroke D Exhause Stroke

Part 1 Section 2 Chapter 5 - Diesel Engines 201
Power Stroke.- The power . stroke begins when the fuel an d au. mix
. t ure is
. igni
• •t e d , b u rns and
expands ai:id forces th e pi st on down. The valves remain closed so that all the force is exerted
on the pi st0 n. The power st roke ends as the piston reaches bottom dead center.
Exhaust Stroke.- The ~xhau st str oke begins when the piston nears the end of the power stroke
and the exhaust valve is o_pened. As the piston moves upward towards top dead center, it push-
es the burnt gases, resultmg from the ignition of the fuel and air mixture, out of the combus-
tion chamber and through the exhaust port. As the piston reaches top dead center, ending the
exhaust stroke, the exhaust valve closes, and the intake valve opens to begin the intake stroke
for the next cycle.
Auxiliary engines on ships can be used for following functions:
• Power generation (commonly known as 'generator engine').

• Driving cargo pumps (pumps are directly connected to the engine).
• Driving large compressors or similar machinery.
Electrical power generation on board is by medium speed diesel engines. In addition to diesel
engines you may have on your ship a steam turbine driven generators (turbo-generators), and or
a shaft generators connected driven off the main engine.
Most of the diesel ships have three generator engines of same size. The power output of each
engine is such that only one engine is sufficient for normal operation at sea and in port.
Before departure and arrival port two engines are run to suffice additional load coming from
mooring machinery, simultaneous operation of two compressors, operation of bow thruster, etc.
pump for deck water and both steering motors, etc. Even if one generator can take the entire load,
it is a normal practice to operate on two engines to safe guard against failure of one engine or
other emergencies. Loss of power during maneuvering can lead to collisions and grounding.
Ships fitted with turbo-alternators may have only two diesel engines. (Turbo-alternator is a gen-
erator operating on steam produced from waste heat of main engine exhaust gases.
Some ships may have shaft-generators driven by the main engine. By means of gears and cou-
plings, main propulsion shaft is arranged to drive a generator that is coupled to the main bus bar.
5 Components and essential system of A/E
Essential systems for the function of engine are:
• AIE Lubricating Oil System-system for lubrication of moving parts.

• AIE Fresh Water Cooling System-system for dissipating heat from the engine parts as there
is continuous heat generation.
• AIE Fuel System-system for giving fuel to the engine.
• AIE Speed regulation and safety system-system for operation of safety devices for the
engine.

202 Part 1 Section 2
Chapter 5 - Diesel Engin es
•
Four stroke medium-speed d1ese • components
1 engine
Fresh ai r
Exhaust gas
a:; Rotary air

Gas u compressor
Turbine C
~
u5
Fuel Air cooler
Cylinder head
Push rod Water cooling
Piston
Exhause · -- · - -- Inlet valve cam

valve cam
Gudgeon pin
bearing
LJ..----"1r---· Cylinder liner
Crankcase
door -...
Crankcase

part 1 Section 2 Ch apter 5 - Diesel Engmes
.
203
Li\ ST
·~ -
. .:. 1, ',
~ ~,
. CLEA ill
12 112 Ill
·-~-
·, C ·t
' 1· :
. ·\
-~~
..\
'
• ·· 11
\
"" :' t ';#
_,~l-
.
.\ •' .,,,.I(".
..,
A Generator engine on Board
:~ : :: :; ~~ ~---_!·x
.~
, ~·~,
~~~~:\· .·- ; " ~.
......c~ ~,,.,;..;.::;..::..._~
A Lube oil Cooler of an auxiliary (generator) engine

Part 1 Section 2
204 Ch apter 5 - Diesel Engines
f[iii_· ,:-~ :\·

,';if, ·" . ; , .:\~ ~
:,.-. ._ . . 'w ~--..
•
- ,.j,,v..·:,,.!;f
J ,. I
t /
Air inlet side Gas side
~~
~,c ~-·<
I --
r Head Co
'( ..
. ',,'.)
)
~: , /
. --~--·
Cylinder Head of an auxiliary (generator) engine

Part 1 Section 2 Ch apter 5 - Diesel Engines 205
Lubricating oil System for Aux. Engine

Cylinders
~ Oil Cooler
l--
J
-
~
Thermostatic
control v/v
Engine Sump
(Crankcase) Gear driven pump
I~ Suction Filter ~ - within the engine
with a suction
~
Discharge Filter l--

'
~ Priming pump I
I
.
I Expansion Tank
-
Cylinders I "'
J
. I
I
F.W. Cooler
1-
·~ Thermostatic
'
control v/v
Engine Sump
(Crankcase)
Engine Driven -
Centrifugal Pump
Basic layout of a Cooling Water System

I I
Fuel Oil Service Diesel Oil Service

tank tank
I
Cylinders .. I: Pumps
Fuel h"'
+ ~
I Fuel Heater
I 1-·~
Suction
Engine Sump Filter
Discharge
(Crankcase)
Fuel Oil
.
~
Filter
Booster Pump
Basic layout of a Fuel Supply System

I I

206 Chapter 5 - Diesel Engines Part 1 Section 2
7 Major components of Main Engine
• Bed plate, Engine frame consisting of crankcase, entablature, and cylinder block.
• Cylinders, piston, gudgeon pin,
• Cylinder heads with inlet & exhaust valves, air starting valve, fuel injector, relief
valve and indicator valve or cock.
• Crank shaft and main bearings,
• Connecting rod and bearing
• Camshaft & camshaft drive gear,
e Fly wheel
Exhaust Valve Cylinder Cover
Turbo Charger
Fuel Oil System
il
Safety Equipment
Starting Air System
~ ru
Crankshaft,
Thrust Bearing &
Turning Gear
Major Components of a Main Engine (Mitsui-MAN-B&W)

part 1 Section 2 Chapter 5 - Diesel Engines
207
Exhaust gas Rocker arm

to boiler Exhaust
valve
Pushrod
---a.-Fuel injector
• Cylinder
head Camshaft
Charge Piston
air under Water jacket
pressure
Air
00
Cooler
---◄-- Scavenge belt
•---+-- Crankcase
sealing gland
Piston rod
guides
Crankcase door
Bottom end Crankshaft

bearing
Typical slow-speed crosshead two stroke diesel engine

Two Stroke Diesel Engine 1 Turbo Charger

2 Exhaust Manifold
(Loop Scavange type)
3 Fuel Injector
4 Scavenge Ports
5 Piston/ Piston R
6 Fuel Pump
7 Cam Shaft
8 Cross Head
9 Connecting Rod
10 Bed Plate
11 Bottom End Beari
12 LO. to Main Brg.
13 C/C Relief Valve
14 Crank Case
15 Link Pipes for LO
16 Stuffing Box
17 Scavenge Manifol
18 Air Cooler
19 Cylinder Liner
20 Exhaust Trunking
10

part 1 Section 2
209
Introduction
Descriptions in this un~t is kept simple and to that commonly found on all ships. Lay out and
components on each ship vary due to type and size of main engine, and the type of ship.
It is essential ~o maintain_ temperature of machinery items within an operating range to pr_ev~nt

undue expans10n. Excessive heat from the combustion spaces and that produced due to fnct10~
between moving parts has to be removed effectively. Due to much higher specific heat per umt
volume of fluid as compared to oil and air, water is the most preferred medium for cooling. Other
advantages of use of water as against oil for cooling are that it can be heated to heated to much
higher temperatures, is readily available at almost free of cost.
Comp
Exhaust Boiler
Cylinder Head
Tank
- - - - - - - -... Cylinder
Charge Air
Piston -----1-, Cooler
Fuel
Pump
Cooling
Water
F.W. Pump
LO. Pump

210 Chapter 5 - Diesel Engines Part 1 Section 2
Crankcase Lubricating Oil

Lubricating oil in the crankcase is used for lubrication of all bearings including thrust bearing,
c~oss head guides, chains, cams, and gears within the crankcase. In modern engines, pressure of
011 supply to crosshead bearing is arranged with a device to boost the pressure.
Basic. functions oflubricating oil are: reducing friction between moving parts in contact, cooling,
cleanmg, and protecting components against corrosion.
Cylinder Lubricating
Cylinder oil reduces frictional resistance between piston rings and liners, neutralises acidic con-
ditions created by the products of combustions, and act as an insulting film between cylinder
wall and hot gases.
Cam Shaft Lubrication

What is the function of Cam Shaft?
Function of the camshaft is to operate fuel pumps for each unit, operate exhaust valves, and it
may operate pilot air valves for starting the engine. On some engines, to prevent contamination
of crankcase oil with fuel leaking past fuel pumps, camshaft lubrication system is independent
of crankcase lubrication.
Gear Lubrication
On ships with gears for propeller drive, shaft generators, turbo charges, etc., a separate lubricat-
ing oil system is provided for each machine.
Turbo-charger Bearing Lubrication

On some ships turbo-charger bearings get supply from the crankcase lubricating oil system.
Otherwise, turbocharger bearings have their own lubrication system on each side
Fuel System
Fuel supplied to the engine needs to be clean and ·at appropriate viscosity and pressure to
achieve required atomization and penetration in the combustion space. This is achieved by fuel
system.
For combustion of fuel and later for removing products of combustion we need sufficient quan-
tity of clean and dry air at a temperature to provide good air density. Supplying air at pressure
higher than atmospheric pressure increases it density and allows for more efficient combustion
of greater quantity of fuel within the same volumetric space in the cylinder.
Sea Water Supply System

Function of Sea Water Cooling system is mainly to cool
► Charge air before it enters cylinder,

► Fresh cooling water in circulation for cylinder cooling and piston cooling
► Lubricating oils that is in circulation
Generally two pumps of same size are provided on ships for this purpose. In most conditions sup-
ply from one pump is sufficient for all requirements but each ship has othe.r pumps.for auxiliary
machinery and standby use, if one in operation fails. Pipelines and valves arrangements vary
from ship to ship.

part 1 Section 2 Chapter 5 - Diesel Engines 211
t of the modern ships, use of sea w t f h ..

In mos .. . . a er or eat exchange at Main Engine, Auxiliary
engl·nes and aux1hanes l'such asstair compressors
. , (FW . coo ers ) h as b een cu t
· , L•O. an d ch arge au
1 1
down and a centra coo mg sy em usmg fresh water is being used, which on turn is cooled by
sea water.
Air Starting & Reversing System

Each main engin~ has an arrange~ent to start it. Compressed air starting and reversing system
is provided for this purpose. On d1~ect _drive ships having fixed pitch propeller, starting system
has an arrangement to start the engme m reverse rotation for astern movement of the ship.
Gear Drive, Cam Shaft, Chains

Camshafts are provided to operate fuel pumps, exhaust valves, and air starting distributor.
Arrangements differ from engine to engine. However, to drive a camshaft in relation to the
crankshaft, gear drive or chain drive is used.
Air Charging System

Function of the air charging system is to supply air to the cylinders. The air entering the cylin-
ders first scavenges (removes products of combustion), and fills up the space with fresh air. The
efficiency of the system has to be such that all exhaust gases are removed and the cylinder gets
charged at pressure higher than the atmospheric (supercharging). Basic arrangement of air sup-
~---Charge Air
Cooler
.c....-- Induction
Manifold
Exhaust --lr--..--
---~~<-+---- Cooled
Compressed Air
Gases

Part 1 Section 2
212 Chapter 5 - Diesel Engines
Main safety features are:
► Relief valve 011 each cylinder head to release excessive pressure in case of pres-
sure built up due to combustion of accumulated fuel or oil.
► Crankcase relief door to limit damage in case of crankcase explosion
► Over-speed trip in case engine tends to go beyond the set limits (run away)
► Detection of concentration oil mist within the crankcase (mist detector). Engine
may be arranged to slow down in case of detection of oil mist in crankcase
► Alarms to indicate development of harmful conditions such as
► High exhaust temperatures,
► High temperature of cooling water from cylinders,
► High temperatures from bearings,
► High temperatures at piston cooling outlets, in cylinder
► High temperature at scavenge
► Low pressure for L.O. supply
► Low pressure for Fresh water supply
► Low level at tanks for fresh water, lubricating oil sump and fuel oil

Chapter 6 - Watch Keeping in the E . R
ngme oom
S cific Objectives
phee tr~inee will have gained knowledge of the followi· .
T ~ .,.., k' k · ng.
1 1a 1ng over,. eep1ng
. and handing over a wat c h
z. Watc h k eep1ng 1n port and at anchorage
3. Preparation before sailing
4. Watch keeping during Maneuvering
5. Watch keeping at sea
6. Preparation for arriving in port
7. Watch keeping at bunkering
8. Watch keeping in dry dock and repair.
1, Introduction:
Let us look at the basics of watch keeping, and what is expected of a person on watch.
The word 'watch' has many meanings but we will keep only two in mind.
1. To look or observe attentively or carefully; be closely observant and vigilant; be alert;

2. To look and wait expectantly or in anticipation.
Thus, the first element of the Watch Keeping is to observe attentively, the second is to anticipate,
but the:p. what?
That brings us back to the fundamental questions of the whole affair. The purpose of watch keep-
ing and beyond:
What to observe/watch?
Why?
What changes to look for?
What to anticipate?
When to watch?
How to observe/ check?
How often?
For how long?
Where to watch?
Where from?
What to do if --- ? And if ---? And if ---?
At the lower most support level of watch keeping, a watch-keeper is just 'keeping_a_n eye' and is
required to inform a superior at regular intervals or if there is change in the cond1t10n or abnor-
mality.
~eyond this, the actual purpose of watch keeping is to control the situation either to maintain it
lll a 'steady state' or to 'change' as required.

Chapter 6 - Watch Keeping in the Engine Room
The end objective of watch-keeping is to maintain 'steady state' or 'within specified range' the
condition of:
• motion (speed, movement) , or
• rest, or
• other physical parameter (temperature, pressure , level, etc.).
and To make specific changes to the above as required, or needed.
And To prevent development of hazardous (unsafe), and uneconomical conditions.
The following are different situations in a watch:

a. Taking Over, Keeping,_and Handing Over a Watch
b. Watch Keeping in Port and at Anchorage
c. Preparation before Sailing
d. Watch Keeping during Maneuvering
e. Watch Keeping at Sea
f. Preparation for arriving a port
g. Watch Keeping at Bunkering
h. Watch Keeping in Dry Dock & Repair
All members of the engineering watch need to know their duties and have the knowledge of:
a. Use and operation of internal communication systems,

b. Escape routes from machinery spaces,
c. Engine-room alarm systems and be able to distinguish between the various alarms
with special reference to the fire extinguishing media alarm, and
d.. Number location and type of fire fighting equipment and damage control gear in the
machinery spaces, together with their use and the various safety precautions to be
observed.
e. Emergency items like bilge suction valve, quick closing valves, emergency lighting
in the engine room; steps to take in case of black out; steps to take in case of main
engine slow down or shut down.
Taking over the watch
Prior to taking over a watch, relieving person shall ascertain the following:
a. Standing order and special instruction of the chief engineer officer relating to the
operation of the ship's system and machinery.
b. Nature of all work being performed on machinery and systems, the personnel
involved and potential hazards.
c. Level and, where applicable, the condition of the water or residues in the bilges,
ballast tanks, slop tanks , reserve tanks, fresh water tanks, sewage tank and any spe-
cial requirements for use or disposal of the contents thereof.
d. Condition and level of fuel in service tanks, settling tank, day tank and other fuel
storage facilities.
e. Any special requirements relating to sanitary system disposal.
f. Condition and mode of operation of the various main and auxiliary systems,
including the electrical power distribution system.
g. Condition and mode of operation of automatic boiler controls systems and other
equipment related to the operation of steam boilers.

Chapter 6 - Watch Keepin g in the Engine Room 215
part 1 Section Z
h. P ossibilities of bad weath er, ice, contaminated or shallow w ater.

1. Special m odes of operation dictated by equipment failure or adverse ship cond i-
ti ons .
j. Engine room bilges w ater level.
Watch keeping on Generator Engine and Main engine - (The most essential)
a. Temperatures - Exhaust, Cooling Water, Lubricating oil, Fu el oil , etc.

b. Pressures: Lube oil, Cooling water, fuel oil, etc.
c. Levels: Lube oil sump, turbo-charger oil, cooling water expansion tank,
fuel service tank.
d. Other items: Abnormal noise, leakage of water - oil - air
Watch keeping on auxiliaries:

a. Air Compressor - Oil level, water level, abnormal noise or vibration, leaks.
b. Pumps: Pressures, load, vibration, leakage from glands or seals , overheat-
ing of motor,
c. Boilers: Water level in the boiler, pressure, water level in hot well , oper-
ation of feed pumps, leakages if any.
Watch Keeping in Port or at Anchorage
While the ship is in port, it may be alongside a berth, or anchored in stream, or in a dry dock.
The conditions on board and in the engine room depend upon whether the ship is loading or dis-
charging or just waiting or bunkering or a combination of such activities.
If the weather is unpredictable, we need to be prepared for any of the likely emergencies.
Naturally, a ship at anchorage is more vulnerable (at risk) in rough weather. Due to unpredictable
weather, or for other reasons, the Captain may decide to keep the ship ready to move at all times
(Stand By), or at a very short notice.
Watch Keeping at Bunkering and during transfer of oil
Every Jhip is required to have a set of procedures for bunkering and transfer of oil assisting oth-
ers. You would appreciate that the main objective during Bunkering or oil transfer is as listed
below:
Main objective during bunkering or oil transfer

a. Oil should go to the selected tanks only
b. There should be no leaks at valves and joints
c. Pressure of supply oil should be well within the maximum pressure the line and com-
ponents can withstand. (Pressure gauges should be working and reliable.)
d. Oil should fill the tanks without causing any air lock (it occurs if the tank is filling in
too fast, or the ship has a list, the vent is not clear, or when the tank is nearly full)
e. The rate of filling should be such that it can be monitored and controlled.
f. Port regulations and procedures must be verified before commencing, during, and after
completion of bunkering or transfer.
g. Communication on board and between ship and shore must be ascertained
h. All scuppers and save all trays to be plugged
i. Saw dust and sponge pads to keep handy to contain spilled oil

Part 1 Section 2
216 Chapter 6 - Watch Keeping in the Engine Room
Modes of Operation
1) Manned Operation
When the machinery spaces are in the manned condition, one of the officers in charge of the engi-
neering watch shall at all times be available in the engine room along with other personnel,
depending on nature of duties.
2) Unattended Machinery Space Operation (UMS)
When the machinery spaces are in the periodic unmanned condition, the designated duty officer
in charge of the engineering watch shall be immediately available and on call to attend the
machinery spaces. For a ship to run in UMS condition all the essential automation should work
satisfactorily.

Chapter 7 - Working with Mach"mes
SpeCI'fie Learning Objectives
Trainees will be able to

Machines
.1 Identify
. d and name major parts of a pedestal dri·11 mac h'me, an d pe d esta1 or a b enc h
grm er:
.2 Drill holes using a fixed and portable drill machine
.3 Use fixed grinding
. machine for grinding plates , chi·sels , an d scrapper h an d t oo1s.
.4 Use hand grmder for grinding plates or parts .
.5 Use buffing or brush attachments for hand grinder.
.6 Lathe machine: Identify parts and common tools,
.7 Explain common tasks that can be performed on a lathe
.8 Explain risks involved while working with machines : Drill, grinder, and lathe
.9 Carry out basic turning and facing operation on lathe .
You will learn to do actual job on Drill machine, grinder and Lathe machine during your prac-
ticals in the workshop. However you need to learn the following while working on machines .
.1 Introduction - Fabrication & Repair

.2 Commonly found machines and Equipment on Board
.3 Basic procedure before commencing fabrication and repair work
.4 Precautions in using metal cutting machines
1. Introduction - Fabrication & Repair
'Fabrication' means to manufacture, create, or produce some thing new by machining, cutting,
joining or assembly. Spare parts, components and using metal cutting machines and welding can
fabricate new structures. Some of the common jobs that are carried out on board are listed below:
Making of new shafts for small pumps, bushes, rods of right dimensions, brackets, pieces of
pipes, etc.
'Repair' means restore, refurbish, revamp, patch up, fix or renovate parts, equipment or a struc-
ture.
Some of the common jobs for repair would be joining broken parts by welding or any other
means, building up worn parts, straightening, etc.
'Overhaul' means opening up machines and components for cleaning, inspection, Calibration
and parts, checking cleanness, lubrication, and if necessary, replace or repair parts.
'Maintain' means to restore machinery, equipments or space to its original or close to original state.
In all of the above cases you will need to use a variety of machines, tools , measuring equipment,

Part 1 Section 2
218 Chapter 7 - Working with Machine
fasteners and welding equipment and other processes.
It is presumed that during your pre-sea training you have learnt and gained certain co_mpetence
of using basic metal cutting machines and basic welding using electric arc and gas weldmg equip-
ment.
It is beyond the scope of this unit as guide as to how to weld or use basic machines and tools.
However, contents you will be reminded of safety aspects of the work and procedures related to
metal cutting machines and welding equipment.
To make exact size parts using a lathe, and for many other purposes, you need to be good at using
Measuring Instruments. Some of the common instruments you must learn to use are:
.1 Calippers - Inside and outside

.2 Steel ruler
.3 Vernier Calliper
.4 Micromenter (outside and inside)
.5 Depth Gauge
6. Dial Guage;
and many others for different uses.
The above come in different sizes and type and the lat est being electronic types that give the
reading immediately. However, first you must learn to read these instruments on your own. You
need to know basic arithmetic and use of decimals.
G K
~--'--1-1-11-J-~ ' - l \ l \ L \ \I\ L\ \ r1_·[!'~

lltTot ''
Steel Ruler

p rf l pt, I
\ 11r 111
ti!. \1 ,, 11111,
for ti urin, 1, 11
d t, r
11 ' 111 '
'()(Jj II td ◄ > d1,11111!1•1· Ill)} 1h11 rtt•
f lt
l,1 1111 ,1111111 11d lllrtl h1111• 1)1
• II • 1 11 I I 111
JI I I \ <I
' , 1• 111 1,111 II fl, di til t · L •ll tl'l'l Il l ~ .11 ,d t ltllll, tll l{1 •l.1ttt tll '
Part 1 Section 2
,,y ii 5
11m 11 .
2 3 4 S 6 7
.J · · wl111.l_wl1
0
Close-up view of the calibration markings on

a vernier caliper. Upper markings on this
caliper are metric, the lower markings are
English. The measurement shown is 4.66 cm.
Thimble

1 Section 2 Chapter 7 - Working with Machine 221
part
2, Commonly found machines and Equipment on Board
hip is equipped with a minimum of equipment to carry out standard procedures for fab -
Ever! s and repair so that the ship will not be stranded for minor items to restore operation of
ricat10n d h . . f l. d
h . ery on boar . T e prov1s10n o mac 1rnery and equipment useful for maintenance an
· to sh"1p. s·1m1·1 ar 1y, t11e size
rnac . Ill ri·es from s111p · an d capacity of maintenance equipment vanes
.
air va
re P h 'IJ to ship . However, commonly found equipment on board is listed below:
from s I
• Centre lathe
• Pedestal drill machine
• Pedestal grinder
• Portable drill machine, with optional attachments for grinding
• Thread cutter
e Hacksaw machine
• Bending machine
e Arc Welding & Gas welding equipment
Engine Room Workshop on Board a ship
. d H an Relations
Seamanship, Marine Engineenng an um
222 Chapter 7 - Working with Machine Part 1 Section 2
Basic procedure before commencing fabrication and repair work
Basic planning is very essential before commencing any work to prevent damages, accidents,
and for efficiency of work.
A simple approach to start preparation would be to answer the following questions
Questions to start with. Remarks

-
a) What is to be done?
-
b) Why is it required?
c) Where is to be done?
-
d) When can it be done?
e) Does it require shutting down of machin-
ery?
f) Does it require isolation of supply of water,
fuel, electricity, etc.?
g) Does it require special permission or per-
mit? If yes, start procedures for permission.
h) Does it require help from others?
i) Does it involve people from other depart-
ments (deck or housekeeping)?
j) Is it a precision job?
k) Does it require any special tools?
1) Does it require any spares?
m)Availability of raw materials like metal
plates , rods, fasteners , joints, welding rods,
etc.
n) Does it involve work on the hull structure
or watertight compartments?
o) What are the risks involved? Accidents ,
pollution, fire, etc.
p) Does it require any lifting gear?
q) Does it require calm weather?
r) Are reqired tools available and in good
working condition?
s) Are required spares and material available
and in good condition?
You can now appreciate that the whole approach to commencing the work, going through it,
and completing would require a lot of thinking, but it will achieve satisfying results without
any accidents and losses.

section 2 Ch apter 7 - Working with Machin e
part 1 223
Personal Safety
DO'S
1. Report any accident, however small, immediately.
2. Wear safety glasses-ALWAYS.
3. Wear safety shoes.
4. Wear your overall buttoned up.
5. Roll up sleeves, or button up the cuffs.
6. Keep hair short, or wear a cap.
7. Ensure all guards are in position before starting machine.
8. Check that work area is clear before starting machine.
9. Ensure everything is•properly secured before starting machine.
10. Inspect slings, etc., for wear before using.
11. Use the correct type and size of sling.
12. Be careful of burrs and sharp edges.
13 . Use correct size tools at all times.
14. Keep hands clear of any revolving grinding wheel.
15. Stand clear when lifting work piece or equipment by crane.
DON'TS
1. Do not wear rings, watches, etc.
2. Do not keep sharp tools (scribes, etc.,) in overall pockets.
3. Do not remove any guard unless machine is stopped.
4. Do not attempt to stop wheel manually.
5. Do not lift any heavy work piece or equipment manually.
6. Do not lean on the machine.
7. Do not wash hands in coolant tanks.
8. Do not leave any lifting tackle lying about the work area.
Mechanical Safety
Replace guards before using machines

Beware of-
(Special danger points are marked in the
illustration with an 'X')
Gear Wheels
. . an d Human Relations
Seamanship, Marine Engmeermg
Chapter 7 - Working with Machine
Projections on rotating shafts
Revolving shafts and couplings
Electric l Safety
Unauthorised interference with electrical apparatus is extremely dangerous and any risk taken
might be the cause of instantaneous death.
Do not take liberties with electricity

Do not interfere with knobs; push buttons or switches on machinery or electrical equipment. If
you wish to know how it works, ask.
Before working on electrical apparatus, switch off the power supply and make sure that it can-
not accidentally be switched on. Isolate from the supply if possible.
Do not rely on a quick touch with your fingers; you will not be quick enough.
Check wiring or components with the approved measuring equipment as directed. Keep away
from danger areas when flash testing is being carried out. Ensure that danger notices are promi-
nently displayed when high voltage tests are carried out.
Safety
Electric shocks result in uncomfortable jolts, serious burns and fatalities. They are all danger-
ous and should be avoided.
You must remember (learn) to apply first aid to the victims of electric shock. First aid, prompt-
ly given, can save lives; delays can be fatal for the victim.
Safety
a) Electric current flowing through a person's hand causes involuntary muscular contraction,
the muscles tighten up and the hand closes tight, the victim cannot let go.
b) Current flowing into one hand and out of the other passes through the chest and the chest
muscles tighten-the victim cannot breathe and suffocates.
Prompt action is essential

1. Switch off the supply at once, or if not possible
2. Drag or knock the victim away from the supply using insulating material. Do not touch vic-
tim with bare hands
3. Apply artificial respiration for case 'b' even if breathing has not stopped.
4. Send someone for immediate assistance.
5. Continue artificial respiration until a doctor tells you to stop.

part 1 Section 2 Ch ap ter 7 - Working with Machine
225
Safety Hrocedure Before working on a drive:

a) Switch off the machine.
b) Switch off the main supply to the m achine and have the fuses removed.
c) Put a warning notice on the mains switch.
d) Check to see if the machine has any other power supplies. If it has, adopt the same
procedure.
e) Check that the drive is stationary.
f) Remove the safety guards.
Before re-starting a machine after repair:

Check that no tools have been left on or near the drive.
Clean surrounding areas
Replace the safety guards.
Restore the power supply and remove the warning notices.
Precautions in using metal cutting machines
General Safety
DO'S DON'T'S
1. Ask if in any doubt. 1 . Do not run in the workshop.
2. Use correct tools or equipment. 2. Do not throw things or play practical
3. Keep tools and equipment tidy on work- jokes.
table when not in use. 3. Do not touch any equipment unless
4. Take care of tools and equipment. authorised to do so.
5. Know the location of the nearest fire 4. Do not leave your machine running when
extinguisher and how to use it. not required.
6. Keep exit and/or fire doors clear at all 5. Do not leave crane hook hanging over
times. machine or surrounding area after use.
7 · Keep gangways clear. 6. Do not direct compressed air at yourself
or workmates. IT CAN KILL.
7. Do not give first aid unless qualified to
do so.

Machine Safety
DO'S
1. Keep machine clean and in a good condition.
2. Ensure you know how to stop your machine, before starting it.
3. Switch off machine immediately if anything goes wrong.
4. Keep machine and surrounding area tidy.
5. Check oil levels of machine before first starting.
6. Check wheel rotation before grinding.
7. Turn coolant off when wheel is stationary.
8. Keep grinding wheels dressed.
9. Report any damage to electrical cables.
10. Replace any badly worn or damaged nuts, bolts, Allen screws, etc.
11. Switch off machine mains at the end of the task.
DONT'S
1. Do not attempt to operate the machine until you are sure you understand it.
2. Do not wind table in "fast" when work piece is near to the wheel.
3. Do not mount or use a cracked wheel.
Wheel
Guard
Light Switch
Bench Grinder Pedestal Grinder

part 1 Section 2 Ch apter 7 - Working with Machine 2 27
step Cone
pulley Belt
Drill ~
Motor
feed
range ,,.
'1.t ';
Spindle
Head
Spindle
Drill
Table
Table
Clamp ~
Column
Base
Drill Machine
G-Clamp
Drill Vice
Seam anship , Marine Engin eering and Human Relations

Part 1 Section 2
Keyless ~ir ?
Chuck Vents
Button
Forward/Reverse
Switch
Variable-
Speed Dial
Side
Handle
Lathe Tools
- Right Right Right Left Left Left -

Hand Hand Hand Hand Hand Hand
Roughing Finishing Facing Roughing Finishing Facing
I,-'
("' ' \ //\\
I
Round Round Round Grooving Radius Threading Threading

Nose Nose Nose Undercutting Forming 80 Acme
Grooving Turning Forming or Parting
L - - - - - - - - - - - - - - - - - - -- - - -- - - - - - -- - -- -- - - - - - - - - - - - - - -
Seamanship, Marine Engineering an d Human Relation s

Chapter 7 - Working with Machine 229
Parts of a Lathe Machine

cone Pully Cover
ear Lever
eacl< G . Head Stock Tool Post Tail Stock
Face Compound
~rse L8"8r
alf Nut Lever .

Feed Change Lever
Tall Stock
Tool Post
Carriage Longifudinal
Hand Wheel Feed Lever
. d Hurnan Relations
. e Engineering an
Seamansh ip , Mann
230 Part 1 Sectio
Chapter 7 - Working with Machin e n2
Parts of a Lathe Machine
1. Gear Box 2. Gear Guards

3. Reverse Lever 4. Back Gear
5. Driver Plate 6. Live Centre
7. Tool Post 8. Compound Rest
9. Carriage 10. Dead Centre
11. Tail Stock 12. Set Over screw
13.Bed 14. Feed Rod
15. Lead Screw 16. Thread Dial Indicator
17. Half Nut Lever 18. Apron
19. Cross Feed Handle 20. Hand Wheel
21. Head Stock 22. Spindle Sleeve

part 1 Section 2 Chapter 7 - Working with Machine
231
work with a Lathe?
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Takea Piece of round bar and put it in the Place the material in between the 1· aws. Open
"three-jaw chuck"• Before you do that, clean the jaws to the need. Clamp the material so
the jaw with your fingers or a brush. that you can turn your material a little bit
and then clamp it hard. Through practice
you will be able to adjust the chuck and its
jaws.
Fix a "tool" in the "tool post". Use a normal Every tool point must be in the center of the
tool tailstock like this. This will become a stan-
dard practice as you do it a few times.

. Marine Engmeenng
Seamans h 1p,
r- - - - - - - - - - - - - - - - - - . - - - - - - - - - - -
Perfect Position
Material
To low
OK
To High
Move the tool post towards the material.

Adjust and align the tool to an angle as
shown.
Incorrect Position

section 2 Chapter 7 - Working with M h'
part 1 ac m e
233
f e turning the lathe, we must check the rotation d f
0
Be or steel with a diameter of 20 mm and a HSS (H'sphe; our material. In this sample of
1
normarnaterial is about 800 turnings/minute ig peed st eel) tool, the rotation speed
of our ·
e tool to your material and fix the slide
:rvfove tl1 ·
Before turning the machine you must protect your eyes.
Next step is to clean the material at the front end of your piece of material.
Move the tool slowly from the outside to the inside. Move the tool 0.1mm to the left and do
this again until the surface is clean.
Perfect
Not good enough
. . • · d Human Relations
Seamanship, Manne Engmeermg an
Chapter 7 - Working with Machine
When it is clean, set the nonius to zero.
Use two hands for doing it. One to fix the handle and one to turn the nonius to zero.
One axis is set to zero. Now do the same with the other axis.
Learn about the movement of tool post in each direction.
You can now proceed to take the necessary cuts.

Chapter 8 - Welding
'fi Learning Objectives

SpeCI C
. elding and cutting: Arc welding, gas welding, gas cutting
Basic w . k . 1 d . . . . .
.1 State ns s invo ve in using and working with weldmg equipment - Arc Welding
and Gas welding
.Z Identify components of arc welding machine used on board, personal protective
equipment, tools and accessories used for welding .
.3 Arc welding: Perform welding of butt joints and lap joints using arc welding
machine. Demonstrate basic procedures and techniques
.4 Take precautions while performing tasks
.S Soldering ferrous and non-ferrous metal plates using gas welding equipment
.6 Use a gas cutting torch for cutting a plate or rusted part.
Welding practice will be carried out in the workshop

under the guidance of an instructor.
Personal Safety for welding

Safety shoes with steel toe-cap
tOverall of suitable size made
and steel support to protect
of flameproof material feet from falling objects, sharp
edges etc.
- Greasy or torn clothes will
not protect you, as they are
hazards in themselves.
Spats to protect the ankles

from melted metal and splatter.
Arm and wrist protectors to

Apron to protect the front of protect your arms from heat,
your body when welding or rays etc.
cutting.
. d Human Relations
. . ·
Manne Eng1n eenng an
Seamans h 1p,
Part l S(i}ction 2
236 Chapter 8 - Welding
Welding gloves made from Protective goggles of rigid and

tanned leather comfortable design for protect-
3- finger and 5-finger type ing your eyes when chipping
Quality to be chosen to suit dif- slag or grinding welds etc.
ferent welding techniques
Thicker quality for handling
sheet metal plate and heavy
objects.
Welding helmet to be fitted

Welding screen, hand held with welding glasses 60 ?
type, to be fitted with welding 110mm.
glasses, 60? 110mm
A welding screen, or a welders'

helmet with protective glasses,
must always be used when
welding. Do never expose your
naked eyes to the light of an
electric arc or a welding torch.
Welding glasses and protective

110mm for welding glasses
screens and welding helmets
colour codes equal to DIN 9,
10, 11, 12 and 13 the protective
glass is a clear pane of glass
that must be mounted in front
of the welding glass.
Protective helmet, ear mufflers The adjustment is done by

and welding helmet with tightening or loosening the
welding glasses as sho"wn special strap inside the helmet.
always adjust the helmet to
suit your head.
(
''
section 2 Chapter 8 - Welding
part 1
237
FaII1iliarisation with welding equipment
2
t rage panel with tool holders and hold-
5
°
fool 1 arning material and a small number of
er for e
booklets.
Electrode holders differ in shape according to

the manufacturer and are made in various
sizes.
The electrode holder is connected to the

welding source by a welding cable.
Welding cables are made in a number of dif-

ferent sizes (cross sections) usually from
25 mm2 up to 120mm2.
. Engmeermg
Seamanship, Manne . · and Human Relations
Chapter 8 - Welding Part 1 Section 2
238
The earth clamp used can also vary in size

and shape and is connected to the work piece
and the welding source by a welding cable.
The cable to the earth clamp should be of the The welder may have to lengthen or shorten
same dimension as the welding cable con- the welding cables by using extension cables.
nected to the electrode holder. These cables are fitted with cable connectors
to guarantee full electrical contact.
Electrode dryer for drying electrodes that

have been exposed to a humid atmosphere.

section 2 Ch apter 8 _ Welding
part 1
239
.-ref source
-==:-~~~;~~;,:--;-~1---~=----------
po,• d . g· sources are designed to lower the
1, Wei. hin electric vo 1tage fr om t h e electric
Mains
sao v / 20 A
220
hig_ s and to provide a suitable current v 110 A r------J
rnain
for welding purposes.
Welding Current
25 - 400 60 - 400 A
2 The welding source is provided with a

· means of controlling the current and the
voltage.
3. The control should be fitted to the source or

to a remote control, which is connected to
the source by a cable.
4. Arc welding sources are classified into two

groups , AC (Alternating Current) or DC
(Direct Current) , according to the output
current.
DC/ DC
5. AC sources are Welding Transformers;

these are usually single operator
machines.

240 Chapter 8 - Welding Part 1 Section 2
6. Welding Generators. These sources can be

DC sources are Welding Rectifiers and
single or multi-operator machines.
7. The welding source should be connected to

the mains in the following way:
(a) Check that the connection plug is undam-

aged and the mains cable is in good con-
dition
(b) Check that the welding source is set for the

correct mains voltage
(c) Check that the switch for the welding cur-

rent is in off position
(d) Connect the mains cable to the mains sup-

ply.
part 1 Section 2 Chapter 8 - Welding
241
Starting the Welding Procedure

1. Before starting m anual arc welding you
must:
• Check safety precautions and fire
precautions
• Check your protective equipment
and personal clothing.
2. Connect the earth clamp to the work piece

and the return lead to the power source
connects the wiring cable-to--the power
source.
3. Check that the electrode holder is undam-

aged and that the welding cable is in good
condition and securely fitted to the
holder.
4. Check that the cable and the 3-phase plug

to the mains supply are in good condition.
. • and Human Relations

Seam an ship , Marine Engineermg
242 Chapter 8 - Welding Part 1 Sect·
ion 2
5 • Connect the power source to the mains

supply.
6. Switch on the power source and adjust the

welding current
• Follow the table on the electrode
package.
8$0
7. Check that you have the correct welding

glass fitted in your welding screen or hel-
met.
8. Put on your Welding Gloves and Welding

Helmet, Protective shoes, & Apron
If necessary put on:

• Ear mufflers

Chapter 8 - Welding
1 section z 243
pa.rt
the work-piece in the required
g. j\rr~~ge clamp the work-piece if neces-
positID:ust the gap and adjust for shrink-
sarY, a J
age.
. Fit the electrode in the electrode holder.

10
11. Support the arm with which you are hold-

ing the electrode 'holder in such a way
that a smooth relaxed movement is possi-
ble do not let the support restrict, the free-
dom of movement of your am keep the
upper arm close to your body, without
holding it there under tension. ·
12. Keep the electrode holder firmly in your

hand as shown in the illustration do not
hold it too tightly as this will make your
hand tremble during welding.

13. Practice handling and moving the elec-

trode without switching on the welding
current
• Hold the electrode holder with just

sufficient grip to give control.
14. Position yourself to avoid stretching and

tensing your muscles.
SAFETY NOTE
e PUT YOUR WELDING SCREEN
IN FRONT OF YOUR EYES
15. Switch on the welding current.
16. Warn observers before you strike the arc.
150
17. Point the electrode at the surface of the

workpiece
• Away from yourself with an angle

of about 700 at the workpiece
• Distance 20-30mm above the

spot where you wish to strike the arc.

Chapter 8 - Welding
·nZ 245
5ect10
part 1
met or screen in position
our h e l
18- put y 'king the arc
before stn
. . position until the arc
• I(eep 1t in
is broken.
'k the arc by lowering the electrode

19 Stn e .
. onto the workpiece
• About 20mm from the place where

the welding run should start.
zo. Strike the arc by tapping or striking gently

against the welding face
• Strike as if you are lighting a match.
21. When the arc is burning
• Immediately withdraw the

electrode end 2-3mm from the
surface of the work-piece.
22
· Mov~the electrode to the place where the
weldmg run should begin.

Part 1 Section 2
246 Chapter 8 - Welding
23. Begin welding
• keeps the arc length equal to the

electrode diameter
• Move the electrode at a speed of
about 150mm per minute.
Correct arc length gives:

• Even bead
• Good penetration fine splatter
24. Too long an arc length will cause low pen-

etration and splatter on the surface on the
workpiece.
Too long arc length gives:

WA
e Flat bead
• Low penetration coarse splatter
-
2 5. Too short an arc length will cause an
uneven bead due to arc failure.
Too short an arc length gives:
• Uncontrolled penetration slag globules

Electrode stuck to weld
26. If the electrode touches the weld, the cir-

cuit will be closed and the electrode will
stick to the weld.

Chapter 8 - Welding
1 section 2 247
part
the electrode movement for a second
z7. Stop nd break the arc
or two a
. •s to build up the weld pool
• T h
Whis ni the wel d poo 1 1s
. su ffi cient
. move
• the :lectrode away quickly.
Progress Check
Each question in this check is has four options of which only one is correct.
1. Before starting arc welding you must: a. Connect the earth clamp to the work-piece
b. Connect the welding cable to the earth clamp
c. Connect the electrode holder to the earth clamp
d. Extend the welding cables
·-
z. When starting to weld you must a. 30°

hold the electrode at an angle b. 50°
of about: C. 70°
d. 90°
3. The welding arc length should be: a. Less than the diameter of the electrode
b. Equal to the diameter of the electrode
c. 6-12mm
d. 20mm
Q.No. Your choice (a orb or c or d)
1.
2.
3.
References:
!~O ~o~ules of Employable Skills, Geneva 1980, Mechanical Engineering - Welding -

Id entifying
entifyi
Welding Equipment for Manual Arc Welding
. ng Are Welding
Identify·
. Sources
Id . ing H and Tools & Measuring Tools used by Welders
entifyi p .
Start· ng ersonal Safety Equipment for Arc Welding
ing th e Welding Procedure

Chapter 8 - Welding Part 1 Section 2
248
Though there is some repetition in the matter given below, take it as a revision.
Welding Processes
Today, there are many welding processes available. The primary difference between them is the
methods heat generation to melt the metal. Once you understand the theory of welding, you can
apply it to most welding processes.
The most common types of welding are oxyfuel gas welding, arc welding, and resistance
welding.
Gas Welding
One of the most popular welding methods

uses a gas flame as a source of heat. In the oxy-
fuel gas welding process, heat is produced by
burning a combustible gas (acetylene), mixed
wit~ oxygen. Gas welding is widely used in
mamtenance and repair work because of the
ease in transporting oxygen and fuel cylin-
ders. Once you learn the basics of gas weld-
ing, you will find the oxyfuel process adapt-
able to brazing, cutting, and heat treating all
types of metals.
-----~
~ \.·. . / . . Welding
\ ,\ · torch tip
Acetylene feather ·.. \
Inner cone
Molten weld met
Soldered . · •·
weld metal ·-• . -· Filler
' · . rod

part 1 Section 2 Chapter 8 - Welding
249
Arc Welding
Arc welding is a process that uses an electri

arc to join the metals being welded. A distinc~
advantage of arc welding over gas welding i
the concentration of heat. In gas welding th:
flame spreads over a large area, sometimes
causing heat distortion. The concentration of
heat, characteristic of arc welding, is an
advantage because less heat spread reduces
buckling and warping. This heat concentra-
tion also increases the depth of penetration
and speeds up the welding operation; there-
fore, you will find that arc welding is often
more practical and economical than gas weld-
ing.
All arc-welding processes have three things in

common: a heat source, filler metal, and
shielding. The source of heat in arc welding is
produced by the arcing of an electrical current
between two contacts. The power source is
called a welding machine. The welding
machine is either electric or motor-powered.
Fusion Welding
Shielded metal arc welding is performed by striking an arc between a coated-metal electrode
and the base metal. Once the arc has been established, the molten metal from the tip of the elec-
trode flows together with the molten metal from the edges of the base metal to forma sound
joint. This process is known as fusion. The coating from the electrode forms a covering over the
weld deposit, shielding it from contamination; therefore the process is called shielded metal
arc welding. The main advantages of shielded metal arc welding are that high-quality welds are
made rapidly at a low cost. You will learn more about shielded metal arc welding in a later les-
son.
Reference
Published by SweetHaven Publishing ServicesBased upon a text provided by the U.S. Navy
Gas Welding Process .
http://www.tpub.com/content/aviation/14018/img/14018_639_l.Jpg

·
Seamans h 1p, Marine Engmeermg
Chapter 8 - Welding
Welding Accessories
Recognise each item and write their common name
Personal Protection

part 1 Section 2 Chapter 8 - Welding 251
'

Gas Welding Equipment (Oxy Acetylene)
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s ection 2 Chapter 8 - Welding 253
part 1
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weldflame.en.alibaba.com/product

Q. - Is there anything missing in this diagram that is must in a modern welding set? Do find
the answer and ensure that the welding set you use has that fitting.
Welding Torch Oxygen Hose

Connection
Working Pressure Cylinder Working Pressure

Guage Pressure Guage Guage
Oxygen
Regulator
l · Cylinder
Pressure Guage
Oxygen
Hose
I-----~1
Acetylene
• Regulator
Spark Lighter
Acetylene
Hose
Apparatus
Wrench Twin Hose
Acetylene t ·
Cylinder
Oxygen Cylinder

Chapter 9 - Lubrication
. Learning Objectives
specific
. ts and lubrication:
Lubr1can 1 State type of oils and greases used on b d .
· crankcase 01•1 , gear 011,
• hydraulic oil) oar in ER and on Deck • (cy1·in d er 01·1 ,
States different methods of lubrication u d h'
·2 'fy . 1 se on mac inery and components
·3 Idenh grease nipp es, greasing and oili'ng equipment.
.4 Demonstrates use of grease guns
·5 Use oil can for . filling in oil in crankcase of a mac h'ine
.6 State precautions
. . to taken
. while working on or near an operating
• mac h'inery.
.7 State nsks involved if oil or grease falls on hot surfaces
Oils and Greases
Oils and greases of dif~erent types vary in their properties even thought the differences in their
composition may be slight. Always, use appropriate lubricant suited for the need.
Safety
Some oils affect skin. When handling oils of this type , protective clothing must be worn and a
barrier cream must be put on the hands.
Oil
Oils vary in viscosity and in their other properties. They can also have additives in them which
modify their properties for special purposes.
Viscosity
"Viscosity" is the term used to describe how fluid oil is, or its resistance to flow. Low-viscosity oil
flows easily and is often called a "light oil" or "thin oil". High-viscosity oil has more body and is
often called "heavy oil" or "thick oil".
Do not confuse oil viscosity with oil type (quality). Oil types are discussed below.
TyPes of oil
d. oi'ls are re f'ine d fr om cru d e miner

Most . a1 01·1·, but some have a synthetic or vegetable base. Oils of
ifferent types must never be mixed.
Types of additives
Thes . . . .
erties, and they are often referred to
by the are chemicals added to the 011 to give ~t s~e~ia1 rop_
ch ~ property they give the oil, e.g. a rust 1nhi?itor. n 011s 1
for different conditions, different
emicals may be used to achieve the same additive property.
. . d Human Relations
Seamanship, Marine Eng1neenng an
256 Chapter 9 - Lubrication Part 1 Section 2
s
' Oil in gear
box
Internal
combustion
Basket of
metal parts
being immersed
in heat
treatment
bath
Oil used
to lubricate
valve
shafts

Part 1 Section 2 Chapter 9 - Lubrication 257
Greases
Grease is made by blending oil w ith special

Wate r resistant grease
applied to bearings in
types of soap. The properties of grease vary
water pump with the type of soap .
Grease to be
applied on cam s
Grease
Heat treatment
High melting point grease plant
is applied here
Seam an ship, Marine Engineering and Human Relations

Chapter g - Lubrication Part 1 Section 2
258
Methods of Lubrication
Splash lubrication
The moving components are inside a protec-

tive housing. During operation components
dip into an oil bath and carry oil to the other
components.
Splash lubrication is often used to lubricate

other components.
Re-circulatory system
The moving components are totally enclosed

in a protective housing. A certain quantity of
oil is contained in a sump formed by the base
of the housing, or in a tank.
Ring, chain and collar feeds
These methods may be used to lubri-cate

plain bearings in low and me-dium speed
machinery.
A ring or endless chain mounted loosely on

the shaft rotates with it carrying oil from a
reservoir below the bearing.
Alternatively, the shaft may have an integral

collar from which the oil is' scraped when it
reaches its highest point of travel.

1 section 2 Chapter 9 - Lubrication
part 259
Wick Feeds and Lubricating Pads
Components requiring a low rate of oil

supply are often lubricated wick feed.
One end of the wick is suspended in an
oil bath and syphon action feeds oil to
the part to be lubricated.
Alternatively, a lubricating pad, usually

of felt, is pre-soaked in oil before use
and held in contact with the parts to be
lubricated.
Drip feed Cup oilers
These may be used to supply a

con-trolled feed to the bearing. The cov-
ered cup containing oil is connected to a
duct or pipe line leading to the bearing.
A needle valve is used to regulate the
flow of oil.
Oil mist
Dry compressed air is used to gene-rate

a mist and carry the lubricant to the
component.
Ensure that any component lubricated
in this way is correctly vented to atmos-
phere. A built up in air pres-sur~ may
result in stopping the flow of lubncant.
. Engineer
Seamanship, Manne . ing and Human Relations
260 Chapter 9 - Lubrication Part 1 Section 2
Grease cups
Some grease lubricated bearings may be sup-

plied with their lubricant from a grease Cup.
There are two distinct types.
Spring operated
Grease held in the cup is contin-uously forced

under spring pressure to the bearing. This
type of cup is suitable only for the thinner
grade of grease, and for short direct feed ducts
or pipes.
Screw operated
Grease is forced through the feed duct or pipe

by the operation of a screw cap. This type of
cup is suit able for thicker grade of grease and
for longer feed ducts or pipes.
Screw
The disadvantage with this type of grease cup
Grease
contained is that the feed is intermittent and controlled
here by manual adjustment of the screw.
Supply to bearing
Grease guns
A grease gun is used to pump grease through

-..:.;--Gr-ease-~
a non-return nipple. After greasing, the nipple
may by left in position, or replaced by a
screwed blanking cap.
Piston Take care to ensure adequate lubri-cation by

Nipple
this method.
Self-contained lubrication
Grease packing are often used in low speed machinery. Grease is held inside the bearing cap
and is in contact with the journal.
Some machines may have porous bronze, steel or iron bearings, which are oil-impregnated.
The oil oozes continually from the bearing to provide lubrication

·nZ Chapter 9 - Lubrication
5ectlO 261
part 1
. System-Maintenance
brjcat1on
Lll f1 b . .
variety o u ncat10n systems and d · • .
use ofth 8 ful 1 . d evices muse, routine servicing and main-
13eca uires care p ann1ng an operation.
,-,ance req
tev
Nfaintenan ee work can generally be divided into two schedules , dai'ly an d peno
• d'1c.
oaHY
aintenance schedule will nor-mally include the following general checks, plus special
The rn pH-cable to the workshop.
becks ap · d 1 1
c k 11 oil bath, reserv01r an sump eve s. (Usually by dipstick or sight glass)
cheC a
. te any points as detailed in the maintenance schedule
1ubnca .
Check visually for any ~bvious signs of damage, e.g. broken pipe securing clips and chafing of
jocor-r ectly supported pipes.
Check all pipes, unions and casing joints for obvious signs of leak-age.
Check all oil pressure gauge rea-dings.
Periodic
If machinery is run for a set number of hours per day, periodic servicing is usually on a time basis:
e.g. weekly.
If machine operation is irregular or intermittent, servicing should be based on running hours.

The schedule will include all items covered in daily servicing plus items such as those shown
below.
Each item should be recorded as it is completed.
. M ann
S eamans h 1p, . e Engi·neering and Human Relations
Chapter 9 - Lubrication Part 1 Section 2
262
Drain sump, oil bath or reservoir. (This is best

achieved when oil is hot)
Remove dirty filter.

Flush system if specified.
Remove Fit new or clean filter as required.
filter
according
to handbook OIL
FILTER
0
Refill system with fresh oil of correct grade.
Re-charge grease lubricated bea-rings as

detailed in schedule.
Carry out any special checks as detailed in

schedule.

part 1 Section 2 Chapter 9 - Lubrication 263
Points to note
In lubrication system maintenance cleanli-

ness is essential.
Lubricants attract dust and grit and dirty

lubricants cause rapid wear and deterioration
in machinery.
Lubricants should always be kept in sealed

containers and only suf-ficient for the job in
hand removed. Where possible this should be
trans-ferred straight into the machinery con-
cerned and not left exposed to atmosphere.
Ensure that excess or spilt oil or grease is

cleaned up immediately and dirty oil waste is
disposed of correctly, as these are serious fire
hazards.
Never mix different grades of lubricants until

confirmed by oil company.
If it should be necessary to use a piece of

lubricating equipment with a different grade
of oil, the equip-ment must be thoroughly
cleaned before putting in the new grade and
thoroughly cleaned again as soon as the job is
completed.
The above notes and diagrams have been adopted from a booklet compiled by the Instructors
of National Vocational Training Centre Dar es salaam, Tanzania under the Swiss Foundation for
Technical Assistance.
***************************************
Oil Can with a pump and nozzle Oil Measures

Chapter 10 - Level Measuring Devices
Level measuring devices and techniques

.1 Identify and name different level measuring devices and equipment listed below:
.2 Dip sticks, sounding rods , sounding tapes, gauge glass and sight glass .
.3 Demonstrate use of dip sticks, sounding rods, sounding tapes, in sounding a level
of liquid in a tank.
.4 Read level gauges to check oil and water levels in tanks
.5 State the type of fitting on a sounding pipe for a double bottom tank .
.6 State the importance of leaving the gauge in a working condition if cocks, air vents
have been tried while testing a gauge.
Much of the information related to this unit is given in Part 3 Ch 3 Instruments in ER (MEK) ,
And Part 2 Ch 6 Cargo Work (GSK)
You need to read the above mentioned chapters. However, the following will strengthen your
knowledge.
Level measuring devices:
Type of Commonly used for What does it look like

devicea
Dip stick (small levels - upto 25-30 cm)
Level of oil in lube oil sump of
small machines such as genera- Overfill
tor engine, compressor, life boat
engine, windlass and winch
gear case, etc. Add Normal
Range
Sounding (medium level upto about 2

rod meters) Level in tanks contain-
ing oil or water with straight
sounding pipe - usually for
double bottom tanks in ER,
cargo hold bilges, coffer dams
etc.

1 section 2 Chapter 10 - Level MeaSurmg
. Devices
part 265
(large levels or ullages of about

sounding
10-15 meters) Level in tanks
tape containing fuel oil or water in
wing tanks, deep tanks, fore
peak, after peak, etc.
Level On small to large tanks (1 meter

gauge to about 6 meters depth) in
engine room or on deck.
Special fittings for boilers water

levels.
Sight Fitted on oil sumps of purifiers,

glass compressors, etc to indicate
minimum and maximum level
or on cooling water expansion
tank (Diesel engine cooling
water head tank)
Remote Generally in addition to other

level mean of open gauges workin~
indicators through floats' electrical sens1-
ti ve tapes, sonic signals, etc.
It may be only means in com-

pletely closed tanks on tankers.
·p Marine Engineering and Human Relations

Seamans h 1 ,
266 Chapter 10 - Level Measuring Devices Part 1 Section 2
·: qnte
ndicat
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part 1 Section 2 Chapter 10 - Leve 1 Measuring Devices
267
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Chapter 11 - Lagging and Insulation
Lagging and insulation

.1 State the purpose of lagging and insulation material on pipes and components in
the engine room .
.2 State the importance of maintaining lagging and insulating material, and preven-
tion of contact with oil.
.3 State the common material used for lagging
.4 State precautions to be taken while handling a torn lagging.
Lagging: insulating material wrapped around pipes , boilers, or tanks to prevent loss of heat
Why? To prevent loss of heat
What is it? Insulating material (poor conductor of heat - compare steel vs wood or cotton
material)
Insulating material? Any material that can resist flow of heat, is safe for use, and is fire resistant.
Examples: Glass wool, rock wool, shredded paper, synthetic substances (foam), plaster of Paris,
cement bricks, etc. (Asbestos, though a very good and cheap material has harmful effects on
health and its use has been banned al together.)
Where used? Around pipes , boiler, hot filters, around tanks and in refrigerated compartments,
partitions, etc.
What does it look like?: It usually comes in the form of a fibrous material that can be stuffed in
a water / heat resistant cloth which can be wrapped around pipes and kept in place by clips,
wires, or metal casing.

part 1 Section 2 Chapter 11 - Lagging and Insulation 269
Precautions: Though insulating material used is generally fire resistant, but it can absorb oil
from leaky pipes and flanges and in that case it becomes a fire hazard.
While working with insulating material such as glass wool , you must protect your body, use
gloves and goggles. While handling any powdery material , use face mask.
Good practice: While dismantling pipes, or equipment that is insulated, take care in remov-
ing the lagging and putting it back after completing the work.
For personal use: you can easily relate insulating material as woolen garments, blankets, quilt,
and synthetic material (Thermal protective aid - TPA).
There is another kind of insulation - electrical insulation - preventing flow of electricity.
See other examples of lagging and insulation on next page.
. . nd Human Relations
eamans h . Marine Engmeenng a
1p,
S
270 Chapter 11 - Lagging an d In sulation P art 1 Section 2
~. 1::u1;
·~!L_i _; ~~~

Chapter 12. El t ·
ec ncal Tools and Fittings
•fie Learning Objectives
SpeCl
1 Hand tools for electrical mainten

'fy b . ance
.1 I d enti asic tools and their safet
. Y aspects
.2 State precautions to be taken while k'
war ing on electrical equipment,
2 Electr~cal C011~ponents and Equipment in ER
.1 Electrical Equipment in ER (ge t .
starters, starter panels nera ors, motors, switch boards, lighting, switches,
.2 Itlenttib.fyl ellectrical components - plugs, sockets, bulbs and tubes cluster lights and
por a e amps ' '
.3 ~ar~y out basic ele~trical maintenance: changing plugs, replacing bulbs and tubes,
ngg1ng_ up cluster lights and portable lamps
.4 States importance of taking care of wires against chaffing
1 Precautionary Measures while working on electrical systems and machinery
1.1 Electric shock
Nearly everyone has experienced an electric shock at some time. At best it is an unpleasant expe-
rience; at worst it is fatal. Anyone who has access to live electrical equipment must be fully aware
of first aid and safety procedures related to electric shock as described in relevant safety acts.
Electric shock is due to the flow of current through your body. This is often from hand to hand
or from hand to foot. A shock current as low as 15mA ac or de may be fatal. Obviously the size
of shock current is related to the applied voltage and your body resistance. Unfortunately, your
body resistance goes down as the applied voltage goes up. This means that the shock current is
further increased at high voltages. The size of your body resistance also depends on other factors
such as your state of health, the degree of contact with live wires and the perspiration or damp-
ness on your skin. Typical dry full contact body resistance is about 5000? at 25V falling to about
2000? at 250V.
The risks of electric shock are much greater on board ship than they are normally ashore because
wetness, high humidity and high temperature (including sweating) reduce the contact resistance
of the body. In those conditions, severe and even fatal shocks may be caused at voltages as low
as 60V. It should also be borne in mind that cuts and abrasions significantly reduce skin resist-
ance.
A notice of instructions on the treatment of electric shock should be posted in everyplace con-
taining electrical equipment and switchgear. Immediate on the spot treatment of an unconscious
patient is essential.
1 .2 Precautions
a) Before any work is done on electrical equipment, fuses should be_ remove_d or circuit b_reak-
ers opened to ensure that all related circuits are dead. If possibl~, s~itches and cucuit
breakers should be locked open or; alternatively, a 'not to be closed notice attached.

272 Chapter 12 - Electrical Tools and Fittings Part 1 Section 2
b) Where a fuse has been removed, the person working on the equipment until the job is fin-
ished should retain it. A check should be made that any interlocks or other safety devices
are operative.
c) Additional precautions are necessary to ensure safety when work is to ?e undertaken on

high voltage equipment (designed to operate at a nominal system voltage in excess of 1 kV).
The work should be carried out by, or under the direct supervision of, a competent person
with sufficient technical knowledge and a permit-to-work should be operated.
d) Some parts of certain types of equipment may remain live even when the equipment is
switched off. Power should always be cut off at the mains.
e) Flammable materials should never be left or stored near switchboards.
f) Work on or near live equipment should be avoided if possible but when it is essential for
the safety of the ship or for testing purposes, the following precautions should be taken:
► A second person, who should be competent in the treatment of electric shock, should
be continually in attendance.
► The working position adopted should be safe and secure to avoid accidental contact
with the live parts. Insulated gloves should be worn where practicable.
► Contact with the deck, particularly if it is wet, should be avoided. Footwear may give
inadequate insulation if it is damp or has metal studs or rivets. The use of a dry insu-
lating mat at all times is recommended.
► Contact with bare metal should be avoided. A hand-to-hand shock is especially
dangerous. To minimise the risk of a second contact should the working hand
accidentally touch a live part, one hand should be kept in a trouser pocket whenever
practicable.
► Wrist watches, metal identity bracelets and rings should be removed. They provide
low resistance contacts with the skin. Metal fittings on clothing or footwear are also
dangerous.
g) Before attempting any electrical work, there are some basic safety precautions you must
bear in mind. The possible dangers arising from the misuse of electrical equipment are well
known.
h) Electric shock and fire can cause loss of life and damage to equipment.
i) Before working on the drive of any machine, isolate it from its power supply in a way that
prevents the machine from being accidentally started.
j) Regulations exist to control the construction, installation, operation and maintenance of

electrical equipment so that danger is eliminated as far as possible. Minimum acceptable
standards of safety are issued by various bodies including national governments, interna-
tional governmental conventions (e.g. SOLAS), national and international standards associ-
ations (e.g. BSS and IEC), learned societies (e.g. IEE), classification societies (e.g. Lloyds),
etc. Where danger arises it is usually due to neglect or contravention of the regulations,
k) You must learn to operate equipment in a safe manner and maintain it in a safe condition
at all times. Failure to do so will not only endanger your life but life of others too. Keep in
mind an essential list of Dos and Don'ts when working with electrical equipment.

section 2 Chapter 1 2 _ El t · l
part 1 ec nca Tools and Fittings 273
Dos
a) DO get to know the ship's electrical system and e ui . , .

. int the location of switche d . q . pment. Study ships diagrams to
pmpo t' ·t f . s an protectrnn devices supplying distribution boards
nd essen ia1 i ems o equipment Writ d h' .
a . . . . · e own t is information in a notebook Note the
normal indicat10ns on switchboard instruments so th t b . ·b · k
a a norma1 operat10n can e quic -
ly d etec t e d .
b) DO operate equipment according to manufacturers' recommendations.
c) DO maintain equipment according to manufacturers' recommendations or ship mainte-

nance procedures.
d) DO ensure that all guards, covers and doors are securely fitted and that all bolts and fix-
ings are fitted and tight.
e) DO inform the Officer of the Watch before shutting down equipment for maintenance.
fl DO switch off and lock off supplies, remove fuses, and display warning notice before
removing covers of equipment for maintenance.
g) DO confirm that circuits are DEAD (by using a voltage tester) before touching conductors
and terminals.
Don'ts
a) DON'T touch live conductors under any pretext.
b) DON'T touch rotating parts.
c) DON'T leave live conductors or rotating parts exposed.
d) DON'T overload equipment.
e) DON'T neglect or abuse equipment.
f) DON'T stand on unstable platform when working at height.
You should think 'safety' at all times. Develop a safety conscious attitude. This may well
save your life and the lives of others. Most accidents occur due to a momenta~y loss of con-
centration or attempts to take short cuts to safety procedures. DO NOT let this happen to

274 Chapter 12 - Electrical Tools and Fittings Part 1 Section 2
SAFETY
{) --
c::::s
{)
Before working on a drive:
a) Switch off the machine.
b) Switch off the main supply to the machine
and have the fuses removed.
c) Put a warning notice on the mains switch.
d) Check to see if the machine has any other
power supplies. If it has, adopt the same
procedure.
e) Check that the drive is stationary.
f) Remove the safety guards.
Before re-starting a drive:

► Check that no tools have been left on or near
the drive.
► Replace the safety guards.
► Restore the power supply and remove the
warning notices.
In Part 1 Chapter 4, we have given most of the tools for day to day work on board. Some of the
tools for working on electrical equipment are given below.
Bearing / Coupling Pullers (Two legged and three legged type

section 2
part 1
275
Insulated Pliers
Philip Screw Drivers
Nose pliers
Stubby
Hevco .=,..
Ball Pien Hammer
Allen Keys
Soft Hammer
Learn more about electrical fittings in the electrical section of the workshop at your inslitut es.

Chapter 12 - Electrical Tools an d Fittings Part 1 Section 2
276
Electrical instruments Multimeter
A Megger for insulation test

Tong Tester or Clamp Tester

Chapter 13 - Chemicals on Board
Chemicals on Board
.1
~tate c~emicals_ used for different purposes on board: cleaning air cooler cleaners;
~mproving quality of water in the boiler, improving quality of fuel, Reduce deposits
in fresh water generator, treatment of sewage before it can be discharged, etc.
.2
State precautions to be taken while using and handling chemicals on board
Introduction
Everything around us and within us has a chemical composition. Each chemical has a property
which can be useful or harmful depending upon the situation. It is the chemical reaction between
chemicals and chemical change that makes the chemical safe or dangerous (hazardous). Thus
chemicals on board are used for the properties they possess and their reaction with other chem-
icals. While we need to use chemicals to our advantage, their misuse can cause dangerous situa-
tions leading to personal injuries, fires, excessive corrosion, etc.
Some of the properties of chemicals we need to be concerned about are: Acidity, Alkalinity,
Reactivity, and Toxicity.
Chemicals on board come in liquid or powder and sometimes in gaseous state; and used for fol-
lowing:
a. Changing and controlling properties of cooling water for diesel engines
b. Changing and controlling properties of boiler water
c. Fuel treatment
d. Cleaning parts
e. Testing quality of water
f. Fire extinguishing (liquid, powder, or gas)
g. Forming protective layers (paints)
Risks involved while working with chemicals:

a. Splash on parts of the body, eyes and clothes leading to chemical burns on unpro-
tected skin
b. Leak from the containers
C. Spill
d. Fumes (inhaled)
e. Fire due to chemical reaction
Precautions necessary while handling chemicals:

a. Understanding risks involved in each chemical - read instructions on the container
b. Understand first aid should there be an accident
c. Proper storage to prevent contact with other substances
d. Using proper container
e. Ensuring that the containers are not leaking
f. Proper handling

278 Chapter 13 - Chemicals on Board Part 1 Section 2
Substances which fall un der the category of hazardous substances are required to have proper
labels an d symbols and instruction s for u se, precautions to be taken, and action to be taken in
emergencies.
Use of personal protective gear while handling chemicals

a. Rubber gloves
b. Goggles
c. Apron
d. Face mask
The chart below summarises the use of chemicals on board. This is only basic information; there
is much more to learn when you go on board.
1) Types of chemicals 2) Where used? Mainly in 3) Risks involved: mainly
a. Alkalies a. Boilers a. Chemical burns on
b. Mild acids b. Cooling system of Diesel unprotected skin
c. Chemical compounds Engine, air compressors, b. Splash in eyes leading to
and other auxiliaries damage
In liquid or powder form C. Toxic fumes
Other uses:
In non corrosive synthetic or a. Fuel treatment
metallic containers, drums b. Cleaning parts
or kegs c. Testing quality of water
4) Who is authorized to use? 5) How are chemicals 6) Precautions needed:
a. Watch keeping officer or added: Protection against contact
b. Watch keeping support a. Using small measuring and fumes
personnel (ratings) as cups , or cans and funnels a. Rubber gloves
instructed by the officer b. In measured quantity b. Goggles
depending upon the c. Apron
need. d. Face mask
c. Directly into the tank or e. Other parts of the body
through a mixing tank need to be properly
covered
Since all substances are chemical, and could be harmful, they need to be stored, handled with
care. There are strict regulations against storage and discharge of chemicals in to the sea, or
release of gases. Even empty container need to be stored and disposed in a proper way.

Chapter 14 - Steering Gear
State function of a steering gear its 1 t·
'
State ch ec k s to be made while taki oca rnn and
. its im port ance for trouble free operat10n.
.
ng a round m the steering flat.
Just as we need steering for a car tru k
big difference is that a ship d' c 'or a motor cycle, we need a steering gear for the ship. The
Moreover water is not hard oes
f not . have any wh ee 1s, an d 1t · 1s
· much bigger
· an d h eav1er.
·
'
does the ship. sur ace 11ke a road · Jus t as cars an d trucks have power steenng
. so
You can imagine the consequence ·f th ·

ing. Similarly, failure of shi 's st s 1 . e steering of a c~r or ~ truck fails while the vehicle is mov-
. f h' . . P eenng can lead to ummagmable consequences leading to sink-
mg o a s 1p, co 111s10ns grounding d h
' , an muc worse - the loss of life and pollution of the sea.
Therefore, it is important the t ·
. s eenng gear operates properly and is available all the time. You
will learn lot more about the ste enng
· gear w h en you see actual steenng
· gear on the ship.
·
A simple representation of ships steering system is given below:
I Steering Gear Components j

Power Unit
I
Actuating Unit Control Unit
Pumps Rams Transmitter (helm)
Pipes/valves Tiller Receiver
Hydraulic fluid Rudder Stock Feedback
fluid
Common components on Bridge of a ship

• Helm (Steering wheel)
• Transmitter (Electrical or electronic or hydraulic) - transmits signal to the steering gear
compartment
• Rudder angle indicator
Transmission system through pipes, electric cables, and electronic instruments
Steering Gear Compartment (aft of the ship)
• Receiver - Amplifier - Lever to move the controls of the power pump (hydraulic).
• Hydraulic oil is pumped to the rams and.cylinder mechanism to move the rudder (located
outside the ship).
• Feedback system: the position of the rudder is indicated on the bridge through rudder
angle indicator.
At this stage you need to learn the most important aspects of watch keeping. While taking
rounds in the steering flat, you need to observe the following:
• Oil level in oil tanks for steering gear system
• Leakage from pumps, pipe joints, etc.
• Abnormal noise or vibrations

280 Chapter 14 - Steering Gear Part 1 Section 2
• Load of the pump on electric motor in Ampere

• Condition of links for controlling pumps, control mechanism, etc.
• Any abnormality must be immediately informed to the duty engineer.
A simple representation of a steering gear unit is shown below
IWheel House I
u~
Control : Auto Pilot l
1-
Unit ..- ,I.
it
I Motor Starter I
I
I.
I Steering Flat I ~
Feedback
Motors j
I
Solenoid
Valve
Valve . ..
Actuator
(Rams/Rudder stock)
I
Pumps .
.
Block
Rudder
Seamanship, Marine Engin eering and Human Relations

Chapter 15 - Storage Tanks
specific Learning Objectives

Storage tanks
.1 State types of storage t k .
. an s - wmg tanks, double bottom tanks tanks within the
engine_ ro?m such as lube oil storage, expansion tank oil sump) '
.2
S t ate liquids stored in tanks: Fuel, lubricating oil, or fresh water.
.3 State _the pur~ose of a 'quick closing valve' .
.4 Identify a quick closing valve .
Storage tanks are very important compartments on board a ship.
Tank is a common name given to compartments where liquids can be stored. The quantity of liq-
uids to be stored depends upon the need and consumption.
There are at least the following liquids used on board requiring tanks for storage. The quantity of
liquids needed depends upon the size and type of a ship though the purpose is no different.
For our purpose, we will focus on storage tanks in the engine room.
• 'Large' means more than 200 Tonnes (200 cubic meters)

• 'Medium' means 50 to 200 Tonnes
• 'Small' means 2-50 Tonnes
Liquids stored Quantity Common names for tanks Other related terms
needed that store such liquids.
Fuel Oils Large Storage (bunker) tank, set- Double bottom, wing tank
tling tank, service tank
Diesel oil Medium Settling tank and service tank Vertical tanks in ER, either on the
side or at mid section
ME crankcase Medium Storage tank, service tank, Vertical tanks in ER usually on the
oil sump post or starboard side
ME Cylinder oil Medium Storage tank, service tank, Vertical tanks in ER usually on the
post or starboard side
Water for boiler Medium feed tank Side tank, hot well, double bottom
tank.
Domestic fresh Small Fresh water tanks After peak, double bottom, or side
water tanks
Ballast Large Ballast tanks Double bottom, wing tank, fore
peak, etc.
There are several other smaller tanks for storing different types of oils, circulating water, storage
of sewage, etc.
Each tank is required to have at least the following:

• Filling connection
• Air vent

282 Chapter 15 - Storage Tanks Part 1 Section 2
• Outlet valve
• Man hole door
• Sounding pipe,
• Overflow line
• Drain valves for tanks above double bottom tanks
Quick Closing Valves
Any oil tank above the double bottom tank

poses a risk of liquid spill. To safe guard against
serious hazards due to oil leakage or spills, is
required to have a remotely operated shut off
valve. Such valves are called 'quick closing
valves' fitted on the outlet line of the tank. An
example of quick closing valve fitted on tanks
is shown on the right.
In case of a serious fire in the Engine room, all

quick closing valves are activated to close all
lines to restrict the fire in case fire damages any
part of the pipe line.
Operation of these valves from a location needs

to be tested at regular intervals.
Sectional View of a Quick Closing Valve

Chapter 16 - Emergencies in the Eng1ne
. Room
. Learning Objectives
5peCl6C
encies in the engine room:
EIIlerg .
.l State
. emergencies
. • . that
. can occur in the engine room (f'ire, fl oo d'ing, bl ac k out, 01·1
1
spill, inJunes, e ectnc shocks, burns,)
.2 State the difference between, machinery failure alarm, general alarm, CO flooding
alarm) . 2
.3 State action to be taken on hearing each type of alarm
.4 State that all alarms in the ER are of Audio Visual Type
What is an emergency? An emergency is a situation which poses an immediate risk to health, life,
property or environment. Most emergencies require urgent action to prevent or minimise damage.
Some of the emergencies that can occur in the engine room are:
.1 Breakdown of generators (Black out)

.2 Breakdown/stoppage of main engine
.3 Fire or risk of fire
.4 Accident (falling objects, personal injuries, etc.)
.5 Flooding of engine room (Hole on the side or breakdown of a seawater pipe)
.6 Grounding of the ship
.7 Explosion (crank case, boiler back fire, etc.)
.8 Emergencies outside the engine room such as fire, oil spill, collision, etc.
Types of alarms on board:

Alarm Signals:
• A general alarm system is used for warning passengers and crew to muster stations.
• This is assisted by a public address system.
• The general alarm system should be audible on all decks.
1. General Alarm:
• The general alarm on the ship is recognized by 7 short ringing of bell followed by a long
ring or 7 short blasts on the ship's horn followed by one long blast.
• The general alarm is sounded to make aware the crew on board that an emergency has
occurred.
2. Fire Alarm: . . . . , .
• A fire alarm when sounded is a continuous ringing of ships electrical bell or continuous
sounding of the ship's horn. .
• Crew members on hearing the fire alarm will assemble at the muster station.
3 • Man Overboard Alarm:

• When a man falls overboard, the ship internal alarm bell sounds 3 long rings and ship whis-
tle will blow 3 long blasts to notify the crew on board and the other ships in nearby vicinity.

284 Chapter 16 - Emergencies in the Engine Room Part 1 Section 2
• Crew members on hearing the Man Overboard Alarm shall assemble at the muster station
and await instructions from Master.
4. Navigational Alarm:
• In the navigation bridge, most of the navigational equipment has failure alarms which
indicate the respective failure.
• On hearing the Navigational Alarm, Duty officer to call the Master immediately.
5. Machinery space Alarm:

• The machinery in the engine room is fitted with various safety devices and alarms for safe
operation. If any one of these malfunctions, a common engine room alarm is operated and
the problem can be identified in the engine control room, control panel, which will display
the alarm both in audio and visual form.
• On hearing the Machinery Space Alarm, The Chief Engineer is to be informed immediately.
6. Machinery Space CO2 Alarm:

• The machinery space is fitted with CO2 fixed with fire extinguishing system whose audi-
ble and visual alarm is entirely different from machinery space alarm and other alarm for
easy reorganization.
• On hearing Machinery Space CO2 Alarm, all crew members must vacate the engine room
and assemble at the muster station.
7. Cargo Space CO2 Alarm:

• The cargo spaces of the ship are also fitted with fire detection and extinguishing system.
The arrangements depend upon the types of ships.
8. Abandon Ship Order:

• When the emergency situation on board ship goes out of control and ship is no longer safe
for the crew to be on board, the master of the ship gives a verbal order through ship's pub-
lic address system.
• All crew will muster for boat stations and follow the instructions given by the team leaders
at that time.
9. Ship Security Alarm System:

All ocean going ships are required to have Ship Board security System and a plan. In case of an
attack by pirates or any other threat to the ship, the bridge / master will activate an alert system
that will inform the appropriate coastal authorities about the location of the ship and threats.
Ship's crew will be guided to follow defined procedures. Every ship is required to have special-
ly designated safe location (called Citadel) within the ship were the crew is required to assemble
and maintain calm.
Except for the Ship Security Alarm system, all of the above alarm have at least two indications:
sound and light (audio-visual) similar that to that commonly seen on Ambulances and Fire
Engines ashore.
*Additional information about safety and alarms is given in Part 2 of the book under chapter 10
- Safety, under the heading of 'Emergencies' (page 191)

section 2 Chapter 16 - Em .
part 1 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ergenc1es
_
in the E .
ngme Room
285
General Alarm and Fire Alarm in Engine Room ...... .... .. CO2 Alarm
CO Alarm in the Engine Room and an emergency exit

2

. . . ui ment in the Engine Room
Chapter 17 - Fire Exhngu1sh1ng Eq p
Fire extinguishing ~quip~ent ~n ~he eng~ne roo~ound in the engine room (Portable extinguish-
.1 List fire extinguishing equipmen~ h d t hoses and nozzles)
ers, non-portable extinguishers, ~ire y ra~ s, (smoke type , heat type, fl
.2 State methods of detecting fire in the engine room a:rne
type) • · f in the ER.
3 State methods of raising alarm on fr nd ing a ire . )
State the function of CO 2 . Water fog, high expansrnn foam .
:!
·
State the purpose and location of pump that supplies water in emergency.
• d · F' hf Course· however, you can learn from

All of the above are part of Fire Prevent10n an Fire ig ing '
the notes given below.
· · h' · t · the engi·ne room is listed below:
The most common fire extingu1s 1ng equ1pmen in
.1 Portable extinguishers (many - foam type, CO2 type, Dry powder type1
.2 Non-portable extinguishers (large extinguisher on wheels - Foam or ry powder
type)
.3 Fire hydrants, hoses and nozzles - strategically located at entrances, and at each
platform .
.4 Fire pump (At least two in the ER and one emergency type outside the ER)
There needs to be an arrangement to extinguish large fires. Such arrangements can be one or the
combination of the following:
.1 CO 2 flooding
.2 Water fog
.3 High expansion foam
.4 Mechanical foam
Fire Extinguishing Media:
a) Dry Chemical Powder: A flame inhibiting powder used in fire fighting
b) Foam/Froth: Result of mixing foam concentrate, water, and air to produce bubbles. (The aer-
ated solution which is used for fire prevention and firefighting).
c) Foam expansion ratio: The proportion of air or gas and liquid in a foam, expressed as a ratio
of the total volume of foam to the volume of liquid in the foam. (low: 50:1; medium: 50-
250:1; high:250-1500:1)
d) Foam, Chemical: Foam formed by the reaction of an alkaline salt solution with an acid solu-
tion in the presence of a foam stabilizing agent.

S ction z Chapter 17 - Fire Extinguishing E . .
part 1 e qu1pment m the Engine Room 287
) Foam , Mechanical: Foam formed by turbul en t m1xmg

. .
0f . 'th
e proportions of foam compound. au WI water containing small
foam Concentrate (Foam compound): The full stren th . . .

D which is diluted and processed_to produce foam. g hqmd received from the supplier
foam solution: A solution of foam concentrate 1·

g) ~ water at th e appropriate concentration.
(Concentration: percentage of foam concentrate mixed with water.)
h) Water fog: A suspension in atmosphere of very fine d 1t f .

. h h rap es o water usually delivered at a
high pressure t roug a fog nozzle for use in firefighting.
Water has a very high

. .latent heat (A high capacity to absorb heat fr om a f'1re w1'th out ch ange 1n
·
temperature) hence 1t 1s an excellent cooling medium.
• It is easily available at sea.
• It is nontoxic.
• When used on oil fires the entire liquid surface should be covered by the water
spray, and surrounding hot metal should be cooled to prevent re-ignition.
• The water droplets should be fine enough (Fog or mist) so that they take heat from
burning vapour more efficiently with immediate cooling effect.
i) Water spray: A suspension in atmosphere water divided into coarse drops by delivery
through a special nozzle for use in firefighting.
j) Carbon Dioxide (CO 2 ):

It's a cold gas which fights a fire by displacing atmosphere, lowering oxygen level and
smothering the fire
• Has a limited cooling effect
• When released from bottle or cylinder it expands 450 times the volume of the liq-
uid.
• Heavier than air
• It is non corrosive, does not deteriorate and does not damage in any way.
• It does not conduct electricity and hence can be used safely on electrical fires.
• It is clean and does not leave a residue.
• It is inexpensive, and can be used on most fires. Except those which liberate oxy-
gen whilst burning.
• It does not support life therefore before CO2 can be released in the engine room,
crew is required to vacate the space.
Emergency Fire Pump and its Location:

• An emergency fire pump with its independent source of power is provided which
is located outside the main machinery spaces.
• This is required so that if the engine room is on fire, water for firefighting can be
provided from this independent fire pump with its own source of power.
• An isolating valve fitted on the fire line separates the engine room fire line from the
deck fire line. It is important to know the location of the fire line isolating valves
for any crew member who joins a ship.

Part 1 Section 2
288
Chapter 17 - Fire Extinguishing Equipment in the Engine Room
Fire Line Diagram:
Fire & Deck

Wash Line
( Main Deck)
( Fire Main J====--~---nk:'.'I
Emergency
Fire P/p (tccommodation)
Isolating Valve
1-- - - - - - - - - - - - - --neck Head·- - - - - -- - - - - - - - - - - - 1
Engine
Room
~
Hydrant

Chapter 1 7 - Fire Extin guishing Equ ipment in the Engine Room 289
part 1 Section 2
fire detection arrangement:
.1 Smoke detectors (most common)

.2 Heat detectors
.3 Flame detectors at specific locations where oil can get ignited readily
Methods of raising alarms:
.1 Push type fire alarms are provided at each platform in the engine room; In case of
a 'glass box' a small hammer will be available to break the glass b efore the alarm
can be activated .
.2 Internal communication - telephone and intercom

290 Chapter 17 - Fire Extinguishing Equipment in the Engine Room Part 1 Section 2
Picture Gallery (Fire Extinguishing Equipment on Board)
OXYGEN
z
0
l-
o :::c
<C
w m
ct: CONTINUOUSLY )>
-I
BURNING
F I R E
FUEL
Fire Triangle Fire Quadrant
Water Type Extinguisher Dry Powder Type Extinguisher

Chapter 1 7 - Fire Extingms
. h'mg E •
part 1 section 2 qmpment in th 8 Engme
. Room
291
Mechanical Foam Type Extinguisher

COz Extinguisher
'...,,i I
i
I I
- I
~ · !
I
Non-portable Dry powder Type Extinguisher

Non-Portable Foam Type Extinguisher

Chapter 17 - Fire Extinguishing Equipment in the Engine Room Part 1 Section 2
292
I
_,..
w heel'
spanner
nozzle kept in the

I Hose kept
connected
to hydrant
! stowage ' osition ready for
/ use
jl.~~P"Jf/
l'
i.
Fire Hydrant, Hose, and Nozzle in the Engine Room
Mechanical Foam Unit for Largr: f ires on Deck Portable High Expansion Foam Generator

part 1 Section 2 Chapter 17 - Fire Extinguishing Equipment 1.n th E . R
e ·ngme oom 293
Combined Jet I Spray nozzle
Shut
Jet and Spray Nozzle
ull
im
queeze
weep
Foam Monitor on the dec k of tanker

294 Chapter 17 - Fire Extinguish ing Equipm ent in the En gine Room Part 1 Section 2
Fire Detector (Flame detector) Smoke Detector
~~~ -,
\ ~' - ' I
COz Cylinders for Engine Room & cargo space fires

Part 1 Section 2
Question Bank 295
Chapter 1 - Familiari sar10n wit

• h the duhes
. of Engine Room Rating
Duties of a Trainee Rating

.1 States duties of a rating in the Eng·1ne room for ass1stmg
· · m · mamtenance
· an d watc h k eep1ng
·
.2 State the person to report to while working in the Engine room

• Assi st ship engineer officers in performing routine maintenance work and repair to
ship's engine, machinery, and equipments.
• Lubricate moving parts of engines, machinery and equipments as instructed
• Operate and maintain pumps and valves under the guidance of ship's engineers.
• Clean engine parts and engine room.
• Look after ER stores and spares
• Paint engine room
• Assist watch keeping in the engine room
• Monitor engine, machinery and equipment indicators and report abnormalities to ship
engineer office on watch.
Engine Room Machinery

• State major items of machinery and their purpose (Main Engine, Shafting, Auxiliary
Engines, Auxiliaries, Boilers,)
1. Which of the following is NOT the job of an 5. Which of the following is within the engine
Engine Room Rating? room?
A) Painting Engine Room A) Purifiers Room
B) Assist in maintenance work B) Cargo Pump Room
C) Operate main engine C) CO 2 Room
D) Assist in watch keeping D) Paint storage Room
2. Which of the following is job of an Engine 6. Which of the following is lower most part
Room Rating of a diesel engine?
A) Report to the bridge about engine condi- A) Piston
tion B) Bed plate
B) Assist in maintenance work C) Exhaust valve
C) Overhaul air compressor D) Turbo charger
D) Start and stop main engine 7. Which of the following is the top most part
3. Which of the following is NOT within the of a diesel engine?
engine room? A) Crankcase Door
A) Generator Engine B) Crank Shaft
B) Air Compressor C) Cylinder Head
C) Mooring winch D) Piston
D) Boiler 1. List 6 duties of an Engine Room Rating
4. Which of the following is NOT within the 2. List 6 major machinery in the ER.
engine room? 3. List 6 of the auxiliary machinery items in
A) Refrigeration Machinery the engine room
B) Fridge Room
C) Fire Pump
D) Fresh water generator
~

296
Q2 Column I Column II
Ql Column I Column II
Equipment Item of machinery Part of the ----- system
Purpose
a) Pump a) Main Engine 1. Ballast
1. Trap solid particles
b) Filter 2. Separate solid and liquids b) Air compressor 2. Fuel oil
c) Centrifugal 3. Pressurise air or gases c) Purifier 3. Bilge
Separator
d) Compressor 4. Pressurise liquids d) Centrifugal Pump 4. Propulsion
e) Valve 5 . Control flow of liquids or e) Boiler 5. Compressed air
gases
f) Level gauge 6. Release tension f) Reciprocating 6. Steam generation and
pump distribution
7. Indicate Level 7. Electrical
8. Indicate pressure 8. Steering
Identify pictures, name them, and state their function (purpose)

Section 2 Question Bank
part 1 297
Chapter 2 - Instruments in Engine Room

Learning Objectives
Instruments .
.1 Identify and name th e in struments in the engine room: Pressure gauges, thermometers,
.2 Read different type of in struments in the engine room: Pressure gauges, thermometers,
1. Bar is a unit for 2. Unit of electrical current is

A) Pressure A) Ampere
B) Temperature B) Volt
C) Mass C) Ohm
D) Length D) Watt
3. Sounding Tape is use for checking 4. Which instrument is used for center
A) Length ing an object on the lathe chuck
B) Water level in the tank A) Micrometer
C) Oil Level in the Gear-box B) Vernier Callipers
D) Noise Level C) Steel Scale
D) Dial Gauge
5. Which instrument if used for measuring 6. The given picture is of a

diameter of a circular rod A) Pressure Gauge
A) Steel Scale B) Vacuum Gauge
B) Micrometer C) Compound Gauge
C) Measuring Tape D) Pressure regulator.
D) Dial gauge
8. The given picture is of a
7. The given picture is of a:
A) Pressure Gauge
A) Pressure Gauge
B) Vacuum Gauge
B) Vacuum Gauge
C) Compound G_auge
C) Compound Gauge
D)Pressure regulator
D) Pressure regulator.'

Part 1 Section 2
298 Question Bank

A) Pyrometer
••
t
A) Pressure Gauge
B) Pocket Thermometer
B) Vacuum Gauge
C) Compound Gauge C) Thermometer 40
D) Regulator Assembly D) Gauge glass 21
11. The given picture is of a 12. The given picture is of a

A) Level gauge A. Level gauge
B) Thermometer B. Thermometer
C) Pyrometer C. Pyrometer
D) Sight glass D. Sight glass
13. Pyrometers are cmmonly used for 14. What is the unit for electrical resistance
A) Exhaust temperature A) Ampere
B) Cooling water B) Ohms
C) Lubricating oils C) Kilowatt
D) Lubricaing oil Pressure D) Volts
Match the items

Q15 Column I Column II Unit Q16 Column I For Column II Instrument
Measuring provided/needed
a) Pressure 1. °C a) Water level in boiler 1. Steel scale
b) Temperature 2. Micron b) Temperature of 2. Thermometer
lubricating oil
c) Sounding 3. Ampere c) Gearbox Oil Level 3. Gauge Glass
d) Tank capacity 4. Meters and d) Pressure in boiler 4. Pressure gauge
Centimeters
e) Current 5. Kg/cm 2 or Bar e) Length 5. Sight Glass
f) Power 6. Cubic meters or f) Diameter 6. Dual pressure gauge
Liters
7. Minutes 7 . Depth gauge
8. Kilowatt 8. Micrometer

part 1 Section 2 Question Bank
299
Fill up the table given below:
Used for measuring
17 Instrument Units
rPressure Gauge
z:- Thermometer
r,- Sounding tape
-4. Steel Scale
.-- Micrometer
5.
6. Vernier Callipers
7. Measuring Tape
8. Dial Gauge
9. Pyrometer
10. Volt Meter
11. Ammeter
12. Watt-meter
18. Identify type of gauges, and where these are likely to be found. What is the pressure range
and units?
INDICATOR
FLOAT
FLOAT
CHAMBER
INDICATOR TUBE
SCALE

Chapter 3 Maintenance and Workshop Practice
Learning Objectives

.1 Common Maintenance Tasks
2 Assembly items
.1 Common Fasteners
.2 Common Bolts and screw
.3 Common Tools and their applications
1. Which of the following is not a 2. Which of the following is used for fixing
'Heat Exchanger'? a moving part to a shaft?
A) Air cooler A) Key and Lock Nut
B) Fuel injector B) Spring Washer
C) Oil heater C) Stud and nut
D) Fridge condenser D) Locking wire
3. Which of the following is not a 4. Which of the following is used for

type of 'Pump'? maintaining tightness of a nut?
A) Reciprocating A) Key
B) Gear B) Spring Washer
C) Non return C) Screw extractor
D) Screw D) Flat washer
From column II, choose one of the maintenance task that is carried out on board for each of the
item listed in Column I
Q5. Column I (Equipment) Column II (Maintenance Task)
a) Pumps 1. Furnace & Tubes Cleaning & Inspection
b) Valves 2. Cleaning, varnishing, baking and insulation check
c) Filters 3. Cylinder head with inlet and exhaust valves overhaul and
inspection
d) Air Compressors 4. Basket cleaning & wire mesh inspection
e) Oil fired boiler 5. De-rusting, cleaning and painting
f) Diesel Generator Engine 6. Impeller, wear rings and rotor assembly inspection
7. Inspection, grinding and gland packing renewal
8. First & second stage valves overhaul and inspection
Short Answer Questions
1. State any four types of heat exchangers you will find on board
2. Write any six jobs of maintenance for Diesel Generator Engine
3. Write any four jobs of maintenance for Oil fired boiler/Exhaust gas economizer
4. Write any six jobs of maintenance for Main Engine

part 1 section 2 Question Bank
301
Identify the equipment in the diagrams given below, their purpose.
NUT
BOLT
COTTER
PIN
D ..
[ f-•-f I· c:---=I
ynnmni 1mmmoomm1~1

Part 1 Section 2
302 Question Bank
e)
0't'
'

303
Chapter 4 - Auxiliar Ma h.
_Auxiliary Mac~i~ery & E~uipment & Maintenance ~orkc mery
.1 Aux1hary Equipment
4 Filters
.2 Valves ·
5 Centrifugal separators
.3 Pumps and Pumping Systems ·
Other Auxiliaries
·--- .4 Joints and Gland Packing -~
Boiler and Steam System
1. During operation, the inner parts of a 2. Function of a pump is to
centrifugal pump
A) Control flow of fluids
A) Rotates B) Pressurize fluids
B) Reciprocates C) Inject fuel
C) Oscillates D) Purify fluids
D) Remain stationary
3. On board ships a bilge pump is a type of 4. A gear pump is most suited +or
A) Reciprocating Pump 1
A) Oil '
B) Gear Pump B) Water
C) Screw Pump C) Air
D) Centrifugal Pump D) Gas
5. Quick Closing Valves are fitted on 6. On board ships a fire pump is a type of
A) Ballast tanks A) Reciprocating
B) Generator engine B) Gear
C) Air Bottles C) Screw
D) Fuel tanks D) Centrifugal
7. Main Sea Water Pump used in Engine 8. Which of the following is NOT a part of
Room is a an air compressor?
A) Screw type A) Filter
B) Centrifugal type B) Shaft
C) Reciprocating type C) Valve
D) Gear type D) Injector
9. Impeller of centrifugal pump is fitted to 10. Most dangerous aspect of an oil fired boil-
A) A Shaft er in operation
B) A gland A) Chocking of water level Gauge-glass
C) The casing B) Fuel Oil contamination with water
D) The motor C) Leaky oil Burner
D) Black Smoke
11. Type of pump used for sea water cooling 12. Pump most commonly used for L.O. sys-
on board is tem of generator engines is ____ type.
A) Axial flow pump A) Reciprocating
B) Reciprocating pump B) Gear
C) Centrifugal pump C) Screw
D) Screw pump D) Vane
13. Oil cargo is discharged from tankers using 14. Fresh water generator on the ships produces
A) Vane type pump A) Drinking water
B) Centrifugal pump B) Fresh water from sea water
C) Gear pump C) Sea water from fresh water
D) Screw pump D) Clean water from bilge water
15. A cooler is a type of _ __ 16. How many safety valves are provided on
A) Heat exchanger a steam boiler
BJ Machine A) One
C) Compressor B) Two
D) Air conditioner C) Three
D) Four

17.Steam from a boiler is used for 18. The exhaust gas economizer on a ship i;
A) Fuel Oil Heaters a part of the
B) Feed tank A) Steam Generation System
C) Safety valve B) Turbo charging
D) Condenser C) Hot water system
D) Oil fired boiler
19.Which of the following is used to check 20. Main function of a Purifier on a ship is to
water level in the boiler? A) Remove human waste before discharging
A) Gauge glass the water
B) Indicator valve B) Clean bilge an d ballast water before dis-
C) Feed water valve charging
D) Blow d own cock C) Clean air before it enter s diesel engine
D) Purify fuels and lubricating oils
21.Wha t is th e common name for item used 22. Ho w many gauge-glasses are provided
for preventing leakage from between on an oil fired boiler
pip e flan ges? A) Two
A) Lagging B) Three
B) Packing C) One
C) Joint D) Four
D) Washer
Match the column type questions.

Items from column II can be chosen more than once or not at all.
Q 1 Column I Column II Q 2 Column I Column II
Auxiliary Machinery Related to Type of valves Most Common Use
a) Boiler 1. Human waste (a) Non return valve 1. Deck water line
b) Fresh Water 2. Starting of Main
(b) Globe valve 2. Ballast line
Generator Engine
c) Sewage treatment (c) Spring loaded
3. Steering 3 . Steam line
plant valve
d) Air compressors 4 . Storing Vegetables (d) Butterfly valve 4. Gauge glass
e) Domestic Fridge 5. Oil (e) Fire hydrant 5 . CO 2 line
f) Purifi ers 6. Power supply (f) Cock 6. Pressure release
7. Steam Generation 7. Exhaust lin e
8. Evaporator 8. Bilge line
Seamanship, Marine Engineering and Hu m an Relation s

305
Q3 Column I Column II
Auxiliary Equipment Q4 Column I Column II
Purpose
Valve actuators Found on
a) Valves 1. Cooling or heating
a) Hand wheels 1. Safety valve
1j)Pumps 2. Control flow
b) Levers/Handles 2. Turbo charger
~ters 3. Remove solid impurities c) Springs
from liquids 3. Electrically operated
T)Heat exchangers 4 . Pressurise fluids
d) Solenoid 4. Butterfly valve
~ir bottle 5 . Store air
e) Cam operated 5. Exhaust Valve
~ Purifier 6. Remove solid impurities f)
- 7. Air conditioning
Hydraulic devices 6. Globe valve
7. Relief Valves
---- 8 . Ventilation
8. Float Valve
Ql Name of the equipment in this diagram:
State whether it allows the flow one way or

both ways:
Identify parts and fill in table given below
1.
:,.....,-~.._3 2.
--~7:~::j-4 3.
4.
--- 5 5.
6 6.
7.
7
8.
~lg----,- 8 9.
10.
9
10

Question Bank Part 1 Section
306 2
Name of the equipment in this diagram:

Q2
State whether it allows the flow one way or

both ways:
~u-- -- 3 Identify parts and fill in table given below

---4
Ml'-,~..,....,-.+-- 5 1.
~~rf~~,i;.';1::1-- 6 2.
3.
v1 ' - ~ t - 7
4.
5.
6.
8
7.
9 8.
9.
10 10.
Q3 Name of the equipment in this diagram:

1
2 State whether it allows the flow on e way or
3 both ways:
4
5
1.
6
2.
7 3.
4.
8
5.
6.
9 7.
8.
10 9.
10.

part 1 Section 2
Question Bank
307
Q4
Name of the equipment in this diagram:
1.
2.
3.
6 4.
~ - - - -- _ _ _ _ _ _ _ _ ____j
5.
~----'- 7 t;:6;--._ __ _ _ __ _ _ _ __ _ _ _ __ j
7.
8.
9.
10.
8
10 - Name of this equipment
Q5 Name of the equipment in this diagram:

10 ♦
1 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
4
~s
6

3 08 Question Bank Part 1 Section 2
Q6 Name of the diagram:
What is it used for?
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Q7 QB Q 9 Itendify each of item

shown below
Identify the items shown in Identify the items shown in ·

the diagram: the diagram:
A: A:
B: B:
QlO. State name of each of the equipment shown below:

309
1. State four common uses of oils on board:

2. What are the two most common items of equipment used for cleaning oils on board?
3. What is the difference between a strainer and a filter?
4. What will happen if a L.O. filter of a generator engine is getting chocked?
5. State at least three advantages of producing fresh water on board.
6. Write down the advantages of producing water on board
7. Name the equipment used on board for producing fresh water from sea water.
8. State at least four uses of steam on a diesel ship.
9. State at least six of the boiler mountings.
10 . State the items you will observe while keeping a watch on the boiler.
11 . State the accidents that can occur while operating a boiler on board , and working with
steams.
12 . List at least four items of waste material that is collected during maintenance work on
board.
1 3. State at least five uses of compressed air on board:

14. State at least four fittings to be found on an air bottle:

15. State at least four checks to be made before starting an air compressor
16. State at least four checks to be made while an air compressor is operating:
17. List six different types of valves used on board ships.
18. State at least six uses of compressed air on board
19. Name at least four material used as joints between flanges of pipes on board
20. What is the difference between a 'packing' and a 'joint'?
21. Name any two safety cut outs which automatically stop the boiler burner.
22. What are the important observations that are made on a running boiler?

Chapter 5 Auxiliary Engine and Main Engine 4. Purpose of fresh water circulation through
Generator Engines diesel engine cylinder is to
.1 Identify and state function of major com- A) Prevent corrosion
pon ents of an auxiliary (generator) diesel B) Remove heat of combustion
engine C) Clean exhaust gases
.2 State important systems needed for opera- D) Lubricate moving parts
tion of a auxiliary diesel engine 5. Turning gear on main engine is provided
(Lubrication, fuel, cooling water, starting, for
air charging and exhaust, safety system, A) Releasing parts if jammed
govern or) B) Turning the engine during overhaul.
.3 List safety devices on an auxiliary diesel C) Remove exhaust gases from cylinders
engine D) Ensure turning of the propeller
.4 Describe preparation needed for starting a 6. Exhaust Gas Economiser produces
auxiliary diesel engine A) Fresh water
.5 State instruments fitted on an auxiliary
B) Steam
C) Inert gas
diesel engine for monitoring its operating
D) Electricity
parameters. Turbo chargers on diesel engines
7.
.6 State checks to be made on an operating
A) Acts as fuel charger
auxiliary engine. B) Decreases the pressure of intake air
Main Engine: C) Increases pressure of intake air
.1 Identify major components of Main D) Increases RPM
Engine (Cylinder head, exhaust valves , 8. Exhau st gases from the main engine go to
indicator valve, fuel injectors, fuel pump , the atmosphere through
piston, piston rod, connecting rod, cross A) Inert gas generator
head and guide, main bearing, cam shaft, B) Oil fired boiler
crank shaft, crank case, crankcase relief C) Exhaust fan
valve.) D) Exhaust gas boiler
.2 State important systems necessary of 9. Relief valves are provided on main Engine
operation of a Main Engine (Lubrication, Cylinders for protection against high
fuel, cooling water, starting, air charging A) Pressure
B) Exhaust temperature
C) Speed
1. Which of these is NOT fitted on the cylin- D) Level of water
der head of a diesel engine: 10. Function of a cylinder head relief valve
A) Exhaust valve is to
B) Turbo charger A) Prevent crankcase explosion
C) Starting valve B) Stop the engine
D) Indicator valve C) Reduce the speed of the engine
D) Release excessive pressure
2. Which of these is NOT a moving part of a Function of a crankcase relief door is to:
11.
diesel engine: Release pressure from crankcase
A)
A) Piston B) Stop the engine
B) Crankshaft C) Reduce the speed of the engine
C) Crankcase D) Detect mist inside the crankcase
D) Connecting rod . . 12. Jf cooling water becomes less in a diesel
3. Generator engine on board ships 1s started engine: Th e engine will:
using A) Make more noise
A) Hydraulic Oil Motors / Pressure B) Cool down too much
B) Compressed air C) Get overheated
C) Turbo generator D) Not start
D) Air compressor
Seamanship, Marin e Engineering and Human Relations

3 12 Question Bank Part 1 Section 2
13. Diesel engine bearings will get damaged if Match items from Column I to those in Column
supply of .. ....... is not enough II and write the results in the Answer Book.
A) Air Items in column II can be used more than once
'
BJ Fuel or n ot at all
C) Water Column I Column II
D) Lubricatin Oil Ql . Mountings on a Purpose
14. Speed of a diesel engine is adjusted by generator engine
changing th e supply of a) Indicator valve 1. Compressed air inlet
A) Air b) Relief valve 2 . Safety
B) Fuel c) Inlet valve 3. Fuel inlet
C) Water d) Exhaust valve 4. Fresh air intake
D) Lubricating Oil e) Starting valve 5. Combustion Gases
15. While a diesel engine is operating, one of f) Injector 6. Blowing through
the important pressures to check is _ 7. Stop fuel
A) Lubricating oil 8. Cooling
B) Starting air
C) Exhaust Gas Q2. Diesel engine What it does:
D) Steam pressure operating medium
16. One of the functions of lubricating oil in a a) Lubricating oil 1. Turns turbo charger
diesel engine is to reduce b) Cooling water 2. Increases air supply
A) Exhaust temperatures c) Fuel oil 3. Gives power
B) Friction between moving parts d) Turbo charger 4. Reduces friction
C) Exhaust gases e) Compressed air 5. Starts engine
D) Weight of the engine f) Exhaust gases 6. Removes heat
17. Function of crankcase lubricating oil in a 7. Controls fuel supply
diesel engine is to reduce friction between 8. Causes explosion
moving parts, cooling the parts and to_
A) Improve combustion Q3. Parts of diesel Movement
B) Prevent corrosion engines
C) Supply power a) Piston 1. Oscillates
D) Turn the crankshaft b) Crank shaft 2. Rotates in place
c) Exhaust valve 3. Moves up and down
d) Connecting rod 4. Stays in place
e) Cylinder head 5. Opens and closes
f) Air starting valve 6. Goes forward and aft
7. Moves from side to

side
8. Opens only at engine
starting

Part 1 Section 2
Question Bank
313
4
Q View of an auxiliary diesel engine. List of parts is given. Against each write the alphabet to
match the parts shown in the diagram (From A to L)
~H---is--r 8
~'"\r."t'-nr~g
Name Part No. Name Part No.

Cylinder head cover Push Rod
Piston Inlet Valve
Bottom end Bearing Crank Pin
Piston Ring Rocker Arm
Dip Stick/ Oil level gauge Connecting Rod
Seamanship, Manne
. Engmeerm
. · g and Human Relations
Part 1 Section 2
Question Bank
314
Q 5 Identify parts in this diagram and fill up the given table.

1
2
20
1
s
9
10
11
12
13
14
15
16
17
18
19
20
10

315
Q 6 Identify parts and fill in table given below

1.
2.
3.
3 4.
5.
4
6.
7.
8.
9.
10.
1. List four of the essential systems of a diesel engine.

2. List 6 major parts of a diesel engine
3. List four of the safety items fitted on a diesel engine
4. List four of the alarms that will come if something is wrong while a diesel engine is
operating
Additional questions for increasing knowledge (Select one correct answer)
1. The lower most ring on a diesel engine 2. The type of engine normally used for gen-
piston is called erators on a ship is
A) Split ring A) 4 stroke
B) Compression ring B) 2 stroke
C) Pressure ring C) 6 stroke
D) Oil scraper ring D) Medium stroke
3. For good combustion, the colour of the 4. When starting Engine on diesel oil, before
exhaust from a diesel engine should be injection the oil is:
A) Light brown A) Heated to same temp as heavy oil
B) Colourless B) Heated if necessary in cold climate
C) Passed through the purifier
C) Light grey
D) Mixed with steam
D) Bluish white
6. A cam shaft on a diesel engine operates _
5. Fuel injectors on diesel engines operate at
a pressure greater than A) Fuel injection pumps
B) Flywheel
A) starting air
C) Fuel valves
B) Compression
D) Starting valve
C) Scavenge
D) Lubricating oil
Ship 's propeller is fitted to 8. Thrust block for main engine is fitted at the
7.
A) Forward side of Engine
A) Stern tube
B) Intermediate shaft
B) Aft side of Engine
C) Tail shaft C) End of the cam shaft
D) Crankshaft D) Tail shaft
-
Seamanship, Marine Engineering and Human Relation s
Chapter 6 - Watch Keeping in the Engine Room

Learning Objectives
1. Taking over, keeping and handing over a 5. Watch keeping at sea
watch 6. Preparation for arriving in port
2. Watch keeping in port and at anchorage 7. Watch keeping at bunkering
3. Preparation before sailing 8. Watch keeping in dry dock and repair.
4. Watch keeping during Maneuvering
1. Before starting a generator engine, LO 2. Before starting an air compressor you will
hand pump should be operated to ensure that
A) Warm up the engine A) Valves are overhauled
B) Turn the engine B) Valves on discharge line are open
C) Check the level of the tank C) Fuel tank has fuel
D) Supply lub oil to moving parts D) Hot work permit is taken
3. UMS stands for 4. While the boiler is operating, you will
A) Unattended Machinery Space Operation ensure that
B) Uniform Machinery Space Operation A) Safety Alarms by-passed
C) Undermanned Machinery Space B) Black Smoke is coming out
Operation C) Vent valve is open
D) Under Machinery Space Operation D) Water level is maintained
5. While keeping a watch what will you 6. While bunkering is going on, what will be
check on a pump that is in operation the most important thing to monitor
A) Line Valves are Open A) Oil sounding in the tank being filled
B) Suction and discharge pressure B) Oil sample is being taken
C) Temperature of liquid C) Temperature of oil being supplied
D) Speed D) Oil sounding in bunker barge
Ql. Column I (Operating machinery) Column II (items to be watched while keeping the watch).
Can be selected more than once or not at all
a) Pump 1. Oil coming out of water side
b) Boiler 2. Discharge pressure of liquid
c) Purifier 3. Exhaust temperature
d) Compressor 4. Steering angle
e) Main Engine 5. Level in the tank
f) Oil transfer pump 6. Air Bottle Pressure
7. Water level
8. Weather conditions
1. List six of the important items any watch keeper in the engine room must know:
2. List six of the most essential items to watch on an operating diesel engine:
3. List four of the important things to watch on an operating air compressor:
4. List four of important item to check before starting an air compressor.
5. List four of the important things to watch on operating pumps in the engine room:
6. List four of the important things to watch on an operating boiler in the engine room:
7. List four of the important things to watch while bunkering of fuel is going on:
8. List four of the main objective during bunkering or oil transfer

Part 1 Section 2
Question Bank
317
Learning Objectives Chapter 7 - Working with Machines
.1 Id~ntify an d name major parts of a p edestal drill machine, and pedestal or a bench
grinder
.2
Drill holes using a fixed and portable drill machine
.3
.4 Use fixed grinding machine for grinding plates, chisels, and scrapper hand tools
Use hand grinder for grinding plates or parts
.5
Use buffing or brush attachments for hand grinder
.6
Lathe machine: Identify parts and common tools
.7
Explain common tasks that can be performed on a lathe
.8
Explain risks involved while working with machines : Drill, grinder, and lathe
.9
Carry out basic turning and facing operation on lathe
1. State two of the risks involved while using a grinding machine

2. State two of the risks involved while using a lathe machine
3. State two of the risks involved while using an electric drill machine
4. Give four of the common machines used for maintenance work found in the workshop of a
engine room on board:
1.During lathe work, goggles protect our 3. NOT a part of a lathe

eyes from A) Chuck
A) Heat B) Head stock
B) Flash Light C) Anvil
C) Metal chips D) Tool post .
D) Fumes 4. To make a new flange for a pipe you will
2, Danger of lifting heavy equipment need:
manually is _ __ A) Grinding machine, drilling machine and
A) Slip pipe cutter . . .
B) Fall B) Welding machine and m1llmg mac?me
C) Sprain C) Chisel, hammer and drilling mac~me
D) Fracture D) Lathe machine and drilling machme
1 II d write the results in the Answer Book. Items
Ql. Column I Machines or Tools needed

Jobs l . Bending machine
a) Cutting plates d. 2
. Grinding machine
b) Removing extra material after wel ing 3. Drill machine
c) Making holes in a plate _ Lathe
machine
4
d) Making an axial hole in a round bar 5. Hack saw
e) Joining two plates . Scissors
6
f) Cutting a joint _ Welding machine
7
,-- 8 . Bearing Extractor
...___-
. an d Human Relations
Seamanship , Marine Engineermg
What is the name of the whole

unit?
10
5
What is the name of the whole unit?

1.
2.
3.
4.
5.
6.
7.
8.
9.
Hint: Carriage Handle, Carriage Lock Screw,
Cross Lever Feed, Half Nut Lever, Threading
Dial, Longitudinal Feed Lever, Tool Post, Cross
3 Feed Hand wheel, Tool Post Slide Hand wheel.

319
A M~ Fl ~ H
Identify each item and write their name in the
table given below
1.
2.
8 9 10 11 12 13 3.
-- - 4.
r n~ n
1 2 3 4
~
5 6
I
,__
7
5.
6.
7.
8.
9.
Hint: Finishing, roughing, grooving, turning, 10.
forming, threading, grooving, facing 11.
12.
13.
8 What is the name of this equipment?

Identify each item and write their name in the
7 -➔-►c::;;::=i=:::;::=:;;;:===sr
table given below
6 9 1.
2.
3.
5 4.
5.
6.
7.
8.
11 9.
10.
11.
1 Hint: Motor, Step cone Pulley, Base, Column,
Drill Feed Handle, Belt, Spindle Head, Spindle,
Drill, Table clamp

Question Bank Part 1 Sect·
ion 2
320
What is the name of this equipment?
Identify each item an d write their name 1, h
nt e
table given below
1.
2.
3.
4.
7.
8.
9.
10.
Hint: Motor, Spark Guard, Tool Rest, Base, Light
Switch, Wheel Guard, Safety Glass Shield, Start
Switch, Stop Switch, Wheel, Dust collector
Short answer questions:
1. State the precautions to be taken while working on a lathe.
2. State the precautions to be taken while working on a pedestal drill machine.
3. State the precautions to be taken while working on a pedestal grinding machine.
4. State first six steps for working on a given task on a lathe.
5. State any six parts of a lathe.
6. State any six parts of a grinding machine.
7. State any six parts of a pedestal drill machine.
8. What will be indications if any of the (lathe, drill, grinding) machine is not working
properly?

Part 1 Section 2 Question Bank
321
Chapter. 8 - ~asic wel~ing ~nd cutting: Arc welding, gas welding, gas cutting
.1
State nsks involved 1n using and working with welding equipment_ Arc Welding and
Gas welding
.2
Identify components of arc welding machine used on board, personal protective
equipment, tools and accessories used for welding.
.3
Arc welding: Perform welding of butt joints and lap joints using arc welding
machine. Demonstrate basic procedures and techniques
.4 Take precautions while performing tasks
.5 Soldering ferrous and non-ferrous metal plates using gas welding equipment
.6 Use a gas cutting torch for cutting a plate or rusted part.
1. Gases used in gas welding are 2.The welding arc length should be:
A) Oxygen and LPG A) Less than the diameter of the electrode
B) CO 2 and LPG B) Equal to the diameter of the electrode
C) Acetylene and LPG C) 6-12mm
D) Acetylene and oxygen D) 20mm
3. Before starting arc welding you must: 4. When starting to weld you must hold the
A) Connect the earth clamp to the work electrode at an angle of about
piece A) 30°
B) Connect the welding cable to the earth B) 50°
clamp C) 70°
C) Connect the electrode holder to the earth D) goo
clamp
D) Extend the welding cables
5. Oxygen and is used in gas welding
on board.
A) LPG
B) Nitrogen
C) Acetylene
D) Argon
Identify the parts of a gas welding unit and write their names against space provided
G A
F
A
B G
S eamans h 1p,
. Manne • a nd Human Relations
. E ng1neermg
.
...
Question Bank Part 1 Sect·

322 ion 2
Q2. Identify the following pictures: (Pictures not to scale)
1. List 6 of the items used for personal protection while arc-welding
2. List 6 of the hazards during welding work
3. List 6 items of arc welding equipment
4. List 6 items of gas welding equipment
5. State first 6 steps for arc welding job.
6. State first 6 steps for gas welding job.

323
Chapter 9 - Lubricants and lubrication
.1 State type of oils and greases used on board in ER d .
crankcase oil, gear oil, hydraulic oil) an on Deck. (cylmder oil,
.2 States different methods of lubrication used on machi·ne d
. . . ry an components
.3 Identify grease nipples, greasing and oiling equipment
.4 Demonstrates use of grease guns
.5 Use oil can for filling in oil in crankcase of a machine
.6 State precautions to taken while working on or near an operating machinery
.7 State risks involved if oil or grease falls on hot surfaces
1. List 6 components of any Lubricating Oil System

2. List four checks to be made on a L.O. System
3. State four different ways a machine can be lubricated
4. State two of the important thing to observe while greasing a bearing through a grease
nipple
5. State 6 different places you will find the grease being used on board
6. State three precautions for care of lubricating oils from getting contaminated.
Ql. Identify the following:

Part 1 Section 2
Question Bank
324
Chapter 10 - Level measuring devices and techniq~es .

.1 Identify and name different level measuring devices and equipment listed below:
.2 Dip sticks, sounding rods, sounding tapes, gauge glass and sight glass .
.3 Demonstrate use of dip sticks, sounding rods , sounding tapes, in sounding a level of
liquid in a tank.
.4 Read level gauges to check oil and water levels in tanks
.5 State the type of fitting on a sounding pipe for a double bottom tank.
.6 State the importance of leaving the gauge in a working condition if cocks, air vents
have been tried while testing a gauge.
2. A dip stick is used for checking
1. A sounding tape is used for
level of oil in a
measuring level of a liquid in a:
A) Crank case
A) Crank case
B) Tank
B) Tank
C) Filter
C) Boiler
Cylinder D) Cylinder
D)
4. A gauge-glass for checking liquid
3. The most common item provided for
checking oil level in a small machine is level is fitted on which tanks
Sounding tape A) Fore Peak Ballast Tank
A)
B) Sounding rod B) After Peak Ballast Tank
C) Sight glass C) Double Bottom Tank
E) Remote level indicator D) Lub Oil Storage Tank
Q 1 What is meant by a self closing cock? Where will you find it in the engine room (give two
examples)?
Q 2 List four of the items that can be used for measuring level of fluid:
Match the Column

Ql.
Column I Column II
Type of level measuring device Commonly used for
(Can be used once, more than once, or not at all)
a) Dip stick 1. Tanks of large depths
b) Sounding rod 2. Multi Purpose
c) Sounding tape 3. Oil level in generator crankcase
d) Level indicator 4. Oil can
e) Gauge glass 5. Tanks of small depths
f) Remote level indicators 6. Grease cans
7 • Small to large tanks within the engine room
8· Sumps of purifiers, compressors, etc -

Qt . Identify the following:
Overfill
Add Normal
range

326
Chapter 11 - Lagging and insulation (SLOs)

.1 State purpose of lagging and insulation material on pipes and components in the
engine room .
.2 State importance of majntaining lagging and insulating material, and prevention of
contact with oil.
.3 State the common material used for lagging
.4 State precaution to be taken while handling a torn lagging.
1. What is used to prevent the transfer of 2. What is the common name for item used
heat from pipes or equipment? for preventing the loss of heat from pipes
A) Insulating material or equipment?
B) Cooling system A) Lagging
C) Air circulation B) Cooling system
D) Turbo charger C) Air circulation
D) Exhaust boiler
3. What materials are banned for use as 4. What material is not a commonly
insulation materials? used as insulation material?
A) Thermocole A) Wood
B) Fiberglass Wool B) Glass Wool
C) Asbestos C) Fire Bricks
D) Fire Bricks D) Plastic
1. What is meant by Insulating material? Give two examples

2. What is lagging?
3. Why is lagging used on pipes and valves? Name one of the common material used for lag-
ging.
4. Where will you find insulating material used on board?
Identify the material covering the equipment in each of the pictures

Chapter 12 - Electrical Tools and Equipment on board
Hand tools for electrical maintenance

.1 Identify basic tools and their safety aspects
.2 State precautions to be taken while working on electrical equipment
Electrical Components and Equipment in ER
.1 Electrical Equipment in ER (generators, motors, switch boards, lighting, switches,
starters, starter panels
.2 Identify electrical components - plugs, sockets, bulbs and tubes, cluster lights, and
portable lamps
.3 Carry out basic electrical maintenance: changing plugs, replacing bulbs and tubes, rig-
ging up cluster lights and portable lamps
.4 States importance of taking care of wires against chaffing
Short Answer Questions:

1 State the risk involved while working on electrical equipment.
2 What precautions on must take before commencing work on an electrical equipment
3 State procedure for trying out a machine after maintenance work is complete
4 Hand tools used for electrical items should be
Identify the following:

Part 1 Section 2
Question Bank
328
Chapter 13 - Chemicals on board:

.1 State chemicals used for different purposes on board: Air cooler cleaners; Boiler water
treatment, fuel oil treatment
.2 State precautions to be taken while using and handlin g chemicals on board
2. If any chemical fall on the body,
1. Chemicals should be stored in _ _
first action should be
A) In accommodation
A) Apply medicine to affected area
B) In Engine Room
C) In separate well ventilated store B) Wipe clean the affected area
D) On deck C) Call for the doctor
D) Thorough! y wash affected area
3. Chemicals onboard are NOT to be used for 4. Disposal of used/expired chemical
A) Cleaning the boiler container should be done by
B) Cleaning the cooking utensils A) Throwing into deep sea
C) Boiler water treatment B) Disposal with ship's garbage
D) Fuel oil treatment C) Disposal as per makers instruction
D) Burning in incinerator
Identify the following:
1. State four of the risks involved in handling chemicals

2. State three of the personal ?rotectiv~ gear to be used while handling chemicals
3. State three purposes for usmg chemicals on board
4. State precautions necessary while handling chemical on board.
5. How will you find whether a container contains a chemical?
6. How will you find the hazards of a particular chemical?

Part 1 Section 2 Question Bank
329
Chapter 14 - Steering Gear

.1 st
St~te function of a eering gear, its location and its importance for trouble free oper-
atwn .
.Z State checks to be made while taking a round in the steering flat
- .
1
Steering Gear is used to turn the 2. Steering Gear is located in the
A) Crane Boom/Jib A) Forward of Engine room
B) Main Engine B) On the bridge
C) Propeller C) In a separate compartment Aft of Engine
D) Rudder Room
D) Forecastle
3. Rudder of the ship is turned by means of a: 4. Which of the following is a
A) Hydraulic pump correct statement
B) Propeller A) Rudder is connected to the propeller
C) Ram and cylinder arrangement B) Propeller is turned by the rudder
D) Steering wheel C) Steering gear is located at aft part of the
ship
D) Rudder is located in the steering flat
1 State the consequences of a steering failure on board a ship
2 State the items to be observed while taking a round of the steering flat

Question Bank Part 1 Section i
330
Chapter 15 - Storage tanks . .

.1 State types of storage tanks_ wing tanks, double bottom tanks, tanks w1thm the engine
room such as lube oil storage, expansion tank oil sump)
.2 State liquids stored in tanks: Fuel, lubricating oil, and fresh water.
.3 State the purpose of a 'quick closing valve' .
.4 Identify a quick closing valve .
1. A 'Quick closing Valve' is fitted on 2. 'Man Hole Door' on a tank is fitted for
A) Boiler steam line A) Allowing entry to the tank when needed
B) Main engine cooling system B) Preventing entry by unauthorized persons
C) Fuel Tanks above Double Bottom Tanks C) Preventing damage to tanks
D) Compressed air line D) Strengthening the tank
3. A 'Quick Closing Valve" 4. Air vent to tanks is provided for
A) Prevents fire from occurring A) Preventing build up of pressure or vacuum
B) Can be remotely closed in an B) Allowing liquid to come out when tank is
Emergency full.
C) Prevents oil spills in engine room C) :Preventing fires
D) Stops air supply to main engine D) For ventilation
5. Sounding Pipe on tanks are fitted for 6. 'Quick Closing Valve' operation
finding is carried out from
A) Level of liquid in the tank A) A Remote location outside Engine Room
B) Pressure in the tank B) Anywhere in the engine room
C) Temperature in the tank C) Steering flat
D) Abnormal sound in the tank D) Navigation Bridge
7. Ballast tanks on a ship are fiJled 8. Settling tanks on ships are provided for
up with _ _ _ _ _ _ __ A) Allowing water and slud¥f to separate
A) Drinking water before oil separator
B) Sea water B) Mixing oils before use
C) Cargo oil CJ Storing oil before its use
D) Water from other tanks D) Filtering water from fuel oil
1. State six different types of tanks (in terms of substance being stored) to be found on board
2. State six of the most common parts of storage tank on board
3. State at least six items each storage tank is required to have.
4. State the function of a quick closing valve. Which type of tank the quick closing valves are
required to be fitted?

Part 1 Section 2 Qu estion Bank
331
Chapter
. 1 6 - Emergencies in the en .
g1ne room:
.1 State emergen cies that can occur in the engine roo m (F u' e, fl oo d 1ng,
' bl ac k out, 01·1
. . . . .
spill , 1n1unes, electric shocks, burns ,)
.2 State the difference between, machinery failure alarms, general alarm and CO flood-
ing alarm. 2
.3 State action to be taken on hearing each type of alarm
.4 State that all alarms in the ER are of Audio Visual Type
1. On finding an injured p erson in the engine 2 . A 'Fire Alarm' in the engine

room, your first action will be to: room is activated:
A) Apply First Aid A) From the bridge
B) Report to the duty officer on watch B) Automatically on machinery failure
C) Bring a stretcher C) Due to a 'black out'
D) Look for the cause of the injury D) Due to a fire in the engine room
3. On hearing a CO2 alarm in the engine 4. A 'machinery failure Alarm' in the
room, your first action will be to: engine room is activated:
A) Report to the duty officer on watch A) From the bridge
B) Use a large fire extinguisher on the fire B) Automatically on machinery failure
C) Use emergency exit to get out C) Due to collision of the ship
D) Raise fire alarm D) Due to a fire in the engine room
5. A 'General Alarm' is activated:
A) From the bridge
B) Automatically on machinery failure
C) Due to a 'black out'
D) Due to a high bilge level
1. State any four of the emergency situations that can occur in the engine room.
2. State different types of alarm fitted in the engine room.
3. What is meant by 'Audio-visual alarm'?
4. What is a General Emergency Alarm, what is the reason for sounding the Alarm?
5. How does a Fire Alarm Sound?
6. List Names of any six types important Alarms on a ship.
7. What is a ship security Alarm?
Identify the difference between the two items What ELSA and where is it normally kept.
shown below

332
Chapter 17 - Fire extinguishing equipment in the engine rooni .J .

.1 List fire extinguishing equipment found in the engine room (Portable extingmshers,
non-portable extinguishers, fire hydrants, hoses and nozzles)
.2 State methods of detecting fire in the engine room (smoke type, heat type, flame type)
.3 State methods of raising alarm on finding a fire in the ER.
.4 State the function of CO 2 . Water fog, high expansion foam) .
5 State the purpose and location of pump that supplies water ·m emergency.
1. Fixed Fire Fighting system for 2. NOT a part of fire triangle

Engine Room? A) Fuel
A) DCP B) Heat
B) CO 2 C) Electricity
C) Inert Gas D) Air
D) Nitrogen
3. Main Fire Pump is located 4. To fight an electric fire you would use
A) On main deck A) Dry powder
B) At the fire station B) Steam jet
C) In the Engine Room C) Water spray
D) In the Steering flat D) Special Foam
5. Means for forcing water out of a 6. High expansion foam system is
portable extinguisher suitable for fighting fires in
A) CO 2 Cartridge A) Accommodation
B) Air Cartridge B) Cargo holds
C) Chemical cartridge C) Engine Room
D) Nitrogen cartridge D) Deck of a ship
7. Which of the following is provided For 8. The emergency fire pump on a
connecting to shore water supply? ship is located
A) Foam tank A) At the poop deck
B) Fixed Foam System B) Inside the Engine room
C) Fire hydrant C) Outside the Engine room.
D) International shore connection D) At the boat deck.
9. Your first actions upon finding a fire? 10. Fire hoses on ships are made of
A) Use portable extinguisher A) Strong canvas
B) Start the fire pump B) Thick cloth
C) Raise an alarm C) Leather
D) Switch off electrical power supply D) Flexible steel
11 . What is used in case the fire in the 12. Which one of the following will be used
engine room becomes out of control? first on a small fire in the engine room:
A) Portable fire extinguisher A) Portable fire extinguisher
B) 45 Liters Foam Fire Extinguisher B) Fire Blanket
C) Fixed CO 2 fire extinguishing system C) Fixed fire extinguishing system
D) Fire pumps and hoses. D) Fire pumps and hoses.
1. List the common types of fire extinguishing equipment for engine room fires.
2. What are the types of fire detectors used in the engine room?
3. List items you will find in a 'fire man's outfit on board.
4. List any 6 Fire extinguishing media used on a ship.
5. What is an Emergency fire pump and where is it located?

Q1 . . Identify
. '-·
the items of equipment and w rite their names in the given chart .
- A. B. C.
OXYGEN
z
0
•
j::
0
< :::c
w
a:
z CONTINUOUSLY ~
i' BURNING
\'. .
t:.:~ <
::c F I R E
~~ -·, 0
FUEL
D. E. F.
G. H.
A D G
B E H
C F I

334
Answer Key
. f100 w1"th the duties of ER Rating
Ch aoter 1 - F am1T1anza
1 2 3 4 5 6 7
C B C B A B C
Chapter 2 - Instruments m t he E n2me

. R oom
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A A B D C A B C C B B C A B
Match the columns:
Ch aper
t 3 - M am
· t enance and Workshop Practice
1 2 3 4
B A C B
Match the columns:
Ch ao t er 4 - A uuT1ary M ac h"mery
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
A B A A D D B D A C C B B B A B A
18 19 20 21 22
A A D C A
I ~~r ~T~;T~i' I ~) I 1 I ~I 2
I Q. I 1 I ~) I ~ I ~ I ~) 121
~ I ~ I ~) I ~) I ~) 121 I Q. 1~ I ~ I ~ I ~) I ~ I 2 I
4
IQ.JI
. an dM.
Ch aoter 5 - A UXIT1ary E ngme am E ngme
.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
B C B B B B C D A D A C D B A B B

Match the columns:
IQ.l I ~ I ~) 1 I ~ 1 ~ 1 ? I
1 1 I ~ I ~ 1~ I ~ 1 ?I
2 2
I Q.Z 1 2 2
2 2
IQ.J I ;> I ~ I 1 I ~ I 1 I 2I
AdditionaI questions i or mcreasmg
. knowledge:
1 2 3 4 5 6 7 8
D A B B B A C B
Chao t er 6 - Wt
ac hKeep1ng ID
· the Engine Room
1 2 3 4 5 6
D B A D B A
Ch aoter 7 - W orki ng with Machines

1 2 3 4
C C C D
Chaoter 8- W eId"ID~
1 2 3 4 5
D B A C C
Ch apter 1O- L eveI Measuring Devices

1 2 3 4
B A C D

Ch a p t er 11 - L 3 !!!!1·ng and Insulation

I 2 3 4
A A C D
Ch a ot er 13 - Ch em1·cals on Board
I 2 3 4
C D B C
Ch apter 14 - Steeri ng Gear

I 2 3 4
D C C C
Ch a per
t 15 - S torai e Tanks
I 2 3 4 5 6 7 8
C A B A A A B A ·•
Ch a o t er 16 - E meri enc1e
· s in the Engine Room
1 2 3 4 5
B D C B A
. h"me: E;q mpment

Ch apt er 17 - F"ire E xtinems
. . . the E ne:me Rom
m 0
1 2 3 4 5 6 7 8 9 10 11 12
B C C A A C D C C A C A
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Seamanship, Marine Entineerint

and Buman Relations ; ~1i::2~~~ion

Published and Distributed by:

India, Pin Code: 400 614

Printed in India by - Siddhi Offse t, Prabhadevi, Mumbai

Part 2 of this series contains chapters on General Ship Knowledge

Aim of BES is 'Enhancement in Quality of Maritime Education and Training in India'.

On behalf of the Board of Examinations for Seafarers Trust

Capt. Subrato Mukherjee

Date: 22 nd September, 2014.

I compliment the Board of Examinations for Seafarers Trust fer this

I am sure, the boaklets will help the candidates, Teachers.and Institutes

I am delighted to learn that the Board of Examinations for Seafarers Trust

I am happy to note that the Board of Examinations for Seafarers Trust

<fi'Gfr,f~.~.W'ft' ~ 'ii!IPl~tl icil<I

No.NA/ Notes/ 2011-12 June 15, 2011

~fflff, ' l { f f i f ~ 'l:!Tffl~.trnf~.

Ministry of Shipping, Road Tranaport & HlghWIY'

My heartiest congratulations to Board of Examination of Seafarers Trust for coming

With Best Wishes,

From Capt. V. N. Aindley Date: 19-09-2014

In my opinion copies of these two volumes on board would prove to be a valuable

With Best Wishes,

Such simplicity is what we require to run ships efficiently and safely.

From: Sanjeev S. Vakil

The section on Marine Engineering knowledge is comprehensive though condensed

I would like to suggest that the pictures of engineering equipment be depicted in

With all good wishes, I remain

It is indeed commendable of the Board of Examinations for Seafarers Trust to have

From Dr. P Misra

With Best Wishes ,

From Capt. P.S. Barve

With Best Wishes,

Message from Capt. N. Hiranandani,

1. To meet future demand resulting from retirements

In the past trainee ratings hailed from traditional family sea£ · dh d1

My congratulation to the Board of Examinations £

Personal Development and Basic Ship Knowledge

Reading Writing Speaking

Personal Development and Basic Ship Knowledge

Chapters Page No.

2 How to improve own English?

4. The Whole Person

5. How to succeed in life

Seamanship, Marine Engineering and Human Relations

10. Team Work

13. Gender Sensitisation

Seamanship , Marine Engineering and Human Relations

Why is learning important in life? Learning is the key to our

► Success You learn something every .d ay

People generally People are able to ...

10% of what they read Define List

30% of what they see

70% of what they

Seamanship, Marine Engineering and Human Relations

Jvocabularvl------l Learning 1----- Memory

Seamanship ' Mari ne Engmeermg

2 How to improve own English?

Reading Writing Speaking

Here are some tips: Reading is to the mind what

Seamanship, Marine Engineering and Human Relations

Start right now with the following exercise:

Seamanship , Marine Engineering an d Human Relations