MARCH 2023:

1. How is a 2 stroke engine started? Describe the sequence of engine starting. (5)
a. Draw the timing diagram of engine starting showing crank position of each step. (6)
b. What is overlap in engine starting? (5)
2. Describe the following terms with respect to diesel engine with suitable diagrams.
a. Piston stroke.
b. Swept volume
c. Clearance volume
d. Compression ratio.
3. Draw a simple sketch of cylinder head of 2 stroke main engine, describing function of
cylinder head. (6)
a. Name the mountings on the cylinder head and their functions. (6)
b. Name the material of cylinder head, giving reasons. (4)
4. Draw a simple sketch of a crankshaft with names of the different parts of the crankshaft. (8)
a. Describe function of crankshaft of 2 stroke diesel engine. (4)
b. Describe fittings on crank shaft for various operation of main engine. (4)
5. What is the importance of measuring bearing clearance in a diesel engine? (4)
a. What is bridge gauge? Describe its usage with diagram. (6)
b. What are the other recommended methods used on board to check bearing
clearances. (6)
6. Draw a diagrammatic sketch of auxiliary boiler on your ship, labelling all the mountings
provided. (8)
a. Describe function of each mounting in brief. (8)
7. What is definition of the following terms: (10)
a. Indicated power
b. Brake power
c. Sfoc
d. Mechanical efficiency
e. Thermal efficiency
i. What is an indicator diagram of a diesel engine? Draw a diagram and show
different points related to diesel engine power measurement.
8. What are the safety interlocks provided in compressed air starting system of main engine?
(8)
a. Describe with a diagram the air starting system of a main engine. (8)
9. Describe how a fuel injector components deteriorate with time. (6(
a. What are the effects of deterioration of fuel injector components? (6)
b. What are the signs of a bad injector? (4)
1. How is a 2 stroke engine started? Describe the sequence of engine starting. (5)
a. Draw the timing diagram of engine starting showing crank position of each step. (6)
b. What is overlap in engine starting? (5)
2. Describe the following terms with respect to diesel engine with suitable diagrams.
a. Piston stroke.
b. Swept volume
c. Clearance volume
d. Compression ratio.
 3. Draw a simple sketch of cylinder head of 2 stroke main engine, describing function of
cylinder head. (6)
a. Name the mountings on the cylinder head and their functions. (6)
b. Name the material of cylinder head, giving reasons. (4)

The cylinder cover mountings are:

1. Air starting valve

2. Fuel valve.
3. Exhaust valve.
4. Indicator valve
5. Safety valve.

Air starting valve:

The starting valve is fitted on the cylinder cover. It is controlled by control air from the starting air
distributor. It’s kept in closed positon by a spring. When the main starting valve is open, the starting
air pipe up to the starting air valve is pressurised. The control air from the control air distributor acts
on the piston of the starting valve. The starting valve opens and the air flows from the starting air
pipe to the cylinder. After starting, the space above the air piston is vented through the vent pipe of
the air distributor.

Fuel valve:

The fuel valve also known fuel injector is fitted on the cylinder cover by two holding down bolts. The
fuel valve atomize the high pressure fuel supplied by fuel ump and injects into the cylinder. In this
fuel valve, the fuel oil is circulated when engine is standby. When the engine is started, the
circulation of oil will stop and the pressurised oil is supplied to the cylinder. The fuel valves consists
of a valve body, valve head and union nut. The non-return valve, thrust spindle with thrust spring
and spindle guides are assembled inside the valve body. The spindle guide consists of spindle guide,
nozzle, thrust piece and cut off shaft. The spindle guide assembly is assembled with press fit. Cut off
shaft is pressed against the tapered valve seat of spindle guide by the action of the thrust spring. The
spring pressure is transmitted through the slotted thrust foot. The thrust spring determines the
opening pressure of the valve. The non-return valve consists of housing, thrust piece, slide and
spring. The non-return valve is assembled with press fit. The slide of the non-return valve is pressed
by a spring against the tapered valve seat inside the non-return valve. In this position, the head of
the slide uncovers a small bore arranged for circulation purposes in the thrust piece.

Exhaust valve:

Exhaust valve is fitted in the central bore of the cylinder cover. It is attached to the cylinder cover by
four studs and forms a gas tight seal. The burnt exhaust gases from the cylinder are expelled through
the exhaust valve to the exhaust manifold. The valve seat is fitted to the bottom of the valve
housing. The valve spindle passes through the spindle guide fitted in the bore of the valve housing.
The valve spindle is made from nimonic alloy. A vane wheel is fitted to the valve spindle at the
bottom part which rotates the spindle when the engine is running. The air piston and hydraulic
piston are mounted at the top of the spindle. The air piston is locked to the spindle by a two piece
conical ring. It keeps the valve closed and acts like a spring. The hydraulic piston opens the exhaust
valve when the oil under pressure acts on top of the piston. A high pressure pipe connects the
hydraulic cylinder on top of the exhaust valve and the actuator mounted on the top pf the camshaft.
Oil is supplied to the hydraulic actuator through a non-return valve. The exhaust valve cam mounted
in the camshaft controls the timing of the exhaust valve. The exhaust valve is water cooled. The
cooling water flows from the bottom through the bores in the valve housing and discharged from
the top of the valve housing.

Indicator valve:

Indicator valves are fitted on each cylinder. It is a double seated valve with spring loaded closing
face. The combustion chamber of the cylinder is connected to the valve through a bore. It is used to
take indicator cards. The indicator valves are kept open while turning the engine or blowing through
the engine with air. Any accumulation of oil or water are expelled through the indicator valve when
blown through with air. This will indicate the cylinders which are having problems. The engine
should not be turned with turning gear motor without opening the indicator valves.

Safety valve:

A safety valve is fitted in each cylinder cover, when the pressure in the cylinder increases above the
maximum allowed peak pressure, the safety valve lifts and releases the excess pressure.
 4. Draw a simple sketch of a crankshaft with names of the different parts of the crankshaft. (8)
a. Describe function of crankshaft of 2 stroke diesel engine. (4)
b. Describe fittings on crank shaft for various operation of main engine. (4)

A crankshaft is a rotating shaft that converts reciprocating motion of a piston into a rotational
motion. In the combustion of the fuel-air mixture, power is produced. This power is transformed into
rotary movement of the crankshaft. The linear motion of the pistons is converted via the connecting
rod into torque. It’s then passed to the flywheel

The crankshaft’s shaft is bored with some holes that feeds the motor with oil. This oil smoothens the
movement. The counterweights aid the adjustment of the framework and the heaviness of the
connecting rod.

Crankshafts also function as load bearing as some load is withstand during the process. One of the
load is the severe bending and torsional stress.

As the rotary movement of the crankshaft is constantly being accelerated and decelerated, further
loads from torsional vibration is added.
 5. What is the importance of measuring bearing clearance in a diesel engine? (4)
a. What is bridge gauge? Describe its usage with diagram. (6)
b. What are the other recommended methods used on board to check bearing
clearances. (6)

The clearance measurement of the main bearing determines the amount of wear down the bearing
has been subjected to.

The clearance of the bearings will depend on the size of the engine but for a 900mm bore engine the
clearance is between 0.40 and 0.70 mm with a maximum allowable of 0.9mm. Similarly for a 500mm
bore engine the allowable clearance is provided as between 0.4mm and 0.55mm

All the modern bearings are usually of the thin wall type with non adjustable clearance. If the
bearing clearance has reached it’s maximum limit or the bearing got damaged, it cannot be
reconditioned and needs to be changed.

BRIDGE GAUGE:

This method is used in SULZER 2 stroke marine engines where the bearing‘s shell is removed along
with the keep (the bearing shell is lined with the keep). After that a bridge is fitted over the top of
journal pin, from port to starboard, making a bridge over the crankshaft with two ends supported on
the cross girder.

A simple vernier type depth gauge is then inserted in the hole provided on the bridge and the scale
of depth gauge is rested on the crankshaft pin. The total depth on the scale is measured and
compared with the previous reading and the reading in the manual for calculating the wear down of
bearing.

In old model SULZER engines, a collar is provided in the bearing shell along with a small hole. Thus
without removing the keep, the bridge is fitted adjacent to the keep and the depth gauge is used
from the hole provided in the shell to measure the shell wear down.

In some engines, after removing the shell and the keep, the bridge is installed as explained in the
above point. Also, in place of depth gauge, a feeler gauge is used to measure the clearance between
the journal pin top and the bridge bottom. The bridge used here is different in terms of height and
the gap between the pin and the bridge is very less as compared to that of the bridge used in the
above mentioned method.
Other methods:

Telescopic or Swedish Feeler Gauge

In engines like MAN B&W, this is the most common method used to measure the bearing clearance
of the top shell. In this method there is no need to remove any connection or keep for measuring the
clearance.

The telescopic gauge is inserted between the gap of the crank web and the bearing keep. When the
tip reaches the shell top, the feeler is inserted between the shell and the pin to check the clearance.

Dial type Depth Gauge

This method is used in new MAN B&W engines (SMC-C) which does not require the top keep to be
removed. The lube oil pipe connection screw hole is in the bearing keep which can be accessed from
the hole on the bearing shell.

The dial gauge is inserted in this screw hole and the reading is taken as the clearance for upper shell.

Lead wire

This is a traditional method and to be used when no other alternative or tools are present. In this
method, lead wire is inserted at different positions between bearing and pin. The bearing housing is
tightened. Ensure not over squeezed the wire more than 1/3 rd of original diameter. General

Method for taking clearance using lead wire:

1. Turn the crank shaft to set the crank at TDC position.

2. remove locking and slacken the nut to lower the bottom half with bolts.
3. Three lengths of lead wires to be inserted or laid circumferential in the bottom half at three
different places.
4. Close the bottom half into position and tighten the nut to its rated tightening torque.
5. Open and lower down the bottom half again.
6. Remove the lead wires and take the measurement.

It must have within the limit, if out of limit, the bearing shell must be replaced with new ones or
readjust the clearance by adjusting shims.
 6. Draw a diagrammatic sketch of auxiliary boiler on your ship, labelling all the mountings
provided. (8)
a. Describe function of each mounting in brief. (8)

Main steam Stop Valve:

The steam generated in the boiler is supplied to ship’s system through this valve. It usually is non-
return type of valve directly mounted on the steam space of the boiler shell. The body is made of
cast iron, and the valve seat is of gunmetal.

2) Auxiliary steam Stop Valve:

In most of the steam system on ships, a separate steam line provided from the boiler for the small
auxiliary system is supplied through this valve. The valve is smaller in size and usually of a non-return
type.

3) Boiler Safety valve:

This is one of the most critical boiler fitting used in the event of unsafe excessive pressure inside the
boiler. The boiler safety valve is designed to come into action to release the overpressure. The lifting
pressure of the valve is set prior to its installation and locked in the presence of a surveyor so that it
cannot be changed later on.

Boiler safety valves are installed in pairs with one valve set at a little higher pressure to ensure boiler
does not explode of overpressure in the event of failure of any one boiler safety valve.
4) Boiler level gauge glass:

Boiler gauge glasses are fitted in pairs for manually checking the water level inside the boiler drum. It
is on the basis of the boiler pressure that the construction of the gauge glass is decided. The boiler
water level indicator is an important boiler fitting as it tells the status of water level inside the steam
drum of the boiler.

5) Air release valve or boiler vent:

This valve is fitted in the headers, boiler drum etc., to avoid imploding of the boiler when it is
depressurized or when initially raising the steam pressure. The term implosion is just opposite of an
explosion. In this scenario, the pressure inside the boiler will reduce sufficiently below atmospheric
pressure to cause the shell to buckle inwards.

6) Feed check and control v/v:

This valve controls the supply of steam supply as per the demand and is fitted in both main and
auxiliary steam line after the stop valve. They are non-return valves with a visible indication of open
and closed position.

7) Pressure gauge connection:

The pressure gauge can be fitted in the superheater, boiler drum and wherever it is necessary to
read the real-time pressure reading from the local station.

8) Boiler blowdown valve:

A bottom blowdown valve is used to empty the boiler either completely for maintenance purpose or
partially for water treatment of boiler when the chloride level in the boiler water is on a higher side.

9) Scum blow down valve:

It’s a shallow dish type arrangement fitted at the normal water level which allows the blowdown of
floating impurities, oil foaming etc. from the water surface.

10) Sampling connection:

Generally, a sampling water cock arrangement is also fitted with the cooler, in series, so that water
sample can be collected at any time for feed water analysis.

11) Whistle valve:

If there is a provision for the steam whistle in the ship, then steam is supplied directly from the
boiler through a small bore type non-return valve known as whistle valve.

12) Low-Level alarm:

This is a device used to initiate audible warning at low water level condition. Another shut down
alarm (burner cut off) is fitted below this level (Low-Low Level alarm) to prevent overheat of boiler
drum.

13) Soot blowers:

Required to blow the soot and the combustion products from the tube surfaces. It is operated by
steam or compressed air.
14) Automatic feed water regulator:

This device is essential to ensure appropriate water level in all load conditions and is fitted in the
feed line. Multiple element feed water control system is used in boilers with high evaporation rate.

15) Manhole:

The boiler is provided with multiple manhole doors, allowing inside access to the crew for
inspection, cleaning and maintenance of boiler tubes and internal parts. Usually, one door is
provided in the steam drum and one in the water drum.

16) Mud box:

The mud box in the boiler is provided at the bottom of the water drum to collect the mud (muddy
impurities) of the water drum.
7. What is definition of the following terms: (10)
a. Indicated power
b. Brake power
c. Sfoc
d. Mechanical efficiency
e. Thermal efficiency
i. What is an indicator diagram of a diesel engine? Draw a diagram and show
different points related to diesel engine power measurement.
 8. What are the safety interlocks provided in compressed air starting system of main engine?
(8)
a. Describe with a diagram the air starting system of a main engine. (8)

Turning gear Interlock. This device prevents the engine from being started if the Turning gear is
engaged.

Running Direction Interlock. This prevents the fuel from being supplied if the running direction of the
engine does not match the Telegraph.

Starting Air Distributor in end position. This prevents starting from taking place if the shifting of the
Distributor has not been completed.

Main Lube. oil pressure, Piston cooling pressure, Jacket water pressure, and important parameters
must be above the required minimum.

Auxiliary Blower Interlock. The Auxiliary Blower is provided in case of Constant pressure turbo
charging.

Air Spring pressure Interlock. In case of the present generation of engines using Exhaust valves shut
by Air Springs, the Air Spring pressure must always be maintained, else the exhaust valve may not
close.

8(a) refer to Q1.

 9. Describe how a fuel injector components deteriorate with time. (6)
a. What are the effects of deterioration of fuel injector components? (6)
b. What are the signs of a bad injector? (4)

Over heating/under cooling

If cooling of the injector is reduced, either by fuel valve cooling system or poor heat transfer to the
cylinder head, then the working temperature of the injector will rise. This can cause:-

· Softening of the needle and seat which increases the possibility of nozzle leakage and/or,

· Fuel to expand/boil out of the fuel sac, leading to carbon trumpet formation, and increased
levels of HC and smoke in the exhaust gases.

Over cooling

More common on older vessels with separate fuel valve water cooling systems. When the injector is
over cooled, the tip of the injector falls below the condensation temperature and acid corrosion due
to the sulphur in the fuel oil occurs. This can severely corrode the injector tip, causing the spray
pattern to be affected.

Nozzle (needle/seat) leakage

This fault will produce carbon trumpets as the dribble of fuel burns close to the tip and the carbon
deposits remain. The formation of the trumpets will have a progressive affect by influencing the
spray pattern of the fuel, and this can be detected in the increased exhaust gas temps and smoke
levels.

Nozzle leakage can sometimes be identified by a seat defect, i.e. the seat is no longer narrow in
appearance, and is caused by:-

· Insufficient cooling,

· Dirt within the fuel damaging/abrading the seating area,

· Excessive needle valve hammering, due to excessive time in service, excessive needle lift or
spring force.

Weak spring

This will cause the injector to open and close at a lower pressure. Thus the size of the fuel droplets
will increase during these injection periods.

Increased droplet size at the start of combustion will decrease the maximum cylinder pressure (late
combustion), whilst increased droplet size at the end of combustion will increase the exhaust
temperature and smoke (afterburning).

Causes of a weak spring are usually metal fatigue, due to an excessive number of operations.
Slack needle

Slight leakage between the needle valve and its body is required to provide lubrication of the moving
parts. However excess leakage due to a slack needle will allow a greater quantity, and larger size of
fuel particle to pass between the valve and body.

The quantity of leakage should not influence injector performance unless excessive, but dirt particles
between the needle and body can increase friction and make the needle action sluggish.

The cause of a slack needle is usually poor filtration of the fuel causing wear between needle and
body.

Poor atomisation

This will increase the size of the fuel droplets, which will increase the time required for combustion.
Thus engine noise, exhaust smoke, exhaust temperatures, etc will increase. Poor atomisation can be
caused by low injection pressure (fuel pump wear), high fuel viscosity and nozzle hole obstruction
such as carbon trumpets.

Poor penetration

This will reduce the mixing which occurs between the fuel and air, and will increase the over-rich
areas in the centre area of the cylinder. Thus only following combustion in the centre area will the
expanding gases move the fuel charge into the air rich outer ring of the cylinder where the greatest
mass of air is present.

This will increase the time required for combustion as the fuel/air mixture is not correct in many
areas, and hence afterburning, exhaust temps, and smoke will increase.

Causes of poor penetration is reduced injection pressure, and nozzle hole blockage such as trumpets
or sac deposits.

Over penetration

This will occur when the air density within the cylinder is reduced, or with over-size holes. The liquid
stream travels too far into the cylinder, so that a high level of liquid impingement on the liner wall
takes place. This will remove the liner lubrication, and once burning will greatly increase the liner
wall temperature, and its thermal stress.

If this over penetration is caused by prolonged low power operations, then “slow speed” nozzles
should be fitted.