1. Why governor spring is conical?

In governor the measured parameter is speed & speed is measured by the flyweights.
Flyweights sense the speed by centrifugal force, so CF = mw2r (where w is angular
velocity). So since the speed is measured in power of square, the correcting action
should also be in power of square. In conical spring the stiffness also behaves in
power of square pattern (stiffness= force/deflection), so when u apply a unit
force, the deflection is in power of square). So the springs are conical.

2. What happens when all the flywheel markings are somehow erased and how will you
check the timings, tappets etc?
The cam shaft will give a brief idea regarding position of the engine. There will
be two units which will be in TDC so just rotate the push rod to see which one is
there in the power stroke because the unit which will be in TDC, the push rods will
be rotating freely and thus we can check the tappet of that engine. for timing also
we have to see the cam position and marking on the pump plunger but it is very
difficult to know the value exactly when fuel injection is starting and stopping as
there is no marking in the flywheel.

3. Pipe Schedule
Pipe Schedule is the term used to describe the thickness of a pipe. The outside
diameter of a pipe is the same for all Schedules in a particular nominal pipe
diameter. These schedule numbers bear a relation to the pressure rating of the
piping. There are eleven Schedules ranging from the lowest at 5 through 10, 20, 30,
40, 60, 80, 100, 120, 140 to schedule No. 160. Regardless of schedule number, pipes
of a particular size all have the same outside diameter (not withstanding
manufacturing tolerances). As the schedule number increases, the wall thickness
increases, and the actual bore is reduced. For example: A 100 mm Schedule 40 pipe
has an outside diameter of 114.30 mm, a wall thickness of 6.02 mm, giving a bore of
102.26 mm. A 100 mm Schedule 80 pipe has an outside diameter of 114.30 mm, a wall
thickness of 8.56 mm, giving a bore of 97.18 mm.

4. What does 15W40 denote?

Here 40 is SAE number. SAE number like SAE 10, SAE 20 corresponds to that having
kinematic viscousity at 100C. Likewise W denotes the winter grade for cold start.
Thus SAE 15W40 denotes that the lube oil of this grade has kinematic viscousity of
40 cst at 100C and its winter grade is 15W ie, the cranking and pump ability of
this lube oil grade has passed tests of 20W and 15W but failed test of 10W at below
zero temperatures.

5. How much is Needle vv lift?

Generally 1mm maximum for 320 bar lifting pressure.

6. Accumulation of pressure test in boiler?

Classification Societies require that that when initially fitted to boilers safety
valves must be subjected to an accumulation of pressure test to ensure the valves
are of the correct discharge capacity for the boiler. To conduct such a test, all
feed inlets and steam outlets to and from the boiler must be closed and maximum
firing load achieved. Accumulation of pressure must then not exceed 10% of working
pressure. Duration of test is not to exceed 15 minutes for cylindrical boilers and
7 minutes for water tube boilers.

7. How induction motor works?

An induction motor or asynchronous motor is a type of alternating current motor
where power is supplied to the rotor by means of electromagnetic induction. An
electric motor turns because of magnetic force exerted between a stationary
electromagnet called the stator and a rotating electromagnet called the rotor. In
an induction motor, the current is induced in the rotor without contacts by the
magnetic field of the stator, through electromagnetic induction. The current in the
primary side creates an electromagnetic field which interacts with the
electromagnetic field of the secondary side to produce a resultant torque, thereby
transforming the electrical energy into mechanical energy. The induction motor does
not have any permanent magnets on the rotor; instead, a current is induced in the
rotor. The stator windings are arranged around the rotor so that when energized
with a polyphase supply they create a rotating magnetic field pattern which sweeps
past the rotor. This changing magnetic field pattern induces current in the rotor
conductors. When current flows through a conductor a magnetic field is produced
around the conductor. This current interacts with the rotating magnetic field
created by the stator and in effect causes a rotational motion on the rotor.

8. How signal is carried to ECR from rpm indicator?

Magnetic pick up sends signal to transducer. An output coming from a transducer is
filtered, signal conditioned and chopped. Finally it is converted into square
waves. The square wave is passed through Phase Lock Loop multipliers. This output
is gated by a precise time base generated through piezo crystals and then counted.
These counts are displayed on bright LED's. It's nothing but R.P.M. with accuracy
of 1 RPM.

9. Insulation of motor is found to be 0.5 mega ohms what we can do to bring back
the insulation?
Disconnect motor
Clean windings
Dry the motor by heating lamp
Check visually for any wires broken
Put fast drying varnish
Test insulation

10. What is a scavenge limiter?

The "scavenge air fuel limiter" is an integral part of an electronic governor and
it limits the fuel according to the pressure measured on the scavenging air
receiver by a transducer. The limiter curve is set according to engine makers
specification. During starting when the scavenge air pressure is low it limits
fuel.

11. What is injection delay?

In jerk type pump when spill port or spill valve and suction port or suction valve
both get closed, at that time injection should start practically, but due to
inertia of fluid and other moving parts of injector, injection does not start
immediately, although oil is considered incompressible but it gets compressed
slightly, and at the same time the high press pipe gets an expansion all way and
after that injection starts. This potential energy gets released during termination
of injection.

12. Why during rudder test we are doing 35 degree and 30 degree & why not both 35
degree?
When rudder is on starboard 35 and then order is given to port 30 or 35, the
variable discharge pump gets huge error signal gives maximum pumping rate but when
it reaches 30 in port the error signal remains very less and it is much lesser than
the error between 0 degree and 5 degree because when at 0 the error is maximum
because floating lever link is at 90 deg to the radius. Again as the error between
30 and 35 is less, the pumping rate also becomes very less and at higher angles the
travel of ram is more for each deg movement as compared to mid position. Moreover
the feedback system on the steering gear gradually reduces the speed of the gear
with in the last 5 degrees of the gears full rotation. If we put to 35 then the
hunting gear will start to reduce the pump stroke and achieving this in a time
frame of 28sec will not be possible. So the test is done from 35 deg to 30 deg.

13. Why engine valve lift is D/4?

Assume that valve is like cylinder and on the top is covered so minimum lift you
will get from equating the cylinder area and circumference of the cylinder. Area of
cylinder is [pi(D)2]/ 4 & circumference of cylinder is piD. By equating both the
equations you will get D/4. That is why valve lift is D/4 to allow uninterrupted
flow when the valve is fully open.

14. What is chock fastening?

At the time of engine installation, the engine is alligned and hot resin bonds are
poured in the mould to take the shape and solidify. This is chock fastening.

15. What is setting for boiler safety valves?

One safety v/v is to be set at 3% of working pressure & other v/v slightly more
say 0.5bar & superheater safety v/v at lesser pressure.

16. Differences between MC/MC-C and ME/ME-C engines

The electrohydraulic control mechanisms of the ME engine replace the following
components of the conventional MC engine: Chain drive for camshaft, Camshaft with
fuel cams, exhaust cams and indicator cams, Fuel pump actuating gear, including
roller guides and reversing mechanism, Conventional fuel pressure booster and VIT
system, Exhaust valve actuating gear and roller guides, Engine driven starting air
distributor, Electronic governor with actuator, Regulating shaft, Engine side
control console, Mechanical cylinder lubricators. The Engine Control System of the
ME engine comprises: Control units. Hydraulic power supply unit, Hydraulic cylinder
units, including: Electronically controlled fuel injection & Electronically
controlled exhaust valve activation, Electronically controlled starting air valves,
Electronically controlled auxiliary blowers, Integrated electronic governor
functions, Tacho system, Electronically controlled Alpha lubricators.

17. Bunker delivery notes

It is a requirement of Regulation 18 that any fuel oil for combustion purposes
delivered to and used onboard shall be recorded by means of a Bunker Delivery Note
(BDN). This implies that a bunker delivery note shall be presented for every barge
delivery and every grade. Bunker Delivery Notes are required to contain all
specific information as follows: - Name and IMO number of receiving ship -
Bunkering Port - Date of commencement of bunkering - Name, address, and telephone
number of marine fuel oil supplier - Product name - Quantity (metric tons) -
Density at 15 oC (kg/m3) - Sulphur content (% m/m) - A declaration signed and
certified by the fuel oil supplier's representative that the fuel oil supplied is
in conformity with regulation 14 and 18 (I.e. that the fuel supplied has a sulphur
level below 4.5% and that the fuel is free from inorganic acid, does not include
any added substance or chemical waste which either jeopardises the safety of ships,
adversely affects the performance of the machinery, is harmful to personnel, or
contributes overall to additional air pollution).

18. Why do we use compound gauge for refer system?

Compound gauge is to see the system is not going into vacuum anyway. If goes to
vacuum then any leak in system will take air in and that is not good for the system
in any condition. Bringing suction pressure below one bar gauge is itself not good.
To prevent this we have low press cut out too to prevent it from vacuum.

19. After you have detected air ingress in a refrigeration system how do you purge
it out? Collect all the gas in the receiver and let it cool and note the temp of
the receiver, then check the pressure of the receiver and the corresponding temp on
the gauge. Then purge the receiver till both the temp are equal. Every refrigerant
will have a saturation pressure corresponding to a particular temp. Air ingress in
the system will show a higher pressure on the gauge. Purging has to be carried out
till it both the pressures are same on the gauge. As per regulation never purge the
air and gas in open atmosphere, always collect it into gas recovery cylinder.

20. How anchor load testing is done?

#1 Anchor Setting and Breakout Test
Test was started with an anchor on the bottom at 5:1 scope. From idle speed, power
is slowly increased to high RPM to enable anchor to set. RPM was increased to 2000
and held continuously (force 9,000lbs) for 30 seconds. Once the anchor was set, the
same exercise was done at 90#, 135# and 170# direction. To pass the Test #1, the
boat anchor must HOLD and not drag or break out from any direction. During the
tests, the anchor must rotate below the bottom surface, without pulling out and
HOLD at the high RPM force 9,000lbs/4 ton. After rotation is completed, the boat
must be stopped in less then 3/1M.
#2 Anchor Breakout Test
Sudden Impact Test When the anchor is set, the boat will relocate above the anchor.
With a slack rode (length for 5:1 and 3:1 scope), the boat is given full throttle
(maximum RPM) so that the anchor would be hit by the sudden and enormous force of
the boat# s mass/speed, simulating hurricane force wind conditions. The sudden
impact test is done at 0# (the previously set direction), and at 90#, 135# and
170# to the original set. To pass the Test #2, the anchor must HOLD and not drag
or break out from 0# up to 135#. The anchor must rotate quickly below the bottom
surface, without pulling out. The vessel must be stopped in less then 3/1M.
(30,000lbs/400HP/12mph). Under maximum RPM and sudden impact force, on 0#
orientation, the rode should break (standard recommended nylon sized for the anchor
weight # for 25 lbs/12kg anchor# 5/8# /16mm nylon rope breaking strength
11,000lbs). The anchor should not be damaged in any way.
#3 Panic Test - Anchor Setting Under Motion - Boat Speed 3 mph @ 5:1 and 3:1 Scope
This test simulates a panic situation where the vessel is in motion due to high
wind. At 3MPH anchor is dropped in the sand bottom at 5:1 and 3:1 scope. To pass
test #3, the anchor must set and HOLD a 5:1 scope. Once set, it must pass tests #1,
2 & 3.
#4 Maximum Load Test-5:1 and 3:1 Scope. Once the anchor is set, vessel makes full
360# circle around the anchor, under constant load (maximum RPM), at 5:1, 3:1 and
2:1 scope. To pass test #4, the anchor must HOLD at lease 5:1 and 3:1 scope.

21. How to remove broken tie rod?

Take out upper part as with clamp provided by maker wd clinging bolts after
loosening top nut then see wd withdrawn piece how deep is breaking part...then
there cut a window in tie rod casing put a rod down from top weld it loose the
bottom nut and take out..later on grind burn metal take a template and close the
window in casing

22. What is the difference between static and dynamic oily water separator?
Dynamic separator is like centrifuge and is not used as oily water separator.
Static OWS is used as we have to separate large quantity of water from small
quantity of oil using heating coil and coalescence of oil. Dynamic type OWS is
hardly used however one example of it is Alfa Laval# s pure bilge.

23. Difference between Product carrier & Crude Oil Tanker?

A. Crude Oil tanker: COW must be there, only one grade of fuel is to be carried B.
Product Carrier: Carriage of refined petroleum products, special coatings for
tanks, Tankers above 20000 DWT must have COW, lesser ones may not. IG not required
below 20000 tonnes (If COW is present IG is mandatory).

24. Steering Gear Safeties?

A. Alarms: Overload, Hydraulic Tank Low level, Power Failure Alarm, Relief v/v,
Bypass v/v, Auto Change over 35 deg : Telemotor limit switch 36 deg : Telemotor
Stopper 36.2 deg : Rudder Angle Limit switch 37 deg : Rudder Stop 39 deg :
Mechanical Stoppers

25. Why ME foundation bolts have long sleeve?

Long sleeve bolts have high resilience. Also they have higher value of elastic
strain when in tension. Owing to the length bending moment is reduced in the bolt
because radius of curvature of the bolt will be much larger when bend.

26. How to order hydraulic pipes?

For ordering hydraulic pipe, we need working pressure, symbol of standard
( ost1/ost2). schedule 80120, manufacturing process s-c, e-c, outside diameter,
thickness and length is optional because standard length is 4 metres and sold by
weight, and made of carbon steel.

27. Difference between ship side v/v and overboard v/v?

SHIP SIDE VALVE IS A BUTTERFLY VALVE I.E, sea suction valve, where as overboard
valve is a screw down non return globe valve, as per the classification society
requirements and overhauling procedure is same like checking for corrosion and
pitting marks and checking the rubber lining in case of butterfly valve. Material
is copper nickel alloy or monel metal for disc and seat and body is nickel alloy.

28. Procedure for Hull Testing? Before fitting:

Hose Test: 2kg/cm2 @ 1.5m
Bend Test,
Tensile Test,
Impact Test
Hammer Test Water head test: 2.45m
After fitting:
Hose Test,
Hammer Test Air test: 0.14 - 0.2 bar Drill test: 20 mm hole ND Tests.

29. Windlass Load Test? Brake Test: The Hydraulic Jack applies Load to winch Brake
through winch drum using a fixture. Amount of Force depends on brake holding
capacity specified by winch manufacturer in 2 minutes. Load Test: (1 cable length =
27.5m : 1 Fathom = 6 feet) Brake is applied after every 15 fathoms (white link)
should hold in 2 sec.

30. Windlass Speeds? Let go speed : 5.75 m/s Lifting : 0.12 ~ 0.2 m/s (9~15 m/min)
{at 4 ~ 6 times load of the anchor} When Mooring light : 0.75 ~ 1.0 m/s

31. What is Slipping Clutch?

Commonly fitted on Electrically Driven Windlass either between the motor & the
gearbox or incorporated in the gear box. This avoids the inertia of the driving
motor being transmitted through the gear system in the event of shock loading on
the cable. Such shock can occur when the anchor is pulled hard into the Hawse pipe
when being housed.

32. Important Clearances Jumping Clearance :- 6 mm At Rhapson slide :- 16 ~ 19 mm

Propeller Drop :- 1 mm / 160 mm diameter of shaft Pintle Clearance :- 1.1 ~ 3.3 m

33. How vertical movement of Rudder is Restricted ? The vertical movement of rudder
is restricted by welding a small flat bar to the bottom of the horn. The clearance
between the rudder & the flat bar should be less than the X-Head clearance. Any
vertical force on the rudder will hence be transmitted to the stern frame & not to
the steering gear.

34. In T/C which type of bearing is used?

There are two types:
1. For the older versions, VTR Types, Ball bearings were used both the sides,
having a small gear pump and an oil bath for lubrication. This is common now also.
2. In the MET Types, which is the latest design, Shell type white metal bearing is
used in the centre of the shaft. The lubrication is by the main system itself and
there is a header connection also for the lub oil to flow when the Engine is
stopped/Lub oil pump stopped. The thrust Bearings for both sides are slotted
bearings and the replacement criteria for the same is the dye check and assesing
the percentage area of contact worn out for each slot. These are the bearings in
the turbocharger.

35. What are the stresses acting on a crankshaft. What are the various parts to be
inspected on a crankshaft.
The major sources of stress are -:
1) The working cycle.
2) Torsional vibration.
3) Axial vibration.
4) Misalignment.
These stresses are found mainly in two regions Around the oil holes in pins &
journals AND Around the fillets.
INSPECTION
1) Crankshaft should be checked for cracks giving special attention to the fillets,
lip of oil holes & other such vulnerable areas.
2) Working surface of journals and pins to be examined for signs of corrosion or
pitting caused by water or acid contamination of lubricating oil.
13) Inspect the shrink fit reference marks.
4) Check for the tightness of the coupling bolts.
5) Tightness of oil pipes and bearing locking devices.
6) Oil holes should be checked for cleanliness.
7) Balance securing arrangement
8) Blank the plugs in oil holes & oil tightness.
9) Check for the crankshaft deflection.

36. Name the special areas as per Annex V of MARPOL 73/78, Regulation 5?
Disposal of all plastics, paper products, rags, glass, metal, bottles, crockery,
dunnage, lining and packing materials are prohibited in:
The Mediterranean Sea
The Baltic Sea
The Black Sea
The Red Sea
The Suez Canal
The Gulfs Area
The North Sea Area
The Antarctic Area
The Wider Caribbean Region

37. Name the special areas as per Annex 1 of Marpol 73 / 78, Regulation 10
The Special Areas are as follows:
The Mediterranean Sea and its gulfs and seas within
The Baltic Sea in Finland
The Black Sea
The Red Sea Area
The Gulf of Aden
The Antarctic