AUGUST 2019

EXAMINATION OF MARINE ENGINEER OFFICER

Function: Maintenance & Repair at Management Level

MARINE ENGINEERING PRACTICE

TIME ALLOWED - 3 HOURS

Q1. With reference to reciprocating air compressors explain the

cause of the following faults. A. Collapse of discharge valve
springs;B. Breakage of plate valves; C. Overheating of the discharge
air with an unrestricted air intake; D. Inoperative piston rings.
2019/FEB 2019/AUG

Answer:- Repeat question. Refer to Q2 MEP FEB2019

Q2. What is Metal-locking? What types of repairs are carried out by

metal-locking? Describe the repair procedure using Metal-
Locking.2019/AUG

Answer:- Metal locking is another name for metal stitching,

which is a cold repair carried out mostly on cast iron and
aluminium components having under gone a fracture or
cracked. This repair is a substitute for welding. Cast iron
welding is not possible , hence metal locking is resorted to.
In the case of aluiminium and its alloys the welding option
available is argon-arc welding and if this facility is not
available metal locking is resorted to. Metal locking has its
limitations and hence cast iron valves and chests where the
pressure is over 3 to 5 bar metal locking will not work. This
repair is mostly used in repairs to cast iron engine blocks
or bed plates which are not subjected to internal pressure.

Following the survey, a report is presented to the

customer in order to get the go-ahead for the repairs. The
 component is then positioned, realigned and held firmly in
position using clamps and special fixtures.
1. Using the Specialist Metalock Jigs, groups of holes are
drilled across the line of fracture to the tool depth of the
casting.
2. The holes are then joined by the use of pneumatic chisels to
conform to the shape of the Metalock Keys.
3. The Metalock Key is a multi-dumbbell shaped section of a
highly ductile alloy that is manufactured in various sizes,
these can be cut to any length required, to suit the type of
fracture.
4. Individual layers of Keys are inserted in the apertures and
peened into a metal-to-metal condition, which becomes
almost integral with the parent metal.
5. Holes are then drilled along the line of the fracture, then
tapped, and filled with studs, each stud biting into its
predecessor, resulting in a pressure-tight join that restores
rigidity to the casting.
6. A Metalock stud is an important aspect of the Metalock
process, bearing in mind that pressure repairs are often
required.
7. The studs are then run down until the heads shear, the
remaining rough metal being removed by pneumatic chisels.
8. The whole repair is ground over until smooth
9. Then it’s the final coat of paint

Q3. With the aid of a simple sketch, explain the “trouble spots” in a
basic air-conditioning unit with reference to your sketch, explain
the following: - i. How the problem of increase in humidity on
cooled air is overcome? ii. How discomfort caused by the excessive
drying effect of heated air is overcome? SR12 2017/SR06
2017/SR07 2017/SR08 2017/SR10 2018/SR08 2018/SR09 2019/JAN
2019/FEB 2019/APR 2019/JUN 2019/JULY 2019/AUG

Answer:- Repeat Question. Refer to Q6MEP JUL 2017

Q4. Describe the procedure for overhauling Main Air compressor

Valves (Plate type) and explain which parts require close attention.
using sketches where necessary. Also describe the procedure for
testing of these compressor valves. 2019/FEB 2019/AUG

Answer:-Repeat Question. Refer to Q6 MEP FEB 2019.

Q5. Explain why auxiliary engine bottom-end bolts are prone to

failure, even under normal running conditions. Identify those
features, incorporated into the design of bottom-end bolts, to
inhibit failure. Explain how this tendency is either aggravated or
inhibited during maintenance and what checks are to be carried
out. 2019/AUG

Answer:- The big end bolts of a four stroke engine are subjected
to the following forces;

 A dynamic tensile force due to centrifugal force of

the mass of connecting rod rotating with the crank pin.
 A dynamic tension loading due owing to inertia forces
of the reciprocating mass of the piston which is
fluctuating with angular displacement of the crank and
having the peak value at an instant of 3600 after the
firing TDC in a cycle of operation.
 A dynamic shear stress at the parting of the two
halves of the bearing housing.

The effect of these variable stresses occurring

regularly in a cyclic fashion leads to fatigue loading of
the bolts and the bolts fail by fatigue.
(b) Features incorporated in bolt design are :
 (1) Generous fillet radii at all locations where the
diameter changes.
(2) smooth surface finish on areas where they fit in
both bearing housing halves.
(3) The diameters at shank and diameter at root of
thread is to be the same.
(4) Undercut fillet at corner of bolt head and shank.

Bolt failure is hastened during maintainance for the

following reasons.:

(1) If bolts are damaged during

maintenance, and are reused without Checking , they are likely to fail.

(2) If bolts have elongated whilst in use

they will fail due to loss of Resilience.

(a) Strategy for prevention of bolt failure is as follows:

(1) Ensure torque spanners or hydraulic jacks are
working well and are caliberated.
(2) If length checking gauges are provided they
should be used.
(3) Some manufacturers recommend renewal of bolts
after 15000 hours of operation ,which should be
strictly observed.
 Q6. Enumerate the maintenance routines carried
out for the proper functioning of the following systems: A. Water
hyper mist system B. Smoke detection system C. Quick closing
valvesD. Fire hydrants and hoses. 2018/SR09 2019/FEB 2019/MAR
2019/AUG

Answer:- Repeat question. Refer to Q3 MEP SEP 2018

Q7. With reference to Auxiliary boiler safety valve; A. Describe with

the aid of Sketch the safety valve for an auxiliary boiler; B. Identify
with reasons. The parts that require particularly close attention
during overhaul; C. Describe how the safety valves are reset after
an overhaul.2019/FEB 2019/AUG

Answer:- Repeat Question . Refer to JAN 2019 MEP.

Q8. If soon after joining a motor ship, you found a number of

holding down bolts slack and fretting to have occurred in the area
of slack bolts describe how you would handle the situation?
2019/AUG

Answer:- This problem would have occurred when the

foundation bolts tightening was carried out during the
planned maintenance schedule.

Fretting of the slack bolts has occurred due to an

increase in the intensity of structural vibration of the engine
frame and the cause may be due to unbalanced peak
pressures and power in all units

Accordingly the necessary indicator cards and their

draw cards will be taken , and the fuel pump adjustments
of the default units will be carried out and final
verification of the power and peak pressures in all units will
be carried out.
 The foundation bolts will be retightened in accordance
with the instructions given in the manual

In the mean time , I would have ordered for spare

foundation bolts from the engine makers , having
corresponded with them through our office earlier.

The old defective bolts will have to be removed

even, if necessary by drilling out the threaded length in the
tank top from the cofferdam inside, the cut bolts removed
and the new bolts fitted in accordance with the engine
makers instructions. I will have the engine makers service
engineer in attendance during the refitting to advise us on
the spot as needed. .

the final tightening will involve slackening all bolts and

proceeding in the order suggested by the sevice engineer
and with the required stages of tightening pressure

A final crank web deflection of all units will be carried

out and compared with past records for any changes. If the
readings are normal , it may be considered that the repair
procedure is satisfactory , but still the montoring of the
tightness of the defective bolts will have to be continued
for about another 1000 hours of eengine running.

Q9. During the past 4 months since you joined the ship as 2nd
engineer a number of main engine exhaust valve have suffered
from cracking and corrosion at the seating faces; Write a report to
the superintendent engineer covering the following points; A. An
explanation detailing how the problem becomes evident; B. Your
action upon recognizing the extent and seriousness of the problem;
C. Your reasoned view regarding the possible cause of the
problem;D. Your recommendation to avoid future incidents.
2018/SR02 2019/FEB 2019/AUG

Answer:- Repeat Question. Refer to Q 4 FEB 2018 MEP.