PY FIVVIYIF,PIIIPIII VI VIX DV TYVIVIVIMVIMI AY il : | ze SHIPBOARD HYDRAULICS Hee aa 3 | owes Longs comm Lcdhar fate wet INDEX Real life incidents / Course objectives = Fundamentals of Hydraulics = Components « Symbols = Hydraulic circuits = Contamination control = Trouble shooting TYy,yYIPIIY ) YEG EPYESEEEN Eve EEE Ey fo REAL LIFE INCIDENTS NY - | | 4 SHIPBOARD HYDRAULICS | |yy yy YYY YY YY YYV YY YY VI yyVIVIVIVE yy»vvV? INCIDENT 1 1,20,000 DWT OBO AT FUJAIRAH = Vessel dropped anchor and was unable to pick up = Oil started getting heated up on repeated trials a Vessel struggled in Fujairah for 3 days before an anchor handling Tug picked it up OFHIRE 3 DAYS INVESTIGATION - Vessel had a history of problems with picking up anchor. But had been getting by. Anchor was dropped deepest during this call due to navigational problems. OBSERVATION - Problem should have been recognized and corrective action taken much earlier. ze SHIPBOARD HYDRAULICS pagesINCIDENT 2 PRODUCT TANKER WITH BALLAST IN HOLDS ARRIVES LOADPORT = Unable to pump out clean ballast from one of the cargo ballast tanks because the tank . valve was inoperative. = Vessel thrown out to anchorage. = Superintendent flies down as ship makes frantic efforts to deballast. = Fault traced to leaky hydraulic line inside tank. = Finally valve opened with compressed air. (NOTE: Chief Officer astonished that valve opened with 7 bar deck air pressure!). Loss to owner - Two days off hire plus extra pilotage. OBSERVATION - Lack of understanding of fundamental principles by operator. Module 4 | ce SHIPBOARD HYDRAULICS Page 2,yYIIIVY yPYI VV FYYYYPYMYYP VY VAY VI YY WV VY Py yy rd dD INCIDENT 3 HANDY MAX BULK CARRIER ARRIVES PORT TO LOAD HEAVY STEEL COILS - CRANES UNABLE TO PICK UP CARGO a Cranes had been operational in the last coal charter. « After various attempts failed vessel lost the cargo as She was required to load and discharge cargo with her own gear. a Loss to owner - Charter hire, costs of repositioning vessel for next cargo, charter’s loss of confidence. INVESTIGATION - Cranes satisfactory performance with small Grabs and coal had given false sense of confidence. Hydraulic motors had fairly high internal ( leakages with prevented it from picking up its rated load. | ze SHIPBOARD HYDRAULICS [ace 5INCIDENT 4 PRODUCT TANKER 28000 DWT Problems with Mooring Winches / Anchor Two nos hydraulic motors were renewed Problem was actually in Hydraulic Pump Since it was observed that the required pressure was being developed - It was assumed that the pumps are allright. Actually the clearances in the pumps had gone beyond limits and a huge volume of oil was slipping past / short circuiting inside the pumps. Total of approx 18000$ was spent without results. ,v ve em eee VD [ ze SHIPBOARD HYDRAULICS | Page og | Module 4 , qeryYIIIIVO rYIYVIVIAIYAYAPVIYIVYV PY IVI VY VD INCIDENT 5 25000 DWT BULK CARRIER WITH PIELSTIC ENGINES ON A REGULAR SEA PASSAGE a M/E lube oil line had an inline conical filter at inlet to engine. « Filter wrongly boxed up, the differential pressure across filter increased causing the mesh to burst and get carried into engine. = Three main bearings ran out, three journals scored, ship towed to next port. a Extensive delay while repairs were carried out. = Loss to owners - Phenomenal OBSERVATION - Failure occurred due to lack of engineering accumen.OTHER INCIDENTS = Vessel with hydraulically operated hatch covers, where hatch cover opening was started 24 hrs prior to berthing as a routine because of various problems on system. « Tanker on which cop seals could not be replaced because bulkhead master valves were not holding. = Tanker on which 2 grades were not being loaded for fear of contamination. s REASON - Valves not shutting 100% because the open / shunt indicators were not synchronised properly. THERE ARE NUMEROUS INCIDENTS INVOLVING GRABS AND CRANES. Py ya eee em eH DDD DY DY DD KY [ zc SHIPBOARD HYDRAULICS [Page ee Se Eee eta FSry yYYVVY Fe Te ee ee ee ee ne ee ABOUT THE COURSE CONSIDERABLE BRAINSTORMING ON APPROACH AND COURSE STRUCTURE. APPROACH IS VERY PRACTICAL AND FROM AN OPERATING ENGINEERS POINT OF VIEW STRUCTURE BASED ON OUR OWN EXPERIENCE AS C/E’S AND FEEDBACK FROM COLLEAGUES ALL OF US HAVE GAPS IN OUR KNOWLEDGE. AS WE GOT OLDER AND MORE “SENIOR” WE ARE EMBARRASSED TO ADMIT TO THESE GAPS. THIS COURSE TRIES TO PLUG THE GAPS BY COVERING THE BASICS. COURSE CONTENT CONFINED TO REQUIREMENTS OF CHIEF ENGINEER. WILL FACILITATE EXCHANGE OF VIEWS AND EXPERIENCES AT A PEER LEVEL. } l ze SHIPBOARD HYDRAULICS HeeCOURSE OBJECTIVE On completion of this course the trainee shall: Have understood the basic theory behind hydraulics and hydraulic systems. Have understood the functions of various components in a circuit. Have built up a hydraulic circuit from basics, introducing components and seeing their behavior in the circuit. Have developed an ability to read ships hydraulic circuits. Have studied various shipboard hydraulics, and developed techniques for rapid comprehension and fault finding. Have understood basics of contamination control. SRE R EERE REE CERES RE ai eb he aE oe he pe Module i | ze SHIPBOARD HYDRAULICS [Page og] Pea a aYYYIIYVIXYIYY FY YY VVYIYIVIVY SAE th yo ) i FUNDAMENTALS OF HYDRAULICS oe - | ez SHIPBOARD HYDRAULICS Page ModuleWHAT IS HYDRAULICS WHAT IS HYORAULICS? HYDRAULICS IS THE SUBJECT! FIELD WHICH USES LIQUID TO TRANSHIIT POWER ICONVERT iT INTO MECHANICAL ENERGY AND ALSO CONTROL SYSTEMS ASSOCIATED WITH IT AS APPROPRIATE. FLUIDS INCLUDE-AIRIGAS ETC ALONG WITH. Liquips Module 2 a. SHIPBOARD HYDRAULICS Page _o1ADVANTAGES OF HYDRAULICS EQUIPMENTS ARE SMALLER IN SIZE FOR LARGE POWER REQUIREMENTS VARIAGLE SPEEDINFINITE) SAFE IN FAZAREOUS ZONE OVERLOAD PROTECTION IS EASY (RELIEF VALVE} AND CONTINUITY OF OPERATION IS GUARANTEED. BETTER SAFETY IN DEALING WITH HEAVY LOADS, z. eae SHIPBOARD HYDRAULICS Module 2 [Page caPascals law: Pressure applied on a ‘Thus resus in 9 10 49 force on every square em ipressure: of || Confined fluid is transmitted the container wl 1] undimnished in all directions and acts with equat force on equal areas and at right a angles to them 10g force on every su Module 2 ze ee SHIPBOARD HYDRAULICS }Page a3 ——]yoy os A large amount of force can be apllied with 2 limited ca ‘ovary Pont of he eonkinas Mud exerts & essUT of HOKE hydraulic pressure by varying ae the cross section area of the “Thes a force af 10kgiex™ x Wem = 100kg fowe acts onthe piston + bottom of he age piston a Fhe emall ton of tow “Ther the biggoe piston of cross sexton hes moves Wem: cross sero woud a ‘Wom ton the fata ie have moved iypluced wl be = fern’s *Oum= 10s : Module 2 - |< me SHIPBOARD HYDRAULICS age OaA large amount of force can ies 4m oe bt na ances ieee te ee Bows tagen 220 hyrdaule pressure by varying | the cross section area of the ocevs forthe sw ent np Ie ge ston wo piston have move oo Inthe smal ester of ters” ‘Them tne bigger piston of cross Sec}on has moves 20cm: ro86 section would Sem ten the rol Hie have moves. spaced wit. Aorn’x T0401 = Ter Module 2 ge eae SHIPBOARD HYDRAULICS Page os_MECHANIGAL/HYDRAULIC LEVERAGE & ENERGY CONSERVATIC Thus when a 10%9 fore is applied on a tom piston # resus in 2 100g ce on & TUE IStOn In omer woes the fore developed s wos properral the aie hg, Ins wterastng to Knew the semtanty batwnes tis simole oes. and the mechrica lever shown 100g — ‘Tne 10kg sil alan mo 104g # the atm afr TOK is 10 times tat oft "005 ~~ &! Module 2 | | 4 A SHIPBOARD HYDRAULICS [eae 2-1MECHANICALIHYDRAULIC LEVERAGE & ENERGY CONSERVATION ‘Then the bigger 28 ot nearetpnensten: imesmnrooorvel® | Energy can wie be created ‘rose section has moved nor destroyed tam hen the total is ‘replaces wo be fom x tem = Tae 10h ‘Tha ews hater heres ‘The ere-gy Wanster nee auto, quate Og x em = 100m 100Kg x tem = “OO Ke “his tne ath the tuncamenia law of conservation ct enesy which status that energy van naner be ct or costoyed, ‘The distance moved by cack pislun s inversely prozertonal ite aren, Whale gained in fore must be sseriiead in distance Conservation of eneray Module 2 ee ae SHIPBOARD HYDRAULICS a