Message to readers We published The BEST SEAMANSHIP "A Guide to Deck Skills" in 2004. This was primarily aimed at deck cadets, deck crew and students who want to become seaman, (0 enable them to learn practical seamanship and various kinds of basic repair work on board. To our delight, this first text book has been praised for its practicality Consequently, we have been asked to produce a new book as an ' using the same style as the "Deck Skills Considering the particularity of the engine space on board, where so many kinds of repair work are required by engine crew, we have produced this publication, ‘The contents of this guide starts with Lathe work, and Gas and Are welding work of several kinds, involving big and small work required on a daily basis in the Engine room. In addition to the basic rope work shown in the "Deck Skills" textbook we have covered some usage of slings , which we believe , are more suitable for engine crew. gine version! ‘The skills covered in the book cannot always be easily understood through written descriptions. So for this reason we have been very liberal in the number of photos and illustrations used to support the text. We also have available an accompanying Video Tape, which shows how to practice the lathing and welding safely. We hope that you will fine this guide helpful for learning new skills and improving your existing engine work techniques. ‘The editorial committeeTHE BEST SEAMANSHIP A Guide to Engine Skills Published by International Mariners Management ‘Association of Japan (IMMAJ) (B1)-3-3580-0833 Sponsored by ITEJSU CA Training Levy Copyright All copyright is reserved. No part of this publication maybe reproduced, stored in a retrieval system, or transmitted in any form or by any means, electroni mechanical, photocopying, recording or otherwise ‘without the prior written permission of the publisher. Supervisor ‘Toshio HIKIMA, Professor, Marine Technical College, Japan Chief Editor Captain Jun WAKI Editor ‘Masaru NAKANO, Engineer KEYMAX MARITIME CO.,LTD. M,O. Marine Consulting, Ltd. Producer WAYTS CO.,LTD. Printed in Japan Oct.31.2005,CONTENTS Message to readers --++++ss++ssesseeeceeecveseseeeesseeeeneesenes LATHE WORK 1 Equipment -~ u 2 Types and Applications of Cutting Tool Bit 15) 2-1 High-Speed Steel Tip Welded Tool Bit - nawaavananitacna 15 2.2 Cemented Carbide Tip (tungalloy) 7 23 HighSpeed Steel Tool Bit (polished square bar) 18 24 Tool Bit Material of High-Speed Steel (black square bar) 18 3 Cutting Speed ideas 19 4 Precautions - 20 4-1 Before Work 20 4.2.Start Up prsunsin Ta sapere: oa sna 43 During Work - > -- . Settee teneeerseierererees QI 44 After Work a Bi Practicars<+-0++s0eescdendesesesnsasssacecscaacswadavenddn occas 2» GAS WELDING 1 Equipment 1 Acetylene Gas Conta 26 1-2 Oxygen Container 26 1-3 Pressure Regulator (Reducing valve) a 1-4 Welding Torch 7 5 Welding Rod and Welding Flux 28 2 Preparation «+ hee + 29 3 Basic of Gas Welding - » 32 4 Application: » Bt 4-1 Flat Butt Welding of 3 mm or Thicker Plates © +++ *> tenes 34 42 Groove for Flat Welding tere panane En 5 Gas Cutting --*>** 36 5-1 Equipment 36 5:2 Preparation ~*~ 36 53 Procedure : ve 37 544 Relation of Thickness to Cutting Speed and Oxygen Pressure 386 Brazing of Brass and Silver 61 Copper to Copper 62 Copper to Brass ARC WELDING 1 Equipment «> 2 1-1 Are Welder a2 1-2 Welding Accessories ” : a 1-3 Welding Rod (electrode) ©=+-+-----+----->+ : 42 D5 CaRLIDAS fol De: TAKER SAM aaioaa Nn eteaNb NS aches btinmealtearattle 43 3 Practice: -~ A 34 Arcing M4 How to Join Weld Bead - 4 33 How to Terminate the Bead settee settee AB 344 Grooving and Tack Welding «+++ +0-0500¢000000065 oe : 46 1 Electrode Holding Angle * 47 4-1 Flat Welding esas . a7 42 Horizontal Welding fee etteeees 7 4-3 Vertical Welding ve : sevtseeeseee 47 444 Fillet Welding © +--+ a7 5 Application: 541 Weaving - eS 3 5-2 Boxing if Fillet Weld Joint --- 53 Improper Weld Joint: 544 Repair Fillet Welding * > 55 Checking and Repairing of the Groove 5-6 How to Repair Breakage on a Stee! Pipe 5-7 How to Prevent Weldment from Deforming rrrteteetereenes 66 58 Are Welding with Coated Electrode of Galvanized Steel 57 5.9 Welding of Cast Iron ve 58 Pht GRINDING AND FACING UP OF VALVES 1 Maintenance of a Main Engine Starting Valve*+~ 1-1 How to Clean the Valve Components -- 1-2 Points to be Checked ---1-3 How to Measure the Bend of a Spindle iis 62 1-4 Grinding Procedure 63 1-5 Precautions for Grinding «+++ > -~ ee 64 2 Replacement of Intake/Exhaust Valve of Diesel Generator (D/G) +++ 65 2-1 Intake/Exhaust Valve * nme i wed tonnes, 65 chaust Valve Seat - moe . 65 2.3 Intake Valve Seat Golid type, valve box type, replaceable type) *+++++605 55 65 3 Checking Bend and Roundness of Valve Spindle cea BG 3-1 How to Measure and Replace Intake/Exhaust Valve Guide . 66 3-2 How to Replace the Guide « -- « nom m 66 4 Maintenance and Facing up of Sluice Valve « 4-1 Overhaul, Maintenance and Chee! nie 4-2 Grinding and Facing up of Sh 4-3 Precautions for Handling a Valve ce 5 Grinding and Face up of Flat and Conical Type of Valve +*+++*++++* 69 541 When a Valve Seat Face has a Significant Flaw or the Width of Valve Face is too Large . wt 69 si 69 5:3 When a Valve and a Seat are Machined or Ground Separately »»--- 69 5-4 How to Grind and Face up the Valve Face which has no Guide Leg (flat valve, conical valve) ease aes EE 70 6 Precautions for Grinding and Facing up Valve and Seat «> 7 Checking the Valve Face of Precision Valve (High Pressure Valve, etc.) -» 72 8 Valve Shapes and Grinding Tool + $1 Flat Valve 82 Conical Valve 83 Grinding Tool for a Flat Valve Seat SLINGING WORKS 1 Wire Rope ++++++++"~ 76 2 Safe Working Load of Sling Wire Rop -79 3 Handling - 8 3-1 Tension Imposed on Wire Slit " 81 3-2 Slinging Hitch -- 7 a os 81 Slinging a Load . 2 Mi laneous # Load Slinging stones ro 1BALIGNMENT BETWEEN PUMP AND MOTOR 1 Tolerance Limit of Alignment se deeoadeeaneasceaeaeceeea BB 2 Installation o Removal of Ball Bearingg-:+>+>-+ “90 241 Installation 90 22 Checking Before Removing the Bearing * aaa cores OO 3 Shrink Fitting -++-++-+++>+>- or { Extraction Pe + 92 4-1 Sample Removal of Bearing (by puller) +» peneann tn 92 42 Removal by a Hand Press «+++ : sae - 92 43 Removal by a Puller : ce coves + 92 5 Coupling «+> eee e eee ee Penne ee eeeeeeee teen cere ee eeeeee se eeeeeee mn CTT phar 65 REPLACEMENT OF STEEL PIPE 1 How to Align Flange Holes: >: +++ +>» 11 How to Align Flange Holes 1-2 How to Align Straight Pipe and Flange + 2 Modeling of a Bent Pipe: 3 Modeling of a Bent Pipe with a Branch Pipe~ 4 Modeling of a Pipe: >> 5 Bending of a Pipe Filled with Sand by Heating 5-1 Filling Sand - +101 52 Modeling the Bent Angle: with a #8 Steel Wire --- 101 5:3 Heating ~ ~ 102 6 Emergency Repair of Cracked Pine » 103 TYPES AND APPLICATION OF PACKING 1 Soft Molded iaskela SEE 11 Paper : 1-2 Fiber 1-3 Rubber 1-4 Seal Tape +++2 Liquid Gasket -- tttteeeeeeeeees corse 107 2 ‘ype of Liquid G: 107, Features of Liquid Gasket *m pues . 107 3 O-ring for General Machine Components oe 108 3-1 "P"number (packing) penne . % 108 3-2 "G"number (gasket) Same ma ~ . 108, 3-3 How to Find the Dimensions of O-ring - «+--+ nee ad 108 GENERAL WORKS IN ENGINE ROOM 1-2 During Dis 1:3 Di mbly Considering Re 110 2 Open/Shut of Valves «+++ ++ seeteeeeeeeees seed Open/Shut of Steam Valve i 2-2 Other High Pressure Valves ut 2-3 Low Pressure Valve Having a Large Capac 2 3 Treatment After Cleaning a Strainer: 34 Air Purging Cheek for Le 33 When the Pr 4 Pump Gland Packing: --+ 41 Additional Tightening of Pump Gland Packing: -- : 14 4-2 Change in the Leakage from the Gland © -+++-+->+> ree 14 4-3 Additional Tightening of a Gland -- 4 5 Handling of a Grinder +++++1eeeeseseeeeee eee seen seeeeee TB 6 How to Maintain the Burner Atomizer of an Auxiliary Boiler «++ -+- 116 7 Adjusting a V Belt: >> “7 age sssure on the Inlet Side is Negative ms 13 nsion of a V Belt nz 7 8 How to Overhaul the Hatch Cover Lifting Hydraulic Jack + “18 9 Cotton Waste => >> >> seeeeeees “119 10 Removal of Seized Bolt and Nut aR +7120 10-1 How to Loosen a Seizing Nut for through Bolt or Stud Bolt» -~ 120 10-2 How to Remove a Tap Bolt 120CONTENTS 10-3 How to Remove a Broken Stud or Tap Bolt =~ : 120 Il Tapping * +9122 11-1 Making a Prepared Hole for a s 122 iece Set Hand Tap «100+ 00sreeosereeesreeees 123 3 Turn the Handle seteeeeeeeeees 193 11-1 How to Remove a Broken Tap siete 124 12 Grinding and its Angle «++++++++++++es822000* : seeeeees 125, 121 Grinding of Cutting Bdge sete +125 12-2 Grinding of Chisel «+++ +--+ vies teres + 126 13 Non-Destructive Test (Test without Destroying the Material) ++++++++++++++++++8++ trees 129 1341 Classification of Non Destructive Test 129 1:42 Detecting Test by Penetrant = 129 13-3 Detecting Test by Magnetic Particle Pree retererrreeericeees IB USEFUL ADVICE 1 How to Install Gland Packings to a Valve +++ ++++++++esse0eee rere 2 How to Remove a Gland Packing which has Gotten Stuck ++ ++ +++ ++ ++ 3 How to Make a Makeshift Ejector Pump 1 How to Parallelize Flanges -~------+->- 5 Bolt and Nut Used on Sea Water Line 6 Emergency procedure for Uneven Mating Surface of Flange -+ 7 How to Install Pure Iron (Fe) or Zinc (Zn) Plate «+ 8 Emergency Procedure to Stop Leakage from Steam Pipe SPECIFICATIONS OF STEEL, BOLT AND NUT 1 Outline of Metallic Material 1-1 Carbon steel 12 Special Steel 2 Hexagon Bolt -- 3 Main Thread Generally Used in Ship « { Types of Thread Generally Used in 41 Metaric Threadoa M7 ine 1968) “= 447 a soled isp of thread M7 5 Nominal Size and Pitch of Metarie Thread ” “148 6 Nominal Size and the Number of Crests of Unified Thread “19 i Pins Threads maiemwoyaatinnnn ceecdecwens ememiaenncdiancaoms 150 8 Nominal Size and the Number Crests of Pipe Thread +++++++++++++++ 151 CLASSIFICATION AND SPECIFICATION OF CARBON STEEL PIPE FOR ORDINARY PIPING 1 Carbon Steel Pipe 3P (carbon s es for ordinary piping) STPG38-E (carbon steel pipes for pressure piping) [PT (carbon steel pipes for high temperature piping) 1-4 STS (carbon steel pipes for high and low temperature piping) With Protruded Surface With Spigot Joint 244 With Protrusion and Groove 33 Prot 1 Specifications for Carbon Steel Pipes for Ordinary Piping -*>>**> >> 5 0.5MPs Ship-on Welding Flange a 6 IMPs Ship-on Welding Flange 7 1.6MPs Ship-on Welding Flange » ion/Groove Ty COPPER TUBE FITTING 1 Copper Tube 2 How to Distinguish the Size of Copper Tube Fitting *~ 162 1633 Types and Shape of Copper Tube Fitting ©+++0s++00seeeeeceee 16H 1 Copper Tube Specification Table: +++++++0 0020s ersceeeeeeeeeens 165 Addendum SI International System of Units - 168 TOOLS Regularly Used in Engine Room +++++++++2++2seeeseeeeeeeees 172Tool stand Drilling, Milling change lever y Dae, | Moving direction change lever Shuttling stand x | / _/ Moving direction | / Three step gear shift “change lever ( / Pushing _/ High and low speed _ Switch lever center stand agusting iger Three step gear shift Parts name of engine lathe Automatic movement lever3 Types and Applications of € 2-1 Higt eed Steel Tip Welded Tool Bit (see the item "Shape and Sample Application") Made by forging special steel, depositing high-speed at the too! bit tip, and quenching and tempering them. @Type Point nose straight tool bit, round nose straight tool bit, diagonal straight too! bit (right, left), round-nose tool bit (right, left), side straight tool bit (right, left), side finishing straight tool bit (right, left), square nose straight tool bit, threading tool bit (male, female), Hale finishing tool bit, boring tool bit, bore finishing tool bit, Hare cutting tool bit, Hare threading tool bit @Workpiece Stellite, steel other than special steel Offset tool bit ‘Square nose Parting tool bit Spring threading (Fight handed/Let handed) | Straight tool bit \) tool bit Circle cutting agg GT 2g BP SS52 eagle st ie Zoi | BRHNG cut-off tool Spring ea i Bore tool bit Female threading to — we Oo), = o ==), =a Bao)4t Bea” Deeg? Sao” ag Round Finishing tool bit Part i i Bound meee bit ‘inishing tool bit -arting tool bit Bore finishing tool ware 1 I Disk Cog 3t 30) ry jo) 53 Ro. Eo Sag 8 a0) dio “Sauare nose bent [Foundnose bent | Parting tool bit | Boring finishing tool) Spring threading tool oo bi i it " oe wR So) C0, ST > 5 see re Aoi Wd ol —S=I0 a found nose straight | Offset tool bit ‘Square nose straight! Parting tool bit Flat cutting bit A Gon A bit ig =H 61 62L. 64 66 gt Point nase Straight ‘Square nose bent ‘Spring finishing feo onenns Center parting tool @ 9 Be Op og it 60 1D} gos 63L 65 5 «r 14aAreas Types and Applications of High-Speed Steel Tip Welded Too! Bit SKH2 _General cutting SKH3 _ High-speed heavy cutting Alminum SKH4A rf ing General material, semi-hardened taaie pore Nea cutting, Cutting steel, brass, martens tic stainless steel (free-cutting) skH4B High-speed heavy cutting, Austenitic stainless steel (hard-to- SKH5 Cutting of hard-to-material \cai iar toeistn toy rekecnect susceptible to work hardening i ys eel ski Cutting of highly hard-to-cut Mild steel, high chrome steel, high material nickel steel, ordinary cast iron “The hard-to-cut material susceptible SKH8 to work hardening SKHS2 _Cutting of general cutting requiring SKH53 toughness SKHS54 SKH55 SKH56 Cutting of hard material requiring comparatively high toughness ' as oe Alloyed cast iron, high manganese | steel2-2 Cemented Carbide Tip (tungalloy) Sinterd alloy tool bit mainly composed of tungsten carbide, having the highest hardness next to diamond. (Because of the brittleness under impact, it is important to make the cutting surface smooth and even with a sander or a grinder before cutting.) @Types and Applications of Cemented Carbide (Tungalloy) Tip ‘Material Symbol | Identification CSTE STIOP Steel, cast steel “ STISE — ST20E Steel, cast steel, ductile iron ST25E _STSOE__ Steel, cast steel ST40E ‘Steel, cast stecl Gite Steel, cast steel, cast iron, high manganese steel, austenitic steel, alloyed cast iron wa High manganese steel, austenitic steel, alloyed cast iron mao ‘Ago Steel, cast steel, free-cutting steel - ~~ = H3 High cast iron, hardened steel, graphite, kot t— H2 hard paper K10 Ht | =I Gast iron, non-ferrous metal K20 (old G2) kao | Mild steel, non-ferrous metal, soft non-metal such as wood @Cemented Carbide Throw-away Inserts In ships, pin lock or cam lock type is used. Be careful not to damage the pin by tightening too hard or insufficiently cleaning the mating surface in holding the tip by a shank. To mount the tip, be sure to clean the mounting face, use a dedicated spanner, and i then mount correctly. r Cam lock tool bit (ML) Pin lock tool bit (MP) chaper 1 @vreau 2.3 High-Speed Steel Tool Bit (polished square bar) Make by heat treating 50 to 100 mm long high-speed steel with square cross section and forming and polishing the too! bit tip in a poper shape. (Sizes: 5x5x5 mm to 13x13x100 mm) @Workpiece the same as high-speed steel tip welded tool bit. 2-4 Tool Bit Material of High-Speed Steel (black square bar) 300 mm long high-speed steel with square cross section. Cutting edge can freely be formed in any shape. Used after heat treated (heat treated after heated by a bumer until it turns red and then smith forged. For heat treatment, heated until turns bright or yellow-red and then oil quenched).3 Cutting Sp In working on a lathe, the cutting speed depends on the radius of the work piece or the distance between the tool bit and its axis of rotation, and the speed of rotation. “D:N 1000:V joo /min Ne Ap pm V : cutting speed D jadius of the work piece in mm ‘evolutions per minute of the work piece @Relation between the outside diameter of work piece and the rotating speed of lathe (rpm of spindle) 30 265 810870 530 680 50 160 190220820 15 70 115 90 160 230 300 100 80 6110 160 210 150 53 a2 74 | 106 140 200 40 32 a) 105 300 26 21 a7 | 88 70 450 18 14 2 85 4 600 13 W 1% 8 35 For peripheral finishing cut, two methods are available; one to cut at high-speed with slow feed and another to cut at low-speed by Hale tool bit. In general, high-speed finishing cut is applied to spring type tool bit, while low-speed finishing cut is applied to carbon. The following shows a relation between bit and revolution. ‘@Bit and Revolution (Cutting speed) 7 7 + Square Comer Vent Tool Bit Roughing 200~300 0.2~0.3 ‘Right tended) Point Comer Straight Tool Bit _ Medium finishing | Oa 0.2, Round Comer Straight Too! Bit Fine finishing Spring Finishing Tool Bit ol . Spring Cut-off Too! Bit Cut-ofting Cut-off Blade Edge-dressing - Offset Tool Bit apie ©Before Work (1) Worker must wear proper working clothes (helmet, working suite, safety shoes) to avoid exposing his bare skin during the work (Protection against burns from heated turnings and against being caught in machinery). (2) Safety goggles must be worn. (3) To remove fine dust and turnings, main part of the machine must be cleaned using waste cotton. Oil leaks and L.O quantity must be checked and, if necessary, L.O must be replenished. Any obstacles to lathe work must be removed. Longitudinal slide and cross slide must be checked so that they are not set at automatic feeding. Main shaft rotation speed must be checked; it should not be set at the maximum from the beginning. Sufficient space must be kept between the bit and the work piece. Mechanical movement must be checked by turning relevant handles, etc.42 Start Up (1) Start & stop switch must be checked for normal functions. (2) Motor, main shaft, etc. must be checked for abnormal noises. (3) Machine as a whole must be checked for abnormal vibrations. 4.3 During Work (1) Main shaft, motor and other rotating parts must be checked for abnormal heating. (2) Machine must be checked for abnormal vibrations. (3) Tools must be removed from the bed of the machine. (4) Cleaning or maintenance must not be carried out during machine operations. A4 After Work (1) Automatic feeding for longitudinal or cross slide, if used, must be released. (2) All parts of the machine must be checked for any abnormality. Any turnings must be removed and the machine must be cleaned using waste cotton. (3) If the machine is installed in a moist area or if the weather is wet, unpainted parts of the machine, such as chuck, tailstock spindle, master screw and slide surface, must be wiped with oiled waste cotton to avoid rust generation.(1) Grinding of high-speed steel bit using a grinder. (2) Grinding using oil stone before setting high-speed steel bit. (3) Centering of tool bit. Adjusting the height of tools bit. Inserting block(4) Roughing and finishing of edge. (5) Center processing by the center drill before centering. (6) Peripheral milling from roughing to medium finishing using the external cylindrical grinder.(8) Grooving using a parting tool bit. @ chanrer 1GAS WELDING oo Equipment Heat for gas welding is supplied by burning a mixture of oxygen and a suitable combustible gas. Gas welding is a method for welding metal using the above mentioned heat. 1-1 Acetylene Gas Container Acetylene gas is likely to explode if subjected to shocks or pressurized to more than a pressure of 2 atmospheres, thus it is dangerous to store it in a gaseous state. Therefore, a granular and porous mass of charcoal powder with a solid mass of calcium silicate as a main component are placed uniformly into a high pressure steel container, called as a "cylinder" (German word “bombe" being more common for Japanese), thus it should be used by keeping vertically. Oxygen Container Oxygen is compressed to a pressure of 150 atmospheres at 35 deg.C (95 deg.F) in a black steel cylinder. Gas leakage from such a high pressure container can lead to a serious accident, thus the following precautions should be taken for handling the cylinder. @keep it away from fire or direct sunlight, as well as from an acetylene cylinder. @Re-cap when not in use. @Handle with care so as not to give any shock. @Mouth ring should be free from oil or grease so as to avoid spontaneous combustion. @valve should be operated gently and the valve handle should be kept in position during work (to cope with backfire promptly). in ea @ comer13 Pressure Regulator (Reducing valve) Oxygen and acetylene should be used at properly reduced pressure suitable for welding, i.e. 0.3~0.4 Kgf/c for acetylene and 3.0~4.0 Kgf/em2 for oxygen. A pressure regulator is equipped with one pressure adjusting screw, two pressure gauges for the in-cylinder pressure and the reduced pressure and one safety valve. 1-4 Welding Torch ie ©0906 868 066 Exterior view 1 Equipment @ Torch head @ Body @ Grip @ Gas hose @ Inner tube O valve @ Needle valve © Hose connector © NozzleChay CS) CSUs ode} This is to mix the acetylene and oxygen gases in an appropriate ratio, and to ignite the flame at the tip of the nozzle. The gas mixture is made in the injection structure; high pressure oxygen spurts out from the center nozzle as illustrated in fig.1, and forms gas mixture by sucking low pressure acetylene surrounding the nozzle. Oxygen throttle valve High pressure oxygen Acetylene Acetylene throttle valve Nozzle \ Injector nozzle fig.1 Basic structure of welding torch The gas mixture is made in the injection structure; high pressure oxygen spurts out from the center nozzle as illustrated in fig.1, and forms gas mixture by sucking low pressure acetylene surrounding the nozzle. In the case of B-type torch (French type), an injector is contained in a blow pipe, and the nozzle diameter of the injector can be changed by the movement of a needle valve shown in fig.2 so as to regulate the oxygen pressure to get the best mixing ratio between acetylene and oxygen. Oxygen Needle valve <—— Acetylene fig.2 Structure of welding torch (French type) 15 Welding Rod and Welding Flux Welding rod are used to fill the gap between the base metals to be welded, and those having the same chemical components and properties as the base metal are recommended for use. Oxide is generated when the welding portion is heated, which hamper welding, thus flux is used to remove such an oxide. Bicarbonate of soda, borax and boric acid are used as flux. © cuter 2(1) Select a safe place, and surely fix the gas cylinders so that they do not fall. @When used, acetylene cylinder must be raised. @'f laid when used, dissolved acetylene may come out. It is desirable to raise also the oxygen cylinder during use (in order to prevent the danger that a fire expands explosively like a rocket engine if oxygen were leaked when the cylinder is laid down). @Welding operations should be carried out at a site where mechanical or natural ventilation can be expected. @During welding operations, always wear safety goggles, hand gloves, a welding apron and arm covers. ‘Oxygen pressure regulator —__ Acetylene pressure regulator Chain Dissolved acetylene | Acetylene J hose (2) Mount each pressure regulator on the oxygen and acetylene cylinders. @surely mount the pressure regulators after checking that a packing with no damage is put on the mount. Before mounting the pressure regulators, open the gas cylinder valves for a moment to blow off dust or foreign material sticking on the joint holes. @ High pressure gauge @ Low pressure gauge © Adjusting handle @ Gas discharge valve @ Rubber hose joint @ Gas outlet @ Clamp Acetylene pressure regulator Oxygen pressure regulator © Safety valve Chapter 2 @She) (3) Connect the hose to the pressure regulators. aT ven when it is hard to connect the hose, do not use oil or the like. When connected, fix it with a hose band. (4) Open the gas cylinder valves. ‘@The gas cylinder valve shall be opened slowly. The acetylene gas cylinder valve must not be opened exceeding 1.5 turns. Fully loosen the handle or pressure regulator before opening the gas cylinder valve. (5) Mount the gas welding torch. @Do not mistake oxygen hose (black) for acetylene hose (brown). (6) Adjust the pressure of oxygen and acetylene. @Set the pressure of acetylene to 1/10 the pressure of oxygen. For gas cutting, oxygen pressure is adjusted according to the thickness of object (as explained separately). @Charging pressure of oxygen and acetylene: Oxygen: 150 kg/cm’ at 35 deg.c. Acetylene: 15 kg/cm’ at 15 deg.C.(7) Adjust the flame. Open the acetylene cock by 1/2 to 1 tur to let acetylene flow at low rate, let oxygen flow at low rate, and ignite with a dedicated lighter. Observing the flame size, adjust the flow rate of acetylene and oxygen to obtain neutral flame. Carburizing flame Flame core Neutral flame >< 2~3mm 3,000~3,200'C a Secondary flame Fiame core Reducing flame (transparent) Oxidizing flame Flame core (8) For putting out, shut the oxygen cock after shutting the acetylene cock and then confirm if the flame is extinguished. chaner 2STMT) Hold a welding rod in your left hand and the torch in your right hand. Direct the oxyacetylene gas flame toward the base metal to preheat it, and place the tip of the welding rod onto the heated metal and start welding from the end. Move the rod from right to left (called forward welding) or from left to right (called backward welding). Forward welding is suitable for welding a thin plate of 5 mm or less in thickness, and backward welding for welding a thick plate. (1) Keep a space between weldment and Approx. 3 to S mm welding bench. «— Welding direction x (2) Adjust the oxygen and acetylene gas torch cocks to obtain neutral flame. igo! ¥ 45° \ AtA \ = AD, \ \y Advancing direction Tilt angle when seen when seen from front from side (3) Because the end point of weldment tends to melt, tilt the torch to release « heat. (4) Keeping the distance from flame core to weldment at 2 to 3 mm. move the torch straight at constant speed while melting the weldiment. 48 +— Welding direction(5) Weld straight while oscillating the torch laterally (in crescent- shaped form) and moving the welding rod up and down, «Welding i desk Groove 1 to 2mm (6) Tack welding shall be done symmetrically from center toward end point.4-1 Flat Butt Welding of 3 mm or Thicker Plates Welding of 3.2 mm thick plates : With the flame core entered in the groove by approximately 1 mm, fuse the base metal. With the torch tilted by 50 to 60 deg. and the welding rod by 45 deg., fuse the rod while moving it up and down. 12 Groove for Flat Welding (1) Applied to this steel plate. Welded by fusing the bent section. No welding rod necessary. 1 t<1mm igt (2) Square butt welding a/at~1/at an (3) Single V butt welding t=1~3 mm(A) Single V butt welding (applied to thick plate) 90° 75 ~90° 75°~90" XY i on 2.4mm (5) Double V butt welding (6) Single U butt welding (applied to thick plate) ale 4.8mm (7) Double U butt welding (applied to thicker plate) Thicker plate i Chapter 2? @Re Mer A= Ee LNc) An oxyacetylene flame is applied to metal to heat it up and fresh oxygen at a high pressure is applied to assist the combustion. The produced oxide of molten metal is blown off by the gas pressure, resulting in cutting of, the metal. -1 Equipment High pressure oxygen valve High pressure oxygen nozzle High pressure oxygen tube Oxygen hose connector Acetylene hose —S connector Torch head € Mixed gas tube Conpenie nie pot “Nozzle Body Mixed gas adjusting valve Pre-heating flame nozzle Gas Cutting Torch 5-2 Preparation (1) Mark a cutting line, and place the object so that the marking becomes horizontal. Put the object on a steel plate so as to keep a space under the cutting line. High pressure oxygen Mixed gas Torch nozzle Advancing direction @ coaveer 2(2) Slightly open the acetylene valve and the adjusting valve and then ignite with a dedicated lighter. (3) Adjust the flame @Operate the flame adjusting valve ss Neutral flame Operate the acetylene valve and the — j_-— >. adjusting valve to obtain neutral flame . @High pressure oxygen is discharged When the high pressure oxygen valve is opened, the flame changes to carburizing flame. ————s —______-—_ > = Carburizing flame ‘@Adjust the acetylene valve Operate again the acetylene valve to = obtain neutral flame. @Siightly oxi ing flame By shutting the high pressure oxygen a valve, cutting flame is obtained, which is a slightly oxidizing flame. Procedure 5. (1) With the nozzle of the torch at right angle to the ‘object material, and keeping the distance from flame core to the object material at 2 to 3 mm, heat the edge of the object material until it tums red. When the edge is red heated, open the high pressure oxygen valve by 1/2 to 1 turn and advance the torch at constant speed. (2) When gas cutting ends, shut the high pressure oxygen valve. Cutting flame Cutting direction — = YY 2~3 mm Rediheat=>] * High pressure > oxygen Cutting __ direction Chapter?COMI he c) @For both gas cutting and gas welding, oxygen and acetylene pressures differ with the thickness of steel plate. For general works in ships, adjust oxygen pressure to 3 to 4 kg/cm? while acetylene pressure to 0.3 to 0.4 kg/em*. @The following metals cannot be gas cut: Cast iron, copper and copper alloy, aluminum and aluminum alloy, stainless steel @Gas cutting of flange bolts in a narrow place Ina narrow place, this work is quite hard. In addition, when in a hurry, we tend to make such a mistake as to damage the flange holes. To avoid this, the bolt should be cut step- by-step (two to three steps) without cutting the bolt at its root at a time. 5-4 Relation of Thickness to Cutting Speed and Oxygen Pressure 4 450~500 5 P 400~480 15 | 350~450 20 | 260~350 25 | 240~270, 30 | 210~250 40 [_ 180~230 | 60 | 160~200 | 80 | 150~180 | 100 | 190~165 |6-1 Copper to Copper To joint copper tubes together, the end of a copper tube being flared by a tubing tool, as shown in the figure below, put other tube on it, and execute brass brazing, (1) The tube end is flared (2) Putothertube. (3) Execute brass soldering so that by a tubing tool. the solder is slightly swollen. 6-2 Copper to Brass To connect a copper tube to a brass cock or pressure gauge, a brass sleeve is soldered on the copper tube. The sleeve cannot be brass brazing, and therefore silver brazing is employed here. (1) Fist of all, sufficiently polish the tube edge and the brass sleeve which are silver brazing. Heat the tube end and the ball by a small excess acetylene flame (carburizing flame) until they turn red, with the flame end faced to the copper tube. (2) Execute soldering, taking the melting point of _— each part into consideration. | Melting point = Copper : Approx. 1100 deg.c = Brass : Approx. 850 deg.C Silver brazing : Approx. 600 deg.C Sufficiently polish and coat borax around the soldered part. (3) When they turn pale red, coat borax around the soldered part, and put a small amount of silver brazing on it. When fused, silver brazing spreads around the periphery and sinks downward. When silver brazing sticks around the tube, immediately turn the flame aside to cool the soldered part. When re-heated after cooled, the silver brazing which has sunk downward comes up again.‘ARC WELDING | Fquipment Arc welding is to weld base metals by melting them with arc heat (about 4,500 deg.C) generated by applying power voltage between the base metals and a welding rod. 1-1 Are Welder ‘Are welder is a device for generating the welding arc, and is classified according to the power source as DC type and AC type. The AC arc welder of simple construction, advantageous in view of maintenance and cost, and is thus widely used today. 12 Welding Accessories (1) Holder A rod holder is not only to hold a welding rod but to deliver a welding current from a conductive cable to the rod. (2) Cable A cable is to connect the welder with the holder. It contains numerous fine conductive wires twisted together and shielded with rubber. (3) Face cover Parts of holder Cable As the arc generates not only high heat but also harmful ultraviolet rays, the welder should not directly expose his eyes and skin to such light beams by using a face cover for protection. The harmful light beams can be absorbed by a black glass of the face cover. Face cover Left: Hand type Middle: Full face type Right: Quick shade type 1.3 Welding Rod (electrode) A welding rod uniformly shielded with flux around its core wire is used in arc welding. © crunvers3 Cautions to be Taken @Welding work should be carried out at a site where mechanical or natural ventilation can be expected. Flammable materials should be removed from around the welding workplace. @Always wear leather gloves, rubber boots, an apron, etc. ‘@Be sure to use a face cover. @Be careful not to inhale the gas generated during welding. @€specially in the arc welding of galvanized steel plates, a large amount of zinc oxide gas is generated, which causes gas-poisoning if inhaled. Thus pay attention to good ventilation and use a gas mask, if available. @Holders and power cables should be those perfectly insulated and a grounding wire should be secured properly. @if a coiled cable is used as shown in fig.1, the resistance of the cable increases and generates unstable arc, which results in an uneven beading. To avoid this, use a welding cable of proper length. When it is inevitable to use a long cable, lay the cable as shown in fig.2. x fig. @To weld a steel plate supported by magnets. In the case of arc welding of a steel plate which is supported by magnets, the arc becomes unstable, which may result in the generation of blowholes (air bubbles) and pits (small dents on the surface). Such magnets shall be removed when tack welding is implemented before starting regular welding. fig.2 Electro shock protector Chapterhe PNR Tam Ney ee Practice 3-1 Areing Generate the arc at a point approximately 1 to 2 em from the point A, and return to starting point A, and then move the electrode straight along the weld line without oscillating the tip of the electrode. While moving the electrode, it is important to keep the arc length and of the electrode tilting angle in constant. Point A (Arc start) End point 4mm 4 ve LLLLAINS GE 2~3 mn 3-2 How to Join Weld Bead (1) At the end of a bead, quickly raise the electrode backward (left side) to scoop up fused metal in the molten pool, thus making shallow dimple on the end portion.(2) Generate the arc again at a point 1 to 2 cm from the end of point of the bead, and quickly move the electrode to the end point of old bead with the electrode raised at right angle, then keep the electrode as the previous posture. 3-3 How to Terminate the Bead At the end of bead, rotate the electrode by 2 to 3 turns likely to make a mound. Co, SSS Starting point End point SOC CGINE: > Starting point Arc start End point3-4 Grooving and Tack Welding Areas to be welded of the base metal should be free from rust and oil as such impurities lead to a defective welding. (1) Prior to main welding, preparatory works such as grooving and tack welding are required. The base metal should be properly grooved (beveled) corresponding to their thickness. tethickness (mm) 2~3 mm 6~15 mm = 15mm enn or more Grooving (or beveling) (2) In order to induce arc discharge, the tip of the welding rod should be contacted instantaneously with the base metal and pulled quickly. (3) To prevent the welding rod from adhering to the base metal and to induce the arc, the tip of the welding rod should be swung little by little like striking a match.1 Electrode Holding Angle 4-1 Flat Welding At right angle to the weldment. At 70 to 80 deg, for advancing direction. re oe Horizontal Welding At 70 to 90 deg. to the weldment. At70 to 80 deg. for advancing direction. 43 Vertical Welding For vertical welding, the same as flat welding. 44 Fillet Welding For fillet welding, 45 to 60 deg. for fillet angle.Chapter ARC WELDING 5-1 Weaving For both flat and vertical weldings, the first layer shall be welded by manipulating the electrode straight or slight weaving. For the 2nd layer, manipulate the electrode a little faster in the middle, while stop it for a moment at both ends so that the weld bead dose not become convex. For the 3rd layer, stop electrode for a moment at the corner of groove to prevent the undercut. For weaving, it's better to oscillate not the tip of electrode but the entire electrode. (CCC Flat welding Vertical welding (1) Various weaving methods There are many other methods of weaving. The point is to make sure to the electrode at the corer of groove to prevent undercut at the toe of weld. To obtain a weld bead of constant width, manipulate the electrode while observing the state of melting penetration. For Multi-layer welding, weld while adjusting the thickness of deposited metal so that the —> 0.5~0.1 mm corner of groove remains by 0.5 to 1 mm before final weld bead is laid.(2) How to Judge the Propriety of the Manipulation of Electrode Cause of unfavorable arc welding. @The width of bead is not constant. Arc length is not kept constant. Electrode ‘maripulating speed is not constant. @The weld bead is scaly or swollen on the side or center. ©The weld bead is narrow with sharp ripple on it. Welding current is too strong. Arc is too long due the electrode being tilted too much. @Bead is melted down. @The sides of bead are roundish. @Bead is scaly. Too small current Too large pitch Too small current Too large pitch Too large weaving width Undercut: The weldment is dug along the toe of weld without being filled with deposited metal, thus and resulted by making a groove-like gap.Gast) 5-2 Boxing if Fillet Weld Joint Basically, boxing is employed for fillet weld joint, where arc is not cut off at the each end of weldment. To prevent a strain arised you can use a prop or change its welding sequence. a a A Al EY 3-3 Improper Weld Joint (1) Propriety of weld joint from the moment point of view th a Xe ed x x ° ree ret @ ctuvters(2) Weld joint to avoid the concentration of weld lines x ° x ° (3) Weld joint to avoid stress concentration x : x ° ee aoe x ° (1) Butt welding for the plates of 1/5 to 1/8 taper different thickness 500 mm (3) Defective repair welding which must be avoided Too large groove Metal stuffing Misalignment of plates Rea Be Boe ChaptersEGR ccs 5-4 Repair Fillet Welding (1) When the root gap is 1.5 mm or less, weld as it is to specified leg length. 1.5 mm or less. oe 1: specified leg length (2) When the root gap is 1.5 to 4.5 mm, the joint may be welded as it is, but leg length must be increased for the increase in root gap. 1.5mm~4.5 mm L (3) When root gap is 45 mm or more, insert a liner or cut out the defective plate by 300 mm or more and replace with proper one. 300 mm5.5 Checking and Repairing of the Groove (1) When groove is 6 mm or less, execute build-up welding on either side (or both sides) until the groove become as specified. PA Ae oy > oe Build-up welding 6 mm orless (2) When root gap is 6 to 16 mm, use a backing strip of approximately 6 mm thickness. @After having welded, gouge out i J the backing strip, or weld all around the strip. ct 6~16 mm (3) When root gap is 16 mm or more, replace the all or part of the plate.Eerste) 5-6 How to Repair Breakage on a Steel Pipe (1) When the water flow cannot be stopped |- Strapped joint Strapped joint Band Packing a \ Band Drain hole *<- Drain hole Packing (1) Prepare a same size or one-size-larger pipe, from which a semicircular is cut out to be used as the strapped joint which covers the breakage at its center. (2) The pipe length shall be approximately twice the diameter of the broken pipe. (3) Cut out a semicircular pipe , and chamfer the corners. (4) Make a drain hole on it, avoiding the section on which strapped joint mounting band is to be applied. (5) Mount a small valve or a pair of bolt and nut on the drain hole to prevent water from dropping on weldment. (6) With a thin flat rubber, packing or sealant on the processed strapped joint, tighten the band. (7) After tack welding the strapped joint, start regular welding from beneath the leaking point (the point on which water drops). It's better, to prepare a larger strapped joint, taking it into consideration that the base metal around the leakage may be thinned. (2) Breakage at a comer of T-shaped pipe Welding —_ Chamfer the corner * Welding » Chamfer the corner Prepare two symmetric ones (1) For the upper part, split a T-shaped pipe into two pieces. (2) For the lower half, prepare a split pipe. (3) Make a drain hole on the lower half, and mount a small plug or valve on the hole. (4) The pipe length shall be 50 to 100 mm according to the size of the pipe. @ ciuvrers(3) Lealage from flanges (1) Prepare a flat bar to make a band which fits the periphery of the flange. (2) Make 2 to 3 holes on the band to fill sealant (It is recommended to use bolt & nut). (3) With a lead plate or a packing put under it, tighten the band. (4) Fill quick drying sealant (silicon, etc.). (5) Check that sealant comes out from underside. (6) When sealant is sufficiently filled, plug the holes. Fill sealant Fill sealant \ ilisealant ~ Bolt and nut Band Weld all around A a Check that sealant is filled (7) If necessary, weld the bolt and nut mounted on both sides of the band or on the filling port. (1) Leakage from the boot of flange or bolt holes of flange (1) Prepare 2 pieces of steel blank flange which are the same in thickness as the flange of the broken pipe but are large in size. (2) Bore the blank flanges, aligning them with the leaking pipe. (3) After boring the blank flanges, prepare 2 pairs of split pipe for strapped joint which fit the outside diamater of the broken pipe and are 50 to 100 mm long, and weld them on the bored split blank flanges (the above sight figure). (4) Prepare a pair of split blank flange-pipe assembly as shown in the figure below, put them on the broken pipe, and weld them. (5) It is recommended to tack-weld the strapped joint assembly at many points, but be small as possible. Joint two flanges by flat bar +e Prepare 2 pairs of split blank flange- ira hole Pipe assemblies (bolt and nut) A Prepare a pair of strapped joint assembly (upper and lower) (Mount a drain plug on the lower assembly) Chapter 3 @Sse Nc) 5-7 How to Prevent Weldment from Deforming (1) Mount the strongback at an angle of approximately 45 deg. against weld line. nt (strongback) (2) In welding the doubling plate, make the deformed original plate come in close contact with the strongback. f S mpe: —_—_ ~~ Strong back @One-side welding is enough for the strong back and dog. (3) Eliminating the clearance between the original plate and the strongback one after another, tack weld all around. Then execute regular welding. Wedge Pea Make no clearance here5-8 Are Welding with Coated Electrode of Galvanized Steel In general, galvanized steel is hard to be electric welded with covered electrode because of poor usability of welding and poor appearance of weldment. This is because the coated zinc has a bad influence on the arc and the physical property of deposited metal. Galvanized steel is roughly classified into two groups according to coating method: galvanized steel and electro-galvanized steel (coated amount: amount of coated zinc per surface area of steel). Coated amount of zinc has a large influence on weldability. The more the coated amount is added, the more notable the following phenomena appears. (1) Influence on usability @Arc becomes unstable and deposited metal is insufficiently covered by slag, resulting in poor conformability of bead and rough surface. @Excess spatter and fume Spatter : Metal particles which fly during arc or gas welding and which do not become deposited metal. Fume — : Smoky gas (2) Influence on the performance of weldment @Generates pits and blowholes, lowering mechanical performance. Pit : Small dent generated at the end point of weldment Blowhole : Cavity generated by gas included in molten metal It is hard to completely eliminate the above mentioned bad influences. But it can be relieved to a certain deg. by the following measures: @Execute welding after removing the galvanized zinc layer along weld line by a grinder or sander. @When high strength is not required, execute brass soldering instead of arc welding with covered electrode. craper 3s @ARC WELDING 5-9 Welding of Cast Iron (1) Basic welding (1) Bead length per each pass shall be 50 mm or less (approximately 20 mm is proper). Execute peening after welding (For multi-layer welding, peening shalll be executed after each pass. For the final bead which does not fuse the base metal, peening is not necessary). (2) Use skip welding, symmetric welding or back step welding. (3) For multi-layer welding, carrying out buttering leads to a good result. (4) Chamfer the edge of the groove. (5) If the deposited metal does not conform to the base metal when welded with nickel type electrode, execute buttering with mild steel rod. (6) Weldment of pure nickel type electrode has higher resistance to crack than iron-nickel type electrode. (2) Procedure for repair welding of cast iron product (1) When cil soaks into the object product of cast iron, sufficiently preheat it to remove oil before welding is started. (2) Sufficiently gouge the part of the defects. If necessary, make stop holes at both ends of the crack. (3) Prepare on edge by grinder or the like. (Round the bottom) 15'~20° 60°~90" if ae. 20 mm or less 20 mm or more(4) According to the size of the base metal, preheat until the specified temperature (Small product needs not be preheated). Preheating temperature : Cast iron. : 100 to 300 deg.C (nickel type electrode). Cast steel : 60 to 250 deg.C (low hydrogen type electrode, ilmenite type electrode). (5) Bead length per pass shall be approximately 50 mm (to prevent overheating, reduce strain and prevent cracking). (6) Be sure to execute peening (remove strain by tapping with a hanmer). For each bead, execute peening until ripple on the bead disappears while the bead is still hot (Tapping by the sharp edge of test hammer is effective). (7) Welding method For comparatively small conical groove, weld spirally starting : From the bottom of the groove. Weld from the center toward periphery @ groove When weld length is long, use back-step welding, skip welding or symmetric welding (to prevent cracking). 50 mm or less 7] (3) |) (3) 4) ~~ @ (4) Se (1) (4) (2) (5)_—(3) KOKO Skip welding Back-step welding Symmetric welding (8) After welding, cool the weldment as slowly as possible. For small or middle size products, wrap them with thermostable sheet after welded and let them naturally cool.Gontainer shipGRINDING AND FACING UP OF VALVE 1-1 How to Clean the Valve Components Carbon or other foreign materials sticking to valve components can easily be removed by dipping them in water for 2 to 3 hours. Oily stains can be cleaned with kerosene. 1.2 Points to be Checked @Fiaws on the working face of a seat and a valve, and the propriety of their contact. @Clearance between a valve spindle and a guide. @Bend of a valve spindle. @Wear of a seat and a valve. 1-3 How to Measure the Bend of a Spindle (1) Measure the bend of a spindle Put two V blocks on a large surface plate or flat steel! plate, set a dial gauge with magnet stand according to the figure below, and the measure bend at several positions while turning the spindle manually. fig.1 How to measure the bend of a spindle (2) Measurement of run-out with a lathe machine Aiter the center holes of the valve have been sufficiently cleaned, set the spindle on a lathe according to the fig.2; then, measure run-outs at points "a", "b" and "c" in that order. When a run-out is detected at point "a", adjust the chuck to re-center the spindle. fig.2 Measurement of run-outs with a lathe machine1-4 Grinding Procedure Grinding when a large flaw exists on the valve face. (1) Cut out the flaw on the valve face by a lathe machine. @Cut the work-piece after centering it with a dial gauge; if necessary support it at the center hole by the tailstock. Before cutting, finely adjust the tool post exactly to the original angle. @Because the valve is worn greatly, cutting shall be minimized, avoiding unnecessary cutting. (2) With the valve set on a lathe chuck, grind the valve face by a middle mesh (#120 to #180) emery cloth which is wound around a flat file until the flaw disappears, while turning the valve at low speed. Grind as well as the original angle. @Be careful so that your working clothe is not caught by the rotating work-piece. (3) When a seat or valve face has a small flaw, stick a piece of emery cloth on the seat or valve face using two-sided adhesive tape and rub them together to remove the flaw. For grinding, stick small pieces of emery cloth to the shaded parts shown in fig.3. The number of pieces of emery cloth to be stuck shall be changed with the size of valve. (4) After removing large flaws by following procedures explained in (3), grind the both seat and valve faces with medium carborundum paste until 2/3 of the periphery comes in contact with the mating valve face. (5) Finishing: Grind with fine carborundum paste until fig.3 Valve stem the both seat and valve faces come to have a blackish luster. Then grind with oil to clean the valve face. (6) Check the valve faces: After finish grinding, wipe out oil, dust and other foreign materials sticking on the seat and valve faces. To check the contact between the seat and valve faces, slightly hit the former against the latter 2 to 3 times. By doing so, you can feel the situation of the contact.1.5 Precautions for Grinding (1) A large size valve is ground by applying the strength of less than its tare. Grind the valve face while lifting and turning it little by little. (2) If the working face of valve is sinking in that of seat, gas leakage may occur. In such cases, cut the top of the seat by a disc grinder file (According to types of valve, the seat can be replaced). Ze =e TE (3) If the valve face is being stepped greatly as the circled section, remove the stepping by lathe machining and re-grind the valve face. (4) To shorten the grinding time, completely remove the flaw by machining, and frequently change grinding powder. (5) Grinding must not be carried out while grinding powder is running out (Otherwise, the valve faces come in direct metal contact with each other, and creates the flaw on the faces). (6) To make the valve face come in contact with mating face at outer diameter. @Change the taper angle by lathe machine. @Grind by adding small amount of grinding paste on the inner side of the valve face while wiping off the grinding powder coming outside with cotton wastes. @ cinoter+eplaceme Or ce aul ‘Valve of Diesel Generator (D/G) By measuring the following parts, determine the timing for replacing the valve or valve seat, referring to the maker's replacement standard for each type. 2-1 Intake/Exhaust Valve Replace when the width of valve face is reaching or in excess of wearing limit. 2.2 Exhaust Valve Seat Replace when the distance between the inner diameter of valve seat face and the diameter packing seat is reaching or in excess of wearing limit. When the width of valve seat face becomes too large, resulting in a narrower flat part of "C",cut the part of "C" to be flat. However, dimension ¥ "A" must be within wearing limit. cf 2-3 Intake Valve Seat (Solid type, valve box type, replaceable type) Replace valve seat when reaching or in excess of wearing limit. @Solid type :Machine the cover to mount the replaceable valve seat. a @Replaceable type: Replace with a spare, _— @valve box type _: Replace the valve box. Be careful that measuring points differ by makers and types. x Exhaust valve seat Intake valve seat Intake / Exhaust valve seat Chapter 1 @pe Mera IKE LZ ch saa LA Ls To grind down the valve face by a lathe, align in advance the deflection run-out of the valve spindle, according to the figure below. To repair the valve face, it is desirable that a contact line is at 1/3 from the outside of the valve face. 3-1 How to Measure and Replace Intake/Exhaust Valve Guide (1) Machine a boundary sample rod (a model rod with a diameter of the original dimension of valve spindle plus the limit clearance between valve spindle and guide) by a lathe machine. Replace the guide when the boundary sample can be inserted in it. (2) Insert a new valve spindle in the guide. Replace the guide if the clearance is too large. (3) Measure the bore of the guide by a cylinder gauge, dial caliper or other proper measuring instruments (Such a measuring instrument is hardly prepared in ships). 3.2 How to Replace the Guide (1) Measure the diameter of the boss inside and the guide outside to see whether they fit or not. (2) Sufficiently clean the boss inside (on the body) and the guide outside. (3) Press and fit the guide after cooling it in a refrigerator, etc. = Hydraulic jack Hydraulic pump4-1 Overhaul, Maintenance and Checking (1) Disassemble the valve, clean the inside, remove scale or other stains sticking on the working face of the seat and valve with an emery cloth, scraper, etc. (2) Check flaws and the state of contact of valve face. (3) Measure the clearance between the body and the bottom of valve disk (No clearance is a defective condition). (4) Check the corrosion on threads, valve body and valve casing. If everything is satisfactory in the above checking, facing-up is not necessary.Chap GRINDING AND FACING UP OF VALVE 4-2 Grinding and Facing up of Sluice Valve (1) When the valve face of seat or valve has a flaw (A valve or a seat having significant flaws cannot be used because the valve sinks too deeply into the valve seat and cannot be closed completely), grind the entire valve face by an oil stone, file, scraper, emery cloth, etc., until the flaws are eliminated. (2) After applying a minimum coating (red lead) to the valve face, insert the valve in the seat to check the state of contact. (3) Grind any part where the contact is too strong using an oil stone, file, scraper, emery cloth, etc. Repeat such steps until the valve comes in contact with the body. Keep a minimum grinding because even a grinding in a small scale may lead to a large drop of the valve (If the valve disk bottom comes in contact with the body, the valve can not be used any longer). 4-3 Precautions for Handling a Valve (1) Changes in temperature sometimes make it hard to open/shut a valve due to expansion of components. Especially at high temperatures, valve should not be shut too firmly. (2) When a valve is not operated for a long time, the threaded section may seize, or scale may stick on the face of seat and the valve. To prevent these problems, valves (especially those installed in the sea water system) shall be operated from time to time. Dilation5 Grinding and Face up of Flat and Conical Type oPvatre= 5-1 When a Valve Seat Face has a Significant Flaw or the Width of Valve Face is too Large (1) A flaw on a valve seat face shall be removed by a seat cutter or by machining, or be ground off using small pieces of an emery cloth which are to be attached to the valve face of mating valve by a two-sided tape. (2) When the width of the valve face is too large, cut out the flat section at upper part of the seat by a seat cutter or by machining to reduce the width (It will be defective conditions if the outside diameter of the valve face of the seat is greater than that of the valve, or if the working face of the valve deeply sinks in that of the seat). 5-2 When a Valve has a Significant Flaw or Step (1) Set the valve on a lathe machine by aligning it with the center of the lathe, adjust the tool post to the angle of the valve (conical valve: 45 deg. ; flat valve: 90 deg.), and machine it. (2) Set the valve on a lathe, and grind it with a file or emery cloth to the original angle. 5-3 When a Valve and a Seat are Machined or Ground Separately (1) Rub them together applying a medium carborundum paste and check for any flaw on the valve and seat faces as well as for the state of contact. (2) Change a grinding paste to a smaller size gradually and continue to rub them together. (3) Finally apply oil grinding to remove stains sticking on the valve faces. comerhapter_ GRINDING AND FACING UP OF VALVE @When a valve and a seat are cut to the same angle by a lathe or a seat cutter, grinding is to be done only to check the angle of contact. @ if their angle of contact is different, correct the angle of valve by lathe works. This method provides a better result than the one acquired from rubbing them together for a long time, and in addition reduces working hours. 5-1 How to Grind and Face up the Valve Face which has no Guide Leg (flat valve, conical valve) Insert a thick packing in the shaded gap in the figure, mount the spindle, and tighten it by nut to fix the spindle and the valve body. Then prepare a guide for grinding, and apply grinding. If the mounted spindle is too long, the face of the valve to be ground moves rattling during grinding works. To prevent this, grind by turning it gradually, caring that the spindle does not move. __— Valve spindle ~~ Valve mounting nut “ Valve Packing gap& Precautions m (1) When a valve has a significant flaw, but large in size and therefore can be machined, the flaw should be removed by machining, which not only reduces working time but also provides an excellent finishing. (2) When a valve or a seat has a significant flaw not removable by machining, grind off the flaw with small pieces of an emery cloth applied by a two-sided tape to the face of the valve or the seat or other type of grinding tools. @When the emery cloth is clogged, blow air to revitalize it. @When the valve and the seat are rubbed together for a long time, the valve face may be stepped as a result of such grinding, resulting in a defective finishing. (3) It is recommended not to rub the seat and the valve together, but is desirable to grind them separately by a valve or seat lapping tool and finally check their state of contact by applying minimum coating (red lead). (4) A grinding paste must not be run out during grinding. Otherwise, the valve face may be flawed, depending on material (especially stainless steel type material). (5) The grinding face of a lapping tool shall sometimes be repaired to be flat by a lathe or on a surface plate.(High Pieasiit' Valve, oe ) (1) Carefully face up with an extra-fine grinding paste (chromium oxide) to finish the facing- up, and then face up with oil. Then clean the valve face with cotton wastes and check the state of contact. eS If the valve face is improper, a blackish shade appears on its face. On the other hand, when the valve face is proper, it gives a white luster. (2) After a finish grinding, wipe off oil and mark several radial lines on the valve face using a soft pencil (4B). If the contact between the valve and the seat is proper, the pencil lines marked on the valve face disappears when they are rubbed together. Material of these valves is very hard, thus removing of even a slight flaw requires a long time. Grind them with small pieces of emery cloth applied to the valve face by a two-sided tape while changing the grain size of an emery cloth gradually to smaller ones (#240 to #600). High pressure valveValve spindle Valve guard Locking washer Valve disc valve disg Valve seat Drive a wooden rod which is used as. handle for grinding 8.2 Conical Valveela eesy ge Aegan Cav 83 Grinding Tool for a Flat Valve Seat Guide plate: cast iron or steel plate. Use a cast iron or steel plate for the grinding tool. a! ae @Before grinding, clean all contact parts other than the valve face to be ground, remove protrusions, if any, by a file or emery cloth to make the surfaces smooth, and coat lubricating oil on the surfaces, so that your fingers do not feel any unevenness during grinding. @During grinding, concentrate your nerves at your finger tips, and you can easily detect ‘the feeling of foreign matter, galling or any other abnormalities if any.SLINGING WORKS (2) Lay The “ordinary lay" has the lay of the rope opposite to that of the strand. The most standard ropes found on board vessels are those of "ordinary Z-lay" The Lang's lay rope has the same lay of the rope as that of the strand and has the tendency to unlay and is liable to kink. It is used in places where both rope ends are unlikely to rotate freely or the rope is kept tensioned at all times. It should not be used for general slinging. \ . a cx Hl is WN m \ i y On ee Le L GG ip Ul Y d IS Ordinary Z-lay Ordinary S-lay X \ \ g o N a & 5 5 é @ a & @Cross section Core of each strand There is no fiber core as well as the core of in a strand. This is the wire rope is afiber used for standing core mostly ona ship. wire. There is no fiber core A strand is used as ina strand. Wire core the core of rope is used in the center _(homo- centric). Used of mooring wires as as the wire for this is more suitable suspension bridge. for the tension placed ‘on mooring wires. @ counters@Structure of cross section Of JIS (Japanese Industrial Standard), No.1 to No.23 wire ropes, the following figure shows No.1 to No.6 wire ropes. No.4 wire rope is mostly used for general and marine purposes. No.1 6x7 6x12 No.3 6x19 No.4 6x24 No.5 6x30 No.6 6x37 7- stranded wire, 6 stranded rope with fiber core 12- stranded wire with a fiber core, 6 stranded rope with fiber core 19- stranded wire, 6 stranded rope with fiber core 24- stranded wire with a fiber core, 6 stranded rope with a fiber core 30- stranded wire with a fiber core, 6 stranded rope with a fiber core 37- stranded -wire 6 stranded rope with a fiber core Standing wire Running wire Standing wire Running wire Standing wire Running wire Standing wire Running wire Running wire(3) Diameter The size of wire rope is nominally represented by the diameter of a circle just enclosing all of its strands. The method of measuring wire rope is to measure the diameters in three directions in a certain section using a caliper as shown in fig.1-2 and the averaged diameter is to be the size of the wire rope. The diameter of a wire rope at the time of manufacturing is somewhat larger than the nominal diameter and the tolerance is to be 07% of the nominal diameter (010% for the wire rope with a nominal diameter less than 10 mm). fig.1 Correct measurement fig.2 Incorrect measurement © cruwters2 Sate Wi Wire ropes are classified into Grade-G, Grade-A, etc. in respect of the strength depending ‘on the tensile strength of the wire and the galvanization status, i.e. galvanized or not galvanized. The breaking strength of each of the two most common wire ropes for sling works, 6 x 24 and 6 x 87 of Grade-G and A, is shown in Table 1. @Tablet. Classification by the breaking strength of a wire Grade-G(1470N/mm’ class) __With zinc coating (including those cold-worked after zinc coating) Grade-A(1620N/mm* class) | With or without zinc coating (including those cold-worked after zinc coating) @Table2. Breaking strength of wire rope sling 8 29.3 31.6 31.6 34.0 9 371 39.9 40.0 43.0 10 45.8 49.3 49.4 53.1 11.2 87.4 618 61.9 66.6 12 65.9 71.0 7101 76.5 12.5 15 77.0 TA 83.0 14 89.7 96.6 96.7 104 16 117 126 126 136 18 148 160 160 172 20 183 197 197 212 22.4 230 247 248 266 24 264 : 284 - 25 286 308 308 332 28 359 387 387 416 30 412 444 444 478 31.5 454 489 4s0 527 33.5 514 553 554 | 596 35.5 577 621 622 669 37.5 644 693 694 747 40 732 789 790 850 42.5 827 890 892 959 45 927 998 1000 1080 47.5 1030 1110 1110 1200 50 1140 1230 1230 1330 (Note) Source; JIS G 3625-1995 “Ordinance on Safety of Crane, etc” requires the safety factor "6" for sling wire ropes. Accordingly a single sling wire rope can vertically hoist up to the maximum load (basic safe load) as shown in fig. Table3. (Diameter to be expressed in mm) Chaper 3 @11.2 12 12.5 14 16 18 20 22.4 SBRR 31.5 33.5 35.5 37.5 40 42.5 45 475 50 53 56 60 Basic Load (t) 0.49 0.63 0.77 0.97 1 1.2 15 19 25 34 3.9 44 4.85 64 7.0 TW 87 9.8 10 12 14 15 7 19 (Diameter to be expressed in mm) 0.53 0.67 0.83 1.0 4.2 13 1.6 24 27 3.3 4.2 5.2 65 15 8.3 9.4 10 W 13 15 16 18 20 0.33 0.53 0.68 0.84 1.0 1.2 13 1.6 24 27 3.3 42 48 5.2 6.5 78 8.3 94 10 1 13 15 16 18 20 23 26 30 ‘The above basic safe load can be worked out roughly by the following formula, = 0,008 x (diameter of wire rope)” 0.35 0.57 0.73 0.90 iA 13 14 Ww 2.3 29 3.6 45 5.6 7.0 84 89 10 1 12 14 16 18 20 22 25 28 323-1 Tension Imposed on Wire Sling - The tension applied to a sling greatly varies, depending on the angle of hosting; the hoisting angle should be less than 60 deg. nate it 1 2.92 a 3.2 Slinging Hitch (1) Eye hitch Wire rope for slinging work has eye splice, ring shackle, etc. This method hitches them on a crane hook hoist the load. Single hitch Double hitch (2) Half hitch This method should be avoided because the wire rope easily slips on the hook, especially when a high-center- of-gravity load is to be hoisted. (3) Single blackwall hitch Single blackwall hitch is the method to wind slinging rope around the main stem of the hook so that the loop works as the eye of slinging wire rope. This method can not be recommended. Do not tap wire rope to fit it to the main stem of the hook. In addition, one-sided loading is very dangerous.Reh ane) (1) Round tum hitch This method is employed to hoist a load which center of gravity is one- sided with thin rope. In this method, a wire rope is wound the hook by ‘one turn so that friction prevents the wire rope from slipping. 3.3 Slinging a Load There are several methods to sling wire rope over a load. Basically, the following methods are employed. Well be understood these methods so that you can properly select a suitable one for each application. (1) Through-eye single rope suspension The suspended load rotates. Basically avoid this method because the lay of the rope may be released “It is hard to judge where the center of gravity is. (2) Round turn and through-eye, single rope suspension When the suspended load rotates, the lay of rope is released. Yo , Firmly draw the rope. a ie __Applied to material mill scale. "This method shall basically be avoided. "Use a hemp rope to prevent the load from rotatin (3) Bound double rope (Cow hitch) suspension Use a twi folded wire rope to prevent the load from rotating. 60"(1) Claspin ee Firmly draw the rope. This method tends to damage wire rope, requiring wire rope to be inspected after work. This method shortens the life of wire rope. "With this method, the rope is sufficiently drawn. (3) Half hitch quadruple suspension / ™ Low-center-of-gravity load. /- [Be careful that the rope easily slips. / For material with mill scale and uniform diameter. (6) Round tum hitch quadruple suspension / Low-center-of-gravit / Insert rug when the load slips. / Symmetricload (7) Through-eye, double rope suspension _/Firmiy draw the rope. Slight drawing J Firmly draw the rope when the load slips. Firm drawing(8) Left-right different through-eye, double rope, suspension Let the rope through the eye differently on both sides. Wire rope hardly kinks. (9) Round tur hitch through-eye, double rope suspension For a material with mill scale, the rope is firmly drawn without slipping. \. Suitable even for a high-center-of gravity, one-sided load. 3-1 Miscellaneous a Load Slinging (1) Quadruple suspension of rectangular load To hoist a rectangular load by quadruple suspension, wind the wire rope around the load by one turn. (3) Two ring suspension Suspend at equal intervals. Firmly draw the rope. For small rings, triple suspension. Wind the rope around the hook by one tum. @ ciwters(1) Bound double suspension for ring (6) Trigonal-pyramid suspension Wire rope on the rear face. (8) Hand-mill suspension Apply the wire / rope at two opposite points (right and left). Firmly draw the wire. (3) Tilting suspension for ring Let the wire rope slip here. ind a thin rope. Use a pin. — _ _ Do not allow the wire rope to slip here. (7) Gripping suspension Cheek the pin ~~ for wearing. For timber, grip at a point lower than the center line, ~~ Carefully check the center of gravity. (9) Disc suspension Apply the rope at 4 equally divided Wire rope on points. the rear face. Chapter @ING WORKS (10) "Hakama" suspension (11) Stage plank suspension Ageasicey segraee and pips. 8 scaffold board or log. Use a “hakama" _/ made of canvas.(aC Ae = 1c aa ar NP oon lionment Alignment must be made within 5/100 mm (7/100 to 8/100 mm may be acceptable). Adjust the clearance between the mating faces of a motor and pump couplings by 3 to 4 mm. Basically, adjustment shall be made on the motor side. Measurement shall be done by setting 1 or 2 coupling bolts and rotating both the motor and the pump. Vertical and sideway differences shall be 5/100 mm or less. 5/100 mm Parallel Feeler (1) Adjust the clearance between the mating faces of the motor and pump couplings on upper and lower sides (measuring instrument: feeler gauge). For adjusting with a liner, insert the liner on the front or rear side of the mating faces. Use a liner of the same thickness on both left and right sides. Turn the coupling by 180 deg. to measure the clearance.Ch a ree eee ay (onrelg) 4 2.1 Installation (1) Amiddle or small size bearing shall be applied by press-fitting at room temperature. => (2) When any interference is required for both inner and outer rings housing the middle or small size bearing, do not tap strongly, but tap slightly to drive the bearing gradually. (3) In the case of a bearing with an adapter sleeve having a clamp on the inner ring side, loosen the mounting nut by giving it several turns. Take out the string by tapping it with a dolly block. 2.2 Checking Before Removing the Bearing (1) Before removing the bearing, be sure that the corner and right angle section of the bearing housing comes in close contact with the end face of the bearing. (2) If the contact is wrong, check the section circled in the figure shown below. lle \ lal(2) Adjustment of the height (measuring instrument: dial gauge) Method to mount a dial gauge corresponding to the shape of coupling and other factors. In adjusting with liners, insert liners of the same. thickness at 4 positions. up y A Pump Motor Down Pump Motor (3) Adjustment of a miss-alignment and a clearance between mating faces of the motor and pump couplings. First adjust a lateral miss-alignment, then adjust a clearance between the mating faces of the motor and pump couplings by slightly tightening the anchor bolts of the motor. Repeat these adjustments. Pump. Motor (4) Repeat procedures of the above (3). (5) After finishing the adjustment, tighten the anchor bolts. Chapter3 Shrink Fieting (1) Bearing is fit on the shaft after expanded in an heating oil bath. Heating temperature: 100 to 120 deg.C (Must not exceed 120 deg.C because the hardness of bearing increases when heated). (2) Make the end face of the inner ring of bearing come in close contact with that of the stepping of shaft until both the bearing are sufficiently cooled. Applied to open type bearing. Sealed bearing must not be dipped in heating oil bath. (3) In case of fitting sealed bearing with large interference on a shaft. Put the bearing on a steel plate, heat the steel plate from down, and sometimes reverse the bearing to evenly heat it. When heated, fit the bearing on the shaft. Carefully check heating temperature so that the shield is not damaged and that oil contained in the shield does not come out.Naan ene) 4-1 Sample Removal of Bearing (by puller) Turning the handle unscrew the bolt, exerting a pulling force on the bearing. 42 Removal by a Hand Press (1) Set the hand press so that the blocks support the (2) To remove by a hammer, be inner ring and that the center line of the bearing sure to use a dolly block so becomes perpendicular. that the shaft is not damaged. Wrong Correct \ \ / Supporting block 4.3 Removal by a Puller (1) To remove a bearing from a Wrong Correct alk shaft, set a puller with the . . beck claw on the inner ring.(2) When hard, give a shock by tapping the head of the (3) If the bearing does not come out even with above puller, with pulling force applied on the bearing. method, heat the bearing by a gas burner with pulling force applied on the bearing, caring that the flame does not reach the shaft. (4) When the bearing does not come out with above explained methods @Cut the outer ring and metal support fitting with gas cutting torch to leave the inner ring. Heat the inner ring by gas cutting (welding) torch, carefully not to heat the shaft, to take it out. @When the bearing cannot be removed even with above method. Cut the inner ring with gas cutting torch. @These methods generally cannot be recommended because they may bend or flaw the shaft, may degrade material, or for other influences. @For gas cutting, use as small flame as possible, as well as minimize the opening of high pressure oxygen valve. @Ajter heating and removing the bearing, the shaft shall be cooled naturally.ALIGNMENT BETWEEN PUMP AND MOTOR recommendable to prepare the fitting shown in the figure below. (2) To prevent the fitting from coming in direct contact with the shaft, wind a copper, brass or lead plate around the shaft. (3) Applying a pressure, and lightly tapping the head of the push bolt, pull out the coupling little by little.1-1 How to Align Flange Holes (1) Place a flange so that two of its holes become on a level with each other, insert a bolt in each of them, and lay a welding rod on the top of these bolts. (A welding rod may be secured using a clamp.) check visually = co C clamp (2) Do the same thing to another flange, and look straight at these welding rods from the front side of the flange faces. ‘Two electrodes overlaps one another aes Tum the flange ‘Two electrodes are parallel to each other (3) Turn either flange until two rods become parallel to each other. When in parallel, apply tack- welding to the flanges. @ Coonter712 How to Align Straight Pipe and Flange (1) With the end of pipe retreated from flange face by apporoximately 5 mm, tack weld the flange. Flange square Flange shall be right angle to the pipe. \ | > — 5mm 5mm - k (2) Holes of the right flange witch is to be tack welded shall be aligned with those of left flange which is regular welded. Regular welding shall be done on both sides. eee Keep a5 mm clearance. Chapter 7 @Spare flange \ Height and sideway positioning of (2) the old pipe with an L-shaped bar Fixing the flange 1 with a band iron Temporary welding to the bed % (3) About 5 mm in clearance evelaing \ between the flange face \ New pipe and the pipe end NY (80° bent) Final welding after removing Se ye, 8 Temporary welding (4 points) \ | Fixing New flange _ — is 1st layer; contact welding welding f_ 2nd layer; weave welding on a small scale ‘Temporary welding between the bent pipe and the straight pipe, and between the straight pipe and ‘the flange; then fixing with a band iron; Finally weld all parts after removing bolts and nuts.A bent pipe can be made in accordance with the above procedures (modeling). Even when a bent pipe is fitted with branch pipes, it can be made by similar method (by modeling the flanges of branch pipes). Weld on welding deck Regular welding after firmly fixing on the main pipe Regular welding It is important to firmly fix the branch pipes to the main pipe so that they are not deformed in the course of a final welding.A pipe can be modeled at site using a #8 steel wire. #8 steel wire Stretch a #8 steel wire along the center line of a pipe to be modeled; the length shall be a little longer than the actual pipe length; apply a mark to the wire at flange positions.Be entineor 5-1 Filling Sand Sand gravel of 5 mm or smaller in size is ideal but fine sand can also be used. Avoid using wet sand which is easily solidified by heat. With the bottom of the pipe plugged with a wood block, fill sand in the pipe while giving hammer-tapping to the periphery of the pipe from the bottom and upward (Area to be bent ‘shall be positioned on the lower side). 5.2 Modeling the Bent Angle with a #8 Steel Wire Mark "A", "B" and "C" at the position where #8 steel wire begins to be bent. Trace the points "A", "B", "C" on the pipe. 48 steel wire Lo 7 % Z c Woodplug A Bg Point Point Point A B cChapter Reais modi es 5-3 Heating Apply heat evenly to the section of a pipe to be bent (Defective bending resulting from uneven heating can hardly be corrected). Do not heat any section other than the curved section from "A" to "C". Heat the section which only becomes inside of the curvature (2/3 of the circumference of the pipe), and do not heat the section which becomes outside of the curvature (1/3 of the circumference of the pipe). Heating the outer plate of the curvature will result in thinner wall thickness and a dent in the pipe. When the bending angle approaches 90 deg., the pipe may create a dent on the outer plate of the curvature. In such a case, give an additional bend to the pipe for about 10 deg., then burn that portion until the surface turn red, and return the bending angle back to 90 deg. On the other hand, the inner plate sometimes becomes wavy before the bending angle reaching 90 deg. In such a case, give hammer-tapping to such portion to regain its normal shape, and then resume burning to increase the bending angle until the surface turns red. Range of curvature _ Bent while heating Restore to the original shape 20. by tappingRemove the rust by disc grinder and clean, Pipe is thinner around the cracking. Cut out a piece of 4 mm thick steel plate which is alittle larger than the crack. Burn with a gas cutting torch Lint the surtaee tums tec When the surface turns red, tap and bend the steel plate along the pipe. Steel plate Na crane @TYPES AND APPLICATION OF PACKING 1-1 Paper Not so strong and easily comes out under high fluid pressure. Especially a cardboard is weak. Short in flexural strength, and susceptible to breakage when removed. When coated graphite on the sealing surface, the packing can easily be removed. Suitable for steam line, pneumatic line, drain oil line, etc. 12 Fiber ‘Applied in dry condition to tap water line and gas line. Also used for steam line. 3 Rubber Mainly composed of synthetic rubber, with which other materials are kneaded to be pressure heated and then vulcanized and molded. 14 Seal Tape “Ethylene tetrafluoride unbaked resin tape for sealing" (raw tape) is the name defined in JIS. 1 1< Leave 1 to Due to excellent usability, chemical i pis 4 resistance, pressure and vibration 7 proofing, cold resistance and heat resistance, widely used to seal threaded joints. @How to wind seal tape As shown in the figure, if seal tape is wound protruding from the end of thread, the piece is torn off to enter an equipment of the facility to cause trouble. Be sure to wind seal tape on thread leaving 1 to 2 jiages: Good ® covers2-1 Type of Liquid Gasket (1) Classification by nature @Non-dry: Does not dry permanently, has fluidity, and can easily be separated. @Semi-di Although the surface dries, the inside does not dry to be hard. @Dry: Solvent evaporates to dry the liquid. (2) Classification by state @Adhesive: Representative liquid gasket which is non-drying and has fluidity. @Visco-elastic: Has both tackiness and elasticity and suitable for padding at a greatly deformed place. @Membrane: Forms a separable membrane. Various soft and hard membrane types are available. @Filling type: The type for filling clearance of various structural can be removed. @Hard sticking: Filled to be hard in a place where gasket is not so frequently replaced. 2-2 Features of Liquid Gasket @Because of liquid, it spreads over the void to prevent leakage along the tangent as well as penetration leakage and provides excellent pressure-proof sealing effect. Proof pressure up to 250 kg/cm’ is standardized. @It does not damage metal surface, and protects there from corrosion. @No deterioration by the aging. @Owing to its fluidity and visco-elasticity, liquid gasket well absorbs and relieves vibration and shock to assure a long service life of components. @lt is possible to improve the resisting pressure performance by using together with solid gasket. @It does not cause any mis-alignment when it is filled in mechanical components. Due to metal touch, it is no necessary to consider the thickness of gasket. @Even for complicated surfaces, it's easily coated with a brush or a spatula. <~ Internal pressure Liquid gasket Internal pressure and Gasket groove : viscous flow Adaptation of gasket to mating face (a) Liquid gasket %Experiments have revealed that the thinner the thickness of coated liquid gasket, the higher the proof pressure is. Maximum limit is 0.1 mm. (b) Solid gasket Chaper 8Eb T= pane Wo oda ec) 3-1 "P"number (packing) Mainly used for running parts. Thicker than “G" number O-rings. 3.2 "G"number (gasket) Used for stationary parts. 3.3 How to Find the Dimensions of O-ring Nominal size of O-ring is determined based on the inner diameter. @Example "P" for running parts (Nominal size denotes the dimensions of X and Y of "P") | aa ==! "G" for stationary parts (Nominal size denotes the dimensions of X and Y of "G' ax oy @Sample use of backup ring ; ‘When pressure exceeds 105 ka/cm*, backup ne ring is used to prevent the O-ring from / ‘ protruding in the clearance. / \ When pressure is When pressure is applied from one side applied from both sidesChapter GENERAL WORKS IN ENGINE ROOM 1-1 Before Disassembly Check (by referring to drawings) on parts to be overhauled and the extent / purpose of the overhaul, and then prepare necessary spare parts and special tools. -2 During Disassembly Use proper tools to prevent parts from damages or missing due to improper disassembly. Use bolts and nuts in correct size, and loosen them with a box wrench, closed wrench, etc. Avoid using a pipe wrench or a monkey wrench unless absolutely necessary. Proper disassembly procedures should be taken, When a loose, cut or damaged part is found, inform the matter to the personnel in charge of the equipment. 1-3 Disassembly Considering Reassembly Any part which has a mating part shall be marked by paint or the like, so that the combination and contact condition of such mating parts do not change after re-assembly. Parts having a mounting direction shall be marked with a match-mark to avoid miss- mounting. Do not give damages to a shaft having an oil seal. Do not carelessly mark with a scriber or the like. Even when a part is fitted too tightly on the shaft and difficult to dismantle, do not tap it to remove. Place disassembled parts in the order of removal, sorting them group-by-group. Small parts shall be put into one box and they shall be kept free from dust and dirt.2 Open/Shut Any pipeline in ship is equipped with valves without fail. Valves are used in many places, such as a boiler pressure container, tank, pump, and in front and in the rear of every strainer. Various types of valve exist, differing in size, shape, application, etc. They must be handled with the greatest possible care, keeping in mind that a miss-operation may lead to a severe accident. 2-1 Open/Shut of Steam Valve (1) Before opening the valve, sufficiently drain the steam line and check that drain does not come out any more. (2) Slightly open the valve (1/32 to 1/16 turn) and check that water hammer (banging) does not occur (A water hammer phenomenon occurs depending on the steam pressure, remaining drain and its temperature in the line on the discharge side of the valve to be opened). (3) After opening the valve by 1/16 turn, open it further by 1/8 turn and then check for water hammer. If water hammer should occur, immediately reduce the opening of the valve or completely shut it, and wait until water hammer disappears. When disappeared, slightly open the valve again and check for water hammer. (4) The valve shall be opened slowly up to one turn. The more the pressures on both sides of the valve differ, the higher noise the steam brings about when passing through the pipe. With the noise becoming low, increase the opening of the valve and check for change in noise. When the noise does not change any more, slowly open the valve to 100 %. 2-2 Other High Pressure Valves The valve opening / shutting procedure is the same as the above. Even when a large differe pressure so that a flow rate gradually increases. pressure exists, open the valve to 100 % by slowly reducing the differential Chapter 9 oO.fay fi pier GENERAL WORKS IN ENGINE ROOM 2.3 Low Pressure Valve Having a Large Capacity The valve opening / shutting procedure is the same as the above. The greatest attention shall be paid when closing the valve. If the valve is closed rapidly, a great impact will be brought about on the valve by the inertia of the fluid stopped within a short time. And if the piping is installed at higher level than that of the valve, similar valve operations will create a reverse flow of the fluid bringing about a significant reverse pressure on the valve. This reverse pressure becomes higher if the vertical distance between the piping and the valve increases. Therefore, the valve shall be closed slowly reducing the flow rate gradually, so that the flow almost stops just before the valve is fully closed. Likewise, valves having a negative pressure on its either side shall be opened carefully according to the above procedure.Various strainers, differing in size, shape and structure, are used at various places. Of these, the strainers on FO, LO and sea water lines are rather frequently cleaned. After cleaning these strainers, check the following items. 3-1 Air Purging With the inlet valve of strainer slightly opened, purge air through the air vent valve (or cock) fitted on the strainer. After confirming that air does not come out any more, shut the air vent valve. 3.2 Check for Leakage After shutting the air vent valve, check for any leakage from the strainer cover, with the inlet valve kept slightly opened. Wipe out the strainer cover and the casing in advance (especially for FO and LO lines) to make a leak check easy. For sea water and fresh water lines, blow air at the mating section of the cover to remove water. 3-3 When the Pressure on the Inlet Side is Negative Remove the valve cover and fill the same fiuid in the casing by using a ladle and restore the cover.Cael =a oA Nn alt i 41 Additional Tightening of Pump Gland Packing As shown in the figure, a seal ring is inserted in the middle of a gland packing to introduce seal water, which prevents shaft-seizing due to the frictional heat generated between the packing and the rotating shaft. Therefore, a small amount of water leakage from the gland is a normal condition. If the gland is additionally tightened to completely stop (or to ‘excessively lower) the leakage of water, the gland becomes hot resulting in burnout and shaft-seizing because of the friction between the shaft sleeve rotating at a high speed and the packing. Therefore, gland packing requires prudent tightening. ~~ Gland Gland packing __— Sleeve ~~ Seal ring __— Neck bush 42 Change in the Leakage from the Gland Discharge pressure of a pump fluctuates with (the pump load, 2 boiler steam pressure in the case of a boiler-related pump, (3hull motion (rolling, etc.), and others. The higher the pump discharge pressure rises, the greater the leakage is from the gland and vice versa. 4-3 Additional Tightening of a Gland To tighten a gland additionally, the above matter shall be borne in mind; a small amount of water shall be allowed to leak from the gland even at a lower pump discharge pressure. When additional tightening is required, tighten each of the gland cap nuts evenly by 1/4 turn (or 1/2 turn) and wait for a while to check the leakage, heat generation and other abnormality; avoid tightening them at a single twist. If the leakage is still excessive, repeat the same procedure.(1) Adjust the clearance between the grinding wheel and the work rest to 3 mm or less. (2) Adjust the height of the work rest to the center line of the grinding wheel. (3) When the surface of the grinding wheel is not even, flatten the surface with a dresser. (Place a dresser on the work rest letting it have a slight contact with the grinding wheel, and move it horizontally until the outer surface of the grinding wheel becomes flat.) (4) Precautions for using a grinder: Wear safety goggles; the side face of the grinding wheel shall not be used; check the grinding wheel for any crack. (5) The tightening nut of the grinding wheel on the left when you face the grinder is a left- handed screw (to be tightened when the wheel rotates). Adjusting plate b: Within 3 mm ¢:3to10mm Work must not be higher nor lower the center line of the workrest. @How to adjust the balance when the grinder vibrates during operation (1) Adjustment when a balance weight is provided, as shown in the above figure. Softly turn the grinding wheel by hand, and the wheel will stop with a heavier part downwards. Move the weight to the opposite side, namely to the top. Repeat this procedure until the wheel stops randomly. (2) Adjustment when a balance weight is not provided. Slightly tighten the nut, adjust the clearance between the shaft and the grinding wheel while rotating the wheel by hand. If this method is not effective, replace the grinding wheel with a new one. Balance weight Make a mark for where the heavier part of the (2pcs.) grinding wheel is at the lower part. Adjusting the balance weight cumer 9@ Outer tube @ End piece, outer piece © End piece, inner piece Cap nut @ atomizer (1) When the dismantled atomizer is not stained with carbon, etc., it is enough only to clean it with a light oil. (2) If stained, dip it in light oil or carbon solvent, etc., and clean the groove with a copper wire or the like. To remove stains sticking on the surface, spread clean cotton wastes on a level block and apply Pikal to them, and then place the atomizer on them and slide it to remove stains. (3) If the mating face of the atomizer or back plate is flawed or their contact is defective, regrind the surface. If flaws are too deep or the diameter of the bore is enlarged, replace it with a new one. (4) Regrinding shall not be carried out by placing on a large level block. A level block dedicated to grinding (with an outside diameter 2 to 3 mm larger than that of the atomizer) shall be made using a lathe. The atomizer shall be placed on it and slid as if writing a “fig.8". (5) The mating surface between an inner tube and a back plate shall be corrected by the same method, with the burner placed perpendicularly. Be careful in grinding with a tool as shown in the figure on the right because the inside and outside cannot be finished in a flat condition. (6) To mount the atomizer, it must not be tightened too strongly. ® center 97 natu ‘As shown in the figure on the right, move the motor to adjust the tension of the V belt while adjusting the parallelism by applying a ruler (if not applicable, a string or a fine steel wire) to the pulley. 7-1 Proper Tension of a V Belt (1) Correct when you can pick up and twist the V belt with your fingers by approximately 90 deg. (2) Correct when you can push down the V belt with your finger by approximately its thickness. 7-2 Handling Precautions (1) Increase the tension if a slipping noise is emitted at the start or during operation. (2) Length of V belt changes with operating time. Properly adjust the tension during operation. (3) When multiple belts are used, they shall be the same in length. For renewal, replace all of them at a time. (4) The shape of a pulley groove has a great influence on the life and transmission efficiency of the belt. If the groove has been greatly stepped, worn or deformed, replace the pulley with a new one or send it to a land-based facility for repair. (5) V belt is structured so that its bottom surface does not come in contact with the bottom of the groove. If the bottom surface of V belt comes in contact with that of the groove due to wear, elongation or for other reasons, replace the V belt with a new one. (6) Oil sticking to V belt is dangerous. Check for oil sticking on V belt. Angle of V belt is 40 deg. irrespective of the type (A, B and C), while angle of pulley differs (34, 36 or 38 deg.) according to the belt size of each type. — ®(1) Pull out the piston (Supply compressed air through the oil intake port). (2) Fix by welding the main body on a bollard (bitt) using angle steel. (3) Weld a thick steel flat bar or rod on the top. (4) Loosen the nut by tapping both ends of the welded flat bar simultaneously. (5) When the nut is too tight to be loosend, heat around NS the main body by gas burner and loosen the nut ‘Angle steel (heat until the dust seal burns to smoke). @Put a block on the top of the nut and tap it with a hammer so that the thread of the nut is not damaged, and the nut can easily be loosened. @If the piston cannot be taken out without removing the nut, process the flat bar as shown in the flange below. ~~ Cylinder Weld the handle on the nutCotton wastes shall be cut to a proper size for economical and easy use. In cutting a large amount wastes, a sheath knife fixed on a vice is easier and more efficient than scissors. @To sharpen the edge of the sheath knife, use a grinder or a fine sander. (Although a sheath knife cuts well when sharpened with an oil stone or a water stone, it soon becomes dull when a large amount of wastes are cut. When sharpened by a grinder or a sander, the edge becomes notched but works well in cutting wastes for a long time. This is the same reason why a knife cannot match a saw in cutting wood however sharp it is.) @Remove braids, buttons, metal fittings or other obstacles from the wastes before cutting. @it is economical to store the wastes, used but not dirty and reusable in later dirty works, in containers separately corresponding to the dirtiness.Chapter GENERAL WORKS IN ENGINE ROOM 9 10-1 How to Loosen a Seizing Nut for through Bolt or Stud Bolt (1) Apply a liquid penetrant to the thread. (2) Tap the side face of the nut with a hammer to give an impact. (3) Turn the nut with a spanner or a caulking chisel. (4) Heat the nut with a gas burner and turn it. (5) Split the nut with a chisel or cut it with a gas torch. Try from item 1 in that order. To split a large nut with a chisel, it is efficient to cut half of the width at a time. 10-2 How to Remove a Tap Bolt (1) Apply a liquid penetrant or oil to the thread, (2) Tap the bolt head to give an impact. (3) Tap the bolt head and turn the bolt with a spanner or a caulking chisel. (4) Repeat the above item 2 and 3 while heating with a gas burner. Greatest possible care shall be given when the bolt is made of brittle materials such as a cast iron or an aluminium alloy. 10-3 How to Remove a Broken Stud or Tap Bolt (1) When a broken part is protruding a little from the surface Remove according to the above procedure of removing a tap bolt. Or weld a pipe or the like to the broken bolt and turn it with a pipe wrench.(2) When the above method does not work Cut out the protruded part evenly, bore a hole to the bottom with a drill smaller in size than the prepared hole, and take the broken bolt with a screw extractor. 2When the above method is not effective, drill a hole in the bolt leaving a thin peripheral wall, and then remove the wall completely with a fine chisel or remove little by little with a sharp scriber or the like. (3) When the broken stud bolt is a fat one On the top of the bolt, place a piece of a pipe having the same diameter with the broken bolt, and then weld the inside of the pipe and turn it to remove the bolt. (4) When thread ridges are defective DRe-tap threads larger than the original ones. Dinstall a helical coil insert. Helical coil insert: a spring-shaped tool which has threads ‘on both inside and outside. Tap a thread which is one size larger than the defective one and install a helical coil insert which enables to use a bolt of the original size. (A dedicated too! for installing a helical coil insert is on the market.) Helical coil insert11-1 Making a Prepared Hole for a Female Screw Example: To tap a female screw of nominal size M10, make a prepared hole with 8 mm drill, although size of the prepared hole is 8.21 mm according to the table below. Relation between the nominal size of metric coarse screw thread and the inner diameter of female screw. 14 i 11.6200 16 | 13.62 | 20 | 17.02 5 | 4 2043 6 | 4.80 : 27 L 23.43 8 6.51 30 25.83 10 | 8.21 36 L 31.23 12 [ 9.91 _ 42 | 36.64 @it is desirable to make a prepared hole for a female screw at right angle to the base metal. Be careful of the perpendicularity, especially when a portable electric drill is used. @To make a prepared hole of a large diameter, first make a hole of a smaller diameter, and then use a drill for a hole of a specified diameter. @in the case of a blind hole, use a drill after making the required depth on it. (a) eect a=—> (b) (c) o = & @ @ Tap handle ” e Right hand Prepared hole ‘Check the perpendicularity 4 piece Left hand Removing the tap11.2 Tapping : 3-Piece Set Hand Tap @Set a #1 tap at the prepared hole perpendicularly as shown in the figure on the right, and slowly turn it clockwise until it bites the prepared hole, caring that the tap does not tilt. @When the tap bites the prepared hole, rotate it by 2 tums and move the handle to check @lf tilted, correct it perpendicularly by turning the tap handle. 11-3 Turn the Handle When the tap is corrected and direction is determined, tun the handle horizontally and evenly by both hands. @Return the handle by 1/4 turn each time it is rotated by 3/4 tum. @Add oil at proper intervals. In the case of a blind hole, take the tap out of the hole to remove chips occasionally. Coarse Coarse Middle Middle Complete thread Work A, Bitten section i Tap a) 2) 3) Tapping of thin work Tapping of deep hole If tapping is so hard that the tap is twisted when you apply a force on the handle, the prepared hole may be too small or the tap must be tilted against the hole. Take the tap out of the hole and widen the hole a little with a round file or the like. In the case of a shallow though-hole, #2 and #3 tap are not necessary, buy a deep through-hole or a blind hole require them.cee Tonnes 11-4 How to Remove a Broken Tap @Pinch the tip of the tap with a hand vice, slowly turn the vice while applying an impact on the work-piece. @ Applying the tip of a punch or a chisel to the edge of the tap, give a tapping impact on the punch or the chisel to turn and remove the tap. @Weld a steel piece on the tap to remove it. @if available, use a tap holder to remove the tap.124 Grinding of Cutting Edge (1) As shown in the figure on the loft, hold the drill, with your left hand placing on the tip side and right hand on the shank side. - - Chisel edge angle: 125 to 135 deg. Angle of relief: 10 to 15 deg. Direction of rotation Included angle 50°+59"=118" Grinding and Tool Angle of Drill (2) With your left hand on the pedestal to keep a cutting edge horizontally, allow the edge to touch the periphery of the grinding wheel so that the included angle becomes 118 deg. (3) Grind the end face of the drill while turning it by your right hand by slightly moving it as if you scoop up the grinding wheel with the end face and shape the cutting edge and the angle of relief. The sharpness of the tip of cutting edge, that of chisel and the angle of relief have a great influence on whether the drill cuts well or not. Therefore, in grinding a drill attention shall be paid to the tip of cutting edge, chisel and the angle of relief (10 to 15 deg.). In addition, the drill shall sometimes be dipped into water for cooling to avoid tempering during grinding (During grinding a drill, pay attention to the angle of relief, included angle and chisel which are marked by thick line in the above figure). Grinding of Cutting edge acer 9 &Chapter GENERAL WORKS IN ENGINE ROOM 9 12.2 Grinding of Chisel Tip line : flat Included angle : 50 to 60 deg. Tip line shall be at right angle to the center line of the chisel. (1) How to grind chisel (1) Grind to flatten the tip until chips and wear disappear. (2) With the chisel on the pedestal, grind it to specified included angle and tip line. ATT rind the chisel while cooling it by water <— so that the edge does not become Welding tempered. @If the edge is tempered, quench the Flatten chisel again. ‘a. @Before grinding, flatten the grinding surface with a dresser. (2) How to Quench a Chisel (1) Before quenching the chisel, finish the tip by grinding until chips and wear Grinding of Chisel disappears. (2) Heat the tip to a quenching temperature (750 to 800 deg.C). When a gas bumer is used to. heat a chisel, keep the nozzle within 3 to 4 om from the edge and heat until the chisel tums red to its core. (3) Dip into water only the part to be quenched (1 to 2 cm) of the chisel until the dipped section tums black. (4) When taken out of the water, the tip will be white in color and gradually change to light yellow, yellow, brown, purple and then deep blue. (5) When the tip becomes dark or light brown (270 to 290 deg.C), dip the entire chisel into water to cool (tempering).If the change in color is not clear, check using a fine file. When the file begins to work, dip the entire chisel into water. sovc = SN 700 750 BONS SN ODS GN 1000¢ Dark Reddish Dark © Middle Bright += Dark ~— Bright" ‘Yellowish Yellow brown brown cherry cherry-—cherry-—sred red red l | | Improper smith work Smith work temperature 10506-1100 1150-1200 —_-1250'C-1300 Bright yellow Yellowish white White ee J Improper smith work Relation between smith work temperature and metal color (3) Boring Jig When a working material cannot be set on a lathe, it is necessary to process a bigger hole than the drill in stock. (1) Machine the following jig by a lathe. Setting bolt Tool hole The taper shall be machined to match the drill sleeve. Use high-speed steel bit or high-speed steel solid bit of approximately 8 x 8 mm. Grind to form the tipRUC =o) Vn else Et eagle) 9 — : @High-speed steel bit (black square tool steel) shall be used after heat treated. @Heat treatment: Heat the tool steel to a specified smith work temperature, and then shape and grind it to a specified shape, and heat it again to the quenching temperature to quench it. @ Quenching: Heat the material until it tums dark or bright brown, and then dip it into oil for quenching. (2) High-speed steel solid bit (ground square tool steel) is already heat treated, so that it can be used only by shaping and grinding the tip. (3) Set the cutting tool. Adjust the protruding length of the cutting tool the bore size (1) How to drill a hole (1) Apply a punch mark to the working material at the center of the hole to be drilled. 2) With the mark at its center, mark a circle of the hole to be drilled using a compass. (3) Fix the working material on the table of the drilling machine with the center aligned with that of the drill. (4) Drill a hole at the center of the working material, with a maximum size drill. (5) Remove the drill, and install the boring jig which was made as the above (Do not miss- align the center of the working material). (6) Adjust the cutting tool fixed to the jig so that it can cut 1 to 2mm deep ata time. (7) Set the drilling machine to the minimum speed and cut the work material little by little. (8) Repeat above steps 6 and 7 until a hole specified in diameter is obtained. Up to 60 to 70 mm holes can be made with onboard drilling machine.13-1 Classification of Non Destructive Test > Visual | Magnetic particle Surface defects Penetrant Electromagnetic induction -— Datact detects Spiral current Ultrasonic wave ~ Interior defects Radiation —— Measurement of strain 13.2 Detecting Test by Penetrant () Process e o (2) Features This test is applicable to either metal or nonmetal materials unless they are affected by the penetrating liquid or have a porous nature. This test is applicable against any extended direction of the defects. This test is useful for materials which surface are damaged and extended interior as a cave. (3) Implementation of test @Clean up the surface for removing dust and oil. @Apply the penetrating liquid (Process fig.- @) Fluorescent penetrant: to observe through ultra violet rays in the dark Dying penetrant: color vision in the light @Clean up the surface (Process fig. @) Wipe out the surface liquid except the one interior of the material. When the applying penetrant include the additive of an emulsifier, the surface should be washed by water.(4) Development ; formation of indicating defects pattern (Process fig.-© ) Dry developing method: Dry developing solution is used Quick dry developing method: developing solution with a voltaic solvent is used Wet developing method: Developing solution dispersed in water is used Non development method: _ process by heat treatment instead of developing solution (5) Finish the test Remove the remaining penetrant by wiping out and /or flushing by water. 413-3 Deteeting Test by Magnetic Particle (1) Process By forcing the magnetic field to act on metal object (2) Features This test shall be applied for strong magnetic substances. This test can detect the defect when it is located interior as deep as 2 or 3mm. This test is superior for detecting a thread shaped defect to a round one. It's difficult to define the defect of its shape and direction. (3) Implementation of test (1) Preparation Spray magnetic particles on metal object, much particles on the defect suspected area and lesser on the left, in order to make it easy to observe the pattern. (2) Magnetization Give an appropriate magnetic field on the object. Turn in the electricity through axis. Followings are the ways to get the magnetic field. @Direct contact method @Cross current method Central conductor method @Coil method @Yoko method @induced current method (3) Application of magnetic particles @kinds of magnetic particles Fluorescent magnetic particle: __to observe through ultra-violet rays in the dark Non fluorescent magnetic particle: color vision in the light @Disperse medium of magnetic particles Wet method: to make mechanical suspension in water Dry metho use the magnetic particle in dry condition @Applicable timing Continuous method: to apply the particles during running magnetizing current turning on electricity Remnant method: to apply the particles after switching off magnetizing current Chaper 9 @Tm == TNM (os MLN as) CY (4) Observation of the pattern of the magnetic particles The observation shall be done during the application of the particle. Depending on the materials, some pretty strong residual magnetism is seen. It's required to remove the residual magnetism for the following cases. The residual magnetism of the tested material disturbs its future processing. The residual magnetism of the tested material affects badly against a measuring instrument and its precision. The tested materials with residual magnetism might absorb some iron particles and cause to hasten friction damages when they are given the role of "sliding surfaces". (5) Finish the test Remove the remaining magnetic particles and apply rust proofing such as anticorrosive painting if it's necessary.+ gs a TS ‘ings to a Valve (1) Gland packings shall be installed so that the cut sections do not overlap each other. (2) Gland packings may be cut diagonally; but they shall be installed as mentioned above. (3) Install as many packings as possible in the gland, insert the gland bush and tighten nuts evenly, and then tighten them further until the valve handle becomes slightly heavy to operate. (4) If there is enough space to accommodate additional packings, add them and tighten according to the above step 3 to secure a sufficient interface between the gland bush and the valve main body. @valve packings used in steam-pipe system shall be carefully installed, because the steam can not be easily stopped. It is effective to apply graphite grease or Molykote to packings. In the case of packings used in the water system, grease will be appropriate.(1) A gland packing used in steam-pipe system tends to stick. In removing such a packing, take off the grand and the spindle, and pound the packing using a screwdriver and a hammer to peel it off from inside. (2) When the tip of a packing too! cannot eat into the packing because the packing is too hard, make a hole on the packing with a scriber by lightly tapping the scriber with a hammer and drive the tip of the packing tool into the hole (Pull out the packing, with the packing tool driven in it as deeply as possible). (3) When the packing was fragile and has been partly torn off, apply the procedure mentioned in the above 2 to the opposite side of the peeled part. (4) During removing the packing using a scriber and a packing tool, the packing will gradually break into pieces which can be removed by air-blow. (5) This is quite a time-consuming work. To ease the work, it is recommended to remove the valve handle and the gland holder in advance. Packing tool Scriber Go-—§ thDuring overhauling a sea water pump for maintenance, a makeshift ejector pump can be used to drain water accumulating in the casing or to remove water slightly leaking from the inlet or discharge valve of the pump. The length of a hose to discharge water shall be determined optionally, but it shall be more than twice the length of the air nozzle. The air nozzle shall be installed on the discharge side if the hose is too long. By doing so, the mixture of air and water can be discharged even when the water level in the casing has lowered. Insert the air nozzle more than 3 cm Vinyl hose, etc.(1) Insert the bolts in the flange holes and tighten the nuts, (2) Heat the pipe and additionally tighten the bolts and nuts. (3) When the mating faces of the flanges came in contact with each other, cool the pipe and flange naturally. (4) If not enough, repeat the above steps 2 and 3.ert Cae aU) (9 Bolts and nuts used in a sea water piping system tend to become rusty and may be broken by twisting when removing. Especially a broken stud bolt remaining in the bed is a nuisance. ‘Some said that they needed three days to re-install a pump body due to a broken stud bolt which fixes the pump to the bottom plating. Ina limited space, such works will be time-consuming. To avoid such situations; @Be sure to apply grease to bolts and nuts without saving labor before tightening them. @Bolts and nuts removed with difficulty shall be thoroughly threaded with a threading nut or tap before they are re-applied.If the mating surface of a flange is uneven and the leakage can not be stopped only with a sheet packing, apply the Debcon to the uneven mating surface, place a packing on the mating surface before the Debcon solidifies, and tighten the flange. Sheet packing Debcon Do not coat Debcon here to prevent it from protruding into the pipe inside in tightening the flange.USEFUL ADVICE Pure iron (Fe) plates or zine (Zn) plate are installed in some parts of the sea water piping as an anti- corrosion measure. Such parts are pipes, heat exchanger, pump and strainer. If the installation is not proper, the life-span may be shortened by corrosion. — Silicon Bolt Washer ~ Rubber ~_ Packing Pure iron (or zinc) plate “~ Rubber packing Main body Must be contacted (1) How to install @Mounting bolt A mounting bolt is used to fix the pure iron (or zinc) plate as well as to electrically connect the plate to the main body. @Washer A washer is to entirely press a rubber packing on the upper side. ‘@Rubber packing A rubber packing is to prevent sea water from entering through the holes of the pure iron (or zinc) plate and corroding the female thread of the main body. If this female thread is corroded, the pure iron (or zinc) plate can no longer be supported to drop, promoting corrosion and making the replacement difficult. @Silicon Silicon is to ensure the air-tightness of the bolt bead (or nut) and the washer to prevent the sea water penetration. (2) Key Points for installation (1) Check (with a tester) the electrical link between pure iron (or zinc) plate and main body. Before installing the plate, grind the contact face of bolt with a sand paper, etc., to remove water stain and rust. (2) Itis recommended to make the pure iron (or zinc) plate free from oil stains, and then grind the surface with a sand paper.Use the following method when a dedicated band is not available. Applicable situation: A lower pressure line (1 to 1.5 MPa or lower depending on the extent of breakage), @Push plate: Make a hole in the center of the push plate with a diameter a little larger than that of a bolt. Place a nut on the hole and weld them. @Facing plate: Make a shallow dent in the center of a plate with a drill. Set the tip of a Push bolt in the dent to prevent the facing plate from sliding when the bolt is tightened. @Push bolt: Sharpen the tip by a grinder so that it fits to the dent of the facing plate. @Packing: Bond the packing and the facing plate together with an adhesive agent or bind the packing on the damaged pipe using twine, etc. Use a cloth packing for a steam line and a rubber packing for a cooling water line. The push plate and the facing plate shall be rounded so that they fit to the curvature of the pipe when the push bolt is tightened. @installation: Place them on the broken part in the order as shown in the figure below, tighten them with a seizing wire and twist the wire so that it is not loosened, and then tighten the push bolt. Weld a nut Push plate Make a shallow dent by drill Packing Seizing wire Sharpen the tip of the bolt Steam line asbestos cloth Cooling water line: rubber packingSPECIFICATIONS OF PS ain oyin Nat UsCems =o] Te Wiles ge Ett 9 Le i In general, iron represents an alloy of iron and carbon. It can have various peculiar features when other metals are added such as nickel and chrome. The latter alloys are called "special steel". ~~ Pure iron (carbon content: 0.006% or less) Hard steel c Carbon steel Iron —~ Steel (carbon content: 0.06% to 2.0%) \— Special steel Mild steel ~ Ordinary cast iron ~ Cast iron (carbon content: 1.7% to 6.67%) “Special cast iron 1-1 Carbon steel Carbon steel is widely used because its properties can easily be changed by carbon content or heat treatment. | Name | Garbon content (%) [Tensile strength (mm) Application Dead soft steel 3 Max.38 Rivet, split pin Mild steel | 38-44 Section steel, steel pipe Ser I | 44-50 "Bolt nut Semi-hard stee!_ 50-60 Gear shaft Hard steel | 60-70 [Shafthammer Extra hard steel 70-100 Spring, tool -2 Special Steel Special steel is an alloy of iron, carbon and more than one other metals such as nickel, chrome, tungsten, molybdenum, manganese and vanadium. Special steel includes: nickel steel, chrome steel, nickel chrome steel, chromium- molybdenum steel and invar. Other special steel: high-speed tool steel (for tools such as tap and die), stainless steel, and silicon manganese steel (for spring).Relation between the Nominal Size of Hexagon Bolt and Hexagon socket Head Bolt and their Width across Flats (Spanner Size). applications. Inmarked nominal sizes are generally used: Parenthesized ones are for special ‘@Material for hexagon socket head bolt: Heat treated carbon steel (S45C, $15C) or type3 chromium-molybdenum steel (SCM3). Unit: mm — 24 3 4 5 12 6 14 8 17 10 19 12 22 14 24 14 27 14 30 17 32 7 36 19 41 19 46 a1 50 a1 55 26 26 26 32Cems) 2 =o] ale) Wao), ge UL tO oS LOL ii ‘Thread pitch gauge: @No.137 (Whitworth thread) @No.156M, -158M, -159M (metric thread) @UNF (unified fine thread) Feature Metric screw Unified fine thread _| Whitworth thread Angle of thread 60" 60" 55" Unit for nominal size_| mm No. or inch. Inch (coarse thread) Unit for pitch Mm - No. of crests per inch | No. of crests per inch Sample expression | M6 4/4-UNC wi/4 Coarse thread 7 [MG6X0.75 | 4-U28UNC, lominal size means the outside diameter for both metric and inch threads. @When a metric coarse thread and a metric fine thread have the same nominal size, the fine thread has a smaller pitch than that of the coarse thread. Example M6 (coarse thread): Outside diameter 6 mm ; pitch 1 mm M6 (0.75 fine thread): Outside diameter 6 mm ; pitch 0.75 mm @When a unified thread and a Whitworth (coarse) thread have the same nominal size, the pitch is the same but the angle of thread differs. Example 1/4-20UNC (unified coarse thread): Outside diameter 1/4 inch; pitch 20 (No. of crests per inch); angle of thread 60 deg. W1/4 (Whitworth coarse thread): Outside diameter 1/4 inch; pitch 20 (No. of crests per inch); angle of thread 56 deg. @JIS has abolished Whitworth thread since 1968.MB (outside diameter 8 mm) Fine thread = M8X1 Unified thread | Coarse thread 3/8 16UNC [Fine thread N08 36UNNC W34 (outside Metric thread Coarse thread | Coarse thread Whitworth thread “diameter 3/4 inch) Fine thread _ Pipe thread Parallel thread (PF), (PS) 3/4 “Taper thread (PT) 1/2 4-1 Metarie Thread @Angle of thread: 60 deg. @Pitch: distance between crests @Unit for nominal size: mm 1-2 Unified Thread @Angle of thread: 60 deg. @Unit for nominal size: inch or No. @Unit for pitch: number of crests per inch (25.4 mm) 1.3 Whitworth Thread ( JIS has abolished this type of thread sine 1968 ) @Angle of thread: 55 deg. @Outside diameter: inch @Unit for pitch: number of crests per inch (25.4 mm) 44 Thread Types @Metric coarse thread: Expressed by "M", angle of thread is 60 deg. @Metric fine thread: Has small pitch. Angle of thread is 60 deg. @Unified coarse thread: Expressed by "UNC". Inch thread. Angle of thread is 60 deg. ‘Unified fine thread: Has small pitch. Inch thread. Angle of thread is 60 deg. @Whitworth coarse thread (abolished by JIS): Expressed by "W". Inch thread. Angle of thread is 55 deg. @ Whitworth fine thread: Expressed by “W". Inch thread. Angle of thread is 55 deg. @Pipe thread: Combination of parallel thread and taper thread (PT, PF, PS) has small pitch and the angle of thread is 55 deg. ©30 deg. trapezoidal thread ©29 deg. trapezoidal threadM12 0.25 02 M20 25 2 M16 0.38 02 7 1.8 m2 oa 0.25 M26 0.45 0.35 M22 25 2 M3 08 0.35 16 Ma 07 05 M24 3 2 Ms 08 05 16 M6 1 0.75 MB 1250001 (ma7) 3 2 | 0.78 15 M10 15 1.28 [ 1 (M30) 35 2 0.75 1.8 M12 1.75 15 ; 1 4.25 (M33) 8S 2 1 15 (M14) 2 15 M36 4 3 1.25 2 to - 1.5 m6 2 1 (m9) 4 3 " a) | (M18) 25 2 18 18 maz 45 | 1 @Unmarked sizes are used by priority: parenthesized ones, only when necessary. @Pitch gauge: No.156M to -159M @Angle of thread: 60 deg.5/16 7.938 | 18 24 18 3/8 9.525 16 24 16 - 76 W412 14 20 14 12 12700218 2 12 one 14.288 Re 18 | 12 5/8 15.875 an 18 | 1" 3/4 19.050 10 16 10 718 22.225 9 14 | 9 1 25.400 8 2 [ 8 11/8 28.575 7 12 7 1481.70 7 12 7 13/8 34.925 6 2 6 12 38.100 6 12 | 6 13/4 44.450 5 | 5 2 50.800 412 41/2 21/4 57.150 | ate L 4 21/2 63.500 4 4 23/4 69.850 4 312 3 76.200 4 31/2 3a 82.550 4 31/2 32 88.900 4 312 33/4 95.250 a 3 4 101.600 4 3 @Angle of thread (UNC): 60 deg. Angle of thread (W): 55 deg. @Pitch gauge: UNC (for UNC thread); No.136 (for W)Pipe thread is mainly used to connect gas pipes (carbon steel pipes for ordinary piping) and has a small pitch and the thread angle of 55 deg. There are two types of pipe thread : parallel thread (PF) and taper thread (PT). @Expression Expressed by the nominal size in inch of the female thread which fits the mating male thread (The size is not equal to the outside diameter of the male thread but is almost equal to the bore of the pipe). @ Combination of pipe threads Parallel pipe thread : Taper male thread (PT) and taper female thread (PT) Taper male thread (PT) and parallel female thread (PS) ("PS" is used for this combination.) Parallel female thread (PS) is used in combination with taper male thread (PT). Specifications are the same for both PS and PT. @sample expression PS 1/4 : Pitch 19 (No. of crests per inch) ; outside dimension of thread = 13.157 mmPS1/8 PSi/e 8.728 — PSH Pst/a 13.157 PSB 16.662 ps2 20.955 Psa/a 26.441 psi | _PS19/4— se Pee — Psai2 | PS21/2 PSS PSB Ps31/2 Ps31/2 100.330 — PS4 113.030 PSs 138.430 PSG 163.830 PST 189.230 PSB 214.630 psa | 240.030 PS1O 265.430 ps2 316.230 @Pitch gauge: No.137 @Angle of thread: 55 deg. @PT thread has a 1/16 taper.eB] ewe SPECIFICATION OF CARBON STEEL PIPE FOR ORDINARY PIPING1-1 SGP (carbon steel pipes for ordinary piping) Working pressure to IMPs Working temperature: -15 to 350 deg.C 12 STPG38-E (carbon steel pipes for pressure piping) Working pressure .5 to 10MPs Working temperature: -15 to 350 deg.C Tensile strength 138 kg/mm? or more @symbol E _: Electric-resistance-welded pipe S-C_ : Cold finished seamless steel pipe $-H_: Hot finished seamless steel pipe B _: Welded steel pipe 1.3 STPT (carbon steel pipes for high temperature piping) Working pressure: 0 to 20MPs Working temperature: 350 to 450 deg.c 1-1 STS (carbon steel pipes for high and low temperature piping) Cold or hot finished seamless steel pipe Working pressure: 10 to 20MPs Working temperature: -15 to 350 deg.C2-1 With Flat Surface (1) When tightened too strongly, the periphery of mating face comes in contact with each other, making it difficult to firmly tighten the gasket. (2) Ifinner pressure becomes high, the gasket may come out. (3) Being used for low pressure steam or water line. 2.2 With Protruded Surface (1) Even when tightened too strongly, the periphery of mating face does not come in contact with each other, making it possible to firmly tighten the gasket. (2) Because a gasket with small width is used, it receives a strong ightening pressure even when the flange is not so strongly tightened. 2.3 With Spigot Joint (1) Mainly a soft gasket is used. Even when inner pressure becomes high, the gasket does not come out. (2) Because a gasket with small width is used, it receives a strong tightening pressure even when the flange is not so strongly tightened. 2-1 With Protrusion and Groove (1) Suitable for higher pressure (SMPs or more) than spigot joint type flanges. (2) Suitable for water, gas, steam and ammonia lines as well as high pressure water line. (3) Copper or steel gasket is used because a soft gasket may come ‘out of the groove. 2.5 With Wavy Surface (1) To ensure a high air-tightness, many concentric grooves are carved on the flange surface. (2) Being used for high pressure line because the grooves prevent gasket from coming out as well as ensure a high air-tightness. (3) Suitable for the oil or acid liquid lines which require a lead gasket. db dh dh dh he Chapter 2 @CLASSIFICATION AND SPECIFICATION OF CARBON STEEL PIPE FOR ORDINARY PIPIN 3-1 Flat Face Type Not suitable for high pressure application. 3-2 Spigot Joint Type Suitable for middle pressure line. 3-3 Protrusion/Groove Type Being able to withstand highest pressure. @ ciunter20a | 3/4 27.2 | 225A 1 | 340 | 328 11/4 | 427 40a 11/2 | 48.6 | 50A, 2 | 60.5 65A 21/2 76.3 | - BoA 8 a1 9A | 312 1016 100A 4 118.8 5 15.1 @The sizes enclosed by double line are used frequently. 18.2 21.4 @Schedule pipes of carbon steel pipes for pressure piping (STPG) and carbon steep pipes for high temperature piping (STPT) have the same wall thickness. @The values for nominal size (A) is determined by approximated inner diameter (mm). @Nominal size (B) is the dimension in inch which is almost equal to the inner diameter of pipe and not equal to the outside diameter of pipe.| | k— po | | Unit: mm (A) © do D t c h 15A 1/2 22.2 80 9 60 12 4 M10 20A 3/4 27.7 85 10 65 12 4 M10 25A ] 4 7 34.5 95 10 75 12 4 M10 324 11/4 43.2 115 12 “90 14 4 M12 40A | 11/2 49.1 120 12 95 15 4 M12 SA 2 ea | 1300014 | 105 15 4 Miz 65A | 21/2 TTA 155, 14 130 15 4 M12 80A 3 90.0 180 14 145 19 4 M16 90A il 31/2 100A 4 115.4 200 16 165 19 8 M16 125A, 5 141.2 235 16 200 19 8 M16 150A 6 166.6 265 18 230 19 8 M16 200A 8 218.0 320 20 280 23 8 M20 250A 10 269.5 385 22 345 23 12 M20 300A 12 321.0 430 22 390 23 12 M20154 We 22.2 95 12 70 15 4 M12 20A 3/4 22.7 100 14 75 15 4 m2 25 4 34.5 125 14 90 19 4 M16 Bea 11/4 40A 11/2, 49.4 140 16 105 19 4 m6 50A 2 61.4 155 16 120 19 4 M16 GBA 21/277 175 18 140 19 4 M16 80A 3 90.0 185 18 150 19 8 M16 90A 31/2 7 1008 4 118.4 20 18 ws | 19, 8 M16 1250, 5 141.2 250 20 210 23 8 M20 150A 6 166.6 280 22 240 23 8 M20 200A 8 218.0 330 22 280 23 12 M20 250A 10 269.5 400 24 355 25 12 M22 3004 12 321.0 445 26 400 25 16 M22Commer ore Wile Pan i= eig Wed A) Unit: mm (a) ®) do D t c h 468 We 22.5 95 | 2 70 15 4 m2 208 | 3/4 | 250 4 35.0 125 02=~«4 90 19 4 M16 32a 14/4 | 40A 112 49.5 140 1% 105 18 4 Mi6 50A 2 61.5 155 16 120 19 8 m6 6A 24/2 | 77.5 175 1% 14018 80A 3 90.5 20020 160 12800280 90a | 32 | 1008 4 1155 | 25522 185 8 8 mao 12585 1415 | 270 22 225 2% 8 M22 150A 6 1675-305 260 | 8 12 M22 200A 8 219.0 | 350 26 395 25 | 12 m22 “50a 10 «| «2708 | 480 8 380 7 12 M24 300A 12—«| «322.5 | 480 | 30 430 ar | 16 Mea @ cinoter 2Has PF (parallel pipe thread). The nut has PF (parallel pipe thread). Has PT (taper pipe thread). For which diameter copper tube to use is defined in JIS (see specifications for copper tube). Union connector Union tee(1) Distinguish tee, elbow or nipple (whether PT thread is used or not). (2) Check the shape of sleeve (which differs with makers and applications). (3) Outside diameter of used pipe (metric or inch size; see the copper tube specification table). (4) Measure the thread pitch to determine the size. @Pipe thread (inch thread) is used for all. @Use No. 147 pitch gauge to measure the thread pitch (Be careful that the pitch gauge for unified thread (UNF) has the angle of thread of 60 deg.). Detemine on the pipe thread specification table, according to measured pitch and thread outside diameter. For the same outside diameter of pipe, 2 to 3 types of pipe fittings with different wall thickness (thread outside diameter is different although pitch is the same) are available. Select one which is best suited to your application.PT (taper thread) Elbow = ‘(in Shape of sleeve BE Used for vinyl hose, etc. @ chaoier isUnit: mm oO 10 12 14 15 16 18 20 22 25 28 30 Dimension in inch 6.35 (1/4) 9.82 (3/8) 12.70 (1/2) 15.88 (5/8) 19.05 (3/4) 22.22 (7/8) 25.40 (1") 31.75 (11/4) Chapter 8SI international System of Units SI Base Units ‘The SI is founded on seven SI base units for seven base quantities assumed to be mutually independent, as given in Table 1. Table 1. SI base units See mass kilogram kg time Sécondl s electric current ampere A thermodynamic temperature kelvin K amount of substance mole mol idininous intensity candela ed For detailed information on the SI base units, see Definitions of the SI base units and their Historical context. SI Derived Units ‘The SI derived units for these derived quantities are obtained from these equations and the seven SI base units. Other quantities, called derived quantities, are defined in terms of the seven base ‘quantities via a system of quantity equations. Table 2 is examples of such SI derived units where it should be noted that the symbol 1 for quantities of dimension 1 such as mass fraction is generally omitted. Table 2. Examples of SI derived units area square meter volume cubic meter speed, velocity meierperseeond acceleration meter per second squared Wave number: reciprocalmeter zi mass density a kilogram per cubic meter ‘Specific volume! cubic meter per kilogram i current density ampere per square meter fmagneie meld Stang auiperé per meter amountofsubstance concentration mole per cubic meter Tininaniee cindela per sauare meter) mass fraction Kilogram per kilogram, whi Fepresented by the number 1 Os22 SI derived units have been given special names and symbols, as shown in Table 3. ——$ $$$ Table 3. SI derived units with special names and symbols Sr hs Perot Derived quantity Name | Symbol| in terms of | other SI units plane angle radian” rad. solid angle steradian® sr’ frequency hertz W force newton. N pressure, stress pascal Pa energy, work, joule J quantity of heat power, radiant fine ‘watt Ww electric charge, coulomb 6 quantity of electricity electric potential difference, volt v electromotive force capacitance —farad F electric resistance Ohi a electric conductance siemens Ss imagnetie flix weber Wo magnetic flux density tesla T inductance henry i Celsius temperature degree Celsius °C Timinousiiux Timen! in illuminance lux lx Activity Gia madiomiclide) ||) becquerel’ Bq absorbed dose, gray Gy specific energy (imparted), na dose equivalent! sievert. Sv. J/kg mst catalytic activi katal kat s'+ mol (@) The and steradian may be used advantageously in expressions for derived units to distinguish between’ quantities of a different nature but of the same dimension; some examples are given in Table 4. (b) In practice, the symbols rad and sr are used where appropriate, but the derived unit "1" is generally omitted. (©) In photometry, the unit name steradian and the unit symbol sr are usually retained in expressions for derived units. (@ Other quantities expressed in sieverts are ambient dose equivalent, directional dose equivalent, personal dose equivalent, and organ equivalent dose. s1@SI international System of ‘The special names and symbols of the 22 SI derived units with special names and symbols given in Table 3 may themselves be included in the names and symbols of other SI derived units, as shown in ‘Table 4. SS Table 4. Examples of SI derived units whose names and symbols include SI derived units with special names and symbols Cg dynamic viscosity pascal second Pass moment of force newton meter N-m surface tension newton per meter N/m ‘angular velocity radian per second rad/s angular acceleration radian per second squared rad/s* heat flux density, irradiance watt per square meter W/m? Heatleapacity entropy joule per kelvin i specific heat capacity, specific entropy joule per kilogram kelvin J/kg K) specific energy joule per kilogram Ike thermal conductivity watt per meter kelvin W/im > K) energy density. joule per cubic meter J/m* electric field strength volt per meter V/m electric charge density coulomb per cubic meter C/m* electric flux density coulomb per square meter C/m* permittivity farad per meter E/m permeability henry per meter H/m molar energy joule per mole J/mol molar entropy, molar heat capacity joule per mole kelvin J/(mol - K) exposure (x and rays) coulomb per kilogram Chg absorbed dose rate gray per second Gy/s radiant intensity watt per steradian W/st radiance watt per square meter steradian W/(m' « st) catalytic (activity) concentration katal per cubic meter kat/m*al ee caerTOOLS Regularly Used in Engine Room Adjustable Angle Wrench Single Open Ended Spanners 5 and 12point Box Wrench Strait Pipe Wrench Double Open End Wrench Solid Steel Bar Wrench Double Open End Wrench Set Combination Open and Spud Wrench 6point T type WrenchSocket Wrench Set Water Pump Prier Double Position Side Cutting Plier & Hand Snip (Curved Edge) Flat Nose Plier Combination Plier Stopling PlierTOOLS Regularly Used in Engine Room Ball Pein Hammer Off Set Corking Chisel - Lead Hammer Hand Taps Plastic Hammer 7 ht Machinists Files Testing Hammer —— Rubber Hammer Center Punch Gold Chisel Pin Rivet Punch Cross Cut Cold ChiselServing Mallet Packing Hook Wood Mallet Hammer om 7 Steel Scriber Vernier Caliper Gear and Wheel Puller Cloth Scissors Round Hole Punch Gasket and Washer CutterOOLS Regularly Used in Engine Room Parallel Bench Vise Claw and Nail Puller Bar Ratchet Type Branch Drill Automatic Screw Driver SHE C-Type Screw Clamp @ 1001sPneumatic Scaling Grinder Hand Grinder a a” Double End Angle Scraper Oval Type Wire Brush Chipping Hammer —_ a