CONFIDENTIAL

NAVAL & MARITIME ACADEMY

SERVICE ENTRY OFFICERS TECHNICAL COURSE 02/2019
AUXILIARY MACHINERY (PAPER I)

Available time: 3 Hours

Instructions to candidate:
1. Answer 05 questions
2. Total Marks: 100 and Pass Mark: 45

1. What are the laws of refrigeration & explain air-conditioning? (04 marks)

a. Draw a neat sketch of the vapour compression system and explain the function of four
basic components briefly? (05 marks)

b. Explain with a neat sketch thermostatic expansion valve and its operation?
(05 marks)

c. What are the 5 properties of an ideal refrigerant? Explain the concept of greenhouse
effect and global warming? (06 marks)

2 What do you understand by Dynamic & Positive Displacement Compressors, State the
classification of pumps? (06 marks)

a. What are the usages of LP & HP air onboard ship? (06 marks)

b. A surface-mounted water pump pulls water out of a well by creating a vacuum,

though it might be more technically accurate to say that the pump works by reducing
pressure in the inlet pipe to a level less than atmospheric pressure, allowing atmospheric
pressure to then push water from the well up the pump’s inlet pipe: Pump Water
Atmospheric pressure Based on this description of pump operation, what is the theoretical
maximum height that any pump can lift water out of a well, assuming the well is located at
sea level? (06 marks)
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2. What are the objectives of associating Fin Stabilizing system and main components of
stabilizers? (06
marks)

a. Briefly explain two modes of stabilizing and state the types of fin stabilizing systems?
(06 marks)

b. Draw the basic hydraulic system diagram of the stabilizing system and briefly
explain? (06 marks)

c. Explain and justify the statement below. (06 marks)

“Stabilizers are normally operated above 8 knots of Ships speed”

3. Briefly explain about Osmosis and reverse osmosis process and give a simple sketch for
each one. (06 marks)

a. Sketch down the principle diagram of the RO plant and briefly explain functions of
each components (Draw the sketch for sand filter and cartridge filter) (06 marks)

b. What do you mean by SMC valve and briefly explain. (06 marks)

c. What is the pulsation damper and briefly explain with a simple diagram. (06 marks)

d. What are the DO’s and DONT’s when plant in operation. (06 marks)
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4. What is Steering Gear and what are the types of steering gears & selection criteria?
(04marks)

a. Write down the types of rudders and what are the main components of Electro
hydraulic Steering Gear? (06 marks)

b. List out various modes/methods of steering and various positions of steering gear
onboard ship? (10 marks)

Briefly explain the methods of separation and the types of centrifuges? (06 marks)

a. Briefly explain all the mains components of the Centrifuge? (06 marks)

b. Brief the procedure of converting a purifier into a clarifier and briefly explain the
gravity disc (08 marks)

…………………………

Examiner

Recommended/Not recommended

………………………………

Director of Academic Studies

Approved/Not approved

………………………………..
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Training Captain
1. Basic Laws of Refrigeration

 All liquids while evaporating take (absolute) heat from the surroundings.
 Any vapour can be condensed back to liquid if it is suitably compressed and cooled.
 The temperature at which any liquid evaporates or boils depends directly upon the
pressure to which the liquid is subjected.

Air Conditioning

Air conditioning can be defined as the process of simultaneous controlling of

temperature, humidity, cleanliness and flow of air or air motion.

c.

Compressor

The function of the compressor is to draw the low pressure refrigerant vapour
from the evaporator, compress it to raise its pressure and temperature to such a point
so that it is easily condensed by the normally available cooling medium. It maintains
a continuous flow of refrigerant through the system. It also satisfies the second law
partly.
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Condenser

The function of the condenser is to provide a heat transfer surface, through

which the refrigerant vapour rejects heat to the cooling medium, condenses or
liquefies and is sub cooled. It can store the total refrigerant charge of the system. It
also satisfies the second law partly.

Expansion Valve (Refrigerating Valve or Throttle Valve)

The function of the expansion valve is to drop the pressure of the liquid
refrigerant from condenser pressure to evaporator pressure so that the liquid
refrigerant will evaporate at low temperature in the evaporator because of the pressure
drop. It controls or regulates the flow of refrigerant into the evaporator according to
the demand or load changes. It also satisfies the third law of refrigeration.

Evaporator

The function of the evaporator is to provide a heat transfer surface so that the
low pressure liquid refrigerant will evaporate absorbing heat from the surroundings
thus producing cooling effect .It also satisfies the first law of refrigeration.

d. Explain with a neat sketch thermostatic expansion valve?

 The operation of this valve is based on the principle of constant degree of

superheat for the vaporator exist i.e. by controlling the flow of liquid refrigerant
through the evaporator.
 The thermostatic expansion valve consists of a needle valve and a seat, a
metallic diaphragm, spring and adjusting screw.
 In addition to this it has a feeder or thermal bulb which is mounted on the
suction line of compressor near the outlet of the evaporator coil.
 The filler bulb is partly filled with the same liquid refrigerant as used in
refrigeration system.
 The opening or closing of valve is depended upon the force on the diagram.
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Operation:

 The remote bulb is charged with fluid which is open on one side of the
diaphragm through capillary tube is firmly to evaporate outlet.
 The pressure (Pb) of the fluid in the bulb tends to open the valve. This
pressure is balanced by pressure due to spring (PS) and in the evaporator (Pe).
 If the evaporator temperature is high or the load on the evaporator increase,
more fluid from feeler bulb will be vapourised and bulb pressure will rises which
exert this force on diaphragm.
 This will widen the valve opening and the refrigerant flow will increase to
meet load demand and if load on evaporator decreases reverse action takes place.

e. Explain the concept of greenhouse effect and global warning?

 All the living organism except trees releases CO2 which at is absorbed by trees
and releasesO2.
 The balance of O2 and CO2 in the atmosphere is responsible for affecting
atmospheric conditions.
 Due to rapid industrialization large forest of were cut which lead to increase in
CO2 in atmosphere.
 The excess of CO2 destroys the stratospheric ozone (O3) layer which protects
the earth from excess heat coming from the sun.
 As the ozone layer thickness is reduced it creates a void which allows solar
rays to directly fall on earth which increase the earth temperature and hence the earth
atmosphere.
 This effect of reducing O3 layer is called greenhouse effect.

Global warming

 The part of the solar energy absorbed by the atmosphere and earths surface is
re-emitted at infrared radiation by them.
 These radiation are absorbed by greenhouse gases like CFC refrigerants, CO2,
O3, NO3 and CH4 present in the lower atmosphere.
 This increases the temperature on the surface of earth which is called as global
warming due to greenhouse effect.

State the desirable properties of ideal refrigerants

 Low boiling and freezing point.

 High critical pressure and temperature.
 High latent heat of vapourisation.
 Low specific heat of liquid and high specific heat of vapour.
 Low specific volume of vapour.
 High thermal conductivity.
 Non-corrosive to metal.
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 Non-flammable and non-explosive.

 Non-toxic.
 Should be low in cost.
 Easily and regularly available.
 Easy to liquefy at moderate pressure and temperature.
 Easy of locating leaks by odour or suitable indicator.
 Ozone friendly.
 High co-efficient of performance.
.

2. Dynamic & Positive Displacement Compressors

a. Positive Displacement Type

In these compressors, energy is periodically added by the application of force of one

or more movable boundaries, resulting in direct increase of the pressure up to the value
required to move the gas into discharge line.

b. Dynamic Type

In these compressors, energy is continuously added to increase the gas velocity within
the compressor casing and at the discharge the velocity is suddenly dropped by means of a
diffuser that results in pressure rise.

Classification of Pumps
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Usage of LP & HP air onboard ship

Uses of LP Air.

a. Controls of Main Engine, Controllable Pitch Propeller etc.

b. Pressure testing of condenser, water tight compartment
c. Blowing of ship’s siren
d. Spray painting
e. Blow down seaweeds in sea chest
f. Filter cleaning/Boiler cleaning
g. Starting of small engines and Diesel Alternators
h. Domestic uses such as pressurized fresh water/sea water system tanks
i. Operating of pneumatic tools (Pneumatic Hammers, Chipping Machine, Grinder,
Butting Machine etc.)

Uses of High Pressure Air.

a. Starting of main engines and D/A

b. Charging/ Loading of torpedoes
c. Torpedo firing
d. Supply of blast air to Gun Mountings
e. Charging of ICABA (International Compressed Air Breathing Apparatus) and DCBA
(Damage Control Breathing Apparatus)

406.9 inches, which is a little bit less than 34 feet. For this amount of “lift height,” the pump would
have to create a near-perfect vacuum in the inlet pipe. To calculate this figure, convert 14.7 PSIA
into inches of water column absolute (14.7 PSIA) (27.68”W.C. / PSI).

Since this kind of water pump works by creating a vacuum (reducing the inlet pressure to
something less than 14.7 PSIA), it is inherently limited in lift height. Since atmospheric pressure is
always 14.7 PSIA (on Earth, anyway), this kind of pump simply cannot suck water any higher than
this amount of pressure expressed in inches or feet of water.

The average barometric pressure in Denver is 24.63 inches of mercury absolute (12.097 PSIA).
This equates to a water-lifting height of 334.9 inches, or 27.9 feet.

Submersible pumps overcome this limit by creating a positive pressure rather than a vacuum. The
pumping action is therefore not limited by the relatively low pressure of Earth’s atmosphere, but
only by the capacity and design of the pump itself:

3. Fin Stabilizer are broadly used to obtain;

a. A steady platform for safe landing / taking off of aircraft

b. Accuracy in gun firing
c. Comfort of ship’s company
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d. Better performance of machineries

e. Betterment of pre-wetting
Main components of stabilizers

a. Variable delivery pump

b. Fin tilting cylinder assembly
c. Fin shaft
d. Fin assembly

Hydraulic System

1. Methods of stabilizing

a. Passive Method - To induce an equal and opposite force on a ship to the force causing
ships roll when ship is underway.

b. Active Method - It has preset control whereby the corrective action initiate itself in
the form of a counteracting movement

Types of fin stabilizing system

a. Retractable trapezoidal stabilizer

b. Non-retractable trapezoidal stabilizer
c. Retractable tail-flap stabilizer
Non-retractable fin stabilizer
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* osmosis is the natural phenomena, which takes place when solutions of different
concentrations are separated by a semi-permeable membrane. the solvent flows from the
weak solution to the strong solution through the semi permeable membrane. thus osmosis tends to
reduce the difference or to equalize concentration of liquids on both sides.

* osmosis process can be reversed, by applying pressure (above osmotic pressure) on the
strong solution side and is called reverse osmosis process.

MEMBRAN
A B E
SEA FRESH
SEA WATER FRESHWATER
WATER WATER SEMI PERMEABLE
MEMBRANE

OSMOSIS R. OSMOSIS

PRE-FILTER SAND CARTRIDGE PRESSURE DT MODULE

RAW PUMP FILTER
a). PUMP FILTER PUMP
WATER PK 20
PK 30 FS 30 FC 40 PP 60 FM 60

AIR SERVO MOTOR

CONNECTION
CONTROL VALVE
VS 60
BRINE

FD 80
PERMEATE
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PRE-FILTER PUMP. pre-filter pump is used to supply sea water to the ro plant filter pump with
sufficient pre-pressure and quantity, and consist of centrifugal pump.

FILTER PUMP. filter pump is designed to supply this raw water received from the pre-filter pump
to the filter system and thereafter to the high-pressure pump with designed pressure and quantity. the
filter pump is also a centrifugal pump.

SAND FILTER. The sand filter contains 3 layers of sand:- fine medium coarse this unit is
designed for rapid filtration of the raw water with back washing facility. the filter system is supplied
with gauges and diverting valves. the normal flow of water is from top to bottom. only the top layer
carries out the function of filtering while others are supporting layers.

CARTRIDGE FILTER. cartridge filter is designed to remove any suspended matter to reduce
organic or inorganic fouling of the membrane up to 10 microns. cartridge filter is supplied with
sufficient pre-pressure from the filter pump
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HIGH PRESSURE PUMP. the high pressure plunger pump system consists of a slow revolution triplex plunger
pump supplied with motor, pulsation damper and pressure relief valve. the high pressure pump is fitted in a
separate frame for alternative installation in case of space shortage and for easy installation.

DE-ACIDIFICATION FILTER. the normal sea water contains carbonates in small percentage. during reverse
osmosis process these carbonates break up and generate co2, which passes over to the permeate side. this
carbon dioxide will combine with water and form carbonic acid. hence, to prevent the corrosion of product
water flowing through coated iron pipes a de-acidification filter is installed. this filter converts free co2 back
in to ca++ and hco3_- by the following chemical reaction.

CACO3 +CO2 + H2O = CA (HCO3) 2

DT MODULE. the dt module consists basically of a disc membrane stack and pressure vessel. the disc
membrane stack is fitted inside the pressure vessel. end flanges with groove rings manifold are designed as
an integral part of the hydraulic disc. the integrated spacer forms the open raw water channel. the
extremely short feed water path across the membrane followed by a 180-degree flow reversal eliminates
polarization concentration. the result is minimum membrane fouling and scaling and a minimum flow path
with low resistance the membrane cushions are stacked on the centre tension rod. each membrane cushion
is covered at top and bottom by a hydraulic disc to form a separate chamber for each cushion. raw water,
which flows under high pressure into the membrane module at raw water inlet on the dt module, enters the
membrane stack at the first membrane. on its way to the next chamber it flows across bottom and top
membrane cushion surface. this permeates drains into the pure water manifold around the tension rod.
from there it is discharged out through permeate line. the brackish water is sealed off with an ‘o’ ring from
the pure water manifold.

b) SERVO MOTOR CONTROL VALVE (SMCV).

the servo motor control valve is located in the brine line after the module. the main function of this valve
is to control the module working pressure (pi-60) as per requirements of the operational mode.

c). PULSATION DAMPER. The pulsation damper is Fitted on the discharge side of the hp pump. The
Pump being triplex plunger type reciprocating Pump the discharge pressure of each cylinder Varies over the
entire length of its stroke. The Pulsation damper evens out the pressure Variations so that the pressure at
the dt module is even and steady
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d) DO'S

*ENSURE CHEMICALS BEING USED FOR CLEANING ARE NOT LIFE EXPIRED (SHELF LIFE OF
CHEMICALS IS 9 MONTHS).
*ELECTRICAL SUPPLY VOLTAGE AND MOTOR CONNECTING SEQUENCE SHOULD BE
CORRECT.
*100 NM TORQUE IS APPLIED FOR TIGHTENING OF MODULE END NUT BEFORE EVERY
START.
*ENSURE THERE IS NO LEAKAGE IN THE S/W SYSTEM AND HP PIPING.
*THE PULSATION DAMPER IS CHARGED TO 30 BARS.
*ENSURE CORRECT POSITION OF VK21, VK32, VK33, VK34, VK 72 AND VK10
*ENSURE PERMEATE PRESSURE IS BELOW 1.0 BAR.
*CHECK CORRECTNESS OF OIL LEVEL IN HP PUMP CRANKCASE.
*THE HIGH-PRESSURE PUMP DRIVING BELTS ARE PROPERLY TENSIONED.
*THERE IS NO BACKPRESSURE IN THE PERMEATE PIPING.
*ENSURE THE HIGH-PRESSURE PUMP PLUNGER AND SEAL IS DROP LUBRICATED BEFORE
STARTING.
*ENSURE ALL SAFETY DEVICES ARE IN WORKING CONDITION.
*ENSURE DE-CHLORINATION OF RAW WATER.

DONT'S

DO NOT OPERATE THE PLANT UNDER ANY OF THE FOLLOWING CONDITIONS.

*UNDER FLUCTUATING OR UNSTEADY UPPLY VOLTAGE.

*UNDER EXCESSIVE PRESSURE DIFFERENCE BETWEEN INLET AND OUTLET OF SAND AND
CARTRIDGE FILTER (2.0 BAR MAXIMUM PERMISSIBLE).
*EXCESSIVE PULSATIONS IN THE HP PUMP DISCHARGE TO THE MODULE INLET (MAXIMUM
2 BAR PERMISSIBLE).
*UNDER BLOCKAGE OF HP PUMP RELIEF PORT.
*WHEN THE FEED INLET PRESSURE TO THE HP PUMP FALLS BELOW 1.0 BAR
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*UNDER FAULTY PRESSURE GAUGE CONDITION.

*WITHOUT CARTRIDGE FILTER ELEMENT IN PLACE.
*WITH CLOSED BRINE OVERBOARD VALVE.
*WHEN CONTROL UNIT DISPLAYS FAULT INDICATION TILL SUCH FAULT RECTIFIED.
*IF THE CONTROL CIRCUIT REPEATEDLY TRIPS.
*DO NOT OPERATE PLANT IN HARBOUR.
*WITHOUT CHECKING MODULE END NUT TORQUE, IT MUST BE 100 NM.
*DO NOT CLEAN OR REUSE CARTRIDGE FILTER.

4. Classification of steering gear

a. Manual steering gear

b. Mechanical steering gear
c. Telemotor steering gear
d. Electro-hydraulic steering gear
e. All electrical steering gear

Basis of selection

The capacity of steering gear is determined on the following Factors;

a. Torque exerted by the rudder

b. Speed of the rudder
c. Maximum rudder angle required

5. Centrifuge

Methods of Separation

i. Filtration

Removal of unwanted particles of materials such as cotton threads, paint, chippings, small pieces of
metal etc. from oil or fuel is called filtration. In this process water cannot be separated from oil or
fuel. To achieve this (separation of water) static separator or filter coal esker are used.

ii. Gravitational Separation

Oil fuel is allowed to stand undisturbed in a settling tank, mediums of higher relative density other
than oil or fuel gravitate to the bottom of the tank where they are discharged periodically through a
drain cock.

iii. Centrifugal Separation

If a liquid is allowed to settle in a tank, the heavy particles suspended in the liquid will fall to the
bottom, due to the action of gravity. If the liquid is subjected to centrifugal force, many times
greater than gravity, this separation will be accelerated considerably and rendered more complete.
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Types of Centrifuges

i. Clarifier

The device use to separate solid particles from a liquid by the action of centrifugal force (water
sealing not required).

ii. Centrifugal separate

The device use to separate two insoluble liquids by the action of centrifugal force (water sealing
required).

iii. Purifier

The device use to separate two insoluble liquids and solid particles at a time by the action of
centrifugal force (water sealing required).