MLC 2006

The Maritime Labor Convention is one of the pillar of IMO, Enter into forced on
August, 2013.

MLC would ensure that seafarers basic rights in terms of working condition,
medical benefits, accommodation facilities, and social security protection.

The Maritime Labor Convention (MLC) is divided into 5 main parts which are:

1. Minimum Requirements for seafarers to work on ships

• Minimum age
• Medical certificate
• Training and certifications
• Recruitment and placement

2. Conditions of Employment

• Seafarer’s Employment Agreement

• Wages
• Hours of rest and hours of work
• Entitlement to leave
• Repatriation
• Seafarer compensation for ship’s loss or foundering
• Manning levels
• Career and skill development

3. Accommodation & Recreation, Food and Catering

• Accommodation and recreational facilities

• Food and catering

4. Medical Care, Welfare and Social Security Protection

• Medical care on board and ashore

• Ship owner’s liability
• Health and safety protection and accident prevention
• Access to shore based welfare facilities
• Social Security
5. Compliance and Enforcement
Flag state responsibility
! Authorization of recognized organization (RO)
! Inspection and enforcement
Port State Responsibilities
! Maritime labor certificate
! On board compliance procedures
! Marine Casualties
! Labor Supplying responsibilities

1. Minimum Requirements for seafarers to work on ships

• Minimum age; to ensure no underage person working onboard.

1) Minimum working age is 16. Below 18 years old classified as young

seafarers
2) Night work for seafarer under 18 not allowed.
3) No hazard task to young seafarer, (entry to boiler, working aloft,
handling mooring line, handling power tools, handling danger
chemicals, service electrical equipment.

• Medical certificate; to ensure seafarer medically fit to perform duties

1) Must have valid and approve certificate issue by approve medical

practitioner
2) Each certificate state person hearing , eyesight, color vision, not
suffering from any condition
3) Medical cert valid for 2 years, young seafarer 1 year
4) Seafarer permitted to work without a valid medical cert until next port to
get a valid cert not exceed 3 months.
5) Cert must be in English

• Training and certifications; ensure seafarers are trained and qualified

for duties
1) All seafarers to be trained and certified as competent according
to STCW
 • Recruitment and placement; ensure all seafarer have access
recruitment
1) All seafarer have a system for finding employment without
charge
2) Ship-owner using recruitment service ensure follows code

2. Conditions of Employment

• Seafarer’s Employment Agreement (SEA); to ensure fair employment

1) Terms and conditions must be clearly written
2) Seafarer can review , seek advice before signing
3) Seafarer must have original, signed copy. SEA readily available
4) SEA to contain
o full name, dob, pob.
o Ship-owner name and address
o Place, date of SEA issued
o Rank
o Wages and leave pay
o Termination agreement and conditions
o Health and social security protection
o Entitlement to repatriation
o Onboard complaint procedure

• Wages; ensure seafarer paid for service

1) Wages to be paid monthly
2) Pay slip given
3) Employers give means to transfer money to family or dependents
4) Overtime record maintain by masters, signed by seafarer
5) No deduction made to retain employment

• Hours of rest and hours of work ; ensure seafarers have regulated hours
of work, and rest
1) Work hours not exceed 14h/day, 72h/week
2) Rest hour not less than 10h/day 77h/week
3) Rest hour max divided to 2 part, intervals between max 14 hours
4) 1 part of rest at least 6 hours
5) Drills conducted to minimized disturbance of rest period
6) UMS alarms, to be compensated with rest
7) Work schedule posted at common area, common language
8) Records in standard format and given.
 • Entitlement to leave; ensure seafarers have adequate leave
1) Seafarer paid annual leave at least 2.5 calendar days/ month
2) To be granted shore leave for wellbeing and health
3) Public holiday, sick leave, shore leave not consider annual leave

• Repatriation; to ensure seafarer can return home

1) To be home at no cost, if contract expire, terminated.
2) Ship owner not allowed to let seafarer make advance payment to
cost.
3) If ship-owner fails, flag state must ensure and shall not refuse.
4) Cost include accommodation, food, pay and allowance until
reaching home.
5) Transportation 30kg and medical treatment
6) Seafarer have right to choose place of repatriation
7) Young seafarer, served 4 months, if unsuited to be sent home
with no expense.

• Seafarer compensation for ship’s loss or foundering; seafarer are

compensated when ship is lost.
1) Seafarer entitled to compensation for injury or loss of
employment
• Manning levels; ensure ship have sufficient personnel for safe and
secure operation of ship.
• Career and skill development and opportunities for seafarer’s
employment; promote career and skill development, employment
opportunities

3. Accommodation, Recreation, Food and Catering ; ensure seafarers has

decent accommodation and recreational facilities.

• Accommodation and recreational facilities.

1) Of required size, and convenient access to ship sanitary facilities.

1 toilet for 6 person, wash basin in each cabin.

• Food and catering; ensure seafarer have good quality food and drinking
water.
1) Cook must be trained and certified.

4. Health Protection, Medical Care, Welfare and Social Security

Protection
 • Medical care on board and ashore; to protect health of seafarer and
access to medical care onboard and ashore
1) To be provide at no cost
2) Standard medical report to be used
3) All ship carry medicine chest, equipment and guide
4) Ship carrying 100 person on voyage more than 3 days shall carry
a doctor
5) If not carry a doctor, require to have a seafarer in charge of
medical care
6) Seafarer to go through 5 years interval of first aid training
• Ship owner’s liability; to ensure seafarer protected from financial
consequence of sickness, injury or death.
• To ensure seafarer work environment promotes occupational safety
and health.
• Seafarer have Access to shore based welfare facilities;
• Social Security; measures to ensure seafarer have access to social
security protection

5. Compliance and Enforcement

• Flag state responsibility; to ensure flag state implement its

responsibility’
• Port State Responsibilities; to ensure port state implement its
responsibility in implementation and enforcement.
• Labor Supplying responsibilities; ensure each member implement
responsibility under convention regards to recruitment and placement,
social protection
• Authorization of RO for inspection
• Maritime labor certificate and declaration of maritime labor compliance
• Ship have complaint procedure.

1) Complaint to be made to head of department, if not master, if not

ship-owner.

• Marine Casualties; flag state to give final report to public.

 LSA and FFA, PSC CHECKS, Tests, routines
LSA:

General requirements

1) To be of proper workmanship and materials, Corrosion resistant,

against seawater, sunlight, oil or fungal.
2) Be of highly visible color and to be fitted with reflective material, assist in
detection.
3) Clearly marked with approval information and with clear instructions

LSA into 3 categories: 1) general 2) personal 3) distress signaling equipment

General LSA:
Survival craft
1) Life raft: PSC check for its structure
! Hydrostatic release unit correctly installed and serviced
! Launch procedure posted,
! Clear of obstruction
! Embarkation arrangement in good condition
! Inflated by CO 2 gas with small amount nitrogen gas to act as
anti-freeze
! Capable of inflated by 1 person
! Carrying capacity of more than 6 person
! Inflation shall be within 1 minute
! If dropped to water from height of 18 m, will not damage
! Capable to withstand repeated jump from 4.5 m
! Location on ship: forward and embarkation station on port and
starboard

2) Lifeboat:
1) Must have certificate of approval,
2) Capable to be launch and towed when ship is at 5 knots
3) Withstand drop from water at least 3 m
4) Rescue side impact against hull with speed 3.5 m/s
5) Minimum 1 lifeboat at each side
6) 1 lifeboat can be assigned as rescue lifeboat
7) Gravity davit have to work even heel at 15°
8) LIFEBOAT ENGINE: fuel flash point must not less than 43°C
9) Lifeboat engine start by batteries or hydraulic
10) Starting within 2 minutes
11) Gearbox capable to enable ahead and astern
 12) Must be able to operate not less than 5 minute

PSC check for its structure:

! Hook release gear,
! Flooring, no wastage
! Inventory not expired.
! Life boat engine can start within 2 minute, operating instructions clearly
posted
! On load release gear correct set at required pressure
! Lifeboat davit well maintained, wire serviced and launch instruction
posted

3) Line throwing apparatus

1) At least 1 piece onboard
2) Reasonable accuracy
3) Line not easily breakable
4) Kept on bridge with safety pin provided

4) Breathing apparatus
Emergency Escape Breathing Device (EEBD)
1) Accommodation min 2 and 1 spare
2) Engine control room: 1
3) Workshop: 1
4) Each platform: 1
5) Service at least 10min
6) Maintenance: check the indicator is green, to ensure no leaks
7) Keep the device case clean
8) Record and check expire date
9) Do not use, but use training piece for training

Self-Contained Breathing Apparatus (SCBA)

Maintenance: cleaning, disinfecting, drying, visual inspection of speech

diaphragm, inhalation valve, exhalation valve

Regulation for SBCA

! The capacity of air bottle should be at least 1200 liters.

! Maximum pressure should about 180-200 bars.

! It should be capable of working 30 minutes & provided with one face

mask.
 ! Fire proof line at least 3 meters should be there and must have enough
length to reach any part of the space to be entered.

! Adjustable safety belt made of fabric.

! Maximum weight should not increase above 19 kg including lifeline,

safety belt, and harness.

! Spare cylinders ready of full 2400 liters of air.

! For ships carryings 5 sets or more, the total spare capacity of free air is
9600 liters(4) or if charging facility is available, free air is 4800 liters.(2)

! It must give an audible warning when 20 % of air is left in the bottle.

! Must be marking of maker & year of manufacturer.

! Hydraulic pressure tested at intervals not more 5 years and hydrostatic

test date must be permanently marked on the bottles.

! Every 5 years complete service check.

Personal: LSA
1) Lifebuoy
! Carrying capacity for ship length under 100m = 8, 100-150m= 10,
150m-200m = 12, above 200m= 14.
! Size: inner diameter not less 400mm, outer diameter not less 800mm
! Accessories:
! a) Retro reflective tape,
! b) Grab line
! d) Buoyant life line
! c) Self-igniting light
! Not sustain burning or melt if caught fire for 2 sec
! Constructed to withstand a drop into water from a height
! Marking is port of registry of ship.

2) Life jacket

PSC checks correct number at correct location with marking

• Carrying minimum capacity; each person onboard have personal
lifejacket + additional for watch keeper +5% extra at muster station.
• Worn: should be worn in 1 minute without any assistance, comfortable
to wear
• Jump: capable to jump from height of 4.5 m into water without injury
• Buoyancy: should not reduce by more than 5% after 1 day in fresh
water.
 • Not sustain burning or melt if caught fire for 2 sec.
• Come with reflective tape, whistle, and manual igniting light.

3) Thermal protective aid

• Have thermal conductance of not more than 7800 W/m-k ( watt.meter
kelvin)
• Capable of unpacked and easily donned, Worn: in 2 minute

4) Immersion suit

• Carrying minimum capacity; each person onboard have personal

Immersion suit.
• Worn: should be unpacked and worn in 2 minute without any
assistance,
• Cover the whole body except face
• Jump: capable to jump from height of 4.5 m into water without injury
• Not sustain burning or melt if caught fire for 2 sec.
• After wear must be capable to do normal work
• Climb up and down vertical ladder at least 5 m
• Able to swim short distance
• Wearer can turn face down to face up not more than 5 sec

5) Anti-exposure suit

• Worn: should be unpacked and worn in 2 minute without any

assistance,
• Cover the whole body except face and hands. Glove and hood
provided.
• Equipped with a pocket to portable VHF
• Not sustain burning or melt if caught fire for 2 sec.
• After wear must be capable to do normal work
• Climb up and down vertical ladder at least 5 m
• Able to swim short distance 25 m
• Wearer can turn face down to face up not more than 5 sec

Distress signaling equipment

1) Emergency position indicating radio beacon. (EPIRB)

 • Minimum 1 onboard
• Battery storage of 5 years
• Located on bridge wing
• When activated emit radio signal at least 2 days

2) Search and Rescue Transponder (SART)

• Min 2 onboard
• Made of reinforce plastic ,Self-floating
• SART mounted on bracket can be fixed to bulkhead of ship
• Portable for use or carry to survival craft
• Should have sufficient battery capacity

3) Global maritime distress signaling system (GMDSS)

• Located on bridge
• Main communication of ship and all external communication
• Operated by master and officer in charge

Pyrotechnics

Rocket parachute type

• 4 per lifeboat and life raft
• Contain in a water resistant case
• Fired vertically, not less than 300 m
• Burn with bright red color
• Expires in 3 year
hand flare
• 6 per lifeboat and life raft.
• Contain in a water resistant case
• Burn with bright red color
• Continue to burn immerse in water

buoyant smoke signal

• Contained in water resistant case
• Not ignite explosively
• Emit smoke of highly visible color
• Not swamp in seaway
• Continue to emit smoke when submerge

FFA (Firefighting appliances)

There are 4 main categories of FFA.

1) Portable Extinguisher
• CO 2
• Water
• Form
• Dry powder

2) Fixed firefighting system

• CO 2 battery
• Water sprinkler
• Hypermist
• Foam

3) Fireman outfit

Regulation for Fireman Outfit

As per SOLAS the minimum number of fire fighter outfit required on board are
as follows:-

All ships shall carry at least two fireman’s outfits complying with the
requirements.

1) For ship between 500-2500 tons, minimum two sets are required.

2) For ship between 2500-4000 tons, minimum three sets are required.

3) For ships, 4000 tons and above minimum four sets are required.

The fire fighter outfit is stored in the fire control room and in places that are
easily accessible during emergencies.

4) A minimum of two two-way portable radiotelephone (VHF) apparatus for

each fire party for fire-fighter’s communication shall be carried on board.

5) Those two-way portable radiotelephone apparatus shall be of an

explosion-proof type or intrinsically safe.

6) To be consist of following

• Rigid helmet
• Waterproof & heat resistance protective clothing
• Electrically nonconductive boots and gloves
• SCBA set
 • Fire proof life line
• Belt for carrying auxiliary
• Axe with insulated handle
• Battery operated safety lamp

4) Emergency fire pump

Regulation for emergency fire pump

• Located outside of engine room,

• Provided in case of emergency like CO 2 flooding, main fire pump not
functional
• Power supply from emergency generator
• Capable of supplying 2 jets (12 meters each )
• Attach to a priming unit

Class of fire, A, B, C, D
Class A – combustible material; not use CO 2
Class B – oil fires; not use water
Class C – metal fire; only can use dry powder
Class D – electrical fire; only can use dry powder and CO 2

Portable extinguisher
• Portable extinguisher for use in space to be near
• CO 2 not allow to be used in accommodation
• Spare charge must be provided

CO 2 system requirements
• CO 2 not to be in forward collision bulkhead
• CO 2 room max 1 deck below main deck
• Ventilation in CO 2 changed 6 times
• Safeguard against unauthorized usage
• Automatic discharge not allowed
• Machinery section valve with alarm
• Operation trigger alarms
• Permanent piping
• Pipes to tank top and bilge tank
• Piping pressure tested to 122 bar
• Cargo hold pipes not pass through ER unless tested
• CO 2 discharge 85% within 2 minute.
 • Capacity for Engine room 40%
• Capacity for cargo hold space: 30%
• 2 separate control must be provided, to open distribution valve and to
release.

CO 2 bottle requirements

• stamped pressure at 52 bar

• bursting disc rapture at 177 – 193 bar at 63°C
• hydraulically tested to 228 bar
• level tested by weighing or radioactive level detection,
• recharge if 5% lost,
• have both manual and auto operation
• clamped against movement
• if more than 10 years, require internal and external exam
• Store in temperature less than 55°C.

Sprinkler firefighting system

• Bulb operating. Green-93°C, yellow-79°C, red- 68°C

• At least 2 source of power for Seawater pump, alarm and detection
system and Fresh water pump
• Sprinkler must be resistant to corrosion
• Each section not to contain more than 200 sprinkler head,
• Each sprinkler must be sufficient to cover area of 16 ㎡
• Highest sprinkler head not less than 4.8 bar pressure
• Gauge should be provided at each section and central station
• Paint locker room must have sprinkler connected to fire main pump

Hypermist firefighting system

• Protect spaces, M/E, A/E, purifier room, incinerator, boiler platform
• Activation give visual and audible alarm.
 Statutory certificates
Certificates as required by law for the ship to sail , window period +- 3 months,
certs must be original, if have supplement certs, must be present.

1. International tonnage certificate; valid for lifetime

2. International load line certificates , valid for 5 years
3. International air pollution prevention certificates valid for 5 years
4. International oil pollution prevention certificate. Form A/B, A for
other ships , B for tankers. valid for 5 years
5. International sewage pollution prevention certificate valid for 5
years
6. International Anti fouling system certificate
7. International ship security certificate
8. International energy efficiency certificate valid for 5 years
9. Maritime labour certificate subject to audit +- 6 months valid for 5
years
10. DMLC, declarance of cert part 1 issued by flag state, part 2 issue
by owner.
11. Certificate in compliance with ISM code
12. *Document of compliance valid for 5 years
13. *Safety management certificate valid for 5 years
14. Cargo ship safety construction certificate valid for 5 years
15. Cargo ship safety equipment + FORM E – attachment valid for 5
years
16. Cargo ship safety radio, + FORM R - attachement valid for 5 years -
17. Passenger ship safety certificate valid for 1 years
18. International pollution prevention certificate for carriage of
noxious liquid substance valid for 5 years
19. International certificate for ship carrying dangerous goods
20. International certificate of fitness for carriage of liquefied gas
valid for 5 years
21. International certificate of fitness for carriage of dangerous
chemical valid for 5 years
22. Minimum manning Cert
23. Document for ISM – audit, annual and company
24. Safety management certificate
25. International ballast management

CIC – Concentrated inspection campaign, conducted yearly 1/9 to 30 Nov

 Draw Air compressor, Reasons too long to fill,
bumping clearance and effect.

a) Reasons taking too long to fill up.

• Unloader leaking
• Bottle drain valve or relief valve leaking
• Air consumption increase due to some valve kept open, someone using
air continuously, air leakage on pipe/ flange.

Factors affecting volumetric efficiency,

• Bumping clearance increase

• Suction & discharge valves sticky, leaky
• Blow by of gas from piston side, liner wear
 • Low cooling water due to clog intercooler
• High temperature of suction air
• Less air intake due to dirty air filter
• Suction valve spring too strong

b) What is bumping clearance? What happens if bumping clearance too

much or too little.

1) Bumping clearance is to accommodate thermal expansion and to avoid

piston hitting the cylinder cover head.
2) A clearance is given between piston head and cylinder head at piston TDC
3) Bumping clearance should be as small possible, high clearance reduce
volumetric efficiency
4) Low clearance will result in mechanical fault
5) Bumping clearance to be checked and measured every major overhaul
6) Bumping clearance normally 6% of swept volume
7) Bumping clearance affect by thickness of gasket and bearing wear,
 Sulzur pump draw and explain

1. A plain plunger reciprocates in a barrel.

2. As the plunger moves up and down, two pivoted levers operate push
rods which open the suction and spill valves.
3. When the cam follower is on the base circle of the cam, the suction
valve is open and the spill valve is closed.
4. As the plunger moves up the barrel, the suction push rod moves
downwards and the suction valve closes.
5. Injection then commences and fuel is delivered via a non-return valve
to the injectors.
6. As the plunger continues upwards so the spill push rod will open the
spill valve, the pressure above the plunger will fall and injection will
cease.
 7. The quantity of fuel delivered can be controlled by altering the position
of the eccentric pivot for the spill valve operating lever. This will cause
the spill valve to open earlier or later.
8. By altering the position of the suction valve pivot, the start of injection
can be similarly controlled, and therefore it can be seen that the pump
utilizes VIT.

Checking timing

! Turn engine to ahead direction, pump plunger at TDC

! Fit dial gauge to suction, set to zero
! Turn engine in astern until pump roller at cam base
! Fit dial gauge to plunger and spill, set to 0
! Turn engine ahead until suction reads 0.02 mm
! At the point suction valve is closing, fuel delivery start
! Note crankangle degree, plunger dial reading (a)
! Turn ahead until spill read 0.02 mm (b)
! Indicate spill valve opening, fuel delivery stop
! Effective stroke (b-a)

Man B&W draw and explain

1) The pump is basically a jerk type with a plunger moving in a matched
barrel

2) Helical grooves machined in the plunger to control the end of injection

by uncovering spill ports and causing the discharge pressure to drop
rapidly, thus causing the needle valve in the injector to close.
 3) Oil is supplied to the barrel via the spill ports and a suction valve.

4) The suction valve, situated at the top of the barrel opens during
downward stroke of plunger, while spill ports are covered by plunger.

5) Replaceable erosion plugs are fitted in the pump housing opposite the
spill ports.

6) The high pressure oil, spilling back, as the edge of the helix uncovers
the spill ports at the end of injection, hit the plugs, which prevent
damage to the pump casing

7) A puncture valve is fitted in the top cover of the pump. It is opened

when compressed air from the control air system acts on top of a
piston fitted in the top cover. Fuel oil from the discharge side is then
returned to the suction side of the pump and no injection takes place.

How to check timing

Optical method

1. Set fuel rack to maximum

2. Open spill plug of pump and clean thoroughly
3. Turn engine 20 degree before TDC
4. Ensure no oil, put light on suction
5. Wear goggle, look through spill port
6. Turn until TDC
7. When light disappear, indicate start of injection

Oil overflow method

1. Stop fuel pump,

2. Fuel rack to max
3. Take out delivery pipe, puncture suction valve,
4. Turn to BDC, put DO, oil will flow out,
5. Turn towards TDC, flow will stop, record start of injection
6. Continue until overflow again, indicate end of injection
Fuel pump Cam Ledad, and how to Cut out Fuel
Checking of fuel pump lead, number of mm , top of plunger lifted above spill
ports when in TDC

Cam lead is the number of mm plunger is lifted from bottom position when
plunger at TDC

Lead of fuel pump is defined as

Planning and preparation

1. Inform master about job and instruct to person involve

2. Go through instruction Manual
3. Check measuring tools
4. Risk assessment carried out, get work permit
5. Immobilization obtain
6. Stop engine. Shut starting air valve and drain the system
7. Open indicating cocks, get propeller clearance and engage T/G
8. Turn engine with lubrication on for 20 minutes
9. Stop LO pump, FO supply pump and FO circuiting pump
10. Shut FO inlet and outlet vlv.
11. Shut FO heater valve,
12. Drain off fuel carefully
13. Ensure personal safety
14. Disconnect puncture valve
15. Disconnect suction valve

Procedure

! FO rack max, VIT rack “zero”

! Reverse mechanism in ahead position
! Take out erosion plug both side
! Set the measuring tool
! Turn the engine in ahead direction until plunger cover spill port, take
measurement “K”
! Compare reading with maker data
! If not correct, may be tool not seated properly. Clean top of plunger
and set again
! When K match, turn unit to TDC and note value. This is “A” value,
pump lead!
 ! Turn the engine in ahead direction until fuel pump roller is at lowest
part of cam
! Push down the gauge, take reading. This is “b” value
! A-b= C, is the cam lead!
! Confirm pump lead and cam lead with maker data

Cutting off the fuel for B&W

The steps are:

1. Operating the Puncture Valve

2. Lift the Fuel Pump Roller.

3. Shut Fuel Oil Inlet Valve (Only for Maintenance purpose – Not During
Running).

Manual actuation of Fuel Pump Lifting Device (148) activates Cylinder 149,
which lifts & locks the Fuel Pump Roller, so that there is a gap (approx. 2 mm)
between the roller and cam.

Cutting of fuel for Sulzer

! Lift fuel pump plunger by manual handle,

! Close the inlet and outlet fuel valve.

 Exhaust valve, overhaul procedure and
inspection details. Check operation of air piston
with external air supply, ( effect of above checks
if not corrected)

Overhaul procedure
1. Conduct a tool box meeting, risk assessment to be done
 2. Make sure proper tools and spares are present. Hydraulic jacks in good
working order.
3. Read the instructional manual carefully.
4. Wear proper PPE
5. Isolate the unit,
6. Drain the cooling water, isolate the exhaust air spring supply,
7. Drain the hydraulic oil, remove the hydraulic pipes.
8. Remove necessary connections, exhaust bellow,
9. Open the hydraulic nuts using hydraulic jack,
10. After removed, place valve on wooden platform
11. Remove the oil cylinder,
12. Release the air from non-return valve of air spring
13. Remove cot ring of spindle remove after tapping down the piston
14. Fit the oil cylinder, and hoist the cylinder to remove the valve spindle
15. Bottom housing remove, remove lock nut
16. Fit lifting tool to piston from air cylinder
17. Fit 2 eye bolts to air cylinder then remove
18. Remove the guide bush

Maintenance aspects:

Exhaust valve stem:

• Inspect the valve cone and its bottom surface using template
• Examine the valve seating area by means of dye-check for any crack
• Check the contact condition of valve stem with valve seat
• Inspect the valve stem for any scratch or any scoring marks
• Inspect the stem tips for any damage

Valve seat:

• Inspect the condition of seat and measure any abnormality by means of

a template
• Inspect for any sign of cracks by means of dye check
• Examine the hot corrosion, burning or pitting

Guide bush:

• Inspect bushing for wear

• Measure the clearance of valve guide bush
• Guide bush clearance must be within limit to avoid overheating

Valve cage:
 • Inspect the valve case for decreasing the thickness due to corrosion
• Inspect and carry out pressure test for cooling water side

Oil cylinder:

• Inspect and check measurement of the bore of the cylinder

• check the wear of the piston ring
• Check the function of damper piston

Air cylinder:

• Check the running surface for wear or possible swing

• Check the piston and rod sealing ring for wear
• Inspect each and every component so that all worn and damaged parts
can be identified and replaced or reconditioned

Hull protection of all kind, Hull painting.

Sacrificial Anodic Protection
1. Sacrificial anodes work on the principle of electrolysis,
2. an anode and a metallic strip are dipped in electrolytic solution,
3. Anode electron will dissolve and deposit over the metallic strip and
make it a cathode.
4. Seawater acts as an electrolyte and transfers the electrons from the
anode to the steel plate and making a protecting layer.
5. If the metal is more active it will be easily oxidized and will protect the
metallic compound by making it act as cathode
6. The anode will corrode first sacrificing itself for the other compound and
it is thus called sacrificial anode
7. Active means more electrochemical potential. ( magnesium, aluminium
and zinc)

Impressed Current Catholic Protection

1. Parts to be protected are made cathodic,

2. The anode does not corrode as electric is not generated by it but
impressed on it
3. The electric current is supplied from ship supply and converted to low
dc voltage
 4. Current is impressed on anodes to reduce the potential difference
between hull and anode. Hence no chemical reaction
5. Reference cell control the amount of current,
6. If too low, corrosion takes place
7. If too much will damage paint and protective coatings

Hull painting

1. International Convention of Anti fouling system to ban the use of

harmful substance in anti-fouling paints used on ship hull.

2. Anti-fouling paints are used to coat bottom of ship to prevent sea life
from attaching themselves to hull, which slowing the ship increasing the
fuel consumption

3. Anti-fouling system is coating, paint, surface treatment, device used on

ship to prevent fouling

4. In the past, metallic compound are used which affect marine life. In the
past anti-fouling paint contain TBT, causes harm to marine life,

5. Todays technology anti-fouling paint, do not contain TBT, provide

slippery surface preventing fouling and making easier to clean.

6. Also self eroding paint which uses weaker biocide, self eroding paint get
eroded slowly, and biocide acts as toxin for marine growth.

Class Society, different RO approve by singapore

1. ABS- American Bureau of Shipping(AB) – USA
2. BV- Bureau Veritas(BV) – France
3. DNV- Det Norske Veritas(NV)- Norway
4. GL- Germanischer Lloyd (GL) – Germany
5. LRS – Lloyds Register of Shipping (LR) – UK
6. NKK – Nippon Kaiji Kyokai (NK) – Japan
7. RIN – Registro Italiano Navale(RI) - Italy
8. KR – Korean Register of shipping - Korea
9. CCS – China Classification Society – China
10. RS – Russian Register of Shipping – Russia

IACS have 12 members, Singapore no accept india and Croatia.

Reverse power relay

! The reverse power relay is prevents power from flowing in the reverse
direction.
! The relay is used in installations where a generator runs in parallel with
another generator
! To prevent power from the bus bar or another generator from flowing back
to the active generator when its output fails.
! If generator voltage falls, it quickly disconnects the generator coil to avoid
power from flowing into the stator coil.
! When the prime mover fails, the generator stops producing power and may
instead start drawing power from the other parallel sources and start
motoring. The reverse power relay senses any reverse direction of power
flow and disconnects the generator to avoid any possible damage.

Reverse power relay Construction and operation

! The relay is made of a lightweight non-magnetic aluminum disc, mounted
on a spindle which has low friction bearings, is positioned in a gap
between two electromagnets.
! The upper electromagnet has a voltage coil connected through a
transformer between one phase and an artificial neutral of the generator
output.
! The lower electromagnet has a current coil also supplied from the same
phase through a transformer.
! The voltage coil is designed to have high inductance so that the current in
the coil lags voltage by about 90°.
! The two magnetic fields which are out of phase, produces eddy current in
the aluminum disc, and this creates a torque that tries to rotate the disc.
! Under normal condition when power is flowing as expected, the trip
contacts of the relay are open, and the disc is against a stop. If a reverse
power starts to flow, the disc rotates in the opposite direction, moves away
from the stop and towards the trip contacts that activates the trip circuit.
Overhead crane Draw and explain safeties
and checks
1) Daily checks

• Check the lubrication

• Check the noise level by operating the crane without load
• Check the heat generation
• Check all the limits and trips are working properly
• Check the contact areas of electrical equipment
• Check the brake operation
• Check condition of clamp in the hook

2) PMS

• Overhauling of motor
• Greasing of wires
• Renewal of wire ropes
• Annual survey
• Load test

1. Grease: Wire ropes, rollers, plain bearings are applied with grease for smooth
working.
2. Oil: Lube oil is used for lubrication of ball bearing and roller bearing of hoisting
and slewing gears. Check the oil level regularly and replenish once the level is
below the mark.
3. Inspect the wire rope for twisting, any unstable, any fracture
4. Inspect The Gears: for any noise, damage on teeth
 5. Check Condition Of Sheave/pulley
6. Hook condition
Brake condition: The engine room crane is equipped with electromagnetic brake with
fail-safe arrangement. This is the most important safety arrangement provided in the
crane.

Air circuit breaker

! Air Circuit Breaker (ACB) is used to provide Over-current and short-circuit
protection.

! Air as an arc extinguishing medium.

Air Circuit Breaker Working

! The main contacts are kept closed and latched against high spring force.

! Quick acting tripping action is provided by releasing spring.

! Cooling and splitting of arc is done by arc chutes. Arcing contacts close
earlier and open later than main contacts.

! Closing coil is provided to close circuit breaker. This coil operates on d.c
power from rectifiers and is energized by a closing relay operated by a
push button.

! The no voltage coil trips the circuit breaker when severe voltage drop
occurs. It also prevent circuit breaker from being closed when generator
voltage is very low or absent.
c) The three faults that may occur in the AC system:

I． Over current

II．Reverse power

III．Under voltage release

d) The ACB over current trip, reverse power trip and contactor under voltage
trip coil and no push button are connected in parallel to each other. In case of
reverse power or over current fault, trip contacts will be closed and cause
current to flow through the contact instead of under voltage coil.

Hence, the coil will be de-energized and close to open the main contacts and
trip the ACB.
 Ram steering gear sketch flow chart, follow up
system
Steering wheel – telemotor transmitter and telemotor receiver – floating level -
hunting rod – tiller1
Follow up system, hunting gear

In this mode, the rudder follows the wheel. If the rudder is put 10° to Starboard,
the rudder will follow to 10° to Stbd and remain there as long as wheel is kept
to 10° to Stbd.

• To bring the rudder to ‘Midship’, the wheel will have to be brought

to ‘Midship’.
• This mode is followed in the following methods of steering
• The hand steering mode in which the steering wheel sets the
rudder angle,
• Auto-steering mode in which the wheel order is automatically
generated depending upon the difference between the ordered
course and the actual course

Non follow up system

 • This mode of steering is not done with a steering wheel but with a NFU
Lever.
• The NFU lever does not have any markings. As long as it is kept
pressed, the rudder will continue turning and stop the moment the
lever is released.
• This mode is used when ships telemotor system fails. In that case, the
NFU lever sends rudder setting directly to the Control Unit.
• To return the rudder to the midship, the NFU lever will have to be
pressed to the opposite side of the initial movement and kept pressed
till the rudder is amidship.

Steering gear regulation

1. Main steering and rudder stock of adequate strength and capable to
steer the ship at max speed
2. Capable to turn rudder from 35° to 35° either side, from 35° to 30° in not
more than 28 sec at deepest draught at max speed
3. Aux steering able to put from 15° to 15° on either side not more than 60
sec at deepest draught and at ½ speed
4. Failure of 1 will not cause the other
5. All components to be of reliable construction
6. Design piping and construction at least 1.25x max working pressure
7. Setting of relief valve not more than design pressure
8. Main and aux arrange to restart automatically after power failure
 9. Aux steering need not be fix if main consist of 2 or more identical
power unit
10. Single failure in piping or 1 of power unit, defect can be isolated, and
steering capability maintained
11. Steering gear control provided on both bridge and steering
compartment
12. Steering gear operated on bridge ( if elective own electrical circuit )
13. Have means provided in steering gear compartment to disconnect
control system from bridge
14. System can operate from bridge
15. Short circuit protection for steering gear control supply circuit
16. Electrical circuit and control system are separated as far from cables
and pipes
17. Means of communication provided between bridge and steering gear
compartment
18. Rudder angle indication independent of control system, indicated on
bridge and steering gear
19. Hydraulic powered steering gear provided arrangement to maintain
cleanliness of hydraulic fluid
20. Low level alarm at each fluid reservoir to ECR, bridge
21. Fix storage tank with gauge, have sufficient capacity for 1 full charge
22. Steering gear compartment shall be readily accessible, separate from
machinery space, provided with rails and non-slip surface in case of
leakage
23. Rudder stock 0.23m diameter, alternate power supply provided in
45sec, supply at least of 30 minute continuous for 10,000 GT, else 10
minute below 10,000 GT
24. Every tanker, 10,000 GT above, main steering got 2 identical unit,
single failure, steering regained in 45sec.
25. Interconnection of hydraulic power system, loss of hydraulic fluid
capable of detection and defective system isolated
26. Means of indicating power unit if running are installed at ER and bridge
27. Power unit have connection to emergency
28. Within 12 hours before departure, checking of steering gear system,
and communication
29. Emergency steering at least in 3 months

Problems with steering gear

Sluggish operation
Hydraulic system

! Filter dirty
! Relief valve leak
! Ram gland leak
! Air in system
! Oil level low
! Oil temperature high

Pump

1) Air lock
2) Single phasing
3) Piston / cylinder wear

Mechanical problem
1) Rudder seized
2) Water ingress in rudder due to crack
3) Rudder damage
4) Pintle bearing damage
5) Rudder carrier bearing damage

Control feedback
1) Linkage loose/ slack link/ loose nut
2) Spring of feedback system failure
3) Controller not tuned properly
4) Pin worn out

Erratic operation

1) Loose linkages
2) Solenoid valve block not working
3) Telemotor pump faulty
4) Electrical contact face problem

Emergency steering procedure to Junior

1) Remote control operation may fail to work and their can be a sudden
loss of steering control from the bridge.

2) This can be due to sudden power failure, any electrical fault in the
system or the control system which includes faulty tele-motor which is
used for transferring the signal from bridge to the steering unit.
3) To have control the steering of the ship at such emergency situation
with manual measure from within the steering gear room, an emergency
steering system is used.

Action in case of Steering Gear Failure:

1. If on Auto-Steering, the first action is to change over to manual.
2. Speed to slow down, proper communication
3. The 1st suspect is ‘Telemotor failure’.
4. Switch over to other Telemotor ‘System’ (Marked as System 1 / 2).
5. If that still does not solve the problem, the next suspect is the
Steering Motor.
6. Change from Steering Motor 1 to Steering Motor 2.
7. It that still does not solve the problem, next suspect is failure of
both telemotor system.
8. Turn the mode selection switch to NFU (non-follow up steering)
9. Even if this does not work, it means that all means from steering
from the bridge have failed and the last resort of Emergency
steering from the Steering gear compartment has to be resorted
to.
10. After each corrective step, the rudder would have to be tried out.
Before doing it, pay heed to traffic around to avoid any Closed
Quarter’ situation.
11. If in restricted waters with traffic around, if steering is not restored
immediately,
12. Inform ships around through safety message
13. The procedure and diagram for operating emergency steering
should be displayed in steering gear room and bridge.
14. A hydraulic motor is given a supply from the emergency generator
directly through emergency switch board (SOLAS regulation). It
should also be displayed in the steering room.
 15. Ensure a clear communication for emergency operation via VHF or
ships telephone system.
16. Normally a switch is given in the power supply panel of steering
gear for tele motor; switch off the supply from the panel.
17. Change the mode of operation by selecting the switch for the
motor which is supplied emergency power.
18. There is a safety pin at the manual operation helms wheel so that
during normal operation the manual operation always remains in
cut-off mode. Remove that pin.
19. Emergency steering gear system is operated by (solenoid button)
whether port or starboard

Details of drills and their periodicity is strictly laid down in ships training
manual.
Drills are carried out regularly and recorded correctly as per the ISM
procedures.

Fuel injectors changing procedure

! Risk accessment
! Ensure generator had stopped, fuel system isolated
! Remove high pressure pipe, remove nuts that are hold the injector
! Use the injector puller tool to extract injector
! Remove the fuel injector from unit, cover with cloth so nothing go
inside
! Do a pressure test first
! Remove according to manual, take all parts,
! Keep nozzle properly
! Put all in clean diesel and remove carbon
! Lapping of needle and nozzle sealing face as per requirement
! Assemble all part and pressure test
 Boiler Safety Valve Sketch, setting and
Testing. Label all parts and materials

Setting
1) Safety valve to be overhauled and reset at every survey
2) At least 2 pressure gauge required
 3) Loosen lock nut, screw down the compression screw few more turns
then previous setting. Measure the height make marking
4) With all mounting in place, shut the main steam stop valve.
5) Fire the boiler on auto
6) Once boiler auto cut off, switch to manual. Rise the boiler manually till
require set pressure
7) At this setting, unscrew the compression till safety valve lift
8) Fire the boiler continuously and check the safety valve lift at set
pressure
9) Stop the boiler and check safety valve sit firmly at seating and no
leakage
10) Safety valve now has been adjusted, tighten lock nut. This valve then
had to be gagged
11) Set the other safety valve in same procedure
12) Remove the gagging tool.
13) Lift the safety valve with easing gear and confirm it sit firmly and no
leakage.

Boiler survey
Conducted every 2.5 years, twice in 5 years
Planning
1. Planning to be done and discuss with technical super.
2. Risk assessment to be done
3. Permit to work obtain
4. Check for necessary tools and spares
5. Check manual for special instruction and check past records
6. Next port steam consumption obtain
7. Personal involve to be briefed

Shutting down for survey

• Inform duty officer
• Change over M/E, A/E and boiler to DO
• Top up do service tank, stop all purifier.
• Stop tank heating and steam tracing
• Changeover boiler from auto to manual.
• Stop the boiler and purge for 3-5min
 • Switch off power on panel and switch off circuit breaker for HFO pump
and feed water pump
• Posted ‘do not start’ sign
• Shut main steam stop valve and shut fuel valve and feed water valve
• Let the boiler cool down
• When boiler pressure ~ 4 bar, carry out blow down
• When boiler pressure ~ 2 bar. Open vent
• Let the boiler cool down
• When sufficiently cooled at atmospheric pressure, open top manhole
door with all safety precaution.
• Knock gently as may contain hot water/ steam
• When nothing coming out, open manhole with support of rope
• Open bottom hand hole door
• Ventilate for few hours.

Prepare for entry

1. Wear proper PPE like safety shoes, helmet , hand gloves

2. Enclose space entry permit to be obtain
3. Keep an inventory of tools taken inside
4. Keep one responsible engineer standby outside with clear emergency
orders
5. Keep emergency breathing apparatus standby
6. Ensure proper lighting of ventilation
7. Carry a gas detector, manually calibrate it in open atmospheric
condition
8. Ensure proper communication

Boiler inspection
1. Shell, tube plate and tubes
a. Check for deformation, corrosion, wastage
b. Check inlet tube end for corrosion
c. Region in way of water level inspected for cavitation pitting
d. Weld crack across valve opening
e. Wastage in way of manhole flange

2. Furnace
a. Check for distortion, cracks due to overheating, flame
impingement
b. Check condition of refectory
 c. Check furnace bottom free of oil deposits

3. Boiler mountings
a. Boiler mounting and safety valve examine at each
survey and open if needed by surveyor
b. Proper operation of safety valve confirmed each
survey
c. Boiler safety valve easing gear examine and tested
4. Foundation
a. Boiler supports, bolting, secure arrangement examine
for corrosion, rusting

Hydraulic test
1) To be carried out on high stress part
2) Major tube renewal has been done
3) Shell plating renewal
4) Usually maximum allowable working pressure 1.5 times
5) Can be requested at discretion of surveyor

External inspection
Upon completion of internal survey, boiler to be examine under steam
Alarm test carried out, water level high, low and low low, force draft fan and
flame failure
Manual emergency shut down tested, test with local emergency stop
function

Boiler Flash up procedure

1. internal surface to be clean and no tools and rags left inside
2. All openings of mountings cleaned properly
3. Mountings to be fixed back with new gaskets
4. Manhole, hand hole , furnace are closed
5. Ensure vent, alarms and pressure gauge connection valves are open
6. Ensure all drain valves are shut
7. Switch on power on boiler panel and put all circuit breaker to normal
8. Open fuel valve and feed water valve and start pump
9. Ensure all system running ok
10. Start filling boiler with water just below normal level as level will swell up
when boiler fired
11. Fire the boiler at lowest possible rate
12. Continue fire intermittently. 1min fire- 10 min stop. After 1st hour, 2min fire-
10 minute stop
13. When steam comes out vent, shut vent
14. Carry out gauge glass blow down
15. Check boiler for abnormalities
16. Adjust safety valve pressure setting
17. Slowly crack open main steam stop valve and open full
18. With boiler running, check all safety alarm.

Boiler combustion controller. ACC

1. Combustion control system correct the proportion the quantities of air
and fuel being burnt.
2. Ensure complete combustion
3. The system measure the flow rates of fuel oil and air in order to
correctly regulate their proportions.
4. Two control elements are used, 'steam flow' and 'steam pressure'.
5. The steam pressure signal is fed to a controller and is compared with
the desired value.
6. Any deviation results in a signal.
7. A high or low signal selector is present to ensure that when a load
change occurs the combustion air flow is always in excess of the fuel
requirements.
8. This prevents poor combustion and black smoke
9. If the master signal is for an increase in steam flow, then when it is fed
to the low signal selector it is blocked since it is the higher input value.
10. When the master signal is input to the high signal selector it passes
through as the higher input.
11. This master signal now acts as a variable desired value for the
combustion air and brings about an increased air flow.
12. When the increased air flow is established, its measured value is now
the higher input to the low signal selector.
13. The master signal will now pass through to bring about the increased
fuel supply to the boiler via the fuel supply sub-loop.
14. The air supply for an increase in load is therefore established before
the increase in fuel supply occurs.
b) ‘Fail-safe’ conditions are ensured by shutting off fuel oil to burners under certain
fault conditions relating to loss of power supplies arising in the ACC.

They are ensured as follows:

 Stern tube, how to fix leakage when ship is
sailing, how to change seal insitu
To fully prevent oil leakage. #3s added as spare ring
In case of leakage, #3s seal ring is put into operation by close the line valve for
#3, #3s will activate

In case of all seal failure,

1. Adjust LO pressure of stern tube to equal or higher then sea water pressure
by changing the gravity tank position. If seawater leaking in
2. If 3 & 3S both damage, stern tube oil pressure can be lowered by adjusting
tank position using temporary oil tank. If oil leaking out.

Changing seal in situ without going to drydock

1. Vessel trimmed forward until propeller shaft above water

2. Staging is rigged below shaft to carry job, staging rigged
3. Propeller rope guard remove and habitat set up around the
arrangement
4. Water pumped out from enclosure
5. Isolate and drain the system
6. Service Engineer carry out job
 7. Loosen the bolt holding cover ring, intermediate ring
8. Special bonding compound used to join 2 ends of new seal ring
9. Reassemble seal ring, intermediate ring, cover ring.
10. Restore lub oil system

Draw and explain Starting air Valve. Its

material and maintenance. If no maintenance
what happen

• Materials

1. The body of the valve could be of mild steel, the spindle of high tensile
or stainless steel, and the valve and seat could have the contact faces
stellited or hardened.

What happen if no maintenance?

2. The main cause of starting airline explosion

3. the oil which is discharged from the air compressor to starting airline
system
4. It will deposit as a thin moist film on the internal surface of the pipes but
not ready to combustion.
5. If starting air valve leaky hot gas or flame may enter the starting air
manifold, and cause starting airline explosion
Lub oil properties of ME & AE, air compressor
oil, purifier oil and cylinder oil.
Oil is selected to improve the engine operation and reduce the wear down rate
and hence the maintenance cost of the machine.

Alkalinity

• When fuel burns, the fumes carry sulphuric acid which can cause acidic
corrosion. Four stroke engines, the main lube oil is responsible
for piston and liner lubrication; alkalinity of lube oil is important for
controlling acidic corrosion.

• For two stroke engines, separate grade of lube oil is used as cylinder oil
and its alkalinity depends on the engine fuel grade

Oxidation resistant

! Lube oil is always in contact with air and thus oxygen presence in oil is
inevitable.

! Oxygen causes sludge formation, acid production and bearing

corrosion..

! Load carrying capacity

! The load subjected to engine parts are high;

! Enough to withstand the pressure inside the engine.

! If not oil will be forced out and metal to metal contact result in wearing
down of the machine.

Thermal conductivity

! engine are always in movement producing heat energy.

! This heat energy has to be carried away or else it might lead to wear
down due to thermal stresses

! good thermal conductivity cool down the parts

Detergency
 ! Additives are added which will prevent the buildup of small deposits in
the metal surface.

! in two stroke engine, the cylinder oil detergency is very important as it

removes the deposits from the ring pack area and keeps the
combustion space as clean as possible

Dispersancy

! Impurities to mix up with itself and keeps them suspended on the

surface.

! This makes it easy for the separator or clarifier to remove it from the
oil.

High Flash Point

! The flash point should always be on the higher side so that in case of
increase in temperature of the oil, fire hazard can be avoided.

! Normally for marine engine lube oils, the flash point is always higher
than 220 ̊ C.

Low Demulsification Number

! The low demulsification number of the oil helps in easy separation of

water from the oil

What are the difference in Cylinder oil and System oil?

! Cylinder oil is detergent oil, with higher alkalinity.

! System oil is straight mineral oil

Air-compressor oil is usually a synthetic oil that does not contain detergents
commonly found in engine oil.

Air-compressor oil is manufactured specifically for use in lubricating the ball

bearings inside air compressor.

How to take LO sample

Explain Sampling Procedure of lube oil?

" Draw samples from a connection that comes directly out of the main oil
supply line to the engine.
" Always sample for the same point.
" Sample only when the oil is up to its operating temperature with the engine
running.
" Depending upon the draw off point, sufficient amount of oil should be
drained out of the line prior to drawing the sample.
" The sample should be filled into a chemically cleaned container after it is
rinsed with sample oil and immediately closed.
" The container should be attached with a label as follows:

Records for Sample

1. Date of sample drawn
2. Point of sample drawn
3. Type of oil
4. Type of machinery use
5. Temperature of sample drawn
6. The period of time since the last renewal of oils.

SOPEP

What is Ship Oil Pollution Emergency Plan (SOPEP)?

When an oil spill occurs at sea, it tends to spread over the surface of
the sea water, leaving a deadly impact on marine mammals, birds, the
shoreline, and most importantly the ocean and the environment.
The cost to clean up an oil spill depends on the quantity and quality of
oil discharged in the sea and is calculated on the basis of factors such
as legal claims, money paid as penalties, loss of oil, repairs and
cleanups, and the most important – loss of marine life and the effects
on human health which cannot be measured against any amount.
As prevention is better than cure, in order to avoid the above
mentioned monitory losses and primarily to avoid marine pollution and
losses of marine species, a prevention plan is carried on board by
almost all cruise and cargo vessels. This plan is known as SOPEP or
ship oil pollution emergency plan.

Understanding SOPEP
SOPEP stands for Ship oil pollution emergency plan and as per the
MARPOL 73/78 requirement under Annex I, an oil tanker 150 GT and
all ships with 400 GT and above must carry an oil prevention plan as
per the norms and guidelines laid down by International Maritime
Organization under MEPC (Marine Environmental Protection
Committee) act.

Master of the ship is the overall in charge of the SOPEP, along with
the chief officer as subordinate in charge for implementation of
SOPEP on board. SOPEP also describes the plan for the master,
officer and the crew of the ship regarding ways to tackle various oil
spill scenarios that can occur on a ship. For oil tankers, action plan
differs according to the cargo handling and cargo tanks containing
huge quantities of oil.

The essential SOPEP requirements for a ship are:

1. The Ship Oil Pollution Emergency Plan must be written following

the provisions of regulation 37 of Annex I of MARPOL

2. The approved plan guides the Master and officers on board the ship
concerning the steps to be taken when an oil pollution incident has
occurred or a ship is at risk of one.

3. It is a requirement under MEPC circular no. 256 that the SOPEP

contains all the information and operational instructions related to the
emergency procedure and SOPEP equipment provided in the SOPEP
kit.

4. The plan must contain important telephone, telex numbers, names

etc., of all the important contacts to be contacted in the event of an oil
pollution

5. A recognised authority has approved the SOPEP, and there are no

changes or revisions made without the prior approval of the
Administration.

6. If there are any changes in the plan which is non-mandatory, it

generally does not require approval from the administration. The
owner and ship manager must update the appendices about the
non-mandatory changes done in the plan

Contents of SOPEP

SOPEP contains the following things:

• The action plan contains the duty of each crew member at the
time of the spill, including emergency muster and actions.
• SOPEP contains the general information about the ship and
the owner of the ship etc.
• Steps and procedure to contain the discharge of oil into the
sea using SOPEP equipment
• It contains the inventory of the SOPEP material provided for
pollution prevention such as an oil absorbent pads, sawdust
bags, booms etc.
• Onboard reporting procedure and requirement in case of an oil
spill is described
• Authorities to contact and reporting requirements in case of an
oil spill are listed in SOPEP. Authorities like port state control,
oil clean up team etc are to be notified
• SOPEP includes drawing of various fuel lines, along with other
oil lines on board vessel with the positioning of vents, save all
trays etc.
• The general arrangement of the ship is also listed in SOPEP,
which includes the location of all the oil tanks with capacity,
content etc.
• The location of the SOPEP locker and contents of the locker
with a list of inventory
• Guidance to keep the records of the pollution incident (for
liability, compensation and insurance purpose)
• Procedure to maintain the record as required by the authorities

Common SOPEP equipment include:

1. Oil boom
2. Oil spill dispersants.
3. Oil sweep
4. Absorbent materials
5. Oil sorbent socks
6. Absorbent roll
 7. Scoops
8. Absorbent granules
9. Shovels
10. Absorbent pads
11. Brooms
12. Mops
13. Empty receptacles (200 ltrs capacity)
14. Oil Truckpack
15. PVC protective gloves
16. IMO disposable bags
17. Non sparking hand pump (portable air driven pumps)
18. Screw driver
19. 7 barrel kits for USCG

The SOPEP locker must be stowed in an easily accessible locker, clearly

marked, and is to be brought on deck ready for immediate use, prior to
all bunkering operations.

The overview of general duties of ships’ crew under SOPEP:

MASTER: He/she is overall in charge of any incident related to the oil

spill and should informing the authorities about it. He/she needs to
ensure all crew members are complying with the plan and records are
maintained for the incident

Chief Engineer: He/she will be the in charge of the bunkering

operation and will instruct the subordinates to prepare SOPEP KIT
prior to any oil related operation (Sludge transfer, lube oil bunkering,
fuel oil bunkering etc.). Chief engineer should keep the Master
informed and updated on the situation, and the results from action
taken to limit oil outflow.

Chief Officer: He/she will be the in charge of complete deck

operation to prevent any oil spill or in the event of a spill, the Chief
officer must keep the master in the loop at all times and update the
situation and action taken to stop or reduce an oil outflow.
Deck Duty Officer: To Assist the chief officer in deck watch and alert
and inform Chief Officer/ Chief Engineer on any potential oil spill
situation.

Duty Engineer: To assist Chief Engineer for any oil transfer operation
which includes preparation of SOPEP material and readiness of
firefighting equipment.

Duty Rating(s): To assist and alert the duty officer and engineer for
detection of potential oil leakage and to immediately assist by all
possible means to restrict and clean an ongoing spill. He/she should
bring the additional SOPEP material to the location for preventing oil
from reaching the ship’s railing.

SOPEP does not only provide details for preventing and fighting an oil
spill, but it also acts similar to any other regulation of SOLAS as it also
has the details to save the ship and crew in the event of mishap such
as fire, collision, listing etc. and other related incident related to oil.

Bilge diagram.
1)Low vacuum- reasons are the filter is chocked,
2)High vacuum- pump worn out, leakage in pipes, filters,
Regulation 13 - Standard discharge connection

To enable pipes of reception facilities to be connected with the ship's

discharge pipeline for residues from machinery bilges and from sludge tanks,
both lines shall be fitted with a standard discharge connection in accordance
with the following table:

Standard dimensions of flanges for discharge connections

Description Dimension

Outside diameter 215 mm

Inner diameter According to pipe outside diameter

Bolt circle 183 mm

diameter

Slots in flange 6 holes 22 mm in diameter equidistantly placed on a bolt

circle of the above diameter, slotted to the flange
periphery. The slot width to be 22 mm

Flange thickness 20 mm

Bolts and nuts: 6, each of 20 mm in diameter and of suitable length

quantity, diameter

The flange is designed to accept pipes up to a maximum internal diameter of

125 mm and shall be of steel or other equivalent material having a flat face.
This flange, together with a gasket

Draw and explain both type of bedplate with

details, Cracks reason, checking and repair
Requirements of bedplate

1) Strength- able to withstand force without failure

2) Rigid- enough to support engine weight and maintain crankshaft
alignment, yet flexible to accommodate hog and sag of ship
3) Lightness- strength to weight ratio, less load on foundation, reduce cost
4) Toughness - measure of resilience and strength, withstand fatigue stress
5) Simple design- easy maintenance, saving cost
6) Access- ease of inspection and maintenance
7) Compact- giving room for engine room space
Bedplate consist of 2 longitudinal girders and many transverse girders.

Longitudinal gives longitudinal strength, transverse gives transverse strength

Longitudinal

• Double plate is more stiff but design more complicated, and difficult to
access holding down bolt.
• Single plate is popular with modern engine.

Transverse
 • Provide stiffness to withstand firing load without bending, which damage
the bearing pocket,
• Double plate give high strength and stiffness, hole In plate for inspection,
which is stiffen by tube to restore strength.

Bedplate material

- Prefabricated steel (light, easy to manufacture and repair but distortion

and cracks due to welding.
- Cast iron (good vibration damping, reduce cracks, but difficult repairs)
- Hybrid. ( mild steel for longitudinal, cast steel for transverse)

Causes of cracks

1) Excessive vibration
2) Slack tie bolts
3) Overloading due to bearing wear
4) Poor welding, stress relieving
5) Stress riser (concentration ) on weld

Repairs for mild/ cast steel

1) Cracks to be chipped and weld, not to distort welded part
2) Use ductile electrode which deposit close to parent metal

Repairs for cast iron

1) Stop the crack by drilling hole near crack
2) Metal lock

Non-destructive testing
Nondestructive testing (NDT) is the process of inspecting, testing, or
evaluating materials without destroying the serviceability of the part

Visual inspection inspect for high splatter, undercut, bad stop start point,
surface crack.

6) Surface inspection

• Magnetic particle
• Liquid penetrant

7) Internal inspection
1. Radiography
2. Ultrasonic

most frequently used test methods

1) Magnetic particle

• Testing magnetic fields to locate surface discontinuities in magnetic

materials.
• When the magnetic field encounters a discontinuity, the flux lines produce a
magnetic flux leakage
• Because magnetic flux lines don't travel well in air, magnetic particles are
applied to the surface of the part the particles will be drawn into the
discontinuity,
• Use of a Yoke to generate magnetic field

2) Liquid penetrant test

• Penetrant is applied to the surface of a part, it will penetrate into cracks.

• Once the excess penetrant is removed, the penetrant trapped in those
voids creating an indication.
• They can be seen in ambient light, or fluorescent, if use of fluorescent liquid
penetrant
• Consist of clean, penetrant and developer.

8) Radiographic method
• Exposing a test object to penetrating radiation so that the radiation
passes through the object being inspected and a recording medium
placed against the opposite side of that object.
• With both, the radiation passing through the test object. causing an end
effect of having darker areas where more radiation has passed through
the part and lighter areas where less radiation has penetrated.
• Use of xray or gamma ray
4) Ultrasonic method
• Ultra-high frequency sound is injected into the part being inspected and
if the sound hits a material with cracks, discontinuity
• Some of the sound will reflect back to the sending unit and can be
presented on a visual display.
• By knowing the speed of the sound through the part and the time
required for the sound to return to the sending unit, differences shows
place of crack.
 • Thus able to find likely area of discontinue by the darker area

High voltage system draw, How to carry out work

and Safeties. Tools, PPE. Isolation of High voltage
transformer? Why are the interlocks used for?
Work permit preparation for HV
PPE
must be of correct insulating class

1) electrically insulating safety helmet

2) insulating rubber gloves
must satisfy international IEC standards, subjected to
dielectrical, mechanical resistance and ageing test.to check if
easily broken
3) Insulating gloves
4) Pneumatic glove tester,
5) Insulating boots
6) Insulation mat
7) Face shield, safety glasses, arc protective hood

High voltage operation procedure

Electrical permit to work, earthing down, circuit earthing, and bus bar earthing.

Circuit earthing – feeder cable connected by earth connection to all 3

conductors. This is done at circuit breaker using a key, circuit breaker cannot
be on unless earth has been remove.

Bus bar earthing, when It is required to work on busbar, they must be isolated
from all possible electrical sources and earth using portable leads.

Follow high voltage check list.

DIE- disconnect, isolate, earthing

Earthing down to ensure any stored electrical energy stored is safely

discharged to earth

Electrical permit to work

1) To issue before start of work, to include description, declare

the isolation and earth down, ensure it is safe to work by
authorizing officer, permit to cancel after job.

2) in the switch room, check for the 6 items

a. danger sign at the front door
b. single line diagram, authorized
c. rubber mat covering entire length of switchboard
d. fire extinguisher mark C
e. first aid chart
 f. electrical installation license
g. key box
h. logbook

3) wear the correct PPE

4) separate the work area from source of power supply by
a. isolate
b. lockout & tag out

5) Check the absence of voltage (prove dead) at source and on site, on each
conductor involve. Using appropriate type of voltage detector which are
verified working.

a. all exposed conductor must be treated as live unless proven dead,

hence to be kept a distance.

6) apply short circuit and earth systems

a. discharge residual voltage

b. apply safety earthing leads

7) Show and warn others and limit of work area.

8) Issue permit to work to work in charge and paste notice against any
interference on equipment that you are working on.

9) where work is carried out on high voltage not under control of authorize
LEW, LEW to arrange a cert from the person having control of the electrical
supply

ISOLATION OF TRANSFORMER

1) get necessary approvals to work on system

2) open the circuit breaker in high voltage system
3) set the circuit breaker in HVS for isolated
4) use earth switch in HVS to ground cable
5) a key in ground switch panel will release
6) place warnings signs on the front on High voltage system
7) use key from HVS to access room transformer placed
8) make sure transformer not under voltage

use mobile grounding device to each phase of transformer

 Load line survey
Task of detecting whether the vessel is over-loaded and it’s freeboard,

It is basically an effort to make the hull watertight below the freeboard and
weather tight above it.

It is a administration requirement for ships

• 150 GT and above
• New ship of length 24m and above

It is calculated by classification to ensure ships

1) Floating stability
2) Reserve buoyancy ( volume of above waterplane to be watertight
increase buoyancy)
3) Freeboard
4) Amount of cargo loaded
5) Watertight integrity

Survey
Ship is subjected to
! Initial survey
! Periodical survey ( not exceed 5 years)
! Annual survey
Certificate
! International load line certificate
! Stability certificate,
! Inclining test certificate

Deck
Scuppers
• check for damage, corrosion, blockage,
• Check for sealing
Air vents
• Height of 0.76m from deck, 0.45m on superstructure deck
• Check for Vent head conditions, damage, corrosion
• Check for Proper flame screen
• Drip tray and plug condition

Fire plan
• Check location of all firefighting appliance according to fire plan

Gangway
• Check for Proper secure arrangement
• Ensure Proper operation
• Check for Good condition of rails and steps
• Check for damage, corrosion

Sounding pipe
• Check for damage, corrosion
• Check self-closing device working
• Check sealing of cap on sounding pipe

Body of hatch
• Check cover , cover gasket
• Check for Sealing gasket
• Securing, locking arrangement

Bosun store
• Check weather tight door for sealing gasket, hinges, securing, locking
arrangement, and watertight integrity.
Ship side
• Load line marking
• Tonnage marking
• Draught marking
• Check for major dents or deformation on ship hull

Accommodation
1) Bulkhead
• Check for Damage, corrosion, watertight integrity,

2) Watertight doors
• Check for Damage, corrosion
• Check Door sealing gasket
• Check Door hinge, door closing device

3) Ventilators
• Check for Damage corrosion
• Check for Gratings, flaps, condition and sealing arrangement
• Closing arrangements, butterfly nuts condition

4) Air con intake ducts

• Check for Damage and corrosion
• Check for Gratings, flaps and sealing arrangement
• Butterfly nuts condition and closing arrangement

5) Port holes
• Check for Sealing gasket, and butterfly nuts condition
• Check for Toughness of glass

Engine Room
 • Check guard rails, hand rails,
• Floor plates and stair case condition
1) E/R entrance door
• check for damage and corrosion
• must be well lighted, clear of obstruction
• check for sealing arrangement and watertight integrity
• door hinges condition, door closing arrangement ok

2) Sky light
• check for damage and corrosion
• check for sealing arrangement, watertight integrity
• door hinges condition, opening and closing arrangement

3) Funnel and blower flap

• Check for damage and corrosion
• Check gratings, flaps and closing arrangement

4) Emergency escape
• Check if well lighted and clear of all obstruction
• Check for safety harness with lifting arrangement

1) D.B tank, cofferdam

• Check Manhole door covers, stud and nuts condition
• Check sounding pipes, cap, and self closing arrangement

2) E/R bilge system

• Check for Bilge well condition
• Test for Bilge well high level alarm
• Emergency bilge suction operation
 3) Sea chest
• Check for corrosion and damage
• Check closing arrangement

4) SW pipes and pumps, overboard valve

• Check for damage, corrosion, leakages

5) Bulkhead
• Check for damage and corrosion

6) Steering gear room

# Check all doors and vents

Tailshaft survey
Scope of tail shaft survey
Propeller to be withdrawn for inspection
1) Visual inspection
2) Crack detection test
3) Check threads for damage
4) Check tapered cone for roughness
5) Scoring on liner
6) Check bearing face and white metal
7) Measurement of tailshaft external diameter to measure wear down.
8) Stern tube analysis report ( check for water,chloride,metal, oil ageing)
9) Seals to be check for condition and replace.

Poker gauge readings

1) Remove rope guard
 2) Remove check and drain plug
3) Turn shaft to 0 marking on chrome liner flange
4) Screw the wear down gauge at top and bottom and note readings
5) Measure same at every dry dock
6) Propeller must not be remove
7) All unit of ME to be in place.

Aux condenser Tubular Heat exchanger, what

material? Leakage identify, plug and
permanent repair, what precaution taken,
percentage allow to plug. Actions in case high
salinity?
Materials
1) Tube: low carbon steel, copper, copper-nickel, stainless steel,
2) Tube plate, same material as tube
3) Shell- carbon steel

Plugging temp repair

1) Identify and plug the leaky tube on both side
2) If leakage is at junction, expand tube using expander,
3) After plugging conduct pretest to confirm

Permanent repair

1. Identify defective tube and drill

2. Take out detective tube using extractor
3. Place a new tube in place
4. Roller expand tube on both side
5. Carry out pressure test, check for leakage

Tests are

1) Pressure test,
 Isolate all valve, remove seawater side, open the hot liquid side slowly,
put on recirculation, leakage can be been on dry surface.
2) Ultrasonic test,
Consist of microphone, with contact probe, gives a visual indication
read by meter
3) Florescent test,
4) Vacuum test, plugging 1 end with test tube, vacuum equipment, drop in
vacuum indicate lead.

Max allowable plug tube is 10%

Actions taken in case high salinity

1) Cascade tank salinity level must be test frequently for leaks

2) If detected a leak, Isolate the steam line, temporary stop the leak by
plugging.

Turbocharger sketch and explain L & M.

Turbocharger surging and how to minimize.
Sealing arrangements, Turbocharger
overhaul and survey. Purpose of shroud ring
L&M

K = It is the distance between the compressor end cover mounting face and
shaft end .Mark it as K.
Pull the rotor shaft towards the compressor side until the impeller comes in
contact with the insert and determine K2.
Impeller clearance L = K - K2

Thrust the rotor shaft towards the turbine side until the turbine disc and nozzle
ring comes in contact with each other and measure K1
Disc clearance M = K1 – K

The above measured clearance is very important as this will determine the
proper functioning of the labyrinth seal between the impeller and exhaust
shield and also the alignment of the shaft.
K
To ensure that rotating impeller does not to touch the stationary blower casing
cover in case of thrust bearing worn out.

Shroud ring
The area around the turbine is always in contact with highly corrosive exhaust
gases.
shroud ring protects the turbine inner casing, can be easily replaced.
Turbocharger surging
" It is the back flow of air from discharge to suction and it is characterized by
noise and vibration of turbocharger.

Causes of Turbocharger Surging

Causes of turbocharger surging

Exhaust System
! Uneven load
! ME load too high
! Exhaust valve defective
! Damage T/C flaps
Fuel
! Defective injector
! Defective suction valve
! Pressure too low, fuel Pump leaking, cir pump/supply pump pressure
low
! Air lock
Scavenge
! Air cooler dirty
! Scavenge port chock
! Too high Scavenge temp
! EGE dirty/fouled
Turbocharger
! Air filter dirty
! Nozzle ring dirty
! Silencer dirty
! Blower side dirty
! Turbine Side dirty
 ! Fans not running
! Load reduction too fast
! Bearing failure
! Heavy Weather
! Scavenge Fire
Action to be taken
! Inform bridge to reduce rpm
! Monitor all parameters
! Conduct Blower side waster washing
! Turbine side grit washing
! Change Air filter
! Check fuel system
! Reduce engine load

Differences between sleeve and roller bearing

Sleeve bearing advantages
! Cheap in design
! Indefinite life
! Not prone to vibration
! Load is disperse to the side
! Low running cost
Disadvantages
! Prone to oil contamination
! Poor performance at low load
! Sensitive to lub oil failure
! High friction at low load

Roller bearing
Advantages
! Low load good performance
 ! Low friction at low and high load
! Not affected by lub oil contamination
! Does not need special oil

Disadvantages
! High running cost
! More prone to damages
! Sensitive to vibration and fatigue

Actions in case surging

1) Inform bridge to slow down , reduce rom
2) Monitor all parameters
3) Conduct blower side water wash
4) Turbine side grit wash
5) Change air filter, check fuel system, reduce load

How is sealing achieve

1) The labyrinth seal on turbine side of turbocharger prevent gas
contaminating with bearing lub oil supply
2) The seals consist of series of fine turns opposite to the steps on casing
3) It provide a narrow space which exhaust gas leaks
4) As gas passes through, it is subjected to throttling, pressure energy
convert to kinetic energy.
5) Kinetic energy dissipate, as it passes down the gland
6) Sealing air is bled from compressor end to mid turbine gland which
expands in both direction.
Air tightness between diffuser ring casing and impeller back
1) Space between the casing and impeller back pressurized from impeller
discharge,
2) Air will attempt to access the exhaust gas passage,
3) Grooves machine behind regulate the leak.