File - 20211111 - 092748 - File - 20210131 - 143419 - Third Engineer Training Report

THIRD ENGINEER TRAINING
REPORT
ENGINE DEPARTMENT
M/V JAL KAMAL
MASTER: NGUYEN CAO CUONG

LEADER: C/E NGUYEN NGOC OANH
ENGINEER IN CHARGE: 3/E. DINH HUU TUAN
COMPILER: OILER. TRAN VAN NUI
1 Oiler Tran Van Nui

LETTER OF INTRODUCTION
Dear Chief Engineer of M/V JAL KAMAL:
My full name is TRAN VAN NUI, I am an Oiler on JAL KAMAL.

During I am working on the ship, under command of Chief Engineer, and help of Engineers. I
learned a lot of things about works and machineries.
Beside main duty of an oiler; keeping watch. I also take part in maintenance work, repair work
under supervision of Chief Engineer and Engineers.
I would like to become Third Engineer in the future. There for, I write this report to submit to
you for assessment. I mainly focus on operation works, maintenance works, repair works
about machineries which Third Engineer in charge of in this report.
There are shortcomings and mistakes in the report. I am very grateful if you can check and fix
them. Your help is powerful that help improving for knowledge, experience in my work.
Finally, I would like to thank for all the help and support I’ve received from all the members
of engine department.
Best regards,
Oiler: TRAN VAN NUI

Comment of Chief Engineer:
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CONTENTS
Duty of an oiler………………………………………..…………………............. …..……………….……………………………… P7

Duty of a third engineer…………………………………………………………………………………………….………………….. P9
Boiler………………………………………………………………………..………………………….……………………….…………….. P11
Inspection and maintenance plan…………………………………..…….………………….……………………………… P11
Alarm test………………………………………………………………………..……………………………………………………… P12
Miss fire alarm………………………………………………………………….……………………………………………… P12
Fan abnormal alarm………………………………………………………….……….…………………………………….. P12
Flame failure alarm………………………………………………………………………………………………………….. P12
Abnormal fire alarm…………………………………………………………………………….…………………………… P12
Fuel oil low pressure alarm………………………………………………………………….…………………………… P13
Fuel oil temperature low alarm………………………………………………………….……………………….……. P13
Fuel oil temperature high alarm…………………………………………….……………….………………………… P13
Exhaust gas temperature high alarm…………………………………………………….………………………….. P13
Low water level alarm……………………………………………………………………………………………………… P14
Low-low water level alarm……………………………………………………………….………………………………. P14
High water level alarm……………………………………………………………………………………..……………… P14
Boiler water analysis………………………………………………………………………………………………………….……. P15
Purpose of water treatment…………………………………………………………………………………………….. P15
Sampling boiler water for analysis……………………………………………………………………………………. P15
Adding chemical for boiler water treatment…………………………….………………………………………. P15
Operation procedure………………………………………………………………………………………………………………. P18
Preparation before operation…………………………………………………………………………………….……. P18
Operation………………………………………………………………………………………………………………………… P19
Inspection and maintenance……………………………………………………………………………………………. P21
Cleaning of burner…………………………………………………………………………………………………..……. P21
Cleaning of strainer………………………………………………………………………………………………….…… P21
Inspection of fan…………………………………………………………………………………………………………… P22
Cleaning of water level gauge…………………………………………………………………………………..…… P22
Cleaning of water detecting rod……………………………………………………………………………………. P23
Surface blow off and bottom blow down………………………………………………………………..…….. P23
High pressure air soot blower…………………………………………………………………………………..…… P24
Cleaning of condenser and inspection of corrosion bar…………………………………………………. P25
Soot cleaning for furnace………………….……………………………………………………………………..….. P26
Soot cleaning for water tubes on main engine exhaust gas side…………………………………… P26
Analysis of trouble shooting……………………………………………………………………………………………. P27
Sewage treatment plant……………………………………………………………………………………………………………… P30
Working principle of sewage treatment plant………………………………………………………………………… P30
Inspection and maintenance plan……………………………………………………………………………………..……. P30
Safety instruction……………………………………………………………………………………………………………………. P31
Operation procedure…………………………………………………………………………….………………………………… P31
Inspection and maintenance…………………………………………………………………..……………………….……… P32
Blower maintenance……………………………………………………………………………………………………….. P32
Inspection of V-belt tension…………………………………………………………………………………………….. P33
Cleaning of bio-filter tank screen……………………………………………………………………………….…….. P33
Back washing and sludge discharge of bio-filter tank………………………………………………………… P34
Cleaning of UV lamp…………………………………………………………………………………………….…………… P35
M.G.P.S…………………………………………………………………………………………………………..……………………………. P36
Working principle of M.G.P.S…………………………………………………………………………………………………… P36

Inspection and maintenance……………………………………………………………………………………………………. P36
Fresh water generator……..……………………………………………………………………………….………………….……… P38
Inspection and maintenance plan………………………………………………………………….……….……………….. P38
Operation procedure…………………………………………………………………………………………………….………… P40
Starting………………………………………………………………………………………………….………………………… P40
Stopping………………………………………………………………………………………………………………………….. P41
Emergency stopping………………………………………………………………………………………………………… P41
Cleaning of scale………………………………………………………………………………………….…………………… P41
Cleaning for condenser…………………………..………………………………………………………………………… P42
Inspection of corrosion bar……………………….……………………………………………………………………… P42
Cleaning for return water strainer………………….……….……………………………………………………….. P43
Cleaning for electrode salinity meter cell…………….………………….……………………………………….. P43
Analysis of trouble shooting……………………………………………………………………………………………………. P44
Air conditioner……………………………………………………………………………………………………..…………………….. P46
Inspection and maintenance plan…………………………………………………………………….……………………… P46
Operation procedure……………………………………………………………………………………………….……………… P47
Starting……………………………………………….…………………………………………………………………………… P47
Stopping……………………..……………………………...…………………………………………………………………… P47
Heating……………………….…………………………………………………………………………………………………… P47
Pump down……………………………………………………………………………………………………………………… P48
Inspection and maintenance…………………………………………………………………………………………………… P48
Cleaning of air filter……………………………………………….…………………………………………………………. P48
Lubrication of the fan bearing…………………..……………………………………………………………………… P49
Inspection of fan belt tension…………………………………………………………………………………………… P49
Cleaning of condenser tube……………………………………………………………………………………………… P50
Inspection of corrosion bar……………………………………….…………………………………………………….. P50
Replacement of dryer element…………………………………………………………………………………………. P51
Charge of refrigerant……………………………………………………………………..………………………………… P51
Detection of refrigerant leakage………………………………………………………..…………………………….. P51
Analysis of trouble shooting…………………………………………………………………………………………………….. P52
Air conditioner for galley and for engine control room………………………………………….…………………….. P54
Inspection and maintenance plan……………………………………………….……………………...…………………… P54
Operation procedure………………………………………………………………….…………………………………………… P54
Caution for operation………………………………………………………….…………………………………………… P54
Cleaning of air filter…………………………………………….……………………………………………………………. P55
Cleaning of the drain pan……………………………………………….………………………………………………… P56
Cleaning of condenser tubes……………………………………………….…………………………………………… P56
Inspection of the anti-corrosive piece………………………………………..…………………………………….. P57
Lubrication of the fan bearing………………………………………………………..………………………………… P57
Inspection of fan belt tension…………………………………………………………………………………………… P58
Refrigerator…………………………………………………………………….…………………………………………………………… P60
Inspection and maintenance plan…………………………………………….……………………………………………… P60
Operation procedure……………………………………………………………………………….……………………………… P60
Preparation before operation………………………………………………………………..………………………… P60
Starting……………………………………………….…………………………………………………………………………… P61
Stopping…………………………………………………………………………………..……………………………………… P61
Defrost timer…………………………………………………………………………………………………………………… P61

Detection of refrigerant leakage…………………………………………….………………………………………… P62
Cleaning of condenser tube……………………………………………………………………………………………… P63
Inspection of anti-corrosive piece……………………………………………………….……………………………. P64
Replacement of dryer element…………………………………………………………………………………………. P64
Replenishment of refrigerant machine oil…………………….………………………………………………….. P65
Removal and replacement of refrigerant machine oil……………………………………………………….. P65
Change over from No.1 compressor to No.2 compressor………………………………………………… P66
Battery and electric system……………………………………………………………………..…………..……………………… P69
Inspection batteries in battery room…………………………………………………….…………….…………………… P69
Check insulation of motor…………………………………………………………………….……………………………….… P69
Free-fall life boat engine……………………………………….……………………………………………………………………… P71
Inspection and maintenance plan………………………………………………………….………………………………… P71
Operation procedure…………………………………………………………………….………………………………………… P71
Preparation before operation……………………………………………………..…………………………………… P71
Starting……………………………………………………………………………………………………..…………………….. P72
Stopping………………………………………………..………………………………………………………………………… P72
Rescue boat engine………………………………………………………………………………………………………………………. P73
Inspection………………………………………………….……………………………………………………………………………. P73
Try the engine………………………………………….……………………………………………………………………………… P73
Preparation before try the engine……………………..…………………………………………………………….. P73
Staring…………………………………………………………..………………………………………………………………… P73
Gear shifting………………………………….…………………………………………………………………………………. P74
Stopping…………………………………………………..……………………………………………………………………… P74
Emergency fire pump…………………………………………………………………………………………………………………… P75
Operation………………………………………………………………………………..……………………………………………… P75
Preparation before operation………………..………………………………………………………………………… P75
Starting…………………………………………………………………………….……………………………………………… P76
Stopping……………………………………………………………………..…………………………………………………… P76
Report of third engineer……………………………………………….……………………………………………………………… P77

DUTY OF AN OILER
When I work on the ship, I keep watch and do other work when Chief Engineer and Engineer
require.
When I keep watch, I check around the engine room every 30 minutes. When I check, I check
main engine, generator engine, boiler, incinerator, purifiers, air compressors, ballast water
treatment system, sewage treatment plant, fresh water generator, oily water separator,
marine growth prevent system, air conditioner, provision plant, steering gear, all of pump in
the engine room to make sure there are not leaking of fuel oil, lubricating oil, water, exhaust
gas and steam. I report to Engineer when I found any abnormalities.
In addition, I drain water in fuel tanks, lubricating oil tanks, air reservoirs, compressed air
system. I sounding tanks, cleaning equipment and engine room floors, ballasting and de-
ballasting when Chief Officer order, transferring sludge under Chief Engineer require,
recording Log book before hand over.
Sometimes, I prepare main engine for departure or arrival in my duty when there is notice
from the bridge to the engine control room.
For departure, I call Chief Engineer and Engineer immediately, and carry out preparing main
engine following procedure:
- Start one more generator engine and synchronizing.
- If temperature of cylinder oil at inlet side of flow meter is less than 30 0C, open tracing
steam valves for heating M/E cylinder oil (maintain it at 35 0C – 40 0C). Close these
tracing valves when cylinder oil temperature is more than 40 0C.
- Start M/E L.O pump (if it is stopped) and check M/E lube oil inlet pressure, check piston
cooling oil, turbo charger lube oil through the sight glasses.
- Start one HPS pump by shift switch from OFF position to MANUAL position and press
START button.
- Press ON of the Prelude button on MOP (in the engine control room) to Pre-lubrication
for M/E cylinder liners.
- Check all indicator valve are opened.
- Engage the M/E turning gear and start turning M/E.
o Every 8 minutes, press Prelude ON one time and check cylinder oil supply
indicator lamp of each cylinder.
o After turn M/E about 30 minutes, disengage the turning gear.
- Check running condition of main cooling S.W pump, M/E cooling F.W pump, M/E F.O
booster pump, M/E F.O circulating pump, HPS pump and Stern tube L.O pump.
- Check temperature of M/E cooling F.W, it is keeping about 65 0C.
- Check temperature, pressure of F.O
- Change HPS pump switch from Manual position to Auto position for both of HPS
pumps.
- Start compressor to charge air for main air reservoirs until auto stop pressure.
- Drain water for main air reservoirs and compressed air system.
- Close drain valve of M/E starting air system.
- Open main air supply valve of main air reservoir.
- Open and set the M/E main starting air valve to service position.
- After Engineer is completed air-blow for M/E, close all indicator valves.

For arrival, I carry out preparing main engine as the follows:
- Start air compressor to charge air for main air reservoirs until auto stop pressure.
- Check and open C.S.W inlet and outlet valves of hydraulic oil cooler for the hatch
covers, mooring winches and windlass system.
- Check and change over from Low sea chest to High sea chest if necessary.
- Check and turn on the Auxiliary Boiler.
- When finished with engine
o Open all indicator valves.
o After Engineer is completed air-blow for main engine, close main air valve of
main air reservoirs.
o Close the M/E main starting air valve and set it at blocked position.
o Open drain valve of M/E starting air system to drain out air until 0.
o Engage the M/E turning gear and turning M/E at least 30 minutes.
o After finished turning M/E, set HPS pump switch at OFF position.
o Open steam inlet and outlet valves of M/E C.F.W heater and maintain main
engine cooling fresh water temperature at about 65 0C by setting at C.F.W
temperature controller.
Beside keeping watch, I also learn operation works, maintenance works, repair works of
equipment Third Engineer in charge of.

DUTY OF A THIRD ENGINEER
When he works on the ship, He keeps watch from 08-12, 20-24 and does other work when
Chief Engineer requires.
When he keeps watch, he checks parameters in the engine control room and repairs troubles
when oiler reports any abnormal.
Sometimes, he prepares main engine for departure or arrival in his duty when there is notice
from the bridge to the engine control room.
For departure, he calls Chief Engineer immediately, and carry out preparing main engine
following procedure:
- If temperature of cylinder oil at inlet side of flow meter is less than 30 0C, open tracing
steam valves for heating M/E cylinder oil (maintain it at 35 0C – 40 0C). Close these
tracing valves when cylinder oil temperature is more than 40 0C.
- Start M/E L.O pump (if it is stopped) and check M/E lube oil inlet pressure, check piston
cooling oil, turbo charger lube oil through the sight glasses.
- Start one HPS pump by shift switch from OFF position to MANUAL position and press
START button.
- Press ON of the Prelude button on MOP (in the engine control room) to Pre-lubrication
for M/E cylinder liners.
- Check all indicator valve are opened.
- Engage the M/E turning gear and start turning M/E.
o Every 8 minutes, press Prelude ON one time and check cylinder oil supply
indicator lamp of each cylinder.
o After turn M/E about 30 minutes, disengage the turning gear.
- Check running condition of main cooling S.W pump, M/E cooling F.W pump, M/E F.O
booster pump, M/E F.O circulating pump, HPS pump and Stern tube L.O pump.
- Check temperature of M/E cooling F.W, it is keeping about 65 0C.
- Check temperature, pressure of F.O
- Change HPS pump switch from Manual position to Auto position for both of HPS
pumps.
- Start compressor to charge air for main air reservoirs until auto stop pressure.
- Close drain valve of M/E starting air system.
- Open main air supply valve of main air reservoir.
- Open and set the M/E main starting air valve to service position.
- Call to the bridge (change over M/E status from Finish to Standby).
- Turn on auxiliary blower by change its switch to Auto start position.
- Carry out air blow for M/E (set Telegraph Receiver switch to DEAD SLOW AHEAD
position -> set The Speed Control Dial knob to START position, keep it about some
seconds to carry out “air blow”).
- After completed “air blow”, set The Speed Control Dial and Telegraph Receiver switch
back to Stop position.
- Close all indicator valves.
- Try M/E running Ahead and Astern.
- Confirm with the bridge “the engine is already standby for manoeuvring” and change
over “M/E control position” to W/H.

- Set speed limit in the engine control room by move the speed control dial knob to fuel
running position.
For arrival, I carry out preparing main engine as the follows:
- Start air compressor to charge air for main air reservoirs until auto stop pressure.
- Check and open C.S.W inlet and outlet valves of hydraulic oil cooler for the hatch
covers, mooring winches and windlass system.
- Check and change over from Low sea chest to High sea chest if necessary.
- Check and turn on the Auxiliary Boiler.
- Confirm with the bridge “the engine is already stand by for manoeuvring”.
- When finished with engine
o Move M/E speed dial knob to Stop position.
o Change over “M/E control position from W/H to C/R.
o Open all indicator valves.
o Air blow for M/E.
o Turn of auxiliary blower.
o Close main air valve of main air reservoirs.
o Close the M/E main starting air valve and set it at blocked position.
o Open drain valve of M/E starting air system to drain out air until 0.
o Engage the M/E turning gear and turning M/E at least 30 minutes.
o After finished turning M/E, set HPS pump switch at OFF position.
o Open steam inlet and outlet valves of M/E C.F.W heater and maintain main
engine cooling fresh water temperature at about 65 0C by setting at C.F.W
Beside keeping watch, He in charge of auxiliary boiler and related system, exhaust gas
economizer, fresh water generator, all kind of pumps, sea water and fresh water system, air
conditioners, provision refrigerating plants, sewage treatment unit, emergency fire pump, life
boat engine and davit, rescue boat engine and davit, electric system, M.G.P.S, calorifier unit,
batteries.

WITH THE BOILER
INSPECTION AND MAINTENANCE PLAN
1. EVERY DAY
• Check ventilation.
• Check surroundings for flammable materials.
• Check funnel.
• Check sea water temperature outlet of condenser (under 50°C) and check water
temperature of cascade tank (keep 75-80°C).
• High pressure air soot blower (at sea).
• Check feed water pump for leaks, abnormal sound and check pressure gauge.
• Drainage fuel service tank.
• Blow off water level gauges.
• Blow off water boiler through surface and bottom.
• Clean strainer suction side for fuel oil pump (if necessary).
• Sample boiler water, test water boiler every 3 days, and add chemical if necessary.
2. EVERY WEEK
• Maintain burner body; and before arrival at port.
• Inspect ignition for cracks and adjustment.
• Inspect nozzle tip (replace every 3 to 12 months).
• Inspect wind box.
3. EVERY MONTH
• Inspect fan.
• Inspect flexible tube (replace once every 1-2 years).
• Inspect burner coupling (replace once every 1-2 years).
• Inspect and adjust drive part of dampers.
• Inspect dirt on flame eye and glass.
• Inspect and clean strainer of fuel oil pump inside.
• Visual inspect wiring.
• Inspect motor, ball bearings (replace bearing once every two years).
• Drain cascade tank and clean filter inside cascade tank.
4. EVERY THREE MONTHS

• Inspect fuel oil solenoid valve.
• Inspect fuel oil thermostat.
• Check nozzle pipe for fuel oil leaks.
• Inspect and adjust coupling for fuel oil pump.
• Inspect air register.
• Measure insulation resistance of each motors.
• Clean water level detecting rods and holder and check insulation.
5. EVERY YEAR
• Clean and inspect fuel oil heater.

• Inspect combustion chamber and clean furnace with air to remove soot.
• Voltage check flame detector.
• Inspect chimney inside.
• Clean cascade tank inside.
ALARM TEST
1. MISS FIRE
- Before igniting burner, remove flame eye on the top surface of wind box and put your
hand over tip.
- Press combustion switch.
- Ignition is attempted after pre-purge; however, flame eye does not detect flame and
determines that there is something wrong.
- Check that audio and visible alarms are issued.
- Press stop buzzer switch (Blinking alarm lamp does not turn off and comes to remain
on.)
- Put flame eye back in place (Alarm lamp does not turn off but remains on.)
- Press alarm reset switch (Alarm lamp turns off and alarm is reset.)
2. FAN ABNOMAL STOP
- Trip fan thermal relay during combustion.

on.)
- Reset fan thermal relay (Alarm lamp does not turn off but remains on.)
3. FLAME FAILURE ALARM
- Remove flame eye during combustion, and put your hand over tip.
on.)
4. ABNORMAL FIRE ALARM
- Remove flame eye during post-purge and illuminate flame eye.

- Alarms should be issued 32-second after post-purge is started (Check that post-purge
is continued.)
on.)

5. FUEL OIL LOW PRESSURE ALARM

- Trip fuel pump thermal relay during combustion or drain out F.O at inlet side F.O
pressure sensor.
- There should be 2-second delay before alarm are issued.
on.)
6. FUEL OIL TEPERATURE LOW ALARM
- Shift fuel oil heater switch to OFF position.

- Higher setting of thermostat for low oil temperature more than actual temperature
during combustion.
- Shift fuel oil heater switch to AUTO position.
- Press stop buzzer switch (Blinking alarm lam p does not turn off and comes to remain
on.)
- Shift fuel oil heater switch to ON position (Alarm lamp does not turn off but remains
on.)
- Reset thermostat for low oil temperature to value in list of principle items.
- Shift fuel oil heater switch to AUTO position.
7. FUEL OIL TEPERATURE HIGH ALARM
- Lower setting of thermostat for high oil temperature during combustion.

- When fuel oil heater is not working, there should be 10-second delay before alarm are
issued. There is no such delay if fuel oil heater is in operation.
on.)
- Reset thermostat for high oil temperature to value in list of principle items.
8. EXHAUST GAS TEPERATURE HIGH ALARM
- Lower setting of thermostat by turning dial during combustion.

- Press stop buzzer switch (Blinking alarm lam p does not turn off and comes to remain
on.)
- Reset thermostat for exhaust gas high temperature to value in list of principle items.

9. LOW WATER LEVEL ALARM
- Close upper and lower water level gauge root valves on one of water level gauges.
- When combustion is started, open water level gauge blow valve slowly.
- Check that water level is lowered to low water level.
- When water level is lowered to low water level, close water level gauge blow valve.
- There should be 10-second delay before alarm are issued.
- Check that combustion is continued.
on.)
- Open upper and lower water level gauge root valves slowly (Alarm lamp turns off.)
10. LOW-LOW WATER LEVEL ALARM
- Close upper and lower water level gauge root valves on the both water level gauges.
- When combustion is started, open water level gauge blow valve slowly.
Check that water level is lowered to low-low water level limit.
- Check that burner of boiler is stopped.
- Press stop buzzer switch.
Audible alarm is stopped. (Blinking alarm lamp does not turn off and comes to
remain on.)
- Close water level gauge blow valve and open upper and lower water level gauge root
valves slowly.
Alarm lamp does not turn off but remains on.
- Press alarm reset switch.
Alarm lamp turns off and alarm is reset.
11. HIGH WATER LEVEL ALARM
- Set feed water shift pump to MANU and select pump for operation then press start
button of feed water pump.
- When water level is raised to high water level, press stop button of feed water pump
- Check that audio and visible alarm are issued. There should be 30-second delay before
they are issued.
- Press stop buzzer switch. (Blinking alarm lamp does not turn off and comes to remain
on.)
- Open bottom blow valve slowly until water level is lowered to high water level
- Press alarm reset switch.
Alarm lamp is turned off and alarm is reset.

BOILER WATER ANALYSIS
1. PURPOSE OF WATER TREATMENT
The purpose of water treatment is to avoid damage boiler, pipes and equipment peripheral
to boiler. That also increase efficient of boiler.
These failures damage boiler include scales, adhesion, corrosion, carry-over.
2. SAMPLING WATER FOR ANALYSIS
Do not forget wearing protective gloves before sampling boiler water.

Open and close salinity valve slowly.
Flash outlet piping of salinity vale before sampling water. Impurities in piping may prevent
accurate analysis of water quality.
TESTING VALUE
- P- ALKALINITY (200-300ppm).
- PHOSPHATE (PO4 20-60ppm).
- CHLORIDES (Cl less than 60ppm).
- PH (boiler water pH 10.8-11.5).
- PH (condensate water pH8.3-9.0).
3. ADDING CHEMICAL FOR BOILER WATER TREATMENT
Do not forget wearing apron, safety gloves, safety mask, safety goggles, safety helmet before
taking out chemical.
DOSING CHEMICAL
- ALKALINITY CONTROL
P-ALKALINITY TABLET P-ALKALINITY TEST DOSAGE (ml/1000L)

As ppm CO3
0 0 506(ml) x tons =
1 10 484 x tons =
3 50 394 x tons =
5 90 304 x tons =
7 130 214 x tons =
9 170 124 x tons =
11 210 SANTISFACTORY
>16 OVER 300 BLOW DOWN
Dose 225ml Alkalinity control / 1 ton of distilled water to raise the P-Alkalinity level by
100ppm.

- HARDNESS TREATMENT
PHOSPHATE TEST DOSAGE OF HARDNESS TREATMENT

Ass ppm PO4 mls/1000L
0 1000ml x tons =(L)
10 750 x tons =
20 500 x tons =
30 SATISFACTORY
40 SATISFACTORY
50 SATISFACTORY
OVER 70 BLOW DOWN
Dose 250mls Hardness Treatment / 1 ton of distilled water to raise the Phosphate level by
10ppm PO4.
- OXYGEN CONTROL
Hydrazine test result in ppm Dosage

Less than 0.1 Increase dosage by 25%
0.1 – 0.3 Satisfactory maintain Daily dosage (1ltr/day)
More than 0.3 Decrease dosage by 25%
Dosage is approximately 1 litter per day.
- CONDENSAGE CONTROL
The condensate water at cascade tank is tested for pH to determine the dosage level. The pH
limits are 8.3 – 9.0
For an average system 10 m3, the dosage is approximately 0.65 litter/day.
!.# × &.'!
ð a system 5.9 m3, the dosage is (& = 0.38 litter/day.
Condensate pH from testing Dosage
Less than 8.3 Increase dosage by 25% for 72 hours and
retest
8.3 – 9.0 Satisfactory maintain Dosage (0.38ltr/day)
More than 9.0 Decrease dosage by 25% for 72 hours and
retest

Tell me the reasons causes high chloride for boiler water. And what should you do if chloride
is too high?
Chloride ion in boiler water will be formed hydrochloride acid (HCl) and concentrated solids.
They are causes corrosion.
Specific gravity of chloride ion is lighter than water. It is floated on surface of boiler water.
Concentrated solids of chloride are heavy more than water. They are settled on bottom of
boiler water.
When chloride ion is determined too high in boiler water. That may be:
- Salt chlorides (MgCl2, CaCl2, NaCl…) fall off into inspection tank, cascade tank.
- Sea water is spilled into inspection tank or cascade tank when cleaning of the
condenser.
- Sea water is leaked to condensate water from condenser water tubes or plates.
- Sea water is leaked to distillate water tank (feed water) from Fresh water generator
or from main hole, air vent pipe of distillate water tank.
- Feed water is contained chloride ion.
When chloride ion in boiler water is too high:
- Drain all out condensate water from inspection tank and cascade tank.
- Renew by distillate water.
- Carry out blow off surface and blow down bottom of boiler water.
- Re-test chloride ion for boiler water and making sure chloride ion value is less than 60
ppm.
- If it is high too:
- Check condition of the condenser, there is broken of water tubes or plates.
- Check condition of feed water by testing chloride contained in distillate water tank.
- Check feed water system, there is leaked sea water into system causes by open valve
incorrectly.
- Check condition of fresh water generator for leakage.

OPERATION PROCEDURE
1. PREPARATION BEFORE OPERATION
Before a new boiler at commissioning or after maintaining, overhauling; to operation the

boiler, we need to check following:
a) Check of around boiler

- Check for water or oil leakage around boiler.
- Check that there are no flammable materials around boiler.
- Check that there are no obstacles around boiler and in walkways.
b) Check of body boiler

- Check equipment, inspection holes, covers, valves and connections for water leakage.
- Check that vales are opened and closed properly.
- Check that water level gauges is not stained and not damage.
- Check that needle of pressure gauges is working properly.
c) Check of feed water system

- Check that cascade tank contains sufficient amount of water.
- Check that feed water is clean and no oil gotten into feed water.
- Check that valves on feed water line are opened and closed properly.
- Check that feed water pump is no leakage.
- Check that needle of pressure gauge and compound gauge are working properly.
- Let out air of pipe on suction side.
d) Check of fuel system

- Check level of fuel tank.
- Drainage for fuel service tank.
- Check that there are no pipes clogging, fuel leakage.
- Check fuel strainer has no clogging.
- Check needles of pressure gauge work properly.
- Air vent for fuel pipe on suction side.
e) Check of burner
- Check that ignition rod, nozzle tip, flame eye are cleaned and installed properly.
f) Check of electrical system

- Check that there is no failure on the control panel.
- Check motor run right direction.
- Check that manual combustion switch on control panel is set at OFF position.

2. OPERATION
AUTO COMBUSTION
a) Feed water to boiler

- Turn on boiler power supply.
- Shift switch of feed water pump to AUTO and select pump for operation.
- Turn on power of feed water pump and start.
- Check water level gauge that feed water is stopped on right level.
- Check that there no leakage.
b) Starting combustion with M.D.O

- Open M.D.O system valves.
- Shift switch to AUTO COMB position.
- Press combustion button.
c) After combustion is started, check that boiler is on normal operation.

- Check fuel flow amount, fuel oil pump discharge pressure, opening of damper.
- Check colour, expansion, and stability of flame.
- Check colour of smoke and leakage of smoke.
- Check vibration or abnormal sound.
- Check steam pressure is increasing and stop combustion automatically at setting
value.
d) Combustion stopping.
- Press combustion stop.
e) Shift from M.D.O to H.F.O

- Heated H. F.O service tank to proper temperature.
- Open steam trace valve of fuel oil pipe.
- Open H.F.O supply valve, and close M.D.O supply valve.
- Check temperature that fuel flow in pipe from H.F.O supply valve to F.O pump unit is
replaced with H.F.O.
- Shift fuel oil heater switch to ALARM CANCEL position.
- When temperature show on thermostat reaches setting value, and pressure is settled,
slightly open drain valve on fuel return line of oil air separator and visually check that
oil has been fully replaced.
- Shift fuel oil heater switch from ALARM CANCEL position to AUTO position.
- Check that boiler is on normal operation.
f) Shift from H.F.O to M.D.O

- Open M.D.O supply valve, and close H.F.O supply valve quickly.
- Close steam trace valve on boiler fuel oil pipe.
- After it is determined that pipe inside from M.D.O supply valve to F.O pump unit is
replaced with M.D.O based on temperature show on thermostat is decreased, shift
fuel oil heater switch to OFF.
- Check that fuel oil heater outlet temperature is decreased and pressure is stable.

- Air vent valve of oil air separator.
- Check that boiler is on normal operation.
MANUAL COMBUSTION
- Check that manual combustion switch is set at OFF.

- Shift manual combustion switch to F.O. PUMP/HEATER.
- Shift manual combustion switch to FAN RUNNING.
- Check that sufficient pre-purge lamp is lightened.
- Shift manual combustion switch to IGNITION.
- Shift manual cam switch to PRI.COMB.
- Shift cam switch to COMB. position.
- After it is confirmed that combustion is normal, shift combustion change-over switch
to HIGH position (high combustion).
Operation Auxiliary boiler when it is cold condition? (after stopped Aux. boiler for long time)
When starting Aux. boiler in cold condition, do not raise steam pressure rapidly because all
part of boiler becomes completely cold. Steps to operate boiler as follows:
- Raise steam pressure gradually to 0.1 MPa by repeating 1 minute combustion and 4
minutes purge. Keep 10 minutes at steam pressure of 0.1 MPa.
- Continued raise steam pressure gradually to 0.2 MPa by repeating 2 minutes
combustion and 3 minutes purge.
- When steam pressure reaches around 0.2 MPa, stop boiler. Tighten bolts and nuts of
each part, check leakage of steam, water.
- Blow water level gauge to make sure it is operated properly.
- Blow boiler water and supply purify water (if necessary).
- Start combustion to maximum steam pressure for general use. Check for steam leaks.
- Open main steam valve and start with automatic operation.

INSPECTION AND MAINTENACE
1. CLEANING OF BURNER
- Complete purge air by fan before burner opening and inspection to make combustion
chamber cold and ventilate, then stop fuel oil pump.
- Take out butterfly bolts for burner fixing on the top of wind box, take out fuel joint
pipe and insulator cap that is inserted in ignition rod to pull out burner nozzle area.
- Wipe away fuel oil from burner nozzle and flexible tubes immediately and dispose of
it properly.
- Disassemble removed baffle plate and burner nozzle into nozzle tip.
- Wash each part with light oil, clean it with air, and assemble them with opposite
procedure as disassemble.
- Size of nozzle tip, baffle plate and spark rod are adjusted base on values on final
drawing basically.
- Burner should be assembled tightly with hexagon socket set bolts, be careful not to
fasten bolt on ignition rod too tightly. That may break or crack rod, causing ignition
failure.
2. CLEANING OF STRAINER
- Confirm that auxiliary boiler is OFF.

- Confirm that rotation of pump motor is stopped.
- Close inlet valve, outlet valve of oil pump.
- Take off strainer cover of oil pump.
- Clean inside strainer with a brush, light oil.
- Assemble strainer of fuel oil pump after cleaning.
- Open inlet valve, outlet valve and of oil pump.

3. INSPECTION OF FAN
- Inspect fan once a month.

- Check for vibration, strange sounds, and abnormal bearing temperature during
operation. When fan is not in operation, turn off power supply, and move impeller by
hand to check for abnormalities.
- Insulation test once every three months.
- Replacement of bearing. Replace bearing once every two years.
4. CLEANING OF WATER LEVEL GAUGE
Blow water level gauge once a day

- Close upper water level gauge root valve and open water level gauge drain valve.
- Boiler water is discharged from water level gauge Inside, and lower water gauge
column connecting pipe is cleaned.
- Close the water level gauge drain valve and lower water level gauge root valve, and
open upper water level gauge root valve.
- Open water level gauge drain valve.
- Steam is discharged, and upper water gauge column connecting pipe and water gauge
column Inside are cleaned.
- Close the water level gauge drain valve and open lower water level gauge root valve.

5. CLEANING OF WATER LEVEL DETECTING ROD
- Water level detecting rod may get dirty with concentrated boiler water and cause
malfunction, pull water level detecting rods out and clean them once every three
months.
- Check continuity and insulation of electrode holder every three months.
- If continuity or insulation failure is found, replace it.
6. SURFACE BLOW OFF AND BOTTOM BLOW DOWN
Blow down of boiler water is to discharge concentrated boiler water out of boiler,
protecting boiler avoid corrosion, scale, over-heating and clogging.
Blow-off surface:
- Carry out blow-off surface in low load.
- Supply water to auto stop pump level.
- Slightly open blow-off surface valve to warm up pipe line.
- Carry out a blow-off efficiently by slight opening 6-second/closing 6-second
the overboard valve alternately.
- when water level of water level gauge is reduced by about 20 mm from auto
start pump level, stop blow-off surface.
- Repeat blow-off by supply water several times alternately.
- Close overboard valve and blow-off surface valve.
Blow down bottom:
- Supply water to high level.
- Slightly open bottom blow-down valve.
- Carry out a blow-down efficiently by slight opening 6-second/closing 6-second
the overboard valve alternately.
- The blow down of about 150mm to 200mm in water level gauge is appropriate.
- Close overboard valve and bottom blow-down valve.

7. HIGH PRESSURE AIR SOOT BLOWER
- Make sure that pressure in air reservoir is at stand-by state.

- Air pressure higher than 2.2 MPa is necessary for high pressure air soot blower to work
properly.
- Make sure that main soot blower valve on boiler side are closed.
- Drain water in reservoir, pipe and close drain valves.
- Open main valve on air reservoir side.
- Carry out soot blower according to following procedure:
Lower soot blower:
- Open main valve of lower soot blower and carry out soot blower for about 20
seconds.
- Carry out lower soot blower opposite side in the same way (Ensure that
operation of lower soot blower is finished in about 40 seconds (20 seconds x
2pcs).
- If pressure is below about 2.2 MPa, wait until pressure air in reservoir is
increased to normal pressure, start next operation after making sure that
pressure air in reservoir is returned to normal pressure.
Middle soot blower:
- Open soot blower main valve of the middle rotary soot blower and carry out
soot blow for about 30 seconds.
- Carry out the middle rotary soot blower opposite side in the same way (Ensure
that the middle rotary soot blower is finished in about 60 seconds (30 seconds
X 2pcs).
Upper soot blower:
- Open main valve of upper soot blower and carry out soot blower for about 20
seconds.
- Carry out upper soot blower opposite side in the same way (Ensure that upper
soot blower is finished in about 40 seconds (20 seconds X 2pcs).
After carrying out soot blower, close main valve on air reservoir side and drain out
water in reservoir, drain air out in soot blower air pipe side.

8. CLEANING OF CONDENSER AND INSPECTION OF CORROSION BAR
Cleaning of condenser:
- Shift from H.F.O to M.D.O.
- Stop combustion.
- Close main steam valve of boiler.
- Close main steam drain valve of the condenser and close sea water inlet, outlet of the
condenser.
- Open the drain and air vent valve to drain cooling water out of the condenser.
- Remove the screws fixing the front cover and open the cover.
- Scrub off the scale deposits inside the cooling tube with a brush and fresh water.
- Assemble the cover with opposite procedure as disassemble.
Check of corrosion bar:

- Remove corrosion bar installation fitting (cap) from the condenser cover.
- Check corrosion bar conditions.
- Scrub off the scale deposits on corrosion bar with a steel brush.
- Replace corrosion bar when exposed part from cap is worn within 2/3 of the volume.
- Install corrosion bar to the condenser cover.
- Close the drain sea water cooling on the condenser cover, and open sea water cooling
inlet valve. Air vent for sea water cooling of condenser, then close air vent.
- Open sea water outlet valve of the condenser.
- Open main steam drain valve of condenser, combustion boiler and open main steam
valve of the boiler.

9. SOOT CLEANING OF FURNACE
- Remove wind box from boiler.

- Visually inspect inside of combustion chamber and check whether or not inside is
blackened by soot.
- Clean combustion chamber with high-pressure air cleaner.
- Open burner chimney cover.
- Collect out soot inside burner chimney also soot in bottom of furnace.
10. SOOT CLEANING OF WATER TUBES ON MAIN ENGINE EXHAUST GAS SIDE
Check that main engine is not working before starting cleaning.

- Open manhole on main engine exhaust gas inlet side, and collect soot that has
accumulated on bottom cover.
- Blow away remaining soot that is on surface of water tubes with compressed air along
with exhaust gas.
- Open manhole on exhaust gas outlet side and collect soot that is accumulated.
- After cleaning, immediately close manholes and start boiler operation.

ANALYSIS OF TROUBLE SHOOTING
1. TROUBLE WITH FEED WATER SYSTEM

a. The feed water pump does not run
- Power is not turned on. => turn power on.
- Wiring is disconnected. => check wire connection, tighten terminal screws.
- Thermal relay is tripped or failure. => check abnormal, reset or replace thermal
relay.
- Water level detecting rods are dirty or failure. => check, clean or replace if
necessary.
- Motor or bearing are failure. => check smooth by hand turn, check insulation
resistance of motor and replace them.
b. The feed water pump is noise or heat generated.
- Bearing and mechanical seal are burned. => check smooth and vibration by hand
turn, replace them.
- There are foreign materials entering in pump. => disassemble and removing
materials.
- Air in pump. => vent air.
c. Feed water pump is running, but it does not feed water
- There air come into pump from suction side. => locate defective piping and repair
it.
- Forgot air vent after maintenance. => vent air for pump.
- There is not water in cascade tank. => feed distillate water to cascade tank.
- Valves, pipe are clogged. => locate and clean inside pipe; check valves opening
properly.
- Impeller and casing are worn abnormally. => disassemble and replace worn parts.
d. Feed water pump is not started/ stopped at specified water level
- Water level detecting rods are dirty. => open and clean them.
- Water level detecting rods are failure (dropped, wrong wire connection, earth
fault, rust joint between detecting rod and lead wire). => check, clean and replace
if necessary
- Forgot open water level root valve. => open water level root valve.
- Water level control cylinder connecting pipe is clogged. => check and clean pipe.
- Water level gauge glass is dirty. => clean water level gauge glass.
2. TROUBLE WITH FUEL SYSTEM
a. Fuel oil pump does not run
- Power is not turned on. => turn on the power.
- Overload of motor and thermal relay failure. => check causes (bearing, mechanical
seal burned, clogged on discharge side, lack of phase) and repair them.
- Foreign materials enter in pump. => disassemble and remove them.
- Breaker for auxiliary equipment is tripped. => check and recover it.
b. Running fuel oil pump sounds loud and overheat
- Fuel oil pump is not filled with fuel. => check clogged on suction side and clean it.
- Air come into pump from suction side. => Remove cause of inclusion of air, and let
out air.
- Bearing or mechanical seal are failure. => disassemble and replace them.
- Discharge side is clogged. => clean pipe or open valve properly.

- Fuel temperature is too high. Evaporation of volatile components in the fuel is
generated air. => lower fuel temperature.
- There sludge is contained in fuel oil. => drain fuel service tank.
- Shock absorbing rubber of coupling is damaged. => replace coupling.
c. Discharge of fuel oil pump is too high
- Pressure gauge is failure. => replace pressure gauge.
- Pipe and valves in outlet side are clogged. => clean pipe, open/close valves
properly.
- Solenoid valve is malfunction. => check, clean or replace solenoid valve.
- Flow path is clogged (nozzle pipe, nozzle tip) => clean them.
- Viscosity of fuel is high. => decrease fuel heating temperature or replace fuel.
- Wrong setting of fuel oil heater. => check heating temperature setting.
d. Fuel oil temperature does not raise
- Heating failure due to inclusion of air. => Remove air sufficiently.
- Temperature controller is set low. => change set value.
- There is broken wire of fuel oil heater element. => Replace element for heating of
heater.
- Wiring of fuel oil heater is contacting failure. => Fasten connection screws tightly.
- Inside of heater is dirty. => Clean inside of heater.
3. TROUBLE WITH COMBUSTION
a. Fan does not run
- Power is not turned on. => turn power on.
- Steam pressure is higher than setting ON combustion switch. => lower steam
pressure.
- Motor or bearing is failure. => replace it.
- Overload motor and thermal relay is tripped. => check causes and reset thermal
relay.
- Wire disconnection or insulation failure. => check wire condition.
b. Miss fire, ignition failure
- Water or sludge is remained in fuel service tank. => drain water, sludge or replace
fuel.
- Burner nozzle is dirty or clogged. => clean burner nozzle.
- Leakage from joint of burner nozzle. => fasten joint of burner nozzle tightly.
- Clogging of fuel system (clogged pipe, open/close valve incorrect). => Remove
cause of clogging.
- Oil pressure switch is failure. => Check and adjust setting of pressure switch. If this
does not work, replace it.
- Ignition transformer is failure. => Replace parts.
- Wire is defective. => Connect the wire properly.
- Dimension of ignition rod is wrong. => Check final drawing and adjust dimensions.
- The tip of ignition rod is dirty and miss spark. => clean ignition rod.
- Fuel temperature is low. => Adjust fuel temperature properly by fuel oil
- Solenoid valve is not working properly. => check, clean parts or replace if failure.
c. Flame failure
- Failure of flame eye or dirt on glass. => Replace flame eye or clean glass.
- Damper is not opened properly. => adjust damper opening.

- Discharge pressure of fuel oil pump (including pilot pump) is not high enough. =>
Remove cause of clogging, replace worn parts of fuel oil pump, check relief valve
condition.
- Flame blowout due to burner nozzle and baffle plate are not correctly positioned
relative to each other. => Adjust their positions with reference dimensions in final
drawing.
- Flame eye does not catch flame due to flame eye is not installed and fixed
correctly. => Install and fix flame eye correctly.
- Pressure drop due to evaporation of moisture in fuel. => Drain fuel service tank to
remove moisture.
d. Combustion is not stopped even after steam pressure rises up to the specified
pressure.
- Pressure gauge is failure. => Replace pressure gauge.
- Steam pressure switch is failure. => Check and adjust setting of pressure switch. If
this does not work, replace it.
e. Flame is not stabilized
- Fuel temperature is low. => Adjust fuel temperature by fuel oil temperature
controller.
- Excessive air flow due to damper is not opened properly. => adjust damper
opening.
- Burner nozzle is clogged with dust. => clean burner nozzle.
- Burner nozzle, baffle plate, and other parts are not correctly positioned relative to
each other. => Adjust their positions based on results of trial operation.
- Fuel oil pressure is low. => check and clean suction strainer, check leakage,
readjust pressure, if this does not work, replace parts.
f. Exhaust gas is black
- Air flow is insufficient. => adjust position of damper opening based on results of
trial operation.
- Fuel oil pressure is high. => readjust pressure, if this does not work, replace parts.
- Fuel temperature is low. => adjust fuel temperature by fuel oil temperature
controller.
- Burner nozzle and baffle plate are dirty. => clean burner nozzle and baffle plate.
g. Exhaust gas is white
- Air flow is excessive. => adjust position of damper opening based on results of trial
operation.
- Fuel oil pressure is low. => check and clean suction strainer, check leakage,
readjust pressure, if this does not work, replace parts.
- Burner nozzle is clogged with dust. => clean burner nozzle.
- Burner and baffle plate dimension are incorrect. => adjust their positions based on
results of trial operation.

SEWAGE TREATMENT PLANT
WORKING PRINCIPLE OF SEWAGE TREATMENT PLAN
Working principle of sewage treatment plan is utilizing a biological film with packing medias.
Packing media are placed in the tank and liquid sewage is circulated around it by means of
aeration. The sewage contacts the biological film causing growth of bacteria on the surface
of packing medias and organic matter is treated by biochemical oxidation.
Process treated as follows:
Sewage from toilets in the ship flows into the Bio-filter Tank. Foreign objects which could
obstruct operation of the plant are held by a screen. Air from a blower causes circulation of
the liquid and breaks up the solids. It also supplies oxygen to the microorganisms attached to
the packing medias.
Separation tank allows static deposition of the suspended solid content included in the
treated water after organic matter has been resolved in the bio-filter tank: a floating scum is
separated from suspended solid, stored in this tank, and finally discharged during cleaning.
The treated water from which suspended solid constituents have been removed in the
separation tank overflows, is mixed with the chlorine which has been dissolved out of the
sterilizer, and then accumulates in the treated water tank, where it is sufficiently sterilized by
chlorine and the UV sterilizer (by circulation). Finally it is automatically discharged outboard
by means of a level control.
1. EVERY DAY
• Check of the treated water.
• Check of the UV lamp indicator.
• Record to Daily check
2. WEEKLY
• Check of the quantity of disinfectant and add chlorine to treated water tank.
3. BIWEEKLY
• Check of the quantity of oil and clean the air filter of aeration blower.
• Check of condition of V-belt.
4. MONTHLY
• Cleaning of the bio-filter tank screen.
• Back washing (remove sludge) and discharging of sludge.
• Scum removal.
• Cleaning of the sterilizer (Glass jacket).
5. YEARLY
• Replacing of UV-lamp.
• Check of discharge pump mechanical seal for leakage.

SAFETY INSTRUCTION
• Do not use chemicals for cleaning of toilet. The chemicals will affect and kill the
microorganisms in the tank. This will cause loss of the purification ability, resulting in
the production of a poisonous gas or a bad smell. Use a cleaner which does not give
damage to the microorganisms.
• The aeration blower should be run continuously. The interruption of its continuous
running will kill the microorganisms within the sewage treatment tank. This will cause
loss of the purification ability, resulting in the production of a poisonous gas or a bad
smell. Also, there is a possibility that the air discharge nozzle clogs.
• Check the air vent pipe for the clogging because of sewage or dewing. If the pipe clogs
in this way, the toilet seal water trap will be broken by the back pressure of the
aeration blower, thereby causing the toilet water to splash and at the same time
resulting in the emission of a poisonous bad smell. Also, the splashes dirty your clothes
and the surrounding area.
• The paper to be used in the toilet should be soluble in water. These stuffs may cause
the clogging or failure of the pump.
• This plant operates satisfactorily with fresh, brackish, or sea water. However, it has to
be used always in the same type of water. Avoid sudden change of the type of water,
for example, from sea water to fresh water, in the tank, since this affects activation of
microorganism.
OPERATION PROCEDURE
- Confirm that all piping is correct by referring to piping diagram.

- Apply power to control panel, and confirm "SOURCE" lamp is light.
- Making sure the pump is rotating correctly, turn the switch to "MANUAL" and push
“START”/"STOP".
- Shut separation tank valve, treated water tank valve and stop valve. Open bio-filter
tank valve.
- Opening cleaning water inlet valve, and flow cleaning water into the plant at (H) level.
- When the indicator lamp marked "HIGH WATER LEVEL" on the control panel lights,
immediately close the cleaning water inlet valve.
- Shut bio-filter tank valve, open treated water valve discharge pump outlet valve and
all valves to storm valve.
- Open the sampling cock situated in the upper part of the sterilizer unit. The cock
should be closed when water has come out of the cock and air has been completely
removed from the cock.

- Turn the discharge pump switch to "AUTO".
- Confirm that discharge pump starts automatically and "HIGH WATER LEVEL" lamp
goes out as water level drops. Confirm that the discharge pump stops automatically.
- Check the quantity of oil in blower by sighting the oil level sight-glass of aeration
blower. Add oil if necessary.
- Open 1St aeration valve, 2nd aeration valve and shut back washing valve.
- Confirm the direction of rotation of the aeration blower by turning the select switch
to "RUN"
- Open the manhole
- Look into the tank to make sure that both the 1St Biofilter tank and the 2nd Biofilter
tank are being aerated.
- The quantity of aeration in the 2nd Biofilter tank should be adjusted by the aeration
adjust valve approximately to 16 kPa on pressure gauge.
- After adjustment, check that the 2nd Biofilter tank is being aerated.
- Open the airlift valve to ensure that air (air bubble) is coming out in the treated water
tank. The quantity of air is made normal if the bubbles come out continuously without
interruption: adjust if excessive.
- Check the UV lamp has been lit from the sight-glass of sterilizer.
- Open the valve on the sewage supply pipe so that sewage may enter the treatment
plant.
1. BLOWER MAINTENACE
- Check the quantity of oil in the oil level indicator of aeration blowers (Sight glass). If
the level is low, replenishment by using the recommended lubricating oils.

- Once every six months (especially when the oil contains dirt and looks black) drain the
oil from the drain opening of the oil bath and refill with new oil to proper level.
- Once every six months replenish the grease by adding grease to threaded caps.
- Remove the air filter cover of aeration blowers. Take out the filter and wash oil, dust
etc. out of the filter with detergent. After drying completely, reassemble the filter and
install as before.
2. INSPECTION OF V-BELT TENSION
- carry out check of the tension of V-belt once in biweekly. If the tension is insufficient,
adjust it.
3. CLEANING OF BIO-FILTER TANK SCREEN
- Cleaning of the bio-filter tank screen. Open the manhole and remove foreign matter
from the screen.

4. BACK WASHING AND SLUDGE DISCHARGE OF BIO-FILTER TANK
Back washing and sludge removal should be done monthly.

- Turn the discharge pump switch to "MANUAL".
- Open back washing valve and shut 1st aeration valve and 2nd aeration valve.
- Turn the blower switch to "RUN". Continue this state about 20 minutes. Fixed sludge
on 1St packing media will be removed.
- After 20 minutes, open 2nd aeration valve, and shut back washing valve.
- Continue this state about 10 minutes. Fixed sludge on 2nd packing media will be
removed.
- After 10 minutes, open 1St aeration valve.
- Shut treated water valve; open stop valve, bio-filter tank valve and separation tank
valve.
- Turn the discharge pump switch to MANUAL before pressing the START button to
discharge the sludge within the tank.
- Open cleaning water inlet valve, and cleaning water flow into the treatment plant.
- When the indicator lamp marked "HIGH WATER LEVEL" on the control panel lights.
Close the cleaning water inlet valve and shut bio-filter tank valve, separation tank
valve and stop valve.
- Open treatment water outlet valve, and turn discharge pump switch to "AUTO".
- Turn the blower switch to "RUN".

5. CLEANING OF UV LAMP
- Close three-way valve on sewage side. Sewage will not flow in the sewage treatment
device, and that it will be discharged outboard directly.
- Change the switch of the discharge pump to “MANUAL". press “START” button to
discharge the treated water from the treated water tank. When the water has been
discharged, press “STOP” button to bring the discharge pump to a stop.
- Turn off the UV sterilizer power source in the control panel, and check that the UV
lamp has been put out.
- Close the treated water valve, and then open the drain valve situated in the lower part
of the sterilizer main unit to drain a residual water.
- Detach the flange of the UV sterilizer, before pulling the UV sterilizer out of the main
unit carefully.
- Wipe completely the outside of the jacket with a piece of soft cloth.
- Visually check, from on the outside of the jacket. If there is no abnormality, attach the
flange for restoration.
- Open the treated water valve and the stop valve and slightly open the cleaning water
inlet valve, in order to directly fill water in the sterilizer main unit. Open the sampling
cock situated in the upper part of the main unit to let air out completely, and then
close the cleaning water inlet valve and the stop valve.
- Turn ON the UV sterilizer power source in the control panel and check that the UV
lamp has been light. Then bring the discharge pump switch to AUTO to let sewage flow
in the treatment device.

M.G.P.S
WORKING PRINCIPLE OF M.G.P.S

Copper is considered one of the three most toxic heavy metals (mercury, lead, copper). The
concentration of copper in solution is more than 2 ppm it can be toxic to humans, if less than
2 ppm it is sufficient to prevent marine life from setting and multiplying. There for, people
often use to paint for the ship bottom.
Marine biology (barnacles, mussels and other lower forms) enter pipework sea water system
and settle on the internal surface of pipes where they rapidly grow and multiply. That sea
water lines can become blocked, corroded, and thinned.
There for, a Marine Growth Prevent System is mounted on the ship to fighting marine growth.
MGPS is based on the electrolytic principle and consist of cooper, aluminium (or ferrous) are
insulated from the hull as anodes which are fed with an impressed electrical current from
control panel, and the hull side as cathode.
When giving the direct current to the copper electrode insulated from the hull as anode, and
to the hull as cathode. The copper (+) ion generated at the copper electrode is beginning to
melt into the sea water. The copper ion in the reaction tank is attached to both inner wall of
the sea chest and the seawater pipes onboard the vessel, they are acted effectively to repress
marine growth growing at in initial stage.
Same with the direct current as above apply to the aluminium electrode insulated from the
hull as anode, and to the hull as cathode. The aluminium hydroxide like a colloid state is
beginning to melt into the sea water. The soluble water aluminium is also attached to the sea
chest inside walls and inner surface of the pipes effectively which make to the film of a weak
alkali to repress corrosion.
INSPECTION AND MAINTENANCE
1. Taking out the scale and trash accumulated in the Reaction tank; This maintenance
interval once every 3 days for 10-20 min. per one.
- Switch "OFF" the power source on the control panel.

- Shut the sea water supply valve for the Reaction tank.
- Fully open the drain valve and air valve.
- When sea water inside reaction tank has been discharged, close drain valve.
- Open the sea water supply valve for the reaction tank and close air valve.
- Turn ON the power source.
2. Flushing work of the Reaction tank;

This maintenance interval, once a month and duration of injection for each Injection
nozzle is for 10~ 20 minutes under following order.
- Switch "OFF" the power source.
- Shut the seawater supply valve for the Injection nozzle on Port. Open the supply valve
for the Reaction tank and for the Injection nozzle on STBD, and to shut the drain valve.
- Seawater amount flow to the Reaction tank shall be supplied far more than the rated
flow amount by adjusting its supply valve.
- After the above work, same flushing work apply to the Port side one.

3. Re-tightness work for the fitting screw of the Electrodes; on the earth bolt and on the
reaction tank inside. The maintenance interval; once after the ship’ s delivery, 3~5
months under following order.
4. Regular maintenance with overhauling of flow-meter and strainer.

This maintenance interval once every 3 ~ 5 months.
Anti-corrosive paint was coated on the flow-meter and strainer of internal surface. If
this paint is found such wear down or, peeling off there, Touch-up painting is
requested.
5. For preventing flapper get in to sticking, requested do handling the inlet valve of
reaction tank with opening and shutting 2 or 3 times every once a week. Switch off
the power before operating the valve.

6. Removal of the scale in the tank and on the electrodes once after ship’s delivery, then
once every 3-5 months under electric power is OFF and remove the scale with open
up the up cover of the tank.
- Put off the electric power of the control panel.
- Shut the seawater supply valves for the Reaction tank and for each nozzle
- Fully open the drain valve, air vent valve, and then take out the sea water in
the tank.
- Take out the upper cover of the Reaction tank and lift up it together with the
Electrodes. Then, eliminate the scale fitted on the Electrodes.
- After that, polish the Electrodes surface with such a kind of sand paper until its
texture comes out.
- Cut only the flaking off part when the insulating tape has flaked off.
Adjust method of flow distribution into 2m3/h for high sea-chest of PORT, 2m3/h for
high sea-chest of STBD, and 4m3/h for low sea-chest with 8m3/h supplying to the
Reaction tank (if using low sea-chest)
It is requested that distribution flow amount to each sea-chest from the Reaction tank
shall be depending on the judgment from the pump capacity and its working
condition.
FRESH WATER GENERATOR
1. DAILY
• Inspection of Fresh Water Generator and peripheral equipment.
• Check of water leaks.
• Check of each part temperature.
• Temperature of main engine jacket water inlet and outlet. Maintaining main engine
jacket fresh water temperature between 80 to 85°C. If temperature difference
between inlet and outlet of main engine jacket water at evaporator is less than 6-7°C,
it may cause scale.
• Temperature of cooling sea water inlet and outlet. If temperature difference between
inlet and outlet is small (less than 8°C), there is possibility that flow rate Inside cooling
pipe of condenser may become too fast and cause erosion. Adjust by sea water outlet
valve.

• Temperature of body inside. When cooling sea water temperature is low and
temperature of body Inside is low (less than 45°C), increase temperature to 48-50°C
by closing vacuum control valve.
• Check of abnormal noise.
• Check of each part pressure.
• Ejector pump inlet and outlet pressure.
• Ejector inlet pressure.
• Shell pressure.
• Sea water supply pressure (Feed water pressure).
• Distilled water pump outlet pressure. Confirm that compound gauge at distilled water
pump outlet is over 0.1 MPa.
• Check of boiling state.
• Check of amount of generated water.
• Check of salinity concentration.
2. EVERY MONTH
• Cleaning of return water strainer.
• Inspection of corrosion bar.
• Inspection of salinity meter.
• Inspection of salinity meter cell.
• Inspection of ejector.
• Inspection distilled water pump.
• Checking and cleaning of sight glass.
3. EVERY 6 MONTH
• Check of scale adhesion and cleaning methods
• Vacuum leakage test
4. EVERY YEAR
• Inspection of ejector
• Inspection and disassemble of distilled water pump
• Inspection and disassemble of ejector pump
• Inspection of fresh water flow meter
• Inspection of return solenoid valve

OPERATION PROCEDURE
1. STARTING
- Check around equipment and make sure no leaking water.

- Check all valves close properly.
- Turn on main power and confirm that power display is lightened.
- Fully open cooling seawater outlet and inlet valve.
- Vent air at air vent valve of condenser, and make sure that air was vented.
- Fully open ejector pump inlet valve and overboard drain valve. Confirm that outlet
valve is closed. Air vent of ejector pump and confirm that air is not contained in water.
- Start operation of ejector pump.
- Confirm that ejector pump is running in right direction.
- After motor reach to normal revolution, check pressure of ejector side.
- Open outlet valve of ejector pump slowly and confirm that inlet pressure is more than
0.47MPa. Open outlet valve of ejector pump immediately may cause pump to
deteriorate sooner.
- Check shell pressure by vacuum gauge, and confirm that shell pressure is less than
- 0.090MPa.
- Open seawater supply inlet valve.
- Adjust seawater supply rate at supply water flow rate control valve. (+0.01 ~
+0.03MPa)
- Light up shell from sight window with a lamp, and confirm that sea water is over flow
from evaporator top part and water level in shell is not raised.
- Open main engine jacket fresh water inlet valve slightly and make sure that sea water
is boiling calmly.
- Vent air at air vent valve of evaporator, and make sure that air was vented.
- Open main engine jacket fresh water outlet valve slowly, and make sure that sea water
is boiling.
- Make sure that distilled water appeared in fresh water level gauge.

- Close slowly main engine jacket fresh water by-pass valve and confirm distilled water
raise quickly.
- Start distilled water pump and open outlet valve of distilled water pump, confirm that
flow meter is operated.
2. STOPPING
- Fully open main engine jacket fresh water by-pass valve.

- Fully close main engine jacket fresh water inlet and outlet valve gradually.
- Confirm that boiling is stopped slowly from sight glass of shell.
- With decrease of distilled water, squeeze outlet valve of distilled water pump.
- Confirm that generating fresh water is stopped.
- Fully close distilled water pump outlet valve.
- Stop distilled water pump.
- Fully close seawater supply inlet valve.
- Fully close ejector pump outlet valve.
- Stop ejector pump.
- Fully close ejector pump inlet valve.
- Fully close overboard drain valve.
- Fully open vacuum release valve.
3. EMERGENCY STOPPING
- Fully open main engine jacket fresh water by-pass valve.

- Fully close main engine jacket fresh water inlet and outlet valve.
- Stop distilled water pump and ejector pump.
- Close each valve.
- Remove cause of abnormal noise or water leaks.
1. CLEANING OF SCALE
When there is a hard layer of scale inside separator and plate, do not remove them. It
may cause damage to interior coating. Soft scale can be washed off with water.
To clean scale in evaporator:
- Make sure that fresh water generator is stopped.
- Make sure that vacuum of body inside is released.

- Remove sight glass.
- supply water to evaporator inside.
- Confirm that seawater is over flow.
- Pour chemical solution from sight window.
- Dilute hydrochloric 30% to 6%. An evaporator capacity 60 litters need 12 litters
hydrochloric + 48 litters fresh water = 60 litters compound liquid.
- Soaking compound liquid for 2-3 hours
- Open drain valve and drain them.
- Neutralized chemical with neutralizer and confirmed that is neutrality with PH test
paper.
- Open drain valve and drain chemical.
- If scale is not removed immediately, repeat cleaning 2 or 3 times.
2. CLEANING OF CONDENSER
- Close cooling water inlet and outlet valve of condenser.

- Open air vent cock and drain valve to drain water in condenser.
- Remove the screws fixing the front cover and open the cover.
- Scrub off the scale deposits inside the cooling tube with a brush and fresh water.
- Assemble the cover with opposite procedure as disassemble.
3. INSPECTION OF CORROSION BAR
- Remove corrosion bar installation fitting (cap) from the condenser cover.
- Replace corrosion bar when exposed part from cap is worn within 2/3 of the volume.
- Install corrosion bar to the condenser cover

- After cleaning of condenser and inspection of corrosion bar, close the drain sea water
cooling on the condenser cover, and open sea water cooling inlet valve. Air vent for
sea water cooling of condenser, then close air vent.
- Open sea water outlet valve of the condenser.
4. CLEANING OF RETURN WATER STRAINER
- Check that fresh water generator is stopped.

- Place case under strainer to prevent fresh water spillage, and remove cap.
Water and impurities in strainer are drained.
- Remove impurities from screen by air pressure, and put cap and plug back in place.
5. CLEANING OF ELECTRODE SALINITY METER CELL
- Make sure that power supply of salinity meter is OFF.

- Remove salinity meter cell.
- Wipe dusts and scale on electrode with soft cloth. Do not polish electrode with
sandpaper or file.
- Install salinity meter cell again.

TROUBLE SHOOTING
1. Salinity concentration is high.

- Distillate water is contaminated by impurities, that lead to increasing electrical
conductivity. => Discharge impurities from distillate water by open air vent of
distillate water pump.
- There are conductive impurities attaching on electrode of salinity meter cell. =>
Check and remove impurities from electrode.
- There is water leaking to salinity meter cell cap inside. => Check, clean and test
insulation of salinity meter cell.
- Volume of generated water is too much because jacket fresh water flow rate is too
high. That lead to steam occurring more than steam separation capacity. => Open
by-pass valve of main engine jacket.
- Water level of body inside is too high, that causes by overboard valve is not opened
or brine piping is stuck. => fully open overboard valve and check line piping,
remove adherence inside brine piping.
- There is leaking of sea water into distillate water from condenser tubes. => Check
leaking of sea water, replace tubes or plug them.
- Demister is dirty, that make impurities falling to distillate water. => Open cover
plate, clean demister by fresh water.
2. Evaporating temperature is too high.
- Thermometer of separator is incorrect. => Replace thermometer.
- Vacuum release valve is open. => Close vacuum release valve.
- Cooling seawater flow rate is too small. => Adjust amount of cooling sea water.
- Temperature difference of condenser inlet and outlet is small. That causes by dirty
in cooling tubes of the condenser or did not air vent for sea water side of the
condenser after cleaning. => clean tubes, air vent for the condenser.
- Vacuum control valve is closed. That lead to air bleed is not performed. => Open
and check vacuum control valve.
- Vacuum is leaked from generator. => Check and repair leaking position.
- Distilled water pump is not working properly. => check outlet pressure of distilled
water pump and repair cause of abnormal.
3. Generated water rate is insufficient.
- Main engine jacket flow rate is small. That makes insufficient of amount of heat
for evaporator. => Squeeze bypass valve of main engine jacket.
- There is air inside heater. => vent air for heater.
- Vacuum control side is insufficient. => Check leaked or stuck of vacuum control
pipe side and open vacuum control valve.
- Insufficient of heat exchange in heater because there is scale formation in heating
tubes. => clean scale.
4. Generated water amount is insufficient.
- Pressure of body inside is insufficient. => Check ejector side, check stuck of vacuum
control piping side and vacuum control valve.
- Return solenoid valve is leaked. => Clean solenoid valve.
- Heater heating pipe outside is dirty. That make to reduce sufficient of heating
exchange. => clean heater heating pipe outside.
- Cooling sea water flow rate is insufficient. => Adjust cooling seawater flow rate.

- Distillate water pump is decline. => check and replace mechanical seal.
- Distilled water pump outlet valve opening is insufficient. => Adjust distilled water
pump outlet valve opening.
- There are unnecessary substances mixed to distilled water pump and suction
piping. => Disassemble and inspection of pump and piping. Remove unnecessary
substances.
- Back pressure of distilled water pump is higher than allowable. => Reduce back
pressure, bringing it to no more than 0.2Mpa.
- Failure of flow meter. => check and replace parts.
5. Malfunction of ejector.
- Ejector inlet pressure is lower than 0.47 MPa. => Confirm direction of motor
rotation; Vent air; Open and inspect of ejector pump, replace parts.
- Discharge pressure of ejector pump is higher than allowable. => Check overboard
drain valve and piping.
- Check valve of air and brine are stuck. => Open and inspect of check valve, replace
parts.
- Worn ejector nozzle. => replace parts.
- There are unnecessary substances mixed to ejector. => Remove unnecessary
substances from ejector.

AIR CONDITIONER
1. DAILY
• Inspection of refrigerant of compressor. Confirm the oil to be visible through the oil
level gauge when the compressor is running.
• Inspection of compressor discharge pressure. Discharge pressure (high pressure) to
be within the range 1.3-2.0 MPa in normal operation.
• Inspection of compressor suction pressure. Suction pressure (low pressure) to be
within the range 0.35-0.7 MPa in normal operation.
• Condenser cooling water temperature. Check of thermometer that difference
between inlet and outlet of cooling water to be 3-5 °C. When the cooling water
temperature is bellow 24°C, maintain the discharge pressure above 1.3MPa by adjust
the cooling water flow.
• Inspection of vibration and noise. No abnormal vibration and noise by auscultation
and palpation.
2. EVERY WEEK
• Cleaning of air filter.
• Greasing up for the suction side of fan bearing.
3. EVERY TWO WEEK
• Greasing up for pulley side of fan bearing.
4. EVERY MONTH
• General inspection of pipe, valve and clean strainer of heater side.
• General inspection of pipe, valve and clean strainer of cooler side.
• Check of V-belts for fan tension.
• Check of leakage by using a gas detector or a soap solution for refrigerant piping.
• Open the front and rear covers and clean the condenser tubes.
• Check and replace of corrosive bars when they had been consumed more than 50%.
• Check the colour of sight glass placed after dryer, and replace the dryer element if
necessary.
6. EVERY SIX MONTHS

• Check of dirtiness and change the oil if dirty.
7. ANNUALLY
• Test of function pressure of dual pressure switch for its cut-out.
- High side: by interrupting the condenser cooling water, check the pressure
gauge to confirm that Cut-out function is executed with a ±0.01 MPa margin
of high pressure set value.
- Low side: by closing the liquid outlet valve of condenser, check the pressure
of the low pressure set value.

OPERATION PROCEDURE
1. STARTING
Before starting cooling operation, start cooling water pump to supply cooling water to the
condenser. When water begin to flows through the condenser, open the air purge cooks
on the water cover to remove the air from the condenser.
- Turn on the breaker for the fan and the compressor on the panel. The pilot lamp for
power source lights up.
- Press the fan START button to start the fan. The fan will start and the pilot lamp for
operation of fan lights up.
- Fully open the discharge valve of compressor and half open the liquid outlet valve of
condenser.
- Open suction valve of compressor by approximate ½ turn.
- Press the compressor START button to start the compressor.
- Low pressure switch act in a few minutes, and the compressor running. Then fully
open outlet liquid valve of condenser.
- Fully open suction valve of compressor gradually.
2. STOPPING
For normal cooling operation

- Close outlet liquid valve of condenser. In a few minutes or so, the compressor will stop
by the low pressure.
- After compressor stops, press compressor STOP button and fan STOP button.
- Close compressor suction and discharge valve.
- In the case that the air conditioning system will be left unused for a long period such
as dry docking, collect the refrigerant to condenser (pump down).
3. HEATING OPERATION
a) STARTING
- Turn on the breaker for the fan on the control panel of the unit.
- Press fan START button to start the fan.
- Open halfway the bypass valve for the temperature regulating valve, and then open
the drain cook fully.
- Open the steam inlet valve gradually so as to prevent water hammer.
- After finishing drainage, open steam outlet valve and close drain cook valve.
- Close bypass valve and then open the steam inlet valve fully.
- Temperature setting of the temperature regulating valve should be 12-15°C higher
than the target room temperature.
- Open humidifying valve by approximate ¼ turn when the room humidity drops to 30%,
and close humidifying valve when the room humidity raised to 50%.

b) STOPPING
- Close the steam inlet valve.

- Open the drain cook in order to remove drain. In a few minutes drain will flow out,
then close steam outlet valve and drain cook.
- Push the STOP button to stop the fan.
- Turn off breaker for the fan.
4. PUMP DOWN
Collecting all the refrigerant circulating in the unit into the condenser is called pump
down.
A pump down procedure should be carried out to stop the system in cooling operation,
before repair work where accidental refrigerant escape is expected or when the air
conditioning system will not be used for a long period.
1. Make sure cooling water pump is running, the unit is ordinary running.
2. Close the liquid outlet valve of the condenser.
3. Operate until low pressure switch begins working.
4. Pressure in the refrigeration system will raise again with residual refrigerant.
5. Repeat above 3 & 4 two or three times.
6. Press the compressor STOP button and close the compressor discharge valve
immediately, also close the compressor suction valve.
7. On completion of pump down, stop water cooling system.
1. CLEANING OF AIR FILTER
- Looses the screws on the cover of the air filter case which is located at the air suction
side of unit, and remove filter air cover.
- Pull the filter in lateral direction and slide out from the filter holder.
- Wash the air filter with clean water or lukewarm water.
- Dry the filter and return it to the original position.
Do not wash the air filters with water over 50°C.
Dry the air filter in the shade.
Do not attach them in wet condition.

2. LUBRICATION OF THE FAN BEARING
- Make sure moisture and dust are not mixed into the grease during lubrication.
- Do not intermix greases.
- Supply the grease to nipples until it come out of the gap of the bearing a little.
3. INSPECTION OF FAN BELT TENSION
If the fan belt is loose, it slips and air flow is reduced. Furthermore, loose of the fan
belt may cause vibration and noise.
When pressed midway between the pulleys it should move about 8mm. If the fan belt
is looser, tighten the belt in proper tension.

4. CLEANING OF CONDENSER TUBE
- Stop the cooling operation (above procedure).

- Start the fan.
- Open cooling water bypass valve.
- Close cooling water inlet and outlet condenser.
- Drain water out of the condenser by opening drain and air vent cock.
- Remove the cover and clean inside the cooling tubes by a brush and fresh water.
5. INSPECTION OF CORROSION BAR
- Remove corrosion bar installation fitting (cap) from the condenser front and rear
covers.
- Replace corrosion bar when exposed part from cap is worn within 50% of the volume.
- Install corrosion bar to the condenser cover.

6. REPLACEMENT OF DRYER ELEMENT
When the surface colour of the sight glass has turned to yellow-green is time to replace
the dryer elements.
Before replacing dryer elements, the system must be pumped down. After replacing dryer
elements, the system should be air vent.
7. CHARGE OF REFRIGERANT
- Start the cooling water pump.

- Press the fan START button to start the fan.
- Fully open the compressor suction valve and compressor discharge valve.
- Fully close liquid outlet valve of the condenser.
- Connecting tube from the refrigerant cylinder to refrigerant charge port.
- Purge air from the tube.
- Press the compressor START button to start the compressor.
- Repeat running of the compressor several times.
When the liquid level of the refrigerant has reached around a 4/5 of the sight glass of
the condenser, the amount is sufficient to operate the system.
- Close refrigerant charge valve and disconnect refrigerant cylinder.
- Air purge for air conditioner plant if necessary.
8. DETECTION OF REFRIGERANT LEAKAGE
Visual check along through the refrigerant circulation line would be useful in detecting
refrigerant gas leakage. In some cases, oil seeping caused by the leakage is found on a
connecting or jointing part of the line. Otherwise a gas detector should be used to identify
where the leak is coming from.

FUSO DC-8Pro refrigerant gas leak detector is using on this ship.
- Turn on the power
- Place the tip of the leak-detector probe as close as possible to the site of the
suspected leak.
- Slowly move the probe part each possible leakage point.
- When the instrument detects a leak source, the audible tone will alarm.
Additionally, the visual indicators will light from left to right, Green LED then
Orange LED then Red LED as increasing of level indicate that the location is
close to the source.
- When that finished leak-checking, turn OFF the instrument and store it in a
clean place.
1. High discharge pressure

- Discharge valve of compressor is closed or its opening is not enough. => fully open
discharge valve of compressor.
- There is air in system. => purge air by loosening cap nut at the top of the
condenser.
- Cooling water of the condenser is insufficient or too warm. => check strainer, pipe,
suction valves for clogging; adjust cooling water inlet and outlet valves.
- Cooling tubes of the condenser are dirty. => Clean cooling tubes of the condenser.
- Division plate of condenser is corroded. => replace cover of the condenser.
2. Low discharge pressure
- Cooling water temperature of the condenser is too low or it flow too much. =>
adjust cooling water inlet and outlet valves
- Refrigerant returning is mixed liquid. => adjust expansion valve opening; check
sufficient of sensing contacting to suction pipe.
- Piston rings are worn out. => replace worn rings.
- Refrigerant in system is insufficient. => check leakage; replace refrigerant.
3. High suction pressure

- Discharge valve is leaky. => repair or replace discharge valve.
- Expansion valve is overfeeding. => adjust expansion valve opening and check
temperature sensing part is contacting to suction pipe.
- Suction valve seat, piston ring or oil ring are worn out. => check and replace them
4. Low suction pressure
- Liquid refrigerant flow is restricted. => fully open valve in liquid refrigerant line;
check and clean magnetic valve in liquid refrigerant line.
- Lack of refrigerant in system. => locate and repair leak, recharge refrigerant to
specific level.
- Expansion valve is clogged with ice or mixing dust. => open and clean expansion
valve with air blower; replace dryer element if necessary.
- Expansion valve is malfunction. => adjust expansion valve opening; check
- Ability of the cooling coil of evaporator is deteriorated. => check fan; clean
evaporator.
5. Compressor short cycles on low pressure control
- Expansion valve is clogged with dust. => open and clean expansion valve.
- Dryer element is clogged. => replace dryer element.
- Thermo sensing of expansion valve is leaked. => replace expansion valve.
- Low pressure switch set too low. => reset value low pressure switch (cut-out at
0.26 MPa, cut-in at 0.45 MPa)
6. Motor frame is overheated
- Discharge pressure is too high. => check causes above.
- Suction gas temperature is too high. => adjust expansion valve opening.
- Compressor discharge valve is leaked. => repair or replace if necessary.
7. Compressor is not running
- Over-current relay is tripped. => check causes and reset over-current relay.
- Loose wiring. => check all wire junctions and tighten all terminal screws.
- Turn off power switch. => turn on power switch.
- Condenser cooling water is non-flow. => check cooling water pump.
- System shut-down by high pressure switch. => check abnormal and reset high
pressure switch.
- Lack of refrigerant. => locate and repair leak, recharge refrigerant to specific level.
- Low temperature switch is tripped. => check abnormal and reset low temperature
switch.
- Low pressure switch is working. => wait until pressure raises, check setting and
adjust if necessary.
8. Compressor is noisy or vibrating.
- Fixing bolts are loosed. => tighten bolts.
- Fan shaft or fan bearing is damage. => inspect and replace them.
- Fan belt is loosening or tension. => adjust tension of fan belt or replace it.
- Liquid mixed gas return to compressor. Adjust expansion valve opening; check
- Compressor components (valve, piston, piston rings, pin, bearing, connecting rod,
…) are worn or broken. => repair or replace compressor.
- Bad contact of each part of magnetic switch due to rust, dust, foreign object. =>
clean, repair or replace magnetic switch.

9. Low oil pressure
- Oil is dirty. => replace oil.
- Bearing is damaged. => replace bearing.
- Oil level is low. => add oil to proper level.
- Liquid mixed refrigerant return to compressor. => adjust expansion valve.
10. High condensing temperature
- There is air in the condenser. => purge air from purge cock of the condenser.
- Condenser cooling tubes are dirty or clogged. => clean condenser tubes.
- Water leak through division plate of condenser cover. => check deterioration of
rubber packing and replace it; check corrosion of division plate and seal gap by
welding or with bonding agent.
- Condenser cooling water is insufficient. => check and adjust flow rate of cooling
water.
AIR CONDITIONER FOR GALLEY AND AIR CONDITIONER FOR ENGINE CONTROL ROOM
1. DAILY
• Inspection of compressor discharge pressure.
• Inspection of compressor suction pressure.
• Inspection of condenser cooling water temperature.
• Inspection of vibration and noise.
2. EVERY MONTH
• Inspection and cleaning of air filter.
• Inspection of fan belt and fan motor.
3. EVERY TWO MONTHS

• Greasing up for fan bearing.

• Inspection and cleaning of drain pan.
• Cleaning of condenser tubes.
• Inspection and cleaning of corrosion bar.
5 EVERY SIX MONTHS

• Changing of corrosion bar.
• Inspection of refrigerant leakage.
OPERATION PROCEDURE
1. CAUTION FOR OPERATION

• Once the air conditioner is stopped, wait three minutes before starting it. If the air
conditioner is restarted before a lapse of three minutes, it may be overloaded and a
fuse blown or circuit breaker thrown.

• Be sure to attach the air filter before operation. If the air filter does not replace, dust
will gather on the air conditioner and operation will become erratic.
• Be sure turn off the operation switch and disconnect the power supply when the air
conditioner is not used for a long period of time.
• When it is restarted, turn on the power switch at least 6 hours beforehand. Because
it is necessary to energize the crankcase heater for smooth starting.
• Do not place any obstacle in front of the air suction grille or air discharge grille,
because the air conditioner may be overload, which may also cause trouble with it.
• Do not use inflammable sprays such as hair spray, paint near air conditioner in
operation because of danger or fire. Only wipe with dry, soft cloth. If it is very dirty,
use a soft cloth soaked in water or neutral detergent.
• Condenser water should be supplying predetermined volume. If the air conditioner is
operated without water supply, the high-pressure switch will function and stop the air
condition. If condenser water supplying volume is excessive, the life of condenser will
be shortened due to corrosion.
• Discharge and suction pressures shall be within the values show below under the
normal condition.
- Discharge pressure gauge: 1.5 – 2.1 MPa
- Suction pressure gauge: 0.47 – 0.66 MPa
- When suction pressure exceeds above range due to the high temperature of
suction air or excessive are flow, it is necessary to reduce air flow by adjusting
damper.
• There is the electric heater mounted on unit. When stop the electric heater after used,
operate the fan for at least three minutes to cool off the electric heater, which
protects the electric heater from trouble and ensures long life.
• When air conditioner prolonged idle period, should be done following procedure:
- Operate the fan only for haft a day to dry out the inside.
- Be sure to turn off the power switch.
- Extract all water from the condenser cooling tubes. If water remain in the pipe,
it may be frozen in cold weather and the piping damaged.
- Clean drain pan and drain pipe.
INSPECTION AND MAINTENANCE
1. CLEANING OF AIR FILTER
- Loosen the knurling screws on the front suction grilles and then remove the grilles.

- The air filter is attached in front of the evaporator.
- Take out the air filter by gripping its frame.
- Dust the air filter and wash it with clean cold or warm water.
- Dry the air filter and return it to its original position.
Do not wash the air filter in water that is over 50 0C
Do not expose the air filter to direct sunlight for long time, or it may shrink.
Clean the air filter more frequently when the air is very dirty.
2. CLEANNING OF THE DRAIN PAN
The drain pan gathers dust when the air conditioner is used for a long time, and clogs the
drain pipe. If the drain pipe is clogged, water may overflow outside the unit, so remove
dust and dirt from the drain pan and its outlet and then wipe them with a wet cloth.
3. CLEANING OF CONDENSER TUBES
- Stop the cooling operation.

- Close cooling water inlet and outlet of the condenser.
- Remove the right and left-end cover and brush off each cooling tube from left to right
alternately with a brush.

4. INSPECTION OF THE ANTI-CORROSIVE PIECE
- Remove anti-corrosive pieces installation fitting from the condenser front and rear
covers.
- Check the anti-corrosive pieces condition.
- Scrub off the scale deposits on the anti-corrosive pieces.
- Replace the anti-corrosive pieces when they are worn within 50% of the volume.
- Install the anti-corrosive pieces to the condenser cover.
5. LUBRICATION OF THE FAN BEARING
- Remove the access cover on the upper front-side plate of the casing.
- The grease nipples can be seen near the fan. Supply the grease from it by a grease
hand pump.
- Supply the grease until it comes out of the gap of the bearing a little.

6. INSPECTION OF FAN BELT TENSION
If the fan belt is loose, it slips and air flow is reduced. Furthermore, loosing of the fan
belt may cause vibration and noise, so inspect fan belt condition every month.
Press lightly with a finger at middle of fan pulley and motor pulley. V-belt tension is
correct if the V belt slack is about 5mm. When it is looser, adjust it correctly.
ALANYSIS OF TROUBLE SHOOTING
1. Both fan and compressor do not run

- Power switch is turned off. => turn on power switch.
- Wrong wiring in power source. => correct wire.
- Power fuse is blown off. => replace fuse.
- Bad contact. => check continuity, repair or replace them.
- Over current relay is tripped. => check continuity, reset or repair them.
- Magnetic switch for fan motor failure. => check continuity, replace it.
2. Fan run, but compressor does not run
- Mode setting is at “HEAT”. => mode setting is at “COOL”.
- Thermostat switch is interrupted due to suction air temperature too low. => try to
warm up temperature sensor.
- Magnetic switch for compressor failure. => check continuity, repair or replace it.
- Compressor motor trouble or burning. => check insulation, continuity wiring of
motor, check bearing, replace them.
- Compressor trouble. => check internal compounds of compressor and replace
them.
3. Both fan and compressor are running, but stop soon
- Condenser cooling water is low flowing rate or high temperature. => check pipe,
valves and pump.
- Condenser tubes are dirty. => clean condenser tubes.
- Refrigerant charge is short. => check leakage, recharge refrigerant.
- Air filter is dirty. => clean air filter.
- Liquid outlet valve of condenser is closed or opening is not enough. => fully open
liquid outlet valve of condenser.
- Dryer is clogged. => replace it.

- Expansion valve is trouble. => check, clean or replace if necessary.
- Fan and compressor motor are over current due to burning. => try to turn shafts
for stick and remove trouble.
4. Cooling is insufficient
- Cooling load is excessive due to heating source is added, window or doors are left
open.
- Air discharge is not directed to chamber or dampers are closed. => inspect and
rectify
- Expansion valve failure or bad adjustment. => adjust expansion valve opening or
replace if necessary.
- Refrigerant is leaked or insufficient refrigerant charge. => check leak position by
detector, repair it and recharge refrigerant to specific level.
- Condenser tubes are dirty or condenser water flow rate is insufficient and water
temperature is high. =>check valves, pipe and pump; clean condenser tubes.
5. Air flow rate is insufficient
- Fan run reversely. => check direction of fan motor and connect wire correctly.
- Blades air discharge are very tight. => open and adjust degree opening of blades
air discharge.
- Opening degree of damper is insufficient. => check and rectify.
- Air passage is wrong due to opening damper direction incorrectly. => check and
rectify.
- Fan belt is slipped due to loosening of fan belt. => inspect and adjust tension of
fan belt.
- Air filter is clogged with dust. => clean air filter.
6. Operation noise and vibration
- Rotor of fan is damage. => inspect and replace it.
- Fan shaft or fan bearing is damage. => inspect and replace them.
- Fan belt is loosening or tension. => adjust tension of fan belt or replace it.
- Liquid hammer in compressor due to adjusting wrong of expansion valve. =>
readjust expansion valve opening, check internal compressor parts and replace if
necessary.
- Bad contact of each part of magnetic switch due to rust, dust, foreign object. =>
clean, repair or replace magnetic switch.
- Loosen screws, bolts. => tighten screws, bolts.

PROVISION PLANT
INSPECTION AND MAINTANANCE PLAN
1. EVERY DAY
• Confirm the oil to be visible through the oil level gauge when the compressor is
running.
• Discharge pressure to be within the range 1.3-2.0MPa in normal operation
• Suction pressure to be within the range 0.05-0.2MPa in normal operation
• Check by thermometer that difference between inlet and outlet of cooling water to
be 3-5 °C. when the cooling water temperature is bellow 24°C, maintain the discharge
pressure above 1.3MPa by adjust the cooling water flow.
• No abnormal vibration and noise by auscultation and palpation.
• Check evaporator of each room. Confirm that excessive frost does not attach to a
cooling fin. If it is judged that frost disturbs the air flow, remove frost.

• Check leakage by used a gas detector.
• Open front and rear covers and clean the condenser tubes.
• Replace anti-corrosive pieces when more than 50% has been consumed.
• Check the colour of moisture indicator, and replace dry element if necessary.
3. EVERY SIX MONTHS

• Check dirtiness and change the refrigerant machine oil if dirty.
4. ANNUALLY
• Test of function pressure of dual pressure switch for its Cut-out
- High side: by interrupting the condenser cooling water, check the pressure
of high pressure set value
- Low side: by closing the liquid outlet valve of condenser, check the pressure
of the low pressure set value.
OPERATION PROCEDURE
1. PREPARATION BFORE OPERATION
• Check of each pipe joint for refrigerant.

• Check of electric power supply.
• Check of oil level of compressor.
• Check of water leakage.
• Check of cooling water temperature.
• Check of cooling water pressure.
• Check of refrigerant liquid level in the condenser.

2. STARTING
- Let cooling water flow into the condenser.

- Air vent for cooling water in the condenser.
- Run the evaporator fan in each refrigerating chamber.
- Fully open the discharge valve of compressor, the outlet valve of oil separator,
the liquid outlet valve of the condenser.
- Half open the suction stop valve of compressor.
- Fully open the inlet and outlet valves of dryer filter on the expansion valve
panel. Close the by-pass valve of filter dryer.
- Fully open the outlet valve of thermo expansion valve and inlet valve of
refrigerant liquid magnet valve on the expansion valve panel. Keep close the
manual expansion valve.
- Fully open the outlet valve of each chamber on expansion valve panel.
- Fully open the inlet valve and close by-pass valve of evaporator.
- After run the compressor, check the oil conditions and oil level, then fully open
the suction stop valve of compressor.
- Check condition of the oil separator oil return pipe.
- Check for refrigerant leakage again.
3. STOPPING
• Close the liquid outlet valve of condenser. In a minute or so the compressor will stop
by the low pressure.
• After the compressor stops, turn switch OFF for compressor.
• Close the compressor suction and discharge stop valves.
• If the compressor stops for a long time, and cooling operation will not be done, close
the cooling water inlet and outlet valves to stop the cooling water flow. Then open
the drain cock of condenser and remove cooling water from the condenser.
4. DEFROST TIMER
a. Rotate the centre knob in arrow direction (clockwise) to set the time. Do
not rotate the knob counter-clockwise.

b. If a power failure occurs, the present time delayed by duration of which
the power failure because the timer is motor-driver. Therefore, after the
power restoration, rotate the knob in arrow direction to adjust the present
time.
c. Gently pushing the centre knob to rotate.
d. Wipe surface of the timer with cloth moistened with soap water or alcohol.
Do not use benzene or thinner.
e. Set up the defrost timer three times per day. When just after cargo loading,
defrosting should be carried out by manual setting the timer. In this case,
defrosting by shut the refrigerant liquid valve just before the magnetic
valve, then the cooler fan is running. Confirm the defrosting condition after
shut off the liquid valve 2-3 hours. Do not use the water spray or strike by
ice picker for taking off ice.
OPERATION
• Set the desired frequency by frequency selector switch.
• Frequency setting
- Set frequency by adjusting the Hz selector with a slot screw driver.
• Setting output
- ON setting: turn the setting element inward, a red mark will appear around
the dial.
- OFF setting: turn the setting element outward, a red mark will disappear.
• Turn the setting element sufficiently until the click is felt.
• Manual switch
- When manual switch is set to AUTO, ON/OFF operation start according to
setting elements.
- When the manual switch is set to ON, output is turn ON irrespective of
setting elements.
1. DETECTION OF REFRIGERANT LEAKAGE
In some cases, oil seeping cased by the leakage is found on a connecting or jointing part of
the line. Furthermore, refrigerant gas might be leaking inside the condenser. In this case, stop
the cooling water flowing, and drain the water out of the condenser by open the drain cock.
Detecting refrigerant gas leakage around the drain cock. If the detector indicates the leakage,
inspect gas leaking points on all tubes and tube plates after removing the front and rear
covers.

2. CLEANING OF THE CONDENSER TUBE
- Stop the cooling operation

- Close cooling water inlet and outlet condenser.
- Remove the right and left-end cover and brush off each cooling tube from left to right
alternately with a brush.

3. INSPECTION OF ANTI-CORROSIVE PIECE
- Remove anti-corrosive pieces installation fitting from the condenser front and rear
covers.
- Check the anti-corrosive pieces condition.
- Scrub off the scale deposits on the anti-corrosive pieces.
- Replace the anti-corrosive pieces when they are worn within 50% of the volume.
- Install the anti-corrosive pieces to the condenser cover.
4. REPLACEMENT OF DRYER ELEMENT
Dryer is located in the refrigerant line coming from the condenser in order to remove foreign
particles as well as moisture in refrigerant flow by adsorption of dryer elements. Observe
periodically the sight glass adjacent to the dryer to see the moisture level. When the surface
colour of the sight glass has turned to yellow-green is the time to replace the dryer element.
Before replacing the dryer element, the system must be pumped down. After replacing the
dryer element, the system should be air purge.

5. REPLENISHMENT OF REFRIGERANT MACHINE OIL
1. Pump down the refrigeration system, there is low suction pressure.

2. Turn off the power on the panel of the unit.
3. Connecting tube from the oil charge port to the oil can. (open the cap of the oil
can before oil charging. Oil charge should be finished within 10 minutes from open
the oil can cap, because ester easily absorbs moisture, which is damaging
compressor).
4. Open the purge port on the compressor discharge valve to discharge refrigerant
remain in compressor, pressure gauge reduced to 0, then close purge port.
5. Turn on the power on the panel.
6. Start compressor several times by low pressure switch.
7. Open the oil charge port valve, the oil through into the compressor by vacuum
pressure itself.
8. When the oil machine level of the compressor has reached around a 2/3 of the oil
level gauge, close the oil charge port valve.
9. Purge air in line charge port lead to the compressor:
- Open the compressor suction valve.
- Slightly open outlet liquid valve of the condenser.
- Open the purge port nut on the compressor discharge valve to escape the air.
- When complete air purging, close the compressor suction and then close
outlet liquid valve of the condenser. Tighten the purge port nut.
- Detection of air leakage on the purge port.
6. REMOVAL AND REPLACEMENT OF REFRIGERANT MACHINE OIL
1. Pump down refrigeration system.

2. Turn off the power on the panel of the unit.

3. Open the purge port on the compressor discharge valve to escape air in the
compressor, the discharge pressure gauge reduced to 0, then close purge port.
4. Open the oil charge valve of the compressor and open the drain nut to drain the
refrigerating machine oil.
5. When drainage completed, close oil charge port valve and drain nut. Connecting
tube from oil charge port to oil can.
6. Turn on the power.
7. Starting compressor 2-3 times by low pressure switch.
8. Replace refrigerant machine oil as above steps 7 – 9 (replenishment of
refrigerating machine oil).
7. CHANGE OVER FROM NO.1 COMPRESSOR TO NO.2 COMPRESSOR
1. In case of both condensers is sharing a refrigerant volume

Pump down to No.1 condenser. Close suction stop valve, discharge valve of No.1
compressor, outlet valve of oil separator. Shift switch OFF for No.1 compressor.
Transfer refrigerant from No.1 condenser to No.2 condenser:
- Let cooling water flow into No.2 condenser.
- Air vent for cooling water in the condenser.
- Close liquid outlet valve of No.2 condenser.
- Open discharge valve of No.2 compressor and half open suction stop valve of
No.2 compressor.
- Shift switch ON/OFF of No.2 compressor several times to check compressor
running condition.
- Open liquid outlet valve of No.1 condenser.
- Shift switch ON to run compressor.
- Check refrigerant level inside No.2 condenser is raising and refrigerant level
inside No.1 condenser is reducing gradually.
- After refrigerant inside No.2 condenser is raised to specific level. Close liquid
outlet valve of No.1 condenser.
- Slightly open liquid outlet valve of No.2 condenser.
- Check oil conditions and oil level, then fully open the suction stop valve of No.2
compressor.
- Check condition of the oil separator oil return pipe.
- Check for refrigerant leakage.
- Close the cooling water inlet and outlet valves to stop the cooling water flow
for No.1 condenser. Then open the drain cock of No.1 condenser and remove
cooling water from No.1 condenser.
2. In case each compressor is working with independent refrigerant volume.
- Pump down to No.1 condenser. Close suction stop valve, discharge valve of
No.1 compressor, outlet valve of oil separator. Shift switch OFF for No.1
compressor.
- Close the cooling water inlet and outlet valves to stop the cooling water flow.
Then open the drain cock of condenser and remove cooling water from the
condenser.
- Start No.2 compressor:
o Let cooling water flow into No.2 condenser.

o Air vent for cooling water in No.2 condenser.
o Fully open the discharge valve of No.2 compressor, the outlet valve of
oil separator, the liquid outlet valve of No.2 condenser.
o Half open the suction stop valve of No.2 compressor.
o Shift switch ON to start No.2 compressor.
o After running No.2 compressor, check the oil conditions and oil level,
then fully open the suction stop valve of No.2 compressor.
o Check condition of the oil separator oil return pipe.
o Check for refrigerant leakage.
1. Compressor does not run

- The power switch is not turned on. => turn on the switch.
- Over current relay is tripped. => reset over current relay.
- Electric wire is loosened. => check all wire junctions and tighten all terminal
screws.
- Low pressure switch is opened. => wait until pressure raises and switch is closed.
Check setting and adjust if necessary.
- Cooling water is not flowed in the condenser. => operate cooling water pump.
- High pressure switch is not reset. => press reset button of switch.
- The refrigerant is leaked. => trace leak point and repair it completely, charge
predesigned volume of refrigerant.
- Thermostat is activating and the contact point is opened. => wait until
temperature room raises and contact point is closed.
2. Discharge pressure is too high
- Discharge valve of compressor is closed or its opening is not enough. => fully open
discharge valve of compressor.
- There is air in system. => purge air by loosening cap nut at the top of the
condenser.
- Cooling water of the condenser is insufficient or too warm. => check strainer, pipe,
suction valves for clogging; adjust cooling water inlet and outlet valves.
- Cooling tubes of the condenser are dirty. => Clean cooling tubes of the condenser.
- Division plate of condenser is corroded. => replace cover of the condenser.
- Refrigerant is overcharged. => drain the excess refrigerant.
3. Discharge pressure is too low
- Cooling water temperature of the condenser is too low or it flow too much. =>
adjust cooling water inlet and outlet valves.
- Refrigerant liquid side stop valve is closed or its opening is not enough. => fully
open the stop valve.
- Expansion valve is clogged or defective. => open, clean or replace expansion valve.
- Components of compressor (bearing, piston rings, pin, connecting rod) are worn.
=> replace parts.
4. Suction pressure is too high
- Chamber temperature is high due to overloaded provision. =>
- Expansion valve is overfeeding. => adjust expansion valve opening.

- Suction valve seat, piston ring or oil ring are worn out. => check and replace them.
5. Suction pressure is too low
- Liquid refrigerant flow is restricted. => fully open valve in liquid refrigerant line;
check and clean magnetic valve in liquid refrigerant line, check or replace
thermostat.
- Suction stop valve of compressor is closed. => fully open suction stop valve.
- Lack of refrigerant in system. => locate and repair leakage, recharge refrigerant to
the specific level.
- Expansion valve is clogged with ice or oil mixing dust. => open and clean expansion
- Expansion valve is malfunction. => adjust expansion valve opening or replace if it
is defective.
- Expansion valve throttling due to wet compression (poor defrosting -> excessive
frosting on evaporator, short circuit blowing air due to overload cargoes in the
chamber, fan is defective). => raise time of defrosting, reduce cargoes in the
chamber, check and repair fan if necessary, readjust expansion valve opening if
necessary.
6. Frosting on compressor
- Expansion valve is excessive opening, that lead to superheat into evaporator
becoming too low. => readjust expansion valve opening.
chamber, check and repair fan if necessary.
7. Cylinder head cover is overheated
the specific level.
is defective.
- Malfunction or closing of liquid solenoid valve. => check and repair thermostat,
replace solenoid valve.
- Compressor is failure. => inspect components (oil, valves, piston, piston rings,
bearing, pin, connecting rod) and replace parts.
8. Poor cooling
- Frequent door opening. => reduce the times of door opening.
- Forgot turn off the light in the chamber. => turn off the light.
- There are high temperature articles inside the chamber. => cool down to normal
temperature before storage.
the specific level.
is defective.

- Expansion valve is excessive opening, that lead to superheat into evaporator
becoming too low. => readjust expansion valve opening.
chamber, check and repair fan if necessary.
- Compressor is failure. => inspect components (oil, valves, piston, piston rings,
bearing, pin, connecting rod) and replace parts.
BATTERY AND ELECTRIC SYSTEM
1. INSPECTION BATTERIES IN BATTERY ROOM
• Turn on the light of battery room

• Before entering battery room, natural ventilation battery room until oxygen
content inside battery room is more than 18 %.
• Do not forget wearing PPE (apron, safety goggle, safety gloves, safety shoes,
safety mask, safety helmet) before checking batteries.
• Check list of battery:
- Temperature room
- Acid level inside batteries
- Temperature inside batteries
- Specific of acid
- Voltage of each battery
- Wire connecting condition
- Leakage of acid
• Record into log book

2. INSULATION RESISTANCE MEASUREMENT
• Turn OFF power supply before measurement.

• Check that the insulation resistance between lead wire and grounding is 1 MΩ
or larger.

FREE-FALL LIFE BOAT ENGINE
INSPECTION AND MAINTENACE PLAN
1. EVERY WEEK
• Starting the engine and running the engine in no load at 1500-1800 min-1 for 5 mins
at least. That is to guard against faulty combustion due to a dirty fuel injection valve
or combustion chamber.
• General check of engine running include:
- Easily start engine,
- Smoothly run engine,
- Correctly operate of warning devices,
- Abnormal vibration or noise,
- Normal colour of smoke,
- Leakage of fuel oil, lubricating oil, coolant,
- Normal of level fuel oil, lubricating oil, coolant tank,
- Operation of the remote control,
- Voltage of batteries condition.

• Drainage of the fuel tank.
• Drainage of the fuel oil water separator.
3. EVERY YEAR
• Cleaning of the fuel oil water separator.
• Replace the fuel oil filter.
• Replace coolant for cooling water.
• Replace lubrication oil.
• Check of V-belt tension.
• Check of electric wire and sensor.
• Check of rubber hose and hose clip.
OPERATION PROCEDURE
• Check and supply fuel oil.

• Check and supply oil.
• Check and supply marine gear oil.
• Check and supply coolant.
• Check the operation of the warning devices.
• Check the operation of the control remote handle.
• Check of batteries condition.

2. STARTING
• Put the control lever in “NEUTRAL” and pull out the neutral knob.
• Select starting battery number is number 1, number 2 or both and turn ON switch.
• If the alarm buzzer and all alarm lamps operate when turning on the power switch on
the instrument panel, the warning devices operate correctly.
• Press the start switch and the glow switch (hold for 1 0 seconds).
• Pushing the start switch turns on the engine. Release the switch after the engine
starts. If the alarm lamps and the alarm buzzer stop operating, the warning devices
operate correctly.
3. STOPPING
• Before stopping the engine, operate it at low speed for 5 minutes.

• To stop the engine, move the remote handle to NEUTRAL (low engine speed) and push
the stop switch on the instrument panel.
• Turn OFF switch.

RESCUE BOAT ENGINE
INSPECTION
Every week, check rescue boat engine as list follows:

• Check the engine oil level.
• Check the lanyard stop switch.
• Inspect the fuel system for leaks.
• Inspect the engine tightness.
• Check the steering system for binding.
• Check the propeller for damage.
• Check batteries condition and recharge if necessary.
• Check running condition of the engine.
TRY THE ENGINE
1. PREPARATION BEFORE TRY THE ENGINE
• Install the flushing attachment so the rubber cups fit tightly over the cooling water
intake.
• Attach a water hose to the flushing attachment. Open the water inlet valve and adjust
the flow so water is leaking around the rubber cups to ensure the engine receives an
adequate supply of cooling water.
• Check fuel oil tank level.
• Loosen the air vent screw on the fuel tank cap.
• Feed fuel to the carburetor by squeezing the primer valve until firm.
• Place the control lever at Neutral (N).
• Warm-up the engine by pull the rewind starter slowly until feel the starter engage,
then pull rapidly to crank the engine. Allow the rope to return slowly.
• Turn ON one of the start batteries
2. STARTING

• Set the lanyard stop switch to run position.
• Move the throttle only lever to the open position.
• Insert, push, and turn the key to the start position.
• When the engine starts, release the key, it will return automatically to the run
position.
• If the engine fails to start in 10 seconds, wait 30 seconds and try again.
• Check and confirmed that there is a steady stream of water flowing out of the water
pump indicator hole. If cooling water is not discharged, and operation continues, it
may cause overheating, resulting in engine damage.
3. GEAR SHIFTING
• Move the throttle only lever to the lower position, then shift the control lever to
Forward (F) position.
• Shift the outboard only when the engine is at idle speed. To change Forward (F) to
Reverse (F), first idle the engine and shift into Neutral (N). With the engine still
running, slowly engage and gradually increase the reverse speed.
4. STOPPING
• Place remote control lever at Neutral (N) and idle the engine.
• Turn the key to the off position, or pull the lanyard stop switch.
• Tighten the air vent screw on the tank cap.
• Turn OFF the start battery.
the lanyard stop switch

EMERGENCY FIRE PUMP
1. EVERY MONTH
• Check of self-priming pump and associated equipment
• Check of pressure gauge

• Check of bearing
• Check of clutch facing
3. EVERY YEAR
• Check of neck bush
• Check of pump shaft
• Check of shaft coupling bolt
• Check and replace of mechanical seal
• Check and replace of O-ring
• Check and replace of casing ring
• Check of impeller
• Check of impeller ring
• Check of impeller key
• Cleaning self-priming pump
OPERATION

• Check around emergency fire pump to make sure there is not leaking water.
• Check the water in the circulating water tank and fill it up with water.
• Check of the bearings are lubricated.
• Turn the pump shaft by hand to make sure it turns smoothly.
• Operation of hydraulic system for open butterfly valve on suction side.
- Turn the hand to OPEN position.
- Move back and forth of the hand pump lever until the needle of hydraulic
indicator move to open position.
• Close valve on the discharge side.
2. STARTING
• Repeat START and STOP button on the panel once or twice to confirming that there is
not abnormal condition.
• After confirmed emergency fire pump is in good condition for running, press START
button on the panel.
• When pump revolutions and pressure have raised, open gradually the valve on the
discharge side until the pressure drops down to the specified pressure.
• During operation, pay attention to bearing temperature, motor temperature,
vibration and noise; if self-priming pump that is not effect within 5 minutes, stop pump
immediately because lack of water may cause overheat.
3. STOPPING
• Press STOP button on the panel.
• Operation of hydraulic system for close butterfly valve on suction side.
- Turn the hand to SHUT position.
- Move back and forth of the hand pump lever until the needle of hydraulic
indicator move to shut position.
• Close valve on discharge side.

REPORT OF THIRD ENGINEER
• F.W.G monthly running report (DK-10-2200(3))

• Auxiliary Boiler monthly working report (DK-10-2100(5))
• Report of lube oil consumption
• Monthly report of chemical
• Boiler water log sheet
• Cooling water log sheet
• M.G.P.S daily record
• Battery check list report
• PMS working report
FUEL CONSUMPTION REPORT
1. TIMES OF FUEL CONSUMPTION REPORT
• Stand-by for departure

• All line clear
• Pilot off
• Run-up
• Noon
• E.O.S.P
• Drop anchor
• Anchor clear
• Stand-by for arrival
• Pilot on board
• Fist line on shore
• Finish engine
How to calculate fuel oil consumption.

• Correct specific gravity (SG) at t℃
SG (toC) = SG (15oC) - [[ t℃ - 15] x 0.00065]
• Calculate fuel oil consumption based on Flow meter
[+,-. /0102 (405-20) 7 +,-. /0102 (85102)] ×:;(1℃)
Consumption = (&&&
(Tons)
• Total Fuel oil remain on board (R.O.B)
R.O.B = R.O.B (before) – Consumption
Noon report data
• Hours under way (H.U.W)
H.U.W AT NOON = HOURS (from ALL LINE CLEAR to NOON)
• Hours propeller (H.P)
H.P AT NOON = HOURS (from RUN UP to NOON)
• Revolution counter (R.C) in a day
R.C (IN A DAY) = R.C (AT NOON) – R.C (AT YESTERDAY NOON)
• Average Revolution Per Minute of M/E (R.P.M) in a day

R.P.M (AVERAGE IN A DAY) = R.C (A DAY) : HOURS : 60 (HOURS = from R/U to NOON or
NOON to NOON)
• Distance by Over Ground (DIS OG) in a day
DIS OG (IN A DAY) = DISTANCE (NOON to NOON) OR (R/U to NOON)
• LOG in a day
• Distance by propeller (DIS PROP) in a day
DIS PROP = R.C (IN A DAY) × C (C = 0.0024446 for JAL KAMAL)
• Speed of ship
SPEED (IN A DAY) = DIS OG (IN A DAY) : HOURS (HOURS = from R/U to
NOON or NOON to NOON)
• Slip of propeller
=>: ?@A?7=>: A;
SLIP (IN A DAY) = =>: ?@A?
× 100
• Calculate Output of M/E based on fuel oil consumption

B/D +.A EAF:GB?H>AF
M/E OUTPUT = B/D :?DE>+>E +GDI A>I EAF:GB?H>AF (KW)
+AE(,J102/K-L2)×:;(5,-. /0102)×(&&&
M/E OUTPUT = :+AE(M/NO/K)×[PQ.R(BS/N;)/ITU(VT1L8,)] (KW)
FOC: fuel oil consumption for Main Engine (liter /hour)

SG: specific gravity of using fuel at flow meter
SFOC: specific fuel consumption rate at 85% of Shop test as conversion into Lcv =42.7
MJ/kg with ISO condition
SFOC = 163.1 with VLSFO
SFOC = 161.0 with MDO
Lcv: low calorific value. In case actual value is not clarified, 40.18 MJ/kg is applied.
• M/E fuel index
• M/E cylinder oil feed rate
• Fresh water generator make-up

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THIRD ENGINEER TRAINING

M/V JAL KAMAL

MASTER: NGUYEN CAO CUONG

1 Oiler Tran Van Nui

Dear Chief Engineer of M/V JAL KAMAL:

My full name is TRAN VAN NUI, I am an Oiler on JAL KAMAL.

Oiler: TRAN VAN NUI

2 Oiler Tran Van Nui

3 Oiler Tran Van Nui

Duty of an oiler………………………………………..…………………............. …..……………….……………………………… P7

4 Oiler Tran Van Nui

5 Oiler Tran Van Nui

6 Oiler Tran Van Nui

7 Oiler Tran Van Nui

8 Oiler Tran Van Nui

9 Oiler Tran Van Nui

10 Oiler Tran Van Nui

INSPECTION AND MAINTENANCE PLAN

4. EVERY THREE MONTHS

11 Oiler Tran Van Nui

2. FAN ABNOMAL STOP

- Trip fan thermal relay during combustion.

3. FLAME FAILURE ALARM

4. ABNORMAL FIRE ALARM

- Remove flame eye during post-purge and illuminate flame eye.

12 Oiler Tran Van Nui

- Press combustion switch.

6. FUEL OIL TEPERATURE LOW ALARM

- Shift fuel oil heater switch to OFF position.

7. FUEL OIL TEPERATURE HIGH ALARM

- Lower setting of thermostat for high oil temperature during combustion.

8. EXHAUST GAS TEPERATURE HIGH ALARM

- Lower setting of thermostat by turning dial during combustion.

13 Oiler Tran Van Nui

10. LOW-LOW WATER LEVEL ALARM

11. HIGH WATER LEVEL ALARM

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1. PURPOSE OF WATER TREATMENT

2. SAMPLING WATER FOR ANALYSIS

Do not forget wearing protective gloves before sampling boiler water.

3. ADDING CHEMICAL FOR BOILER WATER TREATMENT

P-ALKALINITY TABLET P-ALKALINITY TEST DOSAGE (ml/1000L)

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PHOSPHATE TEST DOSAGE OF HARDNESS TREATMENT

Hydrazine test result in ppm Dosage

Dosage is approximately 1 litter per day.

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1. PREPARATION BEFORE OPERATION

Before a new boiler at commissioning or after maintaining, overhauling; to operation the

a) Check of around boiler

b) Check of body boiler

c) Check of feed water system

d) Check of fuel system

f) Check of electrical system

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a) Feed water to boiler

b) Starting combustion with M.D.O

c) After combustion is started, check that boiler is on normal operation.

e) Shift from M.D.O to H.F.O

f) Shift from H.F.O to M.D.O

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