Training for Cadet before Join on Board

Questions before and after training

1. What the "Standard Instruction“ the Main Propulsion Engine Plant ready for maneuvering and
departure port.
2. What Essential items of system lubricating oil that should be tested on regular basis
3. What the likely causes of abnormalities of the Main Propulsion Engine
a. Exhaust Temperature rises in all cylinders
b. Cylinder knocking
c. High turbocharger speed
4. What are the Guidance to Watch Keeping Engineer if ME have abnormalities
a. Crankcase Mist Detector Alarm
b. Scavenge Fire
c. Crankcase Explosion
5. How many categories of causes the turbocharger can be surging and what causes it
6. What "Check List" should be followed periodically regarding safe boiler operation
7. What standard instructions should be applied on board for (i) Cold Start (ii) Shutting Down Oil
Fired Boilers on board
8. Explain the Maintenance standard procedure "Burner" periodically, that can be applied on the
vessel
9. what can affect the "Discharge Condition" of the pumping system to be efficient
10. Explain the main cause of
a. Reduced capacity
b. Loses liquid after starting
c. Vibration
of the pump system
Prepare/Vet "Standard Instruction“ the Main Propulsion Engine
Plant (Crosshead/ Trunk Type & Uni-fuel) ready for
maneuvering and departure port.
■ Generators:
o Start the Second generator and after all checks, take it on load.
o The third generator should be kept on “Standby” condition
o Essential steps to be noted: Turning Engine; Indicator Cocks; Parameters; Abnormal Noise
■ Fuel Oil Service and Settling Tanks
■ Diesel Oil Service Tank
■ Air Systems
■ Lube Oil Systems
■ Turbochargers
■ Cooling Water Systems
■ Checking the Fuel Regulating Gear & Starting System
■ Slow Turning the Engine
■ This must be carried out to prevent damage caused by fluid in one of the cylinders, and to
check the reversing mechanism
■ Before beginning the slow-turning, obtain permission from the bridge
 Inspection on main propulsion engine immediately
upon FEW after long passage
■ Oil Flow
While the circulating oil pump is still running and the oil is warm, open
up the crankcase and check that the oil is flowing freely from all
crosshead, crankpin and main bearings.
(At least 20 minutes after stoppage)
■ Oil Pan
After stopping the circulating oil pump, check the bottom of the oil
pan for fragments of White metal from the bearings.
■ Scavenge Port Inspection
Inspect the condition of the piston rings, cylinder liners, pistons, and
pistons rods
■ Circulating Oil Samples
Take an oil sample and send it to a laboratory for analysis and
comments
 Prepare / vet check list related to HFO Treatment, relevant to
Engine Performance
Mempersiapkan / memeriksa check list yang berkaitan dengan Perawatan HFO, yang relevan dengan Kinerja Mesin

■ Centrifuging
■ Efficiency of Separating Equipment =
f (Flow Rate, Settling Area, and Settling Velocity)
■ Fine Filter
■ Preheating before injection
■ Circulating Pump Pressure
 With reference to Marine Engines (Crosshead & Trunk Type)
burning HFO – Essential items of system lubricating oil that
should be tested on regular basis.
Item penting dari sistem minyak pelumas yang harus diuji secara
teratur.
■ Specific Gravity
■ Viscosity
■ Flash Point
■ TAN (Total Acid Number)
■ SAN (Strong Acid Number)
■ Alkalinity
■ TBN (Total Base Number)
■ Water
■ Conradson Carbon
■ Ash
■ Insolubles
 Vet systematic instruction for “Running-In” a new cylinder liner of large main
propulsion engine.
Instruksi sistematis untuk "Running-In" sebuah liner silinder baru dari mesin penggerak utama besar.

Engineer should be conversant with Engine Operation Manuals

■ Gradual increase of Load over a “Fixed Time Period”

■ Increased Cylinder LO feed rate and gradual decrease over a
“Fixed Time Period”
■ Operation on recommended fuel, if applicable
■ Operation on recommended cylinder LO, if applicable
■ Inspect Liner & Rings through scavenge ports after
recommended RHR
■ Lift cylinder head and inspect after recommended RHR
 Main Propulsion Engine: the likely causes of
abnormalities (listed)
Exhaust Temperature rises in all cylinders
■ Increased scavenge air temperature owing to inadequate air cooler function.
■ Fouled air and gas passages.
■ Inadequate fuel oil cleaning, or altered combustion characteristics of fuel (Pembersihan bahan
bakar tidak memadai atau karakteristik pembakaran bahan bakar yang berubah)
■ Wrong position of camshaft

High turbocharger speed

■ Fouled air filter (Early Stage of Unloading the Compressor)
■ Fire (Early Stage) in the Exhaust - Check Immediately

Cylinder knocking
■ Fuel timing too far advanced
■ Fuel Injector needle sticking
■ Excessive carbon build up on the crown
■ Broken Exhaust valve
■ Mechanical damage in the cylinder
 Guidance to WKE for following abnormalities (ME):
Crankcase Mist Detector Alarm
Never cut-out Mist Detector - Potentially dangerous
■ Inform Bridge and CE
■ Stay away from crankcases
■ Slowdown and stop
■ Start turning on “Gear” immediately for at least 30 minutes to cool down
■ Through investigation of Mist Detector, Crankcase abnormality and moving parts required
Scavenge Fire
■ Inform Bridge and Chief Engineer
■ Do not stand near the relief valves
■ Slow down engine - Ensure that the aux blowers are off
■ In case the fire persists, stop the engine gradually to prevent risk of piston seizure
■ Fire should go off when all deposits burnt out
■ Keep turning the engine with cooling on to prevent seizure of moving parts
Crankcase Explosion
(Most of the cases “Engine” will suddenly stop upon “Explosion”)
■ Inform Bridge and Chief Engineer
■ Evacuate the ER
■ Every (Safe) Effort to be made to turn engine by Turning Gear or Slow Turning for next 30 minutes to
prevent seizure of moving parts
■ Thorough investigation required into the cause of the “Explosion” before re-starting
 To main propulsion engine “Turbocharger Surging”, discuss ,
Causes . Preventive measures/ Instructions to WKE.

Turbocharger surging can be divided into three main categories:

■ Restriction and fouling in the air/gas system.
■ Malfunction in the fuel system.
■ Rapid variations in engine load
Causes
■ Fuel Oil System: Fuel injection system; Fuel line components; Fuel timing; Fuel
■ Exhaust System: Valve; Exhaust passage through turbocharger & boiler
■ Turbocharger
■ Scavenge air system
■ Miscellaneous: Rapid changes in load & RPM; Governor
Immediate Action
Temporarily counteracted by “blowing-off”
Reduce engine load by taking the T/C away from the “Surge Line”
Preventive Measures
Regular maintenance of items mentioned above
Prevent load fluctuations during ballast voyage and bad weather
 The abnormalities that should be
identified in the components.
Piston
■ Cracks & Burning - Crown
■ Cracks - Side Wall
■ Contour Deformation - Crown
Piston Rings
■ Micro-seizure; Sticking; Cracks; Burning; Scratches (Deep); Free Movement; Breakage/Collapse
■ Above mentioned symptoms indicate abnormal operation
■ Rings should be renewed because high MTBO
Ring Grooves
■ Wear
■ Uneven wear - Critical for new rings
■ Carbon deposits
Liner
■ Cracks
■ Corrosion (Cold)
■ Wear (Top)
■ Clover Leafing
■ Scuffing
 With reference to Cylinder Liner, Piston Rings, and
Skirt – list of main factors that are likely to contribute
to “Wear” during operation.

■ Compatibility Liner material, Piston ring material, and Cylinder LO

■ FO quality and treatment
■ Combustion conditions
■ Air quality
■ Turbocharger conditions
■ Moisture/ Condensation
■ Abrasive material
■ Engine load
 “Check List” that should be followed at regular
interval related to the safe boiler operation.

“Check List” covering following items:

■ Boiler water & treatment,
■ Water level,
■ Remote water level,
■ Burner flame eye,
■ Alarms,
■ Cut-outs,
■ Steam and water leakage
 Standard instruction that should be implemented on
board for (i) Cold Starting and
(ii) Shut Down of the Oil Fired Boiler on board.
“Check List” covering following items: (i) Water level (ii) Fuel (iii) Gradual firing (iv) Forced draft fans &
pilot burner (v) Feed pump (vi) HFO (vii) Soot blower before shutting down (viii) Fans on after shutting for
a period (ix) Vent.

Boiler Safety Valves and its operation, discuss following:

■ Super heater “Safety Valves” to be set to “Lift” at “Lower Pressure” than the Drum Safety
valve of a Water Tube Boiler

Difference in “Lifting Pressure” between Steam Drum and Super heater ;

■ Set Pressure: Boiler pressure at which “Safety Valves” begin to lift

Design pressure, Set pressure, Closing pressure, Blow down pressure, Valve lift, and Accumulation of
pressure.
■ Closing Pressure: Boiler pressure at which “Safety Valves” close
(Opening and Closing Pressures not same)
■ Blow Down Range: 1-4% of Set Pressure
■ Valve Lift: Axial valve disc travel from “Closed” to “Open” position
■ Accumulation of Pressure: Maximum pressure “Safety Valves” open and with Steam Stop Valves shut
(Safety valve capacity to release steam must match the steam generation capacity of the boiler)
 “Boiler Water Maintenance”,

Vet “Check List” covering following items:

■ Treatment of feed water
■ Water test
■ Regular blow down
■ Make up water
■ Impurities (Hardness, pH value, Dissolved Oxygen, Chlorine,
Oil/Grease, Silica, Dissolved Solids)
 Inspection of boiler pressurized parts, plan/discuss a
systematic approach that can be adopted on board.
Pemeriksaan bagian bertekanan boiler, rencanakan / diskusikan pendekatan sistematis yang
dapat diadopsi di kapal.

■ Safe Working Procedure,

■ Interval
■ Fireside
■ Soot accumulation
■ Front bank
■ Water wall tubes
■ Cracking
■ Blistering
■ Overheating
■ Sludge, Scaling, Corrosion, and Pitting
 The process of combustion, using poor quality residual
fuel in a modern auxiliary boiler furnace.
Proses pembakaran, menggunakan sisa bahan bakar berkualitas rendah di tungku
pembakaran boiler modern.

■ Heating of fuel at right temperature,

■ High temperature fuel cracking,
■ Rotational energy from burner,
■ Suspended flame
■ Primary & secondary flames.
 “Burner” Maintenance at regular interval, prepare /
vet standard procedure that can be adopted on board.

■ Oil filters,
■ Furnace pressure & gas temperature,
■ Rotary cup,
■ Fan belts,
■ Nozzles,
■ Electrodes,
■ Flame detector,
■ Oil distributor,
■ Bearings.
 Vet standard instruction for regular
maintenance of Soot blower.

■ Head valve,
■ Switching mechanism,
■ Driving part,
■ Element pipe,
■ Seals,
■ Purge air supply,
■ Gaskets.
 “Discharge Conditions” of a pumping system,
discuss the main factors that influence the efficiency.
"Kondisi Discharge" dari sistem pemompaan, mendiskusikan faktor-faktor utama yang mempengaruhi efisiensi.
Efficiency depends on the:
■ Sectional area
■ Internal condition of the pipes and fittings
■ Velocity and viscosity of the liquid being pumped
■ Friction caused by bends, valves and other fittings
■ Discharge pipe design in terms of length
■ Check and Gate Valves placed near the pump
■ Check Valve protects the casing from damage created by “Water Hammer” and prevents
pump rotating in reverse direction
■ Volute Casing, Diffuser Pump (eg Multistage Boiler Feed Water Pump), and Multi-Stage Deep Well Pump
significantly boost “Discharge Conditions”
Instructions that should be provided to WKE in terms of effective starting of Centrifugal Pumps.
■ Line valves properly set
■ Turn the rotor several times by hand
■ Open the vent valves to relieve air in the system
■ Keep the discharge valve closed at initial stage
■ Provide oil to the “Mechanical Seal” as per maker’s recommendation
■ Open the inlet valve
■ Start the pump
■ Once the water comes out from the vent valves and the discharge pressure gauge shows sufficient pressure,
then slowly open the discharge valve
Efisiensi tergantung pada:
■ Area penampang
■ Kondisi internal pipa dan fiting
■ Kecepatan dan viskositas cairan yang dipompa
■ Gesekan yang disebabkan oleh tikungan, katup, dan alat kelengkapan lainnya
■ Desain discharge pipa dalam hal panjang
■ Periksa dan Gate Valves ditempatkan di dekat pompa
■ Check Valve melindungi casing dari kerusakan yang disebabkan oleh "Water
Hammer" dan mencegahnya pompa berputar ke arah sebaliknya
■ Volute Casing, Pompa Diffuser (Multistage Boiler Feed Water Pump), dan Multi-Stage
Deep Well Pump secara signifikan meningkatkan "Kondisi Discharge “

Instruksi yang harus diberikan kepada WKE dalam hal permulaan efektif Pompa
Sentrifugal:
■ Saluran Katup diatur dengan benar
■ Putar rotor beberapa kali dengan tangan
■ Buka katup ventilasi untuk meringankan udara dalam sistem
■ Tutup katup discharge pada tahap awal
■ Sediakan minyak untuk "Mechanical Seal" sesuai rekomendasi pembuat
■ Buka katup saluran masuk
■ Mulai pompa
■ Begitu air keluar dari katup ventilasi dan pengukur tekanan discharge menunjukkan
tekanan yang cukup, lalu buka perlahan katup discharge .
 Predict main causes and advise on action to be
Memprediksi penyebab utama dan menyarankan tindakan yang akan dilakukan

Reduced capacity
■ Pump is not primed
■ Low speed
■ Foreign material lodged in the impeller
■ Excessive air in water
■ Air leakage in inlet pipe or stuffing boxes
■ Mechanical defects

Loses liquid after starting

■ Failure of water supply
■ Water level receding below the lift limit
■ Pump lift incorrect
■ Leaky stuffing box

Vibration
■ Pump out of alignment
■ Impeller partially clogged
■ Piping not well secured
■ Rotating elements touching stationary parts
 MARPOL Regulations for the Prevention of Pollution.

MARPOL Annex I:
Regulations for the Prevention of Pollution by Oil
MARPOL Annex II
Regulations for the Prevention of Pollution by Noxious Liquid Substances in
Bulk.
MARPOL Annex III
Regulations for the prevention of pollution by harmful substances carried in
packaged
MARPOL Annex IV
Regulations for the Prevention of Pollution by discharge of sewage into the sea.
MARPOL Annex V
Regulations for the Prevention of Pollution by Garbage from Ships.
MARPOL Annex VI
Regulations for the Prevention of Air Pollution from Ships.
 Prepare / Vet check list for Fire Fighting
Appliances (FFA) to meet the requirements of
SOLAS.

Engineer should be able to extract information from SOLAS II-2 17.1 and
company policy:
■ Fire mains, pumps, nozzles
■ Emergency Fire Pump
■ Isolating Valves
■ Fire Extinguishers
■ Fixed Fire Fighting Installations
■ Breathing Apparatus, Fireman’s Outfit
■ International Shore Connection
 Identify the location and predict the limitation of each type of Detector eg
Smoke & Flame in the ER of periodically Unmanned machinery space (UMS).

Engineer to be familiar with on board drawing and instructions

Testing of Smoke Detectors

■ Smoke detectors are usually tested by special aerosol sprays which simulate
smoke or smoke bombs
■ Don’t test by actually burning a combustible material and creating a smoke.

Testing of flame detectors

■ A special tester which has a light flashing at 10Hz can be used to simulate a flame
and test the flame detector.

Testing of heat detectors

■ The heat detectors can be tested by using a giving hot air to the detector.
 Life Saving Appliances (LSA): Safe Operation
and Maintenance
instructions on board briefly the “Life Boat” lowering mechanism
■ Check all crew mustered, life jackets properly donned, duties fully understood
■ Check all cables (e.g. electrical cable for battery charging etc) between the boat and
the vessel have been disconnected and cleared off
■ Test the engines
■ Remove the davit securing pins
■ Ensure painter suitably secured, outboard of all shipside obstructions
■ Check falls suitably secured to the hooks and that the release mechanism is “reset’
properly
■ Check over side for any discharges and obstructions
■ Lower the embarkation ladder
■ Lower the boat gently down to the embarkation deck
■ Minimum operational crew needed, as per the muster list, to board the vessel
■ Lower the boat down to the water level and stop about 1 meter above the water
level. Start the engines
■ All crew to board the vessel
■ Lower away to the water level and release the falls
■ Steer away clear of the vessel as soon as possible`
 On board familiarity with Muster List.

■ Fully conversant with his or her duties indicated in the muster list
■ Muster lists exhibited in conspicuous places throughout the ship, including the
navigational bridge, the engine room and the crew accommodation spaces.
■ Muster list must be in accordance with the regulations.
■ Muster list must show the duties assigned to the different members of the crew
■ Muster list must specify which officers are assigned to ensure that life-saving and
fire appliances are maintained in good condition and are ready for immediate use
■ Muster list must specify the substitutes for key persons who may become disabled,
taking into account that different emergencies may call for different actions
■ Muster list must show the duties assigned to crew members in relation to
passengers in case of emergency
■ Muster list must be up to date.
■ Duties assigned to crew members manning LSA & FFA should be in accordance with
the regulations and that a deck officer or certificated person is placed in charge of
each survival craft to be used
Preventive actions on board to minimise risk of “Detailed Inspection & Likely Detention” by PSC with
reference to: Machinery Spaces, Operation of Machinery, Oil and Oily Mixtures from Machinery
Spaces.

Machinery Spaces
■ Inspection of the machinery spaces, frayed or disconnected quick-closing valve wires,
disconnected or inoperative extended control rods or machinery trip mechanisms, missing valve
hand wheels, evidence of chronic steam, water and oil leaks, dirty tank tops and bilges or extensive
corrosion of machinery foundations
■ A large number of temporary repairs, including pipe clips or cement boxes, will
indicate reluctance to make permanent repairs
■ Leaking pump glands, dirty water gauge glasses, in operable pressure gauges, rusted
relief valves, in operative or disconnected safety or control devices, evidence of
repeated operation of diesel engine scavenge belt or crankcase relief valves,
malfunctioning or inoperative automatic equipment and alarm systems and leaking
boiler casings or uptakes
■ If one electrical generator is out of commission, the power should be available to
maintain essential and emergency services and should conduct tests
■ If evidence of neglect becomes evident, the PSCO should extend the scope of an
investigation to include, for example, tests on the main and auxiliary steering gear
arrangements, over-speed trips, circuit breakers and safety devices

Operation of the Machinery

■ Emergency and stand by sources of electrical power
■ Auxiliary steering gear
■ Bilge and fire pumps
■ Any other equipment essential in emergency situations