Irregularities in Operation, Causes and Remedies

Symptom:	Cause:	Remedy:
1. Starting difficulties
Insufficient or no compression.	a) Inlet and exhaust valves leaking.	Grind or replace valves, mill the seats.
b) Inlet and exhaust valves sticking.	Oil the valve spindles with gas oil, or remove valves for cleaning.
c) Insufficient rocker arm clearance.	Adjust valves.
d) Piston rings sticking in grooves, or worn.	Loosen rings and replace them if necessary.
e) Valve springs broken or slack.	Replace springs.
f) Cylinder liner worn.	Replace.
g) Cylinder liner scratched.	Replace.
Fuel valve out of order.	Nozzle needle valve sticking or leaking.	Release it, grind or replace if required.
Fuel pumps give no or insufficient pressure.	a) Pressure valve sticking or leaking	Clean it, replace if required.
b) Pressure valve holder loose.	Tighten.
c) Piston and lining worn.	Replace.
Insufficient or no fuel supply.	a) Air in fuel system.	Ventilate
b) Fuel lift pump defective.	Repair pump and ventilate fuel system.
2. Engine starts, but stops shortly afterwards
Engine starts, but stops after a while	a) Fuel tank empty	Fill tank and remove air from fuel system.
b) Air in fuel system	Airate.
c) Fuel filter choked	Clean the filter.
3. Engine does not reach maximum capacity
Insufficient or no compression.	See under "Starting difficulties".
Fuel valves out of order.	See under "Starting difficulties".
Excessive waste of oil from fuel pumps.	Fuel pump plungers worn.	Replace plungers and sleeves.
Engine takes load only momentarily.	Fuel supply blocked, fuel pump out of order.	Check the whole fuel system thoroughly.
Engine does not reach full speed.	Governor drive broken.	Adjust or replace governor spring.
Engine loses too much speed under load.	Incorrect adjustment of governor, or something in the system works sluggishly.	Adjust governor. Check governor system, and correct the defect.
Smell of heat.	Insufficient cooling water.	Stop engine, fill in cooling water when the engine has cooled off.
4. Engine speed too high
Languid movements of governor arm.	Governor arm has become oblique by blows or the like.	Stop engine quickly by interrupting the fuel supply and check the governor system.
Incorrect adjust­ment of governor.		Adjust governor.
5. Engine knocks.
Ignition too advanced.	Incorrect adjustment of fuel oil pumps.	Adjust correctly.
Mechanical faults.	Connecting rod bolls loose.	Check connecting rod bolts thoroughly. If cracked or defect, replace them. Tighten nuts.
Mechanical faults.	a) Hot or worn bearings.	Replace bearing lining, check lube oil system, correct fault if any before restarting.
b) Flywheel loose.	Tighten nut and lock it.
c) Worn pistons and linings.	Replace them.
6. Engine smokes
Black smoke from engine.	a) Air filter choked.	Clean filter.
b) Fuel valve out of order.	See under "Starting difficulties".
c) Insufficient compression.
d) Engine overloaded.	Reduce load. Never overload.
e) Thermostat valve leaking.	Replace valve.
Black smoke from engine.	Lube oil forces its way past leaky piston and oil rings into combustion chamber.	Replace oil and piston rings.
7. Excessive fuel oil consumption
Engine runs hot.	Engine overloaded.	Reduce load(never overload).
Insufficient compression.	See under "Starting difficulties".
Leaky fuel system.	a) Fuel pipes leaking.	Repair or replace.
b) Fuel pump plungers and linings worn.	Replace defective parts.
Increasing oil level.	Fuel lift pump diaphragm defective.	Replace diaphragm.
Engine smokes.	a) Fuel valves out of order.	Clean and adjust valves.
b) Thermostat valve leaks.	Replace valve.
8. Excessive lubricating oil consumption
Lube oil enters combustion chamber.	a) Oil piston rings worm.	Replace rings.
b)Pistons and cylinder linings worm.	Replace defective parts.
Lube oil leaks out of crank shaft end bearings.	Oil seal rings and bearings worn.	Replace seal rings and repair bearings.
9. Engine runs hot
Smell of heat.	a) No cooling water.	Stop engine, fill up with cooling water when engine cooled off.
b) Engine overloaded.	Unload engine.
Cooling water temperature too high.	Lack of cooling water owing to defective cooling water pump or escape of water from leakage.	Remedy the fault.
Cooling water too high.	a) Defective thermostat.	Replace thermostat.
b) Fan belt too loose.	Tighten belt.
c) Radiator choked.	Clean radiator.
d) Pressure vacuum valve out of order.	Repair valve.
Lube oil pressure insufficient.	a) Lube oil filter choked.	Clean filter.
b) Lube oil pump defective.	Repair pump.
c) Lube oil pressure line leaks.	Repair or replace line.
d) Defective lube oil overflow valve.	Repair valve.
10. Engine jars
Engine misfires.	a) Air in fuel system.	Ventilate. See under "Starting difficulties" and "Engine does not reach maximum capacity".
b) Fuel valves out of order.

Exercise 2. Answer the following questions:

1) What is a diesel engine?

2) How is the diesel engine power expressed?

3) What are the characteristics of slow-speed diesel engine? (name the cylinder bore, rpm, power output).

4) What kind of engine is called a directly-coupled engine, slow or medium-speed?

5) In what kind of ships are medium-speed engines applied? What are their particulars?

6) What are the advantages of slow-speed engines and benefits of medium-speed ones?

7) Where is high-speed diesel engine installed and what are its characteristics?

8) What fuel does each of these types of diesel engines burn?

9) How else can diesel engines be classified?

10)Where is combustion chamber in the double-acting engine situated?

11) Why are double-acting engines obsolete now?

12) What cycles do diesel engines have? Describe them.

13) During what period does the complete cycle of operation take place in the two-stroke engine?

14) What are the advantages of the four-stroke engines over the two-stroke ones?

Exercise 3. Give synonyms to the following words.

To spray, to drive, to pass, to open, to leave, to fall, to occur, to develop, to obtain, to increase, to start, to reach, to include, to finish, to work.

Exercise 4. Give antonyms to the following words.

Low, upward stroke, inlet valve, scavenging port, to reduce, to expand, to drop, to absorb, to stop, above, popular, before, light.

Exercise 5. Explain in English what is meant by:

Combustion chamber, suction stroke, compression stroke, combustion and expansion stroke, exhaust stroke, upward stroke, downward stroke, scavenging port, exhaust valve, fuel injection valve, uniflow scavenging, air charge, burned gases.

Exercise 6. Explain the difference between

1) Single-acting and double-acting principles;

2) Trunk-piston, cross head and opposed-piston types;

3) Two-stroke and four-stroke engines;

4) Upward and downward strokes;

5) Exhaust valve and exhaust port;

6) Air inlet valve and scavenging port;

7) Heavy fuel oil and light fuel oil;

8) Slow, medium and high-speed diesel engines.

Exercise 7.Made up a dialogue of your own based on the one given below.

ENGINE DAMAGE

A.: Which of the several causes of ignition failures is most likely to occur?

В.: Failure of the fuel supply is the most common cause, for the reason that the fuel pump is very sensitive to the presence of air and unless great care has been exercised in clearing air out of the fuel lines, the pump will not deliver oil to the injection valves. This is especially true after the fuel lines or pump have been opened up for any reason.

A.: How is air cleared out of the fuel lines?

В.: Most installations include a by-pass valve in each fuel oil discharge line, adjacent to the injection valve. By opening these valves and operating the hand pumps on the fuel measur­ing pump, oil is forced through the pump and pipe line and out through the by-passes, carrying the air with it. When only oil flows from the by-passes the valves are closed and a few strokes given to the hand pumps to force some oil into the injection valves.

A.: How is the compression pressure measured?

В.: With the indicator, cutting out one cylinder at a time and indicating that cylinder while the rest of the cylinders operate on fuel or starting air. Both methods should be used in order to determine the difference in compression with hot cylinders and with cold.

A.: How is the compression pressure adjusted?

В.: By decreasing or increasing the linear clearance between piston and cylinder head. This is usually done by increasing or reducing the thickness of shims under the foot of the connecting rod.

A.: What are the principal sources of knocks in the Diesel engine?

В.: The large bearings, the valve gear, or the interior of the cylinders. Bearing knocks are caused by too much clearance. Valve gear knocks may be caused by excessive roller clearance, worn or broken rollers, or sticking valve stems. Knocks inside the cylinder are caused by too early injection, excessive lift of air injection valve at low speed, injection air pressure too high, or stuck piston rings.

A.: How is the separation of the two halves of the box usually obtained?

В.: By placing sheet metal shims between the abutting sur­faces.

A.: How is bearing clearance usually measured?

В.: By placing strips of soft lead wire in the bearing and setting up the bolts. The thickness to which the lead wire is mashed will be equal to the clearance.

A.: How is a bearing refitted?

В.: By scraping the bearing surface of the boxes with steel scrapers until all the high spots are removed and even contact is obtained between bearing and boxes.

***

A.: What is the best method of keeping a check on crank shaft alignment and main bearing wear?

В.: By the use of a bridge gauge, on which are stamped the heights of the crank shaft at the main bearings at the time the engine was installed. Periodical measurements with this gauge, compared with the original measurements, will indicate any dropping of the shaft.

A.: How are the cylinders lubricated?

В.: By means of small oil pumps, assembled into multiple units called mechanical oilers, which are operated by linkages from any convenient moving part of the engine. These pumps feed the oil in drops, at a rate that can be regulated by small adjusting screws, into small pipes leading to the cylinders.

A.: For what other purpose is the compressor used besides supplying injection air?

В.: The compressor always has a capacity in excess of the amount required for spraying the fuel. The excess air is by­passed into the starting air tanks to supply air for starting the engine.

A.: Why is the injection air usually compressed in three stages instead of one?

В.: Because the temperature at the end of a single compres­sion would be excessive. By performing the compression in three stages the air can be cooled after each stage in the compression. In this way the heat is easily handled and the amount of power required to compress a given quantity of air is greatly reduced.

Бункеровка

BUNKERING OF SHIPS

Notes to the text:

a compliance – соответствие a sample [s'a:mpl] – образец

a spark – искра sawdust – опилки

spillage – разлив a driptray – поддон

a scupper – шпигат to plug – затыкать

a hose – шланг capacity – вместимость

an amount – количество a manifold – трубопровод

to fine – штрафовать a vent – вентиляционное отверстие

a procedure [pr ∂'si:dz ∂ ] – процедура a grade – марка топлива sulphur content – содержание серы flash point – температура вспышки

Exercise 1. Read the text and be ready to answer the following questions:

1) How many logical parts can this text be divided into?

2) What names can be given to each logical part of text?

The bunkering starts a few days before when the Chief Engineer contacts the operators and discusses the conditions of bunkering operations with them. Before that the shipmanager arranges the delivery of fuel oil, its quantity, grade, and cost.

After the vessel is securely moored to the bunkering tanker (if fuel oil is supplied from the bunkering tanker) the fuel oil certificate is checked. The Bunker Delivery Note is necessary to check the compliance of the delivered oil. It is kept on board for three years after the fuel delivery. The fuel sample is attached. A supplier is responsible to provide this sample but it can be taken onboard as well. The sample is kept onboard for one year.

The Bunker Delivery Note has:

· name and IMO (International Maritime Organization) · product name;

number of the ship; · quantity (metric tones);

· port; · density;

· date of delivery; · sulphur content;

· name, address, and telephone number of fuel oil · flash point.

supplier;

Bunkering is a dangerous operation that must be carried out very carefully. Before it begins the watchkeeping officer informs the crew about the start of the bunkering operation and gives an order not to smoke on the deck. He also checks that red light/flag Bravo is displayed and there are not hot works that cay produce a spark.

Each vessel has a schedule of bunkering operations where crewmembers can learn when they participate in bunkering and what their duties are. They will also have a meeting with the 3^rd or the 2^nd Engineer to discuss actions during bunkering in more detail.

At the same time the crew prepares the bunkering station. They supply it with sawdust, rags, buckets with sand, fire extinguishers, and other oil spill absorbent materials in case of accident spillage, pollution, or fire. Driptrays are placed under the flanges. All drain pipes and scuppers on the deck must be plugged. Flanges of the fuel hoses or pipes are connected and firmly tightened with the help of nuts and bolts.

The service staff is supplied with a portable radio to communicate with the engine-room, bridge, bunkering barge, or coast bunkering personnel. And there must always be a visual watch during the whole operation.

The Third Engineer takes readings in all fuel tanks and writes them down in the log-book. He opens the valves on the tanks that will be filled with fuel. When fuel oil system is prepared the Third Engineer reports to the Chief Engineer that everything is ready for bunkering.

The Chief Engineer orders to start bunkering but first he tests the pressure of flowing liquid. A motorman examines the connection of the hose with the bunkering station flange. If there are no leakages the Chief Engineer orders to continue bunkering with full pressure.

When a tank is filled to 70 % capacity the engineer will give an order to reduce pumping rate to half capacity. When a tank is filled to 80 % capacity the engineer will order the barge to stop pumping for five minutes to avoid air pockets. Then they will continue at a minimum rate until sounding shows 90 %.

After all tanks are full they are checked and readings are taken again. If everything is all right the Chief Engineer signs all documents. Motormen unscrew the connecting nuts of the flanges and remove all fire-fighting equipment. The time when the bunkering was finished and the amount of taken fuel are recorded in the log-book.

Before disconnecting the engineer will ask the barge to blow the hose with air to empty the system. Depending on the contract, the hose will be disconnected by the supplier or by the ship’s personnel. In any case the Chief Engineer must make sure that the hose is empty. A driptray must be placed under the manifold for draining during disconnection. Flanges must be immediately secured on the bunkering hose and the ship’s manifold and fully bolted.

It is necessary to be very careful during the bunkering. In case some fuel oil leaks into the sea, the Port State Control fines the vessel’s officers who were responsible for the leakage. Plus the staff will be punished or fined by the shipowner as well because the fuel oil is very expensive and even the loss of the smallest part of fuel is a big fault of the staff.

Bunkering can cause many problems so the Chief Engineer must be in charge of bunkering. He must prepare written instructions:

· pipeline diagram including location of all valves, pumps, controls, vents, and overflow system;

· number of persons required to be on duty;

· procedures for emergency shut down;

· valve closing procedures;

· pollution reporting procedures;

· scupper plugging reminder;

· ship/shore communication procedures;

· a reminder to check the condition of all bunker hoses and pressure test lines as required.

Exercise 2. Give the Russian equivalents of the following word combinations:

the bunkering tanker; air pockets; the fuel oil certificate; valve closing procedures; the Bunker Delivery Note; pollution reporting procedures; the fuel sample; scupper plugging reminder; a fuel oil supplier; ship/shore communication procedures; the bunkering station flange; bunker hoses; pumping rate; pressure test lines.

Exercise 3. Answer the following questions:

1. What are the actions of the Chief Engineer and the shipmanager before the bunkering starts? 2. When is the fuel oil certificate checked? 3. How many years is the Bunker Delivery Note kept on board after the fuel delivery? 4. What information does the Bunker Delivery Note have? 5. What does the watchkeeping officer do before the start of the bunkering operation? 6. What does the crew prepare the bunkering station with? 7. What is the service staff supplied with? 8. What duties does the Third Engineer have during bunkering? 9. Who reports to the Chief Engineer that everything is ready for bunkering? 10. Who orders to start bunkering and to continue it? 11. What does a motorman examine? 12.What order will the engineer give when a tank is filled to 70 % capacity? 13. Why will the staff be punished or fined by the shipowner because of the fuel oil leakage? 14. What written instructions must the Chief Engineer prepare?

Exercise 4. Find correspondences:

1) the service staff a) must be in charge of bunkering and

prepare written instruction;

2) the engineer b) unscrew the connecting nuts of the

flanges and remove all fire-fighting equipment;

3) the Port State Control c) informs the crew about the start of the

bunkering operation and checks that red

light/flag Bravo is displayed;

4) the crew d) opens the valves on the tanks that will be filled

with fuel;

5) the watchkeeping officer e) fines the vessel’s officers who were

responsible for the leakage;

6) the Chief Engineer f) is supplied with a portable radio to communicate

with the engine-room, bridge, bunkering barge,

or coast bunkering personnel;

7) the Third Engineer g) prepares the bunkering station;

8) motormen h) will order the barge to stop pumping for five

minutes to avoid air pockets when a tank is

filled to 80 % capacity.

Exercise 5. Find the correspondent English equivalents in the text:

обсуждать условия бункеровочной операции; поставка жидкого топлива; быть ответственным за обеспечение этого образца топлива; принимать участие в бункеровке; обеспечивать опилками, ветошью, ведрами и огнетушителями; подписать все документы; проверить соединение шланга; открутить соединяющие гайки фланца; быть оштрафованным судовладельцем.