Operation and maintenance instructions
Lesson 1. IRREGULARITIES IN OPERATION, CAUSES AND REMEDIES I
| regardless of | Невзирая на |
| both . . . and ... | н то, и другое, как . . . так ... e.g. |
| because of | из-за чего-либо |
| instead of | Вместо чего-либо |
| to push out of | Выталкивать из |
| to reach smth | Достигать, доходить до чего-либо |
| twice as many (much) | вдвое больше |
| twice less | вдвое меньше |
| shortly after | Вскоре (сразу) после |
| just before | Непосредственно перед |
| to start | Начинать |
| to communicate with | Связываться с |
| although | Хотя |
| moreover | более того |
| nevertheless | тем не менее |
| however | Однако |
| thus | таким образом |
| under the favorable conditions | при благоприятных условиях |
| to be available | иметь в наличии |
REMEMBER THE FOLLOWING ABBREVIATIONS
| BDC (bottom dead center) | Нижняя мертвая точка |
| TDC (top dead center) | Верхняя мертвая точка |
| cpp (controllable pitch propeller) | винт регулируемого шага (ВРШ) |
| cst (centistoke) | Сантистокс |
| С (Centigrade) | по шкале Цельсия |
| F (Fahrenheit) | по шкале Фаренгейта |
| HFO (Heavy Fuel Oil) | Тяжелое топливо |
| ECR (economic continuous rating) | Длительная экономическая мощность |
| MCR (maximum continuous rating) | Максимальная длительная мощность |
Irregularities in Operation, Causes and Remedies
| Symptom: | Cause: | Remedy: | |||||||||||||||||||||
| 1. Starting difficulties. |
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| Insufficient or no compression. | a) Inlet and exhaust valves leaking. b) Inlet and exhaust valves sticking. | Grind or replace valves, mill the seats. 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/slack. | Replace springs. | |||||||||||||||||||||
| '' | f) Cylinder liner worn. | Replace.
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| '' | 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 FS. | Ventilate | |||||||||||||||||||||
| '' | b) Fuel lift pump defective. | Repair pump and ventilate FS. | |||||||||||||||||||||
| 2. Engine starts, but stops shortly afterwards. |
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| Engine starts, but stops after a while | a) Fuel tank empty | Fill tank & remove air from FS. | |||||||||||||||||||||
| '' | b) Air in FS. | Aerate. | |||||||||||||||||||||
| '' | c) Fuel filter choked. | Clean the filter. | |||||||||||||||||||||
| 3. Engine does not reach maximum capacity |
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| Insufficient or no compression. |
| See under "Starting difficulties". | |||||||||||||||||||||
| Fuel valves out of order |
| '' | |||||||||||||||||||||
| 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 FS thoroughly. | |||||||||||||||||||||
| Engine does not reach full speed. | Governor drive broken. | Adjust/replace governor spring. | |||||||||||||||||||||
| Engine loses too much speed under load. | Incorrect adjustment of governor, or something in system works sluggishly. | Adjust governor. Check governor system, and correct the defect. | |||||||||||||||||||||
| Smell of heat. | Insufficient cooling water. | Stop engine, fill in CW when the engine’s cooled off. | |||||||||||||||||||||
| 4. Engine speed too high. |
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| 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.
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| 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. |
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| Black smoke from engine. | a) Air filter choked. | Clean filter. | |||||||||||||||||||||
| '' | b) Fuel valve out of order. | See "Starting difficulties". | |||||||||||||||||||||
| '' | c) Insufficient compression. |
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| '' | d) Engine overloaded. | Reduce load. Never overload | |||||||||||||||||||||
| '' | e) Thermostat valve leaking. | Replace valve. | |||||||||||||||||||||
| Blue smoke from engine. White smoke from engine | Lube oil forces its way past leaky piston and oil rings into combustion chamber. Water gets into the combustion camber | Replace oil and piston rings.
Check glands and sealing. Replace if damaged. See also 7. | |||||||||||||||||||||
| 7. Excessive fuel oil consumption. |
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| 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. |
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| Lube oil enters combustion chamber. | Oil piston rings worm. | Replace rings. | |||||||||||||||||||||
| '' | 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. |
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| Smell of heat. | a) No CW. | Stop engine, fill up with CW when engine cooled off. | |||||||||||||||||||||
| '' | b) Engine overloaded. | Unload engine. | |||||||||||||||||||||
| CW temperature too high. | Lack of CW owing to defective CW pump or due to leakage. | Remedy the fault. | |||||||||||||||||||||
| Cooling water volume too high. | a) Defective thermostat. | Replace thermostat.
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| '' | 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.
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| '' | 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. |
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| 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. | Repair valve. | |||||||||||||||||||||
Exercise 1. 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?
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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 2. 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 3. 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 4. 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 5. 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 6. Describe the engine installed abroad your vessel using the following words. Mention its rating (output power and RPM).
Slow, medium, high-speed, two or four-stroke, single or double acting, in-line or V-shape, with cross head or trunk piston, direct, coupled or connected, to the propeller bу gear.
Exercise 7. Made up a dialogue of your own based on the dialogues given below.
THE CYLINDER AND PISTON ASSEMBLY I
| cylinder head (cover) | крышка цилиндра |
| surface | поверхность |
| scraping to scrape | шабровка, шабровать |
| machining | машин. обработка |
| to renew | заменять |
| safety valve | предохранительный клапан |
| rocker | коромысло |
| indicating cock | индикаторный кран |
| rod | штанга |
| valve disk | тарелка клапана |
| bush | втулка |
| valve stem | шток клапана |
| turn | обтачивать |
| to cut off | вырубать |
| pin | палец |
| fitting | арматура, пригонка, установка |
| to weld | заваривать |
| to fit into position | устанавливать по месту |
| exhaust valve | выхлопной клапан |
| cylinder assembly | цилиндр в сборе |
The Cylinder Heads
Mr. Wilson - What about the cylinder heads? Do the contract surfaces of the cylinder heads require machining or just scraping?
Ch. Eng. - They need both.
Mr. Wilson - Must all the cylinder headbe renewed or can some of them be repaired?
Ch. Eng. - Well, the starting valves are to be overhauled with later pressure testing. But all the other fittings (the safety valves, the indicating cocks, etc) should be renewed.
Mr. Wilson - Very well. According to the list of repairs you'd like to replace only four exhaust valves. Why not all of them?
Ch. Eng. - The other exhaust valves are O.K. But their disks and stems should be turned.
Mr. Wilson - Do you think that all exhaust valve rockers and rods should be replaced too?
Ch. Eng. - No, I don't think so. But the rocker bronze bushes and pins should be renewed.
Mr. Wilson-Well, I see.
THE CYLINDER AND PISTON ASSEMBLY II
| piston | поршень |
| repair size | ремонт, размер |
| plasma - jet hard facing | плазменная наплавка |
| piston pin | поршневой палец |
| pressure test | опрессовка |
| groove | канавка |
| main bearing | рамовый подшипник |
| ring | кольцо |
| top-end bearing | головной подшипник |
| renewal | замена |
| measure | измерять |
| bottom-end bearing | мотылевый подшипник |
| adjust | регулировать |
| measurement | измерение |
| clearance | зазор |
| adjustment | регулировка |
| to rebabbit | перезалить |
| babbit = white/antifrictional metal | заливка подшипника |
| to bore boring | растачивать расточка |
- Mr. Wilson - Well, let's pass on to the piston. Can you tell me. What should be done about them?
Ch. Eng. - according, to the list of repairs two piston assemblies are to be replaced. The rest require the following repairs, namely:
- plasma jet hard facing and cutting the grooves for the piston rings;
- renewal of the piston rings on all the piston;
- measuring the clearances in the top-end bearings. If required they should be rebabbited and then fitted into position with necessary clearances.
Mr. Wilson - I see. By the way do you want the top end bearings to be rebabbited and adjusted to the new repair sizes of the piston pins or to the old ones?
Ch. Eng. - To the old ones. The pistons will require the pressure testing.
Mr. Wilson - What arc you plans about the piston telescopic system?
Ch. Eng. - Unfortunately it should be completely replaced.
Mr. Wilson - And what about the main bearings?
Ch. Engineer - The main bearings which have big cracks in babbit should be remetalled and then fitted into position. The other bearings should be used depending on their conditions and clearances.
Mr. Wilson - Shall we repair the bottom - end bearings according to the list of repairs?
Ch. Eng. - Oh, yes. Rebabbiting, boring, scraping, fitting and all that I'm sure you know what should be done.
Mr. Wilson - Well, we'll try to do our best.
Exercise 8. Придумайте ответные реплики:
A: Do the contact surfaces of the cylinder heads require machining or just scraping?
B: ......................
A: What are you planning to do with the starting valves?
B: ......................
A: What valves should be replaced?
B: ......................
A: What are your plans about the piston telescopic system?
B: ......................
A: And what about the main bearings?
B: ......................
A: Shall we repair the bottom end bearing according to the list of repairs?
B: ......................
A: How many cylinder liners should be replaced?
B: ......................
Exercise 9. Translate the sentences.
1. Объясните, что главному двигателю необходим кап. Ремонт. Вся дополнительная работа по демонтажу и сборке главного двигателя включена в ремонтную ведомость. Телефоны, датчики и индикаторы будут сняты силами машинной команды.
2. Объясните, что крышки цилиндров требуют машинной чистки и шабровки. Вся их арматура, кроме выхлопных клапанов должна быть заменена. Трещины надо вырубить и перезаварить. Диски и штоки выхлопных клапанов должны быть проточены.
3. Объясните, что вы хотите заменить 2 поршня в сборе и отремонтировать остальные. Объясните, какой ремонт им необходим. Мотылевые подшипники должны быть перезалиты, проточены, отшаброваны и установлены по месту.
4. Объясните, что головка одного из поршней прогорела.
5. Скажите, какой ремонт необходимо сделать. На поршне цилиндра №2 кольца защемлены в канавках. Замерьте, зазоры и прорубите канавки точно по размеру. На поршне цилиндра №3большие отложения накипи, которые необходимо удалить.
Lesson 2. PUMPS
| to flow out | вытекать |
| direction | направление |
| rotation | вращение |
| to indicate | указывать |
| arrow | стрелка |
| acquirement | требование |
| ammeter | амперметр |
| to exceed | превышать |
| possible | возможный |
| rating | расчетная величина |
| tightness | герметичность, зд: затяжка |
| packing gland | сальник, уплотнение вала |
| drop | капля |
| to prevent | предотвращать |
| harmful | вредный |
| output | производительность |
Operation and maintenance instructions
Starting (the centrifugal pump and axial How pump)
1) Open the suction check valve wide, opening at the same time the air vent on the top side.
2) Close the air vent as soon as liquid flows out of it.
3) Start the motor leaving the discharge valve closed.
4) Check that direction of rotation is as indicated by the arrow.
5) Slowly open the discharge check valve until operating requirements are reached.
6) Check on the ammeter that power requirements do not exceed the motor possible rating.
7) Check tightness of the packing gland. Leaks must be reduced to a few drops which is required to prevent harmful heating of the packing and the shaft.
During operation
The pump output is to be controlled by operating on the discharge valve and never on the suction valve which must always remain wide open.
Stopping
After switching off the motor close the suction and the discharge valves of the pump.
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