Marine Workshop Guide

CONTENTS

1. VALVES 2

PANEL 1: VALVE OVERHAUL RIGS 2

PANEL 2: VALVE OVERHAUL RIG 3
PANEL 3: VALVE OVERHAUL RIG 4
PANEL 4: THE TEST TANK 5

2. COOLERS 6

PLATE COOLERS (TYPE APV LR 45) 6

3. PUMPS 7

PUMPS (WEIR TYPE GVA/301/11 CENTRIFUGAL PUMP) 7

4. SHAFTING 8

5. AIR COMPRESSORS 8

6. FUEL VALVE TEST BENCH AND PURIFIERS. 10

7. TURBO-CHARGER AREA 11

8. HYDRAULIC NUT AND BOLT 15

9. OIL MIST DETECTOR TO DEMONSTRATE 16

10. STEERING GEAR DEMONSTRATION 17

11. DIESEL ENGINE OVERHAULING 18

12 MAIN ENGINE CYLINDER LINER CALIBRATION .

13 OILY WATER SEPARATOR

14 THE ELECTRICAL SECTION

SchoolofMarineEngineering Aug10/DC Page1

 Marine Workshop Guide

1. VALVES
Panel 1: Valve Overhaul Rigs

In the first Panel of the valve display we will see sectioned valves of three types.

On the left is the Screw-down non-return valve and in the middle the Screw-lift valve.
The difference can be seen internally, the screw lift valve having a spindle which is
grooved ,and secured by a locknut ,or sometimes a split pin .,so that the valve
moves up and down with the screw action of the spindle ,but can still rotate .

The Screw-down non return valve has a socket to locate the spindle in the valve
head, or plug as it is correctly known, but the spindle is not trapped in any way so the
valve stays shut when the spindle is lifted .This type of valve is used in bilge
systems. The third valve is a Gate valve. Gate valves work best fully open or fully
shut whereas the previous screw lift valve can be throttled.

Lecturers remarks..

Signature of lecturer..

Signature of internal Verifier. .

SchoolofMarineEngineering Aug10/DC Page2

 Marine Workshop Guide

Panel 2: Valve Overhaul Rig

This consists of 6 screw lift valves which a pressurising pumps and a relief valve.
The purpose here is to overhaul and test the valves using different sequences to
ensure the repairs are watertight.

Lecturers remarks

Signature of class lecturer..

Signature of internal Verifier

SchoolofMarineEngineering Aug10/DC Page3

 Marine Workshop Guide

Panel 3: Valve Overhaul Rig

This rig as above but in this case all the valves are screw-down non-return. Apart
from this the same testing procedure as for panel 2 has to be carried out.

Lecturers remarks on students skill level .

Signature of class lecturer
Signature on internal Verifier.

SchoolofMarineEngineering Aug10/DC Page4

 Marine Workshop Guide

Panel 4: The Test Tank

The system demonstrates a typical system of cooling where the seawater circulates
through on side of a cooler, and the cooled medium, in this case blue water,
circulates in the opposite direction.

The system consists of 2 Weir pumps, type GVA/301/11, which take from the header
tanks, circulate through the coolers pipe work, and valves.

Lecturers remarks on students skill level .

Signature of class lecturer
Signature of Internal Verifier

SchoolofMarineEngineering Aug10/DC Page5

 Marine Workshop Guide

2. COOLERS
Plate Coolers (Type APV LR 45)

Plate coolers work by having a number of titanium or stainless steel pressed pattern
plates, jointed with a gasket on one side, where the fluids circulate in opposite
directions through the cooler. Joints are critical, any small leakage causing
contamination. Here we will open up clean check and reassemble the units.

Lecturers comments..
Signature of class lecturer..
Signature of Internal Verifier .

SchoolofMarineEngineering Aug10/DC Page6

 Marine Workshop Guide

3. PUMPS
Pumps (Weir type GVA/301/11 centrifugal pump)

This is a representative pump of a type used throughout the marine industry.

SchoolofMarineEngineering Aug10/DC Page7

 Marine Workshop Guide

The input here is to take the pump apart, and reassemble, proving the pump free to
turn on reassembly!

1. Remove Perspex cover.

2. Remove gland seal pipe
3. Remove shaft gland nuts and raise gland above stud bolts.
4. Remove all the volute casing nuts.
5. Jack off the volute casing.
6. Remove the impeller and wear rings.( note the position of the wear rings)
7. Take all clearances, and reassemble in the reverse order, proving free on
completion of work.

Lecturers comments .
Signature of class lecturer.
Signature of internal Verifier .

4. SHAFTING
Shaft Alignment Rig
This is a pump motor assembly with a fixed pump and a movable motor .The idea is
to align the motor perfectly to the pump ensuring vibration free running. Dial gauges
and straight edges to be used.
Lecturers comments..
Class lecturers signature
Signature of internal verifier..

The Shaft Seal (mechanical type)

This is a demonstration rig of a large mechanical seal as used in a tanker cargo
pump or steamship circulating pump ,or perhaps ballast pump.

The upper sleeve is attached to the shaft with grub screws and this then turns
against the fixed surface. O rings are fitted internally to prevent leakage.

Lecturers comments.

Class lecturers signature

Internal verifiers signature

SchoolofMarineEngineering Aug10/DC Page8

 Marine Workshop Guide

5. Air Compressors

Hamworthy 2 TM 6 (2-stage, water-cooled, 30bar discharge pressure)

The purpose here is to strip and rebuild these machines. Safety is paramount on this
and every job, with the crane in use helmets must be worn. As some of the
components are heavy care must be taken when handling these.

1. Using the Allen Keys provided remove the first and second stage suction and
discharge valves, noting where they are located.
2. Undo the nuts holding down the high pressure cylinder head, the air inlet and
outlet pipe work, the unloader pipe work, and remove it.
3. Disconnect the cooling water bends from the main cylinder head, slacken off
and remove the securing nuts, and using the crane remove the main cylinder
head.
4. Open the crankcase doors, remove the oil dipstick before taking the doors off.
5. Undo the bottom end bolt nuts and carefully remove the bottom halves of both
bearings.

SchoolofMarineEngineering Aug10/DC Page9

 Marine Workshop Guide

6. Turn the machine until the pistons are by turn at top dead centre, and remove.
Lay these parts carefully aside.
7. Remove both high and low pressure intercooler stacks.
8. Inspect both high and low pressure relief valves
9. Inspect the fusible plug ,which is a device designed to melt and release the
HP pressure in the case of cooling failure. It is a lead plug which is designed
to melt at 130 Deg

Reassembly is the reverse of the above.

6. Fuel Valve Test Bench and Purifiers .

Here we test and overhaul the fuel injection equipment including injectors, pumps
and also the viscotherm which is an instrument for measuring fuel viscosity.

The fuel injector test procedure involves very high pressure oil spray, which can

penetrate skin and cause blood poisoning, so care must be exercised!

SchoolofMarineEngineering Aug10/DC Page10

 Marine Workshop Guide

From here we move to the fuel oil purifiers.

These are centrifugal machines for removing heavy unsuitable elements of heavy
fuel prior to use.

The bowl is stripped using the special tools provided. Some threads are LEFT Hand!

When reassembling the dowel must be carefully located.

Lecturers comments.

Class lecturers signature.

Internal verifiers signature

SchoolofMarineEngineering Aug10/DC Page11

 Marine Workshop Guide

7. Turbo-Charger Area
BBC VTR 220 Type

For overhauling the turbo-charger, follow the Procedure as described l.

SchoolofMarineEngineering Aug10/DC Page12

 Marine Workshop Guide

SchoolofMarineEngineering Aug10/DC Page13

 Marine Workshop Guide

The tool kit is kept in the stores and must be collected before work commences.
VTR 200 OVERHAUL PROCEDURE
Dismantling
Compressor side
Fig 2 and 8.1 on page 3 of the instruction manual.
1 Drain the Oil from the sump using the drain plug at the bottom .
2 Remove the air filter by undoing the bolts and lifting it off
3 Remove the bearing cover
4 Refer to Fig 2.1remove the oil thrower plate. 11mm spanner/socket
5 Fasten the locking device on the lubricating disc and with the special spanner
loosen the lock nut .27 mm
6 Remove the locking ring (Schnorr) and the remove the second lock nut
7 Pull out the lubricating disc and insert bush using the puller. And puller ring .
8 Remove the bearing unit with the puller # 1020
9 Do not unscrew the insert bush 7228 as it determines the axial play.
Reassembly is the opposite of the above .
In real life a new bearing housing, which is supplied in a tropical sealed pack ,would
be fitted .
Part 2 Overhauling the turbine side
1 Drain the oil out .
2 Remove the bearing cover 17 mm box key in tool box.
3 Refer to figure 2.2 remove the oil pump and suction pipe.
4 Remove the screws 3303 ,the locking plate and the divergent nozzle.
5 with the supplied spanner,(1130P) loosen the lock nut remove the securing ring ,
(Schnorr) the remove the second lock nut .
5 Remove the lubricating disc and insert bush using puller and ring (tools 1020 and
1022P)
6 Remove the bearing with tool1020.
Reassembly notes
1 The housing must be carefully cleaned .

SchoolofMarineEngineering Aug10/DC Page14

 Marine Workshop Guide

2 the shaft nut must be tightened up hard until the bearing unit is fully home ,then the
nut slackened off and tightened moderately.
3 Replace Schnorr ring and locknut .
4 Refit divergent nozzle and check true running ..
5 fit oil suction pipe ,
6 fit bearing cover
Dont forget to refill with oil!
Lecturers comments

Course lecturers signature.

Internal verifiers signature

Hydraulic Nut and Bolt

SchoolofMarineEngineering Aug10/DC Page15

 Marine Workshop Guide

This is a typical system as used for tensioning cylinder head bolts, tie bolts and
bearing cap securing bolts. Here we witness the extension of the bolt by hydraulic
means and how the bolt is checked .

Lecturers comments
Course lecturers signature..
Internal verifiers signature..

8. Oil Mist Detector to Demonstrate

This device is used to continuously monitor the oily mist inside the crankcase of a
diesel engine and sounds an alarm if the concentration of oil mist reaches
dangerous level where it may cause an explosion.

SchoolofMarineEngineering Aug10/DC Page16

 Marine Workshop Guide

10. Steering Gear Demonstration

This is a four ram hydraulic steering gear representative of a type in use in large
vessels. Ram steering gears are used in larger ships as the rotary vane type does
not give sufficient torque .

Lecturers comments.
Course lecturers signature..
Internal verifiers signature

SchoolofMarineEngineering Aug10/DC Page17

 Marine Workshop Guide

11. Diesel Engine Overhauling

English electric engine

The following checks are done to ensure good running order of the engine .

Tappets Check Y N
C/case deflection Y N
Test run the engine Y N

SchoolofMarineEngineering Aug10/DC Page18

 Marine Workshop Guide

B&W Engine

As in all cases with heavy loads helmets and crane are required!
Using the instruction manual, the following tasks will be carried out.
Tappets Check Y N
Remove and replace cylinder head Y N
Remove and replace a fuel pump Y N

SchoolofMarineEngineering Aug10/DC Page19

 Marine Workshop Guide

Main Engine Cylinder Liner

The calibration of the cylinder liner is done using an internal micrometer

(this unit is stored by the lecturer)
This measurement indicates the wear taking place inside the liner.

SchoolofMarineEngineering Aug10/DC Page20

 Marine Workshop Guide

The calibration is measured in 100/ths of a mm and the maximum wear

is normally 8-10% of the original nominal diameter. On a diesel engine
this reading is normally taken every year ,to ensure that the machine is
not wearing abnormally.
Measurement is taken in two axis
1 Forward to aft
2 Port to Starboard.
Normally about 7 readings are taken from top to bottom using the
locating bar, the greatest wear being at the top where combustion takes
place and the minimum at the bottom where little wear is expected.

OILY WATER SEPARATOR

The last item in the workshop to be demonstrated is the Oily water

Separator, this being used to separate bilge water and entrained oil.
The machine is a requirement of Marpol regulation 1
It works by using a filter and coalescer, extracting the oil in emulsion with
the bilge water, to achieve a maximum discharge ppm of no more than
15. This figure ensures that there is no apparent oil slick on the surface
of the water after discharge .The oil is that is removed, is collected in a
residue tank, and pumped ashore to a collection facility or burned in the
incinerator.
The unit we have here simulates this by taking oil contaminated water
from the inclusive tank, processing it and returning the product to the
tank along with the separated oil.

SchoolofMarineEngineering Aug10/DC Page21

 Marine Workshop Guide

Oily Water Separator

SchoolofMarineEngineering Aug10/DC Page22

 Marine Workshop Guide

Electrical Section
This is an area mainly on the Mezzanine level and at the left end of the Marine
workshop as you enter .In this area you will learn the names and nomenclature of
the various equipments and work on stripping and rebuilding motors.

Main switchboard

Types of motor windings commonly used in marine practice are ;

Induction motor (most common)

o Squirrel cage type
o Wound rotor type (also known as slip ring type)
o Multiple phase winding
DC motors (not very common)
o Shunt
o Series

SchoolofMarineEngineering Aug10/DC Page23

 Marine Workshop Guide

o Compound
Single phase Induction motor
o Capacitor run type

Insulation class is from Y through to C regards temperature rating of 90 to 150 Deg

C

There is a test area for building simple circuits, using various components, motors for
inspection and for stripping down, and a switchboard, representative of Marine
installation.

Dismantling of motors is also carried out here

All cabling should be labelled for ease of reassembly.

Bearings should be extracted using pullers, any shafts requiring tapped should be hit
only by a lead hammer or with a piece of wood between the shaft and hammer to
prevent damage.

In this area you will also find a sectioned motor which lets us see inside. showing the
windings of the rotor, stator and bearing housings.

Other actions here include paralleling of machine on the simulator, and start up of
large plant

Paralleling procedure
Varies from vessel to vessel, and in most cases now is fully automatic with load
sharing equipment. However even the best equipment fails and here is a simple
description of paralleling by hand.

With one machine running, and supplying power to the board, start the second
(incoming machine) and then at the switchboard;

1. Switch on the syncroscope.

2. Switch its supply to the incoming machine.
3. Using the governor speed control switch adjust the incoming machine speed
until the syncroscope needle is turning slowly clockwise.
4. At the 5 to 12 position close the breaker for the incoming machine.

SchoolofMarineEngineering Aug10/DC Page24

 Marine Workshop Guide

5. Switch off the syncroscope and adjust the loads to be the same on each
machine.

The machines are now running in parallel. The final check is always to check the
machines over before leaving them.

SchoolofMarineEngineering Aug10/DC Page25

 Marine Workshop Guide

Switchboard simulator

SchoolofMarineEngineering Aug10/DC Page26

 Marine Workshop Guide

Starter simulator
Motor starters are of two main types

Direct on line for lower powers up to circa 20 KW

Star/Delta soft starters for larger powers.

SchoolofMarineEngineering Aug10/DC Page27