Wednesday, 14 March 2018

crankshaft

Lets learn all about CRANKSHAFT- an important engine component.

INTRODUCTION:

  • The working of other components of the engine, such as camshaft for fuel timing, firing order of each unit, opening of inlet valve and exhaust valve, operation of air start distributer etc depends on correct rotation of the crank shaft.
  • Failure of crankshaft can stall the engine/ship.
  • The parts forming a crankshaft are : journals( crankshaft), crank webs and the crankpins.
  • They are too big to make a single unit and so they are constructed by joining together individual forgings.(will be discussed below how it is done).


MATERIAL:
  1. For slow speed marine diesel engines:
      steel castings or forgings
  2. For medium and high speed M.D.E
      Alloy steel

WEIGHT:
For 2-stroke crosshead engines- over 300 tonns.

CLASSIFICATON:
 They are divided into four depending upon the methods of construction-
(a) Fully built
(b) Semi-built
(c) Welded crankshaft
(d) Solid single piece used in very small engines.

Now we will know the above mentioned classifications one by one in a simple way.

(A) FULLY BUILT
  • As already mentioned above the parts which forms a crankshaft: journal, webs,      crankpins.
  • Journals and crankpins are made from forgings, and the webs may be forged or cast.They are made separately.
  • These parts are shrink-fitted.
  • Webs were heated up and the crank pin and journals fitted into the holes.The holes gets expanded due to heating.
  • Were used on older engines. 
  Let's see the diagram:


BEARING


BEARING

Classification
1) Main bearing
2) Top end bearing = Cross Head / Gudgeon Pin bearing
3) Bottom End Bearing / Crank pin bearing
4) Thrust Pad bearing
5) Pedestal bearing (generator alternator side insulated bearing)

1. MAIN  BEARINGS 
Function : Support crankshaft and keep it aligned.
  To remove heat produced by friction

2. TOP  END  BEARINGS 
Cross head Engines: Transmit load from cross head pin to connecting rod
   Allows relative movement of con rod & cross head pin
Trunk Piston Engines: Transmit load from gudgeon pin to connecting rod
   Allows relative movement of con rod & gudgeon pin

3. BOTTOM  END / CRANKPIN  BEARINGS 
Function: Transmit load from con rod to crankshaft
  Allows relative movement of con rod & journal

Bearing Operation: Depends on  
`  Operating temperature of bearing
`  Working temperature of bearing
`  Minimum oil film thickness
`  Rate of oil flow
`  Rate of heat production
`  Power loss of bearing.

Bearing Loads:
  • Combustion forces, Inertia forces & Centrifugal force of rotating masses 
  •  Varying resultant load from gas forces & inertia forces 
  •  Two stroke engine  No load reversal
  •  Four stroke engine  Load reversals at the end of exhaust stroke hence, wear uniform   & lubrication better.     
  •  Fluctuating gas force results fatigue failure in bearing 

Bearing Material Properties
 Mechanical Strength 

  • Fatigue & compressive strength to carry load – depends upon thickness 0.3 mm white metal can withstand 141 bar pressure and 0.08 mm white metal can withstand 211 bar pressure.
  • Thin lining has poor conformability and too soft material tends to flatten under heavy loads
  • Too hard material withstands high loads, posses high frictional characteristics & may be brittle with poor fatigue characteristics.


 Soft & low melting point material 

  • Softness & modulus of elasticity of bearing alloy should be as low as possible but hard enough to withstand heaviest continuous loading or chock loading without plastic deformation
  • Soft metal flows locally without damaging the harder steel called conformability
  •  Allows abrasive particles to embed to prevent damage to journal 

 Corrosion resistance
To withstand corrosive attack from lub oil

 Antifriction & wear properties –depends upon type of oxide film that material forms on reaction without lube additives.

Bearing Material 
 White Metal = Tin (Sn) +_ Antimony (Sb) + Copper (Cu)

  • Thin walled bearings, stiff cross head assembly    88% Sn + 8% Sb + 4% Cu
  • Thick walled bearing, flexible crosshead & Bottom end bearing  87% Sn + 9% Sb + 4%Cu 

  1. Tin forms soft matrix to accommodate misalignment
  2. Antimony forms hard cubes to withstand load of journal. Tends to float and segregate during  casting
  3. Copper holds antimony in evenly dispersed pattern, solidifies first. 

Basic questions for Marine Engineers


Motor Engineering Knowledge (MEO Class 4)

1.                   What is stroke?
2.                   RPM of Low, Medium and High speed engines?
3.                   Discuss Otto cycle, Diesel cycle, Dual cycle and Actual cycle
4.                   Timing diagram of 2-stroke engine
5.                   Timing diagram of 4-stroke engine
6.                   Difference between 2-stroke and 4-stroke engine?
7.                   Material of Piston, Connecting Rod, etc.
8.                   What is Cross flow, Loop flow and Uniflow scavenging?
9.                   What is over speed trip and how it works?
10.               Types of IC engines
11.               What is stroke to bore ratio?
12.               What is mean effective pressure?
13.               What is turbocharger?
14.               Why air is passes through the air cooler?
15.               How you prepare Main engine in 1 hour notice?
16.               What is the purpose of cylinder relief valve?
17.               At what speed air break for main engine can be given?
18.               Causes of water coming out during blow through?
19.               Procedure to take over a watch?
20.               What is dead man’s alarm?
21.               How to take the liner calibration?
22.               How many types of fuel pumps are used in marine diesel engines?
23.               What action you will do after De-carbonization of an auxiliary engine?
24.               What will be your action on a vibrating turbocharger?
25.               How to overhaul a fuel injector?
26.               What are main engine safety devices?
27.               How differential pressure switch works?
28.               What is CPP?
29.               What is the difference between SMC and ordinary engine?
30.               How will you decarbonise your main engine?
31.               Why noises coming from telescopic pipes?
32.               How oil mist detector works?
33.               How to remove crankshaft?
34.               How to take crankshaft deflection?
35.               How will you take tappet clearance?
36.               How will you check main, big end, thrust and cross head bearing clearances?
37.               What are the normal clearances obtained?
38.               What are the causes of sudden over speed of main engine?
39.               What are the causes of engine power loss?
40.               What are the causes of speed fluctuation of engine?
41.               What are the causes of reduced compression pressure?
42.               What are the causes of knocking?
43.               What is ignition delay and how to reduce it?
44.               What will you do for proper atomisation?
45.               What is the difference between clearance volume and swept volume?
46.               What is overlapping in fuel timing?
47.               What is the material of cooler tubes?
48.               What is stuffing box?
49.               What are the rotating mechanism of exhaust valves?
50.               How is lube oil for cross head is delivered?
51.               What is the difference between stuffing box drain and scavenge drain oil?
52.               What is the role of thrust bearing and location?
53.               Why fuel timing is important and how the same is checked?
54.               How BHP is calculated with indicator diagram?
55.               Why expansion tank is provided in jacket water system?
56.               What is the difference between auxiliary and main engine governor?
57.               What do you understand by specific cylinder oil consumption?
58.               What inspection you carry out after grounding of the vessel?
59.               What is supercharging?
60.               What is the difference between RTA and RND engine?
61.               Describe rudder dismantling?
62.               Describe propeller dismantling?
63.               What are main engine interlocks?
64.               What is crank case explosion and how it occurs?
65.               Scavenge fire reasons and remedy?
66.               Explain about exhaust gas heat recovery system?
67.               Causes of starting air line explosion?
68.               Why tappet clearance is needed?
69.               Describe crankcase relief valve?
70.               What is starting air overlapping
71.               What are the difference between naturally aspirated engine and supercharged engine?
72.               What are the functions of turbocharger inducer, diffuser, diaphram and labyrinth seal?
73.               What is turbo charger surging?
74.               Describe constant pressure and pulse type turbo charger.
75.               What is the quantity of lube oil in 4 stroke and 2 stroke engines?






General Engineering Knowledge (MEO Class 4)

1.                   What is glide?
2.                   Describe bunkering procedure?
3.                   How the tail shaft sealing arrangement is done?
4.                   What are the measures you will take if the gland packing leaks continuously?
5.                   Why intermediate shaft is given?
6.                   How will you take out the valves of air compressor?
7.                   During dry dock what will you check in seachest valves?
8.                   What are the safeties of air compressor?
9.                   What is Heleshaw pump?
10.               Define valves and cocks and their functions
11.               Which valve is suitable for remote controlled operation and why?
12.               What is rudder drop and jumping clearance?
13.               Where and why bursting disc is provided in an air compressor?
14.               What are reasons of lifting up inter stages safety valves in an air compressor?
15.               How to test compressor safety valve?
16.               How will you overhaul a globe valve?
17.               What are the reasons for a sticking gate valve?
18.               What is the theory of density correction?
19.               How does quick closing valve function?
20.               How do you specify pipe sizes?
21.               How do you select correct current setting for welding?
22.               What is the common size between different schedules of pipes?
23.               Where telescopic feeler gauges are used?
24.               What are the safeties of cargo crane?
25.               What are the safeties provided on engine room overhead crane?
26.               Where are wear rings used?
27.               What is hunting gear?
28.               Explain welding surface preparation?
29.               Draw a lip seal and how it works?
30.               Who will you align a pump and its motor?
31.               Sketch exhaust bellow?
32.               What are the testings carried out on steering gear during a drill?
33.               Mention fresh water generator shell temperature, vacuum, and other parameters?
34.               What is the significance of stern tube header tank?
35.               What are the advantages of four ram steering gear?
36.               Describe checks on fresh water generator during watch?
37.               What is the significance of greasing steering gear?

MEO Class Exam Questions

1.                   What is reverse osmosis?
2.                   What is purifier and clarifier?
3.                   Discuss purifier operation?
4.                   What are fuel oil testings done on board ships?
5.                   What on board tests are done in lube oil?
6.                   What is the correct procedure to collect lube oil for testing?
7.                   What is the temperature of fuel oil entering and leaving purifier?
8.                   What are the safeties of fresh water generator, steering gear and oily water separator?
9.                   Why purifier overflows?
10.               What is viscometer?
11.               What is the function of air compressor unloader?
12.               What is the function of expansion valve?
13.               How the unloader works in an ac compressor?
14.               Why fridge compressor is belt driven?
15.               How is the temperature of cold rooms maintained?
16.               What is he difference between air compressor and ac compressor?
17.               What is critical temperature and pressure?
18.               What is latent heat?
19.               What is meant by short cycling in fridge compressor?
20.               Different types of pumps and where they are used?
21.               What is the discharge pattern of reciprocating pumps and other pumps?
22.               What is jumping clearance?
23.               How many types of steering gear are there?
24.               Describe arrangement of stern tube?
25.               How stern tube cooling is done?
26.               How to take crank shaft deflection?
27.               Why the suction pressure of refrigeration plant and ac plant are different?
28.               What is the function of rudder carrier bearing?
29.               How many types of fresh water generator are there?
30.               Why centrifugal pump has no relief valve?
31.               Arrangements for relieving shocks in the steering gear?
32.               What is bell mouth?
33.               What is interface of purifier?
34.               What are swash plate pumps?
35.               Why is oil coming from the water side of purifier?
36.               Explain the significance of heat treatment in steels?
37.               Hosing down procedure for engine room tank top?
38.               What are the precautions before entering inside an air reservoir



General Engineering Knowledge (MEO Class)

1.                   Why certain back pressure is maintained for purifier?
2.                   What is the use of purifier breaks?
3.                   Explain the functions of purifier centrifugal clutch?
4.                   What are ALCAP purifiers?
5.                   Explain the importance of gravity disc in a purifier?
6.                   How will you manage your air compressor without automatic unloader?
7.                   How will you confirm that air compressor valves are not leaking after overhauling?
8.                   Why oil film is coated on a compressor air filter?
9.                   Effect of air filter mesh size in an air compressor?
10.               What is the working principle of an air drier?
11.               Name five non metals used on board ships?
12.               Routine checks on a fixed foam fire fighting system?
13.               How many types of steels and brief their carbon contents?
14.               What is the material of safety valve?
15.               Define flash point, fire point, viscosity?
16.               How many types of propeller?
17.               What will you do if emergency alarm raise?
18.               What is the function of fire detector?
19.               What is saturation temperature?
20.               What is humidity?
21.               What is the material of cooler tubes?
22.               What is specific gravity?
23.               What is vacuum?
24.               What is meant by critical speed?
25.               What do you know about ‘M’ notices?
26.               What s the function of poker gauge?
27.               What s the function of lubricating oil?
28.               What is hydrostatic lubrication?
29.               What is inerting, purging and gas freeing in inert gas system?
30.               What are fire man’s outfit?
31.               What is cetane number and calorific value of a fuel?
32.               How will you buy a boiler?
33.               What is the formula of stress in longitudinal and circumferential joint?
34.               Describe boiler starting procedure from cold?
35.               Why boiler water treatment is required?
36.               How many types of marine boilers are used on ships?
37.               What are the tests carried out for a low pressure boiler water?
38.               What is your action on finding high chloride levels in a boiler?
39.               What will you do if no water level in the gauge glass?
40.               How would you blow down a boiler gauge glass?
41.               What are boiler mountings?
42.               What will you check while watch on a boiler?
43.               What is allowable chloride content in boiler water?
44.               If the steam nozzle of the gauge glass is chocked then how will you confirm water level?
45.               Why purge a boiler furnace?
46.               What is superheated steam?
47.               How many types of boiler safety valve?
48.               Describe boiler survey procedure?
49.               How to check alkalinity, acidity, chloride content in boiler?
50.               Draw the lip clearance of safety valve?
51.               What is the difference between safety valve and relief valve?
52.               What is corrosion, erosion, and abrasion?
53.               Comment on materials of boiler construction?
54.               Why and how soot blowing is done?
55.               Describe automatic combustion system in a boiler?
56.               Why flame failure alarm comes and what will be your action?
57.               When do you start the boiler circulating water pump?
58.               How will you know that EGB is leaking and how to arrest the leak?
59.               How boiler safety valve is set?
60.               Show the calculation of safety valve area?
61.               What do you know about economiser?
62.               Describe setting of safety valve?
63.               What is steam hammering?
64.               What is manometer?
65.               What is steam trap?
66.               How will you prevent uptake fire?
67.               What is dry distillation?
68.               What action o be taken if oil is found in the cascade tank?
69.               What colour flame indicates efficient or poor combustion?
70.               What is Ogee ring?
71.               Where the boiler fusible plugs are used?
72.               What are the densities of boiler water and seawater?
73.               What is the diameter of safety valve?
74.               What is the purpose of blow down ring?
75.               Is there any arrangement for boiler safety valve draining.