OPERATING PROCEDURE FOR AUX. BOILER

01. LINE UP THE VALVES & PUMPS AS REQUIRED.

MANUAL MODE:

01. PUT THE BURNER OPERATION SWITCH TO MANUAL SIDE.

02. FD FAN CUTS IN AND AFTER FEW MINUTES IGNITION READY LAMP WILL LIT.

03. PUSH THAT SWITCH AND WATCH FOR FIRING INSIDE THE BURNER.

04. ONCE STARTED FIRING, SWITCH ON THE MANUAL SOLENOID VALVE.

05. DEPENDS UPON THE REQUIRED PRESSURE SELECT HIGH OR LOW FLAME.

06. FOR STOPPING, PUT THE BURNER OPERATION SWITCH TO STOP.

AUTO MODE:

01. TURN THE BURNER OPERATION SWITCH TO AUTO MODE.

02. BURNER AUTOMATICALLY OPERATES AS PER PROGRAMME AND STARTS & STOPS AUTOMATICALLY AS PER BOILER PRESSURE.

D.O. IN USE:

01. OPEN D.O. INLET VALVE F.D.V7 (CONFIRM FB V44S IS SHUT)

02. PUT OFF THE HEATER SWITCH AND SWITCH ON THERMOSTAT BYPASS SWITCH.

03. FIRE THE BOILER AUTO OR MANUAL MODE.

F.O.IN USE:

01. TURN THE HEATER SWITCH ON.

02. OPEN VALVE FB V44S (CONFIRM VV FD V7 IS SHUT)

03. WHEN THE OIL TEMP REACHES 120 DEG, TURN THE THERMOSTAT SWITCH TO OFF POSITION.

04. FIRE THE BOILER ON AUTO OR MANUAL MODE.

W.O. IN USE:

01. HEAT THE WASTE OIL TANK TO 100 DEG.

02. LINE UP VALVES FOR THE TANK AND RETURN TO SAME.

03. PUT OFF THE HEATER AND SWITCH ON THERMOSTAT BYPASS ON.

04. CHANGE THE 3-WAY VALVE TO WASTE OIL SIDE.

05. SWITCH ON WASTE OIL STRAINER & PUMP.

FIRE THE BOILER ON AUTO OR MANUAL MODE

EMERGENCY AIR COMPRESSOR OPERATING INSTRUCTIONS

FOR STARTING:

01. CHECK L.O. LEVEL IN BOTH COMPRESSOR AND ENGINE.

02. SHUT THE ENGINE EXHAUST PIPE DRAIN VALVE (fig a).

03. PUT THE FUEL LEVER (fig b) ON 75%.

04. PULL THE STARTING LEVER (fig c) SLOWLY AND LEAVE IT. AGAIN PULL THE STARTING LEVER QUICKLY TO START.

05. PUT THE FUEL LEVER(fig b) TO 100%.

FOR STOPPING:

01. PUT THE FUEL LEVER ON (fig b) IDLE POSITION.

02. LIFT THE STOP LEVER (fig d) TO STOP POSITION AND KEEP TILL ENGINE REVOLUTION BECOMES STANDSTILL.

EMERGENCY FIRE PUMP OPERATING INSTRUCTIONS

FOR STARTING:

01. CLOSE THE DRAIN VALVE (fig a).

02. OPEN PUMP SUCTION VALVE.

03. CHECK THAT PUMP DISCHARGE VALVE AND ANY ONE HYDRANT VALVE IS OPEN ON DECK.

04. CONFIRM EMERGENCY FIRE PUMP DELIVERY LINE VALVE IN FIRE CONTROL ROOM IS OPEN.

05. CHECK WATER LEVEL IN PRIMING PUMP SUPPLY TANK (fig b), IF REQUIRED ADD WATER.

06. START THE MOTOR.

07. CHECK THE DISCHARGE PRESSURE (.5 Mpa) AND MOTOR LOAD (40 Amps).

FOR STOPPING:

01. STOP THE MOTOR.

02. OPEN THE DRAIN VALVE (fig a) TO DRAIN THE LINE WATER.

FRESH WATER GENERATOR

STARTING UP:

Before starting,the following valves are to be closed.

*JCW inlet and outlet valves

*vacuum breaker valve

*outlet valve for distillate p/p

*feed water inlet valve for heat exchanger

*bottom blow valve

1.OPEN THE OUTLET AND INLET VALVE OF CONDENSER COOLING WATER.KEEP THE BYPASS VALVE 40% OPEN.

2.OPEN EJECTOR P/P SUCTION V/V,DISCHARGE V/V AND OVERBOARD V/V.

3.START EJECTOR P/P.

4.OPEN FEED WATER V/V AND CONTROL FEED WATER QUANTITY.

5.CHECK CHEMICAL DOSING P/P TK LEVEL AND START DOSING P/P.

6.WHEN THE VACUUM IN THE GENERATOR BECOME ABT 70cmHg (-0.092Mpa),OPEN THE OUTLET AND INLET V/V FOR JCW.

(THE OUTLET V/V OF HEAT EXCHANGER SHOULD BE OPENED SLOWLY TO AVOID EVAPORATOR GETTING OVERHEATED SUDDENLY.

7.THE AIR VENT AT THE UPPER PART OF THE FWG CAN BE CLOSED

AFTER THE AIR IS COMPLETELY VENTED FROM HEATEXCHANGER.

8.SWITCH ON SALINITY INDICATOR.

9.CHECK WATER LEVEL IN THE SIGHT GLASS AND START THE DISTILLATE P/P.ADJUST DISH PRESSURE BETWEEN (0.14-0.22Mpa).

10.CLOSE THE FLOW ADJUST V/V TO HAVE OPTIMUM SHELL TEMP.

STOPPING:

1.STOP THE DISTILLATE P/P AND CLOSE THE P/P OUTLET V/V.

2.SWITCH OFF SALINITY INDICATOR POWER.

3.OPEN THE FLOW ADJUST V/V FULLY AND CLOSE THE JCW INLET AND OUTLET V/V.

4.CHECK M/E JCW OUTLET TEMP AND ADJUST THE SETTING IF NECESSARY.

5.RUN EJECTOR P/P FOR ABT 30 MINUTES TO COOL THE PLANT.

6.STOP THE EJECTOR P/P.CLOSE THE FEED WATER V/V FOR FWG AND CLOSE EJECTOR P/P DISCHARGE AND OVERBOARD V/V.

7.OPEN VACUUM BREAKER V/V.

8.OPEN SW BYPASS V/V FULLY.CLOSE INLET AND OUTLET V/V FOR CONDENSER COOLING SW.

9.AFTER PRESSURE INSIDE THE FWG BECOMES ZERO(ATMOSPHERIC PRESSURE), OPEN AIR VENT ON TOP OF FWG AND OPEN THE DRAIN V/V.

STARTING/STOPPING PROCEDURE OF DIESEL GENERATOR

BLOW THROUGH:

01. CHANGE OVER THE SELECT SWITCH TO ENGINE SIDE.

02. CHECK L.O. SUMP LEVEL & GOVERNOR OIL LEVEL.

03. CHECK L.O. PRIMING PUMP IS RUNNING ON AUTO MODE.

04. KEEP THE FUEL LEVER ON STOP POSITION.

05. OPEN INDICATOR COCK CAP AND VALVE.

06. ROTATE THE ENGINE BY TURNING BAR AND REMOVE IT.

07. OPEN AIR VALVE

08. PRESS THE START BUTTON AND KEPT PRESSING FOR “AIR BLOW THROUGH”.

STARTING:

01. CLOSE THE INDICATOR COCKS.

02. MOVE THE FUEL LEVER TO RUN POSITION

03. PRESS THE START BUTTON AND KEPT PRESSING TILL ENGINE STARTS ROTATING.

CHANGING OVER D.O TO F.O:

01. OPEN F.O. INLET /OUTLET VALVES AND CLOSE THE D.O. INLET/OUTLET VALVES.

CHANGING OVER F.O TO D.O.:

01. OPEN D.O. INLET VALVE AND CLOSE F.O. INLET VALVE.

02. RUN FOR 7 ~ 10 MINUTES.

03. OPEN THE D.O OUTLET VALVE AND CLOSE THE F.O. OUTLET VALVE.

STOPPING PROCEDURE:

01. MOVE THE FUEL LEVER TO STOP POSITION.

02. ONCE ENGINE STOPPED, OPEN THE INDICATOR COCKS.

03. CARRY OUT AIR BLOW THROUGH OPERATION.

04. SHUT THE INDICATOR COCK.

05. MOVE THE FUEL LEVER TO RUN POSITION. AND PUT THE SELECTOR SWITCH TO REMOTE SIDE.

STARTING PROCEDURE OF INCINERATOR

1. CHECK INCINERATOR CHAMBER.

2. CHECK MAIN BURNER, FLAME EYE & SUCTION STRAINER.

3. CHECK OIL TEMPERATURE ON SLUDGE SETTLING TANK,

TEMP. MUST BE 90~95 DEG. CELSIUS.

4. ON THE CONTROL PANEL SWITCH ON THE BREAKER WHILE

PRESSING THE RESET BUTTON.

5. ON THE CONTROL PANEL SWITCH TO START THE RUNNING KNOB.

SO THAT FAN WILL RUN TO AIR PURGE THE INC. CHAMBER.

6. FOLLOWING VALVES ARE TO BE OPEN FOR D.O MODE.

A. VALVE # 2- D.O. INLET.

B. VALVE # 4- 3 WAY V/V, HORIZONTAL POSITION.

C. VALVE # 5- D.O. INLET TO IGN. BURNER PRESSURE.

D. VALVE # 6- FEEDING V/V (SET TO 4.0).

E. VALVE # 7

7. ON THE CONTROL PANEL SWITCH MAIN BURNER KNOB TO ON AND

IGNITOR KNOB TO ON POSITION.

8. INCINERATOR IS FIRING AUTOMATICALLY AFTER FEW SECONDS.

9. CHECK FIRING CONDITION IN THE SIGHT GLASS, ADJUST VALVE # 6 IF NECESSARY.

10. CHECK FOR ABNORMAL SOUND & VIBRATION ON THE FAN & MAIN

BURNER MOTOR ALSO CHECK OIL LEAKAGE & DOOR IF PROPERLY

CLOSED.

11. IF THE FURNACE TEMPERATURE REACHED TO 800 DEGREE CELSIUS

THE INCINERATOR WILL AUTOMATICALLY STOP.

12. THEN CHANGEOVER INCINERATOR FROM DIESEL OIL TO WASTE OIL. OPEN SLUDGE SETT. TANK OUTLET VALVE WHICHEVER THE TANK IN USE, FD-V2 (NO.1 TANK) OR FD-V10 (NO. 2 TANK) TOGETHER WITH THE RETURN VALVE V3 (NO. 1 TANK) OR V9 (NO. 2 TANK), THEN OPEN VALVE # 1 (FOR W.O) & CLOSE VALVE # 2 (FOR D.O.) FOLLOWED BY OPENING VALVE # 4 (3-WAY V/V, VERTICAL POSITION) GOING TO SERVICE TANK FOR THE RECIRCULATION OF THE SYSTEM.

13. AFTER FEW MINUTES IF THE FURNACE TEMP. BECOME LESS THAN 600 DEG. CELSIUS THE INCINERATOR IS AUTOMATICALLY START.

14. NOW INCINERATOR IS IN WASTE OIL MODE.

15. CHECK THE RETURN LINE TEMP. IF INCREASES AND CHECK THE FIRING CONDITION IN THE SIGHT GLASS, GRADUALLY CHANGE THE SETTING ON VALVE # 6 IF NECESSARY.

16. FINAL CHECK FOR LEAK SUCH AS OIL, SMOKE , & ABNORMAL SOUND OF THE SYSTEM.

17. ENSURE THAT NO FLAMMABLE MATERIALS LOCATED NEAR THE

INCINERATOR.

18. CHECK INCINERATOR EVERY 1 HR. FOR FIRING CONDITION & ANY

LEAKAGES.

STOPPING PROCEDURE OF INCINERATOR

1. CHANGE OVER WASTE OIL TO DIESEL OIL.

2. OPEN VALVE # 2 (D. O.), CLOSE VALVE # 1 (W. O.) & OPEN VALVE # 4 (3-WAY V/V, HORIZONTAL POSITION) TO BYPASS THE RETURN LINE.

3. CHECK THE RETURN LINE TEMP. IF DECREASES TO 70 DEGREE.

4. ON THE CONTROL PANEL SWITCH IGNITOR KNOB TO OFF AND MAIN BURNER KNOB TO OFF POSITION.

5. DO NOT SWITCH OFF THE RUNNING KNOB, LET THE FAN RUN TO COOL DOWN THE FURNACE CHAMBER FOR ABOUT 30 MINS.

6. CLOSE ALL THE OPENED VALVES ON THE STARTING PROCEDURE AT THE BACK.

7. ON THE CONTROL PANEL SWITCH OFF THE RUNNING KNOB & THE CIRCUIT BREAKER.

8. FINAL CHECK FOR ANY LEAKS AND OPENED VALVES.

Master Air Admittance Valve

If you remember the air starting system from our previous article, you will notice that a main valve is fitted at the entrance to the main air starting line from the air bottles. This valve has to fulfill the following functions

· To supply pressurized air from the bottles to the engine cylinder via individual cylinder valves

· To ensure that once the engine has started it cuts off the air supply

· To ensure that no products of combustion pass over to the bottle side

The last point is very important since once the engine starts firing, the cylinders are full of hot gases and if these gases find their way across to the main air storage tanks or bottles, the result could be anybody’s guess. It could cause a huge explosion and could lead to damage of life and property and might endanger the ship or start an engine room fire.

In order to ensure this sort of safety, a non-return valve is incorporated inside the starting air valve so that there is only one way passage for the air from the bottle to the engine cylinders but not the other way round. This is all explained in the next section in more detail.

Construction & Working

The construction of the master air starting stop valve is shown clearly in the diagram below which shows the cut section of the valve and all the internal parts and passages are clearly shown and legibly arked for the benefit of the readers.

The inlet and outlet for the starting air are shown in the diagram as well as the drain and the control air path. It must be understood that there is a difference between the control air and the starting air. The starting air actually goes inside the cylinders and makes the engine start, while the control air is used to control the timing of the main starting air and cutting it off at an appropriate time.

The arrangement consists of a spring loaded non-return valve which is used for safety purpose and to prevent blow back of the gases to the engine aided with the flame trap which is also provided there.

There is also an arrangement to operate this valve manually in case it does not open or close automatically due to some problem. Now suppose the control air line suddenly gets faulty so the starting air pressure could keep the valve open, but because of the stop valve it gets shut when blow back gases try to escape to the other side.

It is important to note that the main starting air line is kept in vented position when not in use. This is important to prevent any build up of pressure due and also to remove any condensate in the line which could cause knocking in the line when the compressed air at high pressure whizzes past it. Next to the starting air master valve are the individual cylinder valves which deal with different cylinders, as well shall see in our next article.

OILY WATER SEPARATOR OPERATING INSTRUCTIONS

FOR STARTING:

01. CHECK DRAIN VALVES FOR FIRST / SECOND CHAMBERS ARE CLOSED.

02. OPEN VENT VALVE FOR BOTH CHAMBERS.

03. OPEN INTER CONNECTING VALVES BETWEEN BOTH CHAMBERS.

04. OPEN SEA WATER FILLING VALVE.

05. WHEN THE LEVEL REACHES FIRST CHAMBER, CLOSE SEA WATER FILLING VALVE AND VENT VALVES.

06. OPEN PUMP SUCTION VALVE AND DISCHARGE VALVE.

07. OPEN OWS INLET LINE VALVES

08. OPEN BILGE OVERBOARD VALVE (After getting permission from C/E)

09. CLOSE AIR VENT VALVE

10. SWITCH ON POWER FOR BILGE DISCHARGE CONTROL PANEL AND OWS.

11. OPEN SEA WATER VALVE TO PUMP

12. START THE BILGE PUMP AND CIRCULATE SEA WATER FOR 10 MINUTES.

13. OPEN THE BILGE TANK OUTLET VALVE AND CLOSE THE SEA WATER VALVE .

14. IF DISCHARGING SEPARATED WATER CONTAINS LESS THAN 15 PPM, BILGE WILL BE PUMPED OUT TO OVERBOARD.

15. IF MORE THAN 15 PPM, ALARM WILL BE ACTIVATED AND 3 WAY VALVE WILL CIRCULATE TO TANK.

FOR STOPPING:

01. OPEN SEA WATER VALVE TO THE PUMP SUCTION AND CLOSE THE BILGE TANK VALVE.

02. RUN OWS , FOR 30 MINUTES WITH SEA WATER.

03. STOP BILGE PUMP. AND CLOSE THE LINE VALVES.

04. OPEN AIR VENT VALVE

05. OPEN FRESH WATER VALVE FOR PPM MONITOR AND FLUSH.

06. SWITCH OFF THE POWER.

07. CLOSE THE OVER BOARD VALVE, LOCK IT AND INFORM C/E.

FOR SIMULATION OF PPM MONITOR:( Refer below fig)

01. OPEN THE DOOR OF PPM UNIT, AND PRESS OIL CONTENT SWITCH (FIG A),

PPM WILL RAISE TO 15 PPM AND GIVES ALARM. IN CONTROL ROOM, DISCH LIGHT WILL BE OFF AND CIRC LIGHT WILL LIT.

STARTING PROCEDURE OF INCINERATOR

01. PREPARE THE SLUDGE TANK. i.e FILLING, SETTLING, HEATING AND AGITATING. MAINTAIN THE TANK TEMP. AROUND 90 DEG.

02. SWITCH ON THE BREAKER FOR INCINERATOR, WHILE PUSHING THE RESET BUTTON.

03. OPEN D.O TO MAIN BURNER AND PILOT BURNER AND CONFIRM 3 WAY VALVE POSITION IN RE-CIRCULATION SIDE (VALVE HANDLE HORIZONTAL POSITION)

04. OPEN AIR TO PILOT BURNER.

05. SWITCH ON MAIN BURNER AND IGNITION SWITCHES

06. TURN RUNNING SW TO START POSITION.

07. INCINERATOR, FIRING AUTOMATICALLY ON D.O.

08. CHECK THE LOAD OF FAN, TEMP. OF EXH GAS AND FURNACE TEMP.

09. ONCE FURNACE TEMP. COMES TO 900 DEG. OPEN W.O TANK VALVE (V2 FOR SLUDGE TANK 1 & V10 FOR SLUDGE TANK 2). AND ALSO OPEN RETURN VALVE (V3 FOR TANK 1 & V9 FOR TANK 2).

10. SLOWLY OPEN W.O VALVE FOR MAIN BURNER AND SIMULTANEOUSLY SHUT THE D.O VALVE.

11. PUT THE 3 WAY VALVE TO RETURN TO TANK POSITION.(VALVE HANDLE VERTICAL POSITION).

12. TURN FUEL TO W.O. NOW INCINERATOR WILL FIRE ON W.O.

13. ONCE LEVEL BECOMES LOW IN THE TANK, SHUT THE TANK OUTLET VALVE AND OPEN D.O VALVE (V 8) TO REPLACE W.O IN W.O LINE, TO FLUSH THE W.O LINES.

14. TURN RUNNING SWITCH TO STOP.

15. ONCE INCINERATOR STOPS CLOSE THE VALVES.

CHIEF ENGINEER

M/S GRACE RIVER

AIR CONDITIONING PLANT

STARTING PROCEDURE :-

1. OPEN INLET & OUTLET VALVES OF REFRIGERANT FOR THE COMPRESSOR

AND THE CONDENSER .BE SURE TO CLOSE THE LIDS FOR STOP VALVE.

2. OPEN INLET & OUTLET VALVES OF COOLING WATER FOR CONDENSER.

3. LET THE AIR OUT OF THE COOLING WATER SYSTEM THROUGH THE AIR-PURGE COCK.

4. DRAIN WATER FROM THE STEAM HEATER.

5. START THE FAN MOTOR. CHECK VOLTAGE AND CURRENT.

6. CHECK THE COMPRESSOR CRANKCASE OIL LEVEL AND START THE COMPRESSOR. CHECK SUCTION AND DISCHARGE PRESSURE.

7. CHECK FOR ANY ABNORMAL SOUND OR VIBRATION. IF ALL PARAMETERS ARE NORMAL THEN LET THE A/C PLANT RUN CONTINUOUSLY.

STOPPING PROCEDURE :-

1. IF AMBIENT TEMP. OF THERMOSTAT IS LOWER THAN ITS TEMPERATURE SETTING. THEN SHORT CIRCUIT THE THERMOSTAT.

2. CLOSE THE STOP VALVE AT THE REFRIGERANT OUTLET OF THE CONDENSER.

3. WHEN THE COMPRESSOR CUTS OFF BECAUSE OF LOW SUCTION PRESSURE CLOSE THE REFRIGERANT INLET VALVE TO THE CONDENSER AT ONCE.

4. SWITCH ON THE OIL HEATER IF AMBIENT TEMPERATURE IS BELOW 15⁰ C.

5. IF REQUIRED SWITCH OFF THE FAN MOTOR ALSO.

6. CLOSE THE SEA WATER INLET AND OUTLET VALVES TO THE CONDENSER.

STARTING PROCEDURE FOR PROV. REF. COMPRESSOR

1. LINED UP SEA WATER COOLING TO THE CONDENSER BY OPENING THE FOLLOWING VALVES.

A. FULLY OPEN THE SEA WATER OUTLET VALVE OF THE CONDENSER.

B. FULLY OPEN THE SEA WATER INLET VALVE OF THE CONDENSER.

C. PURGE THE AIR INSIDE THE CONDENSER & CHECK THE PRESSURE OF THE SEA WATER IN THE PRESSURE GAUGE.

2. LINE UP THE VALVES IN THE REF. COMPRESSOR SYSTEM BY OPENING THE FOLLOWING VALVES.

A. FULLY OPEN DISCHARGE VALVE OF THE COMPRESSOR.

B. FULLY OPEN & CLOSE 2 TURN THE SUCTION VALVE OF THE COMPRESSOR.

C. FULLY OPEN THE OUTLET VALVE OR THE KING VALVE OF THE CONDENSER.

3. ON THE CONTROL PANEL SWITCH THE CONTROL KNOB FROM MANU. TO AUTO

4. ON THE CONTROL PANEL SWITCH THE CAPA. CONT. KNOB FROM UNLOAD TO AUTO.

5. AFTER FEW SECONDS THE SYSTEM WILL AUTOMATICALLY START.

6. CHECK THE FOLLOWING IF WORKING PROPERLY.

A. TENSION OF V-BELT

B. OIL LEVEL OF THE COMP.

C. SUCTION & DISCHARGE PRESSURE OF THE COMP.

D. REFRIGERANT LEVEL ON THE SIGHT GLASS OF THE CONDENSER.

7. FINAL CHECK FOR ABNORMAL NOISE, SMELL & REFRIGERANT LEAKS.

STOPPING PROCEDURE FOR PROV. REF. COMPRESSOR

1. PUMP DOWN THE SYSTEM BY CLOSING THE OUTLET VALVE OR

KING VALVE OF THE SYSTEM.

2. AFTER FEW MINUTES THE SYSTEM WILL AUTOMATICALLY STOP.

3. ON THE CONTROL PANEL SWITCH THE CAPA. CONT. KNOB FROM AUTO TO UNLOAD.

4. ON THE CONTROL PANEL SWITCH THE CONTROL KNOB FROM AUTO TO MANU.

5. CLOSE THE FOLLOWING VALVES TO THE SYSTEM.

A. FULLY CLOSED THE DISCHARGES VALVE OF THE COMP.

B. FULLY CLOSED THE SUCTION VALVE OF THE COMP.

6. SECURE THE COOLING SYSTEM FOR THE CONDENSER BY CLOSING THE FOLLOWING VALVES.

A. FULLY CLOSED THE SEA WATER INLET VALVE.

B. FULLY CLOSED THE SEA WATER OUTLET VALVE.

7. FINAL CHECK FOR OPENED VALVES OR LEAKS.