1.With reference to automatic control terminology define and clarify the following. Desired value. Measured Value.

Set Value. Deviation. Controlled Condition Controlled unit. Correcting unit. Offset. Proportional Control. Answer Desired value. The value of the controlled condition that the operator desire to obtain. Set value. The command signal to a process system. Controlling unit. Means of operating the correcting unit according to the difference between the desired and measured value. Deviation. Difference between the measured value of the controlled condition and the set value. Offset. Sustained deviation of the controlled variable from the set value occurring when proportional control action is used alone. Correcting unit. [regulating unit] a devise capable of effecting change in the controlled condition. Controlled Condition The physical quantity or condition of the controlled body, process or machine which is the purpose of the system to control. Controlled condition. Temperature, flow pressure, level. Proportional Control. This is the basic form of modulating control in which the controller is set up so that any change in output is directly proportional to the deviation between the controlled condition and the desired value. The operation of a plant under automatic control in order to control such variables as temperature, level, flow, viscosity etc., is know as Process Control. Here the process is the cooling of the lubricating oil in the heat exchanger. Working round the system from the Process, the Controlled Condition is the temperature of the lubricating oil, and this is monitored by a sensor or Detecting

Element, which could be a filled systems thermometer connected to a Bourdon tube. This operates a nozzle/flapper device which produces a pneumatic signal, known as the Measured Value, which is directly related to the temperature of the lubricating oil. This nozzle/flapper amplifier is known in control engineering terms as a value signal is taken to a Comparing Element or Comparator forming part of the Automatic Controller or Controlling Unit. Here it is compared (one method is shown) with a signal representing the required lubricating oil operating temperature or the set Value (Set Point) or Desired Value. (There could be a difference between these terms which will be explained later in the text). If the Set Value and Measure Value are the same, the beam will not move, but if there is a difference between these signals, known as the Deviation or Error it means that the lubricating oil temperature at the outlet from the cooler is not at the required. Operating temperature (Set Point, etc). Action has to be taken to restore it. The difference in signal pressures on the diaphragms will rotate the beam about the pivot, the movement being the Error Signal and this will operate the Controlling Element.

This develops the signal necessary for the restoration of the oil temperature; the signal may be known as the Controller output Signal or Control Signal. This signal is transmitted to the Motor Element or diaphragm of a control valve which then operates the Correcting Element or valve. This then adjusts the Correcting Condition or cooling water flow to enable the oil temperature to be restored.

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2. With respect to main boiler super heater arrangements: Compare the advantages and disadvantages of contra flow with parallel flow design Describe how the element tube banks are supported yet allow for expansion Describe how boiler carryover affects super heater effectiveness and condition. Answer: (a) Parallel flow 1. High thermal stresses due to high temperature differential at inlet, possible stress corrosion 2. Low temp differential at outlet, therefore inefficient use of tube area. 3. Low mean metal temperature allows low grade metal to be used since the temperature troubles are avoided.

Cross flow or contra flow: More uniform temp gradient gives better overall heat transfer High out let temp of cold fluid may be useful for heat recovery High mean metal temp requires high grade of metal

Boiler carryover Along with steam water droplet gets carried away in the steam line Reason Rate of evaporation too high Excessive chloride or chemicals This wet steam will enter super heater It will evaporate and leave scale forming compound i.e. scale inside super heater tubes will deposit. Once this happens heat transfer will reduce Overheating, drop in efficiency of super heater and ultimately it will melt down. Effect efficiency will drop Won t get superheated temperature. ******************************************************************* *******************************************************************

************** 3.How are heat exchanger protected from corrosion. ANSWER (i) Normally tubes are made of stress relieved aluminium brass tubes (76% Copper, 22% Zinc and 2% aluminium, .04% arsenic is added to prevent dezincification) expanded into Naval Brass tube plates (62% Cu, 37% Zn and 1% Sn). Sacrificial anodes of soft iron fitted in the end covers, while itself corroding, acting as anodes creates protective film of iron ions on the tube surface and thus protecting them from galvanic corrosion. Electrical continuity in the seawater circulating pipework is important where sacrificial anodes are installed. Metal connectors are fitted across flanges and cooler sections where there are rubber joints and O rings, which otherwise insulate the various parts of the system. (ii) Iron may be introduced in the system in the form of frerrous sulphate. The treatment consists of dosing the sea water to a strength of 1 ppm for an hour per day for a few weeks and subsequently dosing again before entering and after leaving port for a short period. This gives a protective coating on tube surface against galvanic corrosion. (iii) To avoid impingement corrosion attack due to pollution of coastal waters or extreme turbulence to excessive sea water flow rates, the upper limit of flow is restricted to 2.5 m/sec. However flow rate should not fall below 1 m/sec, because a minimum flow rate is vital to produce moderate turbulence which is essential to the heat exchange process and to reduce silting and settlements in the tubes. ******************************************************************* ******************************************************************* ************** 4.What is a Stern Tube? Where and for what purposes are heat exchangers used in association with main propulsion engines? Describe the type of heat exchanger used for each

purpose and the coolant used ANSWER

The stern tube, as the name suggests, is a hollow tube like structure at the stern or rear part of the ship. A ship needs a propeller to drive it forward against the waves. The propeller, located outside the ship needs to be connected to the engine inside the ship s engine room. A long shaft known as the propeller shaft is used for connecting the ship s engine and the propeller. This narrow hole in the hull structure at the rear end (aft peak) of the ship, through which the propeller shaft passes and connects the engine and propeller is known as the stern tube. Purpose The stern tube is used to support and seal the propeller shaft as it passes as it passes through the aft hull. It consists of a cast iron tube welded into the stern frame. In the old days, the

shaft inside the tube was bronze coated and run against a longitudinal bearing, made of narrow strips of a very hard wearing wood known as lignum vitae. However nowadays, the propeller shaft has a cuni (Copper Nickel Alloy) liner shrunk onto it. Babbitt metal is applied over this then machined, providing the bearing surface between the cast iron stern tube and the propeller shaft. This is lubricated and cooled by lube oil supplied from a gravity tank located under the aft peak. The propeller shaft has mechanical and/or adjustable gland seals fore and aft to prevent the ingress of oil to the sea and aft bilge well. ******************************************************************* ******************************************************************* ************** 5. With reference to electric arc welding:(a) Draw a labeled sectional sketch of a satisfactory butt weld. (8) (b)Why is alternating current generally more popular then direct current for metal arc welding? (8) ANSWER

No undercut Good root penetration. No blow holes No slag inclusion. No splatter. AS ALL THE ABOVE ARE PRESENT IT IS A SASTIFACTORY BUTT WELD Briefly define the following defects that may occur and how they may have been caused Undercut. This is a groove or channel along the toe of the weld caused by wastage of the parent metal which could be due to too high a welding current or low welding speed. Spatter: Globules or particles of metal scattered on or around the weld. This may be caused by too high a current or voltage making the metal splash or splatter. Inclusion: Any slag or other entrapped matter is an inclusion defect. Surface to be welded must be free from foreign matter, e.g., grease, oil, oil, millscale, metal chipping, etc. During welding the slag must not be allowed to get in front of the molten metal or it may become entrapped. Also when welding is interrupted for changing of electrode or when another run b to be laid, the already deposited metal should

be allowed to cool, the slag should then be chipped and brushed off. Blowhole: This is a large cavity caused by entrapped gas. Incomplete root penetration: Is a gap caused by failure of the weld metal to fill the root. This may be due to a fast welding speed or too low a current. Lack of Fusion: This could occur between weld weld metal and parent metal, between different layers of weld met al or between contract surfaces of parent metal. It could be caused by incorrect current or voltage, dirt or grease, etc. a.c. supply is usually more popular than d.c. for the following reasons. 1) More compact plant. 2) Less plant maintenance required. 3) Higher efficiency than d.c. plant. 4) Initial cost is less for similar capacity plants. Disadvantages of a.c. supply are: 1) Higher voltage is used, hence greater shock risk. 2) More difficult to weld cast iron and non ferrous metals ******************************************************************* ******************************************************************* ************** 6.a) Sketch a simple cross section of the machinery space bilge injection valve and main sea injection valve, showing; i) Details of how the main sea injection valve is fitted to the ship plating; ii) Details of their separate suction and common delivery arrangements; b) Compare the diameter of the bilge injection valve with that of the main sea injection valve.

b) The diameter of the bilge injection valve is not to be less than two thirds the diameter of the main seawater injection valve. ******************************************************************* ******************************************************************* ************** 7.(a) Explain why centrifugal pumps cannot handle air or vapors to effect priming yet turbo-blowers operating on the same principle can. (b) If a vessel is fully laden, how may it be ascertained that the fire pump priming arrangements would operate satisfactorily in the ballast condition. (c) Explain a method of priming suitable for a centrifugal pump. Answer

Reasons are as followsA centrifugal machine works on centrifugal action by displacing liquid or air from its centre to outer periphery and requires a continuous flow at the input centre for it to work effectively. A centrifugal pump cannot create sufficient vacuum to lift liquid from a low level overcoming pipe friction, losses in valves and bends and also failing in the range of vapour pressure, for having limitation in pump design. In the centrifugal blower, it sucks an uncontained fresh air and blows out by the little vacuum it creates. As soon as one elemental volume has been sucked and displaced, next elemental volume is rushing into the blower; in fact, it will really not displace the contained volume of air, because the displaced air will keep circulating. A centrifugal pump is designed for handling and displacing liquid of certain viscosity and it is to be driven at a certain speed to achieve the required delivery. Whereas a blower design is meant for displacing air of much lower viscosity and it is driven at a much higher speed to achieve the required output. Thus a centrifugal pump works fine when a continuous supply of fluid is available at its centre input like a centrifugal blower having free flow of air at the centre works effectively. But neither a centrifugal pump nor a blower can create sufficient vacuum to lift fluid from a low level due to design restriction. Centrifugal machines are good performers for large quantity of discharge i.e. high delivery lift whereas positive displacement machines are good for high suction lift.

Question (b) If a vessel is fully laden, how may it be ascertained that the fire pump priming arrangements would operate satisfactorily in the ballast condition. Answer b) To ensure that the fire pump arrangements would work satisfactorily in ballast, the fire pump would be run while the ship is fully laden, this would ensure the suction line of the fire would be primed/full of water when in ballast, as the discharge valve of the fire pump is of a non-return type. Also on larger vessels, where possible, fire pumps are placed as low as possible in the ship, it may also have it s own priming device, such as water rings primer, or an air educator type, or the fire pump may be situated on the main deck, where this is the case, it will have its own hydraulically driven boost pump which is situated below the water line. c) Explain a method of priming suitable for a centrifugal pump. Answer A method used to improve the suction lift of a centrifugal pump is a water ring

primer as shown in the sketch. The primer consists of a pump with elliptical casing and a rotor, with cover plate which has suction and delivery ports. The casing is partially filled with water to form a seal when the pump is running, for the tips of the vanes. The elliptical casing cause a change in volume between vanes when running, therefore creates a pumping action, thus a vacuum, and enables the centrifugal to be primed via a float valve as shown in the sketch.

SAME Q DIFFERENT ANSWER Answer a) The centrifugal pump is designed to handle incompressible fluids and is inherently not self priming. This is because it is not a positive displacement pump and the impeller is purely a momentum transfer device imparting the energy of rotation to the fluid in contact with. A closed impeller shrouded on both sides with curved wanes shaped to enable a shockless and smooth passage of the incoming fluid is used. Wearing rings are also essential for smooth mechanical running with necessary clearances. These features make this pump unsuitable for handling vapours or air which involves a compressible flow. In contrast a turbo blower is designed to handle compressible flow, the open and straight blade impeller, suitably sealed by face and shaft Labyrinths Since it is designed to handle air and is open to air at both the suction and discharge (atmosphere and scavenge manifold respectively) it is always primed and thrust is able to pump air. Also the pressure ratio in a centrifugal pump handling incompressible fluid is much greater than that of Turbo blower. b) It has been specified that an emergency fire pump should not have a NPSH (Net positive suction head) exceeding 4.5m. It can be ascertained if the pump can meet this specification to function successfully delivering the necessary discharge under all condition of loading of the vessel and draught even as the vessel is fully loaded and a large positive suction head is available. This can be done by shutting the pump s suction valve while the pump is running and check from the compound suction gauge whether the necessary NPSH exists. From it can be ascertained if the running clearances gland sealing etc., are also adequate or inadmissible. c) LIQUID RING PRIMING PUMP: The impeller is concentric with the drive shaft and the impeller is fitted into an eccentric jump casing. Due to the action of centrifugal force there is a rotating ring of water which must follow the shape of the casing. Thus due to the eccentric shape there is alternate increasing and decreasing volume at the suction and discharge ports. This creates a pumping action which is used for air extraction from a central priming tank. This tank is

further connected to various centrifugal pumps in the engine room and has the task of a central priming unit, since it carries out air extraction for all the centrifugal pumps in the engine room. The air suction is via a float operated valve which shuts when the system is primed preventing system water getting into the priming pump. A control valve may be fitted as shown, which is operated, when the system is fully primed to remove water from the priming pump casing and hence reduce shaft load. Alternatively a clutch may be fitted on the drive shaft to allow the drive to be disconnected when the main system tank is fully primed. The reservoir is filled with fresh water to reduce corrosion and a cooling coil may be fitted which is circulated by the main pump discharge. ******************************************************************* ******************************************************************* ************** 8. (a) State TWO methods of determining the presence of oxygen and the effects of oxygen in-boiler water (b) State TWO advantages and TWO disadvantages of each method. (c) Explain the chemical actions of each method. (d) What other means are adopted to eliminate oxygen from the system. Answer To remove traces of Oxygen. Sodium Sulphite or Hydrazine Oxygen ScavengersOxygen scavenging chemicals used for deaerating the water are sodium sulphite or hydrazine. 2Na2s03+02 2Na2s04 The use of sodium sulphite is restricted to boilers operating at pressures upto 40 bars. At high pressure boilers, the sulphite can break down to give hydrogen sulphide (H2S) and sulpher dioxide which can attack steel, brass and copper. Moreover, sodium sulphite reaction rate with oxygen is maximum at about 7 pH, hence the sodium sulphite should be injected into the system before any alkaline ingredients are added. Sodium sulphite also increases dissolved solids content.

Hydrazine solution (60% Hydrazine 40% water) can be used for oxygen scavenging in high pressure boilers. N2H4+02 2H20 + N2 Hydrazine Ammonia + Nitrogen As hydrazine reaction also forms water, it does not increase the boiler density. Excess hydrazine may decompose into ammonia which lead to steam and condensate line corrosion. However, a controlled excess is beneficial to the steam and condensate as it counteracts the effect of carbon dioxide corrosion. Hydrazine should be stored in a cool well ventilated place since. It is toxic and a fire hazard, when handling, protective clothing should be worn as like caustic soda. Hydrazine should be injected into de-aerated feed. ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Internal Corrosion. - Many and various have been the explanations offered for the phenomena of internal corrosion in marine boilers. Professor Vivian B. Lewes - a recognised authority on the subject of marine boiler deterioration - states that in the presence of moisture carbonic acid and oxygen simultaneously attack iron and steel, forming a thin layer of carbonate of iron. This is a very unstable salt, which almost immediately breaks down into iron oxide and ferric hydrate, liberating the carbonic acid, which, with a further supply of atmospheric oxygen, continues the process of corrosion or rusting. This process is further hastened by a certain degree of electrolytic activity between the iron and the electro-negative hydrated iron oxide. Inasmuch as the layer of oxide, or, as it is commonly known, rust, is highly porous, the action progresses without interruption as long as the conditions are favourable. The above general conditions obtain when any iron or steel is exposed to the action of oxygen, carbonic acid, and moisture.