Main and Auxiliary Diesel Engines

Engine Components and Function

• Understanding the construction and function of key diesel engine components: cylinder heads, liners, pistons, connecting rods, crankshafts, camshafts, and valve gear.
• Explanation of cooling systems for cylinder heads and jackets, including fresh water and seawater circuits, temperature regulation, and the role of expansion tanks.
• Lubrication systems: Types of lubricating oils, oil filtration, oil cooling, crankcase ventilation, and the importance of maintaining oil pressure and viscosity.
• Fuel injection systems: Fuel pumps, injectors, fuel filters, fuel timing, and the impact of fuel quality on engine performance. Includes mechanical and electronic fuel injection systems.
• Air intake and exhaust systems: Turbochargers, charge air coolers, exhaust valves, exhaust manifolds, and the impact of backpressure on engine efficiency.

Diesel Engine Operating Principles

• Four-stroke and two-stroke engine cycles: Detailed explanation of each stage (intake, compression, combustion, exhaust) and the differences between the cycles.
• Thermodynamics of diesel engines: Adiabatic compression, heat addition at constant pressure, adiabatic expansion, and heat rejection at constant volume.
• Engine timing: Valve timing, fuel injection timing, and the effects of improper timing on engine performance and emissions.
• Combustion process: Air-fuel mixture, ignition delay, premixed combustion, diffusion combustion, and the formation of pollutants.
• Engine load and speed control: Governors, electronic control units (ECUs), and the response of the engine to varying load demands.

Diesel Engine Maintenance and Troubleshooting

• Routine maintenance procedures: Oil changes, filter replacements, valve adjustments, and inspection of critical components.
• Troubleshooting common engine problems: Loss of power, excessive fuel consumption, abnormal noises, and high exhaust temperatures.
• Use of diagnostic tools: Pressure gauges, thermometers, vibration analyzers, and electronic diagnostic software.
• Cylinder pressure analysis: Interpreting indicator diagrams to identify combustion problems and mechanical faults.
• Overhaul procedures: Disassembly, inspection, cleaning, repair, and reassembly of engine components.
• Performing alignment checks, such as crankshaft alignment and camshaft timing, using precision instruments.

Steam Turbines

Steam Turbine Components and Function

• Understanding the construction and function of turbine blades (impulse and reaction), rotors, casings, nozzles, and diaphragms.
• Steam flow paths: High-pressure, intermediate-pressure, and low-pressure stages.
• Bearing systems: Journal bearings, thrust bearings, and the importance of lubrication and cooling.
• Sealing systems: Labyrinth seals, carbon rings, and the prevention of steam leakage.
• Governing systems: Speed control, load control, and emergency shutdown systems.

Steam Turbine Operating Principles

• Thermodynamics of steam turbines: Rankine cycle, enthalpy-entropy diagrams, and the expansion of steam through the turbine.
• Velocity compounding and pressure compounding: Methods of extracting energy from steam in multiple stages.
• Blade design: Aerodynamic principles, blade materials, and the optimization of blade shape for maximum efficiency.
• Critical speed: Avoiding resonance and vibration.
• Steam turbine lubrication: Importance of maintaining oil purity and preventing water contamination.

Steam Turbine Maintenance and Troubleshooting

• Routine maintenance procedures: Inspection of blades, bearings, seals, and governing systems.
• Troubleshooting common turbine problems: Vibration, blade erosion, steam leakage, and overspeed.
• Balancing procedures: Static balancing, dynamic balancing, and the use of balancing machines.
• Non-destructive testing (NDT) methods: Visual inspection, dye penetrant testing, and ultrasonic testing for detecting cracks and defects.
• Rotor straightening: Correcting rotor bow and ensuring proper alignment.

Pumps and Piping Systems

Pump Types and Operation

• Centrifugal pumps: Impeller design, volute casing, and the relationship between flow rate, pressure, and power.
• Positive displacement pumps: Reciprocating pumps (piston, plunger, diaphragm) and rotary pumps (gear, screw, vane).
• Pump characteristics: Head-flow curves, efficiency curves, and net positive suction head (NPSH).
• Pump selection: Matching pump characteristics to system requirements.

Piping Systems and Components

• Pipe materials: Steel, copper, plastic, and the selection of appropriate materials for different applications.
• Pipe fittings: Elbows, tees, reducers, flanges, and the proper installation techniques.
• Valves: Gate valves, globe valves, check valves, ball valves, butterfly valves, and their applications.
• Pipe supports: Hangers, anchors, and expansion joints.
• Insulation: Types of insulation and their application in reducing heat loss and preventing condensation.

Pump and Piping System Maintenance and Troubleshooting

• Routine maintenance procedures: Inspection of pumps, valves, and piping for leaks, corrosion, and wear.
• Troubleshooting common pump problems: Cavitation, air binding, and mechanical seal failure.
• Troubleshooting common piping system problems: Water hammer, corrosion, and blockages.
• Pipe repair techniques: Welding, soldering, and pipe fitting.
• Pressure testing: Hydrostatic testing and pneumatic testing.
• Analyzing pipe vibration to identify potential failures using spectrum analysis tools.

Auxiliary Systems

Cooling Water Systems

• Central cooling systems: Plate heat exchangers, shell and tube heat exchangers, and their operating principles.
• Fresh water and seawater circuits: Corrosion control, scale prevention, and the use of chemical treatments.
• Expansion tanks: Maintaining system pressure and accommodating thermal expansion.
• Cooling water pumps: Selection, operation, and maintenance.

Fuel Oil Systems

• Fuel oil storage tanks: Tank construction, venting, and safety precautions.
• Fuel oil transfer pumps: Transferring fuel from storage tanks to settling tanks and service tanks.
• Fuel oil purifiers: Centrifugal separators and filters for removing water and contaminants.
• Fuel oil heaters: Maintaining fuel viscosity for proper combustion.

Lubricating Oil Systems

• Lubricating oil storage and handling: Maintaining oil purity and preventing contamination.
• Lubricating oil pumps: Supplying oil to engine bearings and other components.
• Lubricating oil filters: Removing contaminants and maintaining oil cleanliness.
• Lubricating oil coolers: Maintaining oil temperature for proper viscosity.

Compressed Air Systems

• Air compressors: Reciprocating compressors, rotary compressors, and their operating principles.
• Air receivers: Storing compressed air and maintaining system pressure.
• Air dryers: Removing moisture from compressed air to prevent corrosion.
• Air distribution systems: Piping, valves, and regulators for supplying compressed air to various users.

Sewage Treatment Systems

• Overview of the MARPOL Convention and its regulations concerning sewage discharge.
• Types of sewage treatment systems: Biological treatment, physical/chemical treatment, and membrane bioreactors (MBR).
• Operating principles of each system: Aerobic and anaerobic digestion, clarification, disinfection.
• Maintenance and troubleshooting of sewage treatment plants: Monitoring effluent quality, sludge management, and dealing with common operational problems.
• Compliance with environmental regulations: Proper documentation and record-keeping.

Automation and Control Systems

Sensors and Transducers

• Temperature sensors: Thermocouples, resistance temperature detectors (RTDs), and thermistors.
• Pressure sensors: Strain gauges, piezoelectric sensors, and capacitive sensors.
• Flow sensors: Turbine flowmeters, orifice plates, and ultrasonic flowmeters.
• Level sensors: Float switches, pressure transducers, and ultrasonic level sensors.

Control Loops

• Proportional control: Adjusting the control output in proportion to the error signal.
• Integral control: Eliminating steady-state error.
• Derivative control: Improving the response time and stability of the control loop.
• PID control: Combining proportional, integral, and derivative control for optimal performance.

Programmable Logic Controllers (PLCs)

• PLC architecture: Central processing unit (CPU), input/output (I/O) modules, and programming software.
• PLC programming languages: Ladder logic, function block diagrams, and structured text.
• PLC applications in engine room automation: Monitoring engine parameters, controlling pumps and valves, and implementing alarm systems.

Distributed Control Systems (DCS)

• DCS architecture: Centralized control room, remote I/O modules, and communication networks.
• DCS applications in engine room automation: Integrated monitoring and control of all engine room systems.
• Human-machine interface (HMI): Graphical displays and operator controls.

Electrical Systems

Generators and Motors

• AC generators: Synchronous generators and induction generators.
• AC motors: Induction motors and synchronous motors.
• Generator and motor control: Starters, variable frequency drives (VFDs), and protective devices.

Switchboards and Distribution Systems

• Switchboard components: Circuit breakers, fuses, and meters.
• Power distribution systems: Radial distribution, loop distribution, and network distribution.
• Grounding systems: Equipment grounding and system grounding.

Battery Systems

• Lead-acid batteries: Construction, operation, and maintenance.
• Nickel-cadmium batteries: Construction, operation, and maintenance.
• Battery chargers: Charging methods and control systems.

Electrical Safety

• Electrical hazards: Shock, arc flash, and electrocution.
• Safety procedures: Lockout/tagout, personal protective equipment (PPE), and grounding.
• Electrical codes and standards: IEEE, IEC, and national electrical codes.