Как работать в смешанном экипаже = How to work in a mixed crew. Учебное пособие
.pdfone (repaired at p. Hueneme: "Vaughan's Industrial & Marine repair Co.", Paramount, CA).
08.03.97: Cyl. head cracked at Cotonou (Benin). Same repaired on board with local workshop assistance and fixed back due to spare cyl. head remained at Antwerp, w/shop for reconditioning.
09.03.97: Indicator cock replaced with O'hauled one. 15.05.97: Fuel valve (fwd) replaced with O'hauled one. 23.07.97: Unit 1 exhaust valve replaced
UNIT № 3:
18.12.95: Liner renewed. Unit decarbonised. All piston rings renewed. 01.01.96: Missing orifice plate in cyl. hd C.W. outlet line, made and fitted. 22.01.96: Cyl hd cracked during arr anchorage. Same replaced with spare.
Jun 96: Relief v/v replaced with spare.: Indicator cock replaced with spare. : Aft fuel v/v replaced. : Fuel p/p replaced with spare p/p.
Aug 96: Stuffing box O'hauled.
15.05-97: Air starting valve replaced with O'hauled one. 15.06.97: Exhaust v/v replaced with O'hauled one. 17.06.97: Unit decarbonised. All piston rings renewed.
UNIT №4:
16.12.95: Liner renewed. Unit decarbonised. All piston rings renewed. 01.01.96: Missing orifice plate in cyl hd C.W. outlet line, made and fitted. 02.01.96: Both fuel valves replaced with O'hauled valves.
Mar 96: Fuel pump seized. Same replaced with O'hauled pump. Stuffing box O'hauled in place.
May 96: Cyl hd cracked on arr Tokyo. Same replaced with reconditioned Head. Sept 96: Cyl. hd cracked on 28-th of Sept. at sea. Same replaced with recond.
Head (Japan w/s). Exhaust v/v replaced with O'hauled one. Both fuel valves replaced with O'hauled ones.
22.01.97: Exhaust v/v replaced with O'hauled one. Air starting valve replaced with. 18.06.97: Unit decarbonised. All piston rings renewed.
TURBO CHARGER:
16.12.96: O'hauled by Kobe Diesel Service. Impeller of new design fitted. The Diffuser & Air Guide rings also renewed to suit the same.
25.10.96: T/C gas side opened up, observed, turbine nozzle & blades find very dirty. Same cleaned & boxed back.
AIR COOLER:
23.01.96: Chemically cleaned on air side. Quite clean.
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Aug 96: Cleaned on S.W. side. 5 nos tubes badly choked and unable to clear. Oct 96: ACC-9 added to the suction side of T/C regularly in-service.
06.12.96: Chemically cleaned on air side — quite clean. Air cooler cleaner added to the suction side of T/C regularly in-service.
22.04.97: Air cooler air side inspected. Found clear.
CRANK CASE:
01.01.96: C/case inspected. Web deflections taken.
04.01.96: Wear down of Mn Brgs nos 2 to 8 taken. Satisf.
06.01.96: No.l B.E., No.4 X'hd, & nos 3,5,8 Mn Brgs opened and surveyed. Satisf.
Feb 96: Mn Brg nos 2,4 & 6; X'hd brg no.l; B.E. Brg no.3 opened & surveyed. Mn Brg nos I & 7; X'hd brg no.3; survey passed on basis of clearances & drop gauge readings.: Crank case insp. carried out — satisf.
Jul 96: Guide shoe clearances taken — satisf.
24.01.97: Crank case inspection carried out — satisf. Crank web deflections taken — satis.
MISCELLANEOUS:
Jan 96: Spare cyl hd (which was taken out of No.3) repaired by W/shop, by grinding the crack, inserting a pipe in the clg wtr bore, and then welding again.
Mar 96: Exhaust manifold inspected — satisf. Automatic starting air valve O'hauled. Piston rings renewed.
Apr 96: All scav spaces cleaned.
May 96: Foundation bolts hammer tested — satisf.
Jun 96: Spare cyl hd (which was removed from #4) repaired by W/shop. 04.10.96: All scavenge spaces cleaned. Under piston spaces inspected —
satisf. : Scavenge valves inspected — satisf. : Exhaust manifold inspected — satisf. Spare cylinder head (which was removed from #4) repaired by W/shop at p. Hueneme, California, U.S.A.
16.12.96: Scavenge valves and scavenge spaces inspected — satisf.
24.01.97: All scavenge and under piston spaces inspected — satisf. Scavenge valves inspected — satisf. Foundation bolts hammer tested — satisf.
17.06.97: All scavenge spaces cleaned. Under piston spases inspected — satisf. Scavenge valves inspected — satisf.
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Auxiliary engines
GENERATOR №1:
Jan 96: Decarbonised. All piston rings renewed. Crank case lub oil renewed. Deflections taken — satisf, No. 4 unit fuel pump O'hauled.
Feb 96: L.O. cooler cleaned on S.W. side. 1-off zinc anode renewed. : Safeties tried out — not working. Found control air pipe choked. Same cleared. All Safeties tried out — satisfactory.
Mar 96: 750 hr routines being carried out. Found flakes of white metal in the lub oil filter. C/case inspected and found No.l unit crank-web sheared on the Ford side. B.E. Brg opened and found the crank-pin cracked. Brg metal scored on the Ford side.
Apr 96: Genr being dismantled for replacing the broken c/shaft. All mountings removed, air clr and t/c removed from place. Genr entablature ready for removal. Air clr cleaned on both — air and S.W. sides.
May 96: Removed entablature and broken c/shaft. New crankshaft fitted in place. Nos 1 & 7 (thrust brg) Mn brg renewed. Flywheel and alternator aligned and deflections taken.
Jun 96: Entablature put in place, and timing gears fitted. Lub oil pump gears renewed. All pistons fitted with reconditioned conn rod (all old conn rod had cracks in the serrations, and one was oval) and new piston rings. All parts assembled and genr tried out — satisf.
Jul 96: R/arm lub oil no pr. Pump opened & found drive shaft broken Shaft renewed. No spare gear. Old gear welded and fitted — satisf. Alternator air filters cleaned. Alternator quite clean. Air gap: T — 2.2; В — 1.3; P — 1.8;S — 1.6mm.
Aug 96: 750 hr routine carried out — satisf. : T/C O'hauled. Moderately dirty. : Plunger L.O. P/p not building up pr. Trochoid p/p drive gear broken.
GENERATOR № 2:
Feb 96: L.O. cooler cleaned on S.W. side. : Foundation bolts hammer tested. 750 hr routines carried out. #1 unit tappet damaged — temporary measures effected.
Mar 96: All cyl hds replaced with O'hauled hds. Turbocharger O'hauled — very dirty. Apr 96: 750 hr routines carried out — satisf.
Jun 96: 1 500 and 750 hr routines carried out. Deflections taken — satisf. Jul 96: L.O. cooler cleaned on SW side.
Aug 96: Air cooler chemically cleaned on air-side. SW side tubes brushed thru'. 750 hr routines carried out — satisf. Sump oil purified thru' Purif. Alternator air filters cleaned. Air gap checked; T — 2.1; В — 1.3; P — 1.5; S — 1.6 mm.
Sept 96: L.O. cooler cleaned on S.W. side. Oct 96: 750 and 1500 hr routines carried out.
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03.12.96: Air clr cleaned on both — air and S.W. sides. 05.12.96: 750 hrs routines carried out — satisf. 13.12.96: Governor replaced with O'hauled one — satisf.
23.01.97: Decarbonised. All piston rings renewed. Crank web deflection taken — satisf. All unit fuel pumps and fuel injector valves O'hauled. Sump oil purified thru' Purifier. All units fuel injection timing checked. Found between 18–19 Deg.
28.03 97: 750 hrs routine carried out — satisf.
14.04.97: Air cooler and L.O. cooler chemically cleaned on S.W. side. 22.05.97: 750-hrs routine carried out.
GENERATOR № 3:
Jan 96: Turbo-charger O'hauled. Very dirty. Shaft by way of turbine-side brg worn down very badly. Also threads damaged. Both parts built up and machined. Both brgs renewed.
Feb 96: All unit fuel pumps O'hauled. 1500 hr routine carried out.
Mar 96: Alternator air-gap measured and noted; Top — 2.01mm: Bottom — 1.22mm: Port — 1.44mm: Stbd- 1.61mm. Nos 2,4, & 6 cyl hds replaced with O'hauled hds, due to high exh temp and also these hds were not O'hauled during the previous routines.
Apr 96: 750 hr routine carried out — satisf.
May 96: Lub oil pump, drive and idler gears renewed (backlash > l.Smm).
Jun 96: Lub oil cons very high — suspect piston rings bad (run hrs < 5000). Genr decarbonised. All piston rings changed with old rings of #1 Genr (run hrs abt 1000). L.O. clr & Air clr cleaned on S.W. side.
Jul 96: Fuel pump timing checked and adjusted.
Aug 96: 750 hr routine carried out — satisf.: T/C O'hauled — very dirty. Sump oil purified thru' Purifier. Abnormal sound from T/C at load of 200 K.W (suspected due to unbalance of rotor. Have indented for spare in Feb 96. Not reed as yet) : Spare drive gear (Trochoid p/p) made of brass, in place of broken CI one, for Plunger lub oil p/p. Same fitted and tried out — satisf.
Oct 96: T/C O'hauled. New rotor fitted with old bearings. Tried out — satisf, K = 28,7 mm. Nov 96: 1500 and 750 hr routines carried out — satisf. L.O. Cooler cleaned on S.W. side. S.W. inlet valve replaced with old O'hauled valve.
31.12.96: All units fuel timing checked, found between 18–19 Deg. 15.02.97: Fuel pump from unit # 5 replaced with spare O'hauled one. 17.03.97: CMS Survey carried out — satisf.
24.03.97: Air cooler cleaned on S.W. side.
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17.04.97: Cylinder head from unit # 6 replaced with spare O'hauled one due to unable extract the fuel v/v.
25.04.97: All 6 Nos fuel valves replaced with spare O'hauled valves.
26.04.97: L.O. cooler cleaned on S.W. side with chemicals, 3 Nos anticorrosive zinks replaced.
04.05.97: L.O. cooler cooling water side end cover replaced with new spare end cover.
15.05.97: Fuel feed pump found not working due to common shaft worn out. Same replaced with new one. Engine tried out — satisf.
AIR COMPRESSORS COMPRESSOR № 1:
Jan 96: H.P. A L.P. Suс and Disch valves replaced with O'hauled valves. Aug 96: Suction air filter cleaned.
Oct 96: Water leak, from cyl. head. Same replaced, new gaskets fitted. All H4\& L.P. Suc. and Disch. valves replaced with new valves'
12.02.97: Cooling water pump O'hauled, bearings renewed.
25.03.97: All H.P. & L.P. Suс. and Disch. valves replaced with O'hauled v/vs. 14.06.97: Lub. oil in crank case replaced with fresh lub.oil.
COMPRESSOR №2:
Jan 96: Clg wtr pump impeller damaged. Same replaced with spare. L.P. Suc.and disch valves replaced.
Apr 96: Suс and Disch, LP & HP valves replaced with O'hauled valves. One vane of C.W.p/p found broken — same replaced.
Oct 96: All Н.Р. & L.P. Suc. and Disch v/vs replaced with O'hauled ones. C/case inspection carried out.
17.03.97: CMS Survey carried out. All H.P.& L.P. Suc. & Disch. valves replaced with spare O'hauled ones.
14.06.97: Lub.oil in crank case replaced with fresh lub.oil.
Purifiers
HEAVY OIL PURIFIER:
Mar 96: Speed very low. Found friction pads completely worn out. Same renewed.
Purifier completely opened up, cleaned and all damaged firings renewed. Apr 96: Opened, cleaned and boxed back.
Jun 96: Vibrating heavily. Vertical shaft taken out and found the middle brg defective. This brg along with the bottom two thrust brgs renewed. Satisf.
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Jul 96: Foundation bolts checked and found all studs slack. Same tightened. Aug 96: Horizontal shaft brgs renewed. Worn out coupling boss built up and
machined. Noise emanating from c/case due to gear backlash. To be renewed after receiving spare.
Oct 96: Spiral gear (60Hz) and 2Nos oil seal from horizontal shaft are renewed. Nov 96: Vertical shaft taken out and all bearings renewed. Satisf.
DIESEL OIL PURIFIER: (HEAVY OIL PURIF № 2):
May 96: Vibrating heavily while starting. Complete vertical shaft taken out and found the middle ball-brg defective. Same replaced. Also the lower thrust brgs renewed, satisf.
28.01.97: Bowl opened, cleaned and boxed back. Lub. oil renewed.
15.03.97: Vibrating heavily while operating. Complete vertical shaft taken out and found the ball brg # 6209 defective. All bearings on vertical shaft renewed. Satisf.
LUB OIL PURIFIER:
Jan' 96: Completely opened, cleaned and boxed back.
Mar 96: Bowl opened and cleaned. All worn out O-rings renewed.
Apr 96: Bowl opened and cleaned. Pilot valves O'hauled. Operating water paring disc ht found excessive. Same machined and put back — satisf.
Jun 96: Motor rotor burnt. Awaiting new motor.
Jul 96: Purif completely opened, cleaned and boxed back. New motor fitted. Running satisf.
01–03.97: Purifier completely O'hauled. Vertical shaft is found sat down. Bearing Nos: 2305JI,7305J1 & 208J1 renewed, spacer and flat spring renewed. Operating water device renewed Satisf. Lub. oil renewed.
Boiler
AUXILIARY EQUIPMENT:
Mar 96: Trochoid (high pr) pump pr low. Noticed leakage past pump shaft seal. Old pump O'hauled and fitted — satisf. : 2 nos old trochoid pump shaft built-up by way of seal and machined. Kept as spare.
Apr 96: Stbd side smoke box inspected — found fire bricks damaged and the shell plating buckled. Temporarily a MS plate welded and fire clay patched up.
May 96: Burner nozzles O'hauled. Smoke tube brushed and cleaned. Ford gauge glass leaking. Same replaced with new glass and pkg.
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Aug 96: Very Low Level'float taken out, cleaned and tried out — satisf. High pr fuel p/p replaced with O'hauled p/p. Still tripping on Fuel low pr. Pr switch bellow damaged. No spare. Same by-passed.
Sept 96: Burner nozzles O'hauled.
Oct 96: Frwd gauge glass replaced with O'hauled one.
Nov 96: Stbd side smoke box opened — found fire proof bricks damaged and shell plating buckled. Same removed and new doubler put on,thick. = 9.0 mm, fire bricks patched up with Mortar and coating. : Smoke tubes brushed & cleaned.
08.01.97: Burner nozzles O'hauled.: High pressure pump replaced with O'hauled one.
04.04.97: Gauge glass (fwd) replaced with spare O'hauled one.
05.05.97: Smoke tubes brushed and cleaned. Stbd side smoke box inspected, found — satisf.
05.05.97: Gauge glass (aft) replaced with spare O'hauled one.
EXHAUST:
May 96: Smoke tubes brushed and cleaned.
ACCOMODATION A/C & FRIDGE AIR CONDITIONING:
Jan '96: Sue air filter cleaned.
Feb 96: Shaft seal leaking. Seal renewed. : Blower starter switch earthing — same replaced with new.
Apr 96: Sue air filter cleaned in chemical and then high pr water jet. Sept 96: A/C filter cleaned.: Ship's A/C suction filter cleaned.
DOMESTIC FRIDGE:
Feb 96: Compr motor starter panel routines carried out. No.l condenser cleaned on S.W. side. Cond relief valve, which was defective, replaced with new.
Jun 96: Veg room not cutting out. Thermostatic switch lubricated and made operational. No.2 compr Auto-Manual switch, which was defective, renewed. No.2 compr L.P. switch not functioning. Same repaired.
Jul 96: No.2 condenser cleaned on S.W. side. No. l Prov compr O'hauled. All piston rings renewed. Filter / drier silicagel renewed. 5 Kg gas charged. Meat & Veg room exp v/v filters cleaned. Meat room exp v/v defective — same renewed.
Aug 96: Veg room exp v/v adjusted as same not working properly.
Sept 96: No. l prov. reefer compressor oil separator opened up, cleaned and oil added into the compressor.
21.12.96: No.2 prov. reefer compressor O'hauled. New pistons, new rings, new bearing metal, new suction and delivery valves fitted.
Jan 97: Silicagel in drier replaced 3 times. Lub oil renewed.
04.02.97: Suction pipe from meet room repaired with DEVCON plastic putty.
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FRESH WATER GENERATOR:
Jan 96: Condenser and heat exchanger plates chemically cleaned.
Jul 96: Condenser & heat exchanger plates chemically cleaned. Fresh water pump impeller and wear-rings inspected. Found both worn down, so that new wearring is also slack. To make new ring.
Nov 96: Heat exchanger plates chemically cleaned. Chemical "Vaptreat" added regularly in service.
27.12.96: Condenser and heat exchanger plates chemically cleaned.
21.01.97: Condenser plates chemically cleaned. Fresh water pump opened up, new wear ring fitted — satisf.
07.02.97: Heat exchanger plates chemically cleaned by SAF acid.
PUMPS:
Mar 96: S.W. SERV P/P: Not building pr. Pump opened and found impeller worn out & broken. No spare.
May 96: General Service & FIRE P/P: Assembled with new shaft, wear rings, bottom bush and top bush.
Jun 96: EJECTOR P/P: Assembled with new impeller and tried out — satisf. MAIN S.W. P/P: Assembled with new impeller, shaft and wear rings. — satisf. BLR FEED P/P No.l: Coupling bushes very slack. All bushes renewed. BLR FEEQ P/P No.2: Coupling bushes very slack. No spare. OU bushes wrapped in rubber & fitted.
Jul 96: S.W. SERV P/P: Assembled with new impeller, wear rings, and shaft. — satisf. SANIT P/P: O'hauled. New shaft fitted.
Nov 96: DRINKING WATER P/P: Assembled with new wear rings, shaft and bush — satisf. HOT WATER P/P: O'hauled. New bush, wear ring fitted.
17.03.97: BILGE PUMP: O'hauled. New liner, new bucket rings. Satisf.BLR FEED P/P No.2: O'hauled. New shaft sleeve. Satisf.
01.04.97: Vacuum pump of Ballast pump O'hauled. 04.04.97: Vacuum pump of G.S. & FIRE pump O'hauled.
08.05.97: G.S. & FIRE P/P : O'hauled. Assembled with new impellers. New neck bush for same fabricated.
07.06.97: CARGO REEFER COOLING SEA WATER' PUMP No.2: Pump opened and found impeller worn out. Assembled with new impeller, shaft, neck bush and seal cage.
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Heat exchangers
1. A/E F.W. COOLER (UPPER):
Jan 96: Cleaned on S.W. side — very dirty, 6 nos zinc anodes replaced. 2. A/E F.W. COOLER (LOWER):
Jan 96: Cleaned on S.W. side — very dirty. Zinc anodes satisf. 3. STEAM CONDENSOR:
Feb 96: Cleaned on S.W. side and surveyed. 4. CONTROL RM A/C CONDENSOR:
Oct 96: Cleaned on S.W. side. Outlet pipe choked, same cleaned.
06.03.97: Inlet pipe found completely choked. Same removed, cleaned, boxed back.
05.06.97: Cleaned on S.W. side with chemicals. 5. MAIN L.O. COOLER:
May 96: Cleaned on S.W. side. All large zinc anodes renewed. Small anodes partially renewed (no spare).
6. REEFER CONDENSERS:
May 96: Both condensers cleaned on S.W. sides. Large Zn anodes renewed. Small anodes to renew.
Auxiliaries
1. OILY WATER SEPARATOR:
Jan 96: 1st stage filter (found very dirty) cleaned in chemical. 2-nd stage filter (coalescer) also very dirty. Same replaced.
Feb.97: Opened up and filters are cleaned with chemical. 2. OIL TANKS:
Jan 96: M/E L.O. Settle tk internally inspected — satisf. 3. M/E & A/E C.W. HEADER TK:
Jun 96: Drained completely and cleaned internally. 4. INCINERATOR:
Jul 96: Main burner cleaned and O'hauled.
DECK MACHINERIES
1. LIFE BOAT ENGINE (PORT):
Jan 96: Gear case oil low. Same replenished. Jun 96: Fuel filter choked. Same replaced.
Jul 96: Both FO Tks emptied out and filled with gas oil.
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2. LIFE BOAT ENGINE (STBD):
Jan 96: Gear case oil low. Same replenished. Jun 96: Fuel filter cleaned — very dirty (sludgy).
Jul 96: Both FO Tks emptied out and filled with gas oil. 3. DECK MISCELLANEOUS:
Jan 96: Ford Air Horn not working. Found diaphragm ruptured. Same replaced. Feb 96: Hydraulic v/v compartment for No. 1 DB Tks opened and found the space filled with water. Water pumped out and found the leak from the steam inlet pipe, which had earlier been cement boxed. Holed pipe welded with a doubler. Hyd
ram for No.2A hatch, on the Stbd aft side, leaking from seal. Seal renewed. Jun 96: Funnel flaps not closing properly. Same rectified.
Jul 96: Hyd clrs of all mast houses cleaned on SW side. Hyd filters of all Dk machinery cleaned.
Aug 96: Vents of all fuel tanks opened and wire gauze cleaned, rust removed and boxed back. Galley steam boiler internally cleaned (heavily scaled). Leaking area soldered and externally sealed with Devcon.
Sept 96: Hyd. rarn from hold No.2 between С & D deck on the Port aft side. leaking from seal. Seal renewed. Hyd. cyl type DIA125XDIA80X470 stroke.
Oct 96: Flexible hose (H.press) in the hold No.4 on С deck AFT replaced with new one.
Reefer plant
Jan 96: #3 reefer Compr motor O'hauled.
Feb 96: #1 clg water pump surveyed by means of running test. Ice testing of all hold sensors carried out. : #3 compr oil filter renewed.
Jun 96: Nos 1AB & 2AB magnetic contactor (Mitsubishi SK-80) replaced with alternative contactors to suit the operation. MY COM service Engrs attended to problems on board and calibrated the C02 setting. Fuji Electric attended the repair of #4 inverter panel. : All Holds delivery and return sensors ice tested and calibrated. No. 1 Ozone flow rater renewed.
Aug 96: All heat exchanger air filters cleaned.
Sept 96: All U.S.D.A. sensors ice tested for ZERO deflections, print out taken. : All Holds delivery and return sensors ice tested. All 3 cargo reefer compressors system, receiver, condensers and valve header leak tested, detected. A gas leak-at No.3 compressor body, through a bolt plug, Defect rectified.
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