Issue No.

1 Page 1 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

Lesson 1

Learning Module 1 Emergency/Temporary/Repairs (3 hours)

Competence, Course Outcomes, and Learning Outcomes

Competence:

A-III/2.F1.C2: Plan and Schedule operations

A-III/2.F3.C3: Ensure safe working practices

Course Outcome/s:

CO1: Differentiate the various type of maintenance

Learning Outcomes:

At the end of the topic, the student must be able to:

1. explain the purpose of maintenance
2. identify the three types of maintenance
 Planned Maintenance System
 Controlled Maintenance
 Breakdown Maintenance
3. explain emergency/ temporary repair

Overview

Ships are giant structures having large machinery on board, and there are hundreds
of different equipment and devices. Obviously, for the smooth running of the ship, it is
important that these machines, equipment and devices are in proper order. Otherwise, this
would affect the normal operation of the ship and could hamper its mobility or safety. Yet
whatever works need to be repaired and the same is true of the ship and its machinery. So
let us learn the types of ship maintenance and repairs that are required for a vessel to sail
smoothly.

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 Issue No. 1 Page 2 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

Discussion

Maintenance

The technical meaning of maintenance involves functional checks, servicing,

repairing, or replacing of necessary devices, equipment, machinery, building infrastructure,
and supporting utilities in industrial, business, governmental, and residential installations.
Over time, this has come to include multiple wordings that describe various cost-effective
practices to keep equipment operational; these activities take place either before or after a
[Link]

3 Types of maintenance:

Planned maintenance
Planned preventive maintenance (PPM), more commonly referred to as
simply planned maintenance (PM) or scheduled maintenance, is any variety of
scheduled maintenance to an object or item of equipment. Specifically, planned
maintenance is a scheduled service visit carried out by a competent and suitable agent, to
ensure that an item of equipment is operating correctly and to therefore avoid any
unscheduled breakdown and downtime when those tasks are preplanned. Planned
maintenance is a proactive approach to maintenance in which maintenance work is
scheduled to take place on a regular basis. ... Planned maintenance [Link]
maintenance tasks such as checking oil levels,

Controlled maintenance
The organization schedules, performs, documents, and reviews records of routine
preventative and regular maintenance (including repairs) on the components of the
information system in accordance with manufacturer or vendor specifications and/or
organizational [Link]

Breakdown maintenance
Breakdown maintenance is maintenance performed on equipment that has broken
down and is unusable. It is based on a breakdown maintenance trigger. It may be
either planned or [Link]

Emergency repairs
The maintenance agreement should also include provisions for emergency and
nonemergency repairs, as well as scheduled maintenance. At some time, every system
needs an emergency repair; however, not all repairs are emergencies. The maintenance
agreement should define what is an emergency repair (cannot operate the system), and
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 Issue No. 1 Page 3 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

what is a nonemergency repair (a portion of the system not working but its operation is not
immediately critical).ok

Temporary repair
Repairs to an asset that are not intended to be of an enduring nature and are usually
required to address an immediate [Link]

Planned maintenance work flow

Major Benefits of Planned Maintenance

The key benefit of planned maintenance is that the work can be scheduled in ways
such that it does not interfere with the overall production. This may mean scheduling
planned maintenance during times of the year when there is less demand or doing
maintenance at night when most of the facility is not [Link]

Other direct benefits of planned maintenance include:

 Reduces unplanned equipment downtime and improves overall equipment
performance.
 Repair costs are reduced because problems are fixed while they are minor.
 More efficient use of manpower and other resources because maintenance work,
parts inventory, tools, and financial costs, can be spread more evenly throughout the
year.
 Better planning of spare parts uses and ordering.
 Helping to ensure the manufacturer's requirements for warranty compliance are met.
 Reducing overall maintenance [Link]

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 Issue No. 1 Page 4 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

There are also a number of secondary benefits that come from using planned maintenance.
These include:
1. Improved workplace safety.
2. Procedures are established to plan the use of, monitor, and control maintenance
resources.

3. Improves communication between maintenance and operations.

4. Provides a daily plan for maintenance supervisors such that employees have a full
day of work every day.

5. Establishes a performance monitoring system that allows maintenance activities to

be better evaluated and [Link]

Breakdown Maintenance
It is the system when the machinery or equipment automatically shuts down. This is
not a suitable and good method as situations may occur wherein the machinery is required
in an emergency. The only advantage of this system is that the working of machinery parts
is used to its full life or until it breaks. This system might get costly as during breakdown
several other parts may also get damaged… Breakdown maintenance is maintenance
performed on a piece of equipment that has broken down, faulted, or otherwise
cannot be operated. The goal of breakdown-maintenance is to fix something that has
malfunctioned. To the contrary, preventive maintenance is performed in order to
keep something running.

Breakdown maintenance workflow

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 Issue No. 1 Page 5 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

2 Types of Breakdown maintenance

There are two types of breakdown maintenance: planned and unplanned.

Planned breakdown maintenance

Planned breakdown maintenance means that the organization is prepared for a
breakdown and even expects it to happen. The equipment runs until it breaks, which

Initiates a run to failure (RTF) trigger. While RTF triggers can be unplanned,
breakdown maintenance plans use RTF as a way of lowering the cost of maintenance.

This kind of plan needs to be rigorously documented and controlled. Employees

should be clear on exactly which parts will break down and which parts will be maintained
normally via preventive maintenance. Without these checks, a breakdown maintenance plan
can be exploited or run awry. Ok

Unplanned breakdown maintenance

Unplanned breakdown maintenance, on the other hand, occurs when a piece of equipment
fails or breaks unexpectedly—also called an unplanned downtime event. While some
facilities may not utilize a planned breakdown maintenance plan, nearly every facility needs
resources in place for unplanned breakdown maintenance. After all, every piece of
equipment will break or fault at some point in its [Link]

Pros and Cons breakdown for maintenance

Pros Cons
Failed equipment can lead to disastrous The downsides of breakdown maintenance
consequences, but a clearly-documented are especially important to weigh given the
breakdown maintenance plan can actually nature of the maintenance plan. For
have a few significant benefits for an example, breakdown maintenance should
organization. never be used with safety equipment
because a single lapse can cost one or
•Minimizes maintenance cost by cutting out multiple employees their health or their lives.
unnecessary preventive maintenance •Form of waste in a manufacturing
•Lowers cost of replacing disposable items environment
frequently (light bulbs, tools, fuses) •Safety issues can occur with unplanned
•Downtime for repairs is consolidated failures
•Low staffing needs •Can be costly depending on parts that fail
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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

•Simple and easy to understand when •Requires careful planning and execution
maintenance is required. Ok •Can be difficult to pinpoint the source of
issues. Ok

Emergency and temporary repairs

(Wencon Repair Kit on board your vessel )

The Repair Kit equips you with a first aid kit for performing emergency and
temporary repairs when needed. The Repair Kit covers most aspects of emergency repair
and long-lasting maintenance and is suitable for vessels, where repairs and minor
maintenance are carried out [Link]
Thousands of vessels and offshore units are carrying our Repair Kit on board, and are ready
for unexpected situations.

Permanent repair - A repair of an asset that is enduring and lasting, typically endeavoring to
reach the end of the useful life of the asset when the entire assembly is [Link]

Temporary repairs - are repairs made during and immediately following a disaster event
(within 180 days of the event) to restore essential traffic, minimize the extent of damage, or
protect remaining facilities. It is a premise of the ER program that emergency/ temporary
repairs reduce the cost, or additional work required, to accomplish subsequent permanent
repairs. Temporary Repairs Repairs made to piping systems in order to restore sufficient integrity to
continue safe operation until permanent repairs can be scheduled and accomplished within a time
period acceptable to the inspector and/or piping engineer

Temporary and Permanent Pipe Leak Repairs

While most of the pipe repair components have a design

basis in accordance with internationally recognized codes or
standards. In most cases these codes or standards may not
concern piping or pipelines, but concern pressure vessel type
codes, such as ASME Section VIII: Pressure Vessel Code, or API
6H: Specification on End Closures, Connectors and Swivels.
Pressure vessel codes, unlike piping codes, have a greater
degree of flexibility in their [Link]

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 Issue No. 1 Page 7 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

While the crop-and-replace repair method is permanent
repair due to the welding of the replacement section onto the
parent pipe; we shall look into the other categories of pipe leak
[Link]

When the repair component utilized is in the form of a

‘stand-off’ type repair clamp or enclosure, the repair is very
much regarded as placing a pressure vessel around the damaged area – no welding is
involved or ‘substituted’. In these situations one must consider the life-cycle of the repaired
pipe system –will internal metal loss of the pipe underneath the clamp continue? Will
degradation of the elastomeric seal material occur? These considerations will dictate the
need to afford periodic inspection and/or testing to the
repair component. It may be possible to periodically test
the integrity of the seal areas, but this may not provide
any information on the integrity of the pipe wall –
conditions may be approaching the limit of the
remaining pipe wall to carry the internal pressure
imposed axial stresses when the repair clamp does not
have the ability to accommodate these [Link]

For all pipe repairs, the operator needs to perform a structured risk assessment that
includes the consideration of all of the potential future damage or deterioration mechanisms.
The output from this risk assessment will typically be the specification of the necessary
inspection and testing activities, and associated periodicities, to ensure continuing ‘fitness¬-
for-purpose’. The repair component itself may well be regarded as being a permanent repair
(a repair component that is intended to remain in place for the remaining life of the piping
system), but may require periodic examination. This is particularly important when repairs
have been afforded to a safety-critical piping system, where there is a need to demonstrate
that the system “remains in good repair and condition”.Ok

RANGE OF AVAILABLE REPAIR CLAMPS AND REPAIR CONNECTORS/COUPLINGS

One of the fundamental aspects of a damaged/deteriorated pipe that dictates the

type of repair component to be applied is the external pipe surface condition. If the external
surface is damaged to the extent that an elastomeric seal cannot provide sufficient sealing
forces in the immediate vicinity of the damage, or in the relatively unaffected areas adjacent
to the major damage (these areas being used to effect the sealing of ‘stand’-off repair
clamps), the external pipe surface may need to be re-instated using some form of filler
material. Developments using epoxy-filled steel sleeves have been shown to accommodate
such areas of extensive damage and have applications for a whole range of defects,
including corrosion, non-propagating cracks, dents, or gouges in both axial and
circumferential orientation, and girth weld associated anomalies. The epoxy-filled sleeve
repair technique is discussed later within these guidelines. There are three main repair
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 Issue No. 1 Page 8 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

scenarios considered in this guidance document; pipe subject to external metal loss (caused
by corrosion or mechanical damage), pipe subject to internal metal loss (caused by
corrosion, erosion, or erosion/corrosion), and piping components that are leaking. Ok

PIPE REPAIR SCENARIOS

There are three main repair scenarios considered in this guidance document; pipe
subject to external metal loss (caused by corrosion or mechanical damage), pipe subject to
internal metal loss (caused by corrosion, erosion, or erosion/corrosion), and piping
components that are leaking. In addition to these main repair scenarios, the extent of the
deterioration or damage (i.e. localized or extensive) will also be considered when choosing
the repair methods and repair components. These repair scenarios are described further in
the following [Link]

PIPE SUBJECT TO EXTERNAL METAL LOSS

Many pipework failures have been caused by external corrosion. External corrosion
may be present in many forms including simple environmental corrosion (e.g. coating
breakdown and subsequent corrosion, corrosion under insulation, etc.), crevice corrosion,
and galvanic corrosion. Regardless of the actual corrosion mechanism that is active, the
resulting damage is in the form of metal loss – loss of wall thickness. This metal loss may be
localized (as in the case of corrosion underneath a pipe support) or may be extensive (in the
case of corrosion under insulation)Ok

Mechanical damage to pipework may, or may not, be accompanied by metal loss. For
example, an indentation may have simply deformed the pipe locally without any associated
gouging or thinning of the pipe wall. Plain dents up to six percent of the diameter of the
pipe do not need to be repaired. Deeper indentations may need to be repaired or may need
to be removed if their presence could cause operational problems (e.g. interference with
pigging). By virtue of their probable causes, dents are considered to be an example of
localized damage. Cracking (not strictly speaking, damage involving metal loss) of
weldments or of the parent pipe itself, but which has not resulted in leakage of the piping
system requires special consideration. The repair of a cracked section of pipework would
involve arresting any further propagation (providing that the crack itself is not threatening
integrity) or removal/repair. Whatever the cause of the external metal loss, it is assumed
that the prevention of further deterioration will automatically be addressed by the
combination of realizing the presence of the damage/deterioration (measures taken to
prevent re-occurrence) and the repair action [Link]

PIPE SUBJECT TO INTERNAL METAL LOSS

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 Issue No. 1 Page 9 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

Conveyed fluids within piping systems, especially in oil and gas and petrochemical
applications, can present problems of internal corrosion, erosion, or a combination of
corrosion and erosion. Dependent on the severity and extent of the internal
damage/deterioration the pipework may be leaking or be in threat of leaking. The repair
scenario considered here, however, is when an internal metal loss has not resulted in
leakage – the next section deals with pipework leaks. Unlike external corrosion, it may not
be possible to arrest the metal loss mechanism and further time-dependent
damage/deterioration will continue. Unless it is possible to arrest the metal loss mechanism,
the chosen repair components will need to accommodate the effects of the eventual further
deterioration. In these cases, the reinstatement of pipe integrity may only be considered to
be temporary, unless the design of the repair components specifically addresses the effects
of further deterioration, at least up to the remaining life of the piping system. Unlike
external corrosion, internal corrosion, erosion, or corrosion/erosion is more difficult to
quantify, both in terms of the absolute metal loss and the extent of this metal loss.
Inspection 8 techniques are available, such as ultrasonic and radiography, to assist in this
quantification. What is important is to gain as much information as possible on the
damage/deterioration to enable the correct repair method to be chosen. It is particularly
important to obtain information regarding the ability of the sustained damage to
accommodate the axial stresses which, in complex pipe systems, can be significant. Also,
further deterioration of existing internal metal loss may result in the pipe wall being unable
to carry these axial [Link]

PIPE SUBJECT TO LEAKAGE

Leakage may be caused by internal or external metal loss (or, very rarely, a
combination of the two). Leakage may also be caused by cracking of welded seams or joints
or of the parent pipe itself. Depending on the extent of the discovered damage, repair may
require the installation of a repair clamp (localized repair) or the replacement of a section of
pipe utilizing connectors or couplings. In all cases where the pipe contents are leaking, it will
be necessary to consider the suitability of the repair component to not only accommodate
the pressure containment requirements but also to accommodate corrosively and other
effects of the fluids. For example, elastomeric seals utilized within certain repair
clamps/connectors may be susceptible to deterioration in the presence of volatile
hydrocarbons, aromatics, etc. The issues of possible long-term seal degradation/relaxation
and any need to first stem/plug the leak need to be considered. In some cases it may be
possible to install a repair clamp to an actual leaking pipe - the clamp that encloses the
defective, leaking area is provided with a vent plug (as shown in Figure 5) which can be
closed once the clamp has been correctly installed and tightened. The ability of the repair
component(s) to accommodate the axial loadings of the pipe system, especially in the case

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 Issue No. 1 Page 10 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

of a repair employing connectors, also needs to be considered. One other scenario that is
considered within these guidelines is the case of a leaking flange. The leak will most
probably have been caused by corrosion or relaxation of the flange face/gasket area.
However, it is possible to experience leakage of the pipe to flange welds (fillet weld in the
case of slip-on flanges, and circumferential butt weld in the case of welding neck
flanges).Ok

References

R6- Osbourne, Alan. (1994). Modern marine engineer’s manual vol. 1 2 nd ed . Maryland :
Cornell Maritime Press. Inc.
[Link]
[Link]
[Link]
different-types-of-repairs-necessary-for-a-ship/
[Link]
[Link]
[Link]
q=procedure+of+Planned+maintenance&rlz=1C1CHBD_enPH902PH902&sxsrf=ALeKk02rbiGl
PgaIBcYrI-
wQPzKJvWba8A:1590133162018&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiL5JHS-
8bpAhUTyIsBHSWmB5gQ_AUoAXoECA0QAw&biw=1366&bih=608#imgrc=fIwmBYK0DAPVP
M
[Link]
[Link]

Checkpoint

Activity 1

1. Enumerate the correct procedures of the emergency and temporary repair and
precautionary measures about the emergency repair.

Do this
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 Issue No. 1 Page 11 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

Activity 2

1. Explain how to repair patch clamp in a leaking pipe.

Assessment

Pretest
Multiple Choices: Choose the correct letter that corresponds to the correct answer.

1. What type of repair made only to relieve the problems or damages of the
machineries in a short period of time?
A. Emergency repair
B. Permanent repair
C. Temporary repair
D. Nothing to repair

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 Issue No. 1 Page 12 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

2. One simple method of making a temporary repair of a leaky pipe is to carry out
the following except:
A. Wrap the leaky area with a rubber sheet
B. Replace the over-all defective pipe using all available spares
C. Stop the water supply, cut the leaky portion and replace with the rubber
hose
D. Stop the water supply, clean then apply “EPOXY COMPOUND” to leaky are
3. Which of the following method of repair is made to avoid the reoccurrence of the
repair problem?
A. Emergency repair
B. Permanent repair
C. Temporary repair
D. Maintenance repair
4. Which of the following repair method needs more time to carry out?
A. Emergency repair
B. Permanent repair
C. Temporary repair
D. Maintenance repair
5. A permanent repair can be possible. In which of the following condition is
satisfied?
A. Store requisition is required
B. The repair kit needed is available
C. Spares/tools needed is on hand
D. Ships are in port during loading or discharging
6. A vessel encountering trouble may not be able to arrive at the next port safety.
What repair method will the chief engineer do to secure life and property on
board.
A. Emergency repair
B. Permanent repair
C. Temporary repair
D. Maintenance repair
7. How would you repair once a leak of the cooler is identified?
A. Putting plug to leaky area
B. Applying cement over the leaky area
C. Applying epoxy pat6ches over the leaky area
D. Weld the leak areas of the coolers with a gas welding
8. Usually, where can you find the leakage in the cooler?
A. Tube end
B. Tube pins
C. Weld joints
D. Cooler cover

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

9. This repair material makes quick work of emergency valve repairs. Just prepare
the pipe surface, activate with water and it will create permanent repair without
the use of a tool.
A. Epoxy compound
B. Commercial cement
C. Devcon steel compound
D. Special resin-permeated fiberglass tape or cordovan
10. In conducting repair maintenance aboard the ship, appropriate action is taken in
consultation with the responsible engineer to prevent further damage in
accordance with the following:
A. Chief Engineer’s job order
B. Breakdown maintenance system
C. Vessel’s planned maintenance system
D. Vessel’s annually survey

Lesson 2 & 3

Learning Module 2 & 3 Materials for temporary repairs and Methods (3

hours)

Competence, Course Outcomes, and Learning Outcomes

Competence:
A-lll/2. F1. C2: Plan and Schedule operations
A-lll/2. F3. C3: Ensure safe and working practices

Course Outcome/s:

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

Differentiate the various type of maintenance

Learning Outcomes:

At the end of the lesson, the student must be able to:

2.1 Identify the materials to be used for emergency/temporary repairs

3.1 Explain methods for emergency / temporary / repairs of overboard / seawater
suction valves in case of leaking and how to replace it under a float condition

Overview

EMERGENCY TEMPORARY REPAIRS

At times, a pipe may start leaking and the materials needed to repair it permanently
are not on hand. Here, you may have to use a temporary or emergency repair. Keep in mind
that permanent repair should always be made when the proper tools or materials are
available. At times, a pipe may start leaking and the materials needed to repair it
permanently are not on hand. Here, you may have to use a temporary or emergency repair.
Another temporary method of repair for a leaky pipe is to wrap the leaky area with sheet
rubber.

One simple method of making a temporary repair of a leaky pipe is to use a length of
rubber hose. After turning off the water supply, remove the defective section of the pipe by
cutting it with a hacksaw. Then take a piece of rubber hose, slightly longer than the section
of pipe you removed, and slip it over the ends where the cut was made. Ensure the inside
diameter of the hose matches the outside diameter of the pipe. Hose clamps hold the hose
securely in [Link]

Discussion

What is an Emergency Repair?

Upon receiving a report of a repair problem we will prioritize the repair as an
emergency, urgent or non-urgent.. Emergency repairs
The maintenance agreement should also include provisions for emergency and non-
Procedure and remarks for Boiler inspection emergency repairs, as well as
scheduled maintenance. At some time, every system needs an emergency repair;
however, not all repairs are emergencies. The maintenance agreement should
define what is an emergency repair (cannot operate system), and what is a

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

nonemergency repair (portion of system not working but its operation is not
immediately critical).

Examples of repairs that would be considered emergencies are:

 Total loss of electricity or a dangerous electrical fault

 Total loss of water supply or a major leak (such as a burst pipe or water tank within
the property)
 A blocked drain or serious leak of sewerage (the cost of this repair is rechargeable if
the problem was caused by you)
 Any other repair that poses a risk to you or the public or to the structure of the
[Link]

Urgent repairs (undertake within five working days)

Examples of repairs that would be considered urgent are:

 Partial loss of electrical power or light

 Unsafe power, lighting socket, or electrical fitting
 Partial loss of water or gas supply
 Loss or partial loss of space or water heating
 Blocked or leaking drains, or soil stack
 Blocked sink, bath, or basin
 Leak from water or heating pipe, tank or cistern
 Leaking roof Ok

Materials to be used for emergency/temporary

repair:

 Pipe clamps – this is used to keep the

broken pipe intact and is used for
emergency repair [Link]

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

 Epoxy compound – suitable for temporary repairs in cast iron piping application and
it patches up leaks until the pipe can be totally [Link]

 Pipe wraps – for joint leak applications this can be

wrapped around to tighten up the leak temporarilyOk

 Repair sleeve – these are ideal for joint or

pinhole repairs. Can provide a strong fix for a
limited amount of [Link]

 Special resin-permeated fiberglass tape or cordovan –

this repair material makes quick work of emergency
valve repairs. Just prepare the pipe surface, activate
with water and it will create a permanent repair
without the use of [Link]

 Cement – once the leak of the cooler is identified,

it can be repaired by applying cement over the
leaky [Link]

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

 Grinding compound – used for grinding of valve seat for the leaking seawater globe
[Link]

Shell and Tube Type Heat Exchanger

This is the most popular type of design with a shell accompanying

several tubes and the flow of liquid to be cooled is mainly
through tubes, whereas the secondary liquid flows over the tube
inside the [Link]

Shell and tube type heat exchanger is extremely economical to install and easy to
clean; however, the frequency of maintenance is higher than other types.

In this heat exchanger, the complete shell is fitted with a tube stack or commonly
known as the shell. There are two end plates that are sealed on both sides of the shell and
a provision is made at one end to cater to the expansion. The cooling liquid passes through
the tubes which are sealed on either end into the tube plate. The tubes are secured in the
tube plate by bell mouthing and [Link]

Maintenance of Shell & Tube Type Cooler

Observing safety measures, the fluids should be isolated completely and the cooler
should then be opened up.

 The heat transfer surfaces should be cleaned properly which is the basis for the
satisfactory operation of the shell and tube type cooler. The seawater fouls the
cooling surfaces because of plant and animal growth, which is indicated by the
increase in
 The temperature difference between the cooling and the liquid being cooled. Further,
the pressure changes will indicate the sameOK

Excessive corrosion can result in the leakage of tubes. The leakage could be determined by
the following method:

 Discharge the liquid being cooled in the liquid chamber by the drain valve
provided in the bottom and open up the chamber.
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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
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10 August 2020 QMR President

 Fill the main body with fresh water and pressurize it by applying air pressure or
hydraulic pressure from the top. The connection could be fitted, if not given
 The leaking tube could then be identified when completely dried up
 If the leakage happens from the expansion part of the tube in the tube plate,
then it could be expanded slightly, which could arrest the leakage Ok
 The leaking tube could then be plugged from both sides by wooden plugs
provided by the manufacturer or could be made as well
 The leaking tube could be replaced as well, depending on its condition
 The leaking tube could be removed by making a bore inside the tube with a drill
or a reamer of 0.5mm smaller than the outside diameter of the tube to a depth
of the expansion
 Then the tube drawing tool could be inserted and tapped slowly to knock it out
from the other end
 The new tube could be installed by inserting the tube expander to both
sides of the tube and expanding it
 Wall thickness of reduction= (wall thickness of tube before expansion – wall
thickness of tube after expansion) / wall thickness of tube before expansion
X100%
 The above value should be between 5-8%Ok

Maintenance and Repairs

A leaking overboard non-return discharge valve resulted in seawater entering the
engine room of a vessel operating in rough seas. The cooling water caused a blackout
and the engine room began to flood, leading to a critical situation for the vessel and the
crew. As a temporary measure, the leaking overboard valve was isolated and the vessel
towed to port for repairs. During the damage survey, the bottom of the valve was found
to be heavily corroded and holed. Ok

The top of the valve, however, appeared normal. Leaking overboard valves can
lead to water entering the engine room. In severe cases, where the valve completely
gives way, seawater can directly enter the engine room, causing rapid [Link]

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Maintenance and Repairs

Inspection of the valve seating, by partly opening of the valve, would not reveal
the wastage in the bottom without fully dismantling the valve. However, an inspection of
the bottom part of the valve by using a hammer and visual inspection, e.g. a mirror,
could have revealed deterioration of the valve body without being dismantled.

All sea valves, including scuppers and sanitary discharges, are to be thoroughly
examined and fully opened at the time of class survey involving bottom surveys in dry
dock. It is strongly recommended that the sea valves are overhauled at the same time.
The condition of the valve body can be difficult to assess, but there are some easy
regular inspection checks when implemented in the maintenance plan onboard, that help
evaluates the condition of the valves:Ok

 In addition to a visual inspection of the body, a hammer test can be performed to

evaluate thinning and corrosion. (Note: NDT of valve bodies are usually not a good
option since the bodies are cast and usually have minor internal flaws even in a
new condition.)
 Always check the bottom of the valve.
 If rubber lining has been provided in the valves, check that the lining is intact. If
lining is partly peeled off, concentrated local corrosion may occur. Examine the
fastening of the valves to the hull.
 If the body cannot be fully visual surveyed in situ, this is also an indication that
the valve should be fully dismantled, since most likely no one is looking at it in
service. All the more reason for a stringent examination at 5-year intervals.
 Please note there may be external corrosion as well as internal pitting/erosion at
the same spot. A mirror or camera may be helpful tool.
 Systems in which heated seawater is passing may corrode more [Link]

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The costs of the proper examination/overhaul/replacement of a valve are minor
compared to the cost for replacing a broken valve in service with unscheduled repairs and
disrupted service. Upon reassembly, the valves should be tested to confirm the
satisfactory operation of the valves and their actuating mechanism, full closing of the
valve, and tightness of the valve when fully seated (ref. IACS Rec.144).Ok

TYPES OF VALVES

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 Gate valve - are widely used for all types of applications and are suitable for both
above-ground and underground installation. Not least for underground installations, it
is paramount to choose the right type of valve to avoid high replacement [Link]

 Globe valves - is a linear motion valve and are primarily designed to stop, start, and
regulate flow. The disk of a Globe valve can be totally removed from the flow path or
it can completely close the flow path. Conventional Globe valves may be used for
isolation and throttling [Link]

 Plug valves - are valves with cylindrical or conically tapered "plugs" which can be
rotated inside the valve body to control flow through the valve. The plugs in plug

 valves have one or more hollow passageways going sideways through the plug, so
that fluid can flow through the plug when the valve is open. Plug valves are simple
and often economical. When the plug is conically tapered, the stem/handle is
typically attached to the larger diameter end of the plug. Ok

 Diaphragm valves - (or membrane valves) consists of a valve body with two or more
ports, an elastomeric diaphragm, and a "weir or saddle" or seat upon which
the diaphragm closes the valve. The valve body may be constructed from plastic,
metal, wood, or other materials depending on the intended [Link]

 Ball valves - is a form of quarter-turn valve which uses a hollow, perforated, and
pivoting ball to control flow through it. It is open when the ball's hole is in line with the
flow and closed when it is pivoted 90-degrees by the valve [Link]

 Butterfly valve - is from a family of valves called quarter-turn valves. In operation,

the valve is fully open or closed when the disc is rotated a quarter turn. The
"butterfly" is a metal disc mounted on a rod. When the valve is closed, the disc is
turned so that it completely blocks off the [Link]

 Needle valve - is a type of valve with a small port and a threaded, needle-shaped
plunger. It allows precise regulation of flow, although it is generally only capable of
relatively low flow [Link]

 Check valve - clack valve, non-return valve, reflux valve, retention valve or one-way
valve is a valve that normally allows fluid (liquid or gas) to flow through it in only one
[Link]

Check valves are two-port valves, meaning they have two openings in the body, one
for fluid to enter and the other for fluid to leave. There are various types of check
valves used in a wide variety of applications. Check valves are often part of common
household items. Although they are available in a wide range of sizes and costs,
check valves generally are very small, simple, or inexpensive. Check valves work
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automatically and most are not controlled by a person or any external control;
accordingly, most do not have any valve handle or stem. The bodies (external shells)
of most check valves are made of plastic or [Link]

 Pressure relief valve - is a safety device designed to protect a pressurized vessel or

system during an overpressure event.

An overpressure event refers to any condition which would cause pressure in a

vessel or system to increase beyond the specified design pressure or maximum
allowable working pressure (MAWP).Ok

The primary purpose of a pressure Relief Valve is the protection of life and property
by venting fluid from an overpressurized vessel… The pressure Relief Valve must
open at a predetermined set pressure, flow a rated capacity at a specified
overpressure, and close when the system pressure has returned to a safe [Link]

 Control valve - is a valve used to control fluid flow by varying the size of the flow
passage as directed by a signal from a controller. This enables the direct control of
flow rate and the consequential control of process quantities such as pressure,
temperature, and liquid [Link]
 Steam trap - is a device used to discharge condensates and non-condensable gases
with a negligible consumption or loss of live steam. Steam traps are nothing more
than automatic valves. They open, close, or modulate automatically.
Boiler smoke tube maintenance and repair
Repairs in Smoke Tube Boilers: Hydrostatic testing to mark the leaky tubes. Cut
the tubes on one end and clear of the tube plate. Pull out the tube from the collapsed end.
Insert a short tube into the tube plate and weld it in place. Lap the spare tapered plugs on
both studs ends in the tube plates.

Repairs In Smoke Tube Boilers:

Procedure for Plugging of a Damaged / Busted Smoke Tube:

1. Hydrostatic testing to mark the leaky tubes.

2. Cut the tubes on one end and clear of the tube plate. At the other end the tube is
collapsed inside the tube plate.
3. Pull out the tube from the collapsed end.
4. Insert a short tube into the tube plate and weld it in place.
5. Lap the spare tapered plugs on both stud ends in the tube plates.
6. Insert the tube plugs and tack weld it.
7. Alternatively, the plugs can be held in place by a long steel bar threaded and bolted at
both ends.
8. Hydrostatic pressure test to confirm no leaks.
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9. Flush up the boiler and re-inspect the plugs for leaks under full steam [Link]

How to Plug Boiler Tube of Water Tube Boiler

PLUGGING A LEAKING BOILER TUBE. Emergency Boiler Repair – Water Side Removing
Boiler Tubes Use Extra Care When Plugging Boiler Tubes – Hartford Steam Boiler Plugging
rather than replacing tubes is common practice when repairing Boiler points out

How to plug the leaking tube in the boiler?

What is the correct procedure of plugging the leaking tube of water-tube boiler?
Should the firewall be arranged?
Answer:
First of all, if leakage is minor or there is no time o plug the boiler tube in the correct way, the leak may be welded. Depending

on the hole size and location, a welding build-up or doubler may be required.

If decision was made to plug the tube, the general procedure is as follows:

Drain and cool down the boiler

1.
Plug the tube from the water/stem drums side. Plugs may be inserted from the gas side as well after step 3.
2.
Half cut plugged water tube
3.
Put stoppers or seal plates from the gas side in the top and bottom of the cut pipe. Weld stoppers/seal plates to seal
4.
the steam and water drums.

Fabricate L - shaped anchors 50 mm X 50 mm @ 90 degrees

5.
Weld anchors to the remaining wall of tube that was half-cut
6.
Make a fire wall - apply refractory cement over anchors of tube being repaired. Standard type is Pribrico Super
7.
AB

Fix the burner and run the fan continuously for the time stated in the refractory material manual
8.
Slowly warm up the boiler as per the maker’s recommendations
9.

Maintenance procedure of a boiler smoke tubes for inspection

Procedure and remarks for Boiler inspection OK

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1. Shut off the boiler and allow it to cool (below 100°C). The boiler
should NOT be depressurized by lifting the safety valves and then
filled with cold feedwater since the stress induced by too rapid
cooling may cause [Link]
2. Empty the boiler and close all valves. If the boiler is connected to a
second boiler, check that the valves between them are closed.
3. Unscrew and remove the manhole hatch(s) on the boiler and enter
the boiler when it is sufficiently cold. Check the welding in the boiler.
A careful examination should be carried out with respect to any
possible corrosion or crack formation.
4. Special care should be taken to the water line area in the pressure vessel
where oxygen pitting may occur.
5. If deposits are found to be forming in the boiler tubes, the boiler should be chemically
cleaned.
6. It is advisable to consult a company of cleaning specialists who will examine the boiler
deposits and treat the boiler accordingly.
7. After chemical treatment the boiler should be blown-down at least twice a day for
approximately one week. This will ensure that excessive sludge deposits due to
chemical treatment do not collect in the bottom of pressure vessel. Procedure and
remarks for Boiler inspection Ok

References

T1 – 3G E – Learning FL LLC. (2016). Diesel power plant operations and

maintenance: Intermediate UAE. 3G E – Learning
R6 – Osbourne, Alan. (1994). Modern marine engineer’s manual vol. 1 2 nd ed. Maryland:
Cornell Maritime Press. Inc.
[Link]
[Link]
[Link]
[Link]
rlz=1C1CHBD_enPH902PH902&nfpr=1&q=material+used+for+global+valve&spell=1&sa=X
&ved=2ahUKEwiilo3vhMnpAhVN7WEKHdVTAbgQBSgAegQIDBAm&biw=1366&bih=657
[Link]
[Link]
134931

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[Link]
ship/
[Link]
[Link]
rlz=1C1CHBD_enPH902PH902&sxsrf=ALeKk03RDISKFy1YoMOJ0iaDbTKe032bKQ
%3A1590284392739&ei=aNDJXtzPLK-
1mAWM8or4Cw&q=globe+valves+&oq=globe+valves+&gs_lcp=CgZwc3ktYWIQAzIECCMQ
JzIECAAQCjIECAAQCjIECAAQCjIECAAQCjIECAAQCjIECAAQCjIECAAQCjIECAAQCjIEC
AAQCjoECAAQRzoGCAAQFhAeOggIABAWEAoQHlC2DliNIGDfImgAcAF4AIABhgOIAZgUk
gEHMC4zLjYuMpgBAKABAaoBB2d3cy13aXo&sclient=psy-
ab&ved=0ahUKEwjco8iCr8vpAhWvGqYKHQy5Ar8Q4dUDCAw&uact=5
[Link]
q=PLUG+VALVES&rlz=1C1CHBD_enPH902PH902&oq=PLUG+VALVES&aqs=chrome..69i
57j69i59l2j69i60l3.2281j0j7&sourceid=chrome&ie=UTF-8
[Link]
q=DIAPHRAGM+VALVES&rlz=1C1CHBD_enPH902PH902&oq=DIAPHRAGM+VALVES&a
qs=chrome..69i57.10475j0j7&sourceid=chrome&ie=UTF-8
[Link]
q=BALL+VALVE&rlz=1C1CHBD_enPH902PH902&oq=BALL+VALVE&aqs=chrome..69i57j6
9i59l3j69i60j69i61l3.2645j0j7&sourceid=chrome&ie=UTF-8
[Link]
q=butterfly+valve&rlz=1C1CHBD_enPH902PH902&oq=butterfly+val&aqs=chrome.0.0j69i57j
0l6.6266j0j7&sourceid=chrome&ie=UTF-8
[Link]
[Link]
[Link]
[Link]
q=control+valve&rlz=1C1CHBD_enPH902PH902&oq=control+valve&aqs=chrome..69i57.30
37j0j7&sourceid=chrome&ie=UTF-8
[Link]
q=steam+traps&rlz=1C1CHBD_enPH902PH902&oq=steam+traps&aqs=chrome..69i57l2j69i
59j69i58j69i60l3j69i61.3308j0j7&sourceid=chrome&ie=UTF-8
[Link]
q=boiler+smoke+tubes&rlz=1C1CHBD_enPH902PH902&sxsrf=ALeKk01CAJNRevRxGsjZ-
AZDFPcm8bWMaQ:1590285382092&tbm=isch&source=iu&ictx=1&fir=5VSpJmOkZfhLLM
%253A%252CrgJDBhm8cPqFQM%252C_&vet=1&usg=AI4_-
kTdVYcpcYZ1pntMSKuUUE9kbsXpOg&sa=X&ved=2ahUKEwjH0KnassvpAhVly4sBHeM3C
8oQ9QEwBnoECAkQJg#imgrc=5VSpJmOkZfhLLM:
[Link]
[Link]

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Checkpoint

Activity 1

Enumerate the correct procedure on how to perform emergency valve repair of

overboard/seawater suction valve (globe valve) in case of leaking?

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Assessment

Multiple Choices: Choose the correct letter that corresponds to the correct answer.

1. Which of the following materials is suitable for temporary repairs in cast iron piping
application and it patch up leaks until the pipe can be totally replaced?
A. Epoxy compound
B. Pipe wraps
C. Pipe clamps
D. Repair sleeves
2. For the joint leak applications, this can be wrapped around to tighten up the leak
temporarily.
A. Pipe wraps
B. Pipe clamps
C. Repair sleeves
D. Rubber pipe connector
3. Which of the following types of materials that are ideal for joint or pinhole repair?
A. Epoxy compound
B. Pipe wraps
C. Repair sleeves
D. Plastic steel
4. This repair material makes quick work of emergency valve repairs. Just prepare the
pipe surface, activate with water and it will create a permanent repair without the
use of tools.
A. Epoxy compound
B. Commercial cement
C. Devcon steel compound
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D. Special resin-permeated fiberglass tape or cordovan
5. Distinguish the method to determine the leakage of a shell and tube type cooler in
service so it can be repaired.
[Link] testing
[Link] inspection
[Link] and completely dried up
[Link] the suction and discharge pressure

6. What will be the result of a cooler when there is excessive corrosion due to lack of
maintenance?
[Link] of the tube
[Link] of the whole body
[Link] of the inlet cover
[Link] of the outer cover
7. How would you repair the cooler if the leakage happens from the expansion part of
the tube?
A. Apply cement to the leakage tube
B. Plug with wood to the leakage tube
C. Plug with the bronze to the leakage tube
D. Expand slightly to the leakage tube
8. How would you perform to evaluate thinning and corrosion of the overboard
discharge valve?
A. Hammer test
B. Leakage test
C. Pressure test
D. Visual inspection
9. What will happen to a leaking overboard seawater valve, or in severe cases, where
the valve completely give way?
A. It can cause brownout
B. Water entering in the accommodation
C. Water entering in the steering room
D. Water entering in the engine room compartment
10. How would you examine the seawater overboard valve for maintenance purposes?
A. Always check the body of the valves
B. Always check the bottom of the valves
C. Always check the suction pressure of the valves
D. Always check the discharge pressure of the valves

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Lesson 4

Learning Module 4 Safety (4 hours)

Competence, Course Outcomes, and Learning Outcomes

Competence:

A-lll/2. F1. C2: Plan and Schedule operations

A-lll/1. F3. C1: Appropriate use of hand tools, machine tools, and measuring
instruments for fabrication and repair on board

Course Outcome/s:

1. Differentiate the various type of maintenance

2. Disassemble and assemble various pumps based on manufacturers manual

Learning Outcomes:

At the end of the lesson the student must be able to:

4.1 Explain that tools and measuring instruments should be in its proper place and in
good shape and condition to avoid an accident and to ensure the safety of life.
4.2 Describe the necessary control over the power supply to a machine too, basic
differences between the start and stop buttons including the emergency button.
4.3 Wear PPE properly depending on the situation
4.4 Describe the necessary care for hands. Including cuts or abrasion and washing.

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Overview

What is safety and why is it important?

Reduced the likelihood of injury & accidents - Safety reduces the chances of
accidents or injury happening. Improved productivity - A safe work environment with
adequate safeguards promotes an employee to focus on their works instead of the danger
or hazard. Safety reduces injury thereby decreasing lost work hours.
What is personal protective equipment?

Personal protective equipment, commonly referred to as "PPE", is equipment worn to

minimize exposure to hazards that cause serious workplace injuries and illnesses. These
injuries and illnesses may result from contact with chemical, radiological, physical, electrical,
mechanical, or other workplace hazards. Personal protective equipment may include items
such as gloves, safety glasses and shoes, earplugs or muffs, hard hats, respirators, or
coveralls, vests, and full [Link]

Proper Tool Maintenance

It’s important for a tool to be properly maintained and cared for to ensure it
is safe to use when needed to complete a task. This safety bulletin addresses the issue of
maintaining and caring of the tools we use.

 Always store tools in its proper place. That proper place is where the tool will be
protected from damage.
 Make sure that if any oil, grease, the chemical gets on the tool, that the tool is wiped
off and cleaned prior to storing it. This will prevent other tools from getting coated
with these substances rendering them not ready to use. Also, depending on the
chemical, it may damage the tool.
 Some tools need additional maintenance such as sharpening or dressing that makes
it safe to use.
 Check tool handles for defects such as burrs, splinters, missing/loose grips
 Inspecting the tools on a regular basis will help reduce the chance of someone using
an unsafe tool. Ok

Clean, Inspect, and Care for Tools. Make it a habit to clean tools after each use
before you return them to storage. Wipe them down with a rag or old towel and be sure
they are free of dust, grease, and debris before you put them into their proper places. This
is also an opportunity to look for any damage or [Link]

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Discussion

INSPECT YOUR TOOLS. Never issue or use a damaged or defective hand or power tool.
Always make sure they are in good working order before and after each [Link]

PICK THE RIGHT TOOL. Make sure you are using the correct tool for the task at hand. This
also means using the right sized bits, blades and accessories on your power [Link]

WEAR YOUR PPE. Issue personal protective equipment to your employees and make sure
they wear them properly. This comprises of items like safety goggles, hard hats, [Link]

DON’T ALTER YOUR TOOLS. Never remove guards or disable safety devices on power tools.
Don’t paint or cover up your tools as this could prevent you from noticing chips or [Link]

HANDLE WITH CARE. Tools are not toys. Never throw or toss a tool in the direction of or
directly to a coworker. Never use electrical cords to lower or lift a tool to get it to a
[Link]

 KEEP YOUR DISTANCE. When working with hand and power tools be sure you have
enough room to safely operate without coming into contact with other objects or
[Link]

PICK UP AFTER YOURSELF. Don’t leave idle hand tools lying around the job site. They can
lead to tripping or be accidentally knocking on someone’s [Link]

UNPLUG AND DISCONNECT. Don’t leave electric power tools plugged in when not in use,
when making adjustments such as replacing blades and bits, or loading [Link]

KEEP YOUR WORKSPACE CLEAN. A cluttered floor can lead to accidental trips or falls which
can be extremely dangerous when working with hand and power [Link]

TRAINED GET UP. Make sure you and your employees are thoroughly trained on the proper
use of hand and power tools required for the task at [Link]

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 Used hand tools and measuring instrument must be cleaned before returned back on
the proper storage. ok

 First aid kit in the Engine room are not expired ok

 Knowledge in firefighting (classes of fire and equipment to fight the fire)ok

 There must be proper ventilation and lighting in the workshop There must be proper
ventilation and lighting in the workshop
 ok

There are many instruments, tools, and gauges that are used on a daily basis
onboard ship for measurement, fault finding, wear down, etc.

Following are the essential tools, gauges, and mechanical instruments and their uses:

Ruler and scales

They are used to measure lengths and

other geometrical parameters. This tool is one of
the most famous measuring instruments in
mechanical engineering. They can be a single steel
plate or a flexible tape type tool. They are usually
available on a measuring scale of inch or [Link]

Calipers

They are usually of two types- inside and

outside caliper. They are used to measure the
internal and external size (e.g. diameter) of an
object. It requires an external scale to compare the
measured value. This tool is used on those surfaces
where a straight ruler scale cannot be used. After
measuring the body/ part, the opening of the caliper mouth is kept against the ruler to
measure the length or [Link]

Some calipers are integrated with a measuring scale; hence there is no need for
other measuring instruments to check the measured length. Other types are odd leg and
divider caliper

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Micrometer

It is an excellent precision tool that is

used to measure small parameters and is much
more accurate than the Vernier caliper. The
micrometer size can vary from small to large.
The large micrometer caliper is used to
measure large outside diameter or distance.
E.g. large micrometer is used as a special
mechanical measuring tool for the main engine to record the outer diameter of the piston
[Link]

They are available in two types- Inside micrometer (to measure inside diameter) and
Outside micrometer (for measuring outside diameter).
The Least count of the micrometer is 0.01 mm or 0.001cm. ok

Feeler gauge

Feeler gauges are a bunch of fine thickened steel strips of

different thickness bundled together. The thickness of each strip is
marked on the surface of the strip. The feeler gauge is used to
measure the clearance or gap width between surface and bearings.
E.g. the feeler gauge is widely used to measure piston ring
clearance, engine bearing cleaner, tappet clearance, [Link]

Telescopic Feeler Gauge

Similar to the functionality of the feeler

gauge, this type of gauge is also known as
tongue gauge, and it consists of a long feeler
gauge inside a cover with a tongue or curved
edge.

The long feeler strips protrude out of

the cover like a telescope so that it can be
inserted into remote places where feeler
gauge access is not possible. E.g. It is used to
measure the bearing clearance of the top shell.

It is essential that after the use of the telescope gauge, the strip should be cleaned
and retracted back to its housing, else it may damage the feeler [Link]
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Bridge Gauge

As the name suggests, Bridge gauge looks like bridge

carrying the measuring instrument at the center of the
bridge. They are used to measure the amount of wear of
Main engine bearing. Typically the upper bearing keep is
removed, and clearance is measured for the journal. A feeler
gauge or depth gauge can be used to complete the
[Link]

Liner Measurement Tool

A liner measurement tool is a special tool for

marine engines which comes in a set of the
straight rod of different marked length, which
can be assembled together to make the
measuring tool of the required length. It is
used to measure the wear down or increase
the diameter of the engine liner.

It is considered as special tools when

compared to other types of measuring tools and kept separately with other engine special
tools under chief engineer or 2nd engineer supervision.

American Wire Gauge

American wire gauge or AWG is a standard tool which is

circular and has various slots of different diameter in its
circumference. It is used to measure the cross section of
an electric cable or wire. This tool is usually kept in the

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electrical workshop of the ship, and electrical officer uses it for
measuring wire [Link]

Bore Gauge

A tool to accurately measure the diameter of any hole is

known as bore gauge, it can be a scale, dial or digital type
instrument. The most common type which is used on the ship
is dial type bore gauge, which comes with a dial gauge which
is attached to the shaft and replacement rods, also known as
measuring sleds, of different size to measure different hole dimensions. It is usually
calibrated in 0.001 inch (0.0025 cm) or 0.0001 inch (0.00025 cm)ok

Depth Gauge
A depth gauge is used to measure the depth of a slot, hole
or any other surface of an object. It can be of scale, dial or
digital type. The depth gauge can be a micrometre style
type a dial indicator type, or modified Vernier type tool,
which means the measuring base is fitted on the reading
scale of a micrometre, dial indicator or the Vernier scale.
.

Angle Plate or Tool

As the name suggests, this is a tool comprising of two flat

plates which are at a right angle to each other, and it is
used to measure the exact right angle of an object or two
objects joined together. This tool is usually kept in
workshop away from any tools or chemical which may
roughen the surface of the angle [Link]

Flat Plate

The flat plate or a surface plate is a precision flat surface

used to measure the flatness of an object when it is kept
over the flat plate acting as a reference. The flat plate is also
kept in a workshop in a secure location, and a wooden piece
is usually held on the top of the flat surface as the protective

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cover to safeguard the surface. Regular visual inspection and calibration need to be done to
check for wear, scoring etc. on the [Link]

Dial Gauge

The dial gauge is utilized in different tools as stated above and can
be separately used to measure the trueness of the circular object,
jumping off an object, etc. It consists of an indicator with the dial,
which is connected to the plunger carrying the contact point.
Oncethe contact point is kept in touch with an object (to be
measured), any unevenness or jumping will cause the plunger to
[Link]

The plunger is connected to the pointed in the dial. The dial is such attached that it does
not retract but swings in an arc around its hinge point to show the reading in the
[Link]

Lead Wire
It is a conventional method to use soft lead wire or
lead balls to measure the wear down or clearance
between two mating surfaces. The lead wire or balls
of fixed dimension (which is usually larger than the
expected clearance) are kept between two surfaces,
and both are tightened against each just as in normal
condition. The change in the width of the lead wire or
ball will show the clearance or wear down.

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Oil Gauging Tapes

Also known as sounding tapes, these are

special types of gauges only used to
measure the level of the fluid (HFO, DO,
Lubes, Water etc.) inside the ship’s tanks.
The sounding tapes can be of a mechanical
type where the tape is retracted in a coil
and connected to a heavy bob at the end.
The mechanical tapes are the most
commonly used in all dry ships, however, in
tankers ships, electronic sounding gauges,
and electrically powered servo type gauges,
ultrasonic type etc.

Seawater Hydrometer

A small glass instrument for measuring the density and

saturation of the salt in the seawater. This is an essential
tool for deck officers as the draft survey will be determined
using the water density to calculate the cargo weight for
loading. It is also used for ensuring compliance with the
load line survey.

Crankshaft Deflection Gauge

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A form of dial gauge specifically made to measure the crankshaft deflection of the marine
engine. The working is similar as explained in the dial gauge, the only difference is the
construction which let this tool hang between two webs allowing it to measure the deflection
when the crankshaft [Link]

Engine Peak Indicator

A measuring instrument for a marine engine with pressure
indicator dial used to measure the peak pressure generated
inside the engine cylinder. The pressure indicator dial is
connected to the blowdown valve located on the top of the
cylinder. There is a check valve provided before the indicator,
which when opens will the pressurised gases to continually
flow inside the indicator till it reaches the maximum value in
the dial.

Once the pressure is measured, an exhaust valve provided

on the side of the valve is opened which release the
pressurised gas from the instrument. It is an oil filled pressure
gauge instrument which helps in resisting the vibration and
also acts as good heat resistant

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Planimeter

An instrument which is used to measure areas of

irregularly shaped areas of an arbitrary two-
dimensional shape on plans or [Link]

COMMON HAND TOOL TYPES

1. SCREWDRIVERS:

are designed for loosening or tightening

screws. Screwdrivers

Driving a screw seems to be a very easy

operation to perform. However, without the
right screwdriver, good technique or safety
rules, it can sometimes become tricky or even
dangerous.

This simple family of tools forms the basis for nearly every maintenance,
repair and building project. Professional screwdrivers are manufactured to meet all
national and international standards. The range of use is versatile and includes all
industry.

1.2. Specific screwdrivers:

areas of maintenance and

Some screwdrivers have a specific design which

differs a little bit from that of basic screwdrivers.
We are now going to address the most common
types of screwdrivers.

This is the case, for example, of the “Hex. bolster screwdriver”, which is provided with a
hexagon bolster to enable a wrench to be used when extra torque is required (see next
figure).

See below: Hex. bolster screwdriver.

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Bolster screwdrivers can be used give added torque by using a
spanner to turn the shaft.

A hex screwdriver is a type of screwdriver that features a

hexagonal tip for driving certain nuts, bolts and screws. Hex
screwdrivers, like all types of screwdrivers, are available in an
extensive range of both standard and metric sizes.

Note:

When extra torque is required, a classical square-shank driver may also be used with a
wrench to gain added leverage.

Some screwdrivers have a specific design because they are meant for driving inaccessible screws or
working in tight or confined spaces. Let us mention the “offset screwdriver” which is a steel rod bent
at 90° at each end.

Offset screwdrivers

Offset screwdrivers generally feature a different tip at each end.

“Ratchet” screwdrivers (see below) have also a specific design: They are equipped with
a head which maintains the screw in position.

This type of screwdriver is particularly handy, as the

screwdriver tip does not have to be remove to drive the screw.

2.2. Conventional spanners:

Conventional wrenches are composed of a handle at both ends of which they feature
generally two different heads (or ends). spanner A wrench or spanner is a tool
Conventional used to provide grip and mechanical advantage in applying torque to turn
objects—usually rotary fasteners, such as nuts and bolts—or keep them from turning.

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These spanners are sometimes called “starter” spanners, as they work well on starters, or
“obstruction” spanners, as they can get around obstruction.

The half-moon wrench has different size openings at each end and has a curved
shank. The half-moon wrench is used when it is necessary to reach around objects
in tight spaces.

Cranked spanners have also a specific design. They have a

deep offset for reaching over many obstacles.

A wrench or spanner is a tool used to provide grip and mechanical

advantage in applying torque to turn objects—usually rotary
fasteners, such as nuts and bolts—or keep them from turning.

A socket wrench (or socket spanner) is a type of wrench

(spanner in British English) that inserts into a socket to turn a
fastener, typically in theform of a nut or bolt.

Hinged socket spanners are very handy.

The adjustable (crescent) spanner is a useful all-around spanner.

The usefulness comes from its capability of fitting odd-sized
nuts. One jaw of the adjustable open-end wrench is fixed and
the other one is moved along a slide by a thumbscrew
adjustment. By turning the thumbscrew, the jaw opening may
be adjusted to fit various size nuts. Crescent spanners come in
varying sizes. The size selected for a particular job is
dependent upon the size of nut or bolt head to which the
spanner is to be applied. The direction of use for a crescent
wrench is important. Using the wrench in the wrong direction

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will place too much pressure on the adjustable jaws and will cause the wrench to wear out
prematurely or [Link]

An adjustable spanner or adjustable wrench is an open-end wrench with a movable jaw, allowing
it to be used with different sizes of fastener head (nut, bolt, etc.) rather than just one fastener
size, as with a conventional fixed spanner.

Professional pliers are manufactured to meet all national and international standards.

a) Gripping pliers:

Needle nose pliers have very narrow pointed

jaws, as their name suggests. The jaws, when
serrated, are lined with very fine teeth or ridges.

.Gripping pliers whose jaws are connected at

a sliding pivot, permitting them to be temporarily locked in a fixed position for ease
in grasping and turning nuts.

Needle nose pliers are suited for twisting and

bending light to medium wire, for working on delicate
components, and for doing similar light jobs in very
tight places. Special care must be taken not to use
needle nose pliers on heavy wire or large objects for
which they are not designed. As shown in next figure,
some needle nose pliers can have partially cutting
jaws.

- Needle nose pliers definition is - pliers with long slender jaws used for
grasping small or thin objects

Channel lock pliers suit for gripping objects of various sizes while keeping
their jaws practically parallel.

Channel lock pliers are available with both

serrated and non-serrated jaws. Those with non-
serrated jaws were once called water pump pliers;
the primary function was to grip opposite flats of
gland follower nuts on water pumps so that the
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nuts could be tightened or loosened. Although they are not often used for this
purpose today, smooth-jawed channel lock pliers still exist as a useful tool for
gripping unusual size nuts, bolts, and other objects.

Channel lock pliers are a set of pliers that have an angled head where
one handle slides to adjust the size of the opening used to pinch and grab
without affecting the distance between the handles.

b) Cutting pliers

Diagonal cutting pliers, often called dikes, are used

for cutting light material, such as wire and cotter pins, in
areas which are inaccessible to larger cutting [Link]
:

c) Combination pliers

Combination pliers are called such because they

can perform a combination of jobs. They are most
typically used for gripping,compressing,bending
twisting, extracting and cutting various materials.

Combination pliers

Wire cutters are commonly used to cut copper,

brass, iron, aluminum, and steel wire. Some wire
cutters have insulated handles which ensure that you
will not get shocked from the wires you're working
with. Diagonal cutters have intersecting jaws that cut
the wire at an angle, leaving a flat tip.

So called because they are a combination of gripping and cutting

pliers. Often called engineer's pliers, or, if insulated, electrician's
pliers, they are strongly made with flat serrated jaws for gripping
flat surfaces and a rounded section in the jaws for gripping tubes
and pipes. Behind the gripping section of the jaw are the cutters.
Also included in the main body of the pliers is a wire cropper for
cutting thin wire and cable.

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Linesman pliers and combination pliers, or side-cutting pliers are a type of pliers used by
linemen, electricians, and other tradesmen primarily for gripping, twisting, bending and cutting
wire, cable and small metalwork components.

4. HAMMERS AND MALLETS:

The tool nearly everyone buys first is a

hammer. And because hammers are so common, it's
easy to take them for granted--after all, what could
be simpler than pounding nails? Like most tools,
though, there's more here than meets the eye-both
in the tool's design and its use.

Hammer a tool with a heavy metal head mounted atright

angles at the end of a handle, used for jobs such as breaking
things and driving in nails.

A mallet is a kind of hammer, often made of rubber or

sometimes wood, that is smaller than a maul or beetle, and
Mallet
usually has a relatively large head.

5. Files:

There is a large variety of files available for use. They can be

used to sharpen shears, remove burrs, or mark or shape
[Link] proper use and care of files makes for a better and
safer job.

b. Files are hardened steel tools used in cutting, removing, smoothing, and/or polishing of metal.
The major parts of a file, shown in Figure, are the tang, heel, face, edge,
and [Link]

6. C-Clamps:

a tool with a heavy metal head mounted at right angles at the end of a handle,
used for jobs such as breaking things and driving in nails.

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1) Protective Clothing: Protective clothing is a coverall

which protects the body of the crew member from
hazardous substance like hot oil, water, welding spark
etc. It is popularly known as “dangri “or “boiler suit”.

2) Helmet: The most important part of the human

body is the head. It needs utmost protection which is
provided by a hard plastic helmet on the ship. A chin
strap is also provided with the helmet which keeps
the helmet on place when there is a trip or fall.

3) Safety Shoes: Maximum of the internal space of

the ship is utilized by cargo and machinery, which is
made of hard metal and which make it clumsy for
crew to walk around. Safety shoes ensure that
nothing happens to the crew member’s feet while
working or walking onboard.

4) Safety Hand gloves: Different types of hand gloves

are provided onboard ship. All these are used in
operations wherein it becomes imperative to protect
ones hands. Some of the gloves provided are heat
resistant gloves to work on hot surface, cotton gloves for normal operation, welding gloves,
chemical gloves etc.

5) Goggles: Eyes are the most sensitive part of the human body and in daily operations on
ship chances are very high for having an eye injury. Protective glass or goggles are used for
eye protection, whereas welding goggles are used for welding operation which protects the
eyes from high intensity spark.

6) Ear Muff/plug: Engine room of the ship produces 110-120 db of sound which is very high
for human ears. Even few minutes of exposure can lead to head ache, irritation and
sometimes partial or full hearing loss. An ear muff or ear plug is used on board ship which
dampens the noise to a bearable decibel value.

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7) Safety harness: Routine ship operation includes maintenance and painting of high and
elevated surfaces which require crew members to reach areas that are not easily accessible.
To avoid a fall from such heightened area, safety harness is used. Safety harness is donned
by the operator at one end and tied at a strong point on the other [Link]

8) Face mask: Working on insulation surface, painting or carbon cleaning involves minor
hazardous particles which are harmful for human body if inhaled directly. To avoid this, face
mask are provided which acts as shield from hazardous [Link]

 9) Chemical suit: Use of chemicals onboard ship is very frequent and some chemicals
are very dangerous when they come in direct contact with human skin. A chemical
suit is worn to avoid such situations. thermometer (preferably digital)
ok

10) Welding shield: Welding is a very common operation onboard ship for structural repairs.
A welder is provided with welding shield or mask which protects the eyes from coming in
direct contact with ultraviolet rays of the spark of the weld.
First Aid kit cabinet
A basic first aid kit may contain:
 plasters in a variety of different sizes and shapes
 small, medium and large sterile gauze dressing
 at least 2 sterile eye dressings
 triangular bandage
 crêpe rolled bandage
 safety pins
 disposable sterile gloves
 tweezers
 scissors
 alcohol-free cleansing wipes
 sticky tape
 thermometer (preferably digital)
 skin rash cream, such as hydrocortisone or calendula
 cream or spray to relieve insect bites and stings
 antiseptic cream
 painkillers such as paracetamol (or infant paracetamol for children), aspirin (not to
be given to children under 16), or ibuprofen
 cough medicine
 antihistamine cream or tablets
 distilled water for cleaning wounds
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 eye wash and eye bath
It may also be useful to keep a basic first aid manual or instruction booklet with your
first aid kit.
Medicines should be checked regularly to make sure they're within their use-by [Link]
Fire extinguishers are designed to tackle specific types of fire. There are six different classes of fire
and several different types of fire extinguishers.

Classes of fire

 Class A - fires involving solid materials such as wood, paper or textiles.

 Class B - fires involving flammable liquids such as petrol, diesel or oils.
 Class C - fires involving gases.
 Class D - fires involving metals.
 Class E - fires involving live electrical apparatus. (Technically ‘Class E’ doesn’t exists
however this is used for convenience here)
 Class E fires are fuelled by electrical appliances such as TVs, computers and hair
dryers. The appropriate extinguishers used to tackle a class E fire include CO2 gas
or a dry powder extinguisher.
 Class F - fires involving cooking oils such as in deep-fat fryers.
 Class F fires are fires which involve cooking oil or fat. ... Whereas flammable liquids,
such as petrol, usually have low flash and auto ignition temperatures, cooking oil or
fats require temperatures in excess of 340°C to ignite.

Types of extinguishers

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Water extinguishers

Water extinguishers are one of the most cost-effective ways to fight Class A fires,
those fueled by solid materials such as paper, wood and textiles.

There are four different types of water extinguishers: water jet, water spray, water with
additives and water mist or fog.

 Water jet extinguishers work by spraying a jet of water at the burning materials,
cooling them and preventing re-ignition. They should not be used on live electrical
[Link]
 Water spray extinguishers use a very fine spray of water droplets, each droplet is
surrounded by air which is non-conductive. Most water spray fire extinguishers carry
a 35 kV dielectric test approval which means they have been tested on a 35,000 Volt
electrical source at one [Link]
 Water extisinguhers with additives are water extinguishers with foaming chemicals
added. The water loses its natural surface tension meaning that it can soak into the
burning materials more effectively. Adding the chemicals to the water means that a
smaller extinguisher can produce the same fire rating as a larger, water only,
[Link]
 Water mist, or fog, extinguishers apply Water spray extinguishers use a very fine
spray of water droplets, each droplet is surrounded by air which is non-conductive.
Most water spray fire extinguishers carry a 35 kV dielectric test approval which
means they have been tested on a 35,000 Volt electrical source at one meter.
 water in the form of mist, or fog, the droplets are much smaller than those from the
water spray extinguisher. The smaller the droplet, the larger its surface area in
relation to its size, the quicker the droplet evaporates which absorbs the heat energy
faster. The downside is the smaller the droplet the less it weighs and therefore the
less powerful the cloud of water. ok

All water extinguishers have a red label.

Foam extinguishers

Foam fire extinguishers can be used on Class A and B fires. They are most suited to
extinguishing liquid fires such as petrol or diesel and are more versatile than water jet extinguishers
because they can also be used on solids such as wood and paper. The foam extinguishes liquid fires
by sealing the surface of the liquid, preventing flammable vapour reaching the air and starving the
fire of fuel. They are not suitable for use on free flowing liquid [Link]
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Foam extinguishers have a cream label.

Powder extinguishers

Powder extinguishers are a good multi-purpose fire extinguisher because they can be used on
Class A, B and C fires. They can also be used on fires involving electrical equipment however,
they do not cool the fire so it can re-ignite. Powder extinguishers can also create a loss of
visibility and may create breathing problems. They are not generally recommended for use
inside buildings unless there is absolutely no alternative. ok

Powder extinguishers have a blue label.

Carbon dioxide extinguishers (CO₂)

CO₂ extinguishers are ideal for places with a lot of electrical equipment such as
offices or server rooms because they are safe to use on fires involving electrical apparatus.
Carbon dioxide extinguishers do not leave any residue, unlike a foam extinguisher. They can
also be used on Class B fires, those involving flammable liquids such paraffin or petrol. CO₂
extinguishers work by smothering the fire and cutting off the supply of air.
Carbon Dioxide Extinguishers (CO₂) have a black label. Foam fire extinguishers ok

Wet chemical extinguishers

Wet chemical extinguishers are suitable for use on Class F fires involving cooking oils
and fats, such as lard, olive oil, sunflower oil, maize oil and butter. They are extremely
effective, when used correctly. The wet chemical rapidly knocks the flames out, cools the
burning oil and chemically reacts to form a soap-like solution, sealing the surface and
preventing re-ignition. Although they are primarily designed for use on Class F fires, cooking
oils and deep fat fryers. They can also be used on Class A fires (wood, paper and fabrics)
and Class B fires (flammable liquids).
Wet chemical extinguishers have a yellow [Link]

Fire blankets

Fire blankets are primarily for use on hot oil fires such as frying pans or small deep
fat fryers. They can also be used on someone whose clothing has caught fire. They work by
smothering the fire, stopping access to the oxygen fueling it and extinguishing it. ok

Lighting and Ventilation in the Engine room workshop

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Lighting is an important factor when providing a safe working environment. The
lighting needs to be reliable and the luminaires must achieve a certain level of light. But
there is more to it than evenness and light level, the crew should feel comfortable in their
working environment and stay concentrated while working. The crew in the engine room are
working without daylight, therefore the light quality is very important.0k
The system of E/R Ventilation which we are using on the board ship is that of forced
ventilation.
The forced ventilation is carried out by means of a fan which is driven by electric
motor (usually three phase). The purpose of utilizing three phase fan is because it can be
rotated clockwise or counterclockwise by changing two phases (usually by magnetic
contactor, combination of relay and timer).
The heat which is produced by the various machinery such as the main engine, aux.
generators, boiler, pumps, motors, incandescent lights, fluorescent lights, and other
ancillaries’ things adds on to produce the overall heating effect and raising the temperature
inside the engine room. In replacement cool air replaces the warm air thus maintaining
balance. ok
During voyage and in harbor it is necessary to keep good ventilation in our engine
room, which will result in good efficiencies of machinery in the engine room.
Also it helps us to lower the ambient temperature (temperature of surroundings) of
the engine room. Thus maintaining a good working atmosphere inside the engine room.
The other purpose of this forced ventilation system is to provide air in case of turbo
blower and turbocharger failure for the natural aspiration of Main Engine and in case of total
flooding of Engine Room (E/R) the vent is used in reverse to remove carbon dioxide from
the engine [Link]

References

T1 – 3G E – Learning FL LLC. (2016). Diesel power plant operation and maintenance: intermediate
UAE. 3G E – Learning.
[Link]
q=what+is+safety&rlz=1C1CHBD_enPH902PH902&oq=what+is+safety&aqs=chrome..69i57l2j69i59l2j
69i60l2j69i61j69i60.2621j0j7&sourceid=chrome&ie=UTF-8
[Link]
[Link]
on-ships/[Link]
[Link]
[Link]
onboard-ship/
[Link]
q=1ST+AID+KIT+CABINET&tbm=isch&ved=2ahUKEwi9_9eE9MvpAhUHXZQKHSLYCSQQ2-
cCegQIABAA
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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

[Link]
in-my-first-aid-kit/
[Link]
[Link]
[Link]

Checkpoint

Activity 1

1. Draw crankshaft deflection gauge including the meaning and purposes

Do this

Activity 2

Explain in your own words on how to perform an emergency repair of a leaking sea water
pipe and materials to be used in not less than 50 words.

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

Assessment
Multiple Choices: Choose the correct letter that corresponds to the correct answer.

1. When carrying out emergency / temporary repair, the following safety measures
must be observed:
A. Secure work permits
B. Safety gears must be worn in the time of repairs
C. Isolate shipboard machinery involve in the repair
D. Conduct work procedures instruction and safety meeting
2. It is considered as every ones utmost responsibility, in accomplishment of task,
maintenance services, operation of machinery where correct usage and proper
maintenance if tools is a must

A. Ability C. Performance
B. Cleanliness D. Safety

3. The following practice of using hand tools can ensure personal safety and must be
observe in the workshop.
A. Use a screw driver as a screw driver
B. Use a screw driver as a chisel
C. Use a screw driver as a hammer
D. Use a screw driver as a puncher
4. What is the purpose and importance of a well-organized work shop?
A. Safe working environment
B. Happy working environment
C. Relaxed working environment
D. Comfortable working environment
5. Which of the following measures you will follow to ensure safety and to avoid
accident when using hand tools or measuring tools?
A. Safety awareness policy
B. Measuring tools in good order
C. Trained and discipline personnel
D. Surroundings is well lighted and surrounding clean
6. Proper use of tools enables successful completion of the task. This tool used to hold
pieces of material together while they being worked on.
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Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

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A. Adjustable wrench C. Socket wrenches
B. Clamps D. Vises

7. Which of the following tool is specially designed for exerting a twisting strain in
turning hexagonal – bolts and nuts?

A. Adjustable wrench C. Hammer

B. Clamps D. Wrenches

8. What type of extinguisher that is suitable for electrical fires and moderately effective
for Class B fires?

A. CO2 C. Foam
B. Dry powder D. Wet chemical

9. They are required to be placed in the work shop and all work places; usually marked
with a white cross, containing the basic first aid kit.

A. First aid box or cabinet C. Medicine box

B. Emergency kit box D. Surgical box

10. What is the purpose of ventilation system in the workshop?

A. Make the workshop clean
B. Make the workshop cool
C. Extract harmful substance in the workshop
D. Improved good house keeping

Lesson 5

Learning Module 5 Mechanical Knowledge and Skills (2 hours)

Competence, Course Outcomes and Learning Outcomes

Competence:

A-III/2. F3. C2: Detect and identify the cause of machinery malfunctions and
correct faults
A-III/2. F3. C3: Ensure safe working practices

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

A-III/1. F3.C1: Manage the safe and effective maintenance and repair
procedure
A-III/2. F3.C3: Ensure safe working practices

Course Outcome/s:

Differentiate the various type of maintenance

Develop a planned maintenance system for a specific shipboard machinery based on
manufacturers manual

Learning Outcomes:

At the end of the lesson, the student must be able to:

5.1 Discuss the content relevant to the maintenance of certain shipboard machinery
in manufacturers manual
5.2 Determine the factors to consider when planning a maintenance system in
certain machinery to avoid disastrous effects

Overview

Mechanical knowledge and skills of repairing and maintaining equipment

This is skilled mechanical work at the full performance level in the maintenance
and repair of a variety of mechanical equipment in a large City facility or several
facilities. An employee in this class utilizes mechanical trade skills in the maintenance
and repair of machinery and related equipment including, but not limited to
generators, motors, pumps, compressors, fans and valves. Work also includes
performing other basic trade tasks as assigned such as routine plumbing and electrical
work. Employee’s service equipment breakdowns in environments such as offices,
storerooms, basements, roofs, laboratories, laundry, pool, airport and patient care
areas. Significant to the work is inspecting and diagnosing malfunctioning mechanical
equipment to determine equipment problems. Work involves some disagreeable
aspects and physical effort. Employees report to a higher level maintenance
[Link]

TYPES OF MAINTENANCE
Companies (SMEs as well as large groups) know how their productivity
partly depends on their industrial maintenance processes. Five types of
maintenance are in fact recurrent in the industry: corrective, preventive, condition-
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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

based, predictive and predetermined. These concepts are not always easy to
understand or are not well-known by certain people, that’s why they need to be
cleared up. Each company has very precise needs and therefore has to implement
a specific type of [Link]

Discussion

Types of maintenance 1 - Corrective maintenance

Corrective maintenance is implemented right after a defect has been

detected on a piece of equipment or a production line: its objective is to make the
piece of equipment work normally again, so that it can perform its assigned
function. Corrective maintenance can either be planned or unplanned depending on
whether or not a maintenance plan has been created. OK

Type of maintenance 2 - Predetermined maintenance

Predetermined maintenance, probably the less known one of all the

maintenance types presented in this article, doesn’t rely on the actual equipment’s
state but rather on the programs delivered by manufacturers. They elaborate on
these programs based on their knowledge of failure mechanisms as well as on
MTTF (mean time to failure) statistics which they observed on a piece of equipment
and its various components in the past. OK

Type of maintenance 3 - Condition-based maintenance

Among all types of maintenance cited above, condition-based maintenance

is the most complicated to implement. It aims to prevent failures and requires
regular check-ups of the state, the efficiency as well as other indicators of the
system. All this data can be gathered automatically on the field or remotely thanks
to a direct network connection to the equipment, in order to make sure that it is
constantly controlled. Maintenance teams can decide whether they want to operate
constant or regular interval control: they read counters, check parts’ wear, control
motors’ temperatures… These are all actions the teams can undertake to ensure
that no piece will cause a breakdown that would damage the whole production line .
OK

Type of maintenance 4 - Preventive maintenance

Preventive maintenance is applied by the technician’s teams and managers

before any breakdown or failure occurs. Its aim is to reduce the probability of

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

breakdown or degradation of a piece of equipment, component, or spare part. In
order to implement such maintenance, teams have to take the part’s history into
consideration and keep track of the past failures. They are therefore able to
identify the time ranges during which a piece of equipment might break [Link]

Type of maintenance 5 - Towards predictive maintenance

A next-gen CMMS like Mobility Work, a solution that offers a performing

analytics tool able to gather all the data entered by maintenance teams
themselves, aims to progressively help plants evolve towards predictive
maintenance. It allows technicians to anticipate breakdowns: they generate reports
directly in their maintenance management software, they know when a piece of
equipment might break down and therefore proceed to industrial maintenance
operations. Once again, the most important thing is anticipation because any
failure could slow down production and become extremely costly. Predictive
maintenance can be implemented thanks to an intuitive and easy to use CMMS,
which will ease industrial maintenance technicians’ lives and generate tables and
graphs for them thanks to all the data entered by all their [Link]

REQUIRED KNOWLEDGE, SKILLS AND ABILITIES

KNOWLEDGE OF SKILL IN ABILITY TO

• The methods, practices, • The maintenance and repair • diagnose and repair
materials, and tools used of machinery and malfunctioning
in the maintenance of equipment including but machinery and related
machinery and not limited to generators, mechanical equipment
mechanical equipment motors, pumps, and • recognize possible
including, but not limited valves hazardous materials
to generators, motors, • The use and care of tools • give instructions to a group
pumps, refrigeration and equipment used in of skilled and semi-skilled
units, auxiliary diesel the maintenance and workers
generators, fans, repair of various • understand and follow oral
compressors, conveyor machinery and and written instructions
belts, and related mechanical equipment • learn the utilization of
mechanical equipment OK computerized controls on
• The methods, practices, various mechanical
materials and tools used systems and CRT and
in performing various keyboard equipment for
routine trade tasks, such diagnostic and systems
as basic plumbing and control purposes
electrical repairs and • read and interpret
maintenance schematics, blueprints

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

• The occupational hazards and sketches
and safety precautions • make estimates of time and
apparent in the repair of materials
machinery and related • identify possible hazardous
mechanical equipment materials such as
OK asbestos insulation of
P.C.B.'s OK

The position must perform skilled mechanical maintenance work on a variety of

facility machinery and related equipment components.

TYPICAL EXAMPLES OF WORK (ILLUSTRATIVE ONLY)

Regularly perform inspection, maintenance, diagnosing, and servicing of a

variety of mechanical equipment such as, but not limited to, circulation and sump
pumps, refrigeration units, auxiliary diesel generators, fans, air filters bearings,
universal joints, compressors, pumps, conveyor belts, and similar mechanical
equipment; performs preventive and corrective maintenance on machinery including
components of dishwashers, ovens, gas ranges, freezers, automatic doors, laundry
equipment, and steam coolers. uses computerized controls on various mechanical
systems and keyboard equipment for diagnostic and systems control [Link]

Lubricates and cleans equipment components, replaces worn parts, and adjusts and
aligns parts as necessary; disassembles machinery and equipment and inspects component
parts for wear or damage; overhauls machinery and equipment where needed; adjusts
tension and clearance on conveyors and power drive units; reassembles machinery and
equipment assuming proper alignment; determines causes of equipment problems and
performs subsequent repair [Link]

Dismantles or partially dismantles electric motors; disconnects coupling from motors

removes inspection plates, disconnects pipes and removes suction plates; reassembles unit
using hand tools and checks completed work for proper [Link]

Cuts, threads, and installs copper, terra cotta, concrete, or galvanized pipe; installs
plumbing fixtures and makes repairs or adjustments to component mechanisms; performs
various repair and maintenance work on components of sinks, toilets, and [Link]
Performs other trades tasks as assigned including routine painting, plastering, cement
finishing, roofing, electrical and similar [Link]
Repairs a variety of firefighting equipment and brass, steel, and copper fixtures from
fire apparatus; maintains and operates air system supplying air [Link]
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STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

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Erects scaffolding to provide access to work areas and works from heights; uses block
and tackle, slings, hydraulic jacks to support or move machinery.
Gives general or detailed instructions to semi-skilled or unskilled workers; reviews
work in progress and on completion.
Performs routine welding tasks in connection with regular maintenance mechanic
work.
Prepares routine reports on work projects and estimates of labor, time, and
materials; prepares and places orders for replacement parts required for repairs from specified
vendors.
Operators and utilizes automated building control systems, such as HVAC and fire and
security alarm systems as assigned.
Identifies possible hazardous materials such as asbestos insulation and P.C.B.'s;
informs supervisors of the presence of possibly hazardous materials.
Performed related work as required. ok

Maintenance of certain shipboard machinery in the manufacturers manual

operate the ship and its equipment. A technical manual is an essential part of the product
and its usability has considerable importance for the ship operators. Accordingly, the
provision
A shipboard technical manual is a generic term for any document that
explains how to use, maintain, and of suitable shipboard manuals should be
recognized as a major responsibility area.
“Information should be accurate and complete. The text should be clear and concise.
Sentences should be as short and simple as the subject allows. Paragraphs should be
short. Technical descriptions should be system or function-based. Instructions should
be procedure [Link]

The information should be organized in a hierarchical and consistent manner by

the use of headings. Step numbering should be used to support the structuring into
levels of information. Illustrations (photo, drawings, and graphs) should be used to
support information and instruction text”.ok
SHIPBOARD TECHNICAL OPERATING AND MAINTENANCE MANUALS
1. The Maritime Safety Committee, at its eighty-third session (3-12 October 2007),
considered the recommendation that the attention of all relevant stakeholders
needs to be drawn to the importance of ships crews having access to up-to-
date, accurate and user-friendly shipboard technical operating and maintenance
manuals, particularly for safety-critical marine [Link]
2. The Committee noted that there exists a global and competitive marketplace for
marine equipment and that seafarers were expected to assimilate different
equipment fitted onboard quickly and operate them efficiently. Also, seafarers

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

were expected to be able to move from ship to ship with few restrictions; this
flexibility being essential for the efficient management of human resources.
Consequently, seafarers are likely to encounter a wide variety of equipment
fitted [Link]
3. The Committee also noted that the availability onboard ships of up-to-date and
accurate operating and maintenance manuals could be enforced via the
implementation and enforcement mechanisms of the International Safety
Management (ISM) Code ok
4. The Committee further noted IACS Recommendation No.71 (dated September
2000) Guide for the development of shipboard technical manuals and agreed
that this Guide provided a useful reference for those responsible for developing
such [Link]
5. In light of the foregoing, Member Governments are invited to:
 Recognize the necessity for up-to-date, accurate, and user-friendly
shipboard technical operating and maintenance manuals to be available
on board ships;ok
 Recommend that IACS Recommendation No.71 is used as a model for
shipboard technical operating and maintenance manuals;
 Recommend that shipboard technical operating and maintenance
manuals should be provided in the working language of the ship and if
the working language is not English, French or Spanish, a translation
into English, or French, or Spanish should be provided; and ok
 Encourage ship designers and shipbuilders to provide diagrams and
drawings explaining the operation of integrated ship systems as well as
emergency operation of such ship systems, recognizing that ship
systems may be composed of several individual pieces of equipment,
And bring the above to the attention of ship owners, ship masters,
shipbuilders, recognized organizations, and, in particular, manufacturers
of equipment for safety-critical marine [Link]
Shipping Companies and Managers

There is ample support through the ISM Code and ISO 9000 standards and, for British
flag vessels, the Code of Safe Working Practice for Merchant Seaman, for owners to
demand in their purchase orders that supporting documentation in plain English must
be provided before delivery is [Link]

When apportioning accountability for this work:

 Manufacturers are responsible to provide written procedures, in plain English. It
is not appropriate to pass poor documentation to the seafarer/operator and
expect compliant standards of [Link]

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Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

 Ship managers should ensure that the provision of operation and maintenance
manuals in accordance with IMO MSC.1/Circ.1253 is included in the delivery
specification and check that they have been provided in accordance with the
delivery contract. Application of a Management of Change (MOC) process during
any fleet addition or change of equipment is an extremely useful tool; this
should include the transfer of documentation when receiving a new vessel
and/or [Link]
It is important to ensure all manuals reflect the current needs for the operation and
maintenance of the ship and equipment. The ship manager should consult their
Classification Society if there is a need for deviation from equipment manufacturers’
instructions. In all cases where there are significant changes, the seagoing staff should
be consulted for feedback prior to the implementation of the proposed [Link]
Shipping Companies and Manager
There is ample support through the ISM Code and ISO 9000 standards and, for British
flag vessels, the Code of Safe Working Practice for Merchant Seaman, for owners to
demand in their purchase orders that supporting documentation in plain English must
be provided before delivery is [Link]

When apportioning accountability for this work:

 Manufacturers are responsible to provide written procedures, in plain English. It
is not appropriate to pass poor documentation to the seafarer/operator and
expect compliant standards of [Link]
 Ship managers should ensure that the provision of operation and maintenance
manuals in accordance with IMO MSC.1/Circ.1253 is included in the delivery
specification and check that they have been provided in accordance with the
delivery contract. Application of a Management of Change (MOC) process during
any fleet addition or change of equipment is an extremely useful tool; this
should include the transfer of documentation when receiving a new vessel
and/or [Link]
 It is important to ensure all manuals reflect the current needs for the operation
and maintenance of the ship and equipment. The ship manager should consult
their Classification Society if there is a need for deviation from equipment
manufacturers’ instructions. In all cases where there are significant changes,
the seagoing staff should be consulted for feedback prior to the implementation
of the proposed [Link]

Planned maintenance system on ships (PMS)

A planned maintenance system allows ship owners and operators to plan,
perform, and document vessel maintenance at intervals complying with Class and
manufacturer requirements. The objective is to ensure safe and reliable vessel
operations, including equipment, in addition to compliance with all applicable

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

regulations. There are different ways of achieving this, depending on the size and
complexity of the shipping company and the types of vessels in operation. In all
cases, a systematic approach to maintenance is based on risk assessment and
begins with the establishment of a complete database of machinery, equipment,
and [Link]
A planned maintenance system on ships is mandatory according to the
International Safety Management Code (ISM). An effective planned maintenance
system not only helps meet safety and environmental objectives laid out in the
ISM Code, but it is also an investment in the protection of the assets and
optimization of their [Link]
Planned maintenance system implementation support
A ship management system implementation involves capturing and
migration of data from many sources, and it is crucial to have access to domain
expertise and best practice from previous implementations to secure the value of
your data, achieve success, and maximize return on [Link]

Technical ship management system

Ship Manager Technical is the technical ship management system for both
planned and unplanned maintenance, defect reporting, and technical asset and data
management. A planned maintenance system streamlines the planning,
documentation,and implementation of maintenance work and surveys onboard [Link]
Modularized fleet management system for ships

Ship Manager is comprised of individual modules or a complete ship

management system that will cover the full range of ship management needs.
Ship Manager Technical is normally combined with other modules, for
example, shipping procurement, ship safety management system, crew
management system, hull integrity management , and shipping data
analytics (business intelligence). An integrated solution provided the insight that is
needed to gain efficiency, reduce Opex, and remain competitive in the maritime
[Link]

With Ship Manager Technical PMS software you can benefit from:
 Optimization of vessel maintenance management
 Central management of your fleet-wide equipment and maintenance jobs
 Provide all information for powerful, fleet-wide management reporting via Ship
Manager Analyzer

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ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

 Easy-to-use common user interface between ship and shore, improving
communication
 Prepare and document all planned and unplanned maintenance tasks
 Define and schedule counter-/calendar-based and condition-based tasks
 Categorize jobs and elements according to relevant criteria, such as critical,
safety-relevant, class relevant, or origin
 Keep an automatic update of stock counts in consideration of spare parts
consumed for maintenance task
 Keep lifecycle records of each equipment
 Defect management
 Exchange equipment for maintenance and overhaul without losing relevant
information
 Have central task lists for onboard engineers and technical office staff
 Integrate with other Ship Manager software modules
 DNV GL's implementation team with extensive ship management expertise. ok

Today, there is a minimum requirement that one Planned Maintenance

 English language.
 Reports in the Planned Maintenance system should be in English, except when not
suitable for the crew. In that case, a brief English summary is required.
 Planned Maintenance program must include equipment manufacturer requirements.
 Inventory content, i.e. items/systems have to be included in the maintenance
program.
 Maintenance time intervals, i.e. time intervals at which the maintenance jobs are to
take place.
 Maintenance instructions, i.e. maintenance procedures to be followed.
 Maintenance documentation and history, i.e. documents specifying maintenance
jobs carried out and their results.
 Reference documentation, i.e. performance results and measurements taken at
certain intervals for trend investigations from the delivery stage.
 Document flow chart, i.e. chart showing flow and filling of maintenance documents
as planning cards, job cards, [Link]

Signing instructions, i.e. system must contain:

 The description and documentation of the Planned Maintenance system are to be in
the who signs documents for verification of maintenance work carried [Link]
Example of a Planned Maintenance System (computer-based)

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Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
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10 August 2020 QMR President

Diesel Engine Planned Maintenance System

by keeping equipment running safely for as long as possible, without that
equipment deteriorating or having unplanned outages.

PLANNED MAINTENANCE

Planned maintenance is a proactive approach to maintenance in which

maintenance work is scheduled to take place regularly. The type of work to be done
and the frequency varies based on the equipment being maintained, and the
environment in which it is [Link]

The primary objective of planned maintenance is to maximize equipment

performance Planned maintenance activities include any maintenance work
scheduled in advance. For example, changing the oil in a vehicle because the oil light
came on is not planned maintenance. Changing the oil because the vehicle had gone
3,000 miles would be planned maintenance. Planned Maintenance is a scheduled
maintenance activity or service visit, that is done to ensure that the equipment, or
equipment components, are operating correctly and within the manufacturer's
recommendations.

Planned maintenance includes preventive maintenance tasks such as

checking oil levels when those tasks are [Link]
The schedule for planned maintenance tasks can be based on equipment
running hours, the number of items produced, distance traveled, or other
measurable [Link]

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Planned Maintenance - Using Computer Systems
Since planned
maintenance tasks are done
on a regular schedule, they
can be used to provide
information to feed a
computerized system that
tracks maintenance needs,
as well as being themselves
scheduled using a
computerized system.
However, remember that a
computer is only a place to
save information and
schedule tasks. It does not
design your planned
maintenance system nor
determine how to get the
work done .ok
Working with the
production department, and
at times a service
representative from the
manufacturer, equipment
maintenance that needs to be regularly scheduled should be identified and an
appropriate schedule developed. A method for measuring the effectiveness of the
planned maintenance work should also be designed so that the overall planned
maintenance system, as well as the individual tasks, can be evaluated.
One of the key goals of planned maintenance is to ensure the equipment
complies with specifications and to proactively identify potential performance
problems. The objective is to find and correct problems before they cause an
unscheduled outage.
Major Benefits of Planned Maintenance
The key benefit of planned maintenance is that the work can be scheduled in
ways such that it does not interfere with the overall production. This may mean
scheduling planned maintenance during times of the year when there is less demand
or doing maintenance at night when most of the facility is not operating.

Other direct benefits of planned maintenance include:

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 Reduces unplanned equipment downtime and improves overall equipment
performance.
 Repair costs are reduced because problems are fixed while they are minor.
 More efficient use of manpower and other resources because maintenance work,
parts inventory, tools, and financial costs, can be spread more evenly throughout
the year.
 Better planning of spare parts uses and ordering.
 Helping to ensure the manufacturer's requirements for warranty compliance are
met.
 Reducing overall maintenance costs.
 Centralizes maintenance and equipment management into one platform.
 Keeps consistent records of all maintenance tasks.
 Gives easy access to information needed for maintenance planning and reporting.
 Defines necessary tasks, whether based on condition monitoring, meter readings, or
calendar dates.
 Schedules necessary tasks as needed.
 Maintains up-to-date records on individual pieces of equipment.
 Keeps records of stock-counts for MRO [Link]
There are also a number of secondary benefits that come from using planned maintenance.
These include:
1. Improved workplace safety.
2. Procedures are established to plan the use of, monitor, and control maintenance
resources.
3. Improves communication between maintenance and operations.
4. Provides a daily plan for maintenance supervisors such that employees have a
full day of work every day.
5. Establishes a performance monitoring system that allows maintenance activities
to be better evaluated and [Link]

Implementing a Planned Maintenance System

As with any other major change, successful implementation of planned

maintenance requires the agreement and participation of everyone affected by the
timing and quality of maintenance. This includes the maintenance department,
production, safety, and possibly the instrument shop. Also, support from upper-level
management is needed to ensure the necessary resources to get planned
maintenance started are [Link]
Next, get suggestions from, and listen to those who are working with the
equipment. They'll be the most knowledgeable about its operation and its
[Link]
Consider making lean manufacturing techniques such as TPM (Total
Productive Maintenance), Kaizen, and 5S part of your planned maintenance
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[Link]
Make safety a part of establishing a planned maintenance system. When
evaluating equipment to determine the need for planned maintenance, also conduct
a Job Hazard Analysis. This will reveal potential hazards that can occur during
maintenance as well as bringing out safety issues that can develop during normal
[Link]

Department Responsibilities

While the production department will have a major voice in scheduling

planned maintenance, and if TPM is being used equipment operators may perform
some planned maintenance tasks, the bulk of the responsibility for planned
maintenance work will fall on the maintenance department. Besides, in cases in
which outside expertise is required, either manufacturer's field technicians or
qualified third-party service personnel will need to be a part of the planned
maintenance [Link]
The maintenance department's responsibilities might include:

 Training supervisors so they have the necessary skills and knowledge.

 Maintain a sufficient staffing level, without over-staffing, such that all planned
maintenance can be accomplished. Train maintenance workers so they are
competent to perform the required tasks.
 Ensure all work is done to the required specifications (including using appropriate
fluids and replacement parts).
 Inform the purchasing department about planned maintenance needs with sufficient
lead time to allow parts and supplies to be ordered on a normal basis.
 Track maintenance tasks, maintain records of the work that was done and ensure
work is done properly.
 Report on equipment problems noticed during planned maintenance so they can be
addressed during turnarounds or scheduled plant [Link]

The above list is only intended to provide some ideas. The staff in each facility is
organized differently, and there are different priorities. For example, part of the
maintenance department's responsibility might be to minimize staffing through
scheduling and judicious use of [Link]

References
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T1 – 3G E – Learning FL LLC (2016). Diesel power plant operation and maintenance:

Intermediate UAE. 3G E-Learning.
R7 - Osbourne, Alan. (1991). Modern marine engineer’s manual vol.2 2 nd ed. Maryland:
Cornell Maritime Press
[Link]
[Link]
management-shipmanager-technical-1509
[Link]
%20in%[Link]
[Link]
no-progress/
[Link]
[Link]
systems/
[Link]
[Link]
q=YANMAR+Planned+maintenance+system&rlz=1C1CHBD_enPH902PH902&sxsrf=ALeKk01
BcBmUqxZlh6k15iz-
AN7kNb9x6Q:1590374308343&tbm=isch&source=iu&ictx=1&fir=QSfukGxgE0XRkM%253A
%252CkQVYyoWwsE_9MM%252C_&vet=1&usg=AI4_-
kS0PkFjoXrOzdvuBg5FQ3JtGogaug&sa=X&ved=2ahUKEwj3p9X9_c3pAhUIIIgKHccPAFgQ9QE
wBnoECAoQBQ#imgrc=JJ7aNPBTJEAruM

Checkpoint
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Activity 1

Design a planned maintenance system for Auxiliary engine

Assessment

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Short Quiz
Multiple Choices: Choose the correct letter that corresponds to the correct answer.

1. When carrying out emergency / temporary repair, what safety measures must be
observed?
A. Secure work permits
B. Safety gears must be worn in the time of repairs
C. Isolate shipboard machinery involve in the repair
D. Conduct work procedures instruction and safety meeting
2. The following must be taken into account when carrying out shipboard maintenance
repair.
A. Interpret piping diagrams
B. Vessel diagram must be in place
C. Interpret machine drawings and handbooks
D. Use appropriate specialized tools and measuring instruments
3. What must be done before carrying out the repair maintenance of a cargo ballast
pump in the engine room?
A. Check and interpret fuel oil piping diagram
B. Check and interpret lube oil piping diagram
C. Check and interpret seawater piping diagram
D. Check and interpret the freshwater piping diagram
4. Choose the probable answer on how to carry out emergency / temporary repair
following your mechanical knowledge and skills?
A. Action is initiated as required for isolation
B. Damage or faulty equipment are identified
C. Damaged equipment components reported
D. Materials used to be recorded and report to the office
5. Which of the following is important before working on any task, confirmation of the
construction and components of machinery equipment with their drawings and
instruction books?
A. Familiarized with the equipment
B. Avoid maintenance problems
C. Prevent maintenance delay
D. To avoid accident

Lesson 6

Learning Module 6 Fastening (12 hours)

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Competence, Course Outcomes, and Learning Outcomes

Competence:

A-III/2. F3. C2: Detect and identify the cause of machinery malfunctions and correct
faults
A-III/2. F3. C3: Ensure safe working practices
A-III/1. F3.C1: Manage the safe and effective maintenance and repair
procedure
A-III/2. F3.C3: Ensure safe working practices

Course Outcome/s: Differentiate the various type of maintenance

Develop a planned maintenance system for specific shipboard machinery based on
manufacturers manual

Learning Outcomes: At the end of the lesson, the student must be able to:

1. Identifies types of threaded fastener

2. Tightened bolts or nuts correctly

Overview

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Fastener and its importance

Fasteners are the main components used in many sectors such as

automation, manufacturing, infrastructure, and others in which different types of
items are produced that require assembling of machinery or vehicle parts. At once
missing fastener may not be missed but is quite capable of leading to adverse
consequences. Especially in the age of assembly operations where a product is put
together by components manufactured at several different locations. A fastener can
be a special type of nail that has spirals on its side. These are used to make
substances rigid, long-lasting, and look clean as well. These features have led to the
popularity of fasteners which are available in different shapes and dimensions.
Varieties of fasteners are available at the market these days, each with a specific
purpose, made with different metals, non- ferrous and ferrous, and now even of
engineering [Link]

Discussion

Different types of threaded fastener

Fasteners are the mechanical components used to temporarily join two or

more objects. While there are other ways to join objects — welding, brazing,
adhesives, crimping, etc. — fasteners are often preferred because they can be easily
removed. Threaded fasteners are particularly effective at joining multiple objects due
to their threaded design. Featuring either internal or external screw threads,
threaded fasteners are easy to install and equally easy to [Link]
Fasteners come in many different forms. To make it easy for you, we’ve
compiled the data below as a guide for figuring out what each fastener is called.
Scroll down to learn about many different types of nuts, bolts, and screws! .ok
*Note: Bolts are fasteners that require a nut or pre-tapped hole to be
installed. Screws use their threads to provide their own holding power. The terms in
the industry are commonly mixed so sometimes you will see something that is called
a screw or a bolt that is actually the opposite. Example: Lag Bolts and Lag Screws
are the same things. We have them down according to their true definition. ok
Tightening of bolts and nuts

When tightening (torque) the cylinder-head bolts, the bolt force generates
the so-called surface pressure, which is essential for achieving a perfect seal.
Hereby, and in combination with the applied torque method, the bolts have a strong
effect on surface pressure quality.

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1) Screws
The most common type of threaded fastener is a screw. Screws consist of
cylindrical-shaped pieces of metal with a threaded surface wrapping around the
sides. On the top of a screw is ahead, which is used to drive the screw into an object
or workpiece. If a screw has a Phillips's head, for example, a Philips head screwdriver
orbit can be used to turn and install the screw. If a screw has a flat head, on the
other hand, a flat head screwdriver orbit can be used. ok

There are a variety of different screw types, some of which include the following:
 Machine screws
 Hex screws
 Lag screws
 Wood screws
 Drywall screws
 Concrete screws
 Self-tapping screws

2) Nuts
Another common type of threaded fastener is a nut. Consisting of a circular-
shaped piece of metal with a threaded interior surface, nuts are used in conjunction
with a bolt to join two or more objects together. The threaded interior of a nut
connects to the threaded exterior of a bolt. When the nut is turned, it will drive up or
down the bolt depending on the direction in which it’s [Link]

Although there are exceptions, most nuts feature a hexagonal exterior. The
interior is still cylindrical, though the exterior features a hexagonal shape to ease the
process of installation. With six sides, hexagonal nuts are easy to grip, allowing
workers to install or remove them with minimal effort. ok

3) Bolts
The third primary type of threaded fastener is a bolt. Some people assume
bolts and screws are the same, but this isn’t true. Bolts are used to join two or more
unthreaded objects, whereas screws are used to join two or more threaded objects.
Keep in mind that screws often create their own threads during installation.
Regardless, though, bolts are specifically designed to join unthreaded objects by
relying on a [Link]

As previously mentioned, nuts connect to bolts using their respective

threaded surface. The threaded exterior of a bolt acts as a track for the threaded
interior of a nut. ok

Types of Nuts and Bolts

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Fasteners come in many different forms. To make it easy for you, we’ve
compiled the data below as a guide for figuring out what each fastener is called.
Scroll down to learn about many different types of nuts, bolts, and screws!.ok

*Note: Bolts are fasteners that require a nut or pre-tapped hole to be installed. Screws use their
threads to provide their own holding power. The terms in the industry are commonly mixed so
sometimes you will see something that is called a screw or a bolt that is actually the opposite.
Example: Lag Bolts and Lag Screws are the same things. We have broken them down according to
their true definition. ok

Types of Bolts

Hex Head Bolts

Hex tap bolts, hex cap screws, trim head hex cap
screws, and hex serrated flange bolts fall under this category.
They share a hexagonal head and are driven with a wrench.
Referred to as both bolts and [Link]

Shoulder Bolts

Shoulder bolts (also known as shoulder screws or stripper

bolts) are machine screws with a shoulder between the thread of
the screw and the head of the part. Once installed, the non-
threaded portion extends out of the surface of the application
site, allowing the bolts to act as dowels or shafts for moving
parts. They can be installed by hand or with a socket (Allen) [Link]

Socket Cap Screws

Socket cap screws are available in button socket, button

flange socket head, flat socket, and socket cap. Driven with a
socket wrench or a hex Allen key. The term socket head cap
screw typically refers to a type of threaded fastener whose head diameter is
nominally 1.5 times or more than that of the screw shank diameter.

Socket Set "Grub" Screws

Set screws are most often headless (aka blind),

meaning that the screw is fully threaded and has no head.
A blind set screw, known in UK as a grub screw, is almost

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always driven with an internal wrenching drive, such as a hex Allen key. Socket set
screws are installed in threaded holes or inserts. ok

Square Head Bolts

Square Head Bolts are similar to hex cap screws but with a
4-sided head. This head style allows for a wrench to grip more
easily onto the head of the bolt. The head also provides a larger
gripping area as compared to a standard 6-sided hexagonal
[Link]

Types of Screws

Deck Screws

Our deck screws feature a type 17 point (notched point at

the tip) to aid in chip removal during thread cutting which allows for
easy installation in wood and composite deck materials. A bugle
head and square drive help to eliminate the stripping effect
sometimes experienced with other types of [Link]

Hex Lag Screws

Lag screws, also called lag bolts, are large wood screws.
The head is external hex and is driven with a wrench. Used for
lag together lumber for framing, machinery to wood floors, and
other heavy-duty [Link]
Sheet Metal Screws
Sheet metal screws (SMS) have sharp cutting threads that cut
into sheet metal, plastic, or wood. They have a fully threaded shank
and sometimes have a notched point at the tip to aid in chip removal
during thread cutting. ok

Wood Screws
Wood screws are partially threaded with large
cutting threads and a smooth shank. They are designed
to slide through the top piece of wood and tightly pull
all boards together. ok

Types of Nuts

The cap nut, also known as the acorn nut,

gets its name from its shape. The nut has a domed
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top to prevent contact with the external thread. ok

Castle Nuts
Used with cotter pins to prevent loosening, a
castellated nut,
also called a castle or slotted nut, is a not with slots cut into the
top. Used in low-torque applications such as holding a wheel
bearing in [Link]

Coupling Nuts
A coupling nut is a threaded fastener used for joining two
male threads, most commonly threaded rod. The outside of the
fastener is a hex so it can be driven with a [Link]

Flange Serrated Nuts

A flange nut is a nut that has a wide flange at one end

which acts as an integrated washer that does not move or
spin. The serrated flange distributes the pressure of the nut
over the part being secured and creates a locking action to
prevent loosening. ok

Hex Finish Nuts

Hex finish nuts are used for fastening to a hex cap
screw, socket cap screw, or bolt. The most common nuts, hex
finish nuts are hex-shaped with internal threads and driven with
a [Link]

Hex Jam Nuts

A jam nut is often used when a nut needs to be locked
in place without clamping to another object. Hex jam nuts are
hex-shaped with internal threads, but they are thinner than hex
finish nuts.

Heavy Hex Nuts

Larger, heavier, and thicker than a standard hex nut.
Heavy hex nuts are hex-shaped, internally threaded, and
driven with a wrench. Often used with hex cap screws and
carriage [Link]

Hex Machine Nuts

A machine nut is hex-shaped with internal threads.
Smaller than a hex jam or hex finish nut, they are used with
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machine screws under 1/4" [Link]

Hex Machine Nuts Small Pattern

A machine nut is hex shaped with internal threads.
Smaller than a hex jam or hex finish nut, they are used with
machine screws under 1/4" [Link]

Keps-K Lock Nuts

Also known as a keps nut, a k-nut or a washer nut, a
keeps-k lock nut has an attached free-spinning lock washer.
Keeps nuts are designed to make assembly more
[Link]
Knurled Thumb Nuts
A knurled head thumb nut or thumb nut has a
knurled outside surface rather than a hex, which facilitates
tightening by hand. Often used in decorative finishes or
[Link]

Nylon Hex Jam Nuts

A low-profile lock nut is hex-shaped, internally
threaded with a nylon insert. The nylon material prevents
loosening from vibration and cross threads to stop the nut
from backing off of the [Link]

Nylon Insert Lock Nuts

A nylon insert lock nut is hex-shaped, internally

threaded with a nylon insert. The nylon material prevents
loosening from vibration and cross threads to stop the
nut from backing off of the [Link]

Prevailing Torque Lock Nuts (Stover)

Commonly known as stover nuts, prevailing

torque lock nuts have chamfered corners and a conical
top. The distortion in the top threads resists loosening
from vibration. Also called one-way nuts, they can only
be installed one way and are often used in high-
temperature applications because they are all metal with no nylon
[Link]
Slotted Hex Nuts
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Slotted hex nuts are nuts with portions cut out designed to be used with a
cotter ping to create a locking mechanism. These nuts are similar to a castle nut but
have a lower profile which sometimes makes them a better [Link]

Square Nuts

A four-sided nut that may be flat or beveled on top.

Square nuts provide a greater surface contact area which
provides more resistance to loosening. Typically mated with
square head bolts.0k

Structural Heavy Hex Nuts

Structural hex nuts are comparable to finish nuts but are made to
be thicker and much stronger. They are typically used in steel to
steel structural connections.0k
T-Nuts
A t-nut or tee nut is used to fasten wood, particle
or composite board leaving a flush surface. A long thin body
with a flange at one end resembles a T in profile. T-nuts
often have 3 or 4 prongs that sink into the surface providing
better [Link]
Break Away or Shear Nuts
Shear nuts are cone nuts with a hexagonal gripping
point. They are designed with an intentional flaw to snap the
hexagonal head off once the maximum torque is reached.
Leaving behind a protective cone nut that cannot be easily
[Link]

Tri-Groove Nuts

Tri-groove security nuts have a tapered diameter

making them difficult to grip with grabbing devices such as
adjustable wrenches or pliers. These nuts require a spe cial
unconventional gripping device to install them making them
more secure than a typical nut. ok

Wing Nuts

Wingnuts are threaded nuts with wings on each side of the body
allowing for manual turning and installation. Easy hand assembly
and used when the nut needs to be removed often. ok

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A torque wrench is a tool used to tighten nuts and bolts to a predetermined

torque value. This instrument allows fasteners to be tightened to the proper tension,
helping avoid damage from over-tightening or joints coming apart from under-
tightening. This means applying the correct torque measure is important for the
safety, assembly, and performance of [Link]
These tools have been used since the early 20th century, having been
designed in 1918 by Conrad Bahr.

What are Torque Wrenches used for?

These tools are used for a variety of different tasks across many industries –
including home repairs and maintenance, automotive, and construction. ok

It’s important to always use this tool in applications where screws and bolts must be
secure and tight. These tools allow the user to measure the amount of pressure being
applied to fasteners, to ensure it matches the recommended specifications for the job. ok
In the automotive industry, for example, it’s paramount that the right amount of
torque is used for all fasteners on a vehicle, to protect the safety of everyone who comes
into contact with it. ok

Different types and their uses

Torque wrenches are available in many shapes and sizes. The main differences between
them are how they read and how easily they can be adjusted.
Here are some of the different types and what they’re commonly used for: ok
Electronic Torque Wrenches

Also known as digital, they don’t feature any moving parts

and instead work from an electric sensor.
They sense how much twisting force is applied and tells the
user via a digital display.
These tools include small chips which contain a memory
stick to save readings, which can then be accessed on a computer.
ok

Beam

These products are generally inexpensive and easy to use.

They feature a scale, and once the right level of torque has been

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reached it stops at the right number.
The main beam features a handle on it which is used to employ force. When
in use, the beam stays in place and the scale shows the level of torque. These tools
can be used for tightening or loosening. ok

Click
A click torque wrench gives an audible sound
when the correct torque setting has been reached.
This type features a spring-loaded lever which
is adjusted by twisting the handle to the right setting.
When the required torque level is achieved, the lever
breaks which creates a clicking [Link]

Most click types are ratcheting and may be used for tightening or loosening.

Hydraulic Torque Wrenches

This type is often used in industrial settings.
They’re designed to reach the required level of torque
through the use of hydraulics. ok
Micrometer Torque Wrenches
These scales are often used in the manufacturing and transportation of
cargo. Knowing the weight of a load is vital when transporting
large amounts by train, plane, or ship because the weight may
change the distribution of the freight. If it’s not monitored properly,
this could endanger the crew and the rest of the cargo being
transported. ok

Dial Torque Wrenches

Dial torque wrenches are widely considered as one of the most

accurate to use.
They can be wider than other types, so can be harder to use in small
spaces.
As well as regular use in the automotive industry, these tools are used
in the aerospace and defense industries. ok
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1. How Torque Wrenches work

These tools are calibrated to apply a certain amount of torque to a fastener.

The amount of torque that is applied depends on the amount of force on the tool’s
handle and the length of the wrench. To work out the torque, the torque formula is
force x length = torque.
The handle contains an internal mechanical indicator that connects to a
calibrated scale. When the indicator determines the desired torque has been
reached, stop twisting the bolt.
To show how much torque is being applied, the tools generally have an easy-
to-read scale or display [Link]

They can be calibrated to read in lb·ft (pound-foot), lb·in (pound inch), or

N·m (newton meter).

How to use Torque Wrenches

It’s important to use tools that have been properly calibrated. If it’s been
calibrated, it should be demonstrated with a sticker on the tool.

They often have a lock that needs to be disengaged before the handle can be
rotated. Once the lock has been taken off, rotate the handle to line up the number
on the handle with the centerline on the barrel. Then put the lock on to avoid any
risk of adjusting the setting when using it.

When using a click torque wrench, use one hand to hold the pivot in place,
then the other on the handle. Rotate the tool until it makes audible noise. As soon as
that happens, stop turning, as one click is all that’s needed otherwise the fastener
can be overtightened.

Once the tool is no longer needed, position the scale back in its lowest
setting, to prevent impacting its accuracy for future measurements.

Refrain from using them on fasteners which have already been completely
tightened with a conventional wrench or socket, as it could be that the right level of
torque has already been exceeded. Instead, it’s better to loosen the fastener then
re-torque it to the right [Link]

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Diesel engine cylinder head bolts and nuts tightening

Cylinder heads are clamped to the engine block according to measurements

indicated in "foot-pounds." Foot-pounds refer to the amount of torque applied to
the bolts during tightening to produce the clamping force that holds the cylinder
head to the engine block.
The greater the amount of torque applied to the bolts, the greater the
amount of clamping force created. The amount of torque applied to a cylinder head
bolt is measured using a torque wrench, which indicates the amount of force
applied to the bolt during [Link]

Torque Specifications

The amount of torque required to secure a cylinder head to an engine block

varies from one type of engine to the next. The amount of clamping force and
therefore torque needed is determined by the number of cylinder pressures that
will be created by the engine. Each cylinder head bolt creates only one part of the
total amount of clamping force necessary to seal the cylinder heads to the engine
block. To determine how much torque is needed for each bolt it is necessary to
divide the number of bolts by the total amount of cylinder pressure the engine
produces. If an engine produces 1,500 pounds of pressure and the cylinder head
has 8 bolts, then each bolt must be tightenoked to 187 foot-pounds of torque to
secure the cylinder head to the block. ok

Torque Application

For torque to be evenly applied across the sealing surfaces of the cylinder
heads and engine block, the cylinder head bolts must be carefully tightened
incrementally. In most applications, it is necessary to first hand-tighten each bolt
snugly until the head of the bolt is flush with the cylinder head surface. The bolts
are then partially tightened to approximately half of their recommended torque
loading in the order specified by the particular engine's manufacturer. The process
is then performed once again in the same order to bring all of the bolts to their
specified torque loading. ok

Pattern

Every engine has a specific bolt-torquing pattern that must be followed

when tightening cylinder heads. This pattern helps to evenly apply the clamping
force along the surfaces where the cylinder head meets the engine block. If this
pattern is not followed or the bolts are are not tightened evenly, the result can be
weak spots where cylinder pressure can escape or warping of the cylinder head

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surfaces. Either warping or uneven tightening can result in catastrophic failure of
the cylinder head gasket and severe engine [Link]

Torque Limits

Cylinder heads must be tightened to specific torque loads. If too much

torque is applied, the cylinder head surfaces may become warped and allow
burning gases to escape past the cylinder head gasket. Too much torque can cause
bolts to become loaded past their limits when cylinder pressures in the engine rise,
resulting in catastrophic failure of the bolts and thus the seal between the cylinder
head and the engine block. If too little torque is applied there will not be enough
clamping force generated to seal the cylinder heads to the engine block and
combustion chamber gases will escape past the head gasket. Ok
A tightening sequence of cylinder head nuts

Operation of Hydraulic Jacks

In principle, a screw can be tightened when the nut is screwed in during

tensioning of stud by hydraulic force and then release the hydraulic force. This
hydraulic tightening method provides easier working and more reliable results than
manual tightening in general. Therefore, most of the important or big screws are
tightened hydraulically on ships such as cylinder head nuts, exhaust valve nuts, for
crankpin bearing, crosshead bearing, main bearing, tie bolts, etc. A hydraulic
tightened screw always consists of a set of stud and nut which are designed properly
for a hydraulic toolset. The nut has pin holes for turning through the hole of
support for jack as shown in the figure [Link]

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Operation of Hydraulic Jacks

In principle, a screw can be

tightened when the nut is screwed
in during tensioning of stud by
hydraulic force and then release
the hydraulic force.

The hydraulic tool set consists of a hydraulic pump, hoses and a distributing
piece, which are for common use regardless of screw size. Most of the
hydraulic screws are tightened in pair, which need distributing piece for
same tightening pressure. There are two kinds of distributing piece with
different number of ports. Screws on cylinder head need four ports and the
others which need two ports use the corresponding distributing piece.

Each screw also needs own tightening pressure which should be kept absolutely.

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Note: Before pressurizing the hydraulic jack, make sure the pressure gauge is calibrated and
display the actual pressure. Applied oil pressure must be within a range of ±5 bar of given
pressure for each stud type.
Hydraulic Jack Tightening Procedure
1. Check pre-tightening of the stud and tighten by wrench, if loosened.
2. Clean studs, nuts and around seats.
3. Screw the nut manually until the nut contacting the seat closely.
4. Check condition of the hydraulic tool set and make them ready to use.
5. Mount support (extension screw) and screw the jack by hand.
6. Connect hoses from the pump to the jacks via the distributing piece.
7. Close the release valve of the hydraulic pump.
8. Open air venting plug of the jack and check air venting by pumping.
9. Close the venting plug and pressurize up to the specified pressure for tightening the nut.
10. Turn the nut to be screwed firmly by a pin manually through the hole of the support.
11. Release the hydraulic pressure by opening the release valve of the hydraulic pump.
12. Repeat pressurizing and check the nut loosened.
13. Retighten the nut, if loosened.
14. If the stud or nut has been replaced by new ones, repeat the tightening three times
for the first tightening. This repeat is necessary for
the settlement of the threads.
15. Release the hydraulic pressure and dismount the tool set.
Hydraulic Jack Loosening Procedure
1. Clean seat and threads.
Check c
Posted in: Tools | Tagged: Hydraulic Jack Loosening Procedure, Hydraulic Jack Tightening
Procedure, Hydraulic Jacks on Ships, Principle of Hydraulic Jacks
2. ondition of the hydraulic tool set and make them ready to use.
3.[2.] Mount support (extension screw) and jack.
4.[3.] Connect hoses from the pump to the jacks via the distributing piece.
5.[4.] Turn the piston of jack until contacting the nut and then unscrew the piston by about
half turn. This is important to provide space for loosening
the nut.
6.[5.] Close the release valve of the hydraulic pump.
7.[6.] Open air venting plug of the jack and check air venting by pumping.
8.[7.] Close the venting plug and pressurize up to the specified pressure for loosening the
nut.
9.[8.] Unscrew the nut by half turn manually by means of a pin through the hole of the
support.
10.[9.] Be sure to check that loosened nut moves freely without contacting the piston of the
jack. Otherwise, jack and the nut may be stuck each other after releasing hydraulic
pressure. If stuck, increase hydraulic pressure slightly and turn the nut about 1/4 turn
clockwise for loosening from the piston of the jack.
11.[10.] Release the hydraulic pressure and dismount the tool set.
Reference:
Himsen Instruction Book by HYUNDAI HEAVY INDUSTRIES CO., LTD. Engine & Machinery
Division

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References

R7 – Osbourne, Alan. (1991). Modern marine engineer’s manual vol 2. 2 nd ed.

Maryland: Cornell Maritime Press, Inc.
[Link]
[Link]
[Link]
[Link]
q=bolts+and+nuts+tightening+sequence&rlz=1C1CHBD_enPH902PH902&sxsrf=ALe
Kk02PvvEz8XvpV1wONrqRqWGdAvG7TQ:1590389705413&source=lnms&tbm=isch&
sa=X&ved=2ahUKEwjI58ert87pAhWpGKYKHTY6AiAQ_AUoAXoECA8QAw#imgrc=W2
LC2IzIGxwPbM
[Link]
[Link]

Checkpoint

Activity 1

Fastening (how to tightened correctly bolts and nuts)

Assessment
Multiple Choices: Choose the correct letter that corresponds to the correct answer.
1. When carrying out emergency / temporary repair, the following safety measures
must be observed first?
A. Secure work permits
B. Isolate shipboard machinery involve in the repair
C. Conduct work procedures instruction and safety meeting
D. Prepare all tool needed for the repair

2. Which of the following fastener that is threaded on both ends and has no head?
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A. Bolt C. Screw
B. Stud D. Hand tap

3. Bolts and nuts should be tightened equally in the correct sequence to ensure:
A. Warping the connected parts
B. Distortion of connected parts
C. Even the setting of connected parts
D. Mismatch between holes of connected parts

4. The following reasons explain why studs are used:

A. Studs provide the ability to obtain much more accurate torque values.
B. Studs don’t twist during tightening.
C. Studs stretch in one axis alone, providing accurate clamping force.
D. Studs can quickly be tightened.

5. The difference between a stud and a bolt is that:

A. A bolt is threaded on one end only with the the head on the other end
B. A bolt does not provide an accurate torque value
C. A bolt is twisted during tightened
D. A bolt never twist during tightened

 Q6 to Q10. Refer your answer below:

A. Stud D. Stud bolt
B. Screw E. Barrel bolt
C. Cup screw
6. A threaded fastener that hasthreads on both ends where one end is semi-
permanently screwed into a threaded hole is called:

7. An externally threaded fastener that is inserted through holes in an assembly and is

tightened with a nut.

8. An externally threaded fastener that is inserted into a threaded hole and tightened or
released by turning the head called.
9. A fastening screws that are used to lock pulleys or collars or shaft.

10. Which of the following is an example of a threaded fastener?

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Lesson 7

Learning Module 7 Centrifugal Pumps (6 hours)

Competence, Course Outcomes and Learning Outcomes

Competence:

A-III/1. F3. C2: Maintenance and repair of shipboard machinery and

equipment

Course Outcome/s:

Disassemble and various pumps based on the manufacturer’s manual

Learning Outcomes:

7.1 Determine the potential hazards of disassembling and assembling a

pump.
7.2 formulate a procedural checklist on how to isolate various pimps before
disassembling and assembling
7.3 Demonstrate how to disassemble and assemble centrifugal, reciprocating, screw
displacement, rotary vane, and gear pumps based on manufacturer’s manual

Overview

A centrifugal pump is a mechanical device designed to move fluid by means

of the transfer of rotational energy from one or more driven rotors, called impellers .
Fluid enters the rapidly rotating impeller along its axis and is cast out by centrifugal
force along its circumference through the impeller’s vane tips. The action of the
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impeller increases the fluid’s velocity and pressure and also directs it towards the
pump outlet. The pump casing is specially designed to constrict the fluid from the
pump inlet, direct it into the impeller, and then slow and control the fluid before
discharge. ok

A centrifugal pump operates through the transfer of rotational energy from one or more driven
rotors, called impellers. The action of the impeller increases the fluid’s velocity and pressure and
directs it towards the pump outlet. With its simple design, the centrifugal pump is well understood
and easy to operate and [Link]

Centrifugal pump designs offer simple and low-cost solutions to most low
pressure, high capacity pumping applications involving low viscosity fluids such as
water, solvents, chemicals, and light oils. Typical applications involve water supply
and circulation, irrigation, and the transfer of chemicals in petrochemical plants.
Positive displacement pumps are preferred for applications involving highly viscous
fluids such as thick oils and slurries, especially at high pressures, for complex feeds
such as emulsions, foodstuffs, or biological fluids, and when accurate dosing is
[Link]

What is Pump Head? In simple words, the pump head is pressure defined as the height to
which the pump can raise the fluid. It is important as it evaluates a pump’s capacity to do its
job. The most important specifications of a pump are its capabilities regarding flow and
pressure.

Discussion

A Centrifugal pump is a
hydraulic machine which converts
mechanical energy into hydraulic
energy by the use of centrifugal
force acting on the fluid. These are
the most popular and commonly
used types of pumps for the transfer
of fluids from a low level to a high
level.
It is used in places like
agriculture, municipal (water and
wastewater plants), industrial,
power generation plants, petroleum,
mining, chemical, pharmaceutical, and many others.

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Main Parts of Centrifugal Pump

The Main parts of the Centrifugal Pump are:

1. Impeller
It is a wheel or rotor which is provided with a series of backward curved
blades or vanes. It is mounded on the shaft which is coupled to an external source of
energy that imparts the liquid energy to the impeller thereby making it [Link]

Impellers are divided into 3 types

1. Open Impeller
2. Semi-enclosed Impeller
3. Enclosed Impeller

2. Casing
It is a pipe that is connected at the upper end to the inlet of the pump to the
center of the impeller which is commonly known as the eye. The double end reaction
pump consists of two suction pipe connected to the eye from both sides. The lower
end dips into liquid in to lift. The lower end is fitted into the foot valve and
[Link]
Commonly three types of casing are used in a centrifugal pump,

1. Volute Casing
2. Vortex Casing
3. Casing with Guide Blades ok

3. Delivery Pipe

It is a pipe that is connected at its lower end to the outlet of the pump and it
delivers the liquid to the required height. Near the outlet of the pump on the delivery
pipe, a valve is provided which controls the flow from the pump into the delivery
pipe. ok

4. Suction Pipe with Foot Valve and Strainer

The suction pipe is connected with the inlet of the impeller and the other end
is dipped into the sump of water. At the water end, it consists of foot value and
strainer. The foot valve is a one-way valve that opens in an upward direction. The
strainer is used to filter the unwanted particle present in the water to prevent the
centrifugal pump from [Link]

5. Bearing
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The bearing in its current form was developed towards the end of the 19th
century. It was initially made by hand.

Nowadays, bearings are one of the most commonly used machine parts
because their rolling motion makes almost all movements easier and they help
reduce [Link]
Bearings have two key functions:

 They transfer motion, i.e. they support and guide components which turn relative to
one another
 They transmit forces ok

Rolling bearings and sleeve bearings

In a sleeve or plain bearing, the axle and the bearing move in opposite directions
on a sliding surface. By contrast, the two components of a rolling bearing that move
towards one another – the inner and outer rings – are separated by rolling elements.
This design generates significantly less friction than a sleeve bearing. ok

Radial bearings and axial bearings

Bearings can transmit loads in a radial direction or an axial direction (thrust)

and in many cases there is a combination of both radial and axial loads to transmit.
Both designs are available as ball bearings or roller bearings. The choice of bearing
design depends upon the application in question. ok

Components
Bearings usually consist of the
following components:

 Two rings or discs with raceways

 Rolling elements in the form of rollers or balls
 A cage which keeps the rolling elements apart and guides them ok

Inner Ring / Outer Ring

The inner and outer ring are usually made from a special high-purity, chrome
alloy steel. This material has the necessary hardness and purity – both important

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factors for a high load rating and a long service life. ok

Inner Ring Outer Ring

Rolling
Elements
Rolling elements are either balls, rollers, cones, spheres or needles. They are
usually made from a special high-purity, chrome alloy steel. Special materials such
as ceramic and plastics are also [Link]

The rolling elements roll on the specially formed raceways of the rings or
discs and are kept apart and guided by the cage.

Cage
The cage is responsible for keeping the rolling elements apart and guiding
them. The materials used include steel, brass, and plastic. Solid metal cages can be
produced using machining techniques, while pressed cages are made from sheet
metal. Similarly, plastic cages can be machined from solid plastic or injection
[Link]

6. WEAR RING

Wear rings play a crucial role in centrifugal pumps. A centrifugal pump

typically features two adjacent wear rings: a stationary wear ring on the casing and
a rotating wear ring on the impeller. The pump wear ring clearance between these
two rings is critically important to a pump’s [Link]

7. Inlet Bearing Casing

Inlet Bearing Casing injects and regulates the air inlet from the filter house
through the duct into the compressor section. It has the governing feature for air
inlet. It also houses the no 1 bearing of the turbine rotor. The forward leg of the
turbine is mounted onto this. The forward section of the compressor casing mates
with this [Link]

It is widely known as inlet bell mouth.

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8. Discharge piping

Unnecessary pockets should be avoided. The discharge pipe should be the

full size of the compressor outlet or larger, and it should run directly to the
aftercooler if one is [Link]

The discharge pipe should be as short and direct as possible, with long-radius
elbows where bends are necessary and should have as few fittings as possible. If
the design cannot avoid pockets between the compressor and the aftercooler or
receiver, it should be provided with a drain valve or automatic trap to avoid the
accumulation of oil and water mixture in the pipe itself.
9. Suction Valve

The suction valve is a non-return valve which means the only one-directional
flow is possible in this type of valve. This is placed between the suction pipe inlet
and cylinder. During suction of liquid, it is opened and during discharge, it is
[Link]
Working of a Centrifugal Pump
Let us understand in detail, how a Centrifugal pump works. Centrifugal
pumps are used to induce flow or raise a liquid from a low level to a high level.
These pumps work on a very simple mechanism. A centrifugal pump converts
rotational energy, often from a motor, to energy in a moving fluid. ok
The two main parts that are responsible for the conversion of energy are the
impeller and the casing. The impeller is the rotating part of the pump and the casing
is the airtight passage that surrounds the impeller. In a centrifugal pump, fluid
enters into the casing, falls on the impeller blades at the eye of the impeller, and is
whirled tangentially and radially outward until it leaves the impeller into the diffuser
part of the casing. While passing through the impeller, the fluid is gaining both
velocity and [Link]

The following chief factors affect the performance of a centrifugal pump and
need to be considered while choosing a centrifugal pump:ok
 Working Fluid Viscosity – can be defined as resistance to shear when energy is
applied. In general, a centrifugal pump is suitable for low viscosity fluids since the
pumping action generates high liquid [Link]
 Specific density and gravity of working fluid – The density of a fluid is its mass per
unit of volume. A fluid’s mass per unit volume and gravity of a fluid is the ratio of a
fluid’s density to the density of water. It directly affects the input power required to
pump a particular liquid. If you are working with a fluid other than water, it is

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important to consider the specific density and gravity since the weight will have a
direct effect on the amount of work performed by the [Link]
 Operating temperature and pressure – Pumping conditions like temperature and
pressures are an important consideration for any operation. For example - High-
temperature pumping may require special gaskets, seals, and mounting designs.
Similarly, an adequately designed pressure retaining casing may be required for
high-pressure [Link]
 Net Positive Suction Head (NPSH) and Cavitation – NPSH is a term that refers to the
pressure of a fluid on the suction side of a pump to help determine if the pressure is
high enough to avoid cavitation. Cavitation refers to the formation of bubbles or
cavities in a liquid, developed in areas of relatively low pressure around an impeller,
and can cause serious damage to the impeller and lead to decreased flow/pressure
rates among other things. One must ensure that the system’s net positive suction
head available (NPSHA) is greater than the pump’s net positive suction head required
(NPSHR), with an appropriate safety margin. ok
 Vapor pressure of the working fluid – The vapor pressure of a fluid is the pressure,
at a given temperature, at which a fluid will change to a vapor. It must be
determined to avoid cavitation as well as bearing damage caused by dry running
when the fluid has [Link]
Owing to the use in the diverse range of applications, pumps come with
different capacities and in various sizes. You should also consider the pressure and
volume requirements of the specific operations for which you need the pump. The
horsepower required is another important consideration when it comes to volume
and discharge [Link]
Applications of Centrifugal Pumps:
The fact that centrifugal pumps are the most popular choice for fluid
movement makes them a strong contender for many applications and as mentioned
previously, they are used across numerous industries. Supplying water, boosting
pressure, pumping water for domestic requirements, assisting fire protection
systems, hot water circulation, sewage drainage, and regulating boiler water are
among the most common applications. Outlined below are some of the major sectors
that make use of these pumps:ok
1. Oil & Energy - pumping crude oil, slurry, mud; used by refineries, power generation
plants . ok
2. Industrial & Fire Protection Industry - Heating and ventilation, boiler feed
applications, air conditioning, pressure boosting, fire protection sprinkler systems.
3. Waste Management, Agriculture & Manufacturing - Wastewater processing plants,
municipal industry, drainage, gas processing, irrigation, and flood protection
4. Pharmaceutical, Chemical & Food Industries - paints, hydrocarbons, petrochemical,
cellulose, sugar refining, food and beverage production
5. Various industries (Manufacturing, Industrial, Chemicals, Pharmaceutical, Food
Production, Aerospace, etc.) - for cryogenics and refrigerants. ok

Types of centrifugal pumps

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Centrifugal pumps can be classified into several types depending on factors such as design,
construction, application, service, compliance with a national or industry standard, etc. Therefore,
one specific pump can belong to different groups and at times pump is known by its description
itself. Some of these groups have been highlighted below: ok

Depending on the number of impellers in the pump, pumps can be classified

as per the following:ok
 Single-stage – A one impeller pump, a single-stage pump has a simple design and
easy maintenance. Ideal for large flow rates and low-pressure installations. They are
commonly used in pumping services of high flow and low to moderate TDH (Total
Dynamic Head).
 Two-stage – This type of pump has two impellers operating side by side which are
used for medium head applications.
 Multi-stage – pump has three or more impellers in series; for high head service. ok

How does a centrifugal pump work?

The impeller is the key component of a centrifugal pump. It consists of a
series of curved vanes. These are normally sandwiched between two discs (an
enclosed impeller). For fluids with entrained solids, an open or semi-open impeller
(backed by a single disc) is preferred (Figure 1).ok

Fluid enters the impeller at its axis (the ‘eye’) and exits along the
circumference between the vanes. The impeller, on the opposite side to the eye, is
connected through a drive shaft to a motor and rotated at high speed (typically 500-
5000rpm). The rotational motion of the impeller accelerates the fluid out through
the impeller vanes into the pump casing. ok
There are two basic designs of pump casing: volute and diffuser. The
purpose in both designs is to translate
the fluid flow into a controlled
discharge at pressure. ok
In a volute casing, the impeller
is offset, effectively creating a curved
funnel with an increasing cross-
sectional area towards the pump
outlet. This design causes the fluid
pressure to increase towards the outlet
(Figure 2). ok

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The same basic principle
applies to diffuser designs. In this
case, the fluid pressure increases
as fluid are expelled between a set
of stationary vanes surrounding
the impeller (Figure 3). Diffuser
designs can be tailored for specific
applications and can therefore be
more efficient. Volute cases are
better suited to applications
involving entrained solids or high
viscosity fluids when it is
advantageous to avoid the added
constrictions of diffuser vanes.
The asymmetry of the volute design can result in greater wear on the impeller and
[Link]

What are the main features of a centrifugal pump?

There are two main families of pumps: centrifugal and positive
displacement pumps. In comparison to the latter, centrifugal pumps are usually
specified for higher flows and for pumping lower viscosity liquids, down to 0.1 cP. In
some chemical plants, 90% of the pumps in use will be centrifugal pumps. However,
there are a number of applications for which positive displacement pumps are
[Link]

What are the limitations of a centrifugal pump?

The efficient operation of a centrifugal pump relies on the constant, high-
speed rotation of its impeller. With high viscosity feeds, centrifugal pumps become
increasingly inefficient: there is greater resistance and higher pressure is needed to
maintain a specific flow rate. In general, centrifugal pumps are therefore suited to
low pressure, high capacity, pumping applications of liquids with viscosities between
0.1 and 200 cP. Ok
Slurries such as mud, or high viscosity oils can cause excessive wear and
overheat leading to damage and premature failures. Positive displacement pumps
often operate at considerably lower speeds and are less prone to these problems. ok
Any pumped medium that is sensitive to shearing (the separation of
emulsions, slurries, or biological liquids) can also be damaged by the high speed of a
centrifugal pump’s impeller. In such cases, the lower speed of a positive
displacement pump is preferred. ok

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A further limitation is that, unlike a positive displacement pump, a centrifugal pump cannot
provide suction when dry: it must initially be primed with the pumped fluid. Centrifugal
pumps are therefore not suited to any application where the supply is intermittent.
Additionally, if the feed pressure is variable, a centrifugal pump produces a variable flow; a
positive displacement pump is insensitive to change pressures and will provide a constant
output. So, in applications where accurate dosing is required, a positive displacement pump
is preferred. ok
The following table summarizes the differences between centrifugal
and positive displacement pumps.
Pump Comparison: Centrifugal vs Positive Displacement

What
are the
main

applications for centrifugal pumps?Centrifugal pumps are commonly used for pumping
water, solvents, organics, oils, acids, bases, and any ‘thin’ liquids in both industrial,
agricultural and domestic applications. There is a design of a centrifugal pump suitable for
virtually any application involving low viscosity fluids. ok

The Purpose of Wear Rings

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A centrifugal pump’s role in a fluid system is to add pressure to the contents
of the system. The pump’s impeller spins, creating the centrifugal force that
generates the necessary pressure. As the fluid passes through the impeller, it is
expelled through the casing volute channel, passing the volute lip into the case
[Link]
Due to pressure differences, fluids can flow down the sides of the impeller
into the suction inlet at the impeller eye entry. If the recirculation flow rate is very
high, this leaking can cause turbulence in the fluid entering the impeller eye,
increasing the pump’s NPSHR value, and reducing [Link]
Properly selected, a centrifugal pumps wear rings limit the recirculation
flowrate between the sides of the impeller and the impeller eye. A very small, flow-
limiting clearance between the stationary and rotating rings is necessary to prevent
unwanted recirculation. The smaller the wear ring clearance in centrifugal pumps,
the tighter and more

Select Pump Wear Ring Clearance with Care

Extremely narrow clearances require

precise tolerances and material selection to avoid
potentially catastrophic faults. The hydraulic
radial load on the impeller and impeller diameter
typically dictate allowances for a certain amount
of clearance between rotating and stationary
components. ok
If the centrifugal pump wear ring
clearance between rings is too small, they could
scrape against one another. Such friction results
in damaged parts increased heat and vibration, and lower efficiency. It can also
increase the pump’s NPSHR and may cause [Link]

The minimum diametral wear ring clearances listed in API610 11 th Edition are
stated based on the outer diameter (OD) of the impeller wear ring. Compliance with
the standards for API 610 wear ring clearances ensures that wear rings are unlikely
to come in contact with one [Link]
The specified minimum clearances get larger as the rings get larger:
 For a wear ring with 2” diameter or less, API lists the minimum diametral clearance
as 0.010”.
 For every 0.5” increase of the impeller wear ring OD, the 0.010” diametral clearance
increases by 0.001”. So, from 2.000” to 2.499” OD, the diametral minimum clearance
is 0.011”.
 For impeller, wear rings with OD of 5” up to 26”, every 1” increase in the impeller
wear ring diameter results in an additional 0.001” of minimum diametral clearance.
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ok

References

R2 – Gale, Medwin. (2016). Maritime engineering. India: Venus Books Publisher and
Distributor.
R4 – Russel, Paul A. (2013). Motor engineering knowledge for marine engineers. 3 rd ed.
London: Adlard Coles Nautical.
[Link]
[Link]
[Link]
[Link]
[Link]

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Checkpoint

Activity 1

Dismantling of a centrifugal pump.

Do this

Activity 2

Explain the working principles of a centrifugal pump.

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Assessment

Pretest
Multiple Choices: Choose the correct letter that corresponds to the correct answer.

1. To ensure safety in dismantling a centrifugal pump the first step to be done is

to:
A. Switch off the breaker and remove the fuse from the motor starter box
B. Remove the fuse of the motor from the motor starter box
C. Switch off the breaker of the motor starter box
D. Separate the motor from the pump
2. The motor component of a centrifugal pump that is used to increase the kinetic
energy of the flow of fluid is called:
A. Bearing
B. Impeller
C. Volute
D. Wear rings
3. A mechanical component of a centrifugal pump is used to transmit torque from
the motor to the impeller.
A. Bearing
B. Shaft (rotor)
C. Volute
D. Wear rings
4. The component of the centrifugal pimp that receives the fluid being pumped by
the impeller slowing down the fluid’s rate of flow:
A. Pump casing
B. Discharge casing
C. Volute casing
D. Inlet casing

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5. Which of the following types of pumps designed to move the fluid by means of
the transfer of rotational energy from one or more driven rotor or impeller
A. Gear
B. Screw
C. Centrifugal
D. Reciprocating
6. What is the key component of a centrifugal pump?
A. Bearing
B. Impeller
C. Shaft
D. Volute
7. Which of the following pressure defined as the height to which the pump can
raise the fluid?
A. Pressure pump body
B. Pressure pump head
C. Pressure pump casing
D. Pressure pump sleeve
8. What mechanical components of the centrifugal pump that plays a crucial role?
A. Bearing
B. Cage
C. Impeller
D. Wear ring
9. What is the most popular choice of pumps for fluid movement makes them a
strong contender for many applications?
A. Gear pump
B. Screw pump
C. Centrifugal pump
D. Reciprocating pump
10. Which of the following mechanical part that transmits forces and transfers motion
to support and guide components which turn relative to one another?
A. Bearing
B. Impeller
C. Shaft
D. volute

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Lesson 8

Learning Module 8 Reciprocating Pumps (6 hours)

Competence, Course Outcomes, and Learning Outcomes

Competence:

A-III/1. F3. C2: Maintenance and repair of shipboard machinery and

equipment

Course Outcome/s:

Disassemble and assemble various pumps based on the manufacturer’s

manual.

Learning Outcomes:

At the end of the lesson, the student must be able to:

8.1 Dismantles the following parts of the reciprocating pumps:

o Cylinders
o Piston/buckets
o Rings
o Valves
o Join
o Glans
o Relief valve
8.2 Measures wear in cylinders, neck rings, and rods.

Overview

Reciprocating Pump
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A reciprocating pump is a positive displacement pump where a certain

volume of liquid is collected in an enclosed volume and is discharged using pressure
to the required application. Reciprocating pumps are more suitable for low volumes
of flow at high pressures.

Discussion

Main Parts
The main parts of a reciprocating pump are as follows:

1. Suction Pipe

The suction pipe connects

the source of liquid to the cylinder of
the reciprocating pump. The liquid is
sucked by this pipe from the source
to the cylinder. ok

2. Suction Valve

The suction valve is a non-

return valve which means the only
one-directional flow is possible in
this type of valve. This is placed
between the suction pipe inlet and
cylinder. During suction of liquid, it
is opened and during discharge, it is
closed. ok

3. Delivery Pipe

The delivery pipe connects the cylinder of the pump to the outlet source. The
liquid is delivered to the desired outlet location through this pipe. ok

4. Delivery Valve

Delivery valve also non-return valve placed between the cylinder and delivery
pipe outlet. It is in a closed position during suction and in an opened position during
the discharging of liquid. ok

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5. Cylinder

A hollow cylinder made of steel alloy or cast iron. Arrangement of piston and
piston rod is inside this cylinder. Suction and release of liquid take place in this so,
both suction and delivery pipes along with valves are connected to this cylinder. ok

6. Piston and Piston Rod

The piston is a solid type cylinder part that moves backward and forwards
inside the hollow cylinder to perform suction and deliverance of liquid. The piston rod
helps the piston to its linear motion. ok

7. Crank and Connecting Rod

Crank is a solid circular disc which is connected to a power source like a

motor, engine, etc. for its rotation. The connecting rod connects the crank to the
piston as a result the rotational motion of the crank gets converted into the linear
motion of the piston. ok

8. Strainer

A strainer is provided at the end of the suction pipe to prevent the entrance
of solids from the water source into the [Link]

9. Air Vessel

Air vessels are connected to both suction and delivery pipes to eliminate the
frictional head and to give a uniform discharge rate. ok

Besides:

Pressure Relief Valves

A pressure Relief Valve is a safety device designed to protect a pressurized
vessel or system during an overpressure event.
An overpressure event refers to any condition which would cause pressure
in a vessel or system to increase beyond the specified design pressure or maximum
allowable working pressure (MAWP). ok

Gland

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A gland is a general type of stuffing box, used to seal a rotating or reciprocating
shaft against a fluid. The most common example is in the head of a tap (faucet) where the
gland is usually packed with the string which has been soaked in tallow or similar grease.
The gland nut allows the packing material to be compressed to form a watertight seal and
prevent water from leaking up the shaft when the tap is turned on. The gland at the
rotating shaft of a centrifugal pump may be packed in a similar way and graphite grease
used to accommodate the continuous operation. The linear seal around the piston rod of a
double-acting steam piston is also known as a gland, particularly in marine applications.
Likewise, the shaft of a hand pump or windpump is sealed with a gland where the shaft
exits the borehole. Other types of sealed connections without moving parts are also
sometimes called glands; for example, a cable gland or fitting that connects a flexible
electrical conduit to an enclosure, machine, or bulkhead facilitates assembly and prevents
liquid or gas ingress.

Components of Reciprocating Pump

The main components of the reciprocating pump are as follows:

1. Suction Pipe
2. Suction Valve
3. Delivery Pipe
4. Delivery Valve
5. Cylinder
6. Piston and Piston Rod
7. Crank and Connecting Rod
8. Strainer
9. Air Vessel

Working of Reciprocating
Pump

The working of the reciprocating pump is as follows:

 When the power source is connected to the crank, the crank will start rotating and
the connecting rod also displaced along with the crank.
 The piston connected to the connecting rod will move in a linear direction. If the
crank moves outwards then the piston moves towards its right and creates a vacuum
in the cylinder.

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 This vacuum causes the suction valve to open and liquid from the source is forcibly
sucked by the suction pipe into the cylinder.
 When the crank moves inwards or towards the cylinder, the piston will move towards
its left and compresses the liquid in the cylinder.
 Now, the pressure makes the delivery valve to open and liquid will discharge through
the delivery pipe.
 When the piston reaches its extreme left position whole liquid present in the cylinder
is delivered through the delivery [Link]
 Then again the crank rotates outwards and the piston moves right to create suction
and the whole process is repeated.
 Generally, the above process can be observed in a single acting reciprocating pump
where there is only one delivery stroke per one revolution of the crank. But when it
comes to a a double-acting reciprocating pump, there will be two delivery strokes per
one revolution of the crank. ok

Uses of Reciprocating Pump

Reciprocating pump is mainly used for

 Oil drilling operations

 Pneumatic pressure systems
 Light oil pumping
 Feeding small boilers condensate return ok

Reciprocating pump types

A reciprocating pump can be categorized into three types:

1. According to Mechanism:
 Single-acting
 Double-acting Reciprocating Pump
2. According to air vessel:
 Pump with air vessel and
 Pump without air vessel
3. According to the number of cylinders:
 Single cylinder
 Double cylinder
 Triple cylinder ok

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Let’s understand one by one in detail:

Single-acting Reciprocating pump:

As the name itself “single” that means there is only one suction and deliver valve,
suction, and delivery pipe.
The fluid sucks in one direction that is suction stroke and it delivers that is called deliver
stroke. ok

Double-acting Reciprocating Pump:

Here it has two suction and delivers valve, suction and delivery pipe. Consider, when
the piston in a cylinder is in between then one suction and a delivery pipe is on one side
(Piston left) and one pipe at another side (piston right). ok

Pump without air vessel:

Pump without air vessel means there is some amount of air present in the water. As
per the work requirement at the domestic place, these types of pumps are used. ok

Single Cylinder:

Here only one cylinder is connected to a shaft ok

Double Cylinder:

There is a two-cylinder attached to a single shaft. The main difference from the
single-cylinder pump is there is separate suction and the delivery valve is provided to each
cylinder ok

Triple cylinder:

In this pump, there is a three-cylinder connected to it. ok

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Reciprocating Pump Application

The main application of the reciprocating pump is:
 Oil drilling operations
 Pneumatic pressure systems
 Light oil pumping
 Feeding small boiler condensate return, etc. ok

Reciprocating Pump Advantages

There are four major advantages of a Reciprocating Pump and those are the following:
 High pressure is obtained at the outlet
 The priming process is not needed in this pump
 The reciprocating pump provides high suction lift
 It is also used for air. ok

Reciprocating Pump Disadvantages

The major disadvantages of Reciprocating Pumps are:
 It requires high maintenance, because of more wear and tear of the parts.
 Low flow rate (it discharges a low amount of water)
 They are heavy and bulky in size.
 The initial cost is high ok

Balanced Bellows Valves and Balanced Piston Valves

When superimposed back pressure is
variable, a balanced bellow or balanced piston
design is recommended. A typical balanced bellow
is shown on the right. The bellows or piston is
designed with an effective pressure area equal to
the seating area of the disc. The Bonnet is vented
to ensure that the pressure area of the bellows or
piston will always be exposed to atmospheric
pressure and to provide a telltale sign should the
bellows or piston begin to leak. Variations in back
pressure, therefore, will not affect set pressure.
Backpressure may, however, affect flow. ok

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SAFETY VALVE.
A safety Valve is a pressure Relief Valve actuated by inlet static pressure and
characterized by rapid opening or pop action. (It is normally used for steam and air
services.) ok

 LOW-LIFT SAFETY VALVE

A low-lift safety Valve is a safety Valve in which the disc lifts automatically such that
the actual discharge area is determined by the position of the disc. ok
 FULL-LIFT SAFETY VALVE
A full-lift safety Valve is a safety Valve in which the disc lifts automatically such that
the actual discharge area is not determined by the position of the disc. ok

RELIEF VALVE
A Relief Valve is a pressure relief device actuated by inlet static pressure having a
gradual lift generally proportional to the increase in pressure over opening pressure.
It may be provided with an enclosed spring housing suitable for closed discharge
system application and is primarily used for liquid service. ok

SAFETY RELIEF VALVE

A safety Relief Valve is a pressure Relief Valve characterized by rapid opening or pop action,
or by opening in proportion to the increase in pressure over the opening pressure,
depending on the application, and may be used either for liquid or compressible [Link]

 CONVENTIONAL SAFETY RELIEF VALVE

A conventional safety Relief Valve is a pressure Relief Valve which has its spring
housing vented to the discharge side of the Valve. The operational characteristics
(opening pressure, closing pressure, and relieving capacity) are directly affected by
changes in the back pressure on the [Link]
 BALANCED SAFETY RELIEF VALVE
A balanced safety Relief Valve is a pressure Relief Valve which incorporates means of
minimizing the effect of back pressure on the operational characteristics (opening
pressure, closing pressure, and relieving capacity).ok
PILOT-OPERATED PRESSURE RELIEF VALVE
A pilot-operated pressure Relief Valve is a pressure Relief Valve in which the
major relieving device is combined with and is controlled by a self-actuated auxiliary
pressure Relief [Link]

POWER-ACTUATED PRESSURE RELIEF VALVE

A power actuated pressure Relief Valve is a pressure Relief Valve in which the
major relieving device is combined with and controlled by a device requiring an
external source of energy. ok
TEMPERATURE-ACTUATED PRESSURE RELIEF VALVE
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A temperature-actuated pressure Relief Valve is a pressure Relief Valve that
may be actuated by external or internal temperature or by pressure on the inlet side.
ok
VACUUM RELIEF VALVE
A vacuum Relief Valve is a pressure relief device designed to admit fluid to
prevent an excessive internal vacuum; it is designed to reclose and prevent further
flow of fluid after normal conditions have been restored. ok

References

R2 – Gale, Medwin. (2016). Maritime engineering. India: Venus Books Publisher and
Distributor.
R4 – Russel, Paul A. (2013). Motor engineering knowledge for marine engineers. 3 rd ed.
London: Adlard Coles Nautical.
[Link]
[Link]
uses/2914/
[Link]
[Link]

Checkpoint

Activity 1

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What are the parts of a Reciprocating Pump?

Do this

Activity 2

Using your drawing instrument:

Search a picture of a pneumatic Reciprocating pump transferring liquid from the drum to a
storage tank.

Assessment
Multiple Choices: Choose the correct letter that corresponds to the correct answer.
1. Which of the following pump having vanes that rotate in a casing and whirl the fluids
around so that it acquires sufficient momentum to discharge from the extremities
into a volute casing which surrounds the impeller?

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A. Reciprocating pump C. Screw pump
B. Centrifugal pump D. Piston pump
2. What component of a reciprocating pump that moves linearly in the hollow cylinder
of the pump?
A. Cylinder C. Piston
B. Crank D. Valve
3. Reciprocating pumps operate by drawing liquid into a chamber or cylinder by the
action of a piston. What kind of valve used to discharge in a required direction?
A. Check valves C. Relief valves
B. Globe valves D. Screw valves
4. How could you distinguish that this pump is a reciprocating pump?
A. Diaphragm pumps C. Screw pump
B. Plunger pump D. Piston pump
5. What hollow liner component of a reciprocating pump wherein piston moves up and
down?
A. Discharge pipe C. Crankshaft
B. Suction pipe D. Cylinder
6. After dismantling the Reciprocating pump, the C/E or Engineer assigned will examine
and measure for wear the cylinders, neck rings, and measure for wear the cylinders,
neck rings, and ___?
A. Impeller C. Piston
B. Casing D. Rod
 Question 7 to Question 10. Refer your answer below:
A. Crank C. Piston E. Air vessel
B. Cylinder D. Strainer
7. A solid type cylinder part that moves backward, forward inside the hollow to perform
suction and deliverance of fluid.
8. A solid circular disc which is connected to a power source for its rotation.
9. It is provided at the end of a suction pipe to prevent the entrance of solids from the
water source into the cylinder.
10. These are connected to both suction and delivery pipes to eliminate the frictional
head and to give a uniform discharge rate.

Lesson 9

Learning Module 9 Screw and gear pumps (6hours)

Competence, Course Outcomes, and Learning Outcomes

Competence:

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A-III/1. F3. C2: Maintenance and repair of shipboard machinery and
equipment

Course Outcome/s:

Disassemble and assemble various pumps based on the manufacturer’s

manual.

Learning Outcomes:

At the end of the lesson, the student must be able to:

9.1 Dismantles the following:
-rotors and gears
-seals
-bearings
-relief valve
9.2 Reassemble screw and gear pumps

Overview

Screw Pumps

A screw pump is a type of rotary pump which is equipped with screws that
mesh together and rotate within a cylindrical cavity or liner. The fluid enters from the
suction side of the pump and moves linearly along with these intermeshing screws to
the discharge side of the pump. The clearances between the screws and the liner are
very small hence the fluid gains pressure while moving through the [Link]

What is Gear Pump and how does it work?

The gear pump is one of the most important pumps. These types of pumps have gears in it
which can provide pressure energy to the fluid in the pumps. In simple words, we can say
that the gear pumps transfer the fluids from one part to another using a gear mechanism. If
the pressure of the system remains the same then they will provide you with the fixed flow
rate also. The gear pump works by using positive displacement rotary pumps which helps
you to transfer liquid or fluid with the aid of its gear. It has more than two internal gears
which create vacuum pressure to push the fluid in the pump.

Discussion
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A screw pump is a subset of a positive

displacement pump that usess one or more
than one screw; to perform pump-action along
its spindle axis. The complete assembly consists
of two main parts; the driving motor (prime
mover) and the pump assembly. The motor
provides the necessary rotary motion to the
pump drive screw coupled to its shaft; which
combined with low clearance in between screw
creates suction pressure. ok

With better suction capabilities and low maintenance for the same range of
speed; it is also regarded as the most reliable pump for a variety of operations. A
screw pump is known for its low turbulence, ease of use with high viscous fluids, low
vibration; self-primed, and ability to work with a minimal air pocket in fluid with low
operating noise. ok

Screw pumps are best suited for applications such as; fuel transfer, high-
pressure fuel injection, lubrication, and hydraulic power implication. This makes them
suitable for a variety of industrial application inducing; marine industry, refineries,
food processing, chemical plant, heavy industries with hydraulic power control, and
power plants. ok

The main job of screw pumps on the ship is to; transfer fuel oil from the
double bottom tank up to settling tanks. While a screw pump came in a variety of
shapes and types the most common is with three and two screws. The close
clearance in between their screw grooves traps the fluid medium forcing it to move
forward. ok

Parts and Function

A screw pump with one screw is called a single screw pump. The one with
two screws is celled twin screw pumps; while the one with more than two screws is
called multi screw pumps. Irrespective of their design variation and percentage share
in the overall application; screw pumps can be classified into the following key parts.
The driver screw, driven screw, suction port, discharge port, rotary seal, dowel pin,
stationary seal, ball bearing, circlip, driving shaft, and the timing gear. ok

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1) Driver Screw
A driver screw is one of the rotating parts of the screw pump;
that helps pump the fluid at constant volumetric flow at any point of
rotation. With a driving shaft connected on one side and timing gear
on another; it rotates with a close clearance with a driven screw to
push the fluid axially forward along the angle of rotation. A driver
screw is basically a screwed spindle made of high tensile steel. The
main role of the driver screw in a screw pump is to drive the driven
screw using an intermediate connection called timing [Link]

The gentle axial movement of the screw along the

low clearance with the driven screw helps create a low
shear effect. This further improves the working life of the
pump avoiding conditions such as; emulsification of fluid
medium in case of water contamination and negative
impact on other machinery connected in a line. ok

2) Driven Screw

Made of the same material as of driver screw; a driven screw rotates along its
axis in the effect of motion transmitted by timing gear.
Unlike driver screw, it rotates in the opposite direction with
a fixed clearance area. This helps to trap water or any
other fluid medium within the close clearance area. Now
since both the screw spindles rotate in opposite direction
without any change in clearance area; it moves the fluid
axially along the rotating angle to give nonpulsating
output. ok

To ensure the hydraulic balance along the pump central axis; both the driver
and driven screw spindle have opposite screw direction. What i mean is; if the driver
screw is of the right-hand type, the driven screw will be of left-hand type and vice
versa. Moreover, for ideal running condition, a driven screw takes much less; almost
1/12th to 1/14th of the total torque on the driver screw. ok

3) Timing Gear

With both the driver (male rotor) and driven (female

rotor) screw running with a very fine clearance; there is
always a chance of contact. One such contact can wear the
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edge of the screw reducing the output pressure drastically. If remained unchecked it not
only make pump uneconomical and far less efficient; but also trigger the screws to lock to
each other in some cases. Thus a timing gear is installed on a screw pump to check such
events. Ok

The timing gear drives the driven gear in a way such; it does not lead to the
metal to metal contact between male and female rotor assembly. Furthermore, it
ensures that there is no such contact; even when the pump runs dry for a brief
period. In three-screw pump design with no timing gear; the outer two screws
remains idle while the middle driver screw generates the axial fluid motion. ok

4) Suction & Discharge Ports

A screw pump has different suction and

discharge ports as the fluid moves axially along
the screw towards the discharge port. The
suction and discharge ports are designed as
such; it holds enough fluid medium when the
pumps finally stop. This helps to provide initial
fluid medium to the pump; avoiding it to run dry
for a brief period even with an empty or dry suction pipe. The suction port is
subjected to partial vacuum condition; generated due to pressure difference between
the suction port and the pump inlet. ok

This provides the much-needed push to the fluid medium; to get trapped into
different confined areas within thin screw clearance. On other hand, the outlet is
subjected to very high pressure; with the pump pushing even more fluid under all
conditions. This is why the vorticity found at the discharge side of the pump is
always higher than what at the suction port. ok

5) Relief Valve / Recirculation Line

Being a subset of a positive displacement pump; a screw

pump will produce pressure even with the outlet shut. This can
results in severe consequences; with loss of pump and connected
machinery with damage to the operating person. Thus to provide a
sense of protection to the pump, connected machinery, and
operating person; all positives displacement pumps including this
are equipped with relief valve. The other common method used to
neutralize excess pressure is via outlet fluid re-circulation. ok

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This can be achieved using a recirculating valve; that sends back part of the
fluid at the outlet back to the suction port via an internal passage. In many modern
pump designs, these relief valves came with an automatic flow control system; which
maintains the output pressure and flows at any given point in time. They also came
in handy reducing the starting torque for a screw pack subjected to backpressure at
its outlet. ok

6) Bearings

In vertically mounted screw pumps the upper bearing is

subjected to high load; along with radial and axial forces during
pump operation. On other hand, the lower bearings are
subjected to very low load; with an important task to maintain
the alignment of the pump components. In a horizontally
mounted screw pump both the sliding and roller bearings; are
subjected to almost no (Low) load and forces due to pump
action. It is so because the axial and radial forces generated
oppose each other to nullify their effects. ok

7) Rotary and Stationary Seal

Screw pumps are fitted with a

pair of the mechanical seal with one
on both sides; to act as a sealing
surface between the pump's dry side
and the working liquid. This keeps
the bearings and the timing gear
separate on one side of the pump.
While bearings and the shaft
coupling separate on the other side.
In many designs to ensure leak-free
sealing at suction; an additional
gland packing is installed just after the mechanical seal to assist in the process. ok

Any mechanical seal with leakage of more than 6 to 8 drops an hour should
be immediately replaced with a new one. If remained unchecked the leakage will
eventually grow quicker and quicker and damage the pump assembly. Care must be
taken while replacing the mechanical gear; as any direct hand contact with the
carbon sealing, face can damage it. ok

8) Driving Shaft

It is the part of the pump

that connects the pump assembly
to its driving motor. This is
achieved by using a proper set of
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flexible couplings. In many pump designs a driving shaft is an integral part of the
pump; running from one side to another holding a drive screw onto it. In such
designs, these drive shafts are supported by a set of axially fitted bearings. To
ensure the prolonged life of the pump and its bearings it is required to properly align
the pump shaft during pump installation. ok

There is a general tendency of screw pump to see a gradual increase in pump

rpm and its pressure with an increase in shaft power. On most designs shaft that
connects the driving screw to the motor, operation is made of mild steel. ok

The Working of a Screw Pump

A Screw Pump is a type of Positive Displacement Pump. This means that it

moves fluid by continually displacing the area that the fluid occupies. The
screws are encased inside of a liner, usually made of some sort of metal. The
fluid fits into the screw cavities within this liner and is forced through the pump
and out of the discharge as the screws rotate and inter-mesh . ok

Since there needs to be some clearance between the liner and the
screws, it is possible for any fluid that is pumped to slip back into the pump to
lower pressure zones. For high viscosity fluids like this volumetric slippage is
usually a non-issue. As the viscosity decreases, however, this slippage becomes
substantial thus; reducing the efficiency of the pump. This has to be taken into
consideration when pumping water or similar fluid and particularly in multi-
phase applications where vapor slugs are mixed into the fluid stream. In these
cases, all the clearances within the pump must be minimized to reduce slip. ok

When a screw pump is pumping oil or some other type of viscous fluid,
the screws can intermesh closely with very little or no clearance, since the
surfaces are being lubricated as the fluid is pumped. When pumping water,
water/gas mixture, or some other type of lighter fluid, these parts cannot
contact each other, else rapid wear on the parts will occur. For this reason, a
three-screw pump, (where one screw drives the other two screws without the
use of timing gears) should never be used for water service or multi-phase
[Link]

In the case of a triple screw pump, shaft seals are only needed on the
driving rotor. The other rotors, including their bearings, are encased inside the
pumping chamber and do not protrude out. In the case of a two-screw pump or
a four-screw pump, both rotors generally protrude through the pump case, into
a gear case where the timing gears are housed. For this reason, four-shaft seals
are needed in a screw pump with two rotors. ok
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Types of Screw Pumps

Screw pumps are available in a variety of different designs. Following are

short descriptions of the most common types:

One Screw Pump - One screw pump are

referred to as Progressive Cavity Pumps,
sometimes called PC Pumps or Worm Pumps.
These are generally not considered in the
Screw Pump family because the rotor used in
these pumps is not shaped like a typical screw,
but rather a twisted round shaft. A Progressive
Cavity Pump has one shaft that is slightly
twisted in the shape of a screw and is housed
in a pumping chamber that is usually rubber
[Link]

Two Screw Pump - The two-screw pump, also known as

the twin-screw pump, is the most common type for high
power applications such as heavy oil pipeline transfer.
One of the screws is driven from the power source
(motor, engine, etc.), and timing gears are usually
incorporated to rotate the second screw . ok

Three Screw Pump -The three-screw pump, also known as

the triple screw pumps, is typically used for
small applications, such as lubrication
systems. One of the screws is driven from
the power source, which then rotates the
other two screws around it, without the use
of timing [Link]

Four Screw Pump - The four screw pump is essentially

a Two Screw Pump, but with two screws per rotor,
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each facing opposite directions. The four screw pump sucks fluid in the suction
port, then splits equally and is routed to both ends of the pump. The two-fluid
streams flow through the pump towards the middle and join together again
before exiting the discharge port. Like the twin-screw pump, the four screw
pump has timing gears to drive the second rotor. Four screw pumps are often
used in Multi-phase applications as well as oil transfer pipelines. ok

So, what is a Gear Pump?

The Gear Pumps are basically positive displacement rotary pumps which
helps you to transfer liquid or fluid by using its gears. It has more than two internal
gears that create vacuum pressure to push the fluid in the pump. ok

The Gear pumps are the high-pressure pumps

that come in small sizes to provide pulseless as well
as stable fluid flows as compared to other pumps like
peristaltic and diaphragm pumps. There are many
other advantages of the gear pumps which are better
than other pumps like it is a self-priming pump, can
pump high viscosity fluids, user-friendly pump as it is
easy to operate and to maintain as [Link]

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How do you handle an application that demands high discharge, high temperatures,
and high viscosities?

Many pump applications are not as simple as moving water at ambient

temperature and at low pressure. As the viscosity increases, centrifugal pumps
become inefficient and the user needs to consider positive displacement (PD) pumps.
As the pressure requirement increases, some PD pumps max out. As the
temperature increases, others will also fail.
What if you need 5,000-psi discharge pressure, or the temperature is 700-deg F, or you
have viscosities in the hundreds of thousands or even in the millions cP? There are a few
pumps that may be able to handle one or two of these conditions with special designs or
modifications to existing designs. But what if your application has all three?

The answer is a high-performance external gear pump designed for these

extreme operating conditions. These are engineered pumps that are capable of
handling any or all of these conditions using optimized materials, clearances, and
designs. External gear pumps have two meshing gears of the same diameter. The
drive gear shaft is connected to the motor or gear reducer and drives the second
gear. In heavy-duty industrial gear pumps, these gears are usually integral (one
piece) with the shaft and have close tolerance journals on either side of the gear
teeth.

There are three types of gear teeth in use: spur, helical, and herringbone. All
three have advantages and disadvantages, depending on the application.
Spur gears are the simplest and offer the most benefit in high-pressure applications. They
produce no axial thrust and transfer the fluid efficiently from the suction side to the
discharge side.

Helical gears produce slightly lower pulsations in the fluid stream and are
generally quieter running at higher speeds due to the way the teeth are gradually
meshed and unmeshed. However, due to the axial thrust produced with helical
gears, the differential pressures may be limited at lower viscosities depending on the
bearing materials used. The thrust pushes the gear into the face of the bearing so
higher pressures can only be achieved with hard bearing materials or specially
designed surfaces which can handle this thrust.
Herringbone gears are essentially back-to-back helical gears. They offer slightly less
pulsation than spur gears and axially balanced thrust. However, they are expensive to
manufacture and assembly/disassembly can be difficult as they must be installed/removed
as a set. In high viscosity applications, applications where the fluid solidifies, or in very large
pumps, this is a big disadvantage.

What are the main features and benefits of a gear pump?

Gear pumps are compact and simple with a limited number of moving parts.
They are unable to match the pressure generated by reciprocating pumps or the flow
rates of centrifugal pumps but offer higher pressures and throughputs than vane or

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lobe pumps. Gear pumps are particularly suited for pumping oils and other high
viscosity fluids. ok

Of the two designs, external gear pumps are capable of sustaining higher
pressures (up to 3000 psi) and flow rates because of the more rigid shaft support
and closer tolerances. Internal gear pumps have better suction capabilities and are
suited to high viscosity fluids, although they have a useful operating range from 1cP
to over 1,000,000cP. Since the output is directly proportional to rotational speed,
gear pumps are commonly used for metering and blending operations. Gear pumps
can be engineered to handle aggressive liquids. While they are commonly made from
cast iron or stainless steel, new alloys and composites allow the pumps to handle
corrosive liquids such as sulphuric acid, sodium hypochlorite, ferric chloride, and
sodium hydroxide. ok

External gear pumps can also be used in hydraulic power applications,

typically in vehicles, lifting machinery, and mobile plant equipment. Driving a gear
pump in reverse, using oil pumped from elsewhere in a system (normally by a
tandem pump in the engine), creates a hydraulic motor. This is particularly useful to
provide power in areas where electrical equipment is bulky, costly, or inconvenient.
Tractors, for example, rely on engine-driven external gear pumps to power their
services. ok

What are the limitations of a gear pump?

Gear pumps are self-priming and can dry-lift although their priming
characteristics improve if the gears are wetted. The gears need to be lubricated by
the pumped fluid and should not be run dry for prolonged periods. Some gear pump
designs can be run in either direction so the same pump can be used to load and
unload a vessel, for example.
The close tolerances between the gears and casing mean that these types of
pumps are susceptible to wear particularly when used with abrasive fluids or feeds
containing entrained solids. However, some designs of gear pumps, particularly
internal variants, allow the handling of solids. External gear pumps have four
bearings in the pumped medium, and tight tolerances, so are less suited to handling
abrasive fluids. Internal gear pumps are more robust having only one bearing
(sometimes two) running in the fluid. A gear pump should always have a strainer
installed on the suction side to protect it from large, potentially damaging, solids. ok

Generally, if the pump is expected to handle abrasive solids it is advisable to

select a pump with higher capacity so it can be operated at lower speeds to reduce
wear. However, it should be borne in mind that the volumetric efficiency of a gear

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pump is reduced at lower speeds and flow rates. A gear pump should not be
operated too far from its recommended speed. ok

For high-temperature applications, it is important to ensure that the operating

temperature range is compatible with the pump specification. Thermal expansion of
the casing and gears reduces clearances within a pump and this can also lead to
increased wear, and in extreme cases, pump failure. ok

Despite the best precautions, gear pumps generally succumb to wear of the
gears, casing, and bearings over time. As clearances increase, there is a gradual
reduction in efficiency and an increase in flow slip: leakage of the pumped fluid from
the discharge back to the suction side. Flow slip is proportional to the cube of the
clearance between the cog teeth and casing so, in practice, wear has a small effect
until a critical point is reached, from which performance degrades rapidly. ok

Gear pumps continue to pump against back pressure and, if subjected to a

downstream blockage will continue to pressurize the system until the pump,
pipework, or other equipment fails. Although most gear pumps are equipped with
relief valves, for this reason, it is always advisable to fit relief valves elsewhere in the
system to protect downstream equipment. ok

Internal gear pumps, operating at low speed, are generally preferred for shear-
sensitive liquids such as foodstuffs, paint, and soaps. The higher speeds and lower
clearances of external gear designs make them unsuitable for these applications.
Internal gear pumps are also preferred when hygiene is important because of their
mechanical simplicity and the fact that they are easy to strip down, clean, and
reassemble. ok

Applications for Screw Pumps

There are many uses for screw pumps in a variety of different industries,
including Manufacturing, Mining, and Oil & Gas. Most of these applications deal with
high viscosity fluid, such as oil or asphalt, or multi-phase fluid, which means there
are liquid and vapor mixed in the fluid stream. Below are some examples of where
screw pumps are used:
 Hydraulic and Lubrication Systems - Many lubrication systems and hydraulic systems
use a screw pump. These are usually small, triple screw pumps. Lubrication and
hydraulic systems like this are used for supplying lube oil to large machinery,
supplying hydraulic power to high-pressure hydraulic systems, or operating elevators
in [Link]
 Heavy Oil Pipeline - When pumping high viscosity crude oil, screw pumps can offer
an ideal solution for moving it through pipelines. Able to pump higher viscosities than
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a centrifugal pump, and able to pump higher flows than a reciprocating pump, screw
pumps are often used in these applications. In these scenarios, very large pumps are
sometimes used to get to the flow rate required. These pumps are usually driven by
large electric motors or diesel engines. ok
 Multi-phase Pumping - Multi-phase pumping refers to pumping a mixture of fluid and
vapor together, and is known to be one of the most challenging pumping
applications. Serious damage can occur to compressors when liquid enters, just like
serious damage can occur to most pumps when air enters. When built correctly, a
screw pump can be a hybrid between a pump and a screw compressor, being able to
handle both liquid and gas. To prevent damage to a screw pump when air enters,
the screws must not contact each other. For this reason, a four-screw pump is
usually used. In addition to this, the pump must be accompanied by a liquid boot,
which is sometimes built into the pump but can easily be added externally as well. A
liquid boot is a pressure vessel that collects fluid on the discharge of the pump.
When an air slug comes through the supply pipe, a small pump moves the liquid
from the boot and injects it into the pump. This provides slight lubrication to the
screws and liner, as well as seals the clearances between the parts so the air/gas
that is being pumped does not slip backward in the pump to lower pressure zones.
Depending on the capacity of the liquid boot vessel, a multi-phase pump can pump
100% vapor for several minutes. ok

What are the main applications for gear pumps?

Gear pumps are commonly used for pumping high viscosity fluids such as oil,
paints, resins, or foodstuffs. They are preferred in any application where accurate
dosing or high-pressure output is required. The output of a gear pump is not greatly
affected by pressure so they also tend to be preferred in any situation where the
supply is irregular. ok

How does a gear pump work?

Gear pumps use the actions of rotating cogs or gears to transfer fluids. The
rotating element develops a liquid seal with the pump casing and creates suction at
the pump inlet. Fluid, drawn into the pump, is enclosed within the cavities of its
rotating gears and transferred to the discharge. There are two basic designs of gear
pump: external and internal (Figure 1). ok

Internal gear pump

An internal gear pump operates on the same

principle but the two interlocking gears are of different sizes
with one rotating inside the other. The larger gear
(the rotor) is an internal gear i.e. it has the teeth projecting
on the inside. Within this is a smaller external gear
(the idler – only the rotor is driven) mounted off-center.
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This is designed to interlock with the rotor such that the gear teeth engage at one
point. A pinion and bushing attached to the pump casing hold the idler in position.
A fixed crescent-shaped partition or spacer fills the void created by the off-center
mounting position of the idler and acts as a seal between the inlet and outlet ports.
ok
1. As the gears come out of mesh on the inlet side of the pump, they create an
expanded volume. Liquid flows into the cavities and is trapped by the gear teeth as
the gears continue to rotate against the pump casing and partition. ok
2. The trapped fluid is moved from the inlet to the discharge, around the casing. ok
3. As the teeth of the gears become interlocked on the discharge side of the pump, the
volume is reduced and the fluid is forced out under pressure. Internal gear pump
designs only use spur gears.

Assemble and Disassemble of an Internal Gear Pump

1. Switch off the power supply of the motor that
drives the pump.
2. Mark the motor shaft coupling and pump shaft
coupling for assembling reference.
3. Remove the coupling nuts and bolts then free the
pump from the motor.
4. Identify and check the following parts for wear and
deterioration.
4.1 Drive gear/idler gear
4.2 Driveshaft
4.3 Rotor bearing/bushings
4.4 Seals
4.5 Case seals
5. Replace deteriorated and out limit weak parts.
6. Assemble the back dismantled of centrifugal pumps applying the assembling rule
that the “first part to be dismantled will be the last part to be assembled”.ok

External Gear Pump

An external gear pump consists of two identical, interlocking
gears supported by separate shafts. Generally, one gear is driven
by a motor and this drives the other gear (the idler). In some
cases, both shafts may be driven by motors. The shafts are
supported by bearings on each side of the [Link]

1. As the gears come out of mesh on the inlet side of the pump, they
create an expanded volume. Liquid flows into the cavities and is
trapped by the gear teeth as the gears continue to rotate against the pump
[Link]
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2. The trapped fluid is moved from the inlet to the discharge, around the casing. ok
3. As the teeth of the gears become interlocked on the discharge side of the pump, the
volume is reduced and the fluid is forced out under pressure. ok
No fluid is transferred back through the center, between the gears, because they are
interlocked. Close tolerances between the gears and the casing allow the pump to
develop suction at the inlet and prevent fluid from leaking back from the discharge
side (although leakage is more likely with low viscosity liquids). ok
External gear pump designs can utilize spur, helical, or herringbone gears.

Disassembly of an External gear pump

See Figure 1.
Unscrew drain plug (130), loosen air strainer (107), and drain
lubricating oil from gearbox (04). Collect the lubricating oil in a
suitable container. Liftoff gearbox (04) after locknuts (121) have
been removed.

ATTENTION: If the pump has an end-side coupling half,

disassemble before disassembling the gearbox. Remove the key
on the shaft end at this time.

Disassembly of Pump Casing

Disassemble hexagon nut (118) with plain washer (119) of pump casing (01)
and bearing housing (03). Disassemble pump casing (01) by tightening two forcing
screws.

ATTENTION: Threaded holes are located in bearing housing (03).

Disassembly of Screws

See the applicable Cross-Sectional Diagram in Section 2; loosen bolt (141),

disassemble pressing board (21) of screws, and then disassemble left-hand screw and
right-hand screw together. Remove key (135), screw adjusting ring (20), and mechanical
seal adjusting ring (26). Next, label the dismantled items.

Disassemble the rotating and stationary ring unit of the mechanical seal. If space
plate (50) is present, unscrew the screw (146) and disassemble spacer plate (50).

ATTENTION:
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 Immediately label all dismantled parts to avoid confusion during reassembly.
 If seal boxes (09) are in good condition, do not disassemble them! Otherwise,
loosen socket screws (110) and disassemble the seal boxes respectively. ok

Disassembly of Timing Gears

See Section 2 Cross-Sectional Diagrams and Figure 2.

Jam the teeth of the gear wheels (13 & 14) with a copper sheet, loosen and remove
the back-stop washer (129) and locking nut (128) on the driving shaft (05), remove bolt
(115) and spring washer (116) on the driven shaft, use tools (such as a drag wheel tool) to
remove gear (13 & 14), remove the key (134). Loosen screw (126), remove bearing cover
(11) and spacer (17). Be sure to label all disassembled components. ok

ATTENTION:
 Only when the replacement of new timing gears is required, bolts (112) can be
unscrewed so that gear wheel (14) and gear sleeve (15) are separated. At this
time, bolts (112) must be replaced. ok
 Mark the starting point of meshing before removing the timing gears.
 Immediately label all dismantled parts to avoid confusion during reassembly. ok

Disassembly of Bearings

See Section 2 Cross-Sectional Diagrams.

Affix the appropriate-sized auxiliary tool on the side of the screw sleeve that is on the shaft
(05 & 06), use a special tool to hit the auxiliary tool, hit out the shafts (05 & 06) from
bearing housing respectively. ok

Disassemble bearings (101 & 102) and internal, external spacer bushing (18 & 19) from the
driving and driven shafts (05 & 06). Next, label the dismantled items.
ATTENTION: Immediately label all dismantled parts to avoid confusion during reassembly ok

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REASSEMBLY

Install O-rings (103) and oil seal (104) on the sealing box (09). Fasten sealing box (09) to
bearing housing (03) with screw (110). (If spacer plate (50) is present, fasten sealing box
(09) to spacer plate (50) and then fasten both of them to bearing housing). ok

Install bearings (101) onto driving and driven shafts (05 & 06), and then strike outer ring of
the bearing (101) with the appropriate tool, insert them into driving (shaft), and driven
(shaft) bearing bores of bearing housing (03). ok

In sequence, assemble the internal and external spacer bushings (18 & 19) and the bearings
(102) to driving and driven shafts (05 & 06) with appropriate tools. ok

Tighten bearing cover (11) onto bearing housing (03) with screws (126).ok

Assemble the labeled stationary ring of the mechanical seal into the sealing box (09) and
rotating ring of mechanical seal onto driving and driven shafts (05 & 06) at the original
location.

Install the labeled mechanical sealing adjustment ring (20) and screw sleeve adjustment
ring (26) onto the driving and driven shafts (05 & 06) according to the original location
marked during [Link]

Position the screws (07 & 08) onto the driving and driven shafts (05 & 06) by the key (135).
Use bolt (141) and spring washer (142) to push the plate (21) allowing the screws (07 & 08)
to be located on the driving and driven shafts (05 & 06).ok

Place the gasket between bearing housing (03) and pump casing (01), secure with bolts
(117), nuts (118) and flat washers (119). ok

Individually mount spacer bushings (17) on shafts (5 & 6) and

insert key (134) onto shafts. Mount gear wheels (13 & 14) on
shafts (5 & 6) fasten gear wheel (13) to the driving shaft (05)
with locknuts (128) and lock washers (129). Next, mount the
pressing board (16) on the driven shaft, fasten with spring
washers (116), and screw bolts (115). ok

Fasten gearbox unit (04) and gasket (28) to bearing housing

(03) with stud screw bolts (120), screw nuts (121), and flat
washers (122). ok

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Fasten drain screw plug (130), open feed screw plug, and pour clean gear oil. For oil level
reference, please see Figure 3. ok

References

R6 – Osbourne, Alan. (1994). Modern marine engineer’s manual vol. 2 2 nd ed. Maryland: Cornell
Maritime Press, Inc.
[Link]
[Link]
[Link]
[Link]
q=one+screw+pump+label&rlz=1C1CHBD_enPH902PH902&source=lnms&tbm=isch&sa=X&ved=2ah
UKEwifhcLRttPpAhUwxosBHcoIB40Q_AUoAXoECBAQAw&biw=1366&bih=657
[Link]
q=two+screw+pump+label&rlz=1C1CHBD_enPH902PH902&source=lnms&tbm=isch&sa=X&ved=2ah
UKEwj53YPkttPpAhVRE6YKHWTXCCkQ_AUoAXoECA8QAw&biw=1366&bih=657#imgrc=2MljrGJkI2b7
ZM
[Link]
q=three+screw+pump+label&rlz=1C1CHBD_enPH902PH902&source=lnms&tbm=isch&sa=X&ved=2a
hUKEwjUp8fsttPpAhW8KqYKHefKBz0Q_AUoAXoECAoQAw&biw=1366&bih=657
[Link]
q=four+screw+pump+&tbm=isch&ved=2ahUKEwiyiZP1ttPpAhUfyosBHdcgBkIQ2-
cCegQIABAA&oq=four+screw+pump+&gs_lcp=CgNpbWcQA1C-
uyZY1MAmYMXEJmgAcAB4AIABAIgBAJIBAJgBAKABAaoBC2d3cy13aXotaW1n&sclient=img&ei=bQrOX
vKePJ-Ur7wP18GYkAQ&bih=657&biw=1366&rlz=1C1CHBD_enPH902PH902
[Link]
[Link]
q=timing+gear&rlz=1C1CHBD_enPH902PH902&source=lnms&tbm=isch&sa=X&ved=2ahUKEwja1InL
wtPpAhWSLqYKHf8CCTgQ_AUoAXoECBAQAw&biw=1366&bih=657#imgrc=-hH00GajiELhIM
[Link]
q=Relief+Valve+Relief+Valve+&tbm=isch&ved=2ahUKEwign8HvttPpAhXzNKYKHVmvCK0Q2-
cCegQIABAA&oq=Relief+Valve+Relief+Valve+&gs_lcp=CgNpbWcQAzoCCABQq5WDA1i1loMDYNakgw
NoAHAAeACAAZwCiAHYA5IBBTAuMS4xmAEAoAEBqgELZ3dzLXdpei1pbWc&sclient=img&ei=YgrOXqD
mCfPpmAXZ3qLoCg&bih=657&biw=1366&rlz=1C1CHBD_enPH902PH902#imgrc=ZJ2KCjhffDCr-M
[Link]
q=Rotary+and+Stationary+Seal+screw+pump&tbm=isch&chips=q:rotary+and+stationary+seal+scr
ew+pump,online_chips:mechanical&rlz=1C1CHBD_enPH902PH902&hl=en&ved=2ahUKEwiCpeWS0NP
pAhXbx4sBHWQJAAIQ4lYoAHoECAEQFQ&biw=1349&bih=608#imgrc=9qj0JCN20IXwfM
[Link]
q=Bearings&tbm=isch&ved=2ahUKEwidsr3HztPpAhVJ4ZQKHYkOC4sQ2-
cCegQIABAA&oq=Bearings&gs_lcp=CgNpbWcQAzICCAAyAggAMgIIADICCAAyAggAMgIIADICCAAyAgg
AMgIIADICCABQo50FWKOdBWDBoAVoAHAAeACAAZkBiAGZAZIBAzAuMZgBAKABAaoBC2d3cy13aXota

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W1n&sclient=img&ei=OCPOXp22KMnC0wSJnazYCA&bih=657&biw=1366&rlz=1C1CHBD_enPH902PH
902#imgrc=-YwOMNn196vY4M&imgdii=BAteutZpYYfsXM
[Link]
[Link]

Checkpoint

Activity 1
Dismantling of an Internal gear pump.

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Assessment

Multiple Choices: Choose the correct letter that corresponds to the correct answer.
1. What is the first step to being done in dismantling a screw and gear pump?
A. Shut off the breaker and removed the fuse from the motor starter box
B. Remove the coupling bolts and nuts of the driving motor
C. Remove pump foundation bolts
D. Clean all parts and assemble back
2. After dismantling a screw and gear pump, what will be the next step to be done?
A. Clean all parts and assemble
B. Close suction and discharge valves
C. Inspect mechanical seal, bearing and renew if required
D. Remove cover and remove driver screw and mechanical seal
3. After assembling the pump and in service for a week, what will be the next step to
administer in the pump assembly?

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A. Check and clean the filter
B. Re-check the alignment of the coupling
C. Replace all the coupling guards and covers
D. Moving or shimming the pump suction and discharge
4. How would you accomplish the procedures if the alignment of the pump is required?
A. Moving and shimming of the gears
B. Moving and shimming the motor mounting bolts
C. Moving and shimming the pump discharge pipe flange
D. Moving and shimming the pump suction and discharge pipe flange
5. Which of the following screw pump used predominantly to pump non-aggressive
liquids free of abrasive mechanical admixtures?
A. Single-screw pump C. Three-screw pump
B. Double-screw pump D. Four-screw pump
6. Which of the following screw pump used predominantly to pump seawater, fresh
seawater, and mineral water?
A. Single-screw pump C. Three-screw pump
B. Double-screw pump D. Four-screw pump
7. Which of the following screw pump is a volumetric pump?
A. Single-screw pump C. Three-screw pump
B. Double-screw pump D. Four-screw pump
8. Which of the following screw pump often used in multiphase application as well as oil
transfer pipelines?
A. Single-screw pump C. Three-screw pump
B. Double-screw pump D. Four-screw pump
9. Distinguish this kind of pump which is better than others like it is a self-priming
pump, can pump high viscosity fluids, easy to operate and to maintain as well?
A. Centrifugal pump C. Reciprocating pump
B. Gear pump D. Screw pump
10. What kind of pump that features compact and simple with a limited number of
moving parts?
A. Centrifugal pump C. Reciprocating pump
B. Gear pump D. Screw pump

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 Issue No. 1 Page 134 of 134
ST. THERESE- MTC COLLEGES MAINT
Iloilo, Philippines (Maintenance and Repair)
STUDENT LEARNING MODULE
Revision No. 1 Effectivity date: Reviewed by: Approved by:

10 August 2020 QMR President

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