Q5 (16 Marks) Engine Operation & Maintenance
MEP • Written Exam

(a) As Second Engineer, outline your instructions to members of the ship's engineering staff for inspection of the mam engine timing chain. (6)

(b) The inspection in "a" has revealed that the roller chain needs replacement. Describe, how this is achieved. (10)

Appeared In: Jan 2024

Verified Model Answer (Text Solution)

Structured for DG Shipping MEO Class II examination scoring criteria.

Exam Ready
Part (a)

As Second Engineer, outline your instructions to members of the ship's engineering staff for inspection of the main engine timing chain.

Before commencing the inspection, I would instruct the engineering staff to carry out the following:

1. Prepare the Engine Safely

  • Stop the main engine and obtain permission from the Chief Engineer.
  • Isolate the starting air supply and engage the turning gear.
  • Lock out all starting arrangements and display "Do Not Operate" warning notices in accordance with the lockout/tagout (LOTO) procedure.

2. Conduct a Risk Assessment

  • Hold a toolbox meeting to discuss the work scope and associated hazards, such as moving machinery, falling objects, hot surfaces, and confined working spaces.
  • Ensure all personnel wear the appropriate PPE.

3. Open the Inspection Covers

  • Carefully remove the timing chain case inspection covers.
  • Ensure adequate lighting and ventilation inside the timing chain casing.

4. Inspect the Timing Chain

  • Check the chain for elongation (stretch).
  • Examine the rollers, pins, bushes, and side plates for wear, cracks, corrosion, or other damage.
  • Check for stiff or seized chain links.

5. Inspect Associated Components

  • Examine the chain wheels (sprockets) for tooth wear or damage.
  • Inspect the chain guides, tensioning device, and lubrication arrangements.
  • Verify correct chain alignment and tension.

6. Record the Findings

  • Measure chain wear and compare it with the manufacturer's permissible limits.
  • Record all measurements and observations, and report any defects to the Chief Engineer before reassembly.
Part (b)

The inspection has revealed that the roller chain needs replacement. Describe how this is achieved.

The roller timing chain should be replaced in accordance with the manufacturer's instructions using the following procedure:

  1. Obtain the correct replacement chain and verify that it complies with the manufacturer's specifications.
  2. Stop and completely isolate the main engine.
    • Engage the turning gear.
    • Shut off the starting air supply.
    • Lock out all starting arrangements.
    • Display appropriate warning notices.
  3. Open the timing chain casing and thoroughly clean the work area.
  4. Release or remove the chain tensioner in accordance with the maker's instructions.
  5. Rotate the engine on turning gear until the chain connecting link is positioned at an accessible location.
  6. Clearly mark the relative timing positions of the crankshaft and camshaft(s) to preserve the correct valve and fuel injection timing.
  7. Disconnect the old chain at the connecting link. If no connecting link is fitted, cut the chain as specified by the manufacturer.
  8. Securely attach one end of the new chain to the old chain. Slowly rotate the engine using the turning gear so that the old chain pulls the new chain through the sprockets while the old chain is simultaneously withdrawn.
  9. Join the ends of the new chain using the approved connecting link or riveting method specified by the manufacturer. Ensure the connecting link clip or locking device is fitted in the correct direction.
  10. Refit and adjust the chain tensioner to obtain the correct chain tension.
  11. Verify that all timing marks coincide and confirm that the valve timing and fuel injection timing remain correct. If necessary, adjust the timing in accordance with the maker's manual.
  12. Rotate the engine manually through several complete revolutions using the turning gear to ensure smooth operation without binding or interference.
  13. Lubricate the timing chain, inspect the lubrication system, and ensure an adequate oil supply to the chain.
  14. Refit all inspection covers using new gaskets where required, remove all tools and materials, restore the engine to operational condition, and carry out a slow-speed trial while carefully monitoring the timing chain operation.
  15. Record the chain replacement, wear measurements, timing checks, and all maintenance carried out in the engine maintenance records and the Planned Maintenance System (PMS).
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