Cruise Liner Vessel Generator Overhaul

CRUISE LINER VESSEL GENERATOR OVERHAUL 1

Name

Institution

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Cruise Liner Vessel Generator Overhaul

Section One: Analysis of the purpose and planning a shipboard operation

A ship is complicated transport equipment that operates with many types of machinery on

board and can be affected by the failure of any of the vital equipment. Every machine on board

has its shortcomings and is mainly affected by the environment under which the ships operate

(Driscoll and Picozzi, 2004). Ships operate in a marine environment which is characterised by

salty water and high ocean tides that have a strain on the equipment that is on board (Driscoll and

Picozzi, 2004). The ocean environment can lead to the failure of various equipment hence

putting the lives of the people on board as well as the property in great danger. According to

Driscoll and Picozzi (2004), in the recent years, it has been reported that engine failure is one of

the main issues that lead to the stalling of ships.

Many of such failures have been costly due to the mechanical damage that is caused by

the failure of the engine and the associated financial requirements when towing the ship to the

shore for repair (Morelli, 1967). One of the most effective ways of avoiding such costly and risky

failures of ships is by ensuring that the routine maintenance schedule is followed as

recommended by the manufactures. Engine overhauling is one of the key and major maintenance

practices that marine engineers must perform on a regular manner to ensure that the engine is in

good shape to support all the other machinery and also to keep the ship in operation (Morelli,

1967). The engine generator overhauling is a risky and complex process that must be carried out

by qualified personnel and engineers to ensure that no accident or unnecessary occurrences take

place.

Generators are regarded as among the prime machinery that is onboard a ship. Generators

supply power to all the other machines in the ship and are the lifeline of the ship. Just like other

CRUISE LINER VESSEL GENERATOR OVERHAUL 3

machinery onboard, generators should also be maintained through a routine manual to ensure

that it functions well and also to promote safety while on board (Morelli, 1967). Marine engineers

are expected to carry out routine maintenance of the generators as specified by the manufacturers

of the engine and the technical team. The overhaul process can be done for various reasons

which include de-carbonisation which involves the cleaning and removing of carbon from the

vital parts of the engine that are involved in the combustion process.

The cruise liner generators serve the ship with the electrical needs that are required to

keep various components of the ship functioning and also to maintain the comfort of the

passengers. The repair or overhauling of the generator can be done while the ship is on the sea.

The ship can also be towed to ashore for the repair procedures to be carried out. Overhauling of a

generator involves a step-by-step process that should be followed to ensure that the objectives of

the process are met and also promoting safety while on board.

The overhauling process involves the preplanning stage, preparation, opening of major

parts of the generator and performing the major checks as recommended in the maintenance

manual (Morelli, 1967). The proceeding steps involve taking the measurements, closing and

assembling the parts (Morelli, 1967). The last stages of the overhauling process are preparing for

the restarting after the overhaul, running an inspection and alternator maintenance process. The

overhauling process can be done following the procedure highlighted below.

Preplanning for Generator overhaul in ships

Generators are the main sources of power in a ship, and most of the components of the

vessel will not function when the generator is not working. Therefore, one of the main pre-

planning activities to be carried out before generator overhauling is checking the condition of the

supplementary or the emergency power supply system. The preplanning process guidelines are

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given by the SOLAS Regulations II-1/42 (Mollenhauer & TschKe, 2010). The regulations state

that for ships constructed on after the 1

of July 1998 and uses electrical power to restore

propulsion, there must be an alternative source of power that is capable of producing the required

amounts to restore the propulsion. Therefore, as part of the pre-planning process, an alternative

power source should be tested to ensure that it can be able to power the vital components of the

ship during the overhauling process when the main generator is not function. The overhauling

process can take about four to five days due to the complexity of the process.

Preparation for the overhauling process

Preparation for the overhauling process involves gathering the required equipment and

making the necessary preliminary requirements before the actual project commences. Some of

the equipment and resources that will be required during the generator overhaul process include

tools for disassembling the generator such as spanners, box spanners, pulleys and other tools that

are necessary for opening the generator so that a visual inspection can be carried out properly.

Testing the Emergency power sources

Since the generator which is the main source of electric power in the vessel will be

switched off, it is necessary first to test the emergency electric power sources in the ship so that

no casualties will be reported during the overhauling process. Research on marine casualties

during overhauling has shown that most of the incidences occurred as a result of the emergency

power sources failing to function properly. The testing of the alternative power systems can be

conducted following the Marine Guidance Note that provides the steps that should be followed

by the ship operators and the marine engineers in testing the emergency system. The guide

indicates that the ship operators and the marine engineers on board should take responsibility in

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conducting periodic testing of the emergency power systems to reduce the cases of casualties in

case of engine failures.

Safety and Risk Assessment while Performing an Engine overhaul on board

Risk assessment is an important practice in the shipping industry since people working on

the shipboard are exposed to various numbers of dangers. Risk assessment involves

investigating, identifying and responding the hazards that people might be exposed to while

performing the ship operation (Lois et al., 2004). The risk analysis process involves the diagnosis

of all the technical and conditional hazards that may arise during the overhauling process. Risk

refers to the combination of the frequency and the severity of the effects (Lois et al., 2004). The

risk is defined based on two components which include the probability of occurrence and the

severity of the consequences.

According to the provisions of the International Safety Management Code, the company

should define and establish the safeguards against all the risks (Lois et al., 2004). However, the

company is at liberty to choose the appropriate risk management system which is in line with its

operations and organisational structure. The risk management system should ensure that all the

employees are protected from any danger that may arise while they are undertaking their daily

duties. Therefore, during the overhauling process, the engineers should conduct a risk assessment

before the process and plan for how each risk will be reduced or eliminated.

The risk assessment process involves assessing all the activities involved in the

overhauling process and deciding on the cause of action that can be used to minimise or

eliminate the risks. For instance, during the overhauling process of the risk assessment method

should involve four main steps which include:

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Identification of possible hazards during the overhauling process is one of the most

important stages in the risk assessment process as it determines the course of actions to be

followed later (Lois et al., 2004). For instance, the overhaul process will involve handling of the

huge generator parts such as the casings and the large alternator. Therefore, there should be a

material handling equipment at the site so that it can be used in the handling of the parts to avoid

injury to the operators as a result of lifting heavy loads.

The second stage in the safety planning process should involve assessing all the risks

associated with all the identified hazards (Maritime and Coastguard Agency, 2004). The risks

can vary from exposure to high temperatures pollution resulting from pillage and injury due to

falling objects or even lifting heavy components. After identifying all the risk consequences, the

following stage is the application of control to reduce the risks. The application of controls in the

process will help in reducing the risks involved and also ensure that the workers and people

involved in the overhauling process are safe from any danger (Maritime and Coastguard Agency,

2004). Implementing the control regulations will also ensure that the sea is protected from

pollution and other issues that can affect the natural state of the sea ecology.

Section 2 Critical evaluation of the process and outcome of a shipboard operation

Fault Identification

The ship machinery often requires routine maintenance to ensure that they remain in the

best working conditions as recommended by the various statutes and regulations controlling the

operation of ships. A failure of a generator can lead to serious casualties on the ship and hence

apart from the routine maintenance; sometimes the problems are severe that requires a complete

overhaul of the generator (Maes, 2013). However, before deciding to do the overhaul, the marine

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engineers on board should be able to know the signs that the generator engine requires a

complete overhaul.

Some of the important signs that one should consider before doing a complete overhaul

include observing the mechanical and electrical behaviours of the generator. One of the signs

showing that the generator needs a complete overhaul include generator failing to take the rated

load (Prousalidis et al., 2005). If the generator is not taking the rated load, then there are high

chances that there is a severe problem that should be checked by the professionals to restore it to

its normal condition. For instance, the generator can show signs such as the overall temperature

of the generator going off the stipulated limit and the important parameters are also showing

unusual figures and fluctuations. The marine engineers should look for this signs, and if any of

them is noted, then an overhaul of the generator should be recommended to make the necessary

repairs and change of parts as appropriate and as relevant to the issue at hand.

Another indicator that the generator requires a complete overhaul is when the generator

records a power imbalance (Prousalidis et al., 2005). The marine engineers have the

responsibility to keep checking all the parameters in the engine and ensure that the readings are

within the recommended range as specified by the manufacturer or the manual. For example, if

the engineers notice a peak pressure variation as compared with the average pressure in any of

the generators, then there should be a serious issue in the combustion chamber, and an immediate

overhaul would be recommended.

The condition of the engine can also be noticed by looking by checking the status of the

lubricating oil (Prousalidis et al., 2005). The status of the engine can be noted by looking at the

quality of the lube oil. The quality of the lube oil can show the condition of the engine and can

be used to decide whether the engine needs an overhaul or not. For instance, if the inspection of

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the engine lube oil is found to be degraded and there is a need to remove or change it before the

limit for the running hours is completed, then it may show that the engine has a problem that can

be solved only through an overhaul of the generator.

The marine engineers should pay close attention to the sound produced by the generator

while operating as such sounds can be used as an indicator of a fault. The marine engineers

should ensure that the engine only produces the normal sound without any unusual knocking

sound. According to Homik (2010), if the engine produces an unusual knocking sound that is

different from the normal sound that it is supposed to produce, then attention should be given to

the specific parts of the generator. An unusual sound may be as a result of misalignment of the

generator parts, worn out bearings and locking gears, and hence an overhaul of the full engine is

recommended to restore the engine back to its normal working sound and to replace the worn out

parts.

Uncontrolled speeds of the generator are also an indicator that the generator is having a

problem and an inspection of its components is required. The uncontrolled speeds of the

generator can lead to mechanical failure, and serious accidents within the ship and hence the

engineers should initiate a quick response if such a case is noticed (Mollenhauer & TschKe,

2010). The generator running at abnormal speeds can be observed during the starting time, but it

can also continue during the operation. The failure of the generator, in this case, can be

associated with the failing fuel pump or any other thing in the fuel supply system. Therefore, if

an over speeding is observed in an engine, appropriate action should be taken to repair the fuel

system and to ensure that the engine runs at the recommended speeds.

Inspection of the generator condition can also be conducted by looking at the crankshaft

deflection using a dial gauge. The readings of the deflection must be within the recommended

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range, and if it is not within the range, it indicates that there is a problem with the main bearings

or there is a misalignment of the crankshaft.

The Overhaul Process

As already mentioned in the above text, the overhauling process is a complex affair that

requires precautions and high level of professionalism. Therefore, the overhauling process is

regarded as the management process, and hence the engineers and the managers should plan and

decide in consent with the ashore office on how the process will be carried out as well as the

expected outcomes. The following preparations should be made before the actual overhaul is

carried out.

Some of the general preparations before conducted the overhaul include discussing with

all the team members on board about the planned procedure so that everyone is aware.

Communicating the plan to the relevant team members ensures that every member of the team or

the company is aware of the planned operation. Communication is also one way of ensuring that

the safety standard is maintained so that other operators on board do not interfere with the

overhauling process (Lois et al., 2004).

The overhauling process should be planned in such a way that if the main generator fails

to provide the required power, other generators will be available to provide the alternative power

required to propel the ship. Also, the engineers should ensure that all the special equipment

required for the operation are on board and are in sound condition to allow for the operation to be

carried out smoothly. Another important preparation for the overhaul is ensuring that all the

spares required for repairing the engine are available before the action commences. The leading

team should prepare a requisition and submit to the management so that procurements can be

done early enough before the final process.

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During the overhaul process, the leading team should use the overhaul guidelines given

by the manufacturer to ensure that they follow the right procedure for disassembling and

assembling the unit. First, the given generator should be isolated from the main switchboard as

well as the automatic start board so that it is disengaged from the rest of the ship power sources.

Isolating the generator from the main switch and the automatic start panel is the preliminary

safety measure that aims at protecting other auxiliary machinery and the people working at the

overhauled site.

The generator should also be disconnected from other systems such as the water cooling,

the oil and fuel system, air system and the lubricating oil system. After disengaging the generator

from the other systems, the disassembling process can start. However, for safety reasons signing

should be done on the site of operation to protect the members of the board and operators from

hazards (Lois et al., 2004). The work area should be secured with tape, and no entry should be

allowed for any unauthorised personnel until the process is completed. The previous overhaul

reports and documentation can be used as a checklist during the operation to ensure that mistakes

committed during the previously are not repeated.

Also, the previous reports and the manual will give a clear direction on the critical

components that should be checked during the overhaul. Measurements of the working

temperature, the crank deflection and speeds should be taken before the operation commences so

that the results can be compared with the standard values for the same. Risk assessment is the

last step in the preparation stage, and it involves identifying all the risks that can be encountered

during the operation and putting all the necessary mitigation steps in place before the operation

(Soares and Teixeira, 2001).

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During the operation, safety should act as the primary concern of all the people involved

in the overhaul process. All the operations should be done following the manual and the

guidelines given by the manufacturer. The engineers carrying out the operation should ensure

that they follow all the safety precautions stated and recommended by the maritime authorities.

All the operators and engineers on board during the operation must adhere to the safety

requirements by wearing protective gears and following the laid down procedures to ensure that

health and safety of everybody in the ship are guaranteed. All the tools and equipment required

for the operation should be placed in a safe place and properly marked to avoid confusion and

injury that may result from knockdowns and falling equipment. Hydraulic jacks and other lifting

equipment should be used to lift heavy components to protect the worker from injury associated

with lifting heavy loads. All the disassembled parts should then be marked and put in secure

place so that they can be easily returned during the reassembling process.

The parts should clean, measured and all the worn out parts replaced with new ones as

indicated in the manual. Consumable parts such as bearings and other types of fasteners can be

replaced as directed by the maintenance manual. While inspecting the generator, care should be

taken against dropping small tools and parts such as nuts and bolts into the crankcase. After all

the necessary changes and cleaning has been completed, all the parts should be fitted back.

The last step in the overhaul step is to test the reassembled generator by taking the

measurements of the crank deflection, addition of new and clean engine oil. Testing if all the

parts are fitted well and tightened before the generator is started again. Testing and fitting help in

ensuring that people on board are protected from any unnecessary accidents that may occur as a

result of a loose connection of the mechanical parts of the generator. Finally, the reassembled

generator can be restarted and its performance monitored by a senior engineer.

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Section 3 Evaluation of roles and responsibilities of those involved in a shipboard operation

As already mentioned in the latter parts of the paper, generator overhauling is a complex

and major operation that requires the approval of the management onboard and those ashore. An

engine overhaul requires the attention of the entire technical team in the company including the

finance department due to the financial implications that can be incurred during the process.

However, the Engine Room Department is the most important department in the operation as

they are responsible for planning and scheduling the overhauling according to the

recommendations of the manufacturer and other technical needs that may arise. The Engine

Room department is expected to make a communication with the other relevant departments to

facilitate the planning and the execution of the generator overhauling operations. The following

departments must be involved in the operation so that it can be a successful endeavour.

Navigating Officers

In the past, the radio department consisted of one person who was a certified radio-

officer. However, the role has since been taken by the navigating officers in modern ships. The

navigating officers are required to hold a General Operator's Certificate, and the ship must have

the GMDSS units fitted. The navigating officers are associated with the navigation of the vessel,

and they are responsible for receiving the business messages confirming the arrival of the vessel

and the cargo to be loaded. The navigating officers are important members of the shipboard and

are responsible for making important navigation decisions, and hence they have a role in the

overhauling operation. The navigation officers must be consulted about the planned operations

so that they can prepare for any uncertainty and also ensure that they adhere to the safety

standards during the implementation of the generator repair plan.

Engine-Room Department

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The engine-room department onboard is responsible for all the repairs and maintenance

works affecting the engine. The engine department is the most important department in the

present operation as they are the ones who are responsible for diagnosing, planning and

executing the repair process. The main personnel in this department include the Chief Engineer,

Engineer, 3

Engineer and the 4

Engineer. Other personnel include Trainee Engineer, Chief

Mechanic, Oiler, Wiper, Mechanic and the Engine Utility Man. All the members of the Engine

Department are important personnel in the generator overhauling operation, and each one of

them must understand their roles in the process.

Chief Engineer

The Chief Engineer onboard a vessel is charged with the responsibility of overseeing the

operations of the entire engineering department. The Chief Engineer plans and oversees that

execution of all the maintenance works and other operations on all the engineering equipment in

the ship. Therefore, the Chief Engineer has a significant role in the generator overhauling as he is

the one responsible for planning the process. The Chief Engineer must decide to conduct an

overhaul of the generator or the engine as the highest qualified technical personnel on the ship.

The Chief Engineer then oversees the implementation of the plan by supervising the disassembly

of the engine and the reassembly to ensure that all the safety and technical standards are met. The

inspection of the components of the engine must be done under the supervision of the Chief

Engineer, and also the final testing after the overhaul must be done in his presence.

, 3

and 4

Engineer

The 2

, 3

and 4

engineers onboard a ship are responsible for all the maintenance

works done on all the mechanical and electrical equipment within the engine room. The

engineers must have an experience of at least four to six years to be able to take part in

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performing such tasks. The engineer will be responsible for carrying out the overhaul operation

by preparing the necessary equipment, putting down the necessary safety precaution measures

and ensuring that the operation is conducted according to the manual.

Trainee Engineer

The trainee engineers reports to the second engineer and they help in carrying out the

repair and maintenance activities within the engine room. The generator overhaul operation

involves various activities and handling of numerous components hence making the trainee

engineers important in carrying out the operation. The trainee engineers will help in other

activities as directed by the senior engineers.

Chief Mechanic and the Mechanics

The chief mechanic will work together with the engineers to accomplish the mission and

support the operation so that it can meet its specified objectives. The mechanics will help in

disassembling the generator unit under the supervision of the engineers and the chief mechanic.

Section 4 Reflection

The ship generator is an important component as it is the primary source of power for all

the other machinery in the vessel. The generator provides the power required to power other

auxiliary machinery such as the air conditioner, the refrigeration system, pump and other

machinery onboard a ship. Learning about generator overhauling has been challenging and

insightful at the same time as I have gotten the opportunity to dig deep into the specifics of the

operation.

At first, I believed that such a complex operation could not be performed onboard.

However, through this research, I have proved that the main generator used to propel the ship can

be repaired on board, and the ship still has an alternative source of power to propel it. The

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assignment has given me an opportunity to identify many issues about ship engine repair and

maintenance that I did not know before. Through the class lectures and the sources used in this

assignment, I have been able to realise the importance of health and safety in any ship onboard

operations.

Healthy and safety is an important consideration in every shipboard operation, and it is

everyone's responsibility to ensure that all the safety precautions are met and achieved. Through

this assignment and the class lectures, I have learnt that as an engineer, it is my responsibility to

ensure that I observe all the safety precautions while carrying out my duties while on board.

Engine overhauling is a complex procedure that requires cooperation between various personnel

and departments both on board and ashore. The process involves the technical team as well as

the logistical team which are responsible for fulfilling the requisition for the spare parts required.

The latter is contrary to what I had believed before that any engine maintenance practices is to be

conducted the engine department entirely without involving the other departments. However,

through the sources that I have used to do this assignment, it has come to my understanding that

engineers onboard must work in close cooperation with other departments in the shipping

company to ensure that various operations are completed successfully.

I have also been able to identify my roles as an onboard trainee engineer. As a trainee

engineer, my main duties include taking instructions from the senior engineers and completing

tasks as an assignment by them. As a trainee engineer, I am not allowed to work on any task

without supervision from the senior engineers. For instance, my roles in the engine overhaul

process may include fixing or cleaning various components of the engine as instructed by the

Chief Engineer or any other senior engineer on site.

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Communication is one of the most important factors that promote safe operation and

collaboration among all the personnel onboard a ship. Communication involves the way in which

information flows from one person to the other or from one department to the other. Developing

a collaborative team for implementing the engine overhaul process requires the use of an

effective communication system to coordinate the teams so that they can work towards a similar

goal.

Throughout the term learning about shipboard operations, I have enjoyed most of the

lessons and lectures as they were conveyed effectively relating the theory and the practical

environment. This assignment has also given me the opportunity to apply my research skills to

collect sources and make a report about a shipboard operation. The assignment has also given me

the chance to connect the theoretical work with the real world hence making it an effective tool

in knowledge addition. I face several challenges while doing the research but I managed to

handle the majority of them. For instance, the topic had limited academic sources, and most of

the sources that were available did not highlight the specific steps involved in overhauling a

cruise liner vessel engine.

CRUISE LINER VESSEL GENERATOR OVERHAUL 17

References

MARITIME AND COASTGUARD AGENCY (GREAT BRITAIN). (2004). Code of safe

working practices for merchant seamen. London, Stationery Office.

MAES, W. (2013). Marine Electrical Knowledge. Antwerp Maritime Academy, pp.1-52.

ORGANISATION, T. I. M. (1981). International Convention for the Prevention of Pollution of

the Sea by Oil, 1954. London, International Maritime Organisation.

Homik, W., 2010. Diagnostics, maintenance and regeneration of torsional vibration dampers for

crankshafts of ship diesel engines. Polish Maritime Research, 17(1), pp.62-68.

Morelli, J.J., 1967. Maintainability Design Requirements for Future Jet Engines (No. 670330). SAE

Technical Paper.

Driscoll, M.J. and Picozzi, J., 2004, January. Resultant benefits of standardised overhaul

packages for LM2500 propulsion gas turbine engines in US Navy applications. In ASME Turbo

Expo 2004: Power for Land, Sea, and Air (pp. 1793-1799). American Society of Mechanical

Engineers.

Soares, C.G. and Teixeira, A.P., 2001. Risk assessment in maritime transportation. Reliability

Engineering & System Safety, 74(3), pp.299-309.

Lois, P., Wang, J., Wall, A. and Ruxton, T., 2004. Formal safety assessment of cruise

ships. Tourism Management, 25(1), pp.93-109.

Prousalidis, J., Hatzilau, I.K., Michalopoulos, P., Pavlou, I. and Muthumuni, D., 2005, July.

Studying ship electric energy systems with shaft generator. In Electric Ship Technologies

Symposium, 2005 IEEE (pp. 156-162). IEEE.

MOLLENHAUER, K., & TSCHKE, H. (2010). Handbook of diesel engines: with 86 tables.

Berlin, Springer.

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