Ship Machinery Alarms and Protection Devices
Summary
TLDRThe video script highlights the critical role of alarm and protection systems in preventing machinery breakdowns on ships. It emphasizes the importance of proper operation, maintenance, and testing of these systems to ensure reliability and safety. The script provides insights into the hierarchy of alarm priorities, from top-priority systems like main propulsion engines and steering to less critical ones like cargo pumps. It also stresses the necessity for engineers to understand and respond effectively to alarms, underscoring the significance of good engineering practice in averting disasters.
Takeaways
- 🔍 **Importance of Alarm Systems**: The script emphasizes the crucial role of alarm systems and protection devices in preventing machinery breakdowns and disasters on ships.
- 🛠️ **Maintenance and Operation**: It highlights that many breakdowns occur due to inadequate maintenance, incorrect operation, or deliberate disconnection of alarm systems.
- 🚫 **Consequences of Neglect**: The script warns that neglecting alarm systems can lead to serious incidents, including injuries, major breakdowns, and operational disruptions.
- 🔑 **Attention to Detail**: It stresses the importance of duty engineers paying close attention to detail to avoid unforeseen incidents and maintain the reliability of ship systems.
- 🛑 **Protection Circuits**: The text explains that protection circuits not only provide warnings but also initiate shutdown procedures to prevent damage to critical machinery.
- 📊 **Prioritization of Alarms**: It discusses the prioritization of alarm systems based on their importance to the ship's operation, with some being top priority and others less critical.
- 🔬 **Testing and Calibration**: The script insists on the necessity of regular testing and calibration of sensors and alarm systems to ensure their accurate function.
- 📝 **Documentation**: It mentions the importance of recording test results and maintaining documentation for future reference and quality control.
- 👨🔧 **Engineer's Responsibility**: The text underscores the duty engineer's responsibility to understand the alarm and protection systems, including their relative importance and the necessary actions upon activation.
- 🚫 **Avoidance of Premature Reset**: The script advises against pressing the reset on alarms without understanding and addressing the cause, to prevent recurring issues.
- 🛡️ **Confidence in Systems**: Lastly, it concludes with the need for engineers to have confidence in the alarm system and protection devices for timely warning and remedial action.
Q & A
What are the common causes of machinery breakdowns mentioned in the script?
-The script mentions that a large number of machinery breakdowns occur due to mistakes in operation or maintenance of the alarm systems and protection devices, including being deliberately disconnected, clogged up with paint, or neglected and forgotten.
What is the consequence of ignoring alarm systems and protection devices on a ship?
-Ignoring alarm systems and protection devices can lead to serious breakdowns, potential injuries to people, major machine damage, and disruptions to the commercial operation of the vessel, resulting in extra workload for the ship's personnel.
How does a typical alarm circuit function in the context of the script?
-A typical alarm circuit has a censoring device such as a level sensor, thermocouple, or pressure sensor connected to display devices. When certain values are reached, a switch is activated, sending an electrical or pressure signal to the ship's alarm panels, causing an audio-visual warning that remains until acknowledged and the issue is resolved.
What is the purpose of a protection circuit in addition to a warning circuit?
-A protection circuit, in addition to providing a warning, initiates a shutdown procedure of the affected machines by activating one or more switches or valves, causing the machine to halt in a controlled manner to prevent damage.
Why is it important for engineers to understand the alarm and protection systems on a ship?
-It is important for engineers to understand these systems to ensure they can respond appropriately to alarms, know the relative importance of each system to the ship's operation, and maintain the reliability of the ship's systems by preventing potential hazards.
What are some examples of top-priority alarm and protection circuits on a ship?
-Top-priority alarm and protection circuits include those that protect the main propulsion engine, steering system, power generation plant, and steam boilers, as any breakdown in these systems can be catastrophic.
How do level indicators function as part of the alarm system?
-Level indicators monitor liquid levels in tanks and are activated by the liquid itself. When the level rises or sinks below set safety levels, a sensor sends a signal to warning devices, usually with an indicator.
What is a flame out alarm system and why is it important?
-A flame out alarm system uses optical sensors, known as flame eyes, to continuously monitor the presence of flame in a boiler. It provides an instant warning if the flame goes out, which is critical because a sudden loss of flame can lead to undesirable and dangerous consequences.
How should engineers test sensors to ensure the reliability of the alarm system?
-Engineers should test sensors regularly according to the ship's maintenance or test schedules. They must use calibrated test instruments and record the details of the test for future reference. The testing should cover both minimum and maximum limits of the sensor's operation.
What steps should be taken when an alarm is activated on a ship?
-When an alarm is activated, the duty engineer must identify the significance of the alarm, determine the system's importance, take measures to eliminate the cause of the alarm, and execute countermeasures in the correct order. They should never reset an alarm without understanding and addressing the cause.
Why is it essential for engineers to have confidence in the alarm system and protection devices?
-Confidence in the alarm system and protection devices is essential because it ensures that engineers will be given timely warnings of any changing conditions that may lead to a breakdown, allowing them to take remedial action and maintain good engineering practice.
Outlines
🚨 Importance of Alarm Systems and Maintenance
This paragraph discusses the critical role of alarm systems and proper maintenance in preventing machinery breakdowns. It highlights how negligence in checking and maintaining these systems can lead to serious incidents, including major equipment damage and operational disruptions. The text emphasizes the need for engineers to pay meticulous attention to the alarm and protection systems to ensure the reliability and safety of the ship's operations.
🔍 Understanding Alarm and Protection Circuits
The second paragraph delves into the specifics of alarm and protection circuits, explaining how they function using sensors and switches to monitor machinery conditions. It outlines the importance of recognizing priority levels of different systems on a ship, such as main propulsion engines and power generation plants, which are considered top priority due to their critical role in ship operations. The paragraph also introduces the concept of warning-only alarms that do not initiate shutdowns but alert to potential hazards.
🛠️ Testing and Calibration of Sensor Systems
This paragraph focuses on the necessity of regular testing and calibration of sensors to ensure the reliability of alarm and protection systems. It details the process of testing temperature and pressure sensors, emphasizing the importance of using calibrated instruments and recording test results for future reference. The text stresses the need for engineers to understand the critical nature of these systems and to follow proper maintenance schedules to prevent malfunctions.
⚠️ Alarm System Best Practices and Engineer's Role
The final paragraph concludes with best practices for alarm system management and the crucial role of engineers in maintaining these systems. It advises on the importance of understanding the significance of different alarms, following maintenance schedules, and ensuring all sensors and display systems are fully operational. The paragraph also discusses the correct procedures for responding to alarms, including investigating the cause before resetting and never restarting equipment without addressing the underlying issue.
Mindmap
Keywords
💡Machinery Breakdowns
💡Alarm Systems
💡Protection Devices
💡Operational Procedures
💡Maintenance Regime
💡Blackout
💡Consequential Breakdowns
💡Censoring Device
💡Audio-Visual Warning Devices
💡Shutdown Procedure
💡Calibration
💡Test Pump and Gauge
Highlights
A large number of machinery breakdowns occur due to mistakes in operation or maintenance of alarm systems and protection devices.
Engines, generators, boilers, and compressors can be fatally damaged if alarm systems and protection devices are prevented from working.
Attention to detail by duty engineers can avoid unforeseen incidents and major machine breakdowns.
Neglecting alarm systems and protection devices can lead to unscheduled events and consequential breakdowns.
Engineers on board must ensure alarm systems work properly at all times for reliable ship operation.
A typical alarm circuit has a censoring device connected to display devices that trigger an alarm when certain values are reached.
Protection circuits initiate a shutdown procedure of affected machines when limit switches are activated.
Alarm and protection systems are crucial for monitoring and protecting vital ship components like main propulsion engines and steering systems.
Understanding the relative importance of different alarm and protection circuits is essential for engineers.
Boiler water level alarms are critical for ensuring safe operation and preventing dangerous situations.
Flame out alarm systems with optical sensors provide instant warning in case of sudden flame loss in boilers.
Main propulsion engine alarm and protection devices use temperature and pressure sensors for monitoring operational conditions.
Regular testing of sensors in accordance with maintenance schedules ensures accurate function of alarm and protection systems.
Only calibrated test instruments should be used for testing sensors to maintain system reliability.
Engineers must know the alarm and protection systems thoroughly, including their importance to the ship's proper function.
When an alarm activates, the duty engineer must be able to answer critical questions about the alarm and take appropriate measures.
Never press the reset on an alarm without noting the cause to prevent recurrence of the issue.
Adjustments to temperature or pressure switches should be made using calibrated instruments and considering the direction of change.
Engineers must have confidence in the alarm system and protection devices for timely warning of conditions that may lead to breakdowns.
Transcripts
These are scenes of avoidable and expensive disasters did they occur due
to bad design inadequate maintenance or incorrect operational procedures
experience shows that a large number of machinery breakdowns occur due to a
mistake in operation or maintenance of the alarm systems and the protection
devices yes engines generators boilers compressors
do break down sometimes fatally damaged because the alarm systems and the
protection devices monitoring them have been prevented from working sometimes
deliberately disconnected sometimes clogged up with paint and forgotten
abandoned without checking for long periods of time
this of course is asking for trouble when only a little attention to detail
by duty engineers could avoid an unforeseen incident resulting in
possible injuries of people major machine breakdowns upsetting the
commercial operation of the vessel leading to extra workload for ship's
personnel
once are less than meticulous checking and maintenance regime of the alarm
systems is allowed to develop onboard ship things can go wrong at any time the
ship's systems cease to be reliable because no one can be sure which alarm
is working and which is not
now what a blackened
this can occur as a direct consequence of neglecting the alarm system and
protection devices now the search begins what caused the blackout how long will
it take to get things going again why isn't the standby generator or the
emergency generators starting how long will it take to find the answer an
unscheduled event like this can cause consequential breakdowns as well let's
hope it's not too bad
unfortunately a ship cannot run on the basis of hope alone the engineers on
board ship must be sure that the alarm systems work properly at all times there
is no other way
let's leave this nightmare scenario now and look at a typical schematic view of
an alarm and protection system and its function a typical alarm circuit has a
censoring device such as a level sensor a thermocouple or pressure sensor these
are normally connected to display devices
which may have minimum and maximum values marked on them when these values
are reached a switch is activated and an electrical
or pressure signal is sent to the ship's alarm panels and audio-visual warning
devices the light on the panels will remain on or continue flashing until the
alarm has been acknowledged by the duty engineer and the condition which has
caused the alarm to activate is removed if it is a protection circuit as well as
a warning circuit the activation of the limit switch also initiates a shutdown
procedure of the affected machines that is the protection circuit activates one
or more switches or valves causing the protective machine to come to an
unscheduled halt but in a controlled manner this is how the system looks
using internationally recognized symbols
a typical example of this system operates on a main engine or on a
generator diesel the sensor may be a lube oil temperature or pressure sensor
or cylinder liner temperature sensor any one of these may indicate action devices
as well as some less important circuits
do you know which circuits on your ship are very important than which a less sir
if you came across a faulty sensor would you know if it was part of a
top-priority circuit or a relatively less critical one you need to know
all alarm and protection devices would protect the main propulsion engine and
the steering system are of top priority as are those on the power generation
plant and steam boilers these plants are vital components of ship's control any
breakdown or serious loss of these functions can be catastrophic for the
ship and its crew
still very important but not top priority are the alarms and protection
devices monitoring the air compressors air conditioning systems and
refrigeration systems they may not be as critical in the North Sea as they are in
the Gulf other systems such as cargo pump alarms or bow thruster alarms may
be low or high priority depending on the ship's working condition there are
warning only alarm systems which do not protect but warn of
potentially hazardous conditions arising these are normally level indicators or
temperature sensors in tanks and heating or cooling systems
now let's look at census starting with level indicators these monitor liquid
levels in fuel tanks lube oil tanks boilers and the like the simplest
systems are activated by the liquid itself the device is activated by the
level of the fuel rising or sinking a bath or below the set safety levels when
this occurs a sensor sends a signal to the warning devices coupled usually with
an indicator one of the most important level alarms onboard ship monitors the
boiler water level it is critical to maintain the right water level in
pointers especially in high pressure water tube boilers to ensure safe
operation a very dangerous situation can rapidly arise if the water quantity
inside the boiler is not maintained at the correct level there are visual level
indicators as well as alarm sensors monitoring the water level to check that
it is within set safety limits whilst we're dealing with boilers we must
mention a unique sensor and alarm circuit known as the flame out alarm
system a sudden loss of flame inside the boiler can lead to many undesirable
consequences therefore optical sensors flame eyes provide continuous monitoring
of the presence of flame and will give instant warning should the flame go out
the main propulsion engines alarm and protection devices can be looked at as
the most important ones onboard ship
on a typical diesel unit these employ temperature and pressure sensors which
monitor operational conditions to ensure optimum operation and effective
lubrication
for example the temperature sensors check the jacket cooling freshwater
outlet the lube oil inlet the fuel oil inlet and the reduction gear lube oil
inlet these are all of primary importance the pressure sensors monitor
the main lube oil inlet the reduction gear lube oil inlet the turbocharger
lube oil inlet and the cooling fresh water inlet among others these are all
part of the main engines protection system as well as providing warning
signals identical systems operate on other diesel engines such as those
driving the generators
because of their critical function these sensors must be tested regularly in
accordance with the ship's maintenance or test schedules ensuring accurate
function only sensors supplied with a valid certificate or assurance of
calibration should be installed and only calibrated test instruments must be used
for testing
here a temperature sensor is tested at both the minimum and maximum limits of
its operation
the quality control is on the measuring device attached to the testing
instrument
this one is using an oil bath with a controlled heating device and calibrated
thermometer
details of the test are recorded for future reference
the alarm setting can usually be read from the central monitoring system
provided that it can be demonstrated as operational this is done by resetting
the alarm to a normal value or by simulating an alarm value
but the most convenient method for this test is the use of a test pump and gauge
here a lube oil Inlet pressure sensor is tested with a precision testing
instrument
testing level alarms sometimes involves activating the alarm manually in this
case a builds well alarm and monitoring the response in accordance with the set
parameters
the test results should then be recorded for future reference
all these tests are most important to ensure that the monitoring system is
reliable at all times
the ship's manual will provide the necessary details for each test
applicable to the system's onboard
each engineer on board must know the alarm and protection systems thoroughly
including their relative importance to the ship's proper function each time an
alarm activates the duty engineer must be able to answer a number of critical
questions what does not alarm signify how important is the system to which it
relates what measures must be taken to eliminate the cause of the alarm
condition in what order should the countermeasures be executed
in conclusion it is essential that you know your ship's alarm system and
protection devices let you pay special attention to the critical alarm circuits
onboard ship that you always follow the alarm systems maintenance schedule and
ensure that all sensors and display systems are fully functional when an
alarm condition arises never press the reset without noting the cause of the
alarm if an adjustment must be made to temperature or pressure switches it is
essential that a calibrated instrument is used and direction of change is taken
into account for example when setting the starting pressure of a compressor
the setting should be the design figure with the pressure dropping when an
adjustment has been made always repeat the tests at different values no
adjustment should be permitted without checking at least two values afterwards
when an automatic restart circuit is involved in machine control it should
always be switched to manual and off before pressing reset to avoid the
machines starting automatically when reset equipment should never be
restarted or put back into service without rectifying the cause of the
alarm trip any abnormal run indication should always be investigated even if
the equipment is apparently running smoothly
the engineer on watch must have confidence in the alarm system and
protection devices in the engine room
he must be short all times that he will be given timely warning of any changing
condition which may lead to a breakdown so that he can take remedial action this
confidence is an essential component of good engineering practice
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