Kazakhstan Maritime Engine Officer cheat sheet

Two-stroke marine diesel firing order: fuel injection begins 10-20° before TDC; exhaust valve opens 80-110° after TDC; scavenge air ports uncover 110-140° after TDC.

Indicated power per cylinder: IHP = (p_mi × L × A × n × 10) / 60 for a two-stroke, where p_mi is mean indicated pressure in bar, L stroke in m, A piston area in m², n rpm.

Specific fuel consumption (SFSC) = fuel mass flow (kg/h) ÷ brake power (kW). Modern two-strokes: 160-175 g/kWh; four-strokes: 175-195 g/kWh.

Turbocharger surge is caused by low air flow relative to pressure ratio: rapid load reduction, fouled turbine, or scavenge fire. Recovery: reduce load, open auxiliary blower, clean nozzle ring.

Auxiliary boiler safety: low-water level trips the burner; flame failure must shut the fuel valve within 3 s on loss of flame signal; relief valve set at 1.1 × design pressure.

Cylinder liner wear limits: max 0.7-1.0% of bore diameter; ovality max 0.5% of bore; replace when wear rate exceeds 0.1 mm per 1,000 h.

Fuel injection timing too advanced raises peak pressure and NOx; too retarded raises exhaust temperature and fuel consumption.

Governor droop: speed droop % = (n_no-load − n_full-load) ÷ n_full-load × 100. Isochronous governors have zero droop and require load sharing via load-sharing lines.

Insulation resistance minimum for 440 V circuits: 1 MΩ at 500 V DC test voltage; for 220 V: 0.5 MΩ; for 24 V DC: 0.2 MΩ.

Three-phase power: P = √3 × V_L × I_L × cos φ. For a 440 V, 100 A motor at 0.85 PF: P ≈ 64.7 kW.

Generator paralleling: synchronise on voltage, frequency, phase angle and phase sequence; close within ±10° phase angle and < 0.5 Hz slip frequency.

Reverse power protection trips at 5-10% of rated power with 1-3 s delay for a diesel generator.

Preferential trip (load shedding) operates before the main breaker trips: non-essential loads are shed in steps at 90-95% generator load.

Earth fault on an insulated-neutral system: single fault does not trip; locate within 24 h; second fault on another phase causes a short circuit.

Battery charging: lead-acid float voltage 2.23-2.27 V/cell; boost 2.4 V/cell; gassing begins above 2.35 V/cell; hydrogen LEL 4% by volume.

PLC scan cycle = input scan + program execution + output update; typical 5-50 ms. Watchdog timer trips the output module if the cycle exceeds the limit.

Planned maintenance system (PMS) records: job card, running hours, spares consumed, technician, date, and sign-off by the Chief Engineer.

Crankshaft deflection measurement: take at every 5° or defined positions; compare against builder's limits; a change > 0.05 mm between successive readings indicates bearing misalignment.

Non-destructive testing: dye penetrant for surface cracks; magnetic particle for ferrous surface/subsurface; ultrasonic for internal defects; radiography for welds.

Torque values: use calibrated torque wrench; re-torque cylinder head bolts cold or hot per builder's manual; keep a torque log.

Spare parts classification: critical (no sail without), essential, and consumable. Minimum critical spares are listed in the ship's approved PMS and SMS.

Vibration limits (ISO 10816): 2.8 mm/s RMS good; 4.5 mm/s acceptable; 7.1 mm/s alarm; 11 mm/s trip for class II machines.

Lubricating oil analysis: viscosity ±25% of nominal, water < 0.2% for main engines, iron trending; TBN for cylinder oils matched to fuel sulphur (BN ≈ 40 for 2.5% S fuel).

Hot work and repair: permit-to-work, fire watch, gas-free certificate, and Chief Engineer's approval are required before any repair involving ignition sources.

Principal dimensions: length overall (LOA), length between perpendiculars (LBP), moulded breadth, moulded depth, summer draught. Block coefficient C_B = ∇ ÷ (L × B × T).

Metacentric height GM = KM − KG. Positive GM gives initial stability; GM must stay positive in all loading conditions.

Free surface effect reduces effective GM by FSC = (i × ρ) ÷ (∇ × ρ_sw), where i is the free surface second moment of area.

Load line marks: S (summer), W (winter), T (tropical), F (fresh), TF, and WNA; freeboard is measured from the deck line to the appropriate mark.

Double bottom and cofferdam: fuel tanks separated from sea water by cofferdams; sounding pipes must be self-closing on tank tops.

Structural members: longitudinal girders, floors, web frames, stringers, brackets. Tank boundaries require class-approved welding and NDT.

Bulkhead and watertight door classification: A-class (60 min), B-class (30 min) fire divisions; watertight doors must be operable from the bridge.

Engine room skylight, ventilator and casing openings must be closable from outside the space and marked as such.

Relief procedure: the relieving engineer must be satisfied with the plant condition, ongoing work, and standing orders before taking over; the relieving engineer signs the bell book.

Unattended machinery space (UMS) alarm checks: test alarm and safety systems at least once every 24 h; record in the engine room log.

Bridge bell book entries: every engine order, time, and acknowledgement. A wrong order must be challenged and clarified before execution.

Engine room log entries: every 1-2 h record pressures, temperatures, fuel and lube oil levels, and running hours.

Chief Engineer must be called for: loss of propulsion, fire, flooding, blackout, main engine alarm requiring immediate action, or serious injury.

Periodic checks: bilge levels, sea water strainers, fuel oil purifier operation, boiler water level, air receiver pressure, and running machinery temperatures.

Bunkering watch: continuous attendance, scuppers plugged, communication with the barge, tank soundings every 30 min, drip tray monitoring.

Handover to UMS: confirm all alarms tested, no ongoing maintenance, no bypassed safety devices, and the duty engineer is on board.

Closed-loop communication: sender states the order, receiver repeats it, sender confirms. Use for all engine orders and critical operations.

Challenge and response: any crew member may challenge an unsafe order; the challenge must be acknowledged and resolved before execution.

Situational awareness: maintain a shared mental model of plant state; verbalise changes; brief before complex operations such as manoeuvring.

Fatigue management: STCW rest hours minimum 10 h in 24 h and 77 h in 7 days; watch schedules must be posted and records kept.

Authority gradient: a steep gradient suppresses reporting; briefings should invite questions and confirm understanding.

Error chain: most accidents result from a chain of small errors; break the chain by stopping, verifying, and escalating.

Team briefing content: task, hazards, roles, communication method, contingency, and abort criteria.

Emergency team roles: Chief Engineer as emergency coordinator, Second Engineer as damage control leader, duty engineer as initial responder.

STCW 2010 Manila Amendments: minimum age 18, 12 months sea service for OOW, 36 months for Chief Engineer, and 5-yearly revalidation of certificates.

SOLAS Chapter I: certificates (Safety Construction, Safety Equipment, Safety Radio) valid 5 years; annual and intermediate surveys required.

MARPOL Annex I (oil): Oil Record Book Part I for machinery space operations; Part II for cargo; entries for every transfer, disposal, and oily water separator operation.

MARPOL Annex VI: sulphur limit 0.50% m/m global from 1 January 2020; 0.10% in ECAs; NOx Tier III for new ships in NOx ECAs; EEDI/EEXI/CII reporting.

Oil discharge at sea (Annex I): only via 15 ppm oily water separator, outside special areas, ship en route, not within 12 nm of land, with ORB entry.

Port State Control: Paris MoU targets ships by flag, company, and class performance; three or more detentions in 36 months triggers expanded inspection.

ISM Code: Safety Management Certificate valid 5 years; Document of Compliance for the company; internal audits annually.

Flag State responsibilities: survey, certification, casualty investigation, and enforcement of conventions on ships flying its flag.

Fire triangle: fuel, oxygen, heat. Extinguishing by removing fuel (isolate), oxygen (smother), or heat (cool).

Class B fire (oil): use foam, CO2, dry powder, or water spray (not jet). Class C (gas): isolate and use dry powder. Class A: water.

CO2 fixed system: discharge reduces O2 below 15%; space must be sealed and ventilated after discharge; entry only with breathing apparatus.

Fire main pressure: 2.5-6.5 bar at hydrant; hose and nozzle at every hydrant; annual flow test.

Enclosed space entry: permit, atmosphere test (O2 20.9%, LEL < 1%, H2S < 5 ppm, CO < 35 ppm), attendant at entrance, rescue equipment ready.

Hot work permit: gas-free certificate, fire watch, extinguisher, 30-minute post-work watch, and removal of combustibles within 11 m.

Personal protective equipment: safety helmet, safety shoes, gloves, goggles, ear protection, and coveralls in the engine room.

Fire drills: SOLAS requires monthly drills; engine room fire drill at least once every 3 months; record in the official logbook.

Flooding response: sound general alarm, close watertight doors, start emergency fire pump and bilge pump, locate and shore the breach, monitor stability.

Blackout recovery: start emergency generator, restore emergency switchboard, then sequentially restart main generator, lube oil pump, cooling pumps, and main engine.

Steering gear failure: switch to emergency steering, inform bridge, reduce speed, and post a helmsman at the emergency station.

Oil spill response: stop the source, contain with booms, use absorbents, notify the bridge and company, and record in the ORB and log.

SOPEP: Shipboard Oil Pollution Emergency Plan must be approved and carried; includes reporting procedures and coastal state contacts.

Damage control: priority is to save the ship and crew, then cargo, then environment. Flooding and fire are the primary threats to stability.

Emergency fire pump: located outside the engine room, capable of two jets at 0.25 N/mm², and tested weekly.

Muster list: posted in the engine room, accommodation, and bridge; includes duties for fire, abandon ship, and man overboard.

SMCP phrases: "Stand by engine", "Finished with engines", "Dead slow ahead", "Full astern", "Stop engine", "Ring off engine".

Engine order telegraph: acknowledge by repeating the order and moving the telegraph to the ordered position; then execute.

Mayday: distress call on VHF Ch 16, "Mayday, Mayday, Mayday, this is [ship name], position, nature of distress, assistance required".

Pan-pan: urgency call; Securite: safety call. Use plain language where SMCP does not cover the situation.

Bridge-to-engine room communication: use the engine order telegraph, sound-powered telephone, or VHF; confirm every order verbally.

Written communication: engine room log, night order book, standing orders, and defect reports must be clear, dated, and signed.

Numbers and positions: state latitude/longitude in degrees, minutes, and decimals; use phonetic alphabet for call signs.

Emergency communication: internal alarm, PA system, and GMDSS DSC on VHF Ch 70 for distress alerts.

CPR ratio: 30 compressions to 2 breaths for adults; compression rate 100-120/min; depth 5-6 cm.

Recovery position: for unconscious breathing casualties; monitor airway, breathing, and circulation.

Burns: cool with running water for at least 10 minutes; do not remove adhered clothing; cover with sterile non-adherent dressing.

Hypothermia: remove wet clothing, insulate, give warm drinks if conscious; do not rub extremities; handle gently.

Personal survival: lifejacket donned before abandoning ship; immersion suit reduces heat loss; assume HELP position in water.

Abandon ship: muster at station, take survival craft, follow the person in charge, do not jump unless necessary.

First aid kit: check expiry dates monthly; include bandages, antiseptic, gloves, and resuscitation mask.

Medical emergency: call the master, use the ship's medical guide, and request radio medical advice via the coast radio station.