❑ Troubleshooting faults in Bilge and sludge transfer system

Bilge / sludge pump not pumping

❑ Clogged Filter

❑ Loss of vacuum due to leaking suction line, suction valve gland packing, cracked valve body
or valve bonnet

❑ Suction filter gasket or O ring damaged

❑ Extremely high temperature of the liquid medium causing the vapour lock in the pump

❑ Leaking gland packing on suction side pump shaft

❑ Leaking pump suction valves, short circuit between pump suction and discharge

❑ Worn out stator as a result of dry running of the progressive cavity pump (Jabsco pump).

❑ Diaphragm punctured, spool valve stuck / spool valve sealing damaged in case of diaphragm
pumps.

❑ Worn out gears, bushes in case of gear pumps

❑ Leaking pump relief valve

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❑ Troubleshooting faults in operation of Compressor

❑ Compressor capacity is low

❑ Leaking suction/Discharge valve.

❑ Faulty or leaking unloader.

❑ Intake filter clogged.

❑ Leaking relief valves.

❑ Leaking gaskets.

❑ Restricted discharge line.

❑ Cut-in and Cut-off setting too close.

❑ Piston ring, piston / Cylinder liner worn.

❑ Cylinder head gasket has given way between

❑ the suction and discharge, internally.

❑ Increase in bumping Clearance.

❑ Oil Carry over in air

❑ Intake filter clogged.

❑ Oil separator not working,

❑ Piston ring, piston / Cylinder liner worn.

❑ Valves fouled, not seated correctly, valves broken.

❑ High Discharge air temperature

❑ Chocked air suction filter.

❑ High ambient air temperature.

❑ Dirty coolers.

❑ Absence of forced ventilation near the compressor.

❑ Insufficient cooling water.

❑ Crankcase oil Emulsified

❑ Liner / Jacket water leaking.

❑ Leakage in cooler.

❑ Breather Leaking.

❑ Operation in high humid conditions

❑ First Stage Discharge pressure low

❑ Faulty pressure gauge.

❑ Suction filter choked.

❑ First stage unloader is leaking.

❑ First stage suction valve Leaking.

❑ Worn out piston rings.

❑ First Stage Discharge pressure High

❑ Second stage valves leaking.

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❑ Troubleshooting faults in operation of Coolers and Condensers

❑ Failure of sealing O- ring between the two mediums.

❑ Leaking tube.

❑ Erosion on the tube plate face due to high water velocity.

❑ Insufficient thermal capacity or reducing performance

❑ Operating condition not matching design condition.

❑ Fouling of the heat exchanger due to scales, debris and blockages

❑ Too many plugged tubes.

❑ End cover sealing face between the inlet and outlet section damaged leading to direct
bypass.
❑ Loss of vacuum due to ingress of air in case of vacuum condensers.

❑ Improper venting of the heat exchanger / Chocked venting valve.

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❑ Troubleshooting faults in operation of OWS

❑ Problems in suction

❑ Clogged Filter (showing high vacuum).

❑ Loss of vacuum due to hole in suction line,

❑ Suction valve gland leaking,(No vacuum).

❑ Leaking O-ring / gasket of filter cover.

❑ Pump unable to discharge

❑ Pump coupling pin sheared off.

❑ Pump stator damaged.

❑ Pump motor overload

❑ Overboard Discharge valve closed.

❑ Motor Faulty.

❑ Frequent Oil Content high Alarm

❑ OWS initially not primed with FW.

❑ Oil sensor is sensing air as water level is below the probe.

❑ Coalescer dirty and saturated.

❑ Heating not opened, if provided.

❑ Operation in rough weather.

❑ Pneumatic valves not operating

❑ Air to the valves is shut.

❑ Pneumatic actuators stuck, sealing rings damaged.

❑ Defective solenoid valves.

❑ Zero ppm not achieved during initial calibration

❑ Measuring cell tube dirty.

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❑ Troubleshooting faults in Pumps

❑ Problems in suction

❑ Clogged Filter (showing high vacuum).

❑ Loss of vacuum due to hole in suction line . Suction side gland leaking,(No vacuum).

❑ Cavitation

❑ Loss of head due to vaporization.

❑ Air ingestion on the suction side.

❑ Heating of the fluid on the suction side.

❑ No discharge pressure

❑ Faulty discharge pressure gauge.

❑ Pump insufficiently primed.

❑ Insufficient pump speed.

❑ Wrong direction of rotation.

❑ Not building pressure

❑ Damaged impeller.

❑ Worn out wear rings.

❑ Leaking relief valve in case of positive displacement pumps.

❑ Presence of air in the system

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❑ Troubleshooting faults in operation of Purifiers

❑ Excessive Vibrations

❑ Excess accumulation of sludge.

❑ Foundation damper and spring failure.

❑ Worm gear worn out.

❑ Uneven wear of friction clutch.

❑ Motor speed too high or too low.

❑ Purifier Overflow

❑ Incorrect gravity disc size (ID two large).

❑ Too low fuel oil temperature.

❑ Throughput high.

❑ Excessive sludge inside the bowl.

❑ Bowl rotating at low rpm.

❑ Operating water Failure.

❑ Sealing water Failure.

❑ Worn out main seal ring.

❑ Solenoid valve for the feed valve stuck.

❑ Pilot valve stuck.

❑ Main sliding cylinder stuck in open position

❑ Purifier not able to attain the actual speed

❑ Friction pads worn out.

❑ Friction pulley worn out due to pad screws rubbing against the friction pulley.

❑ Excessive sludge in the bowl.

❑ Bearing Failure.

❑ Motor running at overload.

❑ Single phasing of motor.

❑ Vertical and horizontal shaft misalignment

❑ Water content in the oil increasing

❑ Sealing water solenoid valve leaking.

❑ Problems in interface.

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❑ Troubleshooting faults in operation of A.E

❑ Starting Failure (Flywheel not turned)

❑ Starting air pressure insufficient.

❑ Turning gear interlock switch active / limit switch stuck in engaged position.

❑ Air motor pilot solenoid valve defective / air motor stuck due to seized parts.

❑ Start / Stop lever in stop position.

❑ Stop cylinder O ring leaking/Stop cylinder position shifted.

❑ Seizure of moving parts like piston in liner / Seizure of Main Bearing / Cam shaft Bearing.

❑ Flywheel Turns But No Ignition

❑ Fluid Tank empty / Fuel Valve closed.

❑ Clogged Fuel filters / Pipe line.

❑ Failure of Fuel Pumps.

❑ Defect in Fuel injection pump like wear or Seizure of plunger improper assembly (deviation
of match marks).

❑ Problems in Fuel injector like Sticking / Seizure of Needle, Nozzle Spring broken , Excessive
Oil Leak from Fuel Valve, Breakage or improper clamping of HP Pipe.
❑ Poor air tightness of Inlet / Exhaust Valves like damage of seal , valves getting stuck

❑ Rotational Speed drops spontaneously

❑ Clogged Feul filter.

❑ Air / Moisture ingress in fuel oil system.

❑ Defective Fuel Pump / Injector .

❑ Faulty Governor.

❑ Seizure of moving parts like Piston / Bearings / Turbocharger.

❑ Output of each cyl. not in uniformity (Large difference in max. combustion pressure/temp.
deviation too large)

❑ Air / Moisture ingress in fuel oil system.

❑ Wear / Sticking of fuel injection Pump Plunger.

❑ Defective Fluid injector.

❑ Loose / damaged Fluid injection pipe.

❑ Sticking of Inlet / Exhaust valves or damage of valve seat.

❑ Damage of Fuel cam / damage of Suction / Exhaust cam

❑ Bad Color of Exhaust Gas

❑ Defective Fuel injection valve / Fuel Pump.

❑ Improper adjustment of Tappet clearance / Damage of Inlet / Exhaust Valve / Sticking of

Suction and Exhaust valve.

❑ Improper Injection timing.

❑ Damage of Suction and Exhaust cam

❑ Defect of Turbocharger.

❑ Fouling of Air Cooler.

❑ Shortage of Fuel.

❑ Overload.

❑ Drop in Lube Oil Pressure

❑ Loose Lube Oil Pipe.

❑ Clogged Lube Oil Filter.

❑ Defective Lube Oil Pressure regulating Valve.

❑ High Temperature of Lube Oil due to Fouling of Lube Oil Cooler / Shortage of Cooling Water
/ excessive Blow past into crankcase.

❑ Air in Lube Oil System.

❑ Excessive clearance of Crankshaft Bearing.

❑ Knocking During Operation

❑ Excessive clearance of Crankshaft / Camshaft Bearing.

❑ Loose Connecting Rod Bolts / Flywheel clamping Bolts.

❑ Improper adjustment of Tappet Clearance.

❑ Improper Fuel injection Timing.

❑ Malfunction of Fuel injection Pumps / Defective Fuel injection Valve.

❑ Increase of gear Backlash / Wear of Gear Bearing.

❑ Cooling Water Temperature too high

❑ Shortage of Cooling Water Volume.

❑ Sticking / Defe3ct of Cooling Water Thermostatic Valve.

❑ Problems in Cooling Water Pumps.

❑ Ingress of Air in Cooling Water Circuit.

❑ Fouled Cooling Water Cooler.

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❑ Troubleshooting faults in operation of Main Engine

❑ Engine fails to turn on starting air after starting order is given

❑ Valve on air bottle closed/Pressure of air bottle low/

starting air distributor valve closed.

❑ No pressure in control air system.

❑ Main starting air valve locked in closed position./does not open due to active turning gear
interlock.

❑ Starting air distributor piston sticking.

❑ Starting air valves in cylinder cover defective.

❑ Control air signal for starting does not reach the engine.

❑ Propeller blades are not on zero in case of CPP.

❑ Engine does not reverse when order is given

❑ Coil of solenoid valve for the desired direction of rotation does not receive voltage.

❑ Control air signal for the desired direction of rotation does not reach the unit.

❑ Engine runs too slowly or unevenly on starting air

❑ Slow turning not cancelled/ slow turning of the engine adjusted too low.
❑ Faulty timing of starting air distributor.

❑ Defective starting air valve in the system.

❑ Engine turns on air, but stops on fuel order

❑ Shutdown of engine not reset, check pressures and temperatures.

❑ Puncture valve not de aerated.

❑ Sluggishness in the manoeuvering gear.(Lubricate linkages ensure fuel pump racks are free
to move)

❑ Faulty governor.

❑ Engine turns on fuel, but runs unevenly and will not pickup rpm

❑ Auxiliary blowers not functioning.

❑ Scavenge air limit wrongly adjusted.

❑ Fuel filters clogged/ Fuel pressure is too low.

❑ One or more cylinders not firing.

❑ Exhaust temperature rises for all cylinder units

❑ Increase scavenge air temperature owing to inadequate

air cooler function.

❑ Fouled air / gas passages.

❑ Inadequate fuel oil cleaning or altered combustion characteristic of fuel.

❑ Wrong position of camshaft (Misadjusted or defective chain drive)

❑ Exhaust of single cylinder increases

❑ Defective / leaking fuel exhaust valves.

❑ Blow by in combustion chamber.

❑ Wrongly adjusted or slipped fuel cam.

❑ Exhaust temperature decreases all cylinders

❑ Falling scavenge air temperature.

❑ Air/gas/steam in the system.(check FO pump pressures , de aerator valve, suction side of

the supply pump for air leaks ,FO pre heater for steam leaks)

❑ Defective starting air valve in the system.

❑ Exhaust temperature decreases single cylinders

❑ Defective fuel pump suction valve.

❑ Puncture valve or fuel pump plunger and barrel sticking or leaking.

❑ Engine rpm decreases

❑ Exhaust valve sticking in open position.

❑ Air/gas/steam in fuel oil.

❑ Defective fuel valves/ Fuel pumps.

❑ Fuel index limited by torque/scavenge air limiters in the governor due to abnormal engine
load.

❑ Water in fuel.

❑ Fire in scavenge box.

❑ Slowdown/Shutdown activated.

❑ Change in combustion quality of fuel oil.

❑ Fouling of hull ( or sailing in shallow waters)

❑ Smoky exhaust

❑ Air supply insufficient.(Check ER ventilation).

❑ Defective fuel valves.

❑ Fire in scavenge box.

❑ Governor failure/ erratic regulation.

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❑ Troubleshooting faults in operation of Inert Gas system

❑ High Oxygen Content Of Inert Gas

❑ Poor combustion control at the boiler under low load conditions.

❑ Air drawn down the uptake when boiler gas output is less than the Inert Gas Blower demand
(low load conditions).

❑ Air leaks between the boiler uptake and inert gas blower.

❑ Sealing air for boiler uptake valve leaking.

❑ Faulty operation of oxygen analyzer.

❑ Inert gas system operating in the recirculation mode.

❑ Inert gas mode not selected in the boiler control panel.

❑ Inability To Maintain Positive Pressure During Cargo Discharging

❑ Inadvertent closure of inert gas valves/sluggish operation of inert gas valves.

❑ Faulty operation of automatic pressure control system.

❑ Inadequate blower pressure.

❑ Cargo discharge rate is in excess of blower output.

❑ Troubleshooting faults in Refer

❑ Undercharge

❑ Low compressor suction/discharge pressure.

❑ High superheat at compressor suction.

❑ (Possibility of overheating and oil breakdown

at compressor delivery).

❑ Large vapor bubbles in Liquid sight glass

❑ Extended running periods.

❑ Rising room temperature.

❑ Motor current lower than normal.

❑ Overcharge

❑ Excessive flow through the evaporator leading

❑ to icing at compressor suction.

❑ Liquid level in condenser too High.(reduced

❑ Condensing surface with increase in sat Temperature and Pressure)

❑ Air in the system

❑ Small bubbles in the sight glass.

❑ High discharge pressure with normal condensing temperature.

In turn reducing the cooling capacity of the system. (giving long running periods).

❑ Moisture in the System

❑ May freeze at the expansion valve (Giving indication of undercharge).

❑ Will contribute to corrosion in the system.

❑ May cause lubrication problems and oil breakdown.

❑ Flooding (Liquid slugging)

❑ Solenoid valve leaking.

❑ Overcharge.

❑ Incorrect expansion valve adjustment.

❑ Oil contamination of evaporator coils.

❑ Icing on evaporator coils.

❑ High Air Outlet Temperature

❑ Less Gas in the system.

❑ Hot air entering the accommodation through open doors.

❑ Fresh air flap not adjusted properly/leaking / broken.

❑ Thermostat temperature set higher.

❑ Evaporator clogged/dirty.

❑ Malfunction of expansion valve.

❑ Dirty condenser.

❑ AHU Fan through put reduced due to broken/slack V belts.

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❑ Troubleshooting faults in operation of STP

❑ No Vacuum, pump running

❑ Valves shut / tank empty.

❑ Foam instead of liquid in tank

❑ Blockage / leakage in piping system.

❑ Non return Valve chocked.

❑ Incorrect or Wrong rotation of the Motor.

❑ Ejector Pump does not create enough vacuum

❑ Sewage plug in the ejector.

❑ Increased clearance in the pump.

❑ Discharge Pump does not start

❑ No Power / Blown fuse / Motor defective.

❑ Float switch failure.

❑ Impeller defective / increased clearance.

❑ Discharge Pump does not stop

❑ Float Switch Failure.

❑ Too much Water enters the Plant.

❑ Discharge Pump Running But not Pumping

❑ Impeller defective / increased clearance in the pump.

❑ Closed Discharge valve.

❑ Wrong Direction of Rotation.

❑ Overflow in the System

❑ Too much water entering the System.

❑ Pump is clogged.

❑ Discharge Pump Defective

❑ Air Blower Does Not Run

❑ No Power / Blown fuse / Motor defective.

❑ Defective NRV and water in Air Blower.

❑ Impeller Defect.

❑ Timer wrongly adjusted.

❑ Air Blower Running but Insufficient Pressure

❑ Defective NRV.

❑ Wrong Direction of Rotation.

❑ Defective Impeller.

❑ Air Blower Running But no Surface Bubbling in Tanks

❑ Hose or Pipe Defective.

❑ Air Distributors Clogged

❑ Plant Smells

❑ Too much Mineral Sludge.

❑ Presence of Black Sludge indicating Bacteria is Killed.

❑ Discharge of Plant Dirty

❑ Too much Water enters the Plant creating too High

Hydraulic loading.

❑ From Newly started Plant Bacteria is not yet formed.

❑ Bacteria is killed.

❑ No residual Chlorine in the discharged water.

❑ Dosage Level is too low.

❑ Dosing Pump not operational.

❑ Disinfectant Tank is empty.

❑ Disinfectant Chlorine is obsolete.

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❑ Troubleshooting faults in operation of Steering Gear

❑ Lack of Hydraulic pressure

❑ Filters / Relief valves dirty.

❑ Pump Faulty.

❑ Solenoid valve trouble

❑ Solenoid valve burnt.

❑ Spool inside the valve sticking.

❑ Solenoid spring broken.

❑ Push – pin inside the solenoid valve broken.

❑ Repeat back unit limit switch trouble

❑ Defective contact inside limit switch.

❑ The limits which defective.( If rudder does not return after hard – over steering. It is required
to replace the limits which.)

❑ Spool inside the valve sticking.

❑ Solenoid spring broken.

❑ Push – pin inside the solenoid valve broken.

❑ Cylinder operation is low

❑ Dirt in operating hydraulic valves.

❑ Contamination of hydraulic oil / filter clogged with dirt.

❑ Ingress of air.

❑ Rudder moves in one direction / movement sluggish

❑ Solenoid valve problem.

❑ Dust contained in each valve.

❑ Hydraulic pump noisy

❑ Insufficient hydraulic oil.

❑ Pump sucks air.

❑ Oil temperature is low.

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❑ Troubleshooting faults in operation of Stern Tube System

❑ LO Strainer Clogged

❑ Sea water ingress due to failure of #1 and #2 seal rings

or ingress of foreign particles.

❑ Damage to stern tube bearing.

❑ Stern Tube High Temperature (above 55 Deg C)

 ❑ Malfunction of cooler / Defective temp. gauge /

❑ Defective piping.

❑ Deterioration of lube oil.

❑ Failure of stern tube bearing.

❑ Stern Tube Level Continuously Increasing

❑ Failure of #1 and #2 seal rings, or sea water ingress due to

❑ ingestion of foreign particles.

❑ Continuous unexpected stern tube lube oil consumption

❑ Leakage outboard due to failure of #3 seal ring or ingestion

of foreign particles.

❑ Leakage through O ring installed between the clamp ring

and liner at Fwd sealing device.

❑ Fwd Seal Level Continuously Increasing

❑ Lube oil moving to FWD seal device due to failure or ingestion of foreign particles at #4 seal
ring.

❑ Continuous unexpected Fwd Seal oil consumption

❑ Leakage to Engine Room due to failure of #5 seal ring or ingestion of foreign particles.

❑ Aft Seal Level Continuously Increasing

❑ Sea water ingress due to failure of #1 and #2 seal rings or ingress of foreign particles.

❑ Lube oil moving to stern tube due to failure or ingestion of foreign particles at #3 seal ring.

❑ Continuous unexpected Fwd Seal oil consumption

❑ Oil seal leaking due to failure of #1 seal ring and #2.

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❑ Troubleshooting faults in operation of VRCS

❑ Pumps not starting

❑ Electrical supply not available / overload trip not reset

❑ or motor fault.

❑ Low oil level alarm active.

❑ Clogged Filters

❑ Dirty Oil (Improper cleaning after overhauling).

❑ Low grade of oil.

❑ Improper Flushing of oil after maintenance.

❑ Damaged Filter

❑ Abnormal noise from pump

❑ Air ingress at pump suction.

❑ Pump parts damaged or worn out.

❑ Coupling or spider damaged.

❑ Jerky Valve Movement

❑ Air in the system.

❑ Pressure Surge.

❑ Faulty accumulator.

❑ Faulty actuator.

❑ Slow valve movement

❑ Clogged filters.

❑ Low oil pressure / low oil temperature.

❑ Leaking valve actuator.

❑ Needs flow reducer adjustment.

❑ Valve does not close completely

❑ Oil pressure is low.

❑ Operating time is more, requires timing adjustment.

❑ Actuator seal leaking. (Check locally with pump, if the pressure drops quickly, change seal)

❑ Valve not moving

❑ Try operating locally with pump

❑ Leaking pipes / seal.

❑ Clogged flow reducer.

❑ Damaged actuator.

❑ Wrong valve position indicator

❑ Defective flow meter.