Vintage Vessel NCOE

Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS

08/04/2011

Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS
Purpose of the Certification Board: To assess the knowledge, judgment and decision making skill of the candidate to perform all tasks related to inspection of domestic vessel steam propulsion plants. The candidate: A successful candidate should be proficient and confident enough to articulate the minimum regulatory job tasks and understand those tasks in sufficient detail so that supervisors have a comfort level that the candidate will be able to conduct these inspections without supervision, yet recognize when they need back-up for unusual or complex circumstances. Purpose: The purpose of this guide is to assist a Certification Board with development of questions, references and memory keys to assist board members conducting a routine Certification Board. This is not an all inclusive list, but simply a suggested line of questioning. The Board should include standard scenarios as necessary to evaluate the candidates decision making skills and their general knowledge of regulations, policy and industry standards. MISLE casework specific to steam inspection should also be discussed. This guide assumes a candidate is certified as a Machinery Inspector, and covers only Task Nos MI23-MI40 of the Machinery Inspector (Steam) PQS, along with review of WR01-WR-09 (welding). If this strategy and or the answers are not clear to you, perhaps you should NOT be overseeing the certification process for this Marine Inspector skill set. GET HELP! The Vintage Vessel NCOE and the Traveling Inspector staff are available to assist you! There are many good references for preparation and further information such as the theory of the steam cycle. For a list of references contact the Vintage Vessel NCOE. The questions provided in this guide are the minimum questions to ensure the candidate can do what is required by regulation and policy. Real learning and practicing the art of inspection begins on the job, once unescorted and grows with increased exposure to different steam plants. These questions will help the Board determine within the first 15 minutes whether or not the candidate is prepared and if the Board should continue. If possible, the Verifying Officer (VO) who conducted the Verification Inspection (Check Ride), or who conducted the majority of PQS sign-offs, should be included on the Board. A Certification Board should typically last 2-3 hours if the candidate is properly prepared and possesses the requisite experience. This Steam only portion should last 1-1.5 hours. Tools/resources: The following resources should be available to the candidate: 46 CFR Subchapter F Marine Engineering Sample steam ship COI (2) References: Machinery Inspector (Steam) Performance Qualification Standard, Revision Date: 05 October 2007 CG-840- Marine Inspection, Machinery Inspection Steam Rev. 1/01 COMDT (CG-543) Policy Letter 09-04, CH-1 Marine Inspector/Port State Control Officer Certification Policy 46 CFR Subchapter F Marine Engineering; COMDTINST M16000.7, Marine Safety Manual Vol. II Modern Marine Engineers Manual, Vol. 1 (Alan Osbourne) [ISBN 0-87033-063-2] Questions or comments may be directed to: M. C. Cruder, CDR (USCG-Ret.): CG-54-TI Traveler Consultant to the Vintage Vessel NCOE LT Kevin Broyles: Supervisor, Vintage Vessel NCOE Duluth, MN Note: The technical content of this document was created through the collaboration of the CGHQ Traveling Inspection Staff and the Vintage Vessel National Center of Expertise (VVNCOE) in Duluth, MN, including Mr. Eugene Walroos, Chief Engineer, Ret.; Mr. Stephen Petersen, CWO4 Naval Engineer, Ret.; and CWO4 Andrew Adolphson. Final review and consultation provided by the National Centers of Expertise Training Support Staff, Yorktown, VA.

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Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS
This page may be used to document the results of the certification board. A notes page is provided at the end of this guide to assist board members with documenting the proceedings and follow-up actions and may be retained as part of the record.

Machinery Inspector-Steam

Candidate:

______________________________

Date: ___________________________ Unit: ___________________________ _________________________ _________________________

Senior Board Member: _____________________ Additional Board Members: ________________________ ________________________ Prerequisites: Training Schools Complete/Waived* PQS Complete PQS Deferments Pre-board Verification Inspection (Check Ride) Notes:

*Diesel/Steam Engineroom Automation (MS-507) *eLearning-SMI Machinery Course Steam Propulsion Supplement (CVSMS), Course code 502254.

Board Determination: Follow up Actions: Post board assignments (look-ups) completed. Record of Professional Development updated. TMT Entry made. Certification letter issued.

Passed: Deferred pending follow-up: Failed:

______________ ______________ ______________

It is the consensus of this board that this candidate possesses the knowledge, judgment and decision making skill to manage and complete job tasks specific to inspection of domestic vessel steam propulsion machinery and is qualified in all other respects for certification: ____________________________________________ Senior Board Member ____________________________ Date

CG-54-TI Vintage Vessel NCOE 8/4/11

Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS On an inspected freight vessel, what are the major boiler inspections required by the regulations and at what intervals are they conducted? Q.1
Intent: The candidate should be able to recall most, if not all of the intervals. The candidate may refer briefly to the referenced table but must demonstrate the ability to locate the table and retrieve information rapidly and without assistance.

A.1

Q.2 A.2 Q.3 A.3.

Ref: 46 CFR Table 61.05-10 Fireside Examination Twice in 5 years Waterside Examination Twice in 5 years Boiler Hydro (1.25 MAWP) Every 5 years Main Steam Piping Hydro (125 MAWP) Every 5 years Mountings Open Examination Every 5 years Mountings Removed; Studs Examined Every 10 years Safety Valve Testing Twice in 5 years State how and where the intervals for each of the major boiler inspections identified in Q.1. are recorded.
Intent: The candidate should understand and interpret this information as recorded on the COI. The candidate should be able to identify the information on a provided COI.

State if the intervals for each of the major boiler inspections identified in Q.1. are different for fire-tube boilers. If so, where is that information found?
Intent: Explore candidates knowledge of other boiler types as well as proper use of Table 61.05-10.

Yes, see table. Given the major boiler inspections identified in Q.1., describe the inspection for each including: a. How the boiler/components are prepared and readied for inspection; b. Procedures normally used by a marine inspector to conduct an inspection; c. In your answers consider/include: * Key pressures/temperatures/set-points; * Proper operational testing procedures/strategies; and * Concerns with respect to materials issues. General Responses to Q.4.: Fireside examination = Gas Path Where: Burner register; Superheater vestibule; Economizer/Stack. What: Firebox - refractory/tubes sagged/blistered/plugged. Waterside examination = Water/Steam path Where: Hand holes; Steam drum; Mud drums; Headers What: Seating surfaces; corrosion; pitting; scale; oil Hydrostatic Test = 1.25 MAWP (Boiler) Where: Via Boiler Fireside; Lagging; Blanks; 70 Degree F Water Temp. What: Leaks from gaskets/packing glands/pressure components and use of hydro-pumps to keep pressure on while ascertaining leaks as needed. Leaks vs. Weeps understand what will make up tight with heat when boiler is fired.

Q.4

A.4.a

A.4.b

A.4.c

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Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS

A.4.d

A.4.e

A.4.f

A.4.g

A.4.h

Hydrostatic Test = 1.25 MAWP (Piping) Where: Boiler to throttle valve; Main Steam > 3 diameter. What: Ascertain path/blanks/lagging and not over-tightening flexitallic gaskets when cold. Mountings open Where: Minimum number of valves - Main, Generator & Auxiliary steam stops; Main & Auxiliary Feed stops; Surface & Bottom blows; Superheater Vent; soot blower stop; header drains. What: Bonnets removed; internals disassembled stem, disc, seats, valve body, bolts, steam cuts & seating surfaces. Mounting removed/studs examined (ASTM A193 B7 OR B16) marked Where: Same as open plus studs check materials type/condition of stretch or corrosion run a nut or do a sample bend test. What: Vintage (riveted boiler) Installation = remove studs threaded into riveted or welded pressure vessel reinforcing collar. Modern (welded boiler)Installation = first flange holding boiler pressure Safety Valves Operational Test: Ref: 46 CFR Subchapter F; ASME Code; Modern Marine Engineers Manual, Vol. I (Osbournes). Where: Drums; Superheater and/or Superheater Pilot Valve. What: Correct Gag Order Test High to Low; Clean Pop/seat; 2-4% blow down with no excessive blow down below normal steaming pressure; Ensure only 10% spring adjustment range from tagged popping pressure; avoid overheating require cool down if continued adjustment required beyond 2 or 3 tests. Test Remote Manual Easing Gear after re-assembly. Other: Beyond basic boiler inspections, questioning can be expanded to include: - Main condensate system operation and integrity including non-metallic expansion joints and bilge injection valves (focus = flooding hazards); - Auxiliary systems as appropriate including economizers, forced draft fans, feed pumps, soot blowers etc.; and - Personnel safety with respect to lagging and insulation on piping that exceeds a surface temperature of 150 degrees F. Describe the proper repair/replacement procedures for Class I Piping. Identify the appropriate references; - 46 CFR Subchapter F, ANSI B31.1, ASME Code - Determine proper materials; - Determine parameters for a proper welded repair. - Demonstrate familiarity with A.5.b. A.5.e below. Welding procedures (welding recipe for a good weldment) articulate how to determine that weld procedure matches material to be welded and is in the correct thickness range. Welder qualification (execution of an approved procedure) articulate the connection between the welder and the approved procedure including an understanding of welding position and results of physical testing to ensure the right individual has been qualified to the right approved weld procedure for the repair in question. Pre-heat; Maintenance of heat and post heat treatment.
Intent: To ascertain if the candidate can locate and is conversant with 46 CFR Table 56.85-10.

Q.5

A.5.a

A.5.b

A.5.c A.5.d A.5.e

Required NDT
Intent: To ascertain if the candidate can locate and is conversant with 46 CFR 56.95-10.
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Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS On a steam ship without automation, what is the minimum compliment of a Machinery Space watch and where would this information be located?
Intent: To ascertain if the candidate is able to locate this information. Note: Candidate should be able to refer to a sample COI.

Q.6

A.6 Q.6.a A.6.a Q.7

Found in the Route Permitted and Conditions of Operation section of the COI. Fully manned steam plant = 1 licensed engineer; 1 fireman watertender & 1 oiler per watch. COI Operating Details will indicate whether manning is contingent on installed automation. How would you know if manning is reduced and contingent on installed automation? Endorsed in the Route Permitted and Conditions of Operation section of the COI. Explain what an inspector must do when handed Periodic Safety Test Procedures (PSTPs) that are over 30 years old and dont match the boilers present day configuration.
Intent: To ascertain if the candidate understands the process of how PSTPs are approved and how to require changes (if necessary).

A.7

Q.8

Candidate should: - Be able to review procedures and identify if they need to be updated. - Know that Coast Guard approved test procedures are required onboard per 46 CFR 61.40-1(c). - Know if procedures do not reflect installation or have been modified that revised procedures must to be submitted to the Marine Safety Center (MSC). - Know that with MSCs comments the marine inspector will then verify in the field that the test procedures as written and reviewed by the MSC are satisfactory. - Know that when verification is complete, the PSTPs will be marked approved by the OCMI. State what propulsion automation tests are commonly witnessed during an annual examination on a steam propelled vessel with reduced engine room manning. Intent: To ascertain if the candidate understands basic boiler automation controls. Responses should include, but are not limited to, the following Burner management; - Programmable cycle
ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-20(c)

A.8.a

- Flame safety
ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-20(h)

- Operations of the fuel valves

ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-20(f)

Water level controls and alarms. - High level alarm

ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-50, ABS Table 41.1 (1986)

A.8.b

- Low level alarm

ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-50, ABS Table 41.1 (1986)

- Low-low level limit

ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-20(h)

- Sounds with water still in the glass

NVIC 1-69, 46CFR62.10-1(a)

Lube Oil System - Low pressure alarm A.8.c

ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-50, ABS Table 41.1 (1986)

- Auto start of standby lube oil pump

ABS Guide for Centralized Control and Automation 1965, NVIC 1-69, 46CFR62.35-50, ABS Table 41.1 (1986)

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Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS Explain what inspections and tests are conducted on the D. C. heater/deaerating tank & when. Q.9 A.9
Intent: To ascertain the candidate understands the DC heater is examined as part of the waterside exam, is an unfired pressure vessel listed on the COI & the relief valve needs to be tested.

Q.10

The internal inspection is completed at the same time as the waterside exam. The D.C. heater relief valve is tested at the same time as all other relief valves. Besides pressure vessels, describe the different locations where you will also find relief valves in a main propulsion steam plant. Are they required by regulations to be tested? If so how often?
Intent: To ascertain that the candidate knows there are relief valves throughout the system, subject to inspection and tested along with the unfired pressure vessel relief valves.

A.10

The systems noted below & all safety AND safety relief valve settings required to be checked by the marine inspector at Inspection for Certification or twice in 5 years (46 CFR 61.15-5(c) & MSM B1-57) 1. The low pressure side of all reducing stations (46 CFR 56.07-10(b)) 2. All heat exchangers (46 CFR 54.15-15(f) & (g)) 3. Discharge side of all f/o pumps (46 CFR 56.50-65(b)(1) & 58.01-25) 4. Evaporators (46 CFR 54.15-15(g) & 61.10-5(i))
Note: Per the MSM: "The inspector shall observe relief valves on reduced pressure lines, evaporators, and feed water heaters operate satisfactorily. Valves shall be checked at each inspection." Other: A follow-on question or point to be made is: What is the difference between a relief valve protecting gas and steam systems vs. a relief valve protecting a liquid system? Answer = relief valves on steam/gas systems required to have hand lifting device.

Q.11

Explain what a sentinel valve is and where you may find them.
Intent: To ascertain the candidate understands the difference between sentinel and relief valves.

A.11

The sentinel valve is a warning device and is not a relief valve although it appears and acts as one. It should be tested to assure that it works (bench test is satisfactory). Sentinel valves may be found on the economizer if installed prior to 1997 (after 1997 the economizer needs a check valve installed); low pressure main turbine, and on most s/s turbine generators. They are a required safety device, especially on the turbine(s) to warn the Engineer on Watch that there is a loss of vacuum.
Ref: 46 CFR 56.50-30 (b) (6) and 56.50-15 (i)). Note: 46 CFR 61.20-3(a) provides the discretionary authority to conduct tests to main propulsion and auxiliary machinery as necessary to check safe operation.

Explain what tests are performed on the coffin feed pump(s), how they are performed and why. Q.12
Intent: To ascertain if the candidate understands how the tests are performed, different ways to perform the tests and the importance of testing. An undetected low water condition in the D.C. Heater can easily overspeed installed turbine feed pumps. The trip MUST work properly to protect operating personnel.

A.12

The proper overspeed test of a coffin feed pump is performed with two persons; one slowly closing the suction side of the pump while the second person holds a hand tachometer against the end of the shaft. The Chief Engineer may not want to do this and may suggest exercising the manual trip. The manual trip should be exercised but this will not indicate a trip point and only proves that the manual trip works. Check vendors manual for testing procedures. Alternatives include: - Authorized manufacturer rep certification based on disassembly/measuring strength of trip spring; - Authorized manufacturer rep certification based on bench testing overspeed unit prior to installation.
Ref: 46 CFR 61.20-3(a) Note: Historically, the original MSM (CG 203 Chap. 3-5-45(a)(2)) in use through the mid 1970s was explicit about testing this overspeed trip. Chief Engineers were familiar with the procedure described above and commonly witnessed by marine inspectors in place onboard. While subsequent MSM guidance softened, the discretionary authority in 46 CFR 61.20-3(a) is current and applies.
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Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS Describe specific items to examine and/or verify when conducting a walk-through of an engineroom of a steam propelled vessel.
Intent: To ascertain that the candidate knows what other things to look for when making their walk through steam plant machinery spaces.

Q.13

A.13.a A.13.b A.13.c A.13.d A.13.e A.13.f A.13.g A.13.h

Q.14

The candidates response should include: Foundation bolts on forced draft fans, main and ship service turbine generators, all pumps in general, main condenser: [Check for looseness/misalignment]. Main condenser cover bolts/nuts: [Check for excessive wastage/leaks/temp repairs]. (MSM Vol. II, B3-39) Non-metallic expansion joints: [Verify installation date for 10 year replacement, condition, & water tightness]. (46 CFR 61.15-12 & MSM Vol. II, B3-46) Bilge injection valve/Emergency bilge suction. [Verify operation, condition of bolts and water tightness]. Boiler casings: [Inspect for leaks]. (46 CFR 61.20-3) Boilers sliding feet: [Inspect for freeness allowing the boiler to expand]. (46 CFR 52.01-130 (a)(2)) All main steam pipe hangers, and/or supports: [Verify soundness of all hangers, hanger springs, rods, etc]. (MSM Vol. II, B1-57) Lagging and insulation on piping that exceeds 150 degrees F: [Installed where required and in good condition]. (46 CFR 56.50-1 (k)) Explain what tests are performed on steam turbines in general. Intent: To ascertain if the candidate understands that there are required tests on the main turbine as well as the turbine generators. In addition to the ship service turbine generators, the vessel should be able to exercise the main turbine low lube oil alarm and trip and overspeed trip. It is acceptable to write a requirement for the testing of the overspeed trip on the main turbine if the arrangement requires the vessel to be operating to perform this test.
Ref: 46 CFR 61.20-3(a); 46 CFR 56.50-80 (g); ABS 33.43.2 and 33.57.3 (1969 Rules) Note: Main Steam Turbines are designed IAW Class Rules as modified by CG regs and equipped with both low lube oil alarm/trip and overspeed trips. (Historically, the original MSM (CG 203 Chap 3-5-40 B(1)) used thru the mid 1970s was explicit that the inspector determine by whatever practical meansthat the overspeed mechanisms, low oil pressure shutdown devicesare in proper operating condition. Where possible the inspector shall require operational tests to check these devices While subsequent MSM guidance was revised to seemingly not include geared steam turbines, the discretionary authority in 46 CFR 61.20-3(a) is current and applies to this equipment. )

A.14

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Vintage Vessel National Center of Expertise Certification Board Guide for The Steam Portion of the Machinery Inspector-Steam PQS

Notes Page
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CG-54-TI Vintage Vessel NCOE 8/4/11