Marine Engine Fitter

ITI Marine Engine Fitter Syllabus (English)

Course Overview

• Trade Name: Marine Engine Fitter
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in assembling, installing, repairing, and maintaining marine engines and auxiliary systems, equipping them for roles as marine engine fitters, mechanics, or technicians in shipyards, shipping companies, or marine workshops, or for self-employment in marine engine repair services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Marine Engines: Role of marine engines, types (diesel, petrol, two-stroke, four-stroke), applications in ships and boats.
• Safety Practices: Workshop safety, PPE (helmets, gloves, boots), handling fuel and oils, fire hazards, first aid.
• Workshop Tools: Spanners, torque wrenches, micrometers, feeler gauges; usage and maintenance.
• Marine Engine Basics: Components (piston, crankshaft, cylinder), fuel systems, cooling systems, lubrication systems.
• Materials: Properties of steel, aluminum, brass; corrosion resistance in marine environments.
• Fitting Techniques: Filing, drilling, tapping, reaming; precision fitting for engine parts.
• Engineering Drawing: Reading blueprints, engine assembly drawings, piping layouts.

Trade Practical

• Safety Drills: Using PPE, handling fuel spills, operating fire extinguishers, practicing emergency shutdowns.
• Tool Handling: Measuring with micrometers/feeler gauges, filing flat surfaces, drilling holes.
• Engine Disassembly: Dismantling a small marine diesel engine, identifying parts (piston, valves).
• Fitting Practice: Tapping threads, reaming bores, assembling simple engine components.
• Measurement Tasks: Checking clearances (piston-to-cylinder), ensuring tolerances (±0.02mm).
• Drawing Interpretation: Reading engine part drawings, marking components for fitting.
• Project Work: Assembling a basic engine sub-assembly (e.g., piston-cylinder) with proper clearances.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Marine Diesel Engines: Construction, working principles, fuel injection systems, turbochargers.
• Cooling Systems: Water-cooled and air-cooled systems, heat exchangers, maintenance of cooling circuits.
• Lubrication Systems: Types of lubricants, oil pumps, filters; importance in marine engines.
• Fuel Systems: Carburetors, injectors, fuel pumps; calibration and troubleshooting.
• Propulsion Systems: Propellers, shafting, gearboxes; alignment and load distribution.
• Welding Basics: Arc welding, gas welding; applications in engine repairs.
• Quality Control: Inspection of engine parts, BIS standards, tolerances in marine fittings.

Trade Practical

• Engine Assembly: Assembling a marine diesel engine, aligning crankshaft and camshaft.
• Cooling System Maintenance: Cleaning heat exchangers, replacing coolant, checking pump flow.
• Lubrication Tasks: Changing engine oil, replacing filters, inspecting oil pump functionality.
• Fuel System Work: Adjusting fuel injectors, calibrating fuel pumps, testing carburetors.
• Propulsion Checks: Aligning propeller shafts, inspecting gearbox bearings.
• Welding Practice: Performing simple welds for engine mount repairs, ensuring joint strength.
• Project Work: Overhauling a small marine engine (e.g., outboard motor) with functional testing.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Marine Engine Auxiliaries: Bilge pumps, steering systems, exhaust systems; integration with engines.
• Electrical Systems: Starters, alternators, batteries; basics of marine electrical circuits.
• Troubleshooting: Diagnosing engine faults (misfiring, overheating), fuel and oil leaks.
• Maintenance Practices: Preventive maintenance schedules, overhauling procedures, log keeping.
• Hydraulic Systems: Basics of hydraulic pumps, actuators; applications in marine steering.
• Metrology: Precision instruments (dial gauges, CMM), measuring wear in engine components.
• Marine Regulations: Safety standards, pollution control (MARPOL), engine certification basics.

Trade Practical

• Auxiliary Maintenance: Servicing bilge pumps, inspecting exhaust manifolds, repairing steering gear.
• Electrical Work: Testing starters, charging batteries, wiring basic marine circuits.
• Troubleshooting Tasks: Identifying misfiring causes, fixing coolant leaks, adjusting valve timings.
• Overhauling Practice: Disassembling and reassembling a marine engine, replacing worn parts.
• Hydraulic Checks: Inspecting hydraulic lines, testing actuators for leaks and pressure.
• Precision Measurement: Measuring crankshaft wear with dial gauges, documenting tolerances.
• Project Work: Repairing and testing a marine auxiliary system (e.g., bilge pump) with full documentation.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Advanced Marine Engines: High-speed engines, gas turbines, hybrid propulsion systems; modern trends.
• CNC in Engine Repair: CNC machining for engine components, basics of programming for repairs.
• Troubleshooting Advanced Faults: Vibration analysis, fuel efficiency issues, electronic control systems.
• Environmental Practices: Reducing emissions, handling oil waste, MARPOL compliance.
• Entrepreneurship: Starting a marine repair workshop, costing, market trends in shipping.
• Safety Management: Risk assessments, OSHA guidelines, marine workshop safety audits.
• Emerging Trends: IoT in marine engines, automation, smart diagnostics in shipping.

Trade Practical

• Advanced Engine Work: Servicing a high-speed marine engine, tuning for optimal performance.
• CNC Application: Machining engine parts (e.g., valve seats) using CNC lathe, verifying accuracy.
• Vibration Testing: Using vibration analyzers, balancing rotating components like propellers.
• Emission Control: Testing exhaust gases, adjusting fuel systems for compliance.
• Field Exposure: Hands-on training in shipyards or marine workshops (4-6 weeks).
• Safety Audits: Conducting workshop safety checks, documenting hazard controls.
• Project Work: Overhauling a marine diesel engine with CNC-machined parts, full performance testing.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Fuel consumption, torque settings, hydraulic pressure, engine efficiency.
  • Science: Thermodynamics of combustion, fluid mechanics, corrosion principles.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Marine engine assemblies, sectional views, piping and instrumentation diagrams.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Technical reporting, client interaction, teamwork.
  • IT Literacy: Using diagnostic software, CNC programming tools, online marine resources.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like engine assembly, troubleshooting, overhauling, performance testing.
• Evaluation Criteria: Assembly accuracy, repair quality, safety adherence, diagnostic skills.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Marine engine fitter, mechanic, technician in shipyards, shipping companies, or marine workshops.
• Self-Employment: Marine engine repair workshop, consultancy for ship maintenance, spare parts supply.
• Further Studies: Diploma in Marine Engineering, certifications in CNC machining or marine electronics.