Inspection Capabilities for Enhanced Ship Safety D4.2 (WP4): Stakeholders’ data requirements Responsible Partner: BV Contributor(s): USG, LR, RINA, GLAFCOS, DANAOS, APA Dissemination Level PU Public x PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission Services) CO Confidential, only for members of the consortium (including the Commission Services) This document is produced by the INCASS Consortium. The INCASS project is funded by the European Commission under the Seventh Framework Programme (FP7/2007-2013). Grant Agreement n°605200
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Inspection Capabilities for Enhanced Ship Safety
D4.2 (WP4): Stakeholders’ data requirements
Responsible Partner: BV
Contributor(s): USG, LR, RINA, GLAFCOS, DANAOS, APA
Dissemination Level
PU Public x
PP Restricted to other programme participants (including the Commission Services)
RE Restricted to a group specified by the consortium (including the Commission Services)
CO Confidential, only for members of the consortium (including the Commission Services)
This document is produced by the INCASS Consortium. The INCASS project is funded by the European
Commission under the Seventh Framework Programme (FP7/2007-2013). Grant Agreement n°605200
D4.2 (WP4) – Stakeholders’ Data Requirements
This document is produced by the INCASS Consortium, funded by the European Commission (FP7/2007-2013).
Grant Agreement n° 605200.
Page 2 of 86
Document information table
Contract number: 605200
Project acronym: INCASS
Project Coordinator: University of Strathclyde Glasgow
Document Responsible Partner: Bureau Veritas BV
Deliverable Type: Report
Document Title : Stakeholders’ data requirements
Document ID: D4.2 Version: 4
Contractual Date of Delivery: 30/04/2014 Actual Date of Delivery: 07/05/2014
Filename: D4.2 Stakeholders’ data requirements
Status: Final version
Authoring & Approval
Prepared by
Author Date Modified Page/Sections Version Comments
USG 01/02/2014 All V0 Creation of the
document
All Partners 18/03/2014 All V1 Technical content
USG 25/04/2014 All V2 Technical content
update
Glafcos, TSI 04/04/14 Section 3.3 V3 Technical content
This document is produced by the INCASS Consortium, funded by the European Commission (FP7/2007-2013).
Grant Agreement n° 605200.
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Nomenclature
Acronym Meaning BC Bulk Carrier BV Bureau Veritas CAD Computer Aided Design CBM Condition Based Maintenance CM Condition Monitoring CMS Condition Monitoring System D/G Diesel Generator E/R Engine Room ES Emergency FMECA Failure Mode Effects and Criticality Analysis F.O. Fuel Oil FTA Fault Tree Analysis IACS International Association of Classification Societies ID Identification INCASS Inspection Capabilities for Enhanced Ship Safety IS Intermediate Survey ISM International Safety Management ISO International Standards Organization L.O. Lube Oil LR Lloyd's Register M/E Main Engine MARPOL International Convention for the Prevention of Pollution from Ships
(Marine Pollution) MCBM Machinery Condition Based Maintenance MCM Machinery Condition Monitoring MPMS Machinery Planned Maintenance Scheme NORSOK Norsk Sokkels Konkuranseposisjon NSFI Norsk Skipteknisk Forskningsinstitut ODME Oil Discharge Monitoring Equipment PLib Parts Library Standard PMS Planned Maintenance Scheme RCM Reliability Centred Maintenance RPM Rounds Per Minute RINA Registro Italiano Navale R&D Research and Development SCM Screw shaft Condition Monitoring SOLAS International Convention for the Safety of Life At Sea TCM Turbine Condition Monitoring
D4.2 (WP4) – Stakeholders’ Data Requirements
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1 INTRODUCTION
This report presents the outcomes of deliverable D4.2 ‘Stakeholders’ data requirements’
as part of the INCASS (Inspection Capabilities for Enhanced Ship Safety) project, Work
package WP4 ‘Machinery & Equipment Modelling & Analysis’. This report scopes to
lead on the final selection of ship machinery and equipment systems that will be
considered for monitoring. In this respect, this report is structured in six sections. The
first section initiates deliverable D4.2 presenting the overall layout of the report. The
second one presents the Classification Societies requirements for Condition Monitoring
(CM) by introducing the motivation with respect to machinery maintenance, providing
an indication of machinery and equipment systems onboard the Tanker, Bulk Carrier and
Container ships under consideration.
In a similar manner, the third section demonstrates the ship operators/managers/owners
as well as service providers’ requirements for condition monitoring. In addition, the
motivation with respect to machinery maintenance is presented. The fourth section
summarises the input for all three ship types (i.e. tanker, bulk carrier and container ship)
as provided in the previous sections. Hence, it compares main machinery and equipment
systems, sub-systems and components as suggested by the above stakeholders.
The fifth section provides an initial review of databases modelling in use for ship systems,
existing concepts for storing equipment and component related information, also
incorporating directions for the INCASS database to be developed further in future tasks.
In conclusion, the last section of this report provides the final selection of ship machinery
and equipment systems according to the proposed requirements of all relevant
stakeholders also incorporating the results of deliverable D4.1 and moreover sets the
ground for the upcoming task T4.3 ‘Data Collection’.
D4.2 (WP4) – Stakeholders’ Data Requirements
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2 CLASSIFICATION SOCIETIES REQUIREMENTS
2.1 Introduction
This section aims to layout the motivation for Classification Societies data collection
activity, in reference to machinery and equipment, as well as the level of detail monitored
and how this information is collected. The research and requirement identification takes
place independently for each ship under consideration; hence Tanker, Bulk Carrier and
Container ship. Furthermore, a review on condition monitoring standardization rules from
the Classification Societies’ point of view is considered for the final selection of critical
ship machinery systems.
2.2 Motivation with respect to Machinery Maintenance
The role of Classification Societies is to check that safety standards of ships are met
throughout surveys, inspections, tests and controls. As long as ship machinery and
equipment monitoring technologies provide relevant data and information that can
demonstrate that condition of equipment is acceptable to ensure ship safety, they can be
used as a complementary means for Classification Societies to confirm that machinery,
equipment and appliances comply with the applicable rules and remain in satisfactory
condition. Moreover, when Condition Monitoring (CM) techniques are properly applied,
they can enhance decision support and facilitate the work of Class surveyors, thus they
can get an objective opinion on the condition of a surveyed item/system of machinery and
equipment without dismantling it.
The entire control over a vessel is managed by the shipowner or/and ship operator,
including the manner in which it is operated and maintained. In this respect, ship
Classification depends on the shipowner/operator, who by operating in good faith will
disclose any damage or deterioration that may affect the vessel’s Classification status to
the Class Society. If there is any doubt regarding the above, the owner should notify the
D4.2 (WP4) – Stakeholders’ Data Requirements
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Class and schedule a survey to determine if the vessel complies with the relevant Class
standards.
Classed ships are subject to surveys to continue being in Class. These surveys related
with machinery and equipment include the Class renewal (also called “Special Survey”),
Intermediate Survey and the Annual Survey. They also include the tailshaft survey, boiler
survey, machinery surveys and surveys for the maintenance of additional Class notations,
where applicable. Therefore, a Class surveyor may only go on board a vessel once in a
twelve-month period, for the annual survey. At that time it is neither possible, nor
expected that the surveyor scrutinize the entire structure of the vessel or all of its
machinery. The survey involves a sampling, for which guidelines exist based upon
empirical experience, which may indicate those parts of the vessel or its machinery that
may be subject to corrosion, or they are exposed to the highest incidence of stress, or may
be likely to exhibit signs of fatigue or damage.
The surveys are to be carried out in accordance with the relevant Class requirements in
order to confirm that the condition of machinery, equipment and appliances complies
with the applicable rules. A Classification survey is a visual examination that normally
consists of:
an overall examination of the items for survey
detailed checks of selected parts
witnessing tests, measurements and trials where applicable
When a surveyor identifies defects or damage to machinery and/or any piece of its
equipment, which in the opinion of the surveyor affects the ship’s Class, remedial
measures and/or appropriate recommendations/conditions of Class are to be implemented
before the ship continues in service.
In this respect, the ISM Code clarifies that the ship operator (the “Company”) is
responsible for ensuring the safe and pollution-free operation of the ship. In particular,
the Company is required to ensure that the ship’s machinery and equipment are
D4.2 (WP4) – Stakeholders’ Data Requirements
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maintained and operated in accordance with the applicable rules and regulations and any
additional requirements that may be established by the Company. Paragraph 10.1 of the
ISM Code states, “The Company should establish procedures to ensure that the ship is
maintained in conformity with the provisions of the relevant rules and regulations and
with any additional requirements which may be established by the Company”. The
procedures should be documented, and should ensure that applicable statutory, Class,
international (e.g. SOLAS, MARPOL) and port state requirements are met, and that
compliance is maintained in the intervals between third-party surveys and audits. The
maintenance procedures should also include any additional requirements established by
the Company. These may arise, for example, from an analysis of the previous
maintenance files of ship’s machinery and equipment, from the particular demands of
ship’s operations, or from manufacturers’ recommendations. Classification Societies
audit as Recognised Organisation for the existence of such a system. However, data is not
shared among the various stakeholders.
The scope of equipment on which condition monitoring is applied is not fixed by the
Class Society, while the ship operator decides which equipment needs to be monitored.
For a standard PMS scheme (IACS, 2014), the Class Society concerns are to ensure that
the maintenance recommendations from supplier/manufacturers’ manual are respected. If
the ship operator decides to postpone a planned maintenance task/overhaul based on
condition monitoring results, the Class can accept the postponement under certain
circumstances. The different survey techniques that can be applied are defined in IACS
URZ 20 (IACS, 2014):
• Continuous Machinery Survey: overhauls based on calendar time
• Planned Maintenance Scheme: overhauls can be based on running hours of
machinery in normal operation or on condition monitoring by analysing the trend
of significant parameters (vibrations, temperature, pressure, etc.)
The survey scheme may be a combination of the above and must be approved by the Class
Society. Classification Societies can moreover provide guidance on the implementation
and use of Condition Monitoring techniques in order to establish a recognized practice
D4.2 (WP4) – Stakeholders’ Data Requirements
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onboard ships. Their Rules generally provide their own list of equipment whose condition
can be monitored (i.e. electric propulsion motor main diesel engine) as part or
independently from the Planned Maintenance Survey (PMS) scheme. Minimum
parameters to be checked (vibration, temperature, exhaust gas temperature etc.) for each
piece of equipment are agreed with the owner after assessment of the equipment that is
to be included under such a regime. The motivation for data collection by Classification
Societies is laid out summarised as Class Survey and Statutory Survey. The information
collected during these surveys is kept within the Classification Societies database system,
however it is owned by the owner of the vessel.
The resolution of failures recorded is expected to be more granular than failure
information held by the owner/operator. The main reasons for this are the following:
As a Class surveyor may only go on board a vessel once in a twelve-month
period and Classification depends on the shipowner/operator operating in good
faith by disclosing to the Class society any damage or deterioration that may
affect the vessel’s Classification status.
Information is held on failures that are known to Class either having been found
during survey or having been reported by the owner. This is a subset of all
failures on a vessel; the failure is described with remedial measures and/or
appropriate recommendations/conditions of Class are to be implemented before
the ship continues in service.
A cause of failure may not be properly recorded as an in depth analysis of cause
of failure during a survey may not be possible.
2.2.1 Failure records
Failures are described with reference to the Classification Society’s number, vessel name,
Class status, incident date, location and type of failure while the failure record does
include a brief narrative explanation of the failure. The defect location is an individual
category for each vessel derived from the master list. Each data line is owned by the
relevant ship owner and therefore it is only possible to share summarised data.
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In this respect, Figure 1 provides indicative failure records arranged per ship and
machinery type supporting the Classification and in further selection of machinery and
equipment to be monitored. It is essential to highlight that the provided figure aims to
indicate this selection without scaling the Class failure records.
Figure 1 Classification Data: Indicative Failures recorded by ship and machinery
type. Note: Axis without scale as this is only indicative to show what Class failure
records can provide (Source: LR)
As can be observed in Figure 1, the most critical failure records are distributed among Oil
Tanker, Bulk Carrier and Container ship categories respectively. Furthermore, the
majority of failures for all three ship types are sourced from the Oil Engine (or otherwise
Main Engine of the ship), Propeller Unit and lastly the Steering Gear. However, according
to the provided indications Oil Engine appears to face more defects in the case of Oil
Tanker and Bulk Carrier and less on the Container ship. In addition, the Propeller unit
seems to be more critical in the case of the Bulk Carrier ship compared to the other two
ship types. Whereas Steering Gear in all ship types has minor issues compared to the
Engine and Propeller Unit.
2.3 BV - Condition Monitoring
D4.2 (WP4) – Stakeholders’ Data Requirements
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BV Rules for the Classification of Steel ships as in Part A, Chapter 2, Appendix 1 and
Article 6 (BV, 2014) mention with the Requirements for Machinery items surveyed based
on condition monitoring embedded in the Planned Maintenance Survey Scheme. The
extent of condition-based maintenance and associated monitoring equipment to be
included in the maintenance scheme is decided by the Owner. The minimum parameters
to be checked in order to monitor the condition of critical main and auxiliary machinery
are provided, contributing to the final condition monitoring selection tools. These systems
are grouped in items including main systems such as electric propulsion motor, main
diesel engine, main and auxiliary steam turbines, auxiliary diesel engines, as well as
auxiliary systems such as cooling, heating, pumps and filters. With reference to the main
diesel engine the parameters to be checked are the following (section 6.1.3, BV 2014):
power output
rotational speed
indicator diagram (where possible)
fuel oil temperature and/or viscosity
charge air pressure
exhaust gas temperature for each cylinder
exhaust gas temperature before and after the turbochargers
temperatures and pressure of engine cooling systems
temperatures and pressure of engine lubricating oil system
rotational speed of turbochargers
vibrations of turbochargers
results of lubricating oil analysis
crankshaft deflection readings
temperature of main bearings
In addition to the above, more details and indicative information on the main and auxiliary
systems examined as per BV rules are included in Appendix II.
2.4 LR - Condition Monitoring
D4.2 (WP4) – Stakeholders’ Data Requirements
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LR Rules Part 5 Chapter 21 (LR, 2014a) deal with the Requirements for Condition
Monitoring Systems and Machinery Condition-Based Maintenance Systems. An operator
can choose to apply for a number of LR Class notations as appropriate to their needs. If
Machinery Condition Monitoring (MCM), Reliability Centred Maintenance (RCM) or
Machinery Condition Based Maintenance (MCBM) is selected, Machinery Planned
Maintenance Scheme (MPMS) is also required as knowledge of the planned maintenance
systems is a critical element and must be considered during approval of the scheme. LR’s
ShipRight Procedures for Machinery Planned Maintenance and Condition Monitoring
‘Deck and Accommodation Equipment’: cranes, provision cranes, hatch cover
gear, mooring and anchoring, navigation bridge equipment, safety (rescue boat
davits).
3.3.1.2 Sale and Purchase (S&P)
S&P Condition Surveys are differentiated to Condition surveys in that the vessel (usually)
does not belong to the company requesting the survey. The focus is less on the detailed
determination of the maintenance needs of specific machinery and equipment systems
and components but more on the assessment of the overall condition and the identification
of potential future malfunctions. The results of the survey are likely to be used in the
negotiations and the decision making at a less technical level.
3.3.2 Data Collection process
As outlined in the previous section, the data collection activity usually consists of data
already available onboard the ship, collected by the ship crew or the shipping company
personnel, including the results of the visual survey, which are usually documented by
images. The collection of more targeted/specific data is handled by dedicated technical
teams or the manufacturer of the component.
3.3.2.1 Quantitative data
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Before the visual inspection, data are collected by the Chief Officer and the Chief
Engineer. Such records are gathered for all machinery components in the Engine Room
and outfitting equipment in way of Deck and Accommodation spaces. The most important
data that are collected during an inspection are:
Makers’ List: All equipment are listed in correspondence with their maker
contact information. If a potential malfunction cannot be solved by crew, an
authorized service team is called-in by the maker.
Machinery Particulars: the main dimensions and characteristics of machinery
components
Chief Engineer’s Log Book: the file where all the machinery condition is
recorded on a regular basis
Spare Parts List: a list of all the machinery and equipment parts available
onboard
Machinery Components Working Hours: data originating from the Chief
Engineer’s logbook, especially for the Main Engine and Diesel Generator
components (e.g. cylinders, valves, etc.)
Alarm History Record: same as before data originating from the Chief
Engineer’s logbook
Main Engine and Diesel Generator Performance: performance measurements
obtained during the operation of each M/E and D/G collected by the ship’s crew
3.3.2.2 Visual inspection
Visual inspection mainly relies on the experience of the surveyor to identify visible
malfunctions and obtain both a list of equipment which may be in less than sound
condition, as well as obtain a general idea of the overall compartment’s condition.
Depending on the underlying case, the survey may be subject to strict time constraints,
varying (poor) lighting conditions, limited accessibility, non-cooperative crew, etc. hence
increasing the requirements and strain on the surveyor’s side to perform a high-quality
survey. As a general guideline, Table 2 provides a list of the Engine Room key systems
and components assessed during a visual inspection, typically assigned with three levels
D4.2 (WP4) – Stakeholders’ Data Requirements
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of grading: good (system/component assessed as properly working, with no visual
evidence of malfunction), fair (system/component appears to be working properly, but
with signs of upcoming performance degradation, such as small leakage), bad
(system/component appears not to be working within its normal operating boundaries and
necessitates replacement).
Table 2 Example of key machinery systems/components reviewed during an Engine
Room visual inspection
Item Condition Cleanliness Good Hull structure in way Fair Shell and decks Fair Main Boiler Good Turbocharger Good Generators Good Ballast Pumps Good Emergency fire Pump Good Miscellaneous machinery Good Sea connections and valves Good Piping system with valves Good Workshop Good
Similarly to the items listed with regards to the Engine Room area, similar guidelines are
used for the deck equipment as shown in Table 3
Table 3 Example of key machinery systems/components reviewed during a deck
equipment visual inspection
Item Condition Mooring ropes and wires condition Fair/Good Windlasses condition Fair/Good Windlasses foundation Fair/Good Deck Winches Fair/Good Brake linings and pins condition Fair/Good Anchor chain condition Fair/Good Anchor chain securing devices Fair/Good Mooring bits and bollards Fair/Good
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Moreover, proof of the above visual inspections is usually provided in terms of pictures
related to the surveyed items, usually included in the inspection report in order to provide
evidence of the recorded observations (Appendix VIII). Additionally, Tables 4-5 provide
a sample of the final report submitted for a P&I Condition Survey from a real-life
example, regarding the Deck Machinery, the Engine Room, Main and Auxiliary
Machinery. More details on the Engine Room, Main & Auxiliary machinery survey can
be found in Appendix IX.
Table 4 Deck Machinery for a P&I Condition survey
No Deck Machinery Survey Record 1 Are windlass and Winches in order and properly guarded? Yes 2 Are their mountings sounds? Yes 3 Are their brakes working? Yes
4 Are anchors and cables sound? Yes
5 Is the spare anchor sound? No Spare 6 Are fairleads and bollards in good order? Yes 7 Are mooring ropes and wires in good order? Yes 8 Are hydraulic lines free of leaks? No Hydraulic Line 9 Are electrical wiring conduits sounds? Yes 10 Is electrical wiring sound? Yes
Table 5 Engine Room, Main & Auxiliary machinery for a P&I Condition survey
No Engine Room, Main & Auxiliary machinery Survey
Record
1 Is the engine room clean and tidy? Yes 2 Are there any oil leaks? No. see comments 3 Are there any water leaks? No 4 Are engine room floor plates secured? Yes 5 Lighting level in machinery rooms, steering gear
compartment and store. Is it adequate? Yes
6 Main engine, type and condition? ZGODA, SULZER TAD48 Working in good order
7 Condition of main boiler? N/A 8 Number and condition of generators? 3(three), Working in good
order 9 Were generators seen running under load and
working individually and in parallel? Yes, found in good working order. Individually and parallel.
10 Are lubricating and fuel oil purifies working? Yes
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The visual inspection process follows predetermined steps to ensure proper inspection of
the ship machinery and equipment (including their components) and their proper
operation after the inspection. Table 6 provides a sample of the visual inspection process
for the ship Auxiliary Boiler and components. A detailed table of the above visual
inspection is provided in Appendix X. Moreover, Table 7 provides a sample of the visual
inspection process for ship Compressors (detailed information is shown in Appendix XI).
Table 6 Visual Inspection procedure for Auxiliary Boiler and components
Auxiliary Boiler and Components Visual Inspection
1. Dismantle the gauge glass for cleaning. Repack and grease all bolts 2. Check wires for remote closing of the gauge glass and emergency closing devices 3. Exchange all boiler test chemicals with new and mark them accordingly
1. Remove and clean burner nozzles 2. Check and clean sealing surfaces 3. Check clean flame detector and inspect cable connection
Table 7 Visual inspection procedure of Compressors
Auxiliary Boiler and Components Visual Inspection
1. Drain the cooling water from the compressor and remove the cylinder head 2. Clean the cylinder head thoroughly and check for cracks or damages in seating 3. Remove and check the big end bearings for wear 4. Clean and inspect cooler tubes and the compressor water compartments and renew
the zinc anodes 5. Drain off the oil system and clean the crankcase and the oil strainer 6. Reassemble the compressor and refill the oil and the cooling water system
Moreover, the periodical survey specifications for Diesel Engines are included in Table
8. An in depth item list to be inspected also including suggestions on what particular signs
to look for are presented in Appendix XII.
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Table 8 Inspection for Periodical Survey of Diesel Engines
Item Inspect Check / Look For Crankshaft Alignment Deflection record Foundation Chocks
Reversing Starting Function test, inspection control system for wear Function test, wear/leakage in control gear, Distributor and pipes, flame arrester/bursting disc intact
Cylinder cover/valves
Valves and seats Valve stem Valve guides Starting air valve
Ram Temperature Crosshead Deflections cod piece Deflections crosshead boss with keyways Deflections hunting gear Vibration pump-driving motor Vibration
pump-driving motor pump Temperature Vibration
change-over valve Temperature change-over valve pump control rod
Pressure Vibration
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7 REFERENCES
AP227, 2005. Industrial automation systems and integration -- Product data
representation and exchange -- Part 227: Application protocol: Plant spatial
configuration.
BV, 2014. BV Rules for the Classification of Steelships Part A Chapter 2 Appendix 1
Article 6.
IACS, 2014. IACS UR Z-20, Planned Maintenance Scheme (PMS) for Machinery,
9. Shafting Stern Gland (Inboard)Oil Gland (Inboard)/Seal Ring Stern Gland (Outboard)/Oil Gland (Outboard)/Seal Ring
10. Oil Engine/Connecting Rod Bottom End Bearing Assembly
Journal Bearing o Bearing Block (As On Paxman Forked Conn
Rod)/Shell o Cap o Fastener (Bolt/Stud) o Housing o Shell o Shell/Lining o Shell/Locating Pin
Bottom End Bearing Assembly/Roller Bearing/Fastener (Bolt/Stud)
Gudgeon Pin Top End Bearing Assembly Top End Bearing Assembly/Gudgeon Pin Bearing Top End Bearing Assembly/Gudgeon Pin Bearing/Shell/Lining Top End Bearing Assembly/Spherical Bearing
11. Oil Engine/Crankcase Door Relief Valve Shaft Oil Seal
Analysis of the fluid of crankshaft torsional vibration damper (if viscous type) according to maker's instructions
Yes 6 months or as per maker’s instruction
Yes 6 months or as per maker’s instruction
Temperature of main bearings and crankcase pressure
Yes Weekly Where available
Yes Weekly Where available
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Fuel oil analysis (ISO 8217:2005) Yes At every bunkering Yes At every bunkering
Engine load (%) No - Yes Weekly
Alternator load (kW) No - Yes Weekly
Inspection of bedplate structure/ chocks / down bolts
Yes 6 months Yes 6 months
Vibration of bearings of diesel generator and alternator
No - Yes 4 months
(1) To be read by a torquemeter or other equivalent instrument, or through the governor output, or by taking the position of the rack
(2) Reading points of turbocharger's rotational speed and bearing vibrations are to be identified according to the Manufacturer's instructions
Note 1: If the Owner opts to monitor the turbocharger(s) independently of the diesel engine, the following measures are to be taken on a weekly basis as a minimum: • Exhaust gas temperature before/after turbocharger • Charge air pressure at receiver • Turbocharger rotational speed and vibration. Reading points are to be identified according to the Manufacturer's instructions.
Electric Propulsion Motor with Associated Frequency Converter
Method Requirement
Performance Monitoring Propulsion Motor: Continuous or periodical monthly monitoring of: • Supplying current on main switchboard (phases and windings) • Converter current (phases and windings) • Feeding transformer highest winding temperature • Motor highest winding temperature • Rotational speed • Encoder for rotor position check • Bearing temperature at drive end (D.E.) • Bearing temperature at non-drive end (N.D.E.) • Cooling air in temperature • Cooling air out temperature • Highest cubicle temperature • Converter heat exchanger temperatures • Motor D.E. and N.D.E. oil leakage detection Propulsion system insulation resistance: every 12 months
Vibration Monitoring Periodical monitoring of motor bearings. No less than one per month
Lubricant Analysis Regular sampling, laboratory testing. No less than one sampling every 6 months
Oil Transformer analysis
Regular sampling, laboratory testing. No less than one sampling every 6 months
In the case of cooling system equipment such as centrifugal pumps, electric motor driven
it is required periodical check of:
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rotational speed
vibration monitoring with associated readings
pressure at suction/delivery
electric motor current
Alternatively for engine driven pumps, vibration readings are always to be taken at the
same engine speed (rpm). The minimum frequency of checks on a monthly basis are
summarised as sea water cooling pumps, high and low temperature fresh water cooling
pumps, general service low temperature pumps, while on annual quarters as preheating
high temperature cooling system pumps.
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5 APPENDIX V MACHINERY SYSTEMS AND
COMPONENTS FOR TANKER SHIP
The following list presents a sample of machinery systems and components for the Tanker
ship
Component Description Category
Alarm & Monitoring Control System E/R Alarms test Testing
27 FO MDO TRANSFER PUMP 65 AIRCON.-UNITS COOLERS 103 EMERGENCY FIRE PUMP
28 FO PIPES, VALVES, FITTINGS, ACTUATOR 66 AIRCONDITION AIR HANDLING UNIT 104 FFE BREATH.APPARAT.-AIR COMPRESSOR
29 FO/ LO AUTO-FILTER PRESS INDICATOR 67 AIRCONDITION COMPRESSORS 105 FIRE BOXES INCL HOSE, NOZZLE, REEL
30 LO A/E PURIFIER HEATER 68 AIRCONDITION CONTROL & MONITORING 106 FIRE DETECTION & ALARM SYSTEM
31 LO A/E PURIFIER SUPPLY PUMPS 69 AIRCONDITION PIPES, VALVES, FITTINGS 107 FIRE FIGHTING CO2 SYSTEM
32 LO CYL.-OIL SHIFT/TRANSFER PUMP 70 PROV.PLANT CTRL.&MONITOR.SYSTEM 108 FIRE FIGHTING EQUIPMENT
33 LO M/E AUTOFILTER 71 PROVISION REF COOL. COMPRESSORS 109 FIRE FIGHTING SYSTEM
34 LO M/E CROSSHEAD INDICATOR FILTER 72 BALLAST SYSTEM BALLAST PUMPS 110 CO2/FOAM/HALON ALARM
35 LO M/E CROSSHEAD PUMPS 73 BALLAST SYSTEM CONTROL PANEL 111 FIXED FIRE EXTINGUISHING SYSTEM
36 LO M/E PURIFIER HEATER 74 BALLAST SYSTEM HEEL.-PLANT PUMP 112 GENERAL FIRE PREVENTION
37 LO M/E PURIFIER SUPPLY PUMP 75 BALLAST SYSTEM PIPES,VALVES,FITTINGS 113 LIFEBOATS
38 LO MAIN COOLER 76 EVAPORATOR 114 LIFERAFTS
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7 APPENDIX VII CONDITION MONITORING
REQUIREMENTS FOR CONTAINER SHIP
The following figures show the requirements for condition monitoring related to the
container ship
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8 APPENDIX VIII MAIN SHIP MACHINERY SYSTEMS
AND COMPONENTS
The following figures present information provided by inspection companies related to
main ship machinery systems and components as shown next
Figure 3 Sample of alarm history record
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Figure 4 Oil analysis results
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Figure 5 D/G Engine principal particulars
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9 APPENDIX IX ENGINE ROOM, MAIN & AUXILIARY
MACHINERY SURVEY
The following questions form part of the survey for the Engine Room, Main & Auxiliary
machinery systems
1 Is the engine room clean and tidy? Yes
2 Are there any oil leaks? No. see comments
3 Are there any water leaks? No
4 Are engine room floor plates secured? Yes
5 Lighting level in machinery rooms, steering gear
compartment and store. Is it adequate? Yes
6 Main engine, type and condition? ZGODA, SULZER TAD48
Working in good order
7 Condition of main boiler? N/A
8 Number and condition of generators? 3(three), Working in good order
9 Were generators seen running under load and
working individually and in parallel?
Yes, found in good working
order. Individually and parallel.
10 Are lubricating and fuel oil purifies working? Yes
11 When lubricating oil was last analysed, and is
analysis required/overdue? <Date>. see comments
12 Are engine room logs maintained? Yes
13 Does the vessel have a Class approved Planned
Maintenance system? Date of Certificate
Yes. ISM Code (Chapter 10)
<Date> valid to <Date> issued
by <Class>
14 Are switchboards clean and operational? Yes
15 Are all engine room valves and gauges working? Yes
16 Are safety mats in place? Yes
17 Condition of electric wiring and conduits? Good
18 Are settling tanks in good order? Yes
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19 Are bunker tank gauges working? Yes
20 Were the air compressors tested? Yes. <Location, Date>
21 Are sea inlets and overboard discharge valves in
order and without leaks? Yes. Without leaks
22 Does stern gland leak? No
23 Condition of propeller and rudder? Not seen
24 Is spare gear sufficient and well stowed? Yes
25 Were engine room bilge pumps tested and
working?
Yes. <Location, Date>.
Tested Satisfactory
26 Are bilges clean? Yes
27 Bilge alarms, confirm all functional and date last
tested <Date>
28 Bilge Alarm settings, depth bilge well alarm
triggers. Date <Date>
29 Stern Seal, when last renewed. <Date>
30 Main engine slowdowns/shutdowns & Alarms last
tested <Date>
31 Is ballast and general service system operational? Yes
32 Is there a sanitation system and was it working? Sanitation system was found in
good order
33 Were remote closings for skylights and
bulkheads tested and in order? Yes
34 Was steering tested and found in order? Tested. Found in good order.
35 Were emergency steering arrangements tested
and found in order? Tested. Found in good order.
36 Are emergency communications satisfactory? Yes
37 Are CO2 room and CO2 system in good order? Yes.
38 When CO2 system was last tested/inspected? <Date>. There are Records
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39 Was emergency generator started and seen
running? N/A
40 Are emergency steering instructions posted? Yes
41 Is emergency fuel shut offs in order? Yes
42 Are all engine alarms working? Date last tested? Yes. <Date>
43
Are engine room crew provided with and using?
a) protective non-slip footwear b) overalls c) goggles d) safety helmets e) ear defenders f) welder’s mask and gloves
a) Yes b) Yes c) Yes d) Yes e) Yes f) Yes
44 Are safety notices prominently displayed? Yes
45 Is a means of escape provided from the engine
room? Are emergency escape routes well signed?
Yes
Yes
46 Is the engine room manned at all times? Yes
47 Are engine room ladders and handrails sound and
clean? Yes
48 Are all machinery guards sound and in place? Yes
49 Pipe systems labelled or colour coded? Yes. Colour coded.
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10 APPENDIX X AUXILIARY BOILER AND
COMPONENTS VISUAL INSPECTION
Visual Inspection procedure for Auxiliary Boiler and components
1. Dismantle the gauge glass for cleaning. Repack and grease all bolts.
2. Check wires for remote closing of the gauge glass and emergency closing devices.
3. Exchange all boiler test chemicals with new and mark them accordingly.
1. Remove and clean burner nozzles.
2. Check and clean sealing surfaces.
3. Check clean flame detector and inspect cable connection.
1. Dismantle the cover. Clean and inspect the impeller.
2. Clean the bearings and refill with grease.
3. Renew packings as necessary.
1. Check the fan for vibrations.
2. Grease the bearing and check for overheating.
3. Grease or lubricate the fan champer linkage
1. Close all steam and condensate valves and drain off oil and condensates
2. Remove end cover and draw out elements
3. Clean element by immersing in cooler cleaner solution
4. Clean and inspect heater housing
5. Dismantle safety relief valve, check all parts and replace if necessary
6. Remount cooler using new gaskets
For further information reference to the Instruction Manual is made or contact the
manufacturer
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11 APPENDIX XI COMPRESSORS VISUAL INSPECTION
PROCESS
Visual inspection process related to Compressors
1 Drain the cooling water from the compressor and remove the cylinder head 2 Clean the cylinder head thoroughly and check for cracks or damages in seating 3 Remove and check the big end bearings for wear 4 Clean and inspect cooler tubes and the compressor water compartments and renew
the zinc anodes 5 Drain off the oil system and clean the crankcase and the oil strainer 6 Reassemble the compressor and refill the oil and the cooling water system
7 Drain oil from compressor’s crankcase and from delivery separator. Clean oil suction strainer and renew oil filter element. Refill with the correct charge of fresh oil
8 Remove cylinder covers and examine suction and delivery valves and springs. Renew as necessary
9 Remove and renew safety disc 10 Remove and clean, liquid, suction and compressor lubricating oil strainers 11 Remove the end covers of the shell, tube and multi-pass condensers. Clean and
examine tubes and tube plates
For further information reference to the Instruction Manual is made or contact the manufacturer
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12 APENDIX XII DIESEL ENGINES PERIODICAL
SURVEY
Inspection items for Periodical Survey of Diesel Engines
ITEM INSPECT CHECK/LOOK FOR
Crankshaft Alignment Deflection record Foundation Chocks Bolts Loose (hammer, feeler gauge, wear,
cracks) Loose (check torque)
Bedplates and frames
Leakage, cracks (detection while running)
Reversing and starting gear
Reversing Starting Function test, inspection control system for wear Function test, wear/leakage in control gear, Distributor and pipes, flame arrester/bursting disc intact
Cylinder cover/valves
Valves and seats Valve stem Valve guides Starting air valve
Piston/ rod Piston crown Ring grooves Piston skirt Piston rings Piston rod Stuffing box
Cracks, erosion Wear*, deposit, Wear*, deposit below upper ring, seizure marks Wear*, “below by”, scoring, free movement Wear in stuffing box area Seal condition
Worn/broken springs Worn/broken springs, deposit (if possible), damper ring free filled with viscous fluid (oxidation of fluid or lack of fluid may lock damper by clogging or seizure)
Drive for camshaft & attached pumps
Gears Chains
Fitting, scoring of other gear teeth damage Worn bearings Correct tension, wear
Fuel system H.P. pumps L.P. pipes H.P. pipes and injection valves
Leakage, wear of cam, roller, rocker steam and steering Leakage clamping (if necessary : shielding) Leakage, shielding of pipes
Scavenging system Piston underside Air valves receiver
Deposit, drainage Function, deposit Deposit
Supercharging arrangement
Air strainer inlet and outlet Housing Turbine rotor Cooler
Deposit Corrosion (if cooled) Damage on blades, deposit on blades, free running, balance Leakage, deposit (air side), corrosion (water side)
Exhaust system Leakage, insulation *wear measurement to be carried out as specified by maker
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13 APPENDIX XIII DAMAGE, WEAR
CHARACTERISTICS AND FAILURE CAUSES OF
DIESEL ENGINES
Information related to damage, wear characteristics and failure cause of Diesel Engines
DAMAGE TYPE CHARACTERISTICS CAUSE
Wear/abrasive Evenly worn, smooth surface
Lubrication oil contamination (abnormal wear) hard, fine particles
Corrosion Corroded surface deposit
Lubrication oil contamination chemicals water
Fretting corrosion Corroded surface Vibration during stop periods