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4Machinery and other class surveys
General examination of machinery & boiler spaces with particular attention to :
► Propulsion system
► Auxiliary machinery
► Fire explosion hazards
► Escape routes clear
Annual survey of Machinery
5Machinery and other class surveys
► Check the ER log book
► Testing means of communication
Bridge and engine room
Bridge and alternate steering position
► Examination of bilge pumping systems, incl. those external to machinery spaces
Bilge wells
Operation of the pumps, emergency suctions
Remote reach rods
Level alarms
Annual survey of Machinery
6Machinery and other class surveys
► External examination of Pressure Vessels
Safety devices
Foundations
Controls
Relieving Gear
High Pressure & Steam escape Piping
Insulation
Gauges
► Examination of rudder angle indicator
► General alarm system
Annual survey of Machinery
7Machinery and other class surveys
► General examination of the electrical machinery
Main & emergency systems and sources of electrical power
• Automatic mode
Switchgear & other electrical equipment
• Cleanliness & condition of switchboards
• Circuit breaker, trips, fuses, etc.
Megger testing (as necessary)
Annual survey of Machinery
8Machinery and other class surveys
► FIRE FIGHTING EQUIPMENT
Control Plans Posted
Testing Operation of Fire Doors
Testing Fire / Smoke Detection Systems
Inspection & Testing of Fire Main
Inspection & Testing of Fire Pumps
Inspection of Hoses & Nozzles
External examination of CO2 / halon bottles
Examination of fixed fire fighting system controls
Examination of portable & semi-portable extinguishers
Confirmation of the testing of the foam concentrates (twice every 5 years)
Annual survey of Machinery
9Machinery and other class surveys
► FIRE FIGHTING EQUIPMENT
Testing Remote Stops of Fans & Machinery
Testing Operation of Quick Closing Valves
Examination of Closing Arrangements
• Fire doors on accommodations
• Ventilators
• Funnel Annular spaces
• Skylights
• Doorways & Tunnel Accesses
Fireman’s Outfits and Emergency Escape Breathing Devices
FFE for spaces containing paint and flammable products
Annual survey of Machinery
10Machinery and other class surveys
► REFRIGERATING PLANT (covered or not covered by an additional class notation)
External examination of:
• Pressure vessels of the installation
• Refrigerant piping
For refrigerating machinery using Ammonia as refrigerant:
• Ventilation system including functional test
• Water spraying fire extinguishing system
• Bilge system inclluding functional test
• Electrical equipment
• Gas detection system
• Breathing apparatus and protective clothing
Annual survey of Machinery
11Machinery and other class surveys
► OTHER EQUIPMENT
Vessel equipped with thruster installations:
• an external examination of the machinery installation
• an operating test of the complete installation
For the ships where the water ingress detection system is fitted, alarm and detection system are tested
For the ships where the means for draining and pumping ballast tanks fw’d of the collision bulkhead and bilges of dry spaces are fitted, the system to be tested,
Annual survey of Machinery
13Machinery and other class surveys
► Examination of log book for :
Past performance
Operational irregularities
Alarms
Corrective actions
► Examination of control system. Random checking of:
Main measuring equipment
Monitoring devices
Alarms
Alarm system power supply / change over
Automatic shut downs
Engineers’ call system
Annual survey of Automation
14Machinery and other class surveys
► Test of M/E crankcase mist detector
► Automatic change over of stand-by machinery
► Automatic re-start after black-out
► Load shedding
► Bridge control
Emergency stop of main engine
Low air pressure alarm
Limited number of M/E starts from bridge
► Checking operation at random of:
Fire detectors
Flooding alarms
Fuel oil leakage alarms
Annual survey of Automation
15Machinery and other class surveys
► Frequency of bilge pump operation
► Remote operation of sea inlets
► General examination of the machinery space for :
Save-alls
Sounding pipe closing arrangements
Insulation - exhaust manifolds & tanks
Quick closing valves
F.O. double wall pipes & leakage alarm
Annual survey of Automation
17Machinery and other class surveys
► The renewal survey may be carried out using the following systems :
Normal system (SS)
Continuous survey system (CS)
Planned maintenance system (PMS)
► The system used depends on the owner & the type of machinery installation
Renewal survey of Machinery
18Machinery and other class surveys
Continuous Survey Machinery
Each item is surveyed once every 5 years
Chief engineer certified for survey of some items
Alternate surveys of the same item by the chief engineer
Refer to Rules Pt A, Ch 2, App 2
Renewal survey of Machinery
19Machinery and other class surveys
Planned maintenance system
► Surveys performed under the approved owner’s PMS - based on running hours
Inspections performed by ship engineers and verified/confirmed by surveyor
Surveyed at least once every 5 years
Implementation survey and annual audits and confirmatory surveys
Renewal survey of Machinery
20Machinery and other class surveys
Diesel Engines
► Surveyor satisfies himself with the condition of :
Pistons, cylinder heads & associated components,
Connecting Rods & Bearings, Cross head & guides,
Crankshaft & Bearings, Fuel pumps,
Scavenge / turbo charger system & coolers,
Reversing gear clutches, casing doors & safety devices,
Attached pumps & other components as deemed necessary
Renewal survey of Machinery
21Machinery and other class surveys
Main Engines
► LARGE BORE
► SLOW SPEED
► SINGLE ACTING
► TWO STROKE DIESEL ENGINE
Renewal survey of Machinery
22Machinery and other class surveys
Piston, Rod & Stuffing Box
► Check piston for :
Cracking in way of crown & ring grooves
Burning of crown
Ring clearances - vertical & butt
► Check piston rod connection to piston
Inspect rod for abnormal wear
► Check stuffing box for :
Condition & efficiency of seals
Renewal survey of Machinery
23Machinery and other class surveys
Cylinder Heads & Liners
► Check cylinder heads for :
Cracking in combustion space area
Condition of cooling water passages
Head to liner joint faces
► Check liners for :
Excessive & abnormal wear
Cracking and/or scoring
Condition of cooling water side & seals
Renewal survey of Machinery
24Machinery and other class surveys
Exhaust Valve & Cyl. Head Valves
► Check exhaust valve for :
Condition of valve seat & seating
Condition of spindle
Return springs
Operating system (mechanical or hydraulic)
► Other cylinder head valves include :
Air start, relief valves and injectors
Renewal survey of Machinery
25Machinery and other class surveys
Cross Head Bearings
► Check cross head for :
Scoring of jounals
Cracking of journals in the lower part, in radius of jounal
► Check bearing for :
Wear
Break up of white metal (older engines)
Renewal survey of Machinery
26Machinery and other class surveys
Crankshaft
► Check journals for :
Abnormal wear & scoring
Cracking in way of oil holes
Cracking in way of radii
► Check crankshaft coupling bolts
► Flexible coupling
Renewal survey of Machinery
27Machinery and other class surveys
Crankshaft Fractured Originating from Journal Radius
Renewal survey of Machinery
28Machinery and other class surveys
Flexible Coupling - Circumferential Cracking of the Rubber
Renewal survey of Machinery
29Machinery and other class surveys
Bottom End Bearings
► Check bearing for :
Abnormal wear in upper half
► Check B.E. Bearing bolts for :
Cracking & over stressing
Verify life of B.E. Bearing bolts, where applicable
Check bolt heads for damage
Check threads, nuts and locking arrangement
Renewal survey of Machinery
30Machinery and other class surveys
Main Bearings
► Check bearings for :
Excessive wear & scoring
► Check main bearing cap securing arrangement
Locking arrangement of bolts
► Check bedplate bearing pockets for cracking
Renewal survey of Machinery
31Machinery and other class surveys
Cracked Bedplate Adjacent to the Main Bearing Bolt
Renewal survey of Machinery
32Machinery and other class surveys
Crankshaft Deflections & Alignment
► To be taken when vessel is in a similar loaded condition & engine at same temperature
► Check holding down bolts are tight
► Stiff crankshafts - check to see that shaft is in contact with all journals
► Dial gauge to be in designated position between webs
► Check plummer block bearings
Renewal survey of Machinery
33Machinery and other class surveys
Cam Shaft & Drive
► Check cams for :
Profile wear & damage
Securing of cams
Cam followers
► Check cam shaft drive :
Sprockets, chain & tension (if applicable)
Gear wheels (if applicable)
Reversing arrangement
Renewal survey of Machinery
34Machinery and other class surveys
Fuel Pumps
► Check oil tightness of system
► Rack operation
► Cylinder cut out arrangements
► Overspeed control arrangements
Renewal survey of Machinery
35Machinery and other class surveys
Miscellaneous Items
► Verify function of cylinder lubricators & tightness of pipe lines to cylinders
► Vibration damper (if fitted) to be inspected
► Crankshaft balance weights, if fitted, to be examined & bolting checked
► Turning gear to be inspected & cut out tested
Renewal survey of Machinery
36Machinery and other class surveys
Turbochargers
► Impeller to be checked for cracking & damage
► Rotor blades to be check for :
Blade damage
Cracking of blades & shrouding
Blade securing on the hub.
► Rotor shaft to be checked for:
Condition of seals, journals & bearingsCheck condition of lub oil pump & drive
► Check condition of lub oil pump & drive
► Check condition of casings
► Ensure that lagging has been correctly refitted
► Check condition & cleanliness of air cooler
Check thermostatic valve, alarm & cooler drains
Renewal survey of Machinery
37Machinery and other class surveys
Medium Speed – 4 Stroke Diesels
► In addition to the above, where applicable
► Trunk piston vee engines
Piston to inspect in way of the small end
Condition of the gudgeon pin & bushing
► Bottom end bear angled with serrated butts
Cracking iwo of serrations
B.E. Bolts, life & condition to be carefully checked
Renewal survey of Machinery
38Machinery and other class surveys
Medium Speed – 4 Stroke Diesels
► Fitting of cylinder liners in block
► Rotocap system of exhaust valves
Failure leads to cracking of valve
► Cracking iwo stiffeners of bedplate
► Bellows connections on exhaust manifolds
Cracking of bellows
Renewal survey of Machinery
39Machinery and other class surveys
High Speed Engines
► "To open up" or "not to open up", that is the question !!!
► Fully opened Up
The surveyor is able to satisfy himself on the condition of the components
► Not fully opened Up
The survyor must satisfy himself on the documentary evidence on the condition of the components with random dismantling
Renewal survey of Machinery
40Machinery and other class surveys
High Speed Engines
► No documentary evidence, the surveyor cannot satisfy himself
► Documentary evidence
The surveyor must satisfy himself on the validity & completeness of the documentary evidence
Verifying clearances, condition, wear rates, active life of components (BE bearing bolts etc.)
Renewal survey of Machinery
41Machinery and other class surveys
High Speed Engines
► Documentary evidence continued:
Running hours
Operating parameters
• Pressures, temperatures, peak pressure reading, indicator cards, RPM etc.
Planned maintenance
• Nature, extent & frequency of overhauls
Photographs
Spares, consumed & ordered
Renewal survey of Machinery
42Machinery and other class surveys
High Speed Engines
► Random dismantling in the presence of BV
As deemed necessary by the surveyor
► General examination & test to verify that
The concerned items are operating correctly
General condition of the engine room & machinery
► If in doubt - INSIST ON OPENING IT ALL UP
Renewal survey of Machinery
43Machinery and other class surveys
High Speed Engines
► As main engines usually under the normal system
Overhaul based on running hours
Either fully dismantled as they must be removed from the bedplate, OR
Top overhaul only
Renewal survey of Machinery
44Machinery and other class surveys
Gear Boxes
► Types - reduction, reverse reduction
► Pinions
Condition of teeth & meshing
► Bearings
► Lubrication
► Shaft seals
► Power take offs
Renewal survey of Machinery
45Machinery and other class surveys
Electrical Equipment
► Alternators, generators & motors
► Transformers
► Switchboards, switchgear & instruments
► Cables & cable runs
► Insulation test & earth lights
► Navigation lights supply & alarm
► Remote stopping of fans, pumps, etc.
Renewal survey of Machinery
46Machinery and other class surveys
Ancillary Equipment
► Centrifugal pumps
Inspection of seals
Bearings
Impeller
Impeller wear ring
Casing
► Starter, motor & bearings
Megger test
Renewal survey of Machinery