Machinery and other class surveys

Annual Survey of Machinery

Annual survey Machinery Main Engine Crankcase For the large bore, slow speed engines access to the crankcase is relatively easy, the turning gear must be engaged before entry. Inside the crankcase, the surveyor should check the condition of the lubricating oil, it will give a good idea of the nature of the maintenance. This is done by feeling the texture and looking at the colour and appearance. It should be translucent and free from dirt. A leaking piston rod seal will cause a rapid deterioration of the crankcase oil. Whilst inside the crankcase, make a quick examination of the crankcase in way of the main bearing pockets, to see if there is any cracking of the bedplate, or any obvious damage to the crankshaft and bearings. Check all locking arrangements at random selection of the bottom end bolts, the main bearing bolts, and so on. The guide bolts tend to crack from time to time, a fairly common problem on low‑speed engines, particularly the older engines. A hammer test of the guide bolts on a random selection. Check the crosshead to see if there is any damage to the cross head bolts. The crosshead bearing is probably the most heavily loaded bearing in the crankcase, and this can cause major problems. When you are at that level inside the crankcase, you can sight the piston‑rod seal to see if that is in good order, and the piston‑rod itself. If the seal is in poor condition and leaking, then there will be a lot of sludge entering the crankcase from the scavenge space. This will damage the oil and of course lead to excessive wear and tear on the main engine. It is possible to sight the camshaft drive arrangement, whether this is a gear‑drive or a chain‑drive arrangement, to see the condition of the gear teeth or chain and sprockets, whichever the case may be, and to see that there is no obvious damage or cracking of the components.

Annual survey of Machinery General examination of machinery & boiler spaces with particular attention to : Propulsion system Auxiliary machinery Fire explosion hazards Escape routes clear

Annual survey of Machinery 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 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 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 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 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 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 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 Automation

Annual survey of Automation Examination of log book for : Past performance Operational irregularities Alarms Corrective actions Examination of control system. Random checking of: Main measuring equipment Monitoring devices Alarm system power supply / change over Automatic shut downs Engineers’ call system

Annual survey of Automation 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 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

Renewal Survey of Machinery

Renewal survey of Machinery 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 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 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 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 Main Engines LARGE BORE SLOW SPEED SINGLE ACTING TWO STROKE DIESEL ENGINE

Renewal survey of Machinery 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 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 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 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 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 Crankshaft Fractured Originating from Journal Radius

Flexible Coupling - Circumferential Cracking of the Rubber Renewal survey of Machinery Flexible Coupling - Circumferential Cracking of the Rubber

Renewal survey of Machinery 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 Main Bearings Check bearings for : Excessive wear & scoring Check main bearing cap securing arrangement Locking arrangement of bolts Check bedplate bearing pockets for cracking

Cracked Bedplate Adjacent to the Main Bearing Bolt Renewal survey of Machinery Cracked Bedplate Adjacent to the Main Bearing Bolt

Renewal survey of Machinery 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 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 Fuel Pumps Check oil tightness of system Rack operation Cylinder cut out arrangements Overspeed control arrangements

Renewal survey of Machinery 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 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 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 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 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 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 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 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 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 Gear Boxes Types - reduction, reverse reduction Pinions Condition of teeth & meshing Bearings Lubrication Shaft seals Power take offs

Renewal survey of Machinery 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 Ancillary Equipment Centrifugal pumps Inspection of seals Bearings Impeller Impeller wear ring Casing Starter, motor & bearings Megger test

Centrifugal Pump Impeller - Erosion Wear in way of Wear Ring Renewal survey of Machinery Centrifugal Pump Impeller - Erosion Wear in way of Wear Ring