Machinery and other class surveys. Annual Survey of Machinery

Machinery and other class surveys

Annual Survey of Machinery

3Machinery and other class surveys

Annual survey 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



► 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



► 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)



► 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)



► 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



► 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



► 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


► 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


► 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



► 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


► 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



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



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



Main Engines

► LARGE BORE

► SLOW SPEED

► SINGLE ACTING

► TWO STROKE DIESEL ENGINE



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



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



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



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)



Crankshaft

► Check journals for :

Abnormal wear & scoring

Cracking in way of oil holes

Cracking in way of radii

► Check crankshaft coupling bolts

► Flexible coupling



Crankshaft Fractured Originating from Journal Radius



Flexible Coupling - Circumferential Cracking of the Rubber



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



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



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



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



Fuel Pumps

► Check oil tightness of system

► Rack operation

► Cylinder cut out arrangements

► Overspeed control arrangements



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



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



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



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



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



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.)



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



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



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



Gear Boxes

► Types - reduction, reverse reduction

► Pinions

Condition of teeth & meshing

► Bearings

► Lubrication

► Shaft seals

► Power take offs



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.



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


Documents

Machinery and other class surveys. Annual Survey of Machinery