FERRY MACHINERY MAINTENANCE, INSPECTION AND AUDIT
SAFETY WORKSHOP PROGRAM
Presented By:
Khairulmuzammil Yuzri
Research, Development and Planning Unit
CONTENTS
OBJECTIVE
WHY IMPOTRANCE
MAINTENANCE CONCEPT
CLASS CONCEPT
RESPONSIBILITIES
TYPES OF INSPECTION/AUDIT
INSPECTION/AUDIT METHOD
HOW AND WHEN TO MAINTAIN
MACHINERY EQUIPMENT TO BE MAINTAINED
MACHINERY INSPECTION-MAIN ENGINE
TYPICAL MACHINERY FAILRUES
FIRE SAFETY FOCUS DURING MAINTENANCE AND INSPECTION
FACTS
MACHINERY UNSEAWORTHY
POOR MAINTENANCE PRACTICES
CHIEF ENGINEER CHECKSHEET
OBJECTIVE
On completion of course, the participants
shall gain knowledge on a
good maintenance, inspection and audit practices in the ferry
WHY IMPORTANCE?
A combination of good maintenance, inspection
and audit practices are important to avoid failures causing unsafe conditions i.e. fire, explosion, injury,
MAINTENANCE CONCEPT
Traditional View Point:
Rectifying failures
Change lubricating oil
Maintenance through
experienced
MAINTENANCE CONCEPT
(CONTD.)Modern View Point:
Better methods
Better management
Maintenance by records
Reduce down time and eventually overall
Classification Concept
Classification Certificate:
Main Class Hull + Machinery
Renewal Survey Machinery
ISM AUDIT
machinery is considered satisfactorily maintained if normal
RESPONSIBLITIES
Owner/Operator/Manager – policy,
proper planning and management, budget (spares and repairs) and commitment on safety
Ferry Engineers – skill +
knowledge (competent)
TYPE OF INSPECTION/AUDIT
In-house regular inspection
Class annual survey
Class renewal survey
ISM audit
Passenger ship safety survey
INSPECTION/AUDIT METHOD
External visual inspection
Performance test
Running test
Review maintenance history
Internal inspection by opening up partly or fully
HOW AND WHEN TO
MAINTAIN?
As recommended by the machinery manufacturers i.e. periodical maintenance based
on due running hours (daily, monthly, quarterly, yearly etc.)
MACHINERY EQUIPMENT TO BE
MAINTAINED
Propulsion Machinery
Auxiliary Machinery
Pumps
Pipes and Valves
Electrical Installation
Safety and alarms functions Engine monitoring
MAIN ENGINE CUT-OFF VIEW
Machinery Inspection: Main Engine
Item Inspect Check or look for
Crankshaft Alignment Deflection record
Foundation Chocks Loose (hammer, feeler
gauge, wear, cracks)
Bolts Loose (check torque -
hammer units) Bedplates and
frames Leakage, cracks (deflection while running)
Reversing/starting
gear Function test. Inspect control system for
wear/leakages in control gear, distributor and pipes. Flame-arrester/burst disc to be intact
Cylinder cover,
valves Valves and seats Wear*, flame grooves, cracks
Valve stems Wear, corrosion, deposit
Machinery Inspection: Main Engine
Cylinder/ liner Waterside Corrosion, cavitation, deposit
Gas-side Cracks, wear
Piston
crown Cracks, erosion
Ring
grooves Wear*, deposit
Piston skirt Wear*, deposit below upper ring,
seizure marks Piston
rings Wear*. "blow by", scoring. free movement
Connecting
rod End bearing Wear*, wiping, scoring, melting, fatigue, corrosion, deposit
Machinery Inspection: Main Engine
Bottom end
crank-pin Bearing Wear*, wiping, scoring, melting, fatigue, corrosion, cavitation,
erosion, deposit
Housing Wear*/ ovality*, fretting. corrosion,
micro welding
Crank pin Wear*, cracks, fretting corrosion,
corrosion, scoring, hot running Main
bearing and journal
Bearing Wear*, wiping, scoring, melting,
fatigue, cavitation, erosion, corrosion, deposit
Housing Fretting corrosion, micro welding
Journal Wear*, cracks, hot running, fretting
Machinery Inspection: Main Engine
Fuel system H.P. pumps Leakage, wear of cam, roller, rocker stem and steering
L.P. pipes Leakage clamping (if necessary), shielding
H.P. pipes and
injection valves
Leakage, shielding of pipes
Supercharging
arrangement Air strainer Deposit Inlet and
outlet housing
Corrosion (if cooled)
Turbine
rotor Damage on blades, deposit on blades, free running, balance Cooler Leakage, deposit (air side),
corrosion (water side) Exhaust system Leakage, insulation
TYPICAL MACHINERY FAILURES
TYPICAL MACHINERY FAILURES
(CONTD.)
TYPICAL MACHINERY FAILURES
(CONTD.)
TYPICAL MACHINERY FAILURES
(CONTD.)
FIRE SAFETY FOCUS
DURING MAINTENANCE
AND INSPECTION
Protection of High Pressure FO Lines
Insulation of hot surfaces above 220degC Good functioning of FO quick closing valves Cleanliness
Fire retardant material
Good functioning of fire detection and alarm
system
Bare electrical cable termination and
unprotected enclosures
FACTS
2/3 of all fires start in engine
room due to poorly maintenance machine
56% is caused by oil leakage to
hot surface
MACHINERY UNSEAWORTHY
Failure of propulsion and essential equipment
and electrical installation
Insufficient cleanliness of engine room
Failure of emergency source of power
Absence or deterioration of fire detection,
alarms and fighting installation
POOR MAINTAINENACE PRACTICES
IMPROPER HOUSEKEEPING AND CLEANLINESS
POOR MAINTAINENACE PRACTICES
Unapproved material
POOR MAINTAINENACE PRACTICES
Missing/insufficient monitoring gauges/meters
POOR MAINTAINENACE PRACTICES
Uncovered battery terminal
POOR MAINTAINENACE PRACTICES
LO Leaks
POOR MAINTAINENACE PRACTICES
Uncovered turbocharger casing and exhaust manifold temp.>220degC
POOR MAINTAINENACE PRACTICES
Improper cable routing/securing/protection
POOR MAINTAINENACE PRACTICES
Unauthorized socket Installation
POOR MAINTAINENACE PRACTICES
Continuous leaks through main engine FW tank cap
POOR MAINTAINENACE PRACTICES
Bare/unprotected lighting
POOR MAINTAINENACE PRACTICES
Unprotected terminal switches
Q&A
THANK YOU
