FERRY MACHINERY MAINTENANCE INSPECTION A

SAFETY WORKSHOP PROGRAM
FERRY MACHINERY MAINTENANCE,
INSPECTION AND AUDIT
Presented By:
Khairulmuzammil Yuzri
Research, Development and Planning Unit

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Langkawi, Kedah
20th November 2007

CONTENTS
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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

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OBJECTIVE

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On completion of course, the
participants
shall gain knowledge on a
good maintenance, inspection and
audit practices in the ferry
operation

WHY IMPORTANCE?

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A combination of good
maintenance, inspection
and audit practices are
important to avoid failures
causing unsafe conditions
i.e. fire, explosion, injury,
loss of life etc.

MAINTENANCE CONCEPT

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Traditional View Point:
Rectifying failures
Change lubricating oil
Maintenance through
experienced
Costly

MAINTENANCE CONCEPT

(CONTD.)

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Modern View Point:
Better methods
Better management
Maintenance by records
Reduce down time and eventually overall
cost saving

Classification Concept
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Classification Certificate:
Main Class Hull + Machinery
Renewal Survey Machinery
ISM AUDIT

 machinery is considered satisfactorily maintained if normal

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maintenance carried with normal wear and tear

RESPONSIBLITIES

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Owner/Operator/Manager – policy,
proper planning and management,
budget (spares and repairs) and
commitment on safety
Ferry Engineers – skill +
knowledge (competent)
Subcontractors – repairers
Surveyors - verifier
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TYPE OF INSPECTION/AUDIT
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In-house regular inspection
 Class annual survey
 Class renewal survey
 ISM audit
 Passenger ship safety survey

INSPECTION/AUDIT METHOD
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External visual inspection
 Performance test
 Running test
 Review maintenance history
 Internal inspection by opening up partly or fully

HOW AND WHEN TO
MAINTAIN?

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As recommended by the
machinery manufacturers i.e.
periodical maintenance based
on due running hours (daily,
monthly, quarterly, yearly etc.)

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MACHINERY EQUIPMENT TO BE
MAINTAINED

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Safety and alarms functions
Engine monitoring
Emergency lighting

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Propulsion Machinery
 Auxiliary Machinery
 Pumps
 Pipes and Valves
 Electrical Installation

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MAIN ENGINE CUT-OFF VIEW

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

Wear*, flame grooves,
cracks

Valve stems

Wear, corrosion, deposit

Valve guides

Wear, deposit

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Valves and
seats

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Inspect

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Item

Machinery Inspection: Main Engine

Cylinder/ liner

Machinery Inspection: Main Engine
Waterside

Corrosion, cavitation, deposit

Gas-side

Cracks, wear

Piston
crown

Cracks, erosion

Ring
grooves

Wear*, deposit

Wear*. "blow by", scoring. free
movement

End
bearing

Wear*, wiping, scoring, melting,
fatigue, corrosion, deposit

Pin

Wear*, deposit, corrosion

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Connecting
rod

Piston
rings

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Piston skirt Wear*, deposit below upper ring,
seizure marks

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

Bearing

Wear*, wiping, scoring, melting,
fatigue, cavitation, erosion,
corrosion, deposit

Housing

Fretting corrosion, micro welding

Journal

Wear*, cracks, hot running, fretting
corrosion, scoring

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Main
bearing and
journal

Bearing

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Bottom end
crank-pin

Machinery Inspection: Main Engine

Supercharging
arrangement

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

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)
Leakage, insulation

* Wear measurements to be carried out as specified by maker.

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Exhaust system

H.P. pumps

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Fuel system

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Machinery Inspection: Main Engine

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TYPICAL MACHINERY FAILURES

(CONTD.)

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TYPICAL MACHINERY FAILURES

(CONTD.)

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TYPICAL MACHINERY FAILURES

(CONTD.)

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TYPICAL MACHINERY FAILURES

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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
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

FIRE SAFETY FOCUS
DURING MAINTENANCE
AND INSPECTION

FACTS
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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
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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

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IMPROPER HOUSEKEEPING AND CLEANLINESS

POOR MAINTAINENACE PRACTICES

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Unapproved material

POOR MAINTAINENACE PRACTICES

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Missing/insufficient monitoring gauges/meters

POOR MAINTAINENACE PRACTICES

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Uncovered battery terminal

POOR MAINTAINENACE PRACTICES

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LO Leaks

POOR MAINTAINENACE PRACTICES

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Uncovered turbocharger casing and exhaust manifold temp.>220degC

POOR MAINTAINENACE PRACTICES

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Improper cable routing/securing/protection

POOR MAINTAINENACE PRACTICES

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Unauthorized socket Installation

POOR MAINTAINENACE PRACTICES

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Continuous leaks through main engine FW tank cap

POOR MAINTAINENACE PRACTICES

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Bare/unprotected lighting

POOR MAINTAINENACE PRACTICES

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Unprotected terminal switches

CHIEF ENGINEER CHECKSHEET

CHIEF ENGINEER CHECKSHEET

(CONTD.)

CHIEF ENGINEER CHECKSHEET

(CONTD.)

CHIEF ENGINEER CHECKSHEET

(CONTD.)

Q&A

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THANK YOU