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Planned Maintenance System

8.1 General

8.1.1 An approved Planned Maintenance System on board a ship may be accepted in lieu of the regular surveys by IRS Surveyors on CSM basis provided the requirements of this section are complied with.

Any item not covered by PMS is to be surveyed and credited in the usual way. In general the intervals for PMS is not to exceed those specified for CSM survey. PMS is to be programmed and maintained by a computerised system.

8.1.2 A vessel complying with the requirements of section will be assigned the PMS survey notation.

8.1.3 The survey system (PMS) is to be approved by IRS before being implemented. When the system is implemented machinery inspection may be based on calendar or running hours calling for items to be opened for inspection and overhaul at specified periods, or the machinery may be monitored for condition and performance whereby items need only be opened for examination when readings indicate a deterioration. Schemes could be made up of a combination of two or more methods of maintenance control, such as:

- A switchboard is surveyed based on regular 5 yearly intervals.

- A diesel engine is surveyed based on running hours.

- A lubricating oil pump is surveyed based on calendar interval.

- A turbine may be surveyed based on condition monitoring.

8.1.4 When any machinery and components are approved under PMS for condition monitoring and when their condition and performance is within acceptable limits, no overhaul is necessary, unless otherwise specified by the manufacturer.

8.1.5 Other items of machinery and components, which are not subjected to an approved condition monitoring system and part of PMS are required to be surveyed at intervals not greater than those specified for CSM.

8.1.6 Chief Engineer of the vessel will be responsible and in-charge of PMS and is to be approved by IRS as per Sec.1, 1.6 of this Chapter.

8.1.7 The survey of machinery and components (defined at 8.2) & covered by the PMS may be carried out by the Chief Engineer. Survey of machinery and components defined in 8.3 is not eligible to be surveyed by the Chief Engineer.

8.1.8 At the time of the Annual Classification Survey an audit of the planned maintenance system will be carried out to ensure that the system is being correctly operated in accordance with the conditions of approval.

8.1.9 When the annual audit is held, a confirmatory survey will be carried out for those items to be credited which have been examined by the Chief Engineer under the planned maintenance system during the preceding year.

8.2 Machinery acceptable for survey by Chief Engineers under Planned Maintenance System 8.2.1 The following machinery may be surveyed by the Chief Engineer under PMS:

- Main engine cylinder covers.

- Main engine valves and valve gears.

- Main engine cylinder liners.

- Main engine pistons and piston rods.

- Main engine connecting rods, crossheads, top end bearings, guides, gudgeon pins and bushes.

- Main engine crankshafts and bearings (multiple engine installations only).

- Main engine fuel injection pumps and fuel booster pumps.

- M.E. Scavenge pumps, blowers and air coolers.

- Main engine detuners, dampers and balancer units.

- Main engine camshaft and camshaft drive.

- Main propulsion gas turbines (casing, rotor and blading) at alternate surveys provided the monitoring defined in 8.8.1.2 is provided and vibration measurements and full power trials are carried out at the time of the survey in the presence of a Surveyor.

- M.E. driven pumps, e.g. bilge, lubricating oil, cooling water.

- Independently driven pumps and associated motors and cables where insulation resistance readings are supplied e.g. bilge, ballast, fresh water cooling, sea water cooling, lubricating oil, oil fuel transfer.

- M.E. fresh water and lubricating oil coolers.

- Low pressure heaters used in fuel oil systems of internal combustion engines

- Main and auxiliary condensers/drain coolers.

- Air compressors including their safety devices.

- Windlass and windlass machinery.

- Auxiliary oil and steam engines including their coolers and pumps (provided the number of generating sets is such that all services essential to the propulsion and safety of the ship, also the preservation of refrigerated cargo, can be supplied when any two sets are not working.

One of these sets can be overhauled while the other remains as "stand-by").

- Intermediate shafts.

- Main engine thrust bearing.

- Engine room tanks with boundaries not forming part of ship’s structure

Note : In cases where torsional vibration characteristics indicate that there is no susceptibility to damage as a result of uneven firing and the condition monitoring equipment defined in 8.8.1.1 is installed, a special arrangement may be granted whereby the Chief Engineer is permitted to survey the main engine crankshafts and bearings on single engine installations provided a modified confirmatory survey is carried out by IRS Surveyors at the time of the annual audit as follows:

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- Check condition-monitoring records. (See 8.8.1.1)

- Check bearing clearances where possible.

- Check for signs of wiped or broken white metal in crankcase.

- Check witness marks of shrink fits.

- Check bed plate structure inside and outside.

- Obtain Chief Engineer's statements regarding crankpins, journals and bearings.

8.3 Machinery not acceptable for Survey by Chief Engineers

- Main engine crankshaft and bearings in single engine installations where special requirements in 8.2.1 are not complied with

- Reduction/increase gearing, flexible couplings and clutches.

- Holding down bolts and chocks

- Crankcase doors, crankcase and scavenge relief devices

- Maneuvering valves and main stop valves - Steering machinery

- Pumping arrangements for Bilge/Ballast/ Fuel Oil/Fresh Water/Sea water/Lub.Oil/ Fire

- Electrical equipment other than that defined in 8.2.1

- Propellers - Screwshafts - Sea connections

- M.E. controls, bridge, centralised or automatic and controls in unmanned machinery spaces - Engine trial

- First start arrangements trial.

- Starting Air bottles and their relief devices 8.4 System Administration

8.4.1 The Owner is to make a formal request to IRS providing the documentation and information detailed in 8.4.2 below for approval of the system.

8.4.2 The documentation and information to be submitted is to include the following:

a) A description of the system and its application onboard and organizational interface identifying the areas of responsibility ashore and the people responsible for the PMS onboard.

b) The list of items of machinery, equipment and components to be considered for inclusion in the PMS. The list is to be same in terms of description and identification with the identification system adopted by IRS.

c) Time schedules and scope of the maintenance procedures for each item listed in b), including acceptable limit conditions of the parameters to be monitored on items of opened up machinery, based on the manufacturer's recommendations or recognized standards. These are to be laid down in appropriate PMS sheets.

d) For machinery identified to be maintained under condition monitoring, maintenance and condition monitoring methods to be used, the time intervals for monitoring and maintenance of each item, the original reference data where applicable, the list and specifications of the condition monitoring equipment.

The acceptable limits of deteriorated condition should be stated and these are to be derived from manufacturer’s recommendations, applicable severity criteria as defined in applicable Standards, or the Owners requirements when these are more severe.

e) The documentation flow and filing procedure.

This is to include a system for reporting to Owners, records to be maintained onboard and at Owner’s head quarters.

f) A list of all personnel likely to be in-charge of the PMS system.

8.4.3 Computerized system requirement

8.4.3.1 The access to and updating the maintenance documentation and the maintenance program is to be permitted by the Chief Engineer or other authorized person only.

8.4.3.2 The system is to be suitably protected by suitable password access w.r.t. alterations to maintenance schedules, list of items under PMS and noting of damages.

8.4.3.3 The computerized system is to include a backup procedure, which is activated at regular intervals.

8.4.3.4 The functional applications of these computerized systems are to be approved by IRS.

8.4.4 Information to be available onboard.

a) All the documentation listed in 8.4.2, duly updated.

b) Maintenance instructions for each machinery, as applicable (supplied by the manufacturer or the shipyard).

c) The condition monitoring data including all data since last opening of the machinery and where applicable the original reference data.

d) Reference documentation (trend investigation procedures etc.).

e) The records of the maintenance performed, including conditions found, repairs and renewals carried out.

8.5 System Implementation

8.5.1 After the PMS documentation has been approved, an Initial Survey is to be carried out by IRS Surveyors.

8.5.2 Upon successful completion of the Confirmatory Survey, the PMS is considered approved and the survey notation PMS is assigned to the vessel and entered in the Register of Ships.

8.5.3 The PMS is retained throughout the class period of the vessel provided that :

a) An annual report covering the year’s service is submitted to IRS detailing the list of items of machinery and components which were subjected to preventive maintenance in the period under review, together with preventive maintenance sheets, the condition monitoring data including all data since last dismantling and any changes to PMS documentation.

b) An annual audit of the PMS is carried out by IRS.

c) Any change to the PMS is submitted to IRS for approval.

8.5.4 The survey agreement for machinery according to PMS will be withdrawn by IRS if the PMS is not satisfactorily operated in terms of improperly maintained records or unsatisfactory condition of machinery or failure to observe the agreed intervals between overhauls.

8.5.5 The Owner may discontinue the PMS at any time by informing IRS in writing. In such a case the items that have been inspected under the PMS since last annual audit may be credited for IRS records at the discretion of the attending surveyor carrying out confirmatory surveys.

8.5.6 In case of change of management of the ship the PMS will require to be re-approved.

8.6 System Surveys

8.6.1 Initial Survey is to be carried out by an IRS Surveyor within one year from the date of the documentation approval. The scope of this survey is to verify that :

a) The PMS is implemented as per the approved documentation and is suitable to the type and complexity of machinery and systems onboard.

b) The documentation required for the annual audit is available and the adopted system is able to produce such a report.

c) The requirements of surveys and testing for continuing the class status are complied with.

d) The shipboard personnel are familiar with the PMS procedures including documentation.

8.6.2 Annual Audit is to be carried out once the PMS is implemented and approved, to verify the continued compliance with the documented PMS.

The annual audit is carried out in conjunction with the annual class surveys. The scope of the audit is to be as given in the following :

a) The Surveyor is to verify that the PMS is correctly operated and that all items (due for survey in the relevant period) have actually been surveyed in due time.

b) The Surveyor is to verify that the machinery has been functioning satisfactorily upon review of Indian Register of Shipping

the maintenance and performance records since the previous survey or audit and where needed necessary measures have been taken in response to machinery operating parameters exceeding acceptable limits and that the overhaul intervals have been observed.

c) A report detailing overhaul/repairs carried out and spare parts used on items in the list of surveyable items is to be presented by the Chief Engineer. Any machinery part or component, which has been replaced by a spare due to damage, is to be retained onboard and submitted to the attending surveyor’s examination.

d) The attending surveyor after verification of records on board for the identification details of the Chief Engineers who have undertaken the maintenance activity and prepared the reports given in c), for compliance with the approved PMS, and upon satisfactory general examination and confirmatory surveys will credit the items for survey.

e) Scope of the confirmatory surveys

− Where condition monitoring equipment is in use, function tests, confirmatory inspections and random check readings are to be carried out as far as practicable and reasonable at the discretion of the surveyor. Where the condition and performance of the items are within specified approved limits, these items can be credited for survey without opening up.

− Where calendar based or running hour based maintenance is used function tests, review of records for operational parameters and maintenance records are to be carried out as far as practicable and reasonable at the discretion of the surveyor. Where the condition and performance of the items are within specified approved limits, these items can be credited for survey.

f) Written reports of break down or malfunction are to be made available.

g) If the surveyor is not satisfied with results of the PMS i.e. with degree of accuracy as regards the maintenance records and/or the general condition of the machinery, a report will be forwarded to IRS recommending that the special arrangements dealing with machinery surveys be suspended.

h) Upon satisfactory completion of the annual audit the surveyor confirms the validity of the PMS by crediting the PMS Annual audit.

8.7 Damage and repairs

8.7.1 Damage to components or items of machinery covered by the PMS which may affect the class is to be reported to IRS immediately. A surveyor will attend on board, survey the damage and on the basis of the survey results decide whether condition of class is to be recommended.

8.7.2 All parts of machinery or components, which need to undergo substantial repairs, are to be surveyed by IRS before, during and after the repairs, as deemed appropriate by the attending surveyor.

8.7.3 In the case of outstanding conditions of class or records of unrepaired damage, which may affect the PMS, the relevant items are to be taken out of the PMS until the conditions of class are dealt with or the repairs are carried out.

8.8 Guidelines for machinery items surveyed on the basis of condition monitoring

8.8.1 The extent of condition based maintenance and associated monitoring of equipment; to be included in the PMS is decided by the owner. The minimum parameters to be checked in order to monitor the condition of the various machinery for which this type of maintenance is accepted are indicated in 8.8.1.1 to 8.8.1.4.

8.8.1.1 For the main propulsion diesel engine the following parameters are to be monitored.

- Shaft horse power - Engine and shaft RPM

- Indicator diagrams (both power and injection timing), where applicable

- Fuel oil temperature and/or viscosity - Charge air pressure

- Exhaust gas temperatures for each cylinder and before and after turbochargers

- Engine cooling system temperatures and pressures

- Engine lubricating oil system temperatures and pressures

- Turbocharger RPM and vibration - Lubricating oil analysis data - Crankshaft deflections - Main bearing temperatures.

8.8.1.2 For the main and auxiliary steam turbines the following parameters are to be monitored.

- Turbine rotor/bearing vibration - Turbine rotor axial displacement - Shaft horsepower

- Shaft and turbine rotor RPM

- Plant performance data i.e. steam conditions at the inlet and outlet of each turbine, boiler performance data, condenser vacuum, sea temperatures.

8.8.1.3 For the auxiliary diesel engines the following parameters are to be monitored.

- Exhaust gas temperatures for each cylinder and before and after turbochargers

- Engine cooling system temperatures and pressures

- Engine lubricating oil system temperatures and pressures

- Turbocharger RPM and vibration - Lubricating oil analysis data - Crankshaft deflections.

8.8.1.4 For other auxiliary machinery the following parameters are to be monitored.

- Cooler inlet and outlet temperatures and efficiencies

- Inlet and outlet temperatures of heaters

- Pumps and fans vibration and performance data - Differential pressures across filters serving

essential systems.

End Of Chapter

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