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Special Surveys – Machinery

6.1 General

6.1.1 The machinery special survey becomes due five years from the date of build or from the last assigned machinery special survey (SSM) date.

6.1.2 When due to special circumstances a special survey is commenced prior to its due date, the survey is to be completed within a period not exceeding 9 months and not later than the expiry date of the classification certificate including any postponement that may be granted by IRS.

6.1.3 If a craft at the time classification certificate expires is not in a port in which it is to be surveyed, IRS may upon owners request extend the validity of the classification certificate for a period not exceeding 3 months. Such requests will only be considered to enable the vessel to complete its voyage to the port of survey and only in cases where it is considered proper and reasonable to do so.

6.1.4 Upon satisfactory completion of the machinery special survey an appropriate record will be entered in the supplement of Register of Ships.

6.2 Continuous survey of machinery (CSM) 6.2.1 At the request of the Owners and upon approval of the proposed arrangement a system of continuous survey of machinery (CSM) may be undertaken whereby the requirements of special survey of machinery are completed within a five year period. The survey cycle is to be such as would ensure that the interval between consecutive examination of each item does not exceed five years and it is expected that approximately an equal proportion of the machinery would be subjected for survey each year.

6.2.2 Further parts of machinery may require to be opened if any defects are found during the course of Survey of any item and the defects made good to the satisfaction of the Surveyor.

6.2.3 Upon satisfactory completion of the continuous machinery survey cycle, a record indicating the date of completion of the cycle will be shown in the supplement to the Register of Ships.

6.3 Survey requirements: Auxiliary engines 6.3.1 All auxiliary engines driving the generators and other essential machinery together with their coolers and attached pumps are to be opened up and examined as considered necessary by the Surveyor.

Alarms and safety devices fitted on these units are to be included in this survey.

6.4 Survey requirements: Air compressors, receivers and starting air pipes

6.4.1 All air receivers and other pressure vessels for essential services together with their mountings and safety devices are to be cleaned internally and examined internally and externally. If an internal examination of an air receiver is not practicable it is to be tested hydraulically to 1.3 times the working pressure.

6.4.2 Air compressors are to be opened up and coolers tested as considered necessary by the Surveyor. Selected pipes in the starting air systems are to be removed for internal examination and hammer tested. If an appreciable amount of lubricating oil is found in the pipes the starting air system is to be thoroughly cleaned by steaming or other suitable means. Some of the pipes selected are to be those adjacent to the starting air valves at the cylinders and to the discharges from the air compressors.

6.5 Survey requirements: Propulsion system 6.5.1 Athwartships thrust propellers are to be generally examined so far as is possible in dry dock and tested under working conditions afloat for satisfactory operation.

6.5.2 All shafts (except screwshafts and tube shafts, for which special arrangements are detailed in Section 7), thrust block and all bearings are to be examined. The lower halves of bearings need not be exposed if alignment and wear are found to be acceptable.

6.5.3 An examination is to be made as far as practicable of all propulsion gears complete with all wheels, pinions, shafts, bearings and gear teeth,

thrust bearings and incorporated clutch arrangements.

6.6 Survey requirements: Independent fuel tanks 6.6.1 Fuel tanks which do not form part of the ship’s structure are to be examined internally and externally and, if considered necessary by the Surveyor, they are to be tested. These need not be examined at the first engine survey if they are found satisfactory on external examination. All mountings, fittings and remote control devices are to be examined as far as practicable.

6.7 Survey requirements: Pumps, heat exchangers, forced draught fans, etc.

6.7.1 All pumps, heat exchangers, forced draught fans, etc. used for essential purposes are to be opened up and examined as considered necessary by the Surveyor.

6.8 Survey requirements: Pumping and piping system

6.8.1 The valves, cocks and strainers of the bilge system including bilge injection are to be opened up as considered necessary by the Surveyor and together with pipes, are to be examined and tested under working conditions. If non-return valves are fitted in hold bilges, these are to be opened up for examination.

6.8.2 The oil fuel, feed and lubricating systems and ballast connections together with all pressure filters, heaters and coolers used for essential service, are to be opened up and examined or tested as considered necessary by the Surveyor. All safety devices for the foregoing are to be examined.

6.8.3 Non-metallic expansion joints in piping systems, if located in system which penetrates the ship’s side and both the penetration and the non- metallic expansion joint are located below the deepest load waterline, are to be examined and replaced as necessary or at an interval recommended by the manufacturer.

6.9 Survey requirements: Reduction gears, flexible couplings and clutch arrangements

6.9.1 Reduction gears, flexible couplings and clutch arrangements are to be opened as considered by the Surveyor in order to permit the examination of the gears, gear teeth, spiders, pinions, shafts and bearings, reversing gears, etc. Essential parts of

other power transmission arrangements are to be opened up and examined as considered necessary by the Surveyor.

6.10 Survey requirements: Securing arrangements

6.10.1 Holding down bolts and chocks of main and auxiliary engines, gear cases, thrust blocks and tunnel bearings are to be checked.

6.11 Survey requirements: Shafting

6.11.1 Intermediate shafts and bearings, thrust bearings and their seating are to be examined. The lower halves of bearings need not be exposed if alignment and wear are found acceptable.

6.12 Survey requirements: Sea connections 6.12.1 All openings to the sea including sanitary and other overboard discharges in the machinery spaces and pump rooms together with valves and cocks are to be examined internally and externally. The fastenings of valves and cocks to the hull are to be examined and are to be renewed when considered necessary by the Surveyor.

6.13 Survey requirements: Windlass and steering machinery

6.13.1 These are to be examined to ascertain that they are in good working order. Any relief valves fitted are to be included in the above examination.

6.14 Survey requirements: Internal combustion engines for propulsion

6.14.1 All working parts of the engines and their attached pumps are to be opened and examined.

These are to include all cylinders, cylinder heads, valves and valve gear, pistons, piston rods, cross- heads, guides, connecting rods, crankshafts, vibration dampers and all bearings, camshafts and driving gear, fuel pumps and fittings, scavenge pumps, scavenge blowers and their prime movers, superchargers, air compressors, inter coolers, clutches, reverse gears, crankcase door fastenings and explosion relief devices and such other parts of the machinery as may be considered necessary.

Integral piping systems are to be examined. The maneuvering of engines is to be tested under working condition.

Indian Register of Shipping

6.15 Survey requirements: Gas turbines and free piston gas generators for propulsion

6.15.1 The survey is to include opening and examination of the following parts:

• The blading, rotors and casings of the turbines, the impellers or blading, rotors and casing of air compressors, the combustion chambers, burners, inter coolers, heat exchangers, gas and air pressure piping and fittings and reversing arrangements. When gas turbines operate in conjunction with free piston gas generators, the following parts of the free piston gas generators are to be opened and examined: the gas and air compressor cylinders and pistons and the compressor end covers, the valves and valve gear, fuel pumps and fittings, synchronizing and control gear, cooling system explosion relief devices, gas and air piping, receivers and valves including by-pass. The maneuvering of engines is to be tested under working conditions.

6.16 Survey requirements: Unattended machinery spaces/Remote control systems

6.16.1 Where remote and/or automatic controls such as bridge controls, bilge controls and bilge level alarms, local hand controls, fire detection and prevention, alarms warning systems and shut-offs, electric supply, main controls station, are fitted for essential machinery, they are to be examined and tested to demonstrate that they are in good working order.

6.16.2 During such trials the proper operation of the safety devices will be checked, in particular, such as emergency stops, emergency astern movement, standby control of the propelling gear, fire alarm.

6.16.3 The log recording the operating conditions is to be checked. If such scrutiny reveals that certain portion of the automated equipment has behaved abnormally the cause of such failure is to be investigated and appropriate remedies determined.

6.17 Electrical equipment survey requirements 6.17.1 An electrical insulation resistance test is to be made on the electrical equipment and cables. The installation may be sub-divided or equipment, which may be damaged, disconnected for the purpose of this test.

6.17.2 The fittings on the main and emergency switchboards, section boards and distribution boards

are to be examined and over-current protective devices and fuses inspected to verify that they provide suitable protection for their respective circuits.

6.17.3 Generator circuit-breakers are to be tested, so far as is practicable, to verify that protective devices including preference tripping relays, if fitted, operate satisfactorily.

6.17.4 The electric cables and their securing arrangements are to be examined, so far as is practicable, without undue disturbance of fixtures or casings unless opening up is considered necessary as a result of observation or of the tests required by 6.17.1.

6.17.5 The generator prime movers are to be surveyed and the governing of the engines tested.

The motors concerned with essential services together with associated control and switch gear are to be examined and if considered necessary, are to be operated, so far as is practicable, under working conditions. All generators and steering gear motors are to be examined and are to be operated under working conditions, though not necessarily under full load or simultaneously.

6.17.6 Where transformers or electrical apparatus associated with supplies to essential services are liquid filled or cooled by a liquid in direct contact with current carrying parts, the owner is to arrange for samples of the liquid to be taken and tested, by a competent authority, in accordance with the equipment manufacturer’s requirements, and a certificate giving the test results is to be furnished to the Surveyor.

6.17.7 Navigation light indicators are to be tried under working conditions, and correct operation on the failure of supply or failure of navigation lights verified.

6.17.8 The emergency sources of electrical power, where fitted, together with their automatic arrangements and associated circuits are to be tested.

6.17.9 Emergency lighting, transitional emergency lighting, supplementary emergency lighting, general emergency alarm and pump address systems are to be tested as far as practicable.

6.17.10 Where the craft is electrically propelled, the propulsion motors, generators, cables and all ancillary electrical gear, exciters and ventilating plant (including coolers) associated therewith are to

be examined, and the insulation resistance to earth is to be tested. Special attention is to be given to windings, commutators and slip-rings. The operation of protective gear and alarm devices is to be checked, so far as is practicable. Liquids for filling and cooling, if used, are to be tested in accordance with 6.17.6. Interlocks intended to prevent unsafe operations or unauthorized access are to be checked

to verify that they are functioning correctly.

Emergency over-speed governors are to be tested.

6.17.11 Where batteries provide the source of power for any essential services, their installation, including charging and ventilation arrangements, is to be examined.

Section 7