IMO TA303E COMPENDIUM-2004 Survey of Machinery Installations.pdf

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1、MODEL COURSE SURVEY OF MACHINERY INSTALLATIONS 2004 Edition Compendium MODEL COURSE 3.03 SURVEY OF MACHINERY INSTALLATIONS 2004 Edition COMPENDIUM Model course developed under the IMO - IACS Programme INTERNATIONAL MARITIME ORGANIZATION London, 2004 First published in 7989 by the INTERNATIONAL MARIT

2、IME ORGANIZATION 4 Albert Embankment, London SEI 7SR Revised edition, 2004 Printed in the United Kingdom by Ashford Press IMO PUBLICATION Sales number: TA303E ISBN 92-801 -41 86-4 Copyright O IMO 2004 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or

3、 transmitted in any form or by any means, electronic, electrostatic, magnetic tape, mechanical, photocopying or otherwise, without prior permission in writing from the International Maritime Organization. ACKNOWLEDGEMENTS This compendium has been prepared for use by instructors and trainees during t

4、he presentation of IMO model course 3.03 - Survey of Machinery Installations, in which specific references to the appropriate section are made. It supplements the information contained in the course framework. MODEL COURSE COMPENDIUM 3.03 SURVEY OF MACHINERY INSTALLATIONS TABLE OF CONTENTS TABLE OF

5、CONTENTS CHAPTER I : INTRODUCTION 1 . 1 Applicable requirements 1.2 1.2.1 Surveys . 4 1.2.2 Certification I . 3 1.3.1 Rule basis . 9 1.3.3 . 1 Survey and certification . 4 . 5 Classification surveys . 9 I . 3.2 Scope of rules 10 Other related rules 11 1.3.4 IACS Members 12 1.4 Documentation 13 . CHA

6、PTER 2: PREPARATION FOR SURVEY 2.1 2.2 Tools and equipment 17 2.3.1 General 19 2.3.2 Request for surveys 15 2.3 Safety precautions 19 Specific safety precautions applicable to machinery installations : . 20 2.3.3 Confined spaces . 21 . CHAPTER 3: SURVEY METHODS 3.1 3.1 . 1 3.2 3.2.1 3.2.2 Traditiona

7、l survey arrangement 25 Internal inspection (Overhaul) . 25 3.1.2 External inspection 26 Alternative survey arrangement 27 Generally accepted by the Administration . 27 Specially accepted by the Administration 28 CHAPTER 4: NON-DESTRUCTIVE EXAMINATION 4.1 General . 31 4.2 NDE basic requirements . 35

8、 4.2.1 Procedure . 35 4.2.2 Sensitivity 35 4.2.3 Reference documents . 35 4.3.1 Visual examination 36 Magnetic particle examination . 36 4.3.3 Penetrant examination 37 4.3.5 Radiographic examination 39 Certification of NDE operator 40 4.3 4.3.2 4.3.4 Ultrasonic examination 38 4.4 Guidelines for exam

9、ination of welds . 36 CHAPTER 5: SURVEY OF MACHINERY SYSTEMS . 5.1 General 41 5.2 5.3 Scope of initial survey . 45 Scope of annual and renewal survey 47 iii MODEL COURSE COMPENDIUM 3.03 SURVEY OF MACHINERY INSTALLATIONS TABLE OF CONTENTS 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.5 5.5.1 5.5.2 5.5.3 5.6 5.

10、6.1 5.6.2 5.6.3 5.7 5.7.1 5.7.2 5.7.3 5.8 5.8.1 5.8.2 5.8.3 5.9 5.9.1 5.9.2 5.10 5.10.1 5.10.2 5.1 1 5.1 1 . 1 5.1 1.2 5.11.3 Survey of bilge pumping system . 48 General . 48 Initial survey 48 Initial survey . passenger ships . 54 Initial survey . cargo ships 55 AnnuaVRenewal survey 57 Survey of sea

11、 water system 57 Initial survey 58 AnnuaVRenewal survey 58 Dry docking survey . 58 Survey of compressed air system . 59 General . 59 Initial survey of component and equipment . 59 AnnuaVRenewal survey 61 Survey of fuel oil system . 63 General . 63 Initial survey 65 Annual/renewal survey 68 Survey of

12、 lubricating oil system . 69 General . 69 Initial survey 69 Annual/Renewal survey . i 70 Survey of steam pipe system 70 Initial survey 70 AnnuaVRenewal survey 71 Survey of feedwater and condensate water system 72 AnnuaVRenewai survey 73 Initiai Survey . 74 Intermediate/Renewal survey 81 Initial surv

13、ey 72 Survey of cargo system of oil tankers . 74 Annual survey . 80 CHAPTER 6: SURVEY OF BOILERS AND PRESSURE VESSELS 6.1 General . 83 82 6.1.1 I ype of pressure vessels 6.1.2 Pressure vessels classification: 84 6.2 Initial survey 85 6.2.1 Document review 86 6.2.2 Inspection during fabrication . 86

14、6.2.3 Installation on board 89 6.2.4 Testing under steam before putting in service for the first time . 89 6.3 Annual survey . 91 6.3.1 Scope 91 6.3.2 Checklist . 91 Practical considerations 92 6.3.3 6.4 Periodical survey . 92 6.4.1 Scope 92 6.4.2 Checklist: . . 93 6.4.3 Practical considerations 95

15、l? iv MODEL COURSE COMPENDIUM 3.03 TABLE OF CONTENTS SURVEY OF MACHINERY INSTALLATIONS CHAPTER 7: SURVEY OF STEAM TURBINE . 105 7.1 General 7.2 Initial survey 106 7.2.1 Document review 106 7.2.2 7.2.3 Survey during installation 106 7.2.4 7.4 Survey prior to installation . 106 Survey during operation

16、 - sea trial . 107 7.3 Annual survey . 109 Renewal survey 1 o9 CHAPTER 8: SURVEY OF DIESEL ENGINES General . 111 112 8.1 8.2.1 Document review 113 8.2.2 Inspection during construction 115 8.2.3 Installation on board 119 8.2.4 Trials . 119 8.3 Annual survey . 122 8.3.1 Scope 122 8.3.2 Practical consi

17、derations 123 8.4 Renewal survey 124 8.4.1 Scope 124 8.4.2 Practical considerations: . 124 8.2 Initial survey CHAPTER 9: SURVEY OF GEARING ARRANGEMENTS 9.1 General . 137 9.2 Initial survey 138 9.2.1 Initial survey prior to installation 138 9.2.2 Initial survey after installation . 140 9.2.3 Initial

18、survey during sea trial 141 9.2.4 Initial survey after sea trial 142 9.3 Annual survey . 142 9.4 Renewal survey 142 CHAPTER 10: SURVEY OF PROPULSION SYSTEMS 10.1 General . 145 1 O . 1.1 Types of propulsion systems 145 10.1.2 Types of stern tube bearings 145 10.1.3 . Periodicity of tailshaft survey .

19、 146 10.2 Initial survey 147 10.2.1 Document review . 148 10.2.2 Inspection during construction 150 10.2.3 Installation on board 151 10.2.4 Sea trials . 153 10.3 Tailshaft complete survey . 153 10.3.1 Scope 153 10.3.2 Checklist . 155 10.3.3 Practical considerations . 156 . V MODEL COURSE COMPENDIUM

20、3.03 SURVEY OF MACHINERY INSTALLATIONS TABLE OF CONTENTS 10.4 Tailshaft modified survey 162 10.4.2 Checklist . 162 10.4.1 Scope 162 10.4.3 Practical Considerations 163 10.5 Propeller survey 163 10.5.1 Working conditions of propellers . 163 10.5.2 Practical considerations 164 CHAPTER 11 : SURVEY OF S

21、TEERING GEAR SYSTEM 11.1 11.1.1 11.2 11.2.1 11.2.2 11.2.3 1 I . 2.4 11.2.5 1 I . 2.6 11.2.7 11.2.8 1 I . 2.9 1 I . 2.10 1 I . 2.11 11.2.12 11.3 11.3.1 11.3.2 11.3.3 General (see also appendix 1 1 . 1) . 169 Introduction . 169 Initiai survey 177 Documentation . .I . 177 Pressure tests . 178 Test of s

22、teering gear components at workshop 178 Inspection for installation of steering gear . 178 Inspection and testing of piping system during installation . 179 Examination of electric system during installation. 179 Examination of steering gear compartment arrangement . 180 Testing of steering gear aft

23、er assembling . 180 Test remote control system from navigating bridge 180 Test alarms and indicating lights . 181 Test control in steering gear compartment 181 Steering gear test at sea trial 181 Annual survey . 182 General inspection 182 Renewal survey 183 Function test . 182 CHAPTER 12: SURVEY OF

24、EQUIPMENT FOR THE CONTROL OF OIL DISCHARGE 12.1 12.1 .I 12.1.2 12.1.3 12.2 12.2.1 12.2.2 12.3 12.3.1 12.3.2 12.3.3 12.4 12.4. I 12.4.2 12.4.3 12.5 12.5.1 12.5.2 4-4 A IL . I.* FROM MACHINERY SPACE General . 185 Gravity 185 Coalescing 186 Hydro cyclone principle . 186 Bi inechnic I. . 186 Initial sur

25、vey 187 Document review 190 Installation on board 190 Annual survey . 190 Scope 190 Checklist . 191 Practical considerations I91 intermediate survey 192 Scope 192 Checklist . 192 Practical arrangements . 193 Renewal survey 193 Scope 193 Checklist . 194 vi MODEL COURSE COMPENDIUM 3.03 APPENDICES Appe

26、ndix 7.1: Steam turbine surveys of ships in service: short failure analysis SURVEY OF MACHINERY INSTALLATIONS TABLE OF CONTENTS Appendix 5.1 : Some marine machinery failures and their causes . 199 Appendix 1 1.1 : Steering gear: new concepts. 252 254 vi i MODEL COURSE COMPENDIUM 3.03 CHAPTER 1 SURVE

27、Y OF MACHINERY INSTALLATIONS INTRODUCTION CHAPTER 1 INTRODUCTION 1.1 Applicable requirements When the establishment of a specialized agency of the United Nations concerned solely with maritime affairs was first proposed, the main concern was to develop international standards to improve safety at se

28、a. This was understandable for two main reasons. In the first place, seafaring has always been one of the most dangerous of occupations. In the second place, because of the international nature of the shipping industry, it had long been recognized that the action to improve safety in shipping operat

29、ions would be more effective if carried out at an international level rather than by individual countries acting unilaterally and without Co-ordination with others. Although a number of important international agreements had already been adopted, many States agreed that there was a need for a perman

30、ent body which would be able to Co-ordinate and promote further measures on a more continuing basis. It was against this background that the United National Maritime Conference of 1948 adopted the Convention establishing the International Maritime Organization (IMO) as the first ever international b

31、ody devoted exclusively to maritime matters. In the ten years period between the adoption of the Convention and its entry into force in 1958, other problems related to safety, but requiring slightly different emphasis, had attracted international attention. One of the most important of these was the

32、 threat of marine pollution from ships, particularly pollution by oil carried in tankers. An international convention on this subject was actually adopted in 1959, four years before IMO came into existence; and responsibility for administering and promoting this Convention was assumed by IMO at the

33、inception of its work in January 1959. Thus from the very beginning, the improvement of maritime safety and the prevention of marine pollution have been IMOS most important objectives. The governing body of IMO is the Assembly, which meets normally once every two years and consists of all the Member

34、 States. In the period between the sessions of the Assembly, a Council exercises the functions of the Assembly in running the affairs of the Organization. The Organizations technical work is carried out by a number of committees, the most senior of which is the Maritime Safety Committee (MSC). This

35、has a number of sub-committees whose titles indicate the subjects with which they deal. There are sub-committees dealing with: safety of navigation; radio communications; life- saving, search and rescue, standards of training and watch keeping; carriage of dangerous goods; ships design and equipment

36、; fire protection; stability and load lines and fishing vessel safety; containers and cargoes; and bulk chemicals. 1 MODEL COURSE COMPENDIUM 3.03 CHAPTER I SURVEY OF MACHINERY INSTALLATIONS INTRODUCTION The Sub-Committee on Bulk Chemicals is also a sub-committee of another technical committee, the M

37、arine Environment Protection Committee (MEPC), which deals with the Organizations activities for the prevention and control of marine pollution. Because of the legal issues involved in much of its work, the Organization also has a legal Committee, while the Committee on Technical Co-operation co- or

38、dinates and directs IMOS activities in this area. These committees are all recognized by the IMO Convention. Finally, there is the Facilitation Committee, which deals with measures to simplify and minimize documentation in international maritime trafic. This is a subsidiary of the Council. In order

39、to achieve its objectives, IMO has promoted the adoption of conventions and protocols, and adopted a large number of codes and recommendations on various matters relating to maritime safety and the prevention of pollution. The initial work in a convention is normally done by a committee or sub-commi

40、ttee: a draft instrumental is then produced, which is submitted to a conference to which delegations from all States within the United Nations system - including States which may not be IMO Members - are invited. The conference adopts a final text, which is submitted to Governments for ratification.

41、 With the successful adoption of the convention, the onus for action moves to Governments. The speed with which the convention enters into force (that is, becomes binding on States which have agreed to be bound by it) depends upon the time taken by Governments to ratify or accept it. The consent to

42、be bound may be expressed by signature, ratification, acceptance, approval or accession, depending on the wish of the State concerned. This procedure is generally referred to as “ratification”. IMO treaties enter into force after a specific number of States have ratified them. Most IMO conventions r

43、equire that a certain proportion of the worlds total tonnage is covered before they enter into force. A Government ratifying a convention has to ensure that its own national law conforms with its provisions. This usually involves some form of domestic legislative aaic:. After the requirements for en

44、try into force of a convention have been achieved, there is a “period of grace” before it actually comes into force. This period varies from a few months to a year or even two years, and is designed to enable the Governments concerned to take the necessary legislative of administrative measures for

45、implementing the provisions of the convention. As indicated above, IMO has, over the years, adopted a considerable number of conventions but, for the survey courses, two are of particular importance: the International Convention for the Safety of Life at Sea (SOLAS) and the International Convention

46、for the Prevention of Pollution from Ships (MARPOL). 2 MODEL COURSE COMPENDIUM 3.03 SURVEY OF MACHINERY INSTALLATIONS CHAPTER 1 INTRODUCTION The history of SOLAS goes back a long time. The first maritime safety conference was convened in 1914, but the First World War intervened and the convention it

47、 adopted newer entered into force. In the following decades, a number of maritime safety conventions were adopted, the last one in 1974. This Convention, known as SOLAS 74, has been amended a number of times and further amendments are pending. MARPOL has not such a long history. A first conference,

48、held in 1926, did not lead to a convention. The first convention dealing with oil pollution from ships was adopted in 1954, but it only addressed persistent oils. MARPOL, which deals with various types of pollution, was adopted in 1973 and, even before its entry into force, was modified by a Protoco

49、l in 1978. It is now known as MARPOL 73/78 and has also been amended since its entry into force. The third stage is implementation - in many ways the most important stage. Generally speaking, the main responsibility for the enforcement of an international convention lies with the State under whose flag the ships concerned operate. Basically, each Government is responsible for ensuring that ships which fly its flag conform to the requirements of conventions which it has ratified. However, many IMO conventions also contain provisions permitting or requiring other States, particularly p