Every machines has shortcomings, some may never appear untill put to real life
service
Typical ships LNG, Older Most Merchant Small ships Fast ferries Some fast
ships merchant ships, Naval of all types Naval ships ferries
ships auxiliries
Current Unlikely for Most Increasing Dominates Domiantes Increasing
status new ships common use in small ships naval ships use in fast
merchant ferries
ships
Minimum Residual Heavy blend Intermediate Light Light Selected
fuel quality blend distillates distillates light belnds
Fuel High Lowest Lowest Low High High
consumption
Maintenance Least Low High Low Low at sea Moderate
on minimum Overall High
quality fuel
Almost 60-70% failures occur after the maintenance has been done
(what does this indicate?)
Examples:
Filters change but O-rings missed
Fan/Motor insulation checked and windings connected wrong
Wrong tightining of Staybolts, greasing forgotten etc
-Routine
+Greasing, Lubricating, level checking (tanks, sump etc),
+operator checks (buttons/switches, valves/flaps, lamps, item location etc)
+Measurements (guages, clearences, volts/current/frequency, pres./temp)
-Planned
+calender time (every week/each month, quarterly etc, annualy, bi-annualy)
+operating hours
Condition Based
+Almost all CBM are Inspections
+VA (vibration analyses), Oil analyses (lube, hydraulic etc), Visual (endo/boro)
+Performance based (deviation from reference datum), database building
+Also various NDE techniques – ultrasonic thickness/leak detection etc.
Breakdown maintenance
+An old maintenance philosophy - Fix it only when its broken e.g. filters
+Despite all Preventive Maintenance, breakdown does occur sometimes
+Attributable causes – engineering, human factors, operation beyond limits etc.
Staggered and manageable maintenance at each port (e.g one cylinder o/h at a time!)
Auxiliary engines maybe taken out of service while sailing – often technicians travelling
with ship for that very purpose
Asif Munir / asif.munir@tkk.fi
Ship Machinery Maintenance / 28Nov2006 Helsinki University of Technology
Diesel Engine-Maintenance
Preventive
Schedule usually set by engine manufacturer (list of tasks based on op. hours)
Expected life
Exhaust vv 12000h, Inlet vv 36000h, Cylinder liner 60000h, piston rings 12000h
Parameter example:
cylinder exhaust temp, T/C rpm, Compression pressures, Diff. Pressure across filters/coolers,
lube oil analyses, SFC etc
Lifting of piston and cylinder liner large marine engine (Jib crane)
When engine is shut down, indicator cocks at cylinders, drain valaves at air coolers, air
manifolds and exhaust manifolds opened and left open – Any Abnormality can be detected first
hand!
Crankcase doors must never be opened untill crank is cooled down –danger of explosion
Low oil temperatures may indicate high differential pressure at filters even alarm
Running fluid levels are different than static (turbo charger, sump, tank etc)
Propellor shaft must be inserted through stern tube or strust bearing – flange at one end only
Last section of line shafting along with bearing is removed using overhead lifting gear (provided)
and set aside on exclusive landing areas/cradles
Seals, packing glands cleared away, lifting gear/wood blocking used to support the shaft as it is
pulled inboard by chainfall.
Repair or replacement tranport by hole cut in side shell (area designated for this prupose)
Sludge disposal timer (slef cleaning), RPM, correct temperature of fluid are important
LO purifiers on propulsion engines stopped after 12-24 hrs running since engine shut down
Alcap Purifiers
Asif Munir / asif.munir@tkk.fi
Ship Machinery Maintenance / 28Nov2006
Source: Alfa-Laval Brochures Helsinki University of Technology
Pumping Systems
Centrifugal pumps:
Impellor never touches casing
Small clearences, Erroded by liquid
Motor
Many pumps have wear rings both at (currents, rpm)
impellor and in casing,
replacement resoteres performance
Basic Maintenance
External leakages : Renew glands/pack/rings/seals
Plate type
Asif Munir / asif.munir@tkk.fi
Ship Machinery Maintenance / 28Nov2006 Helsinki University of Technology
Maintenance Information
Sea Trials
Adjustments,
Database
repairs,
Or filing
replacements
Need
Shipyard, manufacturer
Vessel Delivery
Owners Maintenance
manual, Procedures
warranty
information,
maintenance
procedures Need
Markings
Clear markings on equipment, for example inspection doors, sampling cocks/points
3 WAVEFORM DISPLAY
2
two impacts per revolution
13-JUL-97 12:33
1 RMS = .5244
0 PK(+) = 3.00
-1
PK(-) = 2.25
-2
CRESTF= 5.73
-3
Ordr: 72.00
0 60 120 180 240 300
Freq: 28800.
Time in mSecs Spec: .00889
Area of broken teeth
Label: 72 tooth gearmesh