Chapter 5- Maintenance and Safety

Maintenance and SafetyOBJECTIVESCorrectly explain what safety measures should be taken with regards to the main propulsion system duringReducing speed due to rough seasAltering courseProviding additional power supplyAuxiliary steering on standbyChecking of LO and FO tank levelsChecking of operational parametersState all the safety measures to be carried on the steering system before departureCorrectly state what safety measures are taken in the engine room during normal operation and during rough seasExplain what routine checks and maintenance are carried out on the main propulsion system during normal operationCorrectly state how the periodic checking shall be carried out on the following emergency machinery;Emergency generatorEmergency fire pumpEmergency compressor Lifeboat enginesENGINE ROOM AND PROPULSION SYSTEM SAFETY MEASURESInternational Safety Management Code (ISM Code)All aspects of seafaring has been modified and improved to incorporate safety. The reason for this is that accidents may cause loss of life, destruction of property, and pollution to the environment.

Safety MeasuresAre a set of procedures to be carried out in particular situations. The measures aid in the continual efficient operation of the machinery in question and oftentimes reduce the occurrence of unsafe acts and decrease the factor for human error. Proper maintenance constitutes the crucial point in obtaining optimum safety in the engine room.

CleanlinessThe engine room should be kept clean and above and below the floor plates. If grit or sand blows into the engine room when ship is in port, the ventilation should be stopped and ventilating ducts, skylights and doors in the engine room should be closed.Welding or work which causes spreading of grit and chips must not be carried out near the engine unless this closed or covered and the turbocharger air intake filters are coveredThe exterior of the engine should be kept clean and the paintwork maintained so that leakages can be easily detected.FireIf the crankcase is opened before the engine is cold, welding and the use of naked lights will involve the risk of explosions and fire. Attention is furthermore drawn to the danger of fire when using paint and solvents with a low flash point. Porous insulating material drenched with oil from leakages is easily flammable and should be renewed.OrderHand tools should be placed easily accessible on tool boards. Special tools should be fastened in the engine room close to the area of application. No major objects must be left unfastened and the floor passages should be kept clear.SparesLarge spare parts should be placed well strapped near the area of application and accessible by crane. The spare parts should be well preserved against corrosion and protected against mechanical damage. The stock should be checked at intervals and replenished in time.LightingAmple working light should be permanently installed at appropriate places in the engine room and portable working lights should be obtainable everywhere. Special lamps for entering the scavenge ports should also be available.

FreezingIf there is a risk of damage due to freezing, engines, pumps, coolers, and pipe systems should be emptied of cooling water.

WarningThe opening of cocks may cause discharge of hot liquids and gases. The dismantling parts may cause springs to be released. The removal of fuel valves may cause oil to run down the piston crown.If the piston is hot, an explosion may then blow out the valve. When testing fuel valves with hand pump, do not touch the spray holes as the fuel may pierce the skin.Entering the Crankcase of CylinderCheck beforehand that the air starting air supply to the engine and also the starting air distributor is shut off and that the turning gear is engaged. Even at the quay, the wake from other ships may turn the propeller and, thus, the engine.

Turning GearBefore engaging the turning gear, check that the starting air supply is shut off, indicator valves are open, and that there is indication of Turning Gear Engaged.

Queen Mary Turning GearFeeling OverWhenever repairs or alterations have been made to the running gear, feel over the machinery until satisfied that there is no undue heating, oil mist formation, blow-by, or failure of cooling water or lubricating oil systems.

Working on a split casing pump inside a ship's engine roomNORMAL OPERATIONWhile the engine is running, it is important to constantly monitor the operational parameters and observe the engine and associated auxiliaries for any deviations. In unmanned engine rooms, care should be given to ensure that all parameters are within normal operating levels before leaving the engine room. This is usually done with the checklist to verify that everything is in place and functioning properly. Any alarms which indicates abnormalities especially in the main engine ancillary systems should immediately responded to and rectified as soon as possible.Examples of items to be checked:Engine speed corresponding to the telegraph orderLubrication of turbochargersLubricating and cooling oil pressureFiring of all cylindersLeaky starting air valvesExhaust gas temperaturesColor of exhaust gas from funnelCylinder jacket water outlet temperaturesExpansion tank levelAll pressures and temperaturesLeaks from the main engineHeavy and abnormal vibrationRough SeasDuring rough seas, the engine load may undergo sudden changes. This may cause the propeller to race and consequently, the turbocharger to surge. It is advisable to reduce speed during rough seas to minimize the possibility of surging turbochargers and the possible damage they could do.The main engine lubricating oil sump tank has a low level alarm which may also trigger the automatic emergency slowdown or emergency stop function.If the vessel undergoes extreme rolling motions, it is best to change the main engine lubricating oil sump tank with additional lubricating oil to ensure that the low level alarm will not be triggered due to temporarily displaced tank contents.In most cases, the lubricating oil sump tank of the auxiliary generator engines are considered to be more delicate than the main engine sump tank.A low level alarm of the auxiliary engine sump tank will cause the generator to trip and if things go from bad to worse, a blackout or electric power failure may resultFuel oil filters may need be cleaned more frequently in bad weather due to agitation of sediments in the tank. Clogging of filters result in low pressure alarms especially in purifier supply pump section line.During passage through rough seas, all items must be secured and fastened if necessary. Unsecured items may fall and may even cause damage to adjacent equipment.As for the steering gear system, the standby steering gear hydraulic pump is normally run in parallel to the one in service during rough seas. This is to provide additional power and faster response for the steering system and in case of failure of one pump, the other pump will already be online to avoid the ship being exposed to hazardous situation.ALTERING COURSEWhen altering the ships course to a few degrees, there wont be much of an effect even when the engine is running at full speed. For emergency alteration, it is advisable to reduce the speed to maneuvering full to avoid heavy rolling of the ship.Crash top - is the reversal of the engine when speed of the ship is high. In that case, the engine will continue to run at slowly decreasing speed when the regulating handle is moved to STOP due to propeller and, thus, the engine being driven by ships wake.PROVIDING ADDITIONAL POWER SUPPLYWhen starting machinery, one should always bear in mind the electric power requirements of the motor. Before starting any electrically powered machinery, especially the ones powered by big motors, check the generator load first. If the generator becomes overloaded, preferential trip will usually be activated causing non-critical machinery to be shutdown to reduce the load.If the load on the generator is not sufficient, for starting additional machinery, additional power supply should be provided by starting another auxiliary engine. It is always better to start the generator engines manually to provide additional power.AUXILIARY STEERING ON STANDBYThe auxiliary steering gear need only be capable of steering the ship at navigable speed, but it must be capable of being brought speedily in to action in an emergency.The auxiliary steering gear must be operated type if the rudder stock exceed 230 mm. for passenger ships and 250 mm. for cargo vessels.STEERING GEAR SYTEMThe steering gear system has strict requirements to be checked especially prior to maneuvering operations. These requirements are implemented by international regulations as well as classification societies.Pre-Departure Testing and DrillsWithin 12 hrs. before departure, the ships steering gear shall be checked and tested by the ships crew. The test procedure shall include the following:Main steering gearAuxiliary steering gearRemote steering gear control systemsSteering positions located on the navigation bridgeEmergency power supplyRudder angle indicators in relation to the actual positions of the rudderRemote steering gear control system power failure alarmsSteering gear power unit failure alarmsAutomatic isolating arrangements and other automatic system2. The checks and tests shall include as follows:Full movement of the rudder according to the required capabilities of the steering gearVisual inspection of the steering gear and its connecting linkageOperation of the means of communication between the navigation bridge and steering gear equipment

3. Simple operating instructions with a block diagram showing the changeover procedures for remote steering gear control systems and steering gear power units shall be permanently displayed on the navigation bridge and in the steering gear compartment.All ships officers concerned with the operation or maintenance of steering gear shall be familiar with the operation of the steering systems fitted on the ship and with the procedures for changing from one system to another.

4. In addition to the routine checks and tests, emergency steering drills shall take place at least once every three month in order to practice emergency steering procedures.5. The administration may waive the requirement to carry out the checks and test for ships which regularly engage on voyages of short duration.6. The date upon which the checks and tests are carried out, and the date and details of the emergency steering drills carried out shall be recorded in the logbook.Emergency EquipmentsEmergency equipments are installed on board a ship to serve a purpose. That purpose is for them to use in emergency.One important aspect of preparation, besides drills, is the maintenance of emergency equipments. Even though these equipments are never actually used for their intended purpose, it doesnt mean that they do not need attention. Regular checks and trials should be made to make sure that they are in optimal condition and ready to start anytime.Emergency GeneratorIt can be used to provide emergency electric power to machinery which is vital to restart the electric power generation system. It also provides power to emergency lighting, one steering gear motor, navigation equipment, and communication systems.It is designed to start automatically (usually within 30 mins.) in case of electrical power failure.

Weekly checks should include the following:

Draining of water from the fuel tankDrain moisture from emergency air receiverChecking the fuel tank levelChecking the lubricating oil levelChecking the radiator water levelCheck the starting system:a. if air started, check for adequate starting pressure in air bottleb. if started by hydraulic power, check for adequate hydraulic oil pressurec. if battery operated, check for sufficient battery load.7.Manually start the engine and keep it running without load until warmed up.Emergency CompressorThe emergency air compressor is fitted specifically for the emergency starting air system. It charges the emergency air receiver with compressed air to be used for starting the emergency generator engine.The emergency air compressor is require to be started independent for the electrical system, meaning, it is usually started by other means. Hand-Cranked motor- most common type of driving mechanism for the emergency air compressor which is built-in fuel tank.Weekly checks include the following items:Check the fuel tank levelCheck the cooling water levelCheck lubricating oil levelStart the engine and top-up the emergency air receiverEmergency Fire PumpIt is a centrifugal type and should be fitted with a priming pump to assist in starting and attaining suction. The location of emergency fire pump is near the steering gear compartment and usually on lower floor. This is because the suction line of emergency fire pump is independent of the engine rooms seawater system arrangements. Starting Procedures:Check that there is power supply to the emergency fire pump panel.Open the suction valve, keep the delivery valve closed.Make sure the valve to the main fire line is open.Make sure that the water level in the priming pump tank is full.Start the pump.The priming pump should engage upon starting and generate vacuum on the suction line.When seawater is finally suctions (the priming pump will automatically disengage) and the delivery pressure rise, open the delivery valve.Lifeboat EnginesLifeboat engines are typically diesel engines. Depending on the type, they could either be hand cranked engines or battery started engines. It is important to carry out engine trial every week to confirm that the lifeboat engines are in optimal condition.

Weekly checks include the following:Check the fuel tank level.Check the lubricating oil level.Lifeboat engine are water cooled and take cooling water from the sea, however a change over valve is fitted and a portable water tank is usually supplied for testing the engines off the water.Start the engine.Engage the propeller and conduct trial run for ahead and astern movement.Steer the helm and confirm that the rudder follows accordingly.For battery started engines, check the battery level and recharge accordingly, some systems are fitted with continuous trickle charging of battery, in this case, make that the battery charging arrangements are functioning properly.