Chapter 25 – Machinery Condition Monitoring 2015
Contents
1. 2 3 Section 3 Requirements for Operation Operating Personnel 11 ierit reed a cete ee 3 2 B Measurements sereni pedi aie dte tiles EA d ide 3 2 C GAM ALYSIS iz Ma nA ede A MI AMNEM A AC A eA NE 3 2 D Reporting eei petto A ee tee eid bete 3 3 Documents available oniBoard 1 ott tiit pese etg yasa dise geo ga n 3 3 Section 4 Surveys A General zx e A et nati tiia ee ice ieu ts 4 2 Implementation Survey aaen ba sand ann Sheet 4 2 Firial Approval zc coven As dean ek es a sk EE ERE Se anl ie Ae ea 4 2 D Annual Survey zii e BER E eet den 4 2 Non periodical SUE Veys ete ite ie iei Me Dele ges 4 2 Annex A Examples for Application ECCO A 2 Cranktrain Bearings of Low speed Diesel A 2 Ge GCentmtugal Purnps ee eee em ORE De ki alam oe ice cu ul e sedie ees A 2 D Accumulator Battery ettet oae Eee re aet Caes OP sanal Milla X ei A 4 Annex B Standards for Lubricating Oil Analysis Ac TR esbMeltliodsz dte2. ba tte ebat Section 1 General SECTION 1 GENERAL GENERAL suec RH aen 1 Scope 2 Purpose 3 Structure of Condition Monitoring Systems 4 Equivalence DEFINITIONS nS RID ER EE ue Baseline Data Condition Based Maintenance Condition Based Survey Condition Monitoring Condition Monitoring Equipment Condition Monitoring System Condition Monitoring Method Machinery Component OR OX NE Machinery System 10 Planned Maintenance System PMS 11 Reference Conditions 12 Reference Values 13 Trend Analysis DOCUMENTS TO BE SUBMITTED seen 1 General 2 Scope of Documentation SURVEY ARRANGEMENT 2 1 4 22 PLANNED MAINTENANCE SYSTEM T RK LOYDU MACHINERY CONDITION MONITORING 2015 1 2 Section 1 General General 1 Scope 1 1 These Guidelines for Machinery Condition Monitoring apply to the machinery of ships which are classified by TL and for which a Survey Arrangement CM has been concluded between the owner operator of the ship and TL 1 2 These Guidelines can be applied to new ships and to existing ships For already existing ships for which a Survey Arrangement CM will be requested special considerations concerning their actual wear and tear condition have to be undertaken 1 3 These Guidelines apply in addition to the TL Rules for Classification and Construction
3. 2 E ANNEXA 2 MI ram rl ANNEXA 4 2 Annex A Examples for Application A B C A Scope 3 Data to be presented 1 The Condition Monitoring scope for a Machinery The following data has to be presented to the TL Component may be such that either the entire condition of the component can be evaluated or only the condition of a part of the component As characteristic example Table A 1 provides some typical Machinery Components with characteristic Condition Monitoring items and a range of relevant parameters that may be monitored 2 The actual Condition Monitoring scope the relevant parameters to be monitored and the limits and Reference Values for parameters are defined for each component on a case by case basis B Cranktrain Bearings of Low speed Diesel Engines 1 Description of method The position of the crosshead assembly is measured by two distance sensors for each cylinder compartment at bottom dead centre of the piston If the surface of a target mounted at each guide shoe side of the crosshead enters the measuring range of the distance sensor the lowest gap is evaluated and recorded The values are compared with Reference Values agreed with the engine designer In case of exceeding a limit value a warning or an alarm can be triggered 2 Special requirements The bearing monitoring system shall include enough data storage capacity to keep at minimum the trend curves of one class period of fiv
4. 14 Guidelines set TL s general requirements regarding Condition Monitoring which are the basis for the acceptance of Condition Monitoring with respect to Condition Based Survey 1 5 Ifa Condition Monitoring System is used in the frame of a monitoring and control system and or a safety system the respective TL Rules for monitoring and control systems and or for safety systems shall be applied see in particular Chapter 5 Electrical Installation Section 9 B 1 6 For propeller shafts running within the stern tube in oil under special conditions the intervals between shaft withdrawals may be prolonged and the Class Notation CM PS may be assigned see Chapter 2 Machinery Section 5 C 2 Purpose 2 1 The purpose of Condition Monitoring Systems is to detect ongoing deterioration especially wear and tear of Machinery Components or parts of them For this purpose values of significant parameters are to be collected with the aid of an adequate measurement chain The values shall be suitable to show an obvious trend of the monitored deterioration over a period of time 2 2 o Condition Monitoring Systems shall be capable of producing relevant data trends from the values collected and compare them with pre defined acceptance criteria e g limit curves 2 3 Condition Monitoring for Machinery Component or parts of it will be accepted by TL if it is capable of producing reliable trustworthy informat
5. 6 For the year where Class Renewal of the ship is due the same Annual Survey as defined above will be executed E Non periodical Surveys 1 Damage and Repair Surveys Damage and repair surveys fall due whenever the Condition Monitoring System or Machinery Components covered by Condition Monitoring have suffered a damage which might affect the validity of the Survey Arrangement CM T RK LOYDU MACHINERY CONDITION MONITORING 2015 Section 4 Surveys 4 3 2 Conversion Surveys In case of conversions of the Condition Monitoring System Machinery Components covered by Condition Monitoring surveys are to be conducted with a scope depending on the type and extent of the conversion and are to be decided case by case 3 Change of ownership or management In case of sale or change of management of the ship the Survey Arrangement CM shall be reconsidered regarding the assumptions on which the Condition Monitoring acceptance was based upon T RK LOYDU MACHINERY CONDITION MONITORING 2015 Annex A Examples for Application Annex A 1 ANNEX A EXAMPLES FOR APPLICATION CRANKTRAIN BEARINGS OF LOW SPEED DIESEL ENGINES 1 Description of Method 2 Special Requirements 3 Data to be Presented CENTRIFUGAL PUMPS 1 Description of Method 2 Special Requirements 3 Data to be Presented ACCUMULATOR BATTERY T RK LOYDU MACHINERY CONDITION MONITORING 2015 Page kal ili ANNEXA 2
6. E mail ankara turkloydu org Atat rk Cad No 378 4 D 402 Kavalalilar Apt 35220 Alsancak ZM R T RK YE Tel 90 232 464 29 88 Fax 90 232 464 87 51 E mail izmir turkloydu or narl Mah Atat rk Cad Aziz Naci Merkezi No 5 K 1 D 2 Seyhan ADANA T RK YE Tel 90 322 363 30 12 Fax 90 322 363 30 19 E mail adana turkloydu org Atat rk Cad 99 Sok No 11 Kat 4 Daire 6 Marmaris MU LA T RK YE Tel 90 252 412 46 55 Fax 90 252 412 46 54 E mail marmaris Oturkloydu org Machinery Condition Monitoring Page Section 1 General A Generali m M 1 2 B Definitions ee eei aue n eiie 1 2 C Documents to be Submitted s s laa i l Entente esce dle d eue inte e 1 4 lt S rvey E 1 5 E Planned Maintenance System dade nine innu 1 5 Section 2 Requirements for the Design of Condition Monitoring Systems A General Requlretients coeur re sail dada peekaa Bx Ra Rb er ce dx RERO 2 2 B Requirements for Installation 2 sn nnne 2 2 C Requirements for SoftWare d aet ches ted end pce doeet d ade eed uve eodd Ere d quete cs 2 3 D 5
7. analysis methods like the periodical analysis of liquids will be defined case by case depending on the application T RK LOYDU MACHINERY CONDITION MONITORING 2015 D E Section 3 Requirements for Operation 3 3 D Reporting 1 Immediate reports 1 1 Any modifications of the Condition Monitoring System its procedures and or schedules have to be reported to TL s Head Office for approval 1 2 TL s Head Office shall be informed if scheduled Condition Monitoring measurements cannot be performed due to failures defects defined in B 5 2 Annual Condition Monitoring Report An Annual Condition Monitoring Report has to be submitted to TL s Head Office at least four weeks prior to the annual survey onboard the ship It shall contain a list of all Machinery Components covered by Condition Monitoring with the condition status of each component and the respective trend curves stated The status and the trend curves are to be based on all results including the latest measurements a summary list of al Machinery Components covered by Condition Monitoring that has been modified repaired and or maintained unscheduled together with a description of the causes a description of any changes made regarding the Condition Monitoring System including a statement of the reason failures and defects experienced with the Condition Monitoring System For the year where Class Renewal of the ship is due the same Annua
8. for data transfer shall comply with the requirements of the TL Rules Chapter 5 Electrical Installation Section 12 33 Condition Monitoring System has to be equipped with a directly connected central recording and processing unit 3 4 Disturbed data collection shall be indicated and recorded in a log file 4 Central recording and processing computer 4 1 The provided central recording and processing computer shall be capable of running the necessary analysis programs The storage capacity shall be suitable to keep the data used for the Annual Condition Monitoring Reports see Section 3 D 2 at minimum since the last Annual Survey T RK LOYDU MACHINERY CONDITION MONITORING 2015 B C D Section 2 Requirements for the Design of Condition Monitoring Systems 2 3 4 2 Computers in systems to be type approved shall meet the requirements defined in Chapter 5 Electrical Installation Section 10 4 3 The computer system has to be only accessible for authorized operating personnel see Section 3 A C Requirements for Software The software for the central recording and processing computer shall meet the requirements defined in Chapter 5 Electrical Installation Section 10 In addition the following requirements shall be fulfilled 1 Data measurement 1 1 Reference Values for the parameters to be monitored shall be accepted by the manufacturer of the monitored Machinery Component the Condition Monit
9. with a glued steel pad for containing warning and alarm limits magnetic sensor coupling or with a mounted bayonet socket trend curves for all covered pumps containing measured pressure difference and power input The measurement chain shall be calibrated together with Reference Values regularly on the minimum once a year protocols of visual inspections esp with respect The personnel has to be qualified for carrying out to shaft seal and coupling vibration measurements Reference Conditions during measurements The vibration measurements shall be carried out according to Table A 1 regularly on the minimum once every three months in case of yellow state the interval shall documentation of maintenance and or repair be shortened according to expert advice actions if done Table A 1 Examples for the scope of Condition Monitoring Characteristic items to be Condition Monitored Machinery Components Condition Monitoring Reference parameters 1 parameters Cranktrain bearings of low speed diesel engines 2 Main bearings crankpin bearings crosshead bearings engine speed displacement of crosshead at bottom dead centre position Centrifugal pump 3 Roller bearings Impeller casing casing wear ring mechanical seal Electrical motor speed bearing vibrations lubrication oil pressure pressure difference between discharge and suction side power output leakage control a
10. Condition Monitoring System In this case the components shall be type approved according to 2 and the overall functioning of the system has to be proven by suitable tests After successful testing a Type Approval Certificate will be issued with the remark that a successful check of the application on board is still pending 4 2 If a system with a Type Approval Certificate according to 4 1 is installed on board of a ship after the sea trials and after an operating time of successful operation the length of which will be defined according to scope and complexity of the system the Type Approval Certificate will get the remark that the application on board has been successful T RK LOYDU MACHINERY CONDITION MONITORING 2015 Section 3 Requirements for Operation 3 1 SECTION 3 REQUIREMENTS FOR OPERATION Page OPERATINGPERSONNEL ae dass ss sana ananas 3 2 MEASUREMENTS pL tr thereto apaa kasim i e E tr ce vn gea ea eot 3 2 Intervals Baseline Data Reference Conditions Documentation of Results RNa Significant Failures and Defects ANALYSIS cos dde t Rd et aee t edet 3 2 1 Documentation 2 Reference Values 3 Special Analysis Methods hizdzeldi cmm c 3 3 1 Immediate Reports 2 Annual Condition Monitoring Report DOCUMENTS AVAILABLE 3 3 T RK L
11. OYDU MACHINERY CONDITION MONITORING 2015 3 2 Section 3 Requirements for Operation A B C A Operating Personnel 1 The chief engineer shall be the responsible person on board in charge of the Condition Monitoring Systems 2 The operation of Condition Monitoring Systems is to be carried out only by assigned personnel 3 The qualification of the operating personnel has to be proven by adequate documents compare Section 4 B 2 Such documents may relate to existing experience with Condition Monitoring and or suitable training received planned for the Condition Monitoring System installed on the ship B Measurements 1 Intervals Measurements for Condition Monitoring purposes shall be taken at defined intervals The length of the intervals depends on the individual monitoring task and has to be defined for each individual task and each component 2 Baseline Data 2 1 Baseline Data shall be taken at Reference Conditions The conditions have to be documented during measurements and shall be adjusted during the period of successful operation according to Section 2 D 3 and D 4 Measurements of Baseline Data have to be carried out to the satisfaction of TL 2 2 For retrofit of a Condition Monitoring System special consideration has to be given regarding the definition of the Reference Values of each component subject to Condition Monitoring This has to be done on a case by case basis 3 Reference Co
12. T RR LOYDU Chapter 25 Machinery Condition Monitoring 2015 Unless otherwise specified these Rules apply to ships for which the date of contract for construction as defined in PR No 29 is on or after 01 January 2015 New rules or amendments entering into force after the date of contract for construction are to be applied if required by those rules See Rule Change Notices on TL website for details General Terms and Conditions of the respective latest edition will be applicable see Rules for Classification and Surveys If there is a difference between the rules in English and in Turkish the rule in English is to be considered as valid This publication is available in print and electronic pdf version Once downloaded this document will become UNCONTROLLED Please check www turkloydu org for the amended and valid version All rights are reserved by T rk Loydu and content may not be reproduced disseminated published or transferred in any form or by any means except with the prior written permission of TL T RK LOYDU Head Office Regional Offices Ankara Adana Marmaris Postane Mah Tersaneler Cad No 26 Tuzla 34944 STANBUL T RK YE Tel 90 216 581 37 00 Fax 90 216 581 38 00 E mail info turkloydu org http www turkloydu org Eskigehir Yolu Mustafa Kemal Mah 2159 Sokak 6 4 ANKARA TURKIYE Tel 90 312 219 56 34 90 312 219 68 25
13. UBRICATING OIL ANALYSIS Page A TEST METHODS emi ci eae Hee diss dee delen alo coe D ANNEXB 2 T RK LOYDU MACHINERY CONDITION MONITORING 2015 2 Annex Standards for Lubricating Analysis A A Test Methods tion Monitoring These standards may especially be used for Diesel engines and stern tube bearings For 1 The Table B 1 lists the necessary scopes and propeller shafts running within the stern tube in oil the standardised test methods which are accepted by TL Class Notation CM PS may be assigned compare for lubricating oil analyses in connection with Condi Chapter 4 Machinery Section 5 C Table B 1 Proposed standards for lubricating oil analyses Diesel ISO Other test methods engine Test property Standard DIN AFNOR Kin viscosity DIN EN ISO 44 mm s ons 3104 Base number DIN EN mg KOH g Pepe 3771 Acid Number D 664 Flash point Pensky Martens D 93 MO 7919 C Water content D 95 DIN ISO vol 3733 Pentane and toluene insolubles D 893 51365 T 60157 m A B Ash content oxide ash Diesel fuel dilution eml Chlorine content no standard test method Oxidation and nitration Wear metal analysis Al Cr Cu Fe Mg Mo Na Ni Pb Si Sn and V Abbreviations T 60100 T 60113 D 482 D 3524 FTIR method ISO The International Organisation for Standardisa
14. al Approval Final approval of the Condition Monitoring System implemented on board is achieved after a period of probation of at least six months During this period the Condition Monitoring System has to prove its fitness under normal operating conditions TL is to be informed of any required modifications the validity of the Survey Arrangement CM It is recommended to carry it out together with the annual Class Survey of the ship and has to prove that the Condition Monitoring System is operated as intended All documents listed in Section 3 E shall be available for the attending TL Surveyor 2 The Surveyor has to verify that the approved Condition Monitoring procedures are met and that the Condition Monitoring System is correctly operated The Surveyor will review the Annual Condition Monitoring Report compare Section 3 D 2 3 During the survey the Surveyor will verify that on board personnel assigned to perform Condition Monitoring tasks is familiar with the Condition Monitoring System especially with the data collection and processing units 4 Recorded data and data trends will be examined and it will be checked if necessary maintenance actions have been carried out 5 At the discretion of the Surveyor function tests on components covered by Condition Monitoring and inspections e g dismantling of components shall be carried out as far as practicable and reasonable e g with respect to condition monitoring data
15. cedures including trend estimation T Condition Monitoring Method The condition Monitoring Method describes the technique for the collection and evaluation of information about the condition of components or parts of it Examples are vibration monitoring oil analysis performance monitoring thermography or motor current signature analysis 8 Machinery Component Machinery Components are units such as diesel engines generators pumps compressors fans Machinery Components consist of machinery parts such as bearings rotors etc 9 Machinery System A Machinery System is a group of Machinery Components providing specific functions for the operation of the ship s machinery and or cargo refrigerating installation Examples for Machinery Systems are fuel oil systems cooling systems ventilation systems etc 10 Planned Maintenance System PMS PMS is a computerized system that organises maintenance and overhaul activities of machinery and electrical plant components according to manufacturers Owners and or Classification Societies requirements system includes maintenance intervals maintenance instructions lists of required spare parts measurement records and other relevant information For the requirement of such a system see Classification and Surveys Section 3 A 4 5 11 Reference Conditions Reference Conditions are operating and or ambient conditions during recording of Condition Monitor
16. e years The trend curve shall show a clear trend i e that fluctuations caused by irregularities of the combustion process or by movements of the ship in rough sea state or by changes in engine speed should be smoothed or compensated 5 A crankcase inspection procedure published by the engine designer and approved by TL shall exist It shall contain clear instructions for inspection of respective parts of the cranktrain and for the corresponding time schedule Surveyor operating hours trend curve of distance values of the past year log file containing log statements for warning or alarm including sensor failures if recognised protocols of crankcase inspections done by the chief engineer according to the engine designer s instructions documentation of maintenance and or repair actions if done C Centrifugal Pumps 1 Description of method In most cases centrifugal pumps consist of the casing with the impeller and the casing wear ring the driving shaft with roller bearings and mechanical seal and the driving electric motor The condition of the roller bearings can be monitored by means of regular vibration measurements with a portable system at marked measurement locations By evaluation of the vibration spectrum and the envelope spectrum developing deterioration can be detected in an early stage and be allocated to the parts of the bearing i e the inner or outer ring the cage or the rolling e
17. echnical acceptance have to be executed 1 Design approval The documentation as defined in Section 1 C has to be submitted to TL Head Office and checked to achieve the design approval 2 Type approval for components of Condition Monitoring Systems All essential components of a Condition Monitoring System have to be type approved For detailed requirements see TL Rules Additional Rules and Guidelines Guidelines for the Performance of Type Approvals and Chapter 5 Electrical Installation Section 10 3 Case by case approval of Condition Monitoring System 3 1 For an approval of a Condition Monitoring System designed for a special singular application on board of a ship the components of the Condition Monitoring System shall be type approved according to 2 32 After installation of the complete fixed or portable system on board of the ship tests will be made in presence of TL representatives considering the overall functioning during the sea trials and after an operating TURK LOYDU MACHINERY CONDITION MONITORING 2015 2 4 Section 2 Requirements for the Design of Condition Monitoring Systems D time of successful operation the length of which will be defined according to scope and complexity of the system the Condition Monitoring System is approved 4 Type approval of Condition Monitoring Systems 4 1 It is possible to get on request also type approval for a complete fixed installed
18. ing data e g operating conditions of the monitored component e g speed temperatures pressures operating conditions of surrounding systems operating conditions of the ship e g speed draft and relevant ambient conditions e g temperature barometric pressure sea state wind TURK LOYDU MACHINERY CONDITION MONITORING 2015 1 4 Section 1 General B C Reference Conditions are described by respective reference parameters Reference Conditions should be reproducible during normal operation 12 Reference Values Reference values are values of the measurement parameters or descriptors that define the condition of a Machinery Component or part of it which is in an acceptable running condition With respect to Trend Analysis Reference Values are also referred to as Baseline Data Reference Values are valid only for predefined Reference Conditions They can be obtained by measurement or observation of a component or part of it which is proven to be free of failure or by rules and standards 13 Trend Analysis A Trend Analysis presents time histories of measurement parameters or descriptors to evaluate the extent and progress of deterioration and the trends for the future C Documents to be submitted 1 General The required drawings documents calculations and supporting documentation are to be submitted in Turkish or English language This shall be done at a sufficiently early date before the Condit
19. ion Monitoring System is installed on the ship For prototype systems special agreements may be considered 2 Scope of documentation If the TL approval for a Condition Monitoring System is requested with the aim to conclude a Survey Arrangement CM see D the following documentation has to be submitted to TL Head Office for approval 2 1 Listing of Machinery Components to be covered A list and description of the Machinery Components to be covered by Condition Monitoring shall be provided 2 2 Condition Monitoring System Descriptions of the complete Condition Monitoring System to be used specifying the following items overview of the system functional description including user manual parameter definition data collection method data handling data analysis method local arrangement including location orientation of measuring points sampling method sampling points if applicable wiring diagram if applicable power supply scheme if applicable parts list including sensors model type manufacturer technical data sheet attachment method and data collection instruments model type manufacturer technical data sheet TL approval for the Condition Monitoring System see Section 2 D if already existing TL approval if already existing for installation of the measuring device e g sensors cables etc on the respective Machinery Component based on the agreement
20. ion for determining the actual condition of the Machinery Component or parts of it 2 4 The condition determination of a Machinery Component or parts of it achieved from a TL accepted Condition Monitoring System will be considered equivalent to condition determination by direct inspection compare Section 4 3 Structure of Condition Monitoring Systems Condition Monitoring Systems are distinguished in three categories fixed installed systems systems with portable measurement equipment sampling systems e g for sampling 4 Equivalence Condition Monitoring Systems deviating from these Guidelines in their type equipment or some of their parts may be accepted provided that they are found to be equivalent to the TL requirements B Definitions The following definitions are used in this Guideline 1 Baseline Data Baseline Data are generally obtained during operation on board where the performance of the component is considered to meet the initial condition Baseline Data are measured or observed Reference Values defining the initial condition of a Machinery Component or parts of it during operation under Reference Conditions T RK LOYDU MACHINERY CONDITION MONITORING 2015 Section 1 General 1 3 2 Condition Based Maintenance Condition Based Maintenance is a form of preventive maintenance which uses the information from a Condition Monitoring System as additional input to adjust the pla
21. l Report as defined above has to be submitted E Documents available on Board The following documentation shall be available relevant manuals for all Condition Monitoring Systems records of measurements including Baseline Data taken sample analyses results received as well as corresponding data trends for the machinery covered by Condition Monitoring calibration protocols and_ functional tests protocols for the Condition Monitoring Equipment reports of modifications on a component repairs or unscheduled maintenance including the analysis of the reasons records of training in the use of the Condition Monitoring Equipment on board similar means to prove adequate qualification for each person assigned to carry out Condition Monitoring procedures all reports concerning Condition Monitoring for at least the last five years of operation T RK LOYDU MACHINERY CONDITION MONITORING 2015 Section 4 Surveys 4 1 SECTION 4 SURVEYS Page GENERAL costo DE MIU E MM IM III DADA aa a dalaman RAM UM 4 2 1 Avoidance of Direct Survey 2 Direct Survey IMPEEMENTATION SURVEY inn pra med oie deli im nii iique lay 4 2 FINAL APPROVAL 5 eo bominem etam sri e eiii ri Un Ee LII 4 2 ANNUAL SURVEY Gee CERE pl lm 4 2 NON PERIODICALSURVEYS ea amasra ananas 4 2 1 Damage and Repair Surveys 2 Conversion Surveys 3 Change of Ow
22. lements The condition of the impeller the casing and the casing wear ring can be monitored by driving the pump against the closed valve The pressure difference between discharge side and suction side together with the power input can be recorded and compared to Reference Values e g derived from the characteristic curve The condition of the shaft seal and of the coupling can be monitored by visual inspection A certain voltage and current should lead to defined pressure difference or medium flow T RK LOYDU MACHINERY CONDITION MONITORING 2015 Annex A Examples for Application Annex A 3 The temperature of the electric motor should be in The performance tests shall be carried out certain limits at defined loads regularly on the minimum once a month The insulation resistance of the electric motor gives 3 Data to be presented information about the conditions of the wiring insulation and dirt or wetness condition inside the motor The following data has to be presented to the TL Surveyor 2 Special requirements operating hours The measurement locations shall be defined according to ISO 13373 1 2002 Table A 1 ISO 10816 3 1998 and VDI Guidelines 3841 2002 traffic light information from vibration measurements for all covered centrifugal pumps in case of yellow or red state trend curves of The measurement locations shall be marked overall levels of vibration and envelope signal permanently e g
23. nditions Measurements for Condition Monitoring purposes shall be taken at Reference Conditions The Reference Conditions have to be documented In case that Reference Conditions cannot be established at the time of the measurements the measured values shall be converted to Reference Conditions applying suitable conversion algorithms 4 Documentation of results To facilitate the comparison of the actual measurement results with the Baseline Data Baseline Data shall be displayed or noted together with the documented results 5 Significant failures and defects Significant failures and defects of the Condition Monitoring System which cause that trends of the measured data cannot be controlled have to be repaired promptly C Analysis 1 Documentation Measurement results shall be documented in tables or graphs The trend of the measured data versus time has to be documented and is in general the relevant information to judge the condition of the monitored Machinery Component 2 Reference Values 2 1 Reference Values shall be presented together with the documented results A comparison of the measured values with the Reference Values provides the basis for the assessment of the condition status 2 2 Reference Values may be reconsidered taking into account the operation experience with the individual machinery on board the ship See also Section 2 C 1 1 3 Special analysis methods The requirements for special
24. nership or Management T RK LOYDU MACHINERY CONDITION MONITORING 2015 4 2 Section 4 Surveys A B C D E A General D Annual Survey 1 Avoidance of direct survey 1 The Annual Survey will be carried out to maintain Information derived from Condition Monitoring of a Machinery Component or parts of it can be accepted by TL as equivalent to direct inspection if the information are giving evidence that the Component or part of it is in an acceptable running condition In this case for the particular Machinery Component or parts of it which are covered by Condition Monitoring the Surveyor may grant a waiver from dismantling of the Component for direct inspection 2 Direct survey Any item of a component not covered by Condition Monitoring shall be surveyed and credited in the conventional way B Implementation Survey 1 An Implementation Survey has to be carried out in presence of a TL Surveyor after installation of the Condition Monitoring System on board to verify that the Condition Monitoring System is implemented accordance with the approved documents and is functioning as intended See also Section 3 B 2 Documents suitable to prove adequate qualification of the assigned operating personnel have to be checked see Section 3 A 3 3 For retrofit of a Condition Monitoring System the actual condition of the respective Machinery Component or part of it shall be verified on a case by case basis C Fin
25. nned activities according to the actual wear and tear condition of a Machinery Component It is recommended to include the so called Condition Based Maintenance actions into the Planned Maintenance System 3 Condition Based Survey A Condition Based Survey for Machinery Components operating under Condition Monitoring is a survey where the TL Surveyor primarily checks the Condition Monitoring Reports defined in Section 3 D If such reports are giving evidence to the Surveyor that the Component or part of it is in an acceptable running condition he may grant a waiver from dismantling of the Component for direct inspection 4 Condition Monitoring Condition Monitoring comprises actions collecting regularly information about machinery condition to detect failures or deterioration of machinery condition Measurements or observations shall be carried out during operation under defined Reference Conditions Within the scope of these Guidelines a clear distinction is made between Condition Monitoring and monitoring for control or safety systems see A 1 5 5 Condition Monitoring Equipment Condition Monitoring Equipment is any equipment used to carry out Condition Monitoring measurements 6 Condition Monitoring System Condition Monitoring System is a system used to detect the condition of a component It consists of Condition Monitoring Equipment procedures schedules as well as methods for data collection and analysis pro
26. of the Component manufacturer 2 3 Details about Machinery Components For each Machinery Component covered by Condition Monitoring the following items shall be specified actual condition of each Component e g information about running hours etc TURK LOYDU MACHINERY CONDITION MONITORING 2015 C D E Section 1 General 1 5 procedure of Baseline Data collection including specification of Reference Condition s procedure and schedule for collection of actual operating data procedure and schedule for data analysis including applied acceptance criteria for parameters and reporting the results procedure and schedule for calibration and functional tests of Condition Monitoring Equipment agreement of Component manufacturer to the Condition Monitoring parameters Condition Monitoring Method Reference Values etc 2 4 Further Documents TL reserves the right to demand other documents where these submitted are not adequate to provide an evaluation of the system 2 5 Modifications extensions of Machinery Components or Condition Monitoring Systems Major modifications of the Machinery Components and or the Condition Monitoring System which may affect the functioning of the approved Condition Monitoring System on a ship under construction or at sea are also subject to approval by TL Documents are to be submitted in due time before conversion D Survey Arrangement 1 Where Machinery Comp
27. ondition Monitoring Systems 3 Case by Case Approval of a Condition Monitoring System 4 Type approval of Condition Monitoring Systems T RK LOYDU MACHINERY CONDITION MONITORING 2015 2 2 Section 2 Requirements for the Design of Condition Monitoring Systems General Requirements 1 Ambient conditions The Condition Monitoring System has to operate under the ambient conditions of ship machinery installations as defined in the TL Rules Chapter 4 Machinery Section 1 The degree of protection of electric electronic components against the ingress of foreign bodies and water according to TL Rules Chapter 5 Electrical Installation Section 1 K is to be considered 2 Interference to machinery control Data acquisition from machinery control and monitoring systems for Condition Monitoring purposes has to be free of reactive effects B Requirements for Installation 1 General 1 1 Correct functioning accuracy measurement of all measurement devices shall be assured by individual functional tests and regular calibration procedures They have to be documented Equipment for functional tests of the measurement devices shall be available on board 1 2 manufacturer of a Machinery Component to be included in the Condition Monitoring System has to give his agreement to the installation of the measuring device on the Component as well as to the Condition Monitoring Method to be introduced f
28. onents subject to Class Surveys are covered by Condition Monitoring a Survey Arrangement CM can be agreed between the owner operator of the ship and TL 2 The Survey Arrangement CM shall follow the relevant requirements defined in the following Sections 3 Machinery Components covered by the Survey Arrangement CM will be listed in the Approval Certificate E Planned Maintenance System The Condition Monitoring System shall be used in the framework of a computerized Planned Maintenance System PMS The elements of the PMS considering the Machinery Components or part of them covered by Condition Monitoring shall be approved by TL according to the TL Rules Classification and Surveys Section 3 A 4 5 T RK LOYDU MACHINERY CONDITION MONITORING 2015 Section 2 Requirements for the Design of Condition Monitoring Systems 2 1 SECTION 2 REQUIREMENTS FOR THE DESIGN OF CONDITION MONITORING SYSTEMS Page GENERAL HEQUIREMENTS un nde guu PI iim 2 2 1 Ambient Conditions 2 Interference to Machinery Control REQUIREMENTS FOR INSTALLATION 0 00 2 2 1 General 2 Portable Systems 3 Fixed Installed Systems 4 Central Recording and Processing Computer REQUIREMENTS FOR SOFTWARE sse enne eee 2 3 1 Data Measurement 2 Data Analyses STEPS OF ACCEPTANCE eR Malak nk Bi Spa balam Soc M Mal all ii I 2 3 1 Design Approval 2 Type Approval for Components of C
29. or the Component On the basis of this agreement TL can approve the above mentioned installation and the Condition Monitoring Method 1 3 All parts of the Condition Monitoring System have to be installed in a way to enable accessibility for survey maintenance repair and calibration 1 4 If parts of Machinery Components or even Components as a whole which influence the design and or operation of the Condition Monitoring System have to be changed renewed it shall be ensured that the Condition Monitoring System is still functioning reliably 1 5 In principle Machinery Components already in service can only be included in a Condition Based Maintenance scheme if evidence is given that the Components are in a condition close to their initial condition In any case an initial survey is mandatory 1 6 It is recommended that the implementation process is assisted by an expert familiar with the Condition Monitoring System and with the respective Machinery Component 2 Portable systems Portable measurement devices are used for such systems The position of the measurement points and in case of directed values the measurement direction shall be marked permanently The coupling of the sensor to the measurement point shall be designed in an adequate way to avoid any human influences 3 Fixed installed systems 3 1 The measuring devices shall be fixed installed at the Machinery Components to be monitored 3 2 cables
30. oring System provider and require approval by TL 1 2 Reference Values shall be displayed together with the trend curves 1 3 Reference parameters defining Reference Conditions and Condition Monitoring data shall be measured within an adequate time window to ensure that the values belong to the same operating conditions 1 4 The sampling rate of the data acquisition shall be adequate for the respective duty of the Condition Monitoring method 1 5 The evaluation rate shall be adequate to ensure detection of failures at the Machinery Components in time 1 6 fixed installed systems all data which define the Reference Conditions of the Machinery Component shall be made available 2 Data analyses 2 1 Monitoring and diagnosis The Condition Monitoring System used to evaluate a component s condition shall provide adequate monitoring and diagnosis functions These functions shall enable a clear evaluation of the actual condition of the component or parts of it 2 2 Trend analysis A trend analysis has to be established for the time development of the measurement values For this the measurement values are to be presented over the operation time considering the Reference Conditions From this presentation it shall be possible to derive the consequences for necessary actions D Steps of Acceptance If an owner operator of a ship requests a Survey Arrangement CM as defined in Section 1 D the following steps of t
31. t mechanical seal current insulation resistance Accumulator battery Advantages 1 parameters describing the Reference Conditions 2 early detection of bearing wear 3 early detection of failures for a greater number of components with one portable system for a fleet where appropriate D Accumulator Battery T RK LOYDU MACHINERY CONDITION MONITORING 2015 voltage capacity temperature 4 Annex A Examples for Application D 1 An algorithm for determining of the capacity and reserve time of the battery working under non stationary regimes will be used for the actual type of battery This process can be based on digital modeling The capacity can be determined by continuously scanning the following parameters current of charge T current of discharge voltage of the battery The temperature of the battery can be monitored for critical values 2 Special requirements The personnel shall be qualified for maintaining batteries 3 Data to be presented The following data is to be presented to the TL Surveyor x age of battery trend curve of the remaining capacity including the minimum required capacity documentation of maintenance especially the filling and the acid condition and refilling if done T RK LOYDU MACHINERY CONDITION MONITORING 2015 Annex Standards for Lubricating Oil Analysis Annex B 1 ANNEX B STANDARDS FOR L
32. tion ASTM American Society for Testing and Materials DIN Deutsches Institut f r Normung AFNOR Association Francaise de Normalisation JIS Japan Industry Specification FTIR Fourier transform infrared Notes 1 Oil change intervals prescribed by Diesel engine makers have strongly to be observed 2 The use of test methods other than mentioned above requires approval of TL T RK LOYDU MACHINERY CONDITION MONITORING 2015
Download Pdf Manuals
Related Search