Section 14 Machinery planned maintenance and condition monitoring, MPMS, MCM and RCM

14.1.1 Within the scope of Vol 1, Pt 1, Ch 2, 4.5 Existing ships – Periodical Surveys 4.5.18 and Vol 1, Pt 1, Ch 2, 4.5 Existing ships – Periodical Surveys 4.5.19, an approved Planned Maintenance Scheme (MPMS) and Condition Monitoring (MCM) can be accepted as an integral part of LR's Continuous Survey Machinery (CSM) cycle.

14.1.2 Planned maintenance systems may be based on calendar or running hours calling for items to be opened out for inspection and overhaul at specified periods. Alternatively the machinery may be monitored for condition and performance, whereby items need only be opened out for examination when readings indicate deterioration.

14.1.3 Navies who operate a planned maintenance scheme that meets the LR requirements will benefit from enhanced arrangements for dealing with machinery surveys. The arrangements provide the following advantages:

1. A more flexible approach to dealing with Classification Surveys of machinery items. The condition as observed and reported by an LR approved Marine Engineer Officer will, subject to annual audit, be sufficient to credit the items for survey.

2. A single system can be operated by the Navy covering maintenance, spare parts' supply and survey requirements.

3. The schemes allow the application of condition monitoring techniques to main and auxiliary items of machinery.

14.1.4 When a Navy decides to apply such arrangements to limit the opening out normally required for survey under CSM then MPMS, MCM (including Condition Monitoring) or RCM (including Reliability Centred Maintenance) class notations can be assigned where the schemes have been approved by LR.

14.2.1 A list of typical machinery master list items that can be surveyed by authorised personnel and those items that remain to be dealt with by LR Surveyors can be obtained from LR’s Southampton GTC Office. It should be noted that LR will continue to inspect, as necessary, where there is a history of mechanical, electrical or control engineering defects in a particular area, either on the ship or on a similar ship.

14.3.1 Types of maintenance are defined as:

1. Preventive maintenance. This calls for items to be opened out for inspection and overhaul at specified time periods or after a specified number of running hours in order to keep the machine/equipment/system in a satisfactory operational condition.

2. Condition based maintenance. This is dictated by the performance or physical state of the machine/equipment/ system, determined by regular or continuous checks of applicable parameters. Maintenance is only undertaken when conditions have approached or reached the lowest acceptable standard and before breakdown or failure occurs.

3. Reliability centred maintenance. This calls for a structured analysis of a system's capability to perform its functions from design through operation to decommissioning. The primary objective is to ensure the functionality of a system and this is achieved through a planned maintenance strategy determined from the detailed analysis. The strategy may include the use of prevention and condition based maintenance.

14.3.2 The types of maintenance described in Vol 1, Pt 1, Ch 3, 14.3 The planned maintenance approach 14.3.1 are the foundations of a Machinery Planned Maintenence System acceptable to LR. Many schemes are made up with a combination of the three methods of control. In addition, to deal with unforeseen circumstances, any Machinery Planned Maintenence System must also be able to deal effectively with breakdown or corrective maintenance, i.e. unscheduled maintenance.

14.4.1 To obtain approval of a MPMS, the Navy is required to make a formal request through either a local office of LR or direct to LR in the Southampton GTC office. The request is to be accompanied by the following information:

1. A numbered index of the items to be included in the scheme. This index is to include at least all CSM items that appear on the Master List of Surveyable Items. The scheme can also cover many items that are not required for classification. The indexing system is to be such that ready cross-reference to the numbers in the LR Master List of Surveyable items can be made. It is also to indicate those items to be dealt with by preventive maintenance, by condition-based maintenance and by reliability centred maintenance.

2. The maintenance and monitoring methods to be used, the time schedules for each item and limits of acceptance/ condition where applicable. Maintenance descriptions are to cover at least the minimum opening out necessary to demonstrate that a satisfactory examination of the item will be made. The extent of the work to be undertaken is to be indicated but it is not necessary for approval purposes to include every detailed job description. A few sample job descriptions will suffice to demonstrate how the system works. Machinery on preventive maintenance must be examined completely for survey purposes at intervals not exceeding six years, although in practice many items will be maintained much more frequently.

3. A system for reporting to the Navy and recording on board ship and at the Navy's headquarters, details of maintenance carried out, the condition as found and any repairs effected, together with a list of spare parts used. The reporting and recording procedures are to be sufficiently comprehensive to demonstrate that both the Navy and the LR Surveyor can verify correct operation of the planned maintenance system at the time of the survey.

4. A description of the scheme regarding its application on board ship and the proposed flow of maintenance documents and method of filing same. The application of the scheme may take the form of simple planning charts or the more complex interactive computer based systems. The language of the MPMS is to be English.

14.4.2 Where a Navy has requested approval of a Reliability Centred Maintenance study, the requirements of Vol 1, Pt 1, Ch 3, 14.4 Basic requirements for approval of MPMS, MCM and RCM schemes 14.4.3 are to be complied with.

14.4.3 The following information is to be submitted to LR for review:

1. Hard or soft copy (with operating systems if necessary) of the studies, conducted in accordance with a relevant national or international Standard, such as ISO 17359, Condition monitoring and diagnostics of machines – General guidelines. This is to include, operating context, details of study team, Risk Assessment (RA, see also Vol 2, Pt 1, Ch 3, 18 Risk Assessment (RA)), algorithm decision sheets, summary of maintenance tasks, summary of ’level of repair analysis’, identification of ’critical’ spares.

2. Details of system/equipment covered by the study.

3. Confirmation that maintenance studies have included where possible, OEM data on failure rates, OEM maintenance recommendations, and associated information necessary to ensure that risk associated with component failure is accounted for accurately.

14.4.4 LR will verify by audit that the following items have been complied with:

1. Study has been undertaken in full compliance of the methodology embodied in an acceptable and applicable standard for RCM.

2. Study team members have adequate experience both of undertaking RCM studies and the systems/equipment under review.

3. Study team members have been present during the study for sufficient time (percentage of total time taken) to contribute properly to the study.

4. No 'Mandatory Redesign' requirements are outstanding.

5. Where spares have been identified as 'Critical', they have been properly identified in the management systems on board.

6. Procedures for collection of condition monitoring information have been established and reporting procedures for submission of this as part of the approved MPMS are clearly documented.

7. Where Standard Operating Procedures have been identified, that an adequate management system is in place to ensure that they are complied with.

8. The RA, see Vol 2, Pt 1, Ch 3, 18 Risk Assessment (RA), is in compliance with an acceptable standard, good marine engineering practice and application of valid reliability data.

14.4.5 A technical audit by LR of individual RCM studies selected by LR will follow the following methodology:

1. Verification that the study covers the entire function being addressed.

2. For each individual study (sub function) within a group function, verification that there is a list that includes the individual assets items, including controls, instrumentation and protective/ emergency devices.

3. Verification that an expected maintenance task list has been drafted, based on typical tasks that would be expected for the relevant item, under any maintenance regime. These would include, but may not be limited to, system performance analysis checks, standard condition monitoring checks (vibration, electrical characteristics, thermography, etc), inspections of items liable to wear or other age related degradation, i.e. fouling, periodic tests of protective devices, operation of reversionary modes of operation, etc.

4. Confirm that the standard tasks have been identified for each sub function.

5. Review the study for justification for items or systems with no scheduled maintenance for tasks not identified.

6. Review any inconsistencies in periodicity for tasks included in maintenance schedule.

7. Carry out a review of RCM logic applied for one sub function. If the review is acceptable and in accordance with the standard for RCM, others will not be fully reviewed. If considered unacceptable, a review of another will be carried out for confirmation. If second also unacceptable, LR will require a complete review of all other sub functions for acceptance.

8. Review LR Master List Surveyable items to verify that all Class items have a maintenance programme associated with credit as part of RCM.

14.4.6 As an alternative to LR carrying out post study audits required by Vol 1, Pt 1, Ch 3, 14.4 Basic requirements for approval of MPMS, MCM and RCM schemes 14.4.4 and Vol 1, Pt 1, Ch 3, 14.4 Basic requirements for approval of MPMS, MCM and RCM schemes 14.4.5, LR can, if requested, provide direct input and advice to the study team(s) on either a full or part time basis to supplement the technical/survey requirement input. If this is undertaken, the scope of the audit will be reduced accordingly.

14.4.7 Where machinery items are maintained on a condition basis the following additional information is required to be submitted:

1. A description of the applicable monitoring techniques and monitoring equipment to be used.

2. A statement as to the acceptable limits of deteriorated condition. These should be derived from the manufacturer's recommendations, applicable severity criteria as defined in recognised Standards, or the Navy's required limits when these are more severe. Rotating machinery on condition based maintenance may be accepted for survey on the basis of the monitored readings without opening out if the condition is shown to be good.

14.4.8 If the planned maintenance scheme is considered to be acceptable to LR a ‘Certificate for Operation of an Approved Planned Maintenance Scheme’ will be issued. The Certificate is to be retained on board the subject ship for the information of the Commanding Officer, Marine Engineer Officer and LR's Surveyors.

14.4.9 The Marine Engineer Officer operating the Scheme on a ship must hold a valid LR Certificate of Authorisation.

14.5.1 It is a condition of the Scheme that the Navy arranges for LR Surveyors to carry out an Annual audit of the machinery maintenance and monitoring records. Annual audits are to be held within three months before or after the due date and it is recommended that they are harmonised with the ship's Annual Survey.

14.5.2 Marine Engineer Officers may carry out surveys of all the machinery items for which they are authorised, at sea or in port, whichever is the most convenient. The following machinery items remain to be dealt with by an LR Surveyor, unless special arrangements have been agreed with the Navy:

• Machinery damage, repairs and alterations, see Vol 1, Pt 1, Ch 3, 14.6 Breakdown or corrective maintenance
• Gas turbines for propulsion and electrical supplies.
• Engines for propulsion and electrical supplies.
• Steam turbines and boilers for propulsion and electrical supplies.
• Control, alarm and safety devices associated with the above main and auxiliary machinery.
• Reduction/increase gearing, flexible couplings and clutches.
• Holding down bolts and chocks.
• Steam pipes and valves on ships with steam turbine installations.
• Air receivers and other pressure vessels.
• Starting air pipes.
• Steering machinery.
• Pumping arrangements for bilge and dewatering systems.
• Electrical equipment other than auxiliary motors.
• Screwshafts, stern bearings and propellers.
• Sea connections.
• Machinery controls and controls associated with Class Notations, e.g. UMS, CCS, ICC and IP.
• Engine Trial.
• First start arrangement trial.

14.5.3 The confirmatory survey carried out at the time of the annual audit by LR's Surveyor will comprise of checks of the condition monitoring records and, if considered necessary, an examination of selected main and auxiliary machinery under working conditions.

14.6.1 LR is required to be notified when a breakdown or defect occurs and has a major effect that affects the Provisions of Classification and repairs are necessary. A major effect is an effect that produces:

1. a significant increase in the operational duties of the crew or in their difficulty in performing their duties which by itself should not be outside the capability of a competent crew provided that another major effect does not occur at the same time; or

2. significant degradation in the operational capability of the ship; or

3. significant modification of the permissible operating conditions, but will not remove the capability to complete a safe journey without demanding more than normal skill on the part of the operating crew.

14.6.2 In discussion with the Navy and the Marine Engineer Officer, LR will advise what repairs and/or renewals are necessary for classification purposes, with the issue of an Interim Certificate of Class.

14.6.3 The required repair and time scale for completion will be the subject of discussion and agreement with LR and the Navy. It is the responsibility of the Navy to decide whether the ship's mission/operational tasking is more important than completing the repairs within the agreed time. It is accepted that such circumstances are occasionally inevitable, and LR would provide advice on the interim measures that could be introduced until such time as the required repairs are carried out and the implications on a ship's operating capability of delays in effecting repairs.

14.7.1 At the annual audit the Marine Engineer Officer is required to make available the maintenance and monitoring records. These records may be in a hard or soft format and should include:

1. Appropriate records of machinery or equipment surveyed under the supervision of the Marine Engineer Officer that are listed in the Master List of Surveyable Items. These statements should give details of repairs carried out and spare parts used.

2. Written details of any breakdown or malfunction of essential machinery. Such details should include the main cause of failure.

These records will be examined in sufficient depth by the LR Surveyors to ensure that the scheme has been correctly operated and that the machinery has functioned satisfactorily since the previous survey. The records should indicate that all scheduled maintenance has been carried out. Any items not dealt with as per schedule will be discussed with the Marine Engineer Officer.

14.7.2 Where condition monitoring of main or auxiliary machinery is incorporated in the PMS the LR Surveyor will examine the records to verify that vibration levels, performance criteria, etc. are within the approved specified limits. The LR Surveyor may require confirmatory readings on available running machinery to be taken for comparison with the ship's records.

14.7.3 As part of the audit, LR Surveyors carry out a general examination of the machinery. As far as is practicable machinery to be credited for survey will be examined under working conditions. If the LR Surveyor is not satisfied with the condition as found he might require to have any items opened out for inspection.

14.7.4 The dates of items to be credited for Class will be aligned to the date of the confirmatory survey regardless of when the Marine Engineer Officer carried out his survey. Any other surveyable items of machinery not covered by the Scheme will be surveyed and credited in the normal way.

14.7.5 For items which the Marine Engineer Officer is authorised to survey and become due for survey between Annual Audits these will be shown as ‘OVERDUE' on the survey status until the Annual Audit has been held and reported.

14.7.6 In the event of the Surveyor not being satisfied that the planned maintenance scheme is being correctly followed, either from the maintenance records or from the general condition of the machinery, a report will be forwarded to LR recommending that the special arrangements for dealing with machinery surveys be suspended.