ISM SHIP MANAGEMENT PTE LTD MPM 10

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CHAPTER 10
MAINTENANCE
10.0 GENERAL

1. Purpose
To establish procedures to ensure that vessels under the Company’s management are maintained in
accordance with the provisions of relevant rules and regulations and with good seamanship and
industry practice.

2. Scope & Application

This chapter covers the Company’s objectives, & procedures on maintenance of ships.

This chapter is applicable to all Company’s managed vessels and personnel both ashore and on board.

3. Contents

10.1 Maintenance Objectives

10.2 Procedures of Maintenance & Monitoring
10.3 Maintenance of Critical Items and Functions
10.4 Maintenance of Standby Equipment/Machinery
10.5 Planned Maintenance System (PMS)
10.6 Special Maintenance Programme
10.7 General Guidelines on Maintenance
10.8 Guidelines on Maintenance of Life-saving Appliances
10.9 Guidelines on Maintenance of Fire-fighting Equipment
10.10 Guidelines on Maintenance of Bridge & GMDSS Equipment
10.11 Guidelines on Maintenance of Hull & Deck Machineries
10.12 Guidelines on Maintenance of Engine Room Machineries
10.13 Guidelines on Maintenance of Critical Items & Functions
10.14 Guidelines on Maintenance of Cargo Gears - Dry Cargo
10.15 Guidelines on Maintenance of Standby Equipment & Machinery
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10.1 MAINTENANCE OBJECTIVES

Maintenance of the vessel’s machinery and equipment is the most important aspect of the Company’s
operation. The condition of a vessel under management reflects on the Shipboard Management
performance and ultimately reflects on the Company’s image.

The Company’s maintenance objectives are:

 To protect the asset value,

 To have an efficient and effective service with zero or minimum stoppages or off-hires,
 To operate at an economical cost level consistent with safety, and
 To comply with all existing maritime laws, codes and guidelines.

To achieve these objectives the Company adheres to the following policies:

 The safety of personnel and environment protection overrides all other consideration.

 The Shipboard Management is responsible for the upkeep and maintenance of the vessel, it’s
machinery, equipment, etc. with the full support of the top management of the Company.

 On every vessel a planned maintenance system, whether manual system or computerized

system or both, shall be implemented.

 Stand-by and critical items are identified, their maintenance routines established and
performance or condition monitoring implemented.

 Spares & stores for planned maintenance shall be maintained on board and procedures for
requisitions and supply established.

 Vessels conditions and performance are monitored by weekly, monthly and quarterly reports
sent to the office by the Shipboard Management and general conditions of the vessels shall
be verified by routine visits of the Superintendent-in-charge on board.

The Company considers the experience feedback from the Shipboard Management as essential in its
operation so that procedures for reporting, analysis and implementation of corrective actions for
deficiencies or defects noted are established.

The Company may from time to time engage the assistance of specialist or riding/repair crew to
complement the maintenance programmes.

10.2 PROCEDURES OF MAINTENANCE & MONITORING

The Company has established procedures for the maintenance of the ships and it's equipment to
achieve the company's maintenance objectives.

All systems, arrangements, functions, equipment and machinery on board vessels managed by the
company are categorised as follows:

 Bridge Navigation and Communication Equipment

 Safety and Contingency Equipment
 Deck Machinery and Fittings
 Engine Room Machinery
 Cargo Handling Gear & Systems
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Critical items and functions including those identified with significant environmental aspect, the
sudden operational failure of which may result in hazardous situation or pollution, are identified and
have been provided with measures aimed at promoting their reliability and good operational condition.
Refer to MPM 10.3.
Stand-by machinery and equipment that are not in continuous use are also identified and guidelines
on maintenance are established to ensure that they will not fail or malfunction during operation. Refer
to MPM 10.4.
Maintenance will be carried out and monitored by a planned maintenance programme that the
Company will implement on board every vessel under management. The Company will implement
two systems of Planned Maintenance Program as follows:
 The Computerised Planned Maintenance System
 The Manual Planned Maintenance System
For the daily and weekly maintenance schedule of various equipment and machinery, the guidelines in
this chapter or the maker’s recommendation should be followed. The shipboard staff should prepare
a checklist for the equipment that requires daily and weekly maintenance and records should be kept
for inspection by the Technical Superintendent. These need not be sent to the office.
The monthly, quarterly, annual, 5-yearly or running hours intervals for maintenance will be shown in
the Planned Maintenance System Schedule. These should be sent to the office for monitoring.
The Company also includes special maintenance program using specialist, equipment or machinery
maker’s technician and riding squads for special maintenance jobs that are beyond the shipboard
personnel capability. Refer to MPM 10.6.
Guidelines on maintenance routines of key machinery, appliances, equipment and systems on board
every vessel managed by the Company are available for reference by shipboard personnel. However,
the Company emphasizes that the equipment or machinery manufacturer manual must be given
preference should it be available.
A procedure for reporting maintenance progress, deficiencies, defects and nonconformities is
established and corrective actions including follow-up actions/maintenance and experience feedback is
included.

1. Monitoring Maintenance
The Company ensures that the maintenance systems are not only implemented but are also
monitored and maintained.

This is done by way of:

1. Verifying weekly, monthly and quarterly technical reports and monthly update on the planned
maintenance programme.
2. Technical Superintendent (or the representative) carry out vessel condition inspection at least
twice a year when practical.
3. Maintaining common records for the vessels and the office where the maintenance records
can be easily identified and located.
4. Monthly review of spares and stores requisition/delivery status.
Regardless of the stipulated maintenance routine frequencies, the daily monitoring of the engine room
machinery spaces and the daily inspections of the deck and deck machinery will be the primary means
of assessing the condition of the equipment in service and the maintenance thereto.
On board, the Master, the Chief Officer and the Chief Engineer shall meet each day, preferably after
the Chief Officer’s watch between 0800H & 0900H to discuss & plan work routines and any problem
that arises.
For general instructions concerning duties or work, the flow of information on board is via the Chief
Officer or Chief Engineer to the respective departmental personnel.
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For long voyages or long port stay, the Chief Officer and Chief Engineer shall prepare a programme
for maintenance covering the period based on the schedule in the current planned maintenance
system.

2. Maintenance Record Keeping

After each activity of maintenance, inspections or testing, it is important for every crew member on
board to put in writing the records of the works done as evidence should the need arises in the future
during audits, vetting inspections or port state inspections.
The form OM 36 – Records of Maintenance, Inspections & Testing shall be used for the
purpose of record-keeping of various maintenance activities. The form will serve as a record of the
history of certain machinery or equipment or structure of the ship.
How to fill up the form OM 36:
- The crew member in-charge shall write the name of the ship, the department, either Deck
or Engine, the name of machinery or equipment or structure which may also include the model
or serial numbers. It is best to have one page for each machinery or equipment, for example: 1
page for unit no. 1 of main engine & another page for unit no. 2.
- After each work, the date carried out shall be entered,
- The jobs that were done should be entered, for example: “Overhaul pump, check for
damage – none found – clean, renew mouth ring & mechanical seal then boxed up. Tested
operation & found satisfactory.”
- Breakdowns or defect shall also be recorded, preferably in red ink, including works
done to repair or rectify them.
- The spares used, if any should be recorded
- The signature or initial of the crew doing the works is also entered. The rank may also be
used when writing the record in a computer.
- At the end of each month, the Master or Chief Engineer shall affix their signature after the
last entry as a proof of their monitoring or at the bottom of the page once the page is
completed.
In general, the entry in OM 36 shall correspond with the entries in the applicable PMS forms.
The Master or Chief Engineer are authorized to amend the format to suit the record-keeping needs of
certain machinery or groups of equipment.
The form OM 36 shall be filed according to records control procedures.

3. Review of Planned Maintenance

The scope and interval of the established planned maintenance schedule shall be continuously
reviewed and re-assessed based on feedbacks from makers, i.e. service letter or casualty information
received.
The review of the changes to the PMS shall be carried out during QAC meeting where decisions will
also be needed.
If required, amendment to the documented management system procedures will be made and sent to
all ships.

10.3 MAINTENANCE OF CRITICAL ITEMS AND FUNCTIONS

The Company, through experience and feedbacks from vessels, have identified critical items and
functions, where sudden loss of functional capability or failure to respond when activated, manually or
automatically, may create hazardous situations or accidents.
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The Management System contains operational control and maintenance routines to be taken to ensure
the reliability of such functions.

Identified critical items & functions are included in the planned maintenance system to ensure
reliability.

The Maker's Manual, Classification and Flag State requirements and company's instructions shall be
the guidelines to be followed by the shipboard staff.

The shipboard management should inform the Office if there is any critical item or functions on board
that is not identified in the management system and provide guidelines for maintenance.

1. Identifying Critical Items and Functions

The tables below show the identified critical items and functions on board with possible consequences
of failure.

The shipboard management, being the one on the spot, should provide feedback to improve the
following lists.

General guidelines for maintenance routines of all critical items and functions are outlined in MPM
10.13.

All safety and contingency equipment are also categorised under stand-by equipment, as they are not
in continuous use. They are categorised as critical because their failure when required will endanger
lives and the safety of the vessel.

All critical equipment spare part list should be prepared on board by T23 Spare inventory control.

A BRIDGE NAVIGATION AND COMMUNICATION EQUIPMENT

S/N Critical Equipment Consequence of Failure or malfunctioning

1 Gyrocompass & Auto-pilot Grounding, stranding, water pollution, port state

detention

2 Radar, ARPA Radar Grounding, stranding, collision, water pollution, port

state detention

3 GPS, DGPS Grounding, stranding

4 GMDSS Equipment Loss of communication, Port state detention, Failure to

request assistance or respond to emergency

5 ECDIS Grounding, stranding, collision, water pollution, port

state detention
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B SAFETY AND CONTINGENCY EQUIPMENT

S/N Critical Equipment Consequence of Failure

1 Emergency generator Black-out, port state detention, Air pollution

2 Emergency fire pump Uncontrolled fire, port state detention

3 Emergency steering Grounding, stranding, collision, water pollution

4 Emergency air compressor Loss of restarting ability

5 Emergency lighting Total black-out

6 Emergency water tight door Flooding

operation

7 Life boats Drowning, port state detention, Injury or death

8 Life rafts Drowning, port state detention

9 Oil spill response equipment Pollution

C ENGINE ROOM MACHINERY

S/N Critical Equipment Consequence of Failure

1 Main engine Collision, grounding, off-hires, air pollution

2 Auxiliary engines Black-out, air pollution

3 Boilers Explosion, air pollution

4 Steering gears Collision, grounding, stranding, water pollution

5 Fuel & Lubricating oil pumps Collision, grounding

6 Oily Water Separator Water Pollution, port state detention

7 Quick closing valves Uncontrolled fire, port state detention

8 ECR Control System Grounding

10.4 MAINTENANCE OF STANDBY EQUIPMENT/MACHINERY

The Company had identified the equipment and functions that are not in continuous use.
It is the Master's responsibility to ensure that any of the standby equipment or items must be
regularly tested or changed over according to the established planned maintenance schedule or as per
maintenance guidelines documented elsewhere in the manuals. Otherwise, these standby items
should be visually checked weekly and tested or operated monthly at least.

Items categorised as stand-by because they are not in continuous use but will present hazard when
they fail to operate as required, are also categorised as critical items.

1. Identifying stand-by equipment/machinery

The following are considered standby equipment or machinery (They stated in PMS separately):

a. BRIDGE NAVIGATION AND COMMUNICATION EQUIPMENT

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 Ship’s Whistle
 Sextants
 Binoculars
 Signalling equipment

b. SAFETY AND CONTINGENCY EQUIPMENT

All safety and contingency equipment are categorised as standby equipment and some are also
considered critical items.

c. DECK MACHINERY AND FITTINGS

 F.O. Hose Davits
 Provision davits
 Pilot Ladders and pilot-assist ladders
 Heaving lines
 Wilden Pumps

d. ENGINE ROOM MACHINERY

 Smoke and fire detectors
 Engine room alarms/whistles
 Incinerators
 Oily Water Separator
 Dead-Man Alarm System
 Foam Plant
 Main Switchboard

e. CARGO HANDLING GEAR

 Grabs
 Deck cranes
 Portable hydraulic pumps for Hatch covers or hydraulic valves

10.5 PLANNED MAINTENANCE SYSTEM (PMS)

To ensure that all vessels in the fleet will be maintained according to required standards, the
Company requires all vessels to implement a planned maintenance system on board whether the
computerised system or the manual system or both.
The manual system is the default system to be implemented on board. Only when the computerised
system is fully operational on board and in the office will the shipboard management stop using the
manual system. This requires prior confirmation from the top management.

1. Computerised Planned Maintenance System

This system uses computer programs to implement and monitor it’s operation.

The Company will endeavour to outsource this system from companies that provide software for the
vessel’s planned maintenance program.

At present there is no such system.

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The procedures of maintenance being followed by the office and shipboard personnel are according to
the operating manual of the company that provides the system.

The shipboard management must ensure that the operation and trouble-shooting manuals including
back-up installation software are on board and must be included in the hand-over notes.

2. Manual Planned Maintenance System

This system uses the PMS Forms that are being update manually to implement and monitor it’s
status. These forms can be found in the Quality Document File Manual.

The shipboard management are authorized to amend the contents of the various forms in order to
make them ship specific. However, the shipboard management must ensure that all critical items and
functions listed as well as all items listed in the Class Continuous Machinery Survey Listing are
included in the appropriate forms. Any amendments made by the shipboard management must then
be forwarded to the Technical Superintendent for reference.

This system is categorised into the following components:

a. Bridge Navigation and Communication Equipment

PMS 01 Navigation and Communication Equipment

b. Safety and Contingency Equipment

PMS 02 Fire Fighting Equipment
PMS 24 Life Saving Appliances
(Refer to Manual for Maintenance of Life saving Appliances as required by SOLAS Ch. III.)

c. Hull and Deck Machinery

PMS 03 Wires Inspection Lubrication and Renewal
PMS 04 Deck Machineries and Fittings
PMS 05 Tank Maintenance Plan

d. Engine Room Machinery

PMS 06 Main Engine
PMS 07 Auxiliary Engines
PMS 08 Air Compressors
PMS 09 HFO Purifiers
PMS 10 LO Purifiers
PMS 11 Other Machineries
PMS 15 Insulation Resistance Megger Test
PMS 16 Critical Items and Functions
PMS 17 Standby Equipment and Machinery
PMS 18 Motors and Pumps
PMS 19 Elevator

e. Cargo Handling Gear & Systems

PMS 22 Cranes and Grabs
PMS 23 Hatch covers

The planned maintenance schedule is prepared by the shipboard management after taking into
consideration the following factors:
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i Survey due within the year

ii Running hours of machineries expected
iii Makers maintenance procedures
iv Condition monitoring
v Performance
vi Trade Patterns
vii Trading Area
viii Cost of spares/repairs prevailing in ports of call.

The planned maintenance forms are sent to the Company at monthly and quarterly intervals as
indicated above and on the last page of each record.

Separate maintenance records are required to describe the details of the maintenance being done for
items specified in the PMS forms.

These maintenance records are to be maintained by the officer or engineer in-charge of the
machinery or equipment.

The Master is to ensure that the maintenance is carried out according to the schedule.

The Technical Superintendent in charge is to monitor the status of the maintenance program on board
by reviewing the PMS reports submitted by the vessel every month.

The above maintenance is supplemented by the following records on board with the Chief Engineer.

 Work history of the various equipment/machinery

 Running hours maintenance schedule and records for major main engine and auxiliary engine
components and other auxiliaries

f. NOTES ON COMPLETING THE PMS FORMS

Maintenance interval - Master and Chief Engineer has the authority to reduce/increase the
maintenance interval to conform with maker’s recommendation, subject to office’s approval.

Last Maintenance Date - Self-explanatory.

Schedule of Maintenance - State which month work is scheduled.
Mega Readings - To record mega readings on this column, if required
Condition - State condition of items whether Good, Satisfactory or Poor
Action Required - Self-explanatory

10.6 SPECIAL MAINTENANCE PROGRAMME

1. Upgrading Teams
The vessel, which is lagging behind in general maintenance, will be assigned with the upgrading team
of personnel after the Management's assessment and approval. This method of upgrading of the
vessels involves a team of specially trained personnel to speed up maintenance work on board. The
period of assignment will be decided based on the scale of upgrading to be done.

2. Makers of Equipment or Machinery

It is the Company's practice to engage the Maker's engineers for some special machinery and various
navigation equipments on adios basis to complement the maintenance done by the Ship's staff.
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A shore-based maintenance agreement should be signed with the maker of GMDSS equipment for
their regular maintenance as required by SOLAS and should be updated annually.

3. Repair Maintenance

a. Major Repairs
The Company’s Technical Superintendent in consultation with the management will arrange repair of a
very special nature, which is beyond the crew capability.

b. Urgent Repairs
In case of an emergency that requires urgent repair to be effected upon the vessel's arrival, the
Master is authorised to organise and co-ordinate repair as per the Company's instructions.

c. Dry-docking
Defects that would not affect seaworthiness and operation of the vessel will be deferred for repairs till
the dry-docking if the defect cannot be repaired in a cost-effective way.

Such work is to be recorded and documented in the defect list as per the Company's instructions and
sent to the Company.

The dry-dock repair specifications are prepared at least three months in advance and on completion,
they are sent to selected shipyards for quotations.

10.7 GENERAL GUIDELINES ON MAINTENANCE

The shipboard management should consult the Manuals provided by the Maker or Manufacturer of
various critical & standby machinery & equipment for their recommended maintenance schedule which
the shipboard management should compare with the Company’s Planned Maintenance System and
documented maintenance guidelines and make adjustments so that the maker’s recommended
programme is as close as possible to the Company’s system.

In the absence of the manual or recommended maintenance schedule, the office should be informed
so that the manual or recommended maintenance schedule maybe acquired from the Maker or
Manufacturer or if the maker is already non-existent, then the Company’s guidelines will be followed.

In the computerized planned maintenance system, work orders are printed out in the beginning of the
month to serve as a guide and record for maintenance to be carried out.

Chief Engineers are advised to print a list of all jobs expected for the duration of his expected stay on
board or at least 4 months as a backup in case the computer breaks down.

For maintenance of the vessel’s structures such as cargo holds, decks, bulwarks, bulkheads, hatch
covers & hatch coamings, the interval will depend on the current state of the condition of the
structures and the types of cargoes the vessel carries.

It can’t be emphasized enough that proper planning is essential for a good maintenance programme
so that materials such as paints and thinners or spare parts are available when needed.

Requirements or provisions of applicable rules and regulations take precedence over the the maker’s
recommendations.

1. Basic Categories of Maintenance

Maintenance normally is divided into four basic categories namely:

 Preventive maintenance
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 Condition based maintenance

 Corrective maintenance
 Life replacement maintenance

2. Preventive Maintenance
This category calls for items to be opened up for inspection and overhauled at specified time period or
after a specified number of running hours. Maintenance is carried out irrespective of machinery
condition in order to retain the machinery or equipment in a good operational condition.

3. Condition Based Maintenance

This is dictated by the performance or physical state of the machinery or equipment, determined by
regular or continuous checks of applicable parameters, and is only undertaken when operating
conditions have deteriorated below a satisfactory standard, but before breakdown or failure occurs.

4. Corrective Maintenance
This is sometimes referred to as breakdown maintenance and is only carried out in order to restore a
machinery or component back to operational condition after a failure or malfunction.

5. Life Replacement Maintenance

In this category, the machinery or component is run to destruction and then replaced. While this
cannot be considered as maintenance of that component, it is maintenance to the overall system.

Of the above maintenance categories, the foundations of the Planned Maintenance Scheme employed
by the Company are the preventive and condition based maintenance. A combination of these two
methods of control maybe employed in a single machinery or equipment.

Breakdown or corrective maintenance will be necessary to deal with unforeseen circumstances and
the Company’s Planned Maintenance System has sufficient flexibility to take into consideration the
unscheduled maintenance.

10.8 GUIDELINES ON MAINTENANCE OF LIFE-SAVING APPLIANCES

“SOLAS Chapter III Regulation 20.2 Operational Readiness – Before the ship leaves port
and at all times during the voyage, all life-saving appliances shall be in working order and
ready for immediate use.”

1. Lifeboats (Conventional & Free-fall)

Any Inspection, servicing and repair should be carried out according to the system for inspection and
services developed by the manufacturer.
A full set of maintenance manuals and associated documentation issued by the manufacturer should
be available on board for use in all operations involved in the inspection, maintenance, adjustment,
and re-setting of the lifeboat and associated equipment, such as davits and release gear.
All inspections and testing of life saving appliances should be recorded in the deck logbook.

a. Weekly Inspections (Usually Every Saturday)

 Inspect the general condition of the boat inside and outside. Drain plugs must be available
and attached to the lifeboat. The plugs must not be inserted. Check that the water can pass
freely through the drains.
 The lifeboat must be ready for immediate launching. The skates must be correctly mounted.
 All hatches must open and close freely.
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 Engine test to be carried out.

 Lifeboat must be moved from stow position as per SOLAS requirement.

b. Monthly Inspections (Maybe carried out together with one of the weekly inspections)
 Carry out weekly inspection as above.
 Check the engine and propulsion system
 Check the sprinkler system, if fitted.
 Check the air supply system, if fitted.
 Check the maneuvering system
 Check the power system and batteries
 Check the bailing system
 Check the release gear

c. Maintenance (Monthly)
 The lifeboat is to be washed and cleaned, and if necessary, wax applied to the outside.
 Retro-reflective tapes must be properly fastened and renewed if necessary. If renewing the
tapes, the new tapes must be placed in the same position as the old ones.
 The markings on the lifeboat (name, port of registry, dimensions of the boat, and permitted
number of persons) must be easy to read and properly fastened.
 Inspect thwarts/benches, gratings and straps. Bolts holding these must not be rusty.
 All ropes are to be inspected and renewed, if necessary.
 Tricing pendants and bowsing tackles are to be checked and relevant parts greased.
 All movable parts are inspected and greased.
 Check all equipment and engine.

d. Test
 Lifeboats must be launched and maneuvered in the water at least once every 3 month.
(SOLAS CH. III Reg. 19.3.3.3)
 Free-fall lifeboats – In the case of a lifeboat arranged for ‘free-fall’ launching, at least once
every three months during an abandon ship drill, the crew shall board the lifeboat, properly
secure themselves in their seats and commence launch procedures up to, but not including
the actual release of the lifeboat (i.e. the release hook shall not be released). The lifeboat
shall then either be free-fall launched with only the required operating crew on board, or
lowered into the water by means of the secondary means of launching with or without the
operating crew on board. In both cases, the lifeboat shall thereafter be maneuvered in the
water by the operating crew.
At intervals of not more than six months, the lifeboat shall either be launched by free fail with
only the operating crew on board, or simulated launching shall be carried out in accordance
with the guidelines developed by the Organization - Refer to Measures to prevent accident
with lifeboats (MSC.1Circ.1206/Rev.1)
(SOLAS CH. III Reg. 19.3.3.4)

 Lifeboats also serving as rescue boats must - where this is found reasonable and practical –
be launched monthly and in any case at least once every 3 months.
(SOLAS CH. III Reg. 19.3.3.6)

e. Special Conditions
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 In lifeboats with a water spray system, the nozzles must be checked weekly and the pump for
the system checked every time the lifeboat is launched.
 In lifeboats with self-contained air support system, the pressure of the compressed-air bottles
must be checked weekly according to the operation manual, taking into consideration that the
pressure is dependent on temperature.
 In free-fall lifeboats, the condition of the safety belts must be checked weekly.
 When sailing in areas with temperatures below zero, necessary precautions must be taken to
avoid frost damage the sprinkler equipment and the engine.

1.2 Lifeboat Equipments

a. Monthly Inspections
 The entire equipment of the lifeboat - except the boat hooks - must be properly secured and
placed in an appropriate way.
 The equipments are to be checked in accordance with the checklist.
 The expiry dates for the pyrotechnics is to be checked and if necessary to request for
replacement in advance.
 Clean and wipe the emergency ration containers. Check that the containers close watertight
and grease the watertight mechanism and gasket, using acid-free Vaseline. If the wrapping is
defective, the food ration must be replaced.
 Fresh water tanks or containers is to be checked and should be normally replaced. When
sailing in areas with temperatures below zero precautions must be taken to avoid frost burst
of the fresh water tanks/containers.
 Check inventory & condition of lifeboat engine spare parts & tools.

b. Maintenance (Monthly)
 Preserved fresh water must be replaced according to the date-stamp, at least every 4th year.
 Check the electric torch. Batteries must be replaced once a year.
 Clean the oars and the mast and apply lacquer/linseed oil if necessary.

c. Special Conditions
 The Certificate of the Medicine Chest must be renewed every year.
 The pyrotechnics are renewed after 3 years from the date of manufacture.

1.3 Lifeboat Engines

a. Weekly Inspections (Usually Every Saturday)

 Check the oil level of the engine and gearbox and refill if necessary (See lubrication chart).
 Check the cooling water level and refill if necessary.
 The engine must be run ahead and astern according to the operation manual for at least 3
minutes.
 Refill the fuel tank after the engine test run.

b. Monthly Inspection (Maybe carried out simultaneous with one of the weekly inspections)
 Carry out weekly inspection as above.
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 Drain water and sediments off the fuel tank and refill to proper level after the test run.
 Check V-belt tension.
 Grease propeller, all bearings, gaskets, etc. according to the lubrication chart.

c. Maintenance (Every 6-months or as per maker’s manual)

 Change oil in both the engine and the gearbox.
 Check the air filter and clean it thoroughly.
 Drain water and sediments off the fuel tank.
 Change fuel filter, clean injector nozzles and lift the pump strainer.
 Drain the cooling water system and check the system inclusive pump diaphragm, thermostat
and strainer. Refill cooling water to indicated level.
 Check V-belt tension.
 Adjust air inlet and exhaust valves.
 Grease propeller, all bearings, gaskets, etc. according to the lubrication chart.
 The engine must be run ahead and astern according to the operation manual, however, at
least 3 minutes. Refill the fuel tank after the test run of the engine.

d. Special Conditions
 When sailing in areas where low temperature may occur, the engine must be protected
against frost, enabling it to start down to -25oC. With respect to the above, attention is
specially drawn to the cooling water, fuel and lubrication oils.

2. Life rafts

a. Weekly Inspection (Usually every Saturday)

 Check the lashings, painter and the general condition of the container.

b. Monthly Inspection (Maybe carried out simultaneous with one of the weekly inspections)
 Carry out weekly inspection as above.
 Check the drain holes of the container are turned downwards and that they are not clogged.
 Check that the markings on the life raft are visible and legible.

c. Maintenance (Annually)
 The life raft shall be inspected at approved servicing station. A new certificate is to be issued.
 The cradle of the life raft is inspected and if necessary cleaned and painted.

d. Special Condition
 Direct hosing of the life raft container is to be avoided, as this may result in the penetration of
water.
 If the container has suffered any damage, it should be taken ashore as soon as possible for
inspection.
 On ships equipped with davit-launched life rafts, one of these must, when practicable, be
inflated and lowered, with intervals of not more than 4 months. (SOLAS CH. III Reg. 18.4.3)
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 Where a special life raft intended for training purposes only and not part of the ship’s life-
saving equipment is used, this life raft must be in an over-all good condition, be clearly
marked and of the same type as the life rafts included in the ship’s life-saving equipment.
This life raft should also be taken ashore for inspection at an approved servicing station with
intervals of 12-17 months.
 If a life raft included in the ship’s life-saving equipment is used, the exercise is to be carried
out only when the ship is in port where it is possible to have the life raft re-packed at an
approved servicing station before the ship’s departure.

2.1. Release Gear

The following should be examined for satisfactory condition and operation:
a. Operation of devices for activation of release gear
b. Excessive free play (tolerances)
c. Hydrostatic interlock system, where fitted.
d. Cables for control and release, and
e. Hook fastening

Note:

 The setting and maintenance of release gear are critical operations with regard to
maintaining the safe operation of the lifeboat and the safety of personnel in the lifeboat. All
inspection and maintenance operations on this equipment should therefore be carried out
with the utmost care.
 No maintenance or adjustment of the release gear should be undertaken while the hooks are
under load.
 Hanging-off pennants may be used for this purpose but should not remain connected at other
times, such as when the lifeboat is normally stowed and during training exercises.

a. Operation Test On-load Release Function

 Position the lifeboat partially into the water such that the mass of the boat is substantially
supported by the falls and the hydrostatic interlock system, where fitted, is not triggered;
 Operate the on-load release mechanism and
 Reset the on-load release mechanism

b. Operation Test Off-load Release Function

 Position the lifeboat fully waterborne
 Operate the off-load release gear
 Reset the on-load release gear
 Recover the lifeboat to the stowed position and prepare for operational readiness
Note: Prior to hoisting, check that the release gear is completely and properly reset. The final turning-
in of the lifeboat should be done without any persons on board.

c. Overhaul of On-Load Release Gear

Overhaul of on-load release gear includes:
1. Dismantling of hook release units
2. Examination with regard to tolerances and design requirements
3. Adjustment of release gear system after assembly
4. Operational test as per above and with a load according to SOLAS regulation III / 20.11.2.3
5. Examination of vital parts with regard to defects and cracks
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Note :
Non-destructive examination (NDE) techniques, such as dye penetrates (DPE), may be suitable.

2.2 Fall Preventer Devices (FPD)

In case of FPD has been installed, master is to ensure it is inspected/tested at following schedule;
a. Weekly inspection to check the condition of slings/strops with outer cover.
b. Monthly installation/remove the FPD test during abandon ship drill.
c. Annually overload testing of the FPD (for the slings or strops type) at minimum 6 times of the
load of Life Boat with it’s accessories should be used.
d. All FPD should be thoroughly examined prior to each use and replaced if any signs of damage
or significant deterioration are found.
e. Where FPD are used suitable clear and simple warning notices should be placed inside the
lifeboat at the release gear access hatches at each end of the boat so as to ensure correct
use of the devices.

2.3 Hydrostatic Release Gears

a. Weekly Inspection
1. Carry out weekly inspection.

b. Monthly Inspection
1. Depending of the type necessary maintenance is carried out in accordance with the maker’s
manual.

c. Maintenance (Annually)
1. Inspection/maintenance/renewal carried out by an approved servicing station.

d. Special Condition
1. Certain types of hydrostatic release gear can be activated if a water hose is used directly
against them.
2. When sailing in areas where icing can occur, the hydrostatic release gear must be kept free of
ice.

3. Rescue Boat

If one of the ship’s lifeboat is approved as a rescue boat, see item 1.

a. Weekly Inspection (Usually every Saturday)

1. By visual inspection ensure that the rescue boat is ready for immediate use.
2. Run the engine according to manufacturer’s instructions for at least 3 minutes.
3. The boat shall be moved from stow position as per SOLAS requirement.

b. Monthly Inspection (Maybe carried out simultaneous with one of the weekly inspections)
Check that the rescue boat and it’s equipment are complete and in good condition.

c. Maintenance (Monthly)
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Maintenance is carried out in accordance with the specifications of the manufacturer.

d. Test

The rescue boat shall, when considered reasonable and practical, be launched each month and in any
case at least once every 3 months ( SOLAS CH. Ill, Reg. 18.3.8 ).

e. Special Condition

Refer to existing flag state regulation regarding carriage of gasoline for the outboard motors.
A maximum of 20 liters of gasoline must be kept in the gasoline tank regardless of it’s size.

3.1 Launching Appliances

a. Weekly Inspection (Usually every Saturday)

The following items should be examined for satisfactory condition and operation:

1. Davit structure, in particular with regard to corrosion, misalignment, deformations and

excessive free play.
2. Wires and sheaves, possible damages such as kinks and corrosion
3. Lubrication of wires, sheaves and moving parts
4. Functioning of limit switches
5. Stored power systems
6. Hydraulic systems

b. Monthly Inspection (Maybe carried out simultaneous with one of the weekly inspections)

1. Grease all grease nipples in accordance with the lubrication chart.

2. Check the oil level in the winches and refill to the marked level if necessary.
3. Hand and centrifugal brakes must be free of oil and grease.
4. Lower the boats to deck level and check that the rollers, auto-stop device and other movable
parts are free.
5. Check that the contact face of the wire has no damage or rust and apply grease if necessary.

c. 5-yearly Operational Testing

Five-yearly operational testing should be done by lowering the boat loaded to a proof load of 1-1
times the maximum working load of the winch, or equivalent load. When the boat has reached its
maximum lowering speed and before the boat enters the water, the brake should be abruptly applied.
d. Maintenance

1. The brake blocks for winches are renewed if necessary.

2. Ensure that the fastening of the wire on the drum is satisfactory. The wire and winch are
greased and the wire is rolled on again.
3. The wire shall be renewed every 4th year or earlier if damage should be found as per SOLAS
regulation III/20 – paragraph 4.2. Oil and grease are cleaned and the wire and winch are
checked for breaks and wear or damage.
4. lf the wire is of stainless steel, AISI 316, or of better quality, the wire is to be renewed only if
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by inspection mechanical failure, corrosion or other possible damage are discovered.

f. Special Condition
When renewing the wire as mentioned under e.2, it must be ensured that both the falls wire
connecting to the pad-eye are mechanically spliced timber ends.

4 Embarkation Ladders (Applicable to Conventional/Rescue Boats & Life rafts)

a. Weekly Inspection (Usually every Saturday)

Lashings, storage and condition of rope and steps are visually inspected.

b. Monthly Inspection
Rope, steps, shackles, furnishings, etc. are to be thoroughly inspected and defective parts renewed.

5. Maintenance of Launching Appliances and On-load Release Gear for Conventional

/Free-Fall Lifeboats, Rescue Boat & Liferaft

SOLAS Description of requirement Interval Application

CH III
REG. Conv. Free-fall Rescue Life
Lifeboat lifeboat boat
raft
20.11.1 Launching appliances (davit and winch) :
20.11.1.1 Maintained in accordance with instructions Manufacturer Yes Yes Yes Yes
for on-board maintenance. recommendat
ions
conducted by ships personnel
20.11.1.2 Thorough examination Annually Yes Yes Yes Yes
Conducted by manufacturers representative
or person trained and certified by the
manufacturer
20.11.1.3 Dynamic test of winch brake with load of Annually Yes Yes1 Yes Yes
empty boat.
Conducted by manufacturers representative
or person trained & certified by the
manufacturer
20.11.1. Dynamic test of winch brake with 1.1 x 5 yearly Yes Yes1 Yes Yes
3 weight of fully equipped and manned boat.
Conducted by manufacturers representative
or person trained & certified by the
manufacturer – and witnessed by Class
Surveyor

20.11.2 Lifeboat on-load release gear:

20.11.2.1 Maintained in accordance with instructions Manufacturer Yes2 N/A Yes2 No
for on-board maintenance. recommendat
ions
Conducted by ship personnel
20.11.2.2 Thorough examination and operational test Annually Yes2 N/A Yes2 No
Conducted by manufacturers representative
or person trained and certified by the
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manufacturer
20.11.2.3 Operational test under 1x1 total mass of 5 yearly Yes2 N/A Yes2 No
lifeboat fully equipped and loaded.
Conducted by manufacturers representative
or person trained & certified by the
manufacturer.

1
Dynamic test of free-fall lifeboat secondary means of launching is required only if design permits. If design
does not permit, meaning that launching is done under power, a controlled lowering to the water with 1.1 x
weight of fully equipped and manned boat should be conducted.
2
Only if fitted with on-load release gear

6. Lifejackets

a. Monthly Inspection
1. Check the condition of the lifejackets including:
- all strings and straps are placed as they should be and that they are not entangled or
tied together.
- the joints are in order and the retro-reflective tapes are fixed in place.
- the whistle is properly secured and is in working order.
- the light on the lifejacket is secured and is in working order.
2. Conduct a tally of all lifejackets and check that the number of lifejackets as minimum
corresponds to the required number, and the lifejackets are placed in the approved places
3. The place where the lifejackets are stowed must be clearly marked.

b. Maintenance
1. Wash and clean the lifejackets if necessary. This is done according to the manufacturers
guidelines.
2. Renew light/battery if necessary, in accordance with the manufacturer’s guidelines.

7. Immersion Suits

a. Monthly Inspection

1. Check the location and stowage of the immersion suits are clean and in order.
2. Examine the joints of the boots to the suit, cuffs and closing mechanisms.
3. Inspect all welding and check the suit for crumbling and wear.

b. Maintenance

1. After use: Rinse the suit in fresh water if it has been in contact with salt water. The suit must
be completely dry before it is re-packed.
2. Wax the zippers with the wax stick supplied.
3. When re-packing the suit, the instructions must be followed, all zippers be open and lining be
in place.

8. Lifebuoys
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a. Monthly Inspection
1. Check the general condition of the lifebuoys and their attachments, ie. lights, M.O.B. signal,
poles and lines.
2. The buoy must be placed correctly and the mountings properly secured. The buoy and it’s
attachments must not be lashed.
3. Check whether the grab lines and lifelines are damaged or worn. Renew as necessary.
4. The retro-reflective tape, the ship’s name and port of registry must be properly fastened,
legible and clean. Damaged retro-reflective tapes must be renewed. When renewing the
tapes, the new ones must be fixed in the same places as the old ones.
5. Check that the number of lifebuoys including the various attachments corresponds to the
required number. Refer to the ship’s safety plan or safety equipment certificate.

b. Maintenance
1. Clean the lifebuoys if necessary. Use water with soap only.
2. Check the self-igniting lights for water penetration. The bulb is checked and the battery to be
renewed once a year or according to the manufacturer’s instructions.
3. The release mechanism of lifebuoys placed on the bridge wings is tested and lubricated; the
expiry date of the M.O.B. signal is checked. (Shall be renewed at the first opportunity before
it’s expiry date)

c. Special Condition
1. In ports with high risk of thief and robbers, the lifebuoys maybe kept in a secured place and
notice of their change of location to be posted in prominent places to inform other ship’s
crew.
2. After each port call, it is considered good practice, in addition to the above monthly
inspection, to examine all lifebuoys and attachments.
3. Certain ships, specially large tankers, have a remote release mechanism on the bridge, and
the lifebuoy and attachments placed on a lower deck. After a temporary fastening of the
lifebuoy and attachments, the system should be tested in accordance with the manufacturer’s
instruction.

9. Pyrotechnics

a. Monthly Inspection
Check that the pyrotechnics are located correctly in the marked places. They must be complete and
without damage or moisture.

b. special condition
Pyrotechnics are to be replaced at first opportunity before the expiry date as indicated by the
manufacturer, normally 3 – 5 years.

10. Line-Throwing Apparatus

a. Monthly Inspection
Check the condition of the line throwing apparatus and the expiry date. Make sure that it is in place
and ready for use.
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b. Special Condition
1. Check that there are at least 4 rockets and 4 lines for the line-throwing apparatus.
2. Renew rockets and 4 lines that are more than 4 years from date of manufacture.

11. SART’s
a. Monthly Inspection
1. Check that the SART and it’s container are clean and the instructions are legible
2. Check the mounting hardware for tightness.
3. Inspect the SART and it’s container for signs of deterioration, cracks or damage.
4. Check expiry date of battery and replace if necessary.

12. EPIRB’s

a. Monthly Inspection
1. Check that the EPIRB’s are located at the marked spots, that they are without any visible
damage and that the instruction is intact.
2. Check the mounting hardware for tightness.
3. Check the antenna, the bracket and the mounting hardware for any sign of corrosion,
deterioration, cracks or other damage.
4. Check the battery replacement date sticker for expiration/replacement date of the battery.
(Normally every 3 years). If battery replacement is indicated contact the authorized service
agent to have the battery replaced.
5. Check the replacement date sticker for the Hydrostatic Release Sensor. if replacement is
necessary, contact an authorized service agent to have the mechanism replaced.

b. Special Condition
1. The EPIRB is to be inspected and tested at least every 12 months, and if necessary it’s
energy source must be renewed, by an authorized service agent of it’s manufacturer within 3
months of annual survey for Safety Radio Certificate.
2. tested at an approved shore-based maintenance facility not exceeding 5 years interval.

13. Portable Radio Apparatus

a. Weekly Inspection
1. Check that the portable radio apparatus is in place at the marked spot without any visible
damage and that the instructions for it’s use are intact.
2. Test the portable radio apparatus and check the reaction on the ammeter.
Note: Tests concerning portable radio apparatus must be made in the Radio Logbook.
Replace the battery if the expiry date has been exceeded. (Normal life for lithium
batteries are 5 years).

14. Alarm Systems

a. Weekly Inspection
The general emergency alarm system should be tested at least once a week and in connection with
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fire and boat drills.

Note. When at sea it is considered good practice to test the ship’s alarm system everyday at noon.

15. Emergency Lighting

a. Monthly Inspection
1. The emergency lighting is to be tested at least once a month preferably during fire and boat
drills.
2. The placement of the ship’s emergency lighting must be shown on the ship’s fire and safety
plan.

b. Special Condition
On some ships the emergency lighting for the lifeboats and liferafts are placed in such a way that the
lamps may be swung over the side. In such case it is good practice to test and lubricate these
arrangements during boat drills or at least once a month.

16. Safety Notices

a. Monthly Inspection
The condition of all notices and signs should be checked.

b. Maintenance
1. All notices and signs are examined and renewed if necessary. If a list of signs is carried on
board, this should be used to check all notices and signs once a year.
2. Outside signs are washed with soapy water if necessary.

c. Examples of Signs Relating to Life-Saving Appliances

1. Bridge:
 Safety Plans
 Lifeboat Muster List
 Copy of rescue signals for use in lifeboats and the bridge
 Lifejacket instructions
 How to release the liferaft
 Instructions in using the hydrostatic release gear
 Guidelines for rescue of shipwrecked crew

2. Radio Space:
 Procedures of transmitting emergency signals

3. Accommodation (Near or in Mess rooms)

 Safety Plans
 Lifeboat Muster List
 Copy of rescue signals for use in lifeboats and the bridge
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 Lifejacket instructions
 How to release the liferaft
 Escape arrows

4. Engine Control Room

 Safety Plans
 Instructions for lifeboat engines

5. Near and in Lifeboats and Liferafts

 According to SOLAS Chapter III, Regulation 9 there must be posters or signs illustrating
the purpose of controls and the procedures for operating the launching appliances.

17. Communication Equipments

1. Communication equipments includes:
- the ship’s automatic telephone system,
- Public address system,
- Walkie-talkies (VHF or UHF)
2. These equipments are being used daily and as such are checked daily and possible defects
are repaired as they occur.
3. As a minimum all communication equipments are checked at least once a month.
4. If sound powered telephones are on board, they are to be tested weekly.

10.9 GUIDELINES ON MAINTENANCE OF FIRE-FIGHTING EQUIPMENT

1. Operational readiness
SOLAS Chapter II-2 Regulation 21 – Ready availability of fire-extinguishing appliances
Fire extinguishing appliances shall be kept in good order and be available for immediate
use at all times.

2. All firefighting equipment are subject to annual Class Survey.

3. Self-Contained Breathing Apparatus (SCBA)

Weekly - Check cylinders for leakages
Monthly - Check 2 spare bottles for each SCBA
Yearly - Check air quality of air recharging system
- Annual Survey
5-Yearly- Hydrostatic tests of cylinders

4. Fireman’s Outfit
Monthly - Check all are in place & in good condition (prepare checklist)

5. Fire Hydrants
Monthly - Check conditions (prepare checklist)
Yearly - Test for operations

6. Fire Hoses & Nozzles

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Monthly - Check all are in place & in good condition (prepare checklist)
6-Monthly - All fire hoses to be hydraulically tested (prepare schedule)

7. Portable Fire Extinguishers

Monthly - Check all are in proper places & no leakage (prepare checklist)
Yearly - Check in proper location, charging pressure & condition
- Specialist servicing
- Annual Survey
2-Yearly - Check contents. Check portable CO2 cylinders by weighing
10-Yearly - Hydrostatic tests of cylinders

8. Fixed Fire Extinguishing Systems

Monthly - Check valves are in proper position
- Check for leakages
- Check conditions of the system
Quarterly- Check CO2 bottle connections for cable operating system clips for tightness
Yearly - Test operation for foam-water & water-spray fixed systems
- Visual inspection of all accessible components
- Inspect control valves
- Air blow through piping of CO2 System
- Foam analysis of fixed foam system after 3rd year in service
2-Yearly- Contents of CO2 cylinders are verified by weight or isotropic measurements (to re-
charge if loss is more than 10%)
5-Yearly - Internal inspections of control valves
20-Years- Hydraulic test all CO2 cylinders

9. Sprinkler System
Monthly - Dry pipe system have appropriate pressure as indicated by gauges
- Pressure tanks have correct levels of water
- Pumps automatically operate at reduction of pressure in the system
Quarterly- All automatic alarms are tested using test valves for each section
Yearly - Test pumps for proper pressure & flows
- Test operations of connections to fire mains

10. Fire Pumps

Monthly - Operation testing.
Yearly - Test operation for proper pressures & flows

11. International Shore Connection

Quarterly- Check condition & location

12. Fire Station

Quarterly- Check inventory of equipment stored & conditions (prepare checklist)

13. Fire Doors & Fire Dampers

Monthly- Test for local operations
6-monthly- Test for remote operations

14. Fire & Smoke Detectors and Cargo Hold Smoke Detecting System
Weekly - Test for proper operation (Prepare checklist or OM 36 Records of maintenance,
inspections & testing for progressive tests)

15. Emergency Escape Breathing Devices (EEBD)

Weekly - Visual inspection
Monthly - Check condition and expiry date of shelf -life
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- Check spare EEBD (1 for <10, 2 for 11-20, 4 for >20 on board)

16. Antifreeze Systems

Yearly - Test for proper solutions

17. Spare Charges for Portable Fire Extinguishers

a. Spare charges shall be provided for 100% of the first 10 extinguishers and 50% of the
remaining fire extinguishers capable of being recharged on board. Not more than 60 total
spare charges are required. Instructions for recharging should be carried out on board.
b. For fire extinguishers which cannot be recharged onboard, additional portable fire
extinguishers of the same quantity, type, capacity and number as determined in above
paragraph shall be provided.

18. Fire Protection - Paint Lockers

Paint lockers shall be protected by:
 a carbon dioxide system, designed to give a minimum volume of free gas equal to 40% of the
gross volume of the protected space; or
 a dry powder system, designed for at least 0.5 kg powder/m 3; or
 a water spraying or sprinkler system, designed for 5 l/m 2 min. Water spraying systems may be
connected to the fire main of the ship; or
 The fitting of a portable fire extinguisher immediately outside the entrance to the paint locker.
The number of portable extinguishers is to be adequate to the size of the paint locker as
determined by the Recognized Organization.
 In any case, the system shall be operable from outside the protected space.

10.10 GUIDELINES ON MAINTENANCE OF BRIDGE & GMDSS EQUIPMENT

The following are guidelines only for maintenance. The officer in-charge of the equipment listed
below should consult the maker’s manual and follow the recommended maintenance schedule.
1. Gyrocompass
Daily – check that repeaters value are the same as in the operating panel & displayed latitude is the
same as ship’s actual latitude.
Yearly – check by maker service engineer as per the recommendation stated in manual.

2. Autopilot
Daily during operation – operate & check on different modes
6-monthly – take rudder turning time from 0° – 30° P&S & compare with the manual
Yearly - as per the recommendation stated in manual.

3. Radar & ARPA Radar

monthly – clean air filters or ventilation openings, check tightness of bolts & nuts, visual check of
internals for corrosions & rust spots, visual check of cabling & wave guide.
6-monthly – supply grease to the oil seal chamber & oil reduction gear of the scanner, apply grease to
the main shaft driving gear of the scanner
2-yearly – as per the recommendation stated in manual.

4. Magnetic Compass
Daily – check compass deviation at least during each watch at sea when practical
Yearly – carry out compass calibration by certified compass adjuster
2-yearly – as per the recommendation stated in manual.

5. AIS
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Monthly – check conditions, cabling & connections & antenna.

Yearly – as per the recommendation stated in manual.

6. Speed Log
Daily – check master unit display & speed receiver display is the same, Lamp test
3-monthly – check sensor for electrode contamination, Insulation check, connector check
2-yearly – as per the recommendation stated in manual.

7. Course recorder
Daily – check that course & time indicated in the recorder is the same as the ship’s course & time.
Check paper feed correctly
2-yearly - as per the recommendation stated in manual.

8. Echo sounder
Monthly – clean the recorder & check all moving parts
2-yearly - as per the recommendation stated in manual.

9. GPS & DGPS

Monthly –check antenna & cables, ground terminals for tightness, rusts, damage or water leaks
4- yearly – replace lithium battery
2-yearly - as per the recommendation stated in manual.

10. Navtex
Weekly – carry out self-diagnostic test & printer test & record results in radio logbook.
2-yearly - as per the recommendation stated in manual.

11. MF/HF
Daily – carry out DSC, Radiotelephony & NBDP self-test & operation
Weekly – carry out external test by DSC to coast station
2-yearly - as per the recommendation stated in manual.

12. VHF
Daily – test operation & printer
Weekly – carry out DSC self-test
2-yearly - as per the recommendation stated in manual.

13. Two-way Portable VHF

Weekly – check battery & operation
Monthly – check functions & operations

14. Weather facsimile

Monthly – clean the unit & test operation & printer
2-yearly - as per the recommendation stated in manual.

15. Inmarsat C, B or F
Daily – clean the equipment
2-yearly – as per the recommendation stated in manual.

16. Bridge-E/R control system

Prior arrival/departure ports or maneuvering – test operations
6-monthly – test auto slowdown override

17. Voyage Data Recorder / Simplified Voyage Data Recorder

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Prior arrival/departure ports or maneuvering – test operations

Monthly – clean the unit & test operations as per VDR operation Manual.

Yearly – as per the recommendation stated in manual.

The voyage data recorder system, including all sensors, should be subjected to an annual
performance test. The test should be conducted by an approved testing or servicing facility to verify
the accuracy, duration and recoverability of the recorded data. In addition, tests and inspections
should be conducted to determine the serviceability of all protective enclosures and devices fitted to
aid location. A copy of the certificate of compliances issued by the testing facility, stating the date of
compliance and the applicable performance standards, should be retained on board the craft.

18. Electronic Chart Display and Information System (ECDIS)

Test and check ECDIS working condition ever watch as per OM04-1.
Where one ECDIS alone is operated in such a case as ocean navigation, ECDIS shall be switched over
every watch to use ECDIS alternatively and shall carry out function test of Back-up ECDIS which is not
in continuous use.
Testing of ECDIS from Emergency Source of Power
As per SOLAS Ch.2-1, Regulation 43.2.4, it should be possible to operate ECDIS and all equipment for
its normal functioning for a period of 18hrs when supplied by an emergency source of electrical
power. Changing from one source of power supply to another or any interruption of the supply for a
period of 45 seconds should not require the equipment to be manually re-initialized.
As per this requirement, please try out the ECDIS fitted onboard from the emergency power Source
while the situation permitted as per maker’s instruction. Inform office if abnormal found.
The test given should due regard to the safety of navigation. It is recommended to plan and carry out
the test when the vessel is alongside berth or while at Anchorage.

10.11 GUIDELINES ON MAINTENANCE OF HULL & DECK MACHINERIES

The following equipment & fittings on deck should be maintained as required in the following
guidelines:
1. Anchor windlass
Monthly - lubricate all lubrication points, check hydraulic system
- Brake lining to check for excessive wear / renew if require
- Derust & paint external areas if necessary
6 monthly - Hydraulic oil test, renewal as necessary
5 yearly - Carry out Brake Holding Test & mark on the windlass body

2. Mooring winches
Monthly - lubricate all lubrication points, check hydraulic system
- Brake lining to check for excessive wear / renew if require
- Derust & paint external areas if necessary
6 monthly - Hydraulic oil test, renewal as necessary
5 yearly - Carry out Brake Holding Test & mark on the winches body

3. ETA (Emergency Towing Arrangements)

Monthly – check conditions & carry out maintenance if necessary
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4. Fairleads & Rollers

Monthly – lubricate all lubrication points & paint if necessary

5. Mooring ropes
Monthly – check condition & turn or replace if necessary

6. Accommodation & Gangway Ladders

Weekly – Visually check main frame, hand rail, stanchion, step, turn table, upper platform, lower
platform, davit, hinge section, sheave section ,wire and attachment no corrosion, bend
and dent.
Monthly – lubricate all lubrication points, check motor & oil level, test operation of davit, hinge and
sheave section.
3 monthly – grease wires.
2.5 yearly – renew fall wires, subject to actual condition, load test.

7. Pilot ladders
Monthly – check conditions of steps & ropes & renew if necessary

8. Pilot Assist Ladder

Weekly – Visually check main frame, hand rail, stanchion, step, turn table, upper platform, lower
platform, davit, hinge section, sheave section ,wire and attachment no corrosion, bend and
dent.
Monthly – lubricate all lubrication points, check motor & oil level, test operation of davit, hinge and
sheave section.
3 monthly – grease wires.
2.5 yearly – renew fall wires, subject to actual condition, load test.

9. Jacobs & Aluminum Ladders

Monthly – check condition & carry out maintenance if necessary

10. Ballast tanks

6 monthly – carry out inspections of topside tanks & side tanks
Remote control valve hydraulic oil send for analysis
Yearly – carry out inspections of double bottom tanks
*For Tanker – Ballast tanks should be inspected every 6 monthly.

11. Main deck & cross decks

6-monthly - repaint if necessary

12. Deck fittings

3-monthly – check conditions & carry out maintenance if necessary

13. Air Pipe, Sounding Pipe, Ventilator & Funnel Flaps

Weekly – check conditions
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Monthly – lubricate & test opening & closing operations

14. Watertight Doors

Monthly – lubricate moving parts & test operations, check water tightness of rubbers.

15. Provision Crane / Davits

Monthly – carry out inspections of condition
3-monthly – grease wires & all lubrication points
5-yearly – Renewal of all wires, subject to actual condition

16. FO Hose Davits

Monthly – carry out inspection of condition
3-monthly – grease wires & all lubrication points
5-yearly – renewal of all wires, subject to actual condition

10.12 GUIDELINES ON MAINTENANCE OF ENGINE ROOM MACHINERIES

The following is the guidelines for maintenance of machineries in the engine room. If the
maintenance routine for a machinery is different from the maker’s recommended maintenance
schedule, then the planned maintenance programme should be adjusted to suit the maker’s
recommendation.
For items under the Class Continuous Machinery Survey (CMS) Programme, the interval should be as
per Class requirements, generally every 5-years with at least 20% of the items to be carried out each
year. The Class Status listing should be consulted and the planned maintenance programme should
be adopted to the Class schedule.

If the Chief Engineer is allowed by the Class to carry out the survey, the limitations imposed by the
Class should be observed.

1. Main Engine
a. Every 4,000 RH
1. Air coolers – inspection/clean, overhaul as required

b. Every 6,000 RH
1. Exhaust valves – check and overhaul

c. Every 8,000 RH
1. Safety valves – check and overhaul if required
2. Fuel Nozzles – renewal
3. Fuel valves – overhaul and test
4. Foundation bolts – check and fasten as required

d. Every 12,000 RH
1. Cylinder cover – overhaul
2. Stuffing box – check or overhaul depending on condition
3. Crosshead & crankpin bearing – check the condition
4. Camshaft coupling fitted bolts – check the condition
5. Main & thrust bearing – check condition
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6. Air starting valve – check the condition

7. Pistons – overhaul
8. Cylinder liner – overhaul

e. Every 16,000 RH
1. Tie rod - check and fasten as required

f. Every 35,000 RH

1. Turbocharger – overhaul

g. Every 3 months
1. Crankshaft deflection – measurement
2. Crankcase – inspection condition
3. Scavenge – inspection/cleanliness
4. Exhaust gas manifold drain pipe – inspection and clean as necessary
5. Lub oil – send for analysis
6. Fuel leak alarm - test

h. Every 12 months
1. ME Remote Control System – check and service as required
2. Sump tank – check all fittings for tightness

i. Every 5 years
1. Fuel pump – overhaul (as per condition)

2. Auxiliary Engines & Generator

a. Every 1500 RH
1. Fuel injector V/V – drawing out/check/adjustment

b. Every 2000 RH
1. Turbocharger - check/clean
2. Thermostatic V/V - disassembly/check

c. Every 4000 RH
1. Cylinder head top – overhaul
2. Fuel injector – overhaul

d. Every 8000 RH
1. Major overhaul

e. Every Months
1. Crankcase – inspection

f. Every 3-Months
1. Safety devices (lub oil low pressure, CW high temp) – test
2. Alarms and monitoring equipment (Fuel leak tank) – test
3. Governor (over speed/shutdown) – test
4. Lub oil – send for analysis
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3. Auxiliary Steam Boiler & Exhaust Boiler

a. Monthly
1. Boiler safety trips & alarm – check/test
b. 3-Monthly
1. Boiler economizer – inspection and clean
c. 2.5-Years
1. Boiler-Water& smoke space – inspection and clean

d. Every 3000RH
1. Burner Equipment – check and overhaul

4. Purifiers
Maintenance as per maker’s recommendation.

5. Main Air Compressor

Maintenance as per maker’s recommendation.

6. Air-con & Reefer Plant

a. Every 6-Months
1. Check and clean
b. Every 6000 RH or 2 years
1. Compressors – overhaul

7. Incinerator
a. Every year
1. Main burner - overhaul
2. Solenoid valves – overhaul
3. Ignition burner - overhaul

8. Pumps
a. Every 6-Months
1. Pump Motor - Insulation resistance megger test

9. Steering Gear
a. Every Month
1. Alarms system - test
2. Filters/strainers – clean
3. Check for oil leakage

b. Every 3-Months
1. Rudder trunk/post - check

10.13 GUIDELINES ON MAINTENANCE OF CRITICAL ITEMS & FUNCTIONS

A Bridge Navigation and Communication Equipment

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See MPM 10.10 for guidelines on maintenance of the following equipment:

1 Gyrocompass & Auto-pilot
2 Radar, ARPA Radar
3 GPS, DGPS
4 GMDSS Equipment
5 ECDIS

B Safety and Contingency Equipment

1. Emergency generator
a. Weekly
1. Simulation test
2. Battery - check
b. Monthly
1. Lube oils, fuel oil - check
c. 3-Monthly
1. Black out and auto start test
d. Yearly
1. V belt - check, renewal if required
2. Lube oils – renewal
e. 2-Yearly
1. V belt – renewal
2. FO, LO, Air filters – renewal

2. Emergency fire pump

See MPM 10.9.

3. Emergency steering
See MPM 10.12

4. Emergency air compressor

See MPM 10.12

5. Emergency lighting
See MPM 10.8 item 18.

6. Emergency water tight door operation

See MPM 10.9.

7. Lifeboats
See MPM 10.8 item 1.

8. Life rafts
See MPM 10.8 item 4.

9. Oil spill response equipment

a. Weekly
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1. Visual inspection of condition

b. Monthly
1. Check condition
2. Check inventory

C Engine Room Machinery

1. Main engine
See MPM 10.12.

2. Auxiliary engines
See MPM 10.12.

3. Boilers
See MPM 10.12.

4. Steering gears
See MPM 10.12.

5. Fuel & Lubricating oil pumps

See MPM 10.12.

6. Oily Water Separator

a. Weekly
1. Function Test

7. Quick closing valves

a. Monthly
1. Function test
2. Lubricate with grease

8. Bridge ECR Control System

a. 6-Monthly
1. Operation Test

10.14 GUIDELINES ON MAINTENANCE OF CARGO GEARS - DRY CARGO

The following are guidelines for the maintenance of cargo handling gears on board dry cargo vessels.
A. Deck Cranes
The following parts of deck cranes should be inspected and maintenance carried out as required:
1. Monthly
a. Structural parts – To inspect conditions of body & jib paint coating, lubrication of gears &
bearings, foundation bolts and cargo hooks & blocks
b. Safety devices – To check hoisting, slewing & luffing limits are as per maker’s
recommendation and other safety devices
c. Mechanical equipment – Check conditions of hoisting, luffing & slewing brakes and conditions
of hoisting & luffing wires
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d. Hydraulic system – Check oil levels and clean filters

2. Quarterly
a. Mechanical equipment – Carry out pressure check of hoisting, slewing & luffing motors and
pump unit
b. Hydraulic system – check gears & hydraulic hoses conditions & clean oil cooler
c. Electrical equipment – Check space heaters & carry out insulation tests of motors

3. 6-monthly
a. Carry out slip ring inspections & switchboard cleaning

4. Annual
a. Carry out motor maintenance as per maker’s recommendation
b. Carry out Maker technician inspections if required
c. Cargo Gear Survey as per class’s status

5. 5-yearly
a. Renew hoisting & luffing wires, subject to condition and running hours
b. Cargo Gear Survey & load test as per class’s status

B. Grabs
The following parts of grabs should be inspected and maintenance carried out every Month as
required:
a. Structural parts – To inspect conditions of body paint coating & lubrication of bearings,
b. Safety devices – To check magnetic contactors, thermal & auxiliary relays, timers set point,
etc.
c. Mechanical equipment – Check conditions of tugwires & cabtyre cables, roller guides
d. Hydraulic system – Check oil levels and clean filters
e. Carry out function tests.

f. Overhaul electric motor as per maker’s recommendation.

C. Hatch Covers
1. Weekly
a. Visual check Hyd' piping if any leaking, repair as necessary

b. Visual check Hyd' joint if any leaking, repair as necessary

c. Visual check drain valves of hatch coaming, repair as necessary

d. Check the electric connection if any, ensure water tight, and repair as required

2. Monthly
a) Packing(Seals) - Tightness test (Hose test as per manual) on monthly basis, or before cargo
loading
b) Lubrication of moving parts (Wheels, hinge, stoppers, Lub points)
c) Cleats - Adjust compression of elastic washer to be 2-3mm thick by means of nut as
necessary
d) Driving chain/wire rope - Check elongation, adjust it with turn buckle. If unable to adjust,
cut off two links of chain
e) Hydraulic hoses, pipes and couplings, replace as necessary
f) Oil level/condition of the pump unit, refill as necessary
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g) Filter of the pump unit - clean/renew as necessary

h) "Dust seal of Jack cylinder -
i) Check/Renew if damage found"
j) Control stand - Check condition, repair any defect immediately

3. Quarterly
a) Drain valves - Check and renew as necessary
b) Cleats - Lubrication, free/easy up
c) Cleats -To repaired or replaced as necessary
d) Rest pads-To be replaced/repaired if worn or damaged
e) "Wedge stoppers/stowage position lock -To be replaced/repaired if worn or damaged "
f) Hinge pins/eye plates - Check/Lubricate
g) Jack cylinders pins/bearings - Check/lubricate
h) Wheel bearings - Lubricate
i) Wheel condition - Check
j) Gas sampling plugs - Lubricate
k) Ventilators - Check/lubricate
l) Operation valves and shut-off valves - Check
m) Emergency stop button - Check
n) Emergency operation pump - Test
o) Jack cylinders condition - Check
p) Air-breeding of jack head - Check
q) Dust seal of Hyd' motor shaft Check/renew if damage found
4. 6 Months
a) Packing(Seals) - Tightness test (Chalk test, measure as per manual), Repair/renew if any
leakage"
b) Hatch cover and coaming steel structures - Check and rust/corrosion free
c) Piping - Rust/corrosion free
d) Attached bolt, nut, and etc - Rust/corrosion free
e) Bulge/Wasting of Rubber hose - Check, and renew if damage/leakage found
f) Electrical system - Check insulation condition
g) Oil of the pump unit - analysis
h) Control stand - Check condition, rust/corrosion free
5. 2.5 Yearly Docking

a) Packing(Seals)- Permanent set measured as per manual, replace the seals if it greater than
5mm; A tightness test to be carried out after renewal"
b) Hatch cover bearing pads- Check, repair the worn set immediately Check and rust/corrosion
free"
c) Locator & Stopper - Check the presence of the crack and repair the defective part at once"

d) Hatch cover construction- Repair any damage part and paint

D. Lashing Materials
All lashing materials condition should be checked & maintained monthly & inventory updated.

10.15 GUIDELINES ON MAINTENANCE OF STANDBY EQUIPMENT/ MACHINERY

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ISM Code 10.3 requires that the safety management system provides for specific measures aimed at
promoting reliability of critical equipment or systems. These measures should include the regular
testing of standby arrangements & equipment or technical systems that are not in continuous use.
The following are identified as standby items with the guidelines for maintenance to ensure they will
be ready when required. They are covered in the company’s planned maintenance system.

1. Bridge Equipment
a. Ship’s Whistles
Daily - Test operation
b. Binoculars
Weekly - Check condition
b. Sextants
3 Monthly - Check accuracy & condition
c. All Signaling Equipment
Monthly - Check conditions

2. Deck Machinery
a. FO Hose Davits
See MPM 10.11
b. Provision Davits/Cranes
See MPM 10.11
c. Heaving Lines
Monthly – Check conditions & renew if necessary.
d. Wilden Pumps
Monthly – Check conditions.

3. Engine Room Machinery

a. Smoke And Fire Detectors
See MPM 10.9.
b. Engine Room Alarms/Whistles
Weekly – Test operation & functioning
c. Incinerators
See MPM 10.12.
d. Oily Water Separator
See MPM 10.13.

e. Dead-Man Alarm System

Monthly – Carry out operation test.
f. Foam Plant
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See MPM 10.9.8

g. Main Switchboard
6-Monthly – Preferential relay trip test
- Low insulation alarm test
- Reverse power trip test
- Over current trip test

h. Sequential Starting
4-Monthly – each generator as standby auto-start test
- sequential starting test of auxiliary machineries after black-out

4. Cargo Handling Gear

a. Grabs
See MPM 10.14.B
b. Deck cranes
See MPM 10.14.A
c. Portable hydraulic pumps for Hatch covers or hydraulic valves
Monthly – Carry out operation tests