GBT 34001-2016 China Ship Repairing Quality Standard

CONTENT
FOREWORD ......................................................................... IV
1 SCOPE OF APPLICATION ......................................................... 1
2 NORMATIVE REFERENCES ........................................................ 1
3 GENERAL PROVISIONS ........................................................... 2
3.1 Materials for ship repairing .................................................... 2
3.2 Documents for approval ........................................................ 3
3.3 Main inspection list for ship common repairing ................................ 3
4 HULL ............................................................................ 14
4.1 Steel material ................................................................. 14
4.2 Marking ...................................................................... 17
4.3 Cutting ....................................................................... 17
4.4 Forming ...................................................................... 19
4.5 Structure renewal .............................................................. 21
4.6 Reinforcements................................................................. 23
4.7 Doublers on plating .......................................................... 25
4.8 Welding ...................................................................... 26
4.9 Finishing ...................................................................... 30
4.10 Deformation .................................................................. 32
5 DOCK REPAIRING ENGINEERING ................................................ 35
5.1 Shafting ...................................................................... 35
5.2 Propeller ...................................................................... 45
5.3 Rudder system ................................................................ 48
5.4 Steering gear ................................................................. 56
5.5 Side thruster.................................................................. 58
6 MACHINERY ..................................................................... 59
6.1 Main Engine ................................................................. 59
6.2 Prime mover of diesel generator.............................................. 74
6.3 Marine boiler ................................................................. 80
6.4 Marine pumps ................................................................ 86
6.5 Heat Exchanger ............................................................... 97
6.6 Marine sewage treatment plant ................................................ 99
6.7 Marine oil pollution prevention plant ......................................... 100
6.8 Piston-type air compressor .................................................... 102
7 DECK MACHINERY ............................................................. 105
I
7.1 Windlass ..................................................................... 105
7.2 Mooring winch .............................................................. 107
7.3 Marine cargo winch ......................................................... 107
7.4 Life boat davit ............................................................. 109
8 OUTFITTING .................................................................... 111
8.1 Cargo hold hatch cover ..................................................... 111
8.2 Fixed steel ladder ........................................................... 115
8.3 Steel door................................................................... 117
8.4 Side scuttle ................................................................. 118
8.5 Small hatch ................................................................. 120
8.6 Accommodation ladder ........................................................ 122
9 PIPING SYSTEM REPAIRING ................................................... 124
9.1 Pipe ......................................................................... 124
9.2 Valve ........................................................................ 128
10 ELECTRICAL ENGINEERING ................................................... 131
10.1 Cable ...................................................................... 131
10.2 Electric motor .............................................................. 135
10.3 Main switch board and emergency switch board ............................ 139
10.4 Distribution box and control box ........................................... 141
11 AIR CONDITIONING UNIT, REFRIGERATION PLANT AND VENTILATION DEVICE
................................................................................... 142
11.1 Air conditioning unit and refrigeration plant ................................. 142
11.2 Ventilation device ........................................................... 145
12 FIRE-EXTINGUISHING ENGINEERING ........................................... 147
12.1 Water fire-extinguishing systems .............................................. 147
12.2 Fixed fire detection and fire alarm systems ................................ 148
12.3 Fixed gas fire-extinguishing systems ......................................... 149
12.4 Foam fire-extinguishing systems .............................................. 150
12.5 Water mist, water spray and automatic sprinkler systems .................... 152
12.6 Fixed dry chemical powder systems......................................... 153
13 PAINTING ...................................................................... 154
13.1 Steel surface preparation .................................................... 154
13.2 Coating system ............................................................. 156
14 SPECIAL EQUIPMENT.......................................................... 157
14.1 Stainless steel cargo tanks .................................................. 157
14.2 Inert Gas System .......................................................... 159
14.3 Dredger pump apparatus .................................................... 160
14.4 Dredge reamer .............................................................. 163
14.5 Dredger mud bucket ........................................................ 164
II
14.6 Ramp of a RO-RO ship .................................................. 165
14.7 Pilot door of container vessel .............................................. 167
14.8 Lashing bridge and container socket of container vessel .................... 168
REFERENCE ........................................................................ 170
III
FOREWORD
This standard is drafted according to the requirements of GB/T1.1 - 2009.

This standard is proposed by Ministry of Industry and Information Technology of the People's Republic
of China.
This standard is under the jurisdiction of National Sea-going Ships Standardization Technical
Commission (SAC/TC12).
In case of any dispute as to the interpretation, the Chinese version shall prevail.
This standard is drafted and compiled by the experts from COSCO Shipyard Group Co., Ltd., China
Institute of Marine Technology & Economy, COSCO Dalian Shipyard Co., Ltd., COSCO Guangdong
Shipyard Co., Ltd., COSCO Shanghai Shipyard Co., Ltd., COSCO Zhoushan Shipyard Co., Ltd., Tianjin
Shiprepairing Technology Research Institute,Chengxi Shipyard co.,ltd.,China Association of the National
Shipbuilding Industry,China Classification Society,Shanhaiguan Shipbuilding Industry Co.,Ltd., Huarun
Dadong Dockyard CO.,LTD., Dalian Liaonan Shipyard, Yiu Lian Dockyards(Shekou)Co.,Ltd., China
Shipping Industry Co., Ltd., Qingdao Beihai Shipbuilding Heavy Industry CO., LTD., Shanghai Shipyard
Co.,Ltd., Chengxi Shipyard (Guangzhou) CO.,LTD., Dalian Ocean Shipping CO.,LTD., CSSC Huangpu
Wenchong shipbuilding Co., Ltd., Zhoushan Longshan Shipyard CO., LTD., Zhoushan IMC-Yongyue
Shipyard & Engineering Co.,Ltd., Qingdao Qianjin Shipyard, Tianjin Xingang Shipbuilding Heavy Industry
Co., Ltd., Zhoushan Xinya Shipyard CO.,LTD., Fujian Baozhong Ocean Engineering CO.,LTD.
Drafting & editing committee of the standard is listed as below:
Zhan Shuming, Chen Yingtao, Li Zhengjian, Li Qiang, Zhao Zhijian, Wang Zhian, Sun Changling, Li
Tianyi, Chen Yingzhan, Wang Xuebin, Wei Hongyu, Xu Huichao, Zhu Yulei, Gong Weibing, Zhao Guikai,
Zhang Guoxiang, Sun He, Wu Yuhong, Liang Miaosen, Bai Xinjian, Wan Li, Wang Gezhan, Cui Jinhuan, Zuo
Jingmin, Ling Yunfeng, Li Zhuqi, Wei Chonghua, Wang Jiafei, Zhou Yaruo, Gao Xuefeng, Wu Jing, Liu Wei,
Sui Shenghua, Sun Qi, Shi Changbai, Teng Hongda, Zhang Bo, Li Zhongqi, Lei Panfeng, Liu Xue, Zhou Qing,
Yin Qiang, Wang Xianming, Yang Zhongliang, Liu Bin, Li Fubo, Gu Wei, Cai Yuliang, Zhao Shi, Chen Jie,
Tang Jiahe, Song Shuqing, Sun Xuerong, Yao Jun, Cao Jiwei, Zhao Jinwen, Zhou Jinxu, Zhou Jianhua, Sun
Shumeng, Fang Yucuan, Zhu Taiyuan, Fan Weilin, Zhang Shutong, Liu Jingchun, Zhao Lijia, Lin Long, Chen
Xinhua, Li Zhenen, Liu Jin.
English reviewer of the standard is listed as below:
Zhou Qing, Jing Jiangcheng, Guo Xuefeng, Chu Jianshu,Wang Chun.
IV
GB/T XXXXX-XXXX
CHINA SHIP REPAIRING QUALITY STANDARD
1 SCOPE OF APPLICATION
This standard sets forth and specifies the requirements of materials, the main inspection list, the key
points of inspection, the quality requirements for repair, the quality control in the repair process and the
requirements of acceptance for common ship repairing.
This standard applies to common repairs on sea-going steel ships of 500 gross tonnage and above. Other
ships can refer to the standard. The standard shall not apply to ship conversion.
2 NORMATIVE REFERENCES
The following rules and standards are necessary for this document. For the references with an indicated
date, only the dated edition shall apply to this document. For the references without a date, the latest edition
(including all the amendments) shall apply to this document.
GB/T 34000—2016 China shipbuilding quality standard
GB/T 1184—1996 Geometrical tolerancing - Geometrical tolerance for features without individual
tolerance indications.
GB 3766—2001 Hydraulic fluid power - General rules relating to systems
GB/T 6414—1999 Castings - System of dimensional tolerances and machining allowances
GB/T 8923.1—2011 Preparation of steel substrates before application of paints and related products -
Visual assessment of surface cleanliness - Part 1: Rust grades and preparation grades of uncoated steel
substrates and of steel substrates after overall removal of previous coatings
Visual assessment of surface cleanliness - Part 2: Preparation grades of previously coated steel substrates after
localized removal of previous coatings
Visual assessment of surface cleanliness - Part 3: Preparation grades of welds, edges and other areas with
surface imperfections
Visual assessment of surface cleanliness - Part 4: Initial surface conditions, preparation grades and flash rust
grades in connection with high-pressure water jetting
Surface roughness characteristics of blast-cleaned substrates - Part 2: Method for the grading of surface profile
of abrasive blast-cleaned steel - Comparator procedure
IMO/MSC.215（82） Performance standard for protective coatings for dedicated sea water ballast tanks in
all types of ships and double-side skin spaces of bulk carriers (PSPC)
1
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3 GENERAL PROVISIONS
3.1 Materials for ship repairing
3.1.1 General requirements of materials
General requirements of materials are as below:

a) Requirements of the materials used in ship repairing shall be in accordance with the original ship;
b) The materials intended for use in ship repairing shall be produced as per the types and grades by the
suppliers with industry qualification;
c) The materials used in ship repairing shall be provided with a product certificate according to the
requirements of the classification society. In special cases or for small amount of materials, it can be
replaced by other materials, but shall be approved by the classification society;
d) For "Transfer of Class", the materials shall be as per the requirements of the classification society;
e) If the material used in ship repair is different but equivalent with original ship, the equivalent
material grade shall be evaluated by the classification society, and the evaluation shall include at
least the following:
1) Heat treatment / delivery status;
2) Chemical composition;
3) Mechanical properties;
4) Negative tolerance of thickness.
3.1.2 Material substitution principles for steel plate
The steel plate's thickness not more than 50 mm and the steel grade max to EH40, the principles of
material substitution for steel plates is as below:
a) For the steel plates with same strength properties, the high grade steel can substitute the low grade
steel;
b) Higher-strength steel can substitute ordinary-strength steel;
c) For the steel plates with same strength properties, thick plate can substitute thin plate;
d) If the lower strength steel is intended to substitute the higher strength steel, it shall be calculated and
approved by classification society.
3.1.3 Material substitution principles for profile
The principles of material substitution for profiles is as below:

a) The material grade of substituted profile shall be in accordance with the requirements of 3.1.2, the
section modulus of substitute profile (including effective plate) shall not be less than the original
design, and the substitution shall be approved by classification society;
b) If the profile is a welded structure, the section modulus shall be in accordance with the above
requirements.
3.1.4 Material substitution principles for pipe
The principles of material substitution for pipes is as below:
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GB/T XXXXX-XXXX
a) The mechanical properties of the substituted pipe shall be no less than the original pipe. The higher
grade pipe can substitute the lower grade pipe. Seamless pressure pipes shall not be substituted by
welded or cast pressure pipe;
b) For the pipes with the same material grade, the pipe with larger wall thickness can substitute the pipe
with a smaller wall thickness, but the internal diameter shall be not less than the original pipe.
3.1.5 Material substitution principles for paints
The principles of material substitution for paint is as below:

a) The type of substituted paints shall be in accordance with original paints;
b) High performance paint products can substitute the low performance paint products, and the dry film
thickness shall be adjusted according to the requirements of the paint supplier;
c) The same type of surface paints with different colors shall not be substituted with each other;
d) Special paints for special tanks shall not be substituted.
3.1.6 Equipment renewal principles
The principles of equipment renewal is as below:

a) The performance of the new equipment shall not be less than the design performance of the original
equipment;
b) The technical specification of the new equipment shall be in accordance with the requirements of
relevant rules and standards;
c) Certificates approved by classification society shall be provided for new equipment.
3.2 Documents for approval
For common repairs, the approval of classification society may not be necessary. For local conversion or
renewal, the repair procedure shall be carried out and the technical documents shall be submitted to
classification society for consideration in advance.
3.3 Main inspection list for ship common repairing
3.3.1 Explanation
The inspection list in this document provides key inspection items to be submitted to Surveyor and Owner.
The list can be increased or decreased as per the different requirements of ship type, service limitation and flag.
According to the repair progress, the Builder shall invite the Owner and the Surveyor to attend the inspection
as per below requirements:
a) Inspection declaration shall be submitted to Owner and Surveyor before the end of the working day;
b) The Owner and the Surveyor shall be promptly advised if the inspection will be delayed;
c) The inspection for painting can be an exception to the above.
3.3.2 Hull
The inspection list for hull shall be in accordance with the requirements in Table 1.
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GB/T XXXXX-XXXX
Table 1 Inspection list for hull
No. Items Content Stage Surveyor Owner

1 Hull steel plates and profiles Material quality certificates and Before
2 Welding consumables visual inspection installation
Structural integrity and visual After
inspection of quality of welding completion
Back gouging inspection for all areas After back
3 Hull structure
of FPW (full penetration welding) gouging
After
Non-destructive examination √ √
completion
Before
Installation validity
Important equipment foundation welding
4 (e.g. generator, hydraulic cylinder After

Visual inspection of welding seam
seat of hatch cover) completion
Before
Sub structural reinforcement
5 Foundation of windlass and winch welding
Note: Symbol “√” indicates an inspection is necessary, Symbol “─” indicates no inspection is necessary.
3.3.3 Dock repairing
The inspection list for dock repairing shall be in accordance with the requirements in Table 2.
Table 2 Inspection list for the dock repairs

Dimension verification After marking
Load line and
1 After √
draft marks Accuracy of installation
installation
Sacrificial
anodes and
2 impressed Correctness and integrality of assembly
current
After ─
protection
completion
Funnel marks √
3
and ship name Dimensions and installation position
4 Hull marks
5 Drain plug Correctness and integrality of assembly
Status of cleaning and lapping Before
6 Sea chest valve √
Hydraulic test installation
7 Bottom plug Vacuum test
After
Hydraulic Integrality of installation ─
8 completion
steering gear Performance test √
4
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Table 2 (continued)

Alignment of fore flange and after flange of intermediate
shaft
Clearance of intermediate shaft bearing
Intermediate bearing load test

Stern tube measurement and installation
Propeller shaft and stern tube measurement During
9 Shafting Tail shaft bearing measurement fabricating
Tightness test after stern tube seal installation
Propeller shaft and stern tube bearing wear down

measurement
N.D.T. for root of taper part and keyway of stern shaft
Operational test of shafting After

Inspection of propeller blade separating completion
Pitch measurement and static balancing test √
Before √
Taper hole fitting，checking the fit between key and
installation
keyway
10 Propeller
Before
N.D.T for root of propeller blade
installation
After
Installation verification
completion
Sighting for rudder system and shafting to be checked for
boring, Before
Measurement and verification of the rudder stock , rudder installation
pintle and rudder bearing.
Rudder After
11 Rudder bearing clearances measured
system completion
Rudder construction centre verification and zero During
position confirmation fabricating

After
Steering gear test √
completion
Bow thrust During
12 All mechanical parts cleaned and measured ─ √
equipment fabricating
3.3.4 Machinery engineering
The inspection list for machinery engineering shall be in accordance with the requirements in Table 3.
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Table 3 Inspection list of machinery engineering

Position and installation Before installation ─
Liner fitting/epoxy cast √
Measure the crankshaft deflection After completion
─
Tighten up holding down bolt
Holding down bolt N.D.T
Coloring of the main bearing resting on the bed
plate fitting
Check the alignment of crankshaft, surface
repairing and N.D.T.
Main bearing, connecting rod bearing and cross
head bearing to be disassembled and checked,
√
and the clearance to be measured.
Cylinder liner inspection, repair and
measurement Before installation
1 Diesel engine
Piston and piston rod inspection, repair and
measurement
Gudgeon pins and cross head pins inspection
and measurement
Piston re-assembly and alignment inspection
Cylinder cover and piston Tightness test √

Indicator cock, starting air valve, exhaust valve
and fuel injector to be Tightness tested ─
Injection pump inspection, timing adjustment
Before installation
Governor repair, inspection and workshop test
Governor operation test

After completion
Full operation test and load test
Turbocharger disassembly, cleaning,
measurement, and re-assembly
Before installation √
2 Turbocharger Turbocharger rotor inspection and dynamic
balancing testing checking
Turbocharger operational test After completion
3 Heat exchanger Heater and cooler cleaning and Tightness test ─

Before installation
Crane (disassemble, Steel wire renew and installation

repair, main parts Operation function test, load test, brake test
4 √
renewal and After completion
Loading test
installation)
6
GB/T XXXXX-XXXX
Table 3 (continued)

Boiler tube strength test and Tightness test.
Before installation
Tube/tube plate assembly and weld inspection
5 Boiler Boiler cleaned and inspected, and hydraulic test √
Raising steam performance test
Pressure gauge verification
Various pumps (sea
After completion
water, fresh water,
6 lub oil, fuel oil, Installation inspection and operational test
─
cargo oil, hydraulic
oil etc.)
Disassemble, repair, inspection
7 Safety valve
Workshop test Before installation
Main compressed Disassemble, repair and inspection, Tightness test
8
air valve Performance test After completion
Disassemble, repair, inspection and Tightness test Before installation
9 Main steam valve
Performance test After completion
10 Ship side valve
Fore √
11 Ship side pipe Fit, welding, Tightness test welding/After

welding
√
Ballast water Disassemble, repair, inspection and Tightness test Before installation
12 remote control After

System function test
valve completion
13 Cargo oil valve
14 PV valve
15 Breathing valve Workshop test and function test
Piping fabrication
16 Hydraulic test in the workshop
in the workshop Before installation
Hydraulic pipe, lubrication oil pipe, and fuel pipe
cleaning and inspection ─
17 Piping installation Checking integrality of pipe assembly
CO2 pipe flow through test After completion
√
Tightness test of pipe system
7
GB/T XXXXX-XXXX
Table 3 (end)
Starting air
18 Operational test
compressor
After completion
All pipe systems in Tightness test of pipe systems and system
19
the vessel function test
Bottle valve inspection and Tightness test
Compressed air
20 Strength test
reservoir √
Tightness test Before installation
21 Fan Impeller dynamic balancing checking
Oil tank outfitting Tightness test
22 √
repair Installation checking and performance test
23 Pressure water tank Tightness test and performance test
24 Oily water separator
25 Purifier ─
Sewage treatment
26 Performance test √
equipment
27 Fresh water generator
Fresh water Disassemble, repair and inspection Before installation ─
28
depurate plant
3.3.5 Deck machinery and outfitting
The inspection list for deck machinery and outfitting shall be in accordance with the requirements in
Table 4.
Table 4 Inspection list of deck machinery and outfitting

Brake test
Anchoring test
Anchor, anchor chain and fitting’s
Mooring winch , windlass， material quality documents
1
anchor and anchor chain Anchor, anchor chain visual inspection √
After completion √
Anchor, anchor chain and fittings visual
inspection of embossing seal mark
Anchor chain ring measurement
2 Mooring equipment Correctness and integrality of assembly ─
3 Pilot ladder Correctness and integrality of assembly √
8
GB/T XXXXX-XXXX
Table 4 (continued)

Integrality of assembly and quality of
welded seams
4 Cargo hatch covers
Tightness test
Operation test
Water-tight doors and Tightness test
5
weather-tight doors Operational test
6 Container Securing devices Correctness of assembly
Compartment fireproof
7 Integrity of fireproof material
material
Boom and drum body welded seam
surface checking After completion
8 Hoisting equipment Welded seam N.D.T.

Crane operation test
Loading test
Cabinet tank, oil tank and
9 water tank repair and Tightness test √
fabrication
Load test and Tightness test for the
lifeboats
√
10 Life-Saving Appliances Boat recovering test
Boat lowering function test
Steel wire renew and installation

Before installation
Cargo gear crane Steel wire renew and installation
(disassemble, inspection Operational test
11
and main parts renew and After completion
Load test
installation)
Accommodation ladder Steel wire renew and installation Before installation
12
and main parts renew and After completion
Load test
installation)
Provision crane Steel wire renew and installation Before installation ─
13
and main parts renew and After completion √
Load test
installation)
Slewing hatch cover winch Steel wire renew and installation Before installation ─
14
and main parts renew and After completion √
Load test
installation)
9
GB/T XXXXX-XXXX
Table 4 (end)

Switch hatch cover winch Steel wire renew and installation Before installation ─
15 (disassemble, repair and √
inspection)
Operation test, load test After completion √
3.3.6 Electrical engineering
The inspection list for electrical engineering shall be in accordance with the requirements in Table 5.
Table 5 Inspection list for electrical engineering part
No. Items Contents Stage Surveyor Owner
Before
Cable pipe on main deck fabrication ─
Electrical outfitting installation
1
Cable tray installation After √
Completeness of cable laying completion
Measuring of insulation resistance ─
2 Main cable laying Measuring of cable core breaking After
High-voltage endurance test for HV installation
cable
Check all cable penetrations installation √

After
3 Cable penetrations
Check tightness of all cable installation
penetrations √
Check the correctness of installation &
√
cable connection
Check for maintenance & cleaning ─
Measure insulation resistances √
Test protective devices
Main switchboard &emergency After √
4 Test ACB effective function
switchboard completion
Meter calibration, check accuracy of the
─
meter indication
Test electric inter-locking function
Full function test √
Check the completeness of the system
10
GB/T XXXXX-XXXX
Table 5 (Continued)

cable connections ─
Check for maintenance & cleaning
Alarm device test √
5 Generator set(s) Measure insulation resistance ─
Loading characteristics test
Parallel operation test
√
Automatic operation test
cable connections
Check for maintenance& cleaning ─
Measure insulation resistance
Alarm device test
6 Emergency generator set(s)
Automatic start test
Power supply test
Loading characteristics test After
Automatic power supply test completion
√ √
Alarm test
Battery charging & discharging
7 Function test
panel, batteries
High voltage endurance test
Test run without loading, effective
motor function test of the alternator
after overhaul
Test for no-load,test for effective
function, and measure the cold state /
Electromotor, alternator and hot state insulation of electromotor &

8 ─
alternator
control device
Rotor dynamic balancing
Testing of brake device
Testing of alarm functions
Check the earthing cable & earthing
reliability
11
GB/T XXXXX-XXXX
Table 5 (Continued)
Emergency stop system for the oil

9 Function test
pump & ventilator
10 Normal lighting Function test

11 Emergency lighting Function test

√
& the rudder angle indicator
12 Steering gear Alarm test
Steering operation test
Interior alarm system (including
fire alarm system, CO2 release
alarm system, general alarm
system, cold chamber call alarm After
13 Function test
system, hospital call system, completion √
watertight door indicator system,
E/R column alarm system, etc.)
Interior communication system
(including public address & talk
back system, auto telephone
14 system, sound power telephone Function test

system, electric quartz clock,
─
marine broadcast & TV system,
local-area network system, etc.)

15 Galley electrical equipment
Function test
16 E/R water mist system Function test
Testing of alarm function

Navigation lights & signal light √
17 Function test
system
12
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Table 5 (End)
Clean view screen & window After

18 Function test ─
wiper system completion
19 ICCP, shaft earthing system
20 Echo sounder
Effectiveness test
21 Speed log
22 Tyfon system
Error calibration and effectiveness
23 Magnetic compass
test
24 Gyro compass √
25 GPS
26 Radar
27 Auto identification system
28 ECDIS
29 Bridge nautical alarm system
30 Autopilot system
31 VDR Effectiveness test
32 NAVTEX √
33 Weather facsimile After finish ─

34 VHF
35 GMDSS radio console
Inmarsat system earth station
36
system
37 SART
Annual simulation test or
38 EPIRB
maintenance ashore
Testing of alarms
39 M/E maneuvering system Testing of M/E telegraph device √
M/E maneuvering operational test
Function test or simulation test for
alarm points
Function test for engineer watch
40 E/R monitoring & alarm system
duty alarm
Effectiveness test for unmanned E/R
automatic operation
41 VRC & LRM system Function test
13
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3.3.7 HVAC
The inspection list for HVAC shall be in accordance with the requirements in Table 6.
Table 6 Inspection list for HVAC part

Air conditioning system, refrigeration
After
1 system (pipe system modification or Performance test ─ √
completion
equipment renewal)
3.3.8 Painting
The inspection list for painting shall be in accordance with the requirements in Table 7.
Table 7 Inspection list for painting
Paint
manufacture
Rust Steel surface
After rust removal
removal Cleaning
1 ─ √ √
and
Dry film thickness After completion
painting
2 TBT free antifouling √ ─ ─
3 The Coating Technical File (CTF) for PSPC √ ─ ─
4 HULL
4.1 Steel material
4.1.1 Quality requirements for steel material
4.1.1.1 Minus tolerance thickness for steel plate of hull structure shall be in accordance with the
requirements in Table 8.
Table 8 Minus tolerance thickness of hull structural steel plate Unit: mm
Items Limits
Minus tolerance thickness of hull structural steel 0.3
The mean thickness of the steel plate to be measured shall not be smaller than the nominal thickness of the plate, and the upper
limit shall be in compliance with relevant standard or the contract
4.1.1.2 Minus tolerance thickness for steel plate of machinery structure shall be in accordance with the
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Table 9 Minus tolerance thickness of machinery structural steel plate Unit: mm
Thickness t0 Limits
≥5～8 0.4
≥8～15 0.5
≥15～25 0.6
≥25～40 0.8
≥40 1.0
4.1.1.3 Surface defects of steel plate shall be in accordance with the requirements in Table 10.
Table 10 Limits of surface defect of steel plate
Items Requirements
d0 1) Zone A is in an excellent condition, with very slight surface defects less
0.90 than 0.15 mm and no repairs are needed;
t1 50mm
0.80 2) Zone B is in a good condition, with a certain amount of permissible
D E
0.70 surface defects, the plate thickness is less than 20 mm and no repairs
t
D 1 50mm
Hard spot, peeling, rolling skin, nick and air cavity
0.60
20mm t1 50mm
are needed;
0.50
C 3) Zone C is in a good condition, with a certain amount of permissible
0.40
B surface defects, the plate thickness is from 20 mm to 50 mm and no
0.30 t1 20mm
0.20 repairs are needed;
0.15
0.10 A 4) Zone D is in a good condition, with a certain amount of permissible
0 5 10 15 20 surface defects, the plate thickness is more than 50 mm and no repairs
Defect area ratio,% are needed;
d0— depth of defect, mm; 5) Zone E is in a bad conditon and repairs are needed, the repair methods
t1 — thickness of steel plate, mm for surface defects are:
d0<0.07t1 (and d0≤3), by grinding;
0.07t1≤d0≤0.2t1, by built-up welding and followed by grinding.
In the case where the depth of defect exceeds 20% of the plate
thickness, and defect area exceeds 2% of the plate area, this part of
plate shall be replaced according to the requirements in Table 11
“Severe lamination”
4.1.1.4 The lamination of steel plate shall be treated in accordance with the requirements in Table 11.
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Table 11 Treatment for steel plate lamination
Items Requirements
1) If the area of lamination is less than 2% of the plate area, and the defect is less than
20% of the plate thickness, it can be chipped out and built-up by welding as shown
Local lamination
in sketch (a);
2) If the area of lamination is less than 2% of the plate area, and the defect is near the
(a) (b) plate surface, the remedial can be carried out by re-welding as shown in sketch (b);
3) If the length of lamitation welding exceeds 20% of the plate edge length, NDT is
required for checking quality of welding
1) If the area of lamination is more than 2% of the plate area, and the defect is more
than 20% of the plate thickness, it is recommended that the remedial action shall
be by local insert plates as shown in sketch.(c);
Severe lamination
2) The minimum breadth or length of the plate to be replaced shall be:

1600 mm for shell and strenth deck plating in way of cruciform or T-joints;
800 mm for shell,strength deck plating and other primary members;
(c) 300 mm or 10 times plate thickness (whichever is greater) for other structural
members.;
3) If the lamination area reaches 5% of the plate area and the depth of defect reaches
above 20% of the thickness, the whole steel plate shall be replaced
4.1.1.5 Defect treatment for cast steel surface shall be in accordance with the requirements in Table 12.
Table 12 Defect treatment for cast steel surface
Items Requirements
Severe defect (the depth of defect is over 20% of the plate thickness or Repair and building up by specified processing method
the defect is over 25 mm in depth and 150 mm in length) and NDTshall be done
Chipping out and then grindingaccording to specified
Ordinary defect（the defect is less thanthe above description）
processing method and NDT shall be done
4.1.2 Quality control of repairing process
4.1.2.1 The steel material shall be provided with the approval mark of the classification society, material
traceability procedure and product quality certification.
4.1.2.2 Necessary pre-treatment such as flattening, straightening and derusting are to be carried out for
steel plates and profiles before cutting (which includes pitting treatment).
4.1.2.3 The visual inspection for steel materials shall be done after pre-treatment completion, and the steel
material shall be free of visible air bubbles, flow hole, scraps, crack, tension fractures, slag and oxide skin. In
addition, the negative thickness tolerance and flatness of the steel plate are to be checked.
4.1.2.4 The chemical composition and mechanical properties of the new plate shall be the same as or
equivalent to the original plates.
4.1.2.5 The thickness of new plate shall be no less than the thickness of original plates.
4.1.2.6 The rolling direction of renewal shell plates, deck plates, tank top plates and longitudinal bulkhead
plates are to be placed along ship’s longitudinal direction.
16
GB/T XXXXX-XXXX
4.1.2.7 Key points for the quality control of steel material are:
a) The size, specification, heat number and batch number;
b) The minus tolerance in thickness for plates and sections;
c) The surface qualities;
d) Any defects in large forgings and castings.
4.2 Marking
4.2.1 Quality requirements of marking
4.2.1.1 Position deviation of the marking shall be in accordance with the requirements in Table 13.
Table 13 Position deviation of the marking Unit: mm
Items Standard range Allowable limit Remark

Centerline, theoretical line, alignment line, check
≤1.5 ≤2.5 —
line and installation position line
4.2.1.2 Deviation of marking lines for structure elements shall be in accordance with the requirements in
Table 14.
Table 14 Deviation of marking lines for structure elements Unit: mm
Length ±2.0 ±3.0

—
Breadth ±1.5 ±2.5
Difference between diagonals ±2.0 ±3.0 For rectangular plates
Curved configuration ±1.5 ±2.5 —
l0≤4m 1.0 1.5

l0——length of straight edges of
Straightness 4m＜l0≤8m 1.5 2.0
part or member
l0＞8m 2.0 2.5
Angle For every meter

±1.5 ±2.0
Cut out, opening —
4.2.2.1 Material properties, heat number, batch number and thickness shall be recorded for primary
members according to the requirements.
4.2.2.2 Key points for the quality control of the marking are:
a) Dimension deviation;
b) Geometric tolerance;
c) Markings such as processing symbols, codes and marks;
d) Markings of material properties and batch number shifting to margin plate.
4.3 Cutting
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GB/T XXXXX-XXXX
4.3.1 Quality requirements of cutting
4.3.1.1 The surface roughness of gas cutting shall be in accordance with the requirements in Table 15.
Table 15 Surface roughness of gas cutting Unit: mm

Automatic gas cutting 0.10 0.20
Important parts
Edge free Manual, semi-automatic gas cutting 0.15 0.30 a) Use manual
of members Non-important Automatic gas cutting 0.10 0.20 gas cutting for
parts Manual, semi-automatic gas cutting 0.50 1.00 section bars;
Automatic gas cutting 0.10 0.20 b) Remove the
Important parts
Welded Manual, semi-automatic gas cutting 0.40 0.80 burr on free
edge Non-important Automatic gas cutting 0.10 0.20 edges
parts Manual, semi-automatic gas cutting 0.80 1.50
4.3.1.2 The dimension deviation and geometric tolerance of gas cutting shall be in accordance with the
Table 16 Dimension deviation and geometric tolerance of gas cutting Unit: mm
Standard Allowable
Items Remark
range limit
Straightness Automatic welding seam 0.4 0.5
of plate edge Semi-automatic and manual welding seam 1.5 2.5
0
Angle of groove θ0 ±2° ±4°

—
d 1 d1
Dimension of Depth of groove d1 ±1.5 ±2.0

groove
l1 According to the requirements of

Length of transitional
±0.5d2 ±1.0d2 classification society, l1 can be
section l1
d2
3d2,4d2 or 5d2
e.g. members with high

Primary members ±2.5 ±4.0 requirement such as floors and
Dimension girders in double bottom
of members Secondary members ±3.5 ±5.0
+ 4.0 —
Breadth of flange ±2.0
- 3.0
4.3.2 Quality control of repair process
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GB/T XXXXX-XXXX
4.3.2.1 Cable, piping and equipment that blocks the way shall be removed before cutting, and
corresponding protective measures shall be taken to fit them back after cutting.
4.3.2.2 Oxide layer near the cutting area shall be removed and ground after cutting, and the deformation
near the cutting area shall be corrected.
4.3.2.3 Key points for the quality control of cutting are:
a) Cutting accuracy;
b) Cutting direction of groove;
c) Regular inspection for accuracy of NC cutting equipment.
4.4 Forming
4.4.1 Quality requirements for forming
4.4.1.1 Deviation of flanges shall be in accordance with the requirements in Table 17.
Table 17 Deviation of flanging Unit: mm

Breadth of flange, b0 b0
±3.0 ±5.0 ─
θ1
Depth of web, h0
r0
Angle of flange, θ1 ±2.5 ±4.5 Per 100 in breadth
h0
≥3t2
Flanging bending radius, r0 t2 2t2 ─
≥4.5t2(applicable for CSR ship)
Straightness in the plane of flange Per 10 m in
10 25
Straightness in the plane of web length
4.4.1.2 Deviation of corrugated plate shall be in accordance with the requirements in Table 18.
Table 18 Deviation of corrugated plate Unit: mm

Depth of corrugated, h1 1
±3.0 ±6.0 ─
Breadth of corrugated, b1、b2
h1
b2
Straightness of corrugated 10 25 Per 10 m in length
4.4.1.3 Deviation of cylinder shall be in accordance with the requirements in Table 19.
Table 19 Deviation of cylinder Unit: mm
D0
±D0/200 ±D0/150
Diameter of cylinder, D0 ─
Maximum ±5 Maximum ±7.5
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GB/T XXXXX-XXXX
4.4.1.4 Bending deviation of profiles and built-up profiles shall be in accordance with the requirements in
Table 20.
Table 20 Bending deviation of profiles and built-up profiles Unit: mm
Standard Allowable
Items Remark
range limit
0
Angular
deformation, ±1.5 ±2.0 Per 100 in h2
2
δ0
Profiles
λ
Local bending Per 1m in length.
±1.0 ±1.5
λ 1000 Compared with template.
girder
Bending δ1 Per 10 m in length.
δ 1
sample ±2.0 ±4.0
deviation, δ1 Compared with template.
Inclination of
±1.5 ±3.0 Per 100 in b3
flange, δ2
3
4
δ3
Built-up Angular
profiles deformation ≤3+b4/100 ≤5+b4/100 ─
of flange, δ3
Straightness
of flange and 10 25 Per 10 m in length
web
4.4.1.5 The bending deviation of shell plate shall be in accordance with the requirements in Table 21.
Table 21 Bending deviation of shell plate Unit: mm
Single-cu Gap between curved face and template

≤2.5 ≤5.0 Within
rved plate Straightness of check line on triangular template
each
Deviation between drawn line and reference line on template ±2.0 ±3.0
Double-c frame
urved Gap between plate and box template in breadth direction. ≤4.0
plate ≤5.0 spacing
Gap between plate and box template in lengthwise direction ≤3.0
4.4.1.6 Steel heating shall be in accordance with the requirements in Table 22.
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GB/T XXXXX-XXXX
Table 22 Requirement of steel heating

Water cooling after
Below 650 ℃ 650 ℃
heating
High-strength steel
（AH32-EH32 & Air cooling after
AH36-EH36） Below 900 ℃ 900 ℃
heating
TMCP high-strength
Between 900 ℃ and Between 900 ℃
steel（AH36-EH36） Formula for
Air cooling and then 500 ℃ and 500 ℃
Ceq>0.38％ water cooling after carbon equivalent
(air cooling) (air cooling)
heating Below500 ℃ Below500 ℃ Ceq ：
Maximum (water cooling) (water cooling)
TMCP high-strength C eq=C+
heating temp. 6
steel（AH32-DH32 & Water cooling or air
cooling immediately Below 1000 ℃ 1000 ℃ Cr+Mo+V
of surface AH36-DH36） +
after heating 5
Ceq≤0.38％ Ni+Cu
+
TMCP high-strength Water cooling or air 15
steel（EH32-EH36) cooling immediately Below 900 ℃ 900 ℃
Ceq≤0.38％ after heating
Between 900 ℃ and Between 900 ℃
TMCP Air cooling and then 500 ℃ and 500 ℃
water cooling after (air cooling) (air cooling)
low-temperature steel heating Below500 ℃ Below500 ℃
(water cooling) (water cooling)
Note: Refer to GB 712—2011 for the information of steel material and grade.
4.4.2.1 Forming by cold or hot bending of steel plates and profiles shall be performed according to the
specified requirements based on material properties and grades.
4.4.2.2 Key points for the quality control of forming:
a) Heating temperature;
b) Number of times of heating;
c) Radius of cold bending;
d) Accuracy of forming;
e) Surface quality.
4.5 Structure renewal
4.5.1 Key points for the survey
The key points for the survey ofstructure renewal are as below:
a) Corrosion, deformation and damage of structural members are to be inspected;
b) Mark the structural members needing to be repaired;
c) Protective measures are to be considered for oil tank, piping, cable and equipments when inspecting
the structural members in fore ship, aft ship and engine room.
4.5.2 Quality requirements for the structure renewal
4.5.2.1 The deviation when assembling welding joints and structural members shall be in accordance with
the requirement of GB/T 34000—2016 5.1.6.1 and 5.1.6.2 accordingly.
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GB/T XXXXX-XXXX
4.5.2.2 Renewal of steel plate shall be in accordance with the requirements in Table 23.
Table 23 Renewal of steel plate Unit: mm
Items Standard range Allowable limit Treatment

Welding procedure ①→②
Length, L0
2 L0 2
≥300 ≥200
B0
Breadth,B0 2 1 2
Rectangular plate insert
L0 2
≥5×thickness
2
B0
Radius, R0 —
and ≥100 R0
1 2
Circular plate insert Diameter, D1 ≥200 — —
4.5.2.3 Renewal of profile or built-up profile shall be in accordance with the requirements in Table 24.
Table 24 Renewal of profile or built-up profile Unit: mm
Items Standard range Allowable limit Treatment

Welding procedure ①→②→③→④
3 L1 3
3
Insert length of
≥300 ≥200 2 1
profile, L1 150 150
4 4
4
4.5.2.4 The structure in large areas to be cut and renewed shall be fabricated in blocks.
The requirement of block assembly shall be in accordance with GB/T 34000—2016 5.1.6.3.
4.5.3 Quality control for the repairing process
4.5.3.1 The cutting line of the damaged plate shall be set at the location of original plate seam.
4.5.3.2 Before fitted into the ship structure, curved structural members are to be pre-formed using proper
shape templates.
4.5.3.3 Structural members are fitted up by dog plate or tack weld, the quantity of which shall be as few as
possible. The welding consumables for tack weld shall be same as the executable weld. The defects in the tack
welds shall be cleared up before welding.
4.5.3.4 The welding seam joined with new plate shall be welded first.
4.5.3.5 The original joint shall be extended and cut, and the length of cutting shall not be less than 150 mm.
4.5.3.6 When structural members need to be cut and renewed in large areas, hull deflection measurements
shall be taken before cutting and the result is to be recorded.
22
GB/T XXXXX-XXXX
4.5.3.7 Large scale renewal of structural members shall be done in a controlled sequence. Calculations for
strength and deformation shall be carried out if necessary and the proper reinforcement measures shall be
applied as per the calculation results.
4.5.3.8 Large scale renewal for structural members in water shall be done under reasonable ballast
condition which can reduce the loads on the hull as far as possible.
4.5.3.9 Key points for the quality control for structural renewal are:
a) Geometrical dimensions of structural members;
b) Assembly clearance;
c) Structural alignment accuracy;
d) Straightness of internal members.
4.5.4 Inspection & test for acceptance
Inspection & test for acceptance for structural renewal are:

a) A visual inspection for steel material and welding consumables shall be carried out, and the material
quality report and classification society certification shall be provided;
b) Check fabricating accuracy of structural members;
c) Check the bevel and assembling accuracy;
d) Check structural integrity.
4.6 Reinforcements
4.6.1 Quality requirements for reinforcements
4.6.1.1 Application of doubling straps end treatment shall be in accordance with the requirements in Table
25.
Table 25 Doubling straps end treatment
L2
Tapering L2/b5≥3 — Assymmetrical arrangment
R1
Strap
b5
Radius, R1 0.1b5 ≥30 mm Increased throat

thickness
Symmetrical arrangment L2
Throat thickness to Strap

b5
Weld size —
be increased 15％
Increased throat
thickness
4.6.1.2 Reinforcements for opening shall be in accordance with the requirements in Table 26 and Table 27.
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GB/T XXXXX-XXXX
Table 26 Reinforcement condition for openings Unit: mm
Items Requirements Remark
Requirements There shall be no opening within area Δ. Any

200 200 200
of opening opening cut within area Δ shall be approved by 200
position theengineering department.
Δ Δ Δ Δ
Reinforcement is required when a circularopening in

a frame or longitudinal space is cut and satisfiesany
condition shown as below:
1) d3＞25％H0
deck
2) 25％H0≤c0≤40％H0
H0
d3 —— opening diameter; web beam(stringer)
Reinforcemen d3
c0
H0 —— height of web of the beam;
t conditions
c0—— distance between lower edge of opening and
for circular
front panel of beam.
opening
Reinforcement is required when more than one S0
circular opening in a frame or longitudinal space are

deck
cut and satisfiesany condition shown as below:
web beam
1) Each of the circular opening cut satisfies the d4 (stringer)
d5 longitudinal beam
condition with reinforcement; (cross beam)
2) （d4+d5+……）＞60％S0
S0 —— spacing between frames
Reinforcement is required when aan elongated S1
opening in a frame or longitudinal space is cut and
satisfies any condition show as below:
deck
1) b6＞25％H1
b6
H1
web beam
2) l2＞60％S1或l2＞H1 (stringer)
Reinforcemen l2
3) 25％H1＜c1＜40％H1
c1
longitudinal beam
t conditions (cross beam)
l 2—— length of opening
for kidney
openings Reinforcement is required when more than one
l3 l4
kidney opening in a frame or longitudinal space are deck
cut and satisfiedwith any condition shown as below: web beam

(stringer)
1) Each of the kidney opening satisfies the
longitudinal beam
condition with reinforcement; (cross beam)
2) （l3+l4）＞60％S2 S2
24
GB/T XXXXX-XXXX
Table 27 Reinforcement requirement for opening cuts
Items Requirement Remark

The material of the doubler shall be the same as that being
reinforced,and t3≥t4, l5≥30 mm;
t3 —— thickness of doubler plate; beam web plate deck
ι5
pipe
Reinforcement t4 —— thickness of web plate;
d6≤60%H2
H2
with doubler l5—— overlap distance between doubler plate and web plate;
plate H2 ——height of web of the beam; t3 reinforced
doubler plate
t4
c2
c2 ——distance between lower edge of opening and front face plate of beam
panel of beam;
d6 ——opening diameter.
The material shall be same as that of the base material if it is a
ring plate. If stainless steel is used,then use steel brand 10,15
and 20 and weld it to the web plate by double side continous
deck
t5
welding. The sum of the area of the upper and lower web
plates on the same ring plate shall be equivalent to, or larger ring plate
d 7≤60%H3
H3
Reinforcement than, the cross sectional area of the opening on beam web
with ring plate plate. And t5≥t6 web plate of beam
face plate of beam t6
c3
t5 —— thickness of ring plate;
H3 ——height of web of the beam;
c3 ——distance between lower edge of opening and front
panel of beam;
d7 ——opening diameter.
4.7 Doublers on plating
4.7.1 Quality requirements for doublers on plating
4.7.1.1 Doublers on plating shall be in accordance with the requirements in Table 28.
Table 28 Doublers on plating Unit: mm

Original thickness of base
— ≥5 Ld
plating, tp
longi.
Thickness of doubler, td tp/3≤td≤tp — R2
Area of doubler,Ld×Bd — ≥300×300

Bd
td
Radius, R2 — ≥50
d8
Normal size of slot （80～100）×2td — tp

Pitch
Distance from doubler edge and Slot
≤15td ≤500
between slots,d8
Distance between slots — ≤200 Doublers welded on primary strength members:
Weld leg size, When td＞K0+5，the edge to be tapered as 1:4

0.85×td —
K0(Circumferencial and in slots)
25
GB/T XXXXX-XXXX
4.7.2.1 Local doublers are normally only allowed as temporary repairs.

4.7.2.2 Make sure there is no crack and grooves on the base plate. The surface condition of the repair area
and the residual thickness of the steel plate shall be sufficient to ensure effective welding.
4.7.2.3 The entire defective area shall be covered with one piece of large doubler rather than multiple
pieces of small doublers.
4.7.2.4 Prior to assembling doublers, a tightness test shall be performed for watertight members to ensure
no leakage.
4.7.2.5 Prior to assembling doublers, the salient part of the butt weld on the base plate shall be ground flush
with an abrasive wheel. Rust on the interface between the base plate and the doublers shall be removed and the
anticorrosion paint shall be applied.
4.7.2.6 Besides fillet welding for the edge of doublers, slot welding shall be applied if the breadth of the
doublers is greater than the frame space of this area.
4.7.2.7 Key points for the quality control of doublers on plating are:
a) The size of the doublers;
b) The surface quality of base plate;
c) The residual thickness of base plate;
d) The size and pitch of slots.
4.8 Welding
4.8.1 Quality requirements for welding
The arc strike, ambient temperature and preheating temperature shall be in accordance with the
26
GB/T XXXXX-XXXX
Table 29 Arc strike, ambient temperature and preheating temperature
Allowable
Items Standard range Remark
limit
Repair with the below method
ifan arc strike is generated:
High-strength steel,cast
a) Weld a seam (length ≥
steel, mild steel of grade
Not-allow 50mm) along the strike
Arc strike E , TMCP high strength —
ed line;
steel, steel for
b) Grind flush hardened
low-temperature
part of weld with
abrasive wheel.
Mild steel grade A, B,
Ambient ＜-5 ℃
D, E Preheating temperature shall
temperatu
TMCP be not less than 20 ℃ unless
re at AH32～
high-strengt ＜0℃ — the additonal
which EH32
h steel requirementsin thewelding
preheating AH36～
High-strengt procedure are approved.
is needed EH36 ＜5 ℃
h steel
a) The calculation formula
Carbon equivalent Ceq T0≤50 50＜T0≤70 T0＞70 —
of carbon equivalent Ceq
Ceq≤0.39 — — 50 ℃ is shown in table 22;

b) T0 is the multi-thickness
0.39＜Ceq≤0.41 — — 70 ℃
of weld joint
T0=∑ti
Preheating 0.41＜Ceq≤0.43 — 50 ℃ 100 ℃
Details see below sketch：
temperatu
0.43＜Ceq≤0.45 50 ℃ 100 ℃ 125 ℃ = =
re —
t7
t8
0.45＜Ceq≤0.47 100 ℃ 125 ℃ 150 ℃
t9
t11
0.47＜Ceq≤0.50 125 ℃ 150 ℃ 175 ℃

t10
4.8.1.1 Dimension deviation of butt weld shall be in accordance with the requirements in Table 30.
27
GB/T XXXXX-XXXX
Table 30 Dimension deviation of butt weld Unit: mm
Standard Allowable
Items Remark
range limit
Height of bead, h3 ≤0.2B1 ≤6.0 Correction against over-sizing

θ2
h3
cut and grind
Flank angle, θ2 B1 ≤60° ＜90° make-up welding
B1 —— breadth of bead
4.8.1.2 Dimension deviation of fillet welds shall be in accordance with the requirements in Table 31.
Table 31 Dimension deviation of fillet welds Unit: mm
h4 In case the dimensions of

weld leg are not within
the allowable limit, then a
Ka ≥0.9k0
k0 — weld-up with a fine
ha ≥0.9h4
electrode is required. Care
k 0—— specified weld leg size；
should be taken not to
Ka —— actural weld leg size；
create short beads.
h4——specified weld throat size ；
ha —— actural weld throat size
4.8.1.3 Requirements of weld undercuts shall be in accordance with the limit in Table 32.
Table 32 Requirements of weld undercuts Unit: mm

Primary
≤0.5
a0
member
a) a0 = 0.5～0.8，The sharp edge
Secondary
a0 ——undercut of butt shall be repaired even if the
member
weld — angle of undercut is not more
than 90°;
a0 ≤0.8
b) The sharp configuration of the
fillet weld is to be repaired
a0 —— undercut of fillet weld
4.8.1.4 Deformation at welding joints shall be in accordance with the requirements in Table 33.
28
GB/T XXXXX-XXXX
Table 33 Deformation at welding joints Unit: mm
Standard Allowable
Items Remark
range limit
Shell plate within 0.6L3 midship ≤6 L3 —— ship length

In case it exceeds
Shell plate of fore and aft part ≤7 allowable limits, it can be
—
a1
recified or reassembleded
Other a1—— deformation of shell ≤8 and welded after cutting

plate in frame spacing apart
4.8.1.5 Repairing welding crack shall be in accordance with the requirements in Table 34.
Table 34 Repairing welding crack

The groove cut for a penetrating crack shall be
treated as a butt joint
Groove to Angle : θ3=45º～60º， 3
be cut R3=5 mm
—
R3
If the crack is located at the end, welding shall be

End type End slope 1:3
extended to an arc plate
Maximum length of crack on
Crack arresting hole shall be opened to prevent
plate is 400 mm, groove by Maximum length of linear
crack growth at both ends of crack. The back
Scope gouging shall be extended by 50 crack on plate is 500 mm
welding method shall be used for the crack with a
mm beyond the position of without branch.
length more than 300 mm
crack end.
4.8.2 Quality control for repairing process
4.8.2.1 All welding consumables shall have certification and be approved by the classification society.
4.8.2.2 All welding procedures shall be submitted to the classification society for approval.
4.8.2.3 When the base plates have different material grades, generally the welding consumables can be
chosen as per the lower grade base plate, except where there is discontinuous structure and/or a high stress
concentrated area.
4.8.2.4 Welding shall be done by a welder with a valid welding qualification issued by the classification
society.
4.8.2.5 The welding zone shall be free of rust, scales, grease, moisture or other dirt. If welding shall be
done in wet, windy and cold weather, shelter and protection shall be performed.
4.8.2.6 The welding equipment shall be used within period of validity.
4.8.2.7 For multi-layer welding, the surface of deposited metal area shall be cleaned before the next layer
of welding.
29
GB/T XXXXX-XXXX
4.8.2.8 For double-sided welding, when one side of the welding is completed, back gouging shall be
carried out and the weld shall be grounded smoothly to remove crack, air bubbles, slag and other defects.
4.8.2.9 The base plate shall not be damaged when gouging or removing temporary welds, tack welds and
defects.
4.8.2.10 Crack-arresting holes shall be drilled at both ends of a crack first to prevent its growth before the
crack treatment.
4.8.2.11 The re-weld shall be applied with a small diameter electrode and little welding current.
4.8.2.12 NDT shall be performed for welding grooves and seams according to corresponding procedures.
4.8.2.13 Tightness tests shall be executed for the welding of watertight structures according to the
requirements of the classification society.
4.8.2.14 Welds that do not pass the testing shall be repaired and inspected again.
4.8.2.15 Key points for the quality control of welding are:
a) Welder qualification certification;
b) Welding consumables certification;
c) Welding procedures;
d) Welding equipment;
e) Preheat and temperature preservation;
f) Welding deformation;
g) Weld size and surface quality;
h) NDT;
i) Tightness test.
The inspection & test for acceptance of welding are:

a) Weld size and surface quality;
b) The structural deformation reports;
c) The NDT report;
d) The tightness test report.
4.9 Finishing
4.9.1 Quality requirements for finishing
4.9.1.1 Staging sockets and lifting eye pieces are to be removed in accordance with the requirements in
Table 35.
30
GB/T XXXXX-XXXX
Table 35 Staging sockets and lifting eye pieces finishing

In water and oil tanks May be retained totally a) Any lifting eye pieces affecting
In engine room Only those affecting appearance and appearance and passage shall
passage are to be removed be removed and the root shall
Staging
In cargo hold Only those at lower level and on hatch be finished flush with the
sockets
coaming are to be removed base plate;
On exposed parts of shell To be removed totally b) Such pieces may be removed
and upper deck, etc. by gas cutting with root
In engine room May be retained provided not effecting retained. The root in the
passage strength structure shall be
lifting eye In cargo hold Root may be retained on back side of made smooth and flush after
pieces deck plate cutting
On exposed parts of shell To be removed totally Except fixed eye pieces
and upper deck, etc.
4.9.1.2 Temporary pieces are to be removed in accordance with the requirements in Table 36.
Table 36 Temporary pieces finishing

Temporary pieces are not to be fixed, or are to
Outside surface of shell plate, deck and superstructure are
Where good be kept as few as possible, on sheer strakes and
to be chipped flush and smooth. Under-cut of temporary
appearance is on corner plates of a strength deck with
pieces may have a depth of 0.5mm. Above this limit, the
required under-cuts welded over and ground flush
cut is to be welded over and ground flush.
completely
Temporary pieces inside holds and similar places are to
be chipped off if they are at particularly conspicuous
Where good places.
appearance is not Undercutting may have a depth of 0.5~1.0 mm and a —
required length not more than 30mm. Over these limits they are to
be welded over and finished, but may not be chipped off
and ground.
4.9.1.3 Holes cut erroneously are to be treated in accordance with the requirements in Table 37.
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GB/T XXXXX-XXXX
Table 37 Treatment of erroneously cut holes Unit: mm
Items Allowable limit Remark

If the opening is over 75 mm in Method A:Repair by spigot piecea;
Main strength
diameter, then repair using method 2
members on
A.Or if the opening is less than a2
θ
t13
4
shell plate or
Diameter 200mm in diameter, then repair using
upper deck
12
D2＜200 method B
ι6
If the opening is over 200 mm in
Others diameter, then repair using method B, l6= 50 ; a2= 4～6;
C or D 0.5t13≤t12≤t13 ; θ4= 30º～40º.
Main strength Method B:Repair by insert plate;
members on Method C:Repair by lap welding(with lap plate
Repair using method B
shell plate or thickness the same as base plate);
t15
upper deck
t14
ι7
Diameter
D2≥200 t14＝t15 ; lmin= 50.
Method D: In case it is difficult from a structual point
Others Repair using method B or C
of view to cut an opening over 200mm in diameter, it
may be repaired by welding with low hydrogen
electrode after preheating and followed by
radiographic exmination or ultrasonic inspection
a Repairing by spigot piece in high tension stress and fatigue area shall be approved by surveyor.
4.9.1.4 Surface defects on the plate shall be treatedin accordance with the requirements in Table 38.
Table 38 Treatment of surface defects on the plate Unit: mm
Items Requirement
d9
d9≤0.07t16
Defect shall be ground smoothly
(Max=3)
t16
Defect shall be ground, but the ground depth shall be not more
d9 —— depth of defect； d9＞0.07t16 or
than 0.2t16, the over ground part shall be rewelded 1.5 mm above
t16 —— thickness of plate d9＞3
the surface , then the weld shall be ground smoothly again
4.10 Deformation
4.10.1 Quality requirements for deformation
4.10.1.1 The deformation of plating within every frame spacing shall be in accordance with the
32
GB/T XXXXX-XXXX
Table 39 Deformation of plating within every frame spacing Unit: mm
Standard Allowable
Items Remark
range limit
Parallel mid-body (side plate,
≤4
Shell plate bottom plate)
Fore and aft curved parts ≤5
Double bottom Tank top plate ≤4
≤8
Bulkhead ≤6
Parallel mid-body(including
longitudinal and transverse ≤4
Upper deck structure)
Fore and aft parts ≤6
≤9
b7
Non-exposed parts ≤7
Exposed parts ≤6 ≤8
Second Deck
Non-exposed parts ≤7 ≤9
b7 —— Deformation between
Forecastle Exposed parts ≤4 ≤8
frames
deck,after deck Non-exposed parts ≤6 ≤9
Superstructure Exposed parts ≤4 ≤6
deck Non-exposed parts ≤7 ≤9
Platform ≤5 ≤7
Exposed parts ≤4 ≤6
House walls Non-exposed parts ≤6 ≤8
Non-exposed part in two parts ≤7 ≤9
Internal members（girders, web plates of beams） ≤7
≤5
Girders or beams of tank top plates ≤8
4.10.1.2 The deformation of a whole panelshall be in accordance with the requirements in Table 40.
Table 40 Deformation ofa whole panel Unit: mm

b8
Parallel midbody ±2l8/1 000 ±3l8/1 000

Shell plate
b8
Fore and after parts

±3l8/1 000 ±4l8/1 000
Deck, platform, tank top plate
l8
Bulkhead ±4l8/1 000 ±5l8/1 000
b8 —— deformation of whole panel
Superstructure l8—— measuring distance
Measuring method: measure between one web
±5l8/1 000 ±6l8/1 000
Others frame, but the minimum measuring distance is
3000 mm
4.10.1.3 The straightness of internal support members shall be in accordance with the requirements in
Table 41.
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GB/T XXXXX-XXXX
Table 41 Straightness of internal support members Unit: mm
Main members, such as strength

beams, web frames, floors and
5 8
δ4
deep deck girders (one span
length) δ4 —— straightness
Secondary L4≥1 000 10 13 δ5

δ5
members, such
as longitudinal,
frame, beam
L4＜1 000 5 8
and stiffeners δ5 —— straightness;
L4 —— length
"H" type pillars between decks 4 6 δ6
δ6 —— straightness
Cross tie 6 10 —
4.10.1.4 Deformation of the hull girder shall be in accordance with the requirements in Table 42.
34
GB/T XXXXX-XXXX
Table 42 Deformation of the hull girder Unit: mm
Allowable
Items Standard range Remark
limit
Within the Per 100 m,
whole length take keel plate
-δ7
+δ 7
between fore ±50 — centerline as
Deflection of and aft peak measurement
keel plate at tanks reference
centerline,δ7 Between
+δ 7
adjacent
±15 — —
transverse
bulkheads
Take mould
line as
Bow warping up ±30 —
measurement
h5
reference
Bow and stern

warping up, h5
Take mould
Stern warping
±20 — line as
up
measurement
reference
h5
Take mould
line as
Transversely warping up,δ8 ±15 —
_ δ8
measurement
+
reference
5 DOCK REPAIRING ENGINEERING
5.1 Shafting
5.1.1 Key points of the survey
The key points of the survey for shafting are as below:

a) Sailing inspection;
b) Disassembly inspection;
c) Alignment inspection;
d) Propeller and propeller shaft fitting inspection;
35
GB/T XXXXX-XXXX
e) Propeller shaft and stern tube disassembly inspection;

f) Visual inspection of shafting;
g) Inspection and measurement of propeller shaft, stern tube shaft, intermediate shaft and thrust shaft;
h) Inspection and measurement of stern tube bearings, intermediate shaft bearing and thrust bearing;
i) Stern tube glands disassembly and inspection ;
j) Operation status of shafting related piping and fitting.
5.1.2 Quality requirements of the repairing
5.1.2.1 Quality requirements of shaft journal repairing are as below:

a) Circularity and cylindricity of shaft working journal shall be in accordance with the requirements in
Table 43;
Table 43 Circularity and cylindricity of shaft journal at the bearing Unit: mm
After Wearing limit of intermediate

Wearing limit of propeller shaft and stern tube shaft
Machined shaft and thrust shaft
Diameter of
Circularity Cylindricity
shaft d10 Circularity &
Circularity Cylindricity Water Oil Water
Cylindricity Oil Lubricated
Lubricated Lubricated Lubricated
≤80 0.08 0.09 0.10 0.13 0.13 0.15
0.010
80～120 0.09 0.10 0.12 0.15 0.15 0.18
120～180 0.10 0.12 0.14 0.17 0.17 0.22
0.015
180～260 0.12 0.14 0.16 0.20 0.20 0.28
260～360 0.14 0.16 0.18 0.23 0.23 0.36
0.020
360～500 0.16 0.19 0.20 0.27 0.26 0.45
500～700 0.18 0.23 0.23 0.32 0.29 0.55
0.025
＞700 0.20 0.26 0.26 0.35 0.32 0.65
b) Cylindricity of a non-working shaft journal shall be 2.5 times the specified value in the Table above;
c) If the length of the working shaft journal is more than two times of the shaft diameter at the journal,
the cylindricity tolerance may be increased by 0.005 mm per each increasing of 100 mm;
d) With regards to the diameter of the propeller shaft and of the stern tube shaft: the shaft journal at the
bearing after final machined may be reduced to (but shall not be less than) the diameter of the
non-working shaft journal;
e) The wearing limits of circularity and cylindricity are the limits for working shaft journal before
repair when bearing being replaced.
5.1.2.2 Radial run-out of the propeller shaft and the stern tube shall be in accordance with the requirements
in Table 44.
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GB/T XXXXX-XXXX
Table 44 Radial run-out of propeller shaft and stern tube Unit: mm
The ratio of the Working shaft journal and cone parts Non-working shaft journal
shaftlength to the
Standard Range Sailing Limit Standard Range Sailing Limit
journal dia. L5/d11
≤20 0.03 0.12 0.12 0.36
20～35 0.04 0.16 0.16 0.48
35～50 0.05 0.20 0.20 0.65
50～65 0.07 0.24 0.24 0.72
65～80 0.09 0.28 0.28 0.84
80～95 0.12 0.32 0.32 0.96
5.1.2.3 The end face of the propeller shaft coupling flange shall not be convex, but the depression of 0.03
mm～0.05 mm is allowed. The run-out of the propeller shaft radial circular and of the end face of stern tube
coupling flange shall be in accordance with the requirements in Table 45.
Table 45 The run-out limits of radial circular and end face
at the coupling of propeller shaft and stern tube shaft flanges Unit: mm
Radial and end-face run-out after Limit of radial circular Limit of end face circular
Diameter of flange d12
machined run-out run-out
≤120 0.10 0.05
120～180 0.02 0.12 0.06
180～260 0.14 0.07
260～360 0.16 0.08
360～500 0.03 0.18 0.09
500～700 0.20 0.10
＞700 0.04 0.24 0.12
5.1.2.4 If the area of damage and corrosion for the propeller shaft keyway is not more than 15% of the
working area, repair is permitted. If it exceeds 15%, the keyway shall be milled straight and widened again,
the two sides of keyway and flat key shall be smooth and clean, and the machining accuracy shall be in
accordance with the requirements in Table 46.
Table 46 Machining accuracy of keyway and flat key
Object Requirements
Depth of Foreward and afterward depth shall be consistent with the design depth.When measured in any position, in each
keyway 10 mm depth the toleranceshall not be more than 0.10 mm, and the greatest tolerance shall not exceed 0.25 mm.
Both sides After the repair of the two sides, the keyway shall be parallel to the shaft centerline. In every 100 mm length, the
of keyway parallelism shall not exceed 0.01 mm, and the total shall not exceed 0.05 mm.
Both sides After the repair of the two sides, of the flat key, the sides may be multistep. The offset of upper and lower pasts
of flat key shall not exceed 5% of the key width and the maximum offset shall be no more than 3 mm.
Width of The width shall be consistent. When measured in any position at keyway, the tolerance shall be 0.02 mm～0.05
keyway mm (depend upon the width of key). The keyway limit width is 0.33 times the average diameter of the cone.
37
GB/T XXXXX-XXXX
5.1.2.5 After shafting repairs, the surface roughness of each part refers to Figure 1.
Unit : micron
1.6
3.2 1.6
1.6
1.6
1.6 1.6
3.2
1.6
1.6
1.6
1.6 3.2 1.6 1.6
1.6
1.6
0.8
1.6 1.6
1.6
Figure 1 Surface roughness after repairs
5.1.2.6 If the repair to the shaft journal and cone part is by means of built-up welding, it shall be approved
by the classification society if the carbon content of shaft material is greater than 0.23%, and the preheating
temperature shall be in accordance with requirements in Table 47.
Table 47 Preheating temperature
Object Requirement
Carbon content of shaft /％ ≤0.2 0.2～0.3 0.3～0.4
Preheating temperature/℃ 100～120 120～150 150～250
5.1.2.7 If the repair to the shaft journal is by means of steel sleeve heat-fitting, the material of the steel
sleeve shall be equivalent to the shaft material. The minimum thickness of the steel sleeve shall be in
Table 48 Minimum thickness of steel sleeve Unit: mm
Requirement
Object Diameter of shaft d13
≤80 80～120 120～180 180～260 260～360 360～500
Min. thicknesst 6 7 8 10 12 15
5.1.2.8 The repairing requirement of cracks and corrosion on the shaft surface shall be in accordance with
the requirements in Table 49.
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GB/T XXXXX-XXXX
Table 49 Repairing requirement of crack and corrosion for shaft surface
Content Crack and corrosion degree Fix method

a) Chisel grind to smooth (If strength is
satisfactory);
b) Weld up (if the strength is not satisfactory by
Crack depth ≤5％ of the shaft diameter, crack
Longitudinal crack chisel or carbon content does not exceed
length ≤25％ of the shaft diameter
0.23％);
c) By means of spray or high polymer material to
fix
Small crack Linear dimension ≤7％ of the shaft diameter Chisel or grind to smooth
Corrosion width ≤9％ of the circumference,
Corrosion on Corrosion depth ≤3％ of the shaft diameter
propleller cone root Corrosion width ≤5 ％ of the circumference, Inspect and clean the corrosion point, grind to smooth
part Corrosion depth ≤2％ of the shaft diameter
Corrosion depth ≤1.5％ of the shaft diameter
5.1.2.9 After machining, the surface roughness of the internal hole for the propeller shaft copper sleeve
shall be Ra=1.6 µm. Circularity and cylindroids shall be in accordance with the requirements in Table 50.
Table 50 Circularity and cylindroids of copper sleeve inner bore Unit: mm
Requirement
≤120 120～180 180～260 260～360 360～500 >500
Circularity 0.020 0.025 0.030 0.035 0.040 0.050
Cylindricity 0.025 0.030 0.035 0.040 0.045 0.050
5.1.2.10 The interference of the copper sleeve for the propeller shaft and stern tube shall be in accordance
with the requirements in Table 51.
Table 51 Interference of copper sleeve Unit: mm
Requirement
≤120 120～180 180～260 260～360 360～500 500～700 700～900
Interference % 0.12～0.13 0.11～0.12 0.10～0.11 0.09～0.10 0.08～0.09 0.07～0.08 0.06～0.07
Interference 0.10～0.14 0.14～0.20 0.20～0.26 0.26～0.32 0.32～0.40 0.40～0.50 0.50～0.60
5.1.2.11 The thickness of the propeller shaft copper sleeves shall be in accordance with the requirements in
Table 52, and the maximum thickness of the sleeve at gland may be reduced by 25% in accordance with
requirement in Table 52.
39
GB/T XXXXX-XXXX
Table 52 Thickness of copper sleeve Unit: mm
Thickness of new parts Thickness of non-work shaft neck Thickness during repairing Limited thickness
≥0.03d16 +7.5 ≥0.75d16 ≥0.02d16+5 0.015d16+3.5
Note: d16 —— diameter of shaft
5.1.2.12 The concentricity limit of the cylindrical stern tube bush at each outside diameter is 0.03 mm. The
concentricity limit between internal and external diameter of the bush is 0.05 mm. The perpendicularity of the
flange to the center line is 0.12 mm. 80% of the faying surface of the bush shall not allow insertion of a 0.05
mm feeler. The surface roughness of external fittings shall be Ra=1.6 µm～3.2 µm. Therefore the circularity
and cylindricity of the internal and external faying surfaces shall be in accordance with the requirements in
Table 53.
Table 53 Circularity and cylindricity of internal
and external faying surfaces of the bursh Unit: mm
Requirement
Object Outside diameter of bush D3
≤120 120～180 180～250 250～315 315～400 400～500 500～630 630～800
Circularity and
0.015 0.018 0.020 0.023 0.025 0.027 0.030 0.032
Cylindricity
5.1.2.13 The concentricity limit of each part of the stern tube is 0.04 mm. The concentricity limit between
the internal dia. and the external dia. is 0.06 mm. The perpendicularity limit of the flange plane to the axis is
0.15 mm. The roughness limit at the internal and external fitting surface is Ra=3.2 µm. The circularity and
cylindricity at internal and external fitting parts shall be in accordance with the requirements in Table 54.
Table 54 Circularity and cylindricity at internal
and external fitting parts of the stern tube Unit: mm
Requirement
External diameter of stern tube d17
Object
120～ 180～ 250～ 315～ 400～ 500～ 630～ 800～1
≤120
180 250 315 400 500 630 800 000
Circularity and
0.018 0.020 0.023 0.025 0.027 0.030 0.032 0.036 0.040
Cylindricity
5.1.2.14 Deviation between the stern frame hub hole boring axis and the hub hole positioning centerline
shall not exceed 0.20 mm. The perpendicularity of bossing end face and the plane of the aft bulkhead flange to
the axis is 0.15 mm. The circularity and cylindricity of the hub hole shall be in accordance with Table 55.
40
GB/T XXXXX-XXXX
Table 55 Circularity and cylindricity of hub hole Unit: mm
Requirement
Diameter of hub hole D4
Object
120～ 180～ 250～ 315～ 400～ 500～ 630～ 800～1
≤120
180 250 315 400 500 630 800 000
Circularity and
0.035 0.040 0.046 0.052 0.057 0.063 0.072 0.080 0.090
Cylindricity
5.1.2.15 The machining of the main parts of the rubber ring sealing shall be in accordance with
requirement as below：
a) Surface roughness of corrosion protection bushing Ra=0.80 µm;
b) Circularity of the corrosion protection bushing is 0.03 mm and cylindricity is 0.05 mm;
c) Concentriciality between inner and external circles of corrosion protection bushing is 0.05 mm;
d) Fitting clearance between the corrosion protection bushing bore and propeller shaft journal shall be
in accordance with requirement in Table 56.
Table 56 Fitting clearance between bushing bore and propeller shaft journal Unit: mm
Requirement
Fitting clearance External diameter of bushing D5
≤150 150～220 220～310 310～500 >500
Flange shoulder 0.30～0.36 0.35～0.40 0.40～0.45 0.45～0.50 0.50～0.60
positioning
Bushing and shaft 0.10～0.15 0.15～0.20 0.20～0.25 0.25～0.30 0.30～0.35
jpurnal positioning
e) Rubber rings shall be used within the validity period. The interference limits between the inner hole
of the rubber ring and bushing is 1%～1.5% of the bushing external diameter, and the interference
shall be in accordance with the requirements in Table 57.
Table 57 Interference of rubber ring inner hole and bushing Unit: mm
Requirement
Object External diameter of bushing D6
＞150～200 200～330 330～420 420～560 ＞560
Interference 2.8～3.5 3.0～4.0 3.5～4.5 4.0～5.0 5.0～5.5
5.1.2.16 The requirements for machining end face of elastic ring sealing device are as below:
a) The perpendicularity limit between the end face of friction surface and flange plane to axis is 0.08
mm;
b) Friction surface flatness shall be 0.02 mm;
c) Grind the friction surfaces and then make sure the contact area shall be greater than 90％;
d) Where there is an oil groove on the friction disk plane, the distance between the top of the oil
groove and the flange edge shall be between 20 mm～30 mm (depending on the width).
41
GB/T XXXXX-XXXX
5.1.2.17 Fitting size and thickness limits between the main parts of the metal ring type seals shall be in
Table 58 Fitting size and the thickness limits Unit: mm
Requirements
Item Liner Outer Diameter D7
＞100～150 150～220 220～310 310～360
Clearence Flange convex
0.30～0.36 0.35～0.40 0.40～0.45 0.45～0.50
between liner shoulder positioning
inner diameter
Liner with axial
and propeller 0.10～0.15 0.15～0.20 0.20～0.25 0.25～0.30
positioning
shaft journal
The thickness limits of liner 5 6 7 8
Metal ring and liner clearance 0～0.015 -0.010～0.010 -0.015～0.005 -0.025～0
Ring and ring plate, plate and liner radial
4.0～4.5 4.5～5.5 5.5～6.5 6.5～7.0
clearance
Ring plate thickness limits 3.5～4.0 4.0～4.5 4.5～5.0 5.0～5.5
The thickness of the rubber 6～8 8～10 10～12 12
5.1.2.18 The requirements for machining to the parts of the forward stern tube glands are as below:
a) Inside and outside concentricity tolerance shall be 0.10 mm (except with eccentric assembly);
b) Concentricity and cylindricity tolerances for the inside and outside circulars shall be 0.05 mm;
c) The perpendicularity tolerance of the end face to axis shall be 0.12 mm;
d) The split parts of the gland shall go through the axis; two planes on the split parts shall be 80%
contacted in length.
5.1.3.1 The quality control requirements for repairing propeller shafts, stern tube shafts, intermediate shafts
and thrust shafts are as below:
a) Material grade, material type, heat treatment and machining etc. for the new propeller shaft or tail
shaft and couplings shall meet the requirements of the design drawings approved by the
classification society;
b) NDT or drilling hole method may be used for checking crack length and depth;
c) The welding repair procedure for shaft crack welding repair shall be approved by the ship’s
d) When end crack or local wearing is serious for the propeller shaft bushing, replacing only local
damaged parts may be permitted, but the continuity and completeness of the copper bush shall be
insured;
e) One end of the propeller shaft copper bushing with layer contact shall be machined into a backward
zigzag and this shall guarantee the water tightness after cladding;
f) A hydrostatic test shall be performed for the propeller shaft bushing after rough machining,
g) Propeller shaft bushing shall be evenly heated to prevent deformation;
42
GB/T XXXXX-XXXX
h) If the inner surface scratching area of the bolt hole of the flange and the bolts is not more than 25%
of the total area, the scratched parts may be reused after polishing. But if the bolt hole is badly
damaged, the hole shall be reamed or bored and the connecting bolts shall be replaced.
5.1.3.2 The quality control requirements for repairing bearings, stern tubes and piping are as below:
a) Stern castings for bearing bushing shall not have any crack or slagging defects affecting the strength
and tightness. A tightness test shall be carried out after rough machining of the bushing; the bushing
with the smaller defects may be used after repair.
b) Bearing alloy casting surfaces shall not have any defects such as crack, shrinkages and porosities.
Small defects can be repaired by built-up welding. The joint of the bearing alloy lining and bearing
bushing shall be tightly without lamination. When bearing alloy falls off or bites on the shaft journal
seriously, it shall be replaced;
c) The new bearing seat or heavy casting bearing alloy shall be subject to a hydraulic pressure test, and
built-up welding may be used to repair individual leakage, then a hydraulic pressure test shall be
carried out again after repair;
d) The fitting in bearing and the bearing cover with a convex shoulder should be machined to be
matched each other;
e) The stern tube shall be subject to a hydraulic test after machining, and if any leakage was found,
built-up welding may be used to eliminate the leakage, then a hydraulic pressure test shall be carried
out again;
f) After the stern tube is installed, a tightness test shall be carried out for the stern tube cooling water
tank;
g) Sea water pipes shall be of galvanized steel pipes or corrosion resistant materials. Copper pipes shall
be subject to an annealing treatment before a water tight test;
h) The curved sections of oil or water pipes shall be smooth and no significant creases or sagging. Pipes
shall be clear of residual dirt inside and be cleaned thoroughly before installation;
i) A tightness test shall be carried out for the cooling water and lube oil piping systems after repair.
5.1.3.3 The quality control requirements for assembling are as below:
a) If the radial clearance of the rubber stern bearing is out of tolerance, it is not allowed to eccentric
grind strip rubber stern bearing, but the rasping on the back panel can be performed to meet the
requirement of the bearing clearance. On repairing, the upper and lower rubber strip may be
exchanged for reuse;
b) If the rubber stern bearing is ageing, shelling or seriously peeling off, it shall be replaced
c) The hot oil heating shall be used for rolling bearing assembly into axle neck;
d) If the rolling bearing is overheated, corroded, eroded, cage rupture, a serious roller (ball) wearing, or
torpid operation, it shall be replaced;
e) Where an oil lubricated bearing is installed, the inside of the bearing shall be filled with lubricating
oil. The oil level in sump shall be not less than the centre of the lowest roller (ball);
f) The rubber tightness device shall be provided when assembling propeller shaft with copper bushing
and propeller.
5.1.3.4 The quality control requirements for sealing devices are as below:
43
GB/T XXXXX-XXXX
a) The corrosion protection bushing of rubber ring sealing devices shall be subject to a hydraulic
pressure test after machining, to make sure the rubber ring has good contact with the lining sleeve for
the corrosion protection;
b) During rubber seal ring assembly, the rubber ring lips shall be protected from any contamination
entering, and to avoid lips twisting. Before installation, the sizes of propeller, propeller shaft, stern
tube, stern bearing and sealing device, etc shall be checked;
c) The split seams of sealing devices with an end face of elastic rings shall be closely integrated. The
spring or pre-tightening force of the elastic ring shall be adjusted according to the specification;
d) The sand holes, brittleness and other casting defects are not allowed on anticorrosive bushing of the
tail metal ring seal. Once removed from the metal ring assembly, a new one shall be replaced. The
inner arc of rubber plate shall be smooth, and the rubber shall not be aging without crack. The lips of
the inner hole through the cutting shall be smooth without crack and gaps;
e) The packing gland cover of the gland seal on the forward stern tube shall be flexible moving forward
and afterward. The clearance between the gland flange and the stern tube flange shall be equal after
stuffing. The inside circle of the gland bushing and the shafts are not allowed to be in contact, and
the clearance in each direction shall be equal as much as possible.
5.1.3.5 The quality control requirements for repairing shafting are as below:
a) The material of new parts and components in shafting;
b) Machining accuracy of shafting parts;
c) The fitting of keyway and key of propeller;
d) Shaft surface crack repair;
e) Inspection and handling of corrosion on cone root of propeller shaft;
f) Inspection and measurement for bushing before replacement;
g) Assembling and machining of propeller shaft and stern tube shaft copper bushing;
h) Seam interface of copper bushing;
i) Copper bush thickness requirements;
j) Sealing parts machining accuracy;
k) Shaft assembly accuracy.
The inspection & test for acceptance after shaft repair are as below:
a) Submit material certificates of new parts, accepted test report and product certificates issued by the
b) Inspection report of the shafting machining accuracy;
c) Check and record assembly clearance of shaft and bearing;
d) Check the gap and sag between the flanges of propeller shaft and stern tube shaft with adjacent
intermediate shaft being connected, and submit inspection records;
e) Oil lubrication stern bearing seal or stern tube packing box in the shaft shall be subjected to a
hydraulic test after assembling and submit the test report;
f) The inspection report of pushup value for propeller installation;
g) Original and realigned records of shaft centerline;
h) Record the shafting and the bearing's working status in sea trial;
44
GB/T XXXXX-XXXX
i) Deflection records for the main engine crank shaft;

j) Jack up test report for bearings.
5.2 Propeller
The key points of the survey of the propeller are as below:

a) Propeller surface inspection;
b) Hub inspection
5.2.2.1 Defect limits of the propeller shall be in accordance with the requirements in Table 59.
Table 59 Defect limits of the various regions Unit: mm
Maximum Maximum allowable defect Allow area

The minimum
a
Defects regions Defects type allowable part in 150 mm×150 mm with a dense
distance defect
limit (pieces) defect
Nonlinearb 15 S3
A area
Linear 3.2 6 4S3 No greater
Nonlinear 20 S3 than of the
B, C area
Linear 8 4S3 surface of
6.4
Nonlinear 15 S3 each partition
Hub surface
Linear 9.5 6 4S3 or 25（Smallest） 5％
Cone and keyway Nonlinear 6.4 5 S3
surface Linear 9.5 3 4S3 or 25（Smallest）
C C
0.7R 4
0.7R 4
B B
A
Ci 0.4R 4
0.2 0.1
5C
i
suction face pressure face

R4 —— section Arc length
Ci —— propeller radius
Note 1: refers to the length of the linear defects than the defects of greater than 3.
Note 2: S3 - the larger the size of the defect.
a Not less than 1.6 mm density defects are not included in the total number of defects.
b When there is no linear defect, the number of nonlinear defect shall be increased to twice times of both allow number.
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GB/T XXXXX-XXXX
5.2.2.2 If the defect depth shall be in accordance with the requirements in Table 60, the propeller can be
polished for further use.
Table 60 The depth of the defect
Defect location Requirement

A area ≤4 mm, or the maximum depth doesn’t exceed 1 /40 the blade thickness
B area ≤3mm, or the maximum depth doesn’t exceed 1 /30 the blade thickness
C area Blade edges and surface imperfections
5.2.2.3 For the propeller welding, the preheating temperature, the corrective heating temperature and
annealing temperature shall be in according with the requirements in Table 61
Table 61 Weld preheating temperature, correct the
heating temperature and annealing temperature Unit: °C
The corrective heating

Material Weld preheating temperature The annealing temperature
temperature
Brass 150～400 500～800 350～550
Bronze 50～200 700～850 450～650
Chromium nickel Stainless
100～250 200～450 —
steel
Cast steel 100～150 600～700 500～600
Cast iron 600～700 — 650～700
5.2.2.4 After repair, the propeller radius and pitch tolerance (expressed as a percentage of the design value)
may refer to the new propeller technical requirements or a lower limit, but shall not exceed the requirements in
Table 62.
Table 62 Propeller diameter and pitch tolerance
Item Grade S Grade 1 Grade 2 Grade 3

The radiusR4 ±0.25％ ±0.5％ ±0.75％ ±1％
Cross section pitch h6 ±1.5％ ±2.5％ ±3.5％ ±4.5％
Leaf blade pitchH4 ±1％ ±1.5％ ±2.5％ ±3.5％
The total average
±0.5％ ±1％ ±2％ ±3％
pitchH5
5.2.2.5 The surface roughness on the propeller with different precision grades shall be low to next grade
based on Table 63.
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GB/T XXXXX-XXXX
Table 63 The propeller surface roughness Unit: mm
The propeller The surface roughnessRa

Scope of application
specifications GradeS Grade 1 Grade 1 Grade 3
The surface of the Medium and small 1.6 3.2 3.2
blade section 0.3 R4 6.3
large 6.3
outward 6.3
The surface of the Medium and small 3.2
blade section 0.3 R4
large
inward 12.5 12.5
12.5
Large, medium and
Hub suface 6.3
small
Note:R4—— The propeller radius
5.2.3.1 After bending correction of the blade, carry out visual inspection to check crack, sagging and other
defects which should not exist, and if necessary, carry out non-destructive testing. For large bending correction
areas, the pitch re-measurement is necessary. For serious bending correction areas, the annealing treatment
shall be carried out based on material property.
5.2.3.2 If the cavitation and corrosion depth on the surface of the blade is less than 5 mm, a manual or
mechanical method to clear the rust and dirt in etched surface hole shall be used.
5.2.3.3 Repairing adhesive or metal spraying methods shall be used for the repair of slight cavitation and
sagging on the blade if the built-up welding is not be carried out.
5.2.3.4 The material of built-up welding shall match with the parent metal body for propeller repairs.
5.2.3.5 Welding is not allowed on area A in propeller repairing, and welding on area B should try to be
avoided..
5.2.3.6 In addition to the edge of area C, small defects can be repaired by built-up welding in other areas.
The propeller shall be removed in order to carry out built-up welding, and it is preferred that the welding
repairing is done on the level position.
5.2.3.7 After welding repairs, the residual high of the weld shall be smooth, visual inspection shall be done,
and if necessary, the non-destructive testing shall be carried out.
5.2.3.8 If the propeller undergoes the built-up welding for breaking block or large-area welding repairs, the
static balance test shall be carried out. For controllable pitch propellers, if the static balance test is impossible,
the test shall use blade weighing and decorate installation evenly to achieve a relative balance.
5.2.3.9 The key points of quality control for Propeller repairing are as below:
a) Hub inspection;
b) Weld preheating temperature;
c) Welding repair process;
d) Geometric dimensions;
e) The surface roughness;
f) Static balance test.
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GB/T XXXXX-XXXX
The inspection & test for acceptance of propeller repairs are as below:
a) Carry out non-destructive testing and provide the report;
b) Preheating and annealing recorded, cone fitting inspection report;
c) Geometric dimensions measurement report;
d) Carry out a static balance test and provide the report.
5.3 Rudder system
The key points of the survey for rudder system are as below:
a) If the rudder system is overhauled, check the rudder movement before the rudder is disassembled;
b) Check and record the clearance between the rudder tiller and the hydraulic piston cross;
c) Check the alignment between the rudder angle indicator in steering gear room and actual position of
rudder;
d) Check the clearance of the rudder bushing, the rudder stock and the rudder pintle;
e) Check the corrosion of the rudder stock and the rudder blade;
f) Check the deviation of each rudder bushing hole center;
g) Check the deviation of the rudder stock, the rudder pintle and the rudder plate’s centerline;
h) Check the wearing down condition after the rudder stock and rudder pintle are disassembled.
5.3.2.1 The diameter of the rudder stock after repairing shall be in accordance with the requirement of the
design. The surface of the working shaft neck shall be kept if there are only a few separate corrosion points,
but the depth of these points shall not exceed 1% of rudder stock diameter. The decrement of the non-working
shaft neck for the rudder stock shall exceed 7% of the original design diameter, and the decrement of the
working neck diameter shall not exceed 10% of the normal diameter after machining.
5.3.2.2 If the straightness of the rudder stock is not more than 0.7 times of the fitting clearance, it shall be
reused.
5.3.2.3 The circularity, cylindricity and coaxiality of the working shaft neck for the rudder stock shall be in
Table 64 Circularity，Cylindricity and coaxiality for shaft neck Unit: mm
Diameter of Circularity and Cylindricity

coaxiality
tiller d18 shrink fit clearance fit
＞50～80 0.040 0.10 0.06
80～120 0.045 0.12 0.08
120～180 0.050 0.14 0.10
180～260 0.055 0.16 0.15
260～360 0.060 0.18 0.20
360～500 0.065 0.20 0.25
500～800 0.070 0.24 0.30
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GB/T XXXXX-XXXX
5.3.2.4 The wall thickness of the rudder stock sleeve and the shrink fit shall be in accordance with the
Table 65 The wall thickness and interference fit of the rudder stock sleeve Unit: mm
Wall thickness of stainless steel Interferance fit Interferance fit

Diameter of Wall thickness of copper sleeve
sleeve of copper of stainless
rudder stock d19
Standard scope Sailing limit Standard scope Sailing limit sleeve steel sleeve
＞80～100 5.0～6.0 2.5 0.017～0.106 0.014～0.085
5.0 2.5
100～120 6.0～8.0 3.0 0.025～0.114 0.020～0.091
120～140 0.029～0.132 0.023～0.110
8.0～10.0 4.0 6.0～8.5 3.0
140～160 0.037～0.140 0.026～0.112
160～180 0.045～0.148 0.036～0.120
10.0～12.0 5.0
180～200 8.0～12.0 4.0 0.050～0.168 0.040～0.134
200～225 0.058～0.176 0.046～0.141
225～250 12.0～16.0 6.0 0.068～0.186 0.054～0.149
10.0～14.0 5.0
250～300 0.077～0.210 0.062～0.168
300～315 0.089～0.222 0.071～0.178
315～355 16.0～20.0 8.0 14.0～17.0 7.0 0.101～0.247 0.081～0.198
365～400 0.119～0.265 0.095～0.212
400～450 0.135～0.295 0.108～0.236
20.0～24.0 10.0 17.0～21.0 8.0
450～500 0.155～0.315 0.124～0.252
500～550 0.175～0.325 0.140～0.252
24.0～30.0 12.0 21.0～26.0 10.0
550～600 0.195～0.345 0.156～0.276
600～800 30.0～35.0 14.0 26.0～30.0 12.0 0.215～0.365 0.172～0.292
5.3.2.5 The fit clearance between the partial underhung rudder pintle and the rudder bushing shall be in
Table 66 Fit clearance between the partial underhung rudder pintle and the rudder bushing Unit: mm
Diameter of rudder Copper and bearing alloy Resin synthetic material

pintle d20 Standard scope Sailing limit Standard scope Sailing limit
≤50 0.30～0.45 2.50 0.35～0.50 3.00
50～80 0.45～0.60 3.00 0.50～0.65 3.50
80～120 0.60～0.80 4.00 0.65～0.85 4.50
120～180 0.80～1.10 0.85～1.15
4.50 5.00
180～250 1.10～1.45 1.15～1.50
250～315 1.45～1.78 1.50～1.80 5.50
5.00
315～400 1.78～2.20 1.80～2.25 6.00
400～500 2.20～2.70 6.00 2.25～2.75 6.50
5.3.2.6 Assembly clearance of the lower rudder bearding of the double support balanced rudder and duct
rudder shall meet the requirements in Table 67. For vessels sailing in shallow water, race water or a narrow
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GB/T XXXXX-XXXX
sea-route, the assembly clearance is 75% of the standard values, with the minimum value for the rudder stock
bearing and the maximum value for the rudder pin bearing.
Table 67 Assembly clearance of the lower rudder bearding
of double support balanced rudder and duct rudder Unit: mm

stock d21 Standard scope Sailing limit Standard scope Sailing limit
≤80 0.35～0.50 3.00 0.40～0.55 3.00
80～120 0.50～0.60 4.00 0.55～0.65 4.00
120～180 0.60～0.70 0.65～0.80
4.50 4.50
180～250 0.70～0.85 0.80～0.95
250～315 0.85～1.00 5.00 0.95～1.15 5.00
315～400 1.00～1.15 5.50 1.15～1.35 5.50
400～500 1.15～1.35 6.00 1.35～1.60 6.50
5.3.2.7 Assembly clearance of a through blade rudder bearing shall be in accordance with the requirements
in Table 68.
Table 68 Assembly clearance of a through blade rudder bearing Unit: mm

≤80 0.50～0.60 3.00 0.55～0.65 3.25
80～120 0.60～0.65 4.00 0.65～0.75 4.50
120～180 0.65～0.76 0.75～0.90
4.50 5.00
180～250 0.76～0.90 0.90～1.10
250～315 0.90～1.03 5.00 1.10～1.25 5.25
315～400 1.03～1.20 5.50 1.25～1.50 5.75
400～500 1.20～1.40 6.00 1.50～1.75 6.25
5.3.2.8 Assembly clearance of an under hung rudder bearing shall be in accordance with requirement in
Table 69
Table 69 Assembly clearance of an under hung rudder bearing Unit: mm
Diameter of rudder Copper and bearing alloy rudder bushing Resin synthetic material rudder bushing
＞180～250 0.50～0.60 4.50 0.70～0.80 5.00
250～315 0.60～0.70 5.00 0.80～0.90 5.50
315～400 0.70～0.80 5.50 0.90～1.00 6.00
400～500 0.80～0.95 6.00 1.00～1.15 6.50
500～630 0.95～1.15 6.50 1.15～1.35 7.00
630～800 1.15～1.30 7.00 1.35～1.50 7.50
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GB/T XXXXX-XXXX
5.3.2.9 The installation clearance of a multi support normal rudder bushing shall be in accordance with the
requirements in Table 70. Rudder bottom pin bearing clearance can be more than 20% of value in Table 70.
Table 70 Multi-support rudder pintle bearing fitting clearance Unit: mm

≤50 0.50～0.60 3.00 0.025～0.630 3.20
50～80 0.60～0.80 4.00 0.630～0.840 4.20
80～120 0.80～1.00 0.840～1.050
4.50 4.80
120～180 1.00～1.20 1.050～1.260
180～250 1.20～1.40 5.00 1.260～1.470 5.40
250～315 1.40～1.60 5.50 1.470～1.680 5.80
315～400 1.60～1.80 1.680～1.890
6.00 6.50
400～500 1.80～2.00 1.890～2.100
5.3.2.10 The thickness of the trust plate of the plane sliding rudder carrier shall not be less than 70% of the
design thickness. The fitting clearance between the rudder stock and the rudder carrier shall be in accordance
Table 71 Fitting clearance between rudder stock and rudder carrier Unit: mm
Diameter of rudder Rudder stock and upper rudder bush Upper rudder carrier bearing and
Rudder stock direction
stock d25 Standard scope Sailing limit rudder carrier
≤50 0.25～0.33 1.20 0.030～0.041 0.005～-0.059
50～65 0.005～-0.071
0.33～0.40 1.60 0.041～0.049
65～80 0.003～-0.073
80～100 0.003～-0.086
100～120 0.40～0.46 2.30 0.049～0.057 0～-0.089
120～140 0～-0.103
140～160 -0.002～-0.105
0.46～0.58 2.90 0.057～0.065
160～180 -0.005～-0.108
180～200 -0.005～-0.123
200～225 0.58～0.70 3.50 0.065～0.075 -0.008～-0.126
225～250 -0.012～-0.130
250～280 -0.013～-0.146
0.70～0.80 4.00 0.075～0.084
280～315 -0.017～-0.150
315～355 -0.019～-0.165
0.80～1.00 4.50 0.084～0.093
365～400 -0.025～-0.171
400～450 -0.029～-0.189
1.00～1.20 5.40 0.093～0.103
450～500 -0.035～-0.195
500～560 -0.040～-0.200
1.20～1.40 6.30 0.103～0.147
560～630 -0.045～-0.210
630～800 1.40～1.60 7.00 0.147-0.197 -0.050～-0.220
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GB/T XXXXX-XXXX
5.3.2.11 The fitting clearance of the cylindrical upper rudder bearing repair shall be in accordance with the
Table 72 Fitting clearance of the cylindrical upper rudder bearing and stock Unit: mm
Diameter of rudder Outer circumference of bearing and inner hole Inner bearing hold and rudder stock journal fitting
stock d26 fitting clearance clearance
≤80 0.010～0.015 -0.030～-0.049
80～120 0.020～0.070 -0.036～-0.058
120～180 0.025～0.080 -0.043～-0.068
180～250 0.029～0.090 -0.050～-0.079
250～315 0.032～0.100 -0.056～-0.088
315～400 0.036～0.110 -0.062～-0.098
400～500 0.040～0.120 -0.068～-0.108
500～630 0.044～0.130 -0.074～-0.118
630～800 0.050～0.140 -0.080～-0.128
＞800 0.056～0.150 —
5.3.2.12 The fitting clearance of the plane thrust rolling components shall be in accordance with the
Table 73 Fitting clearance of the plane thrust rolling
upper rudder bearing components Unit: mm
Diameter of rudder The clearance between ring washer and rudder The interference fit between ring washer and
stock d27 stock thrust rolling rudder bearing
≤50 0.100～0.124 -0.037～-0.021
50～80 0.124～0.148 -0.045～-0.026
80～120 0.148～0.174 -0.052～-0.030
120～180 0.174～0.200 -0.061～-0.036
180～250 0.200～0.230 -0.070～-0.041
250～315 0.230～0.260 -0.079～-0.047
315～400 0.260～0.280 -0.087～-0.051
400～500 0.280～0.310 -0.095～-0.055
500～630 0.310～0.480 -0.107～-0.059
630～800 0.480～0.680 -0.114～-0.063
5.3.2.13 The wearing decrease of the rudder pintle shall not be more than 10% of the original design
diameter. The thickness of the brass bushing shall meet the requirements in Table 74. The thickness of the
stainless steel bush could be reduced by 20% of the requirements in Table 74.
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GB/T XXXXX-XXXX
Table 74 The thickness of bushing and installation clearance Unit: mm
Pintle and bushing fitting

Diameter of Rudder Pintle Jounal d28 Standard range Max allowance
Wring
＞80～120 ≥10 5 0.08～0.11
120～180 ≥12 6 0.11～0.16
180～260 ≥14 7 0.16～0.20
260～360 ≥16 8 0.20～0.25
360～500 ≥18 9 0.25～0.30
5.3.2.14 Assembly of rudder system components

a) The assembly values of the rudder tiller and the rudder stock shall be in accordance with the
requirements in Table 75;
Table 75 Rudder tiller and rudder stock fitting standard Unit: mm
Diameter of Rudder stock d29 Integrated tiller fitting Divided tiller installation Quadrant tiller fitting
interference value clearance
≤80 0.04～0.06 0.03～ -0.02 0.08～0.09
80～120 0.06～0.08 0.03～ -0.03 0.09～0.13
120～180 0.08～0.09 0.04～ -0.03 0.13～0.17
180～250 0.09～0.11 0.04～ -0.03 0.17～0.23
250～315 0.11～0.13 0.05～ -0.04 0.23～0.27
315～400 0.13～0.15 0.05～ -0.04 0.27～0.33
400～500 0.15～0.17 0.05～ -0.05 0.33～0.37
b) The working surface parallelism of the rudder stock key way shall be 0.15 mm/m, and the depth
deflection of the key way shall be no more than 0.15 mm. After the key is fitted in, a 0.05 mm feeler
gauge shall not be inserted in at both sides, while partly repaired; the insert depth shall be less than
15% length of the key;
c) The flange connection of the rudder stock and the rudder blade: after the flange installation, the
clearance between the flat key and top surface of the key way shall be 0.30 mm～0.50 mm. The
fitting and machining accuracy of the connection bolts and holes shall be in accordance with the
requirements in Table 76. The strength of connection bolts shall be stronger than rudder stock.
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GB/T XXXXX-XXXX
Table 76 The fitting and machining accuracy of connection bolts and holes Unit: mm
Bolt diameter d30 ≤30 30～50 50～70 70～100 100～120 120～160

Fitting standard 0～+0.01 -0.005～ +0.005 -0.01～ 0 -0.02～-0.005 -0.025～-0.01 -0.03～ -0.015
Cylindricity 0.02 0.03 0.035 0.04
Hole
Roundness 0.01 0.025
0.02 0.03
Cylindricity 0.015 0.03
Bolt
Roundness 0.01 0.015 0.02
d) Rudder stock and rudder tapering connection; after tapering end nut tightened, the 0.05mm feeler
gauge insertion depth between the nut and the support surface could be no more than 10mm, and the
inserting length shall be no more than 10% of the nut circumference;
e) The fitting clearance of a balanced rudder with axle technological bushing shall be in accordance
Table 77 Technological bushing fitting clearance Unit: mm
D Diameter of technological bushing D8 Requirement

≤80 -0.015～ +0.060
80～120 -0.020～ +0.070
120～180 -0.020～ +0.080
180～250 -0.025～ +0.095
250～315
-0.030～ +0.110
315～400
400～500 -0.030～ +0.120
500～630 -0.030～ +0.140
5.3.2.15 Centralising and alignment requirements of the rudder system are as below:
a) The deflection between the rudder center and the shafting center shall be not more than the value
calculated by the formula;
δ 9 = ±0.0013 L6
Where:
Δ9—relative position deflection, unit:m
L6—length of the ship, unit;m
b) For a multi-support rudder, when the base point is chosen at the upper and lower steering gearing
during rudder repairing work, the deflection of all other middle steering gearings center line and base
center line shall be no more than 1/2 of its fitting clearance, and 50% of above standard could be
applied for overhaul.
5.3.2.16 The plane symmetry tolerance of the key way central line and the rudder tiller central line is no
more than 0.10mm. The parallelism tolerance of both the working face and of the key way is no more than
0.15mm/m, and the depth deflection of key way is no more than 0.15mm
5.3.2.17 The taper is 1/10~1/15 for the fitting of the rudder stock tapering end and the rudder blade
tapering hole. The contact area shall be more than 70%.
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GB/T XXXXX-XXXX
5.3.3.1 If the journal of the rudder stock was seriously corroded and the rudder bearing fitting clearance
exceeds the maximum allowance, then repair welding could be a solution to add the diameter of the journal.
Before repair welding, rough machining shall be carried out to remove any rust from the journal.
5.3.3.2 Quality control requirements for the repair of the upper rudder bearing are as below:
a) Sliding upper rudder carrier: if the surface of the stopper is corroded or pitted seriously, machining
shall be applied to repair;
b) Direct flame heating is not allowed when installing a rolling bearing as the rolling upper bearing. If
the components of the bearing are cracked, abraded or corroded seriously, it shall be replaced.
5.3.3.3 Quality control requirements for the lower rudder bearing repair are as below:
a) Repair or replace the bushing when the rudder bearing bushing and main body was loosened;
b) To meet the rudder system alignment requirement, the middle rudder bearing and lower bearing
bushing could be machined with eccentricity;
c) When the lower water-tight sliding rudder bearing was repairing, the rubber gasket shall be renewed.
5.3.3.4 Quality control requirements for rudder pintle repair are as below:
a) Pressure fitting or epoxy adhesive could be applied for the outer circumference of the rudder pintle
bearing;
b) If the rudder pintle was seriously abraded or corroded, machining or repair welding could be applied.
It is a good method to use stainless steel welding for repairing the journal of the rudder pintle.
5.3.3.5 Quality control requirement for fitting the journal of the rudder pintle and rudder stock repairing are
as below:
a) For a journal that is partly corroded, scratched or damaged, and if the depth is less than 1% of the
journal diameter, it could be repaired and used;
b) If the corroded or scratched area of the inner hole of the rudder tiller is less than 15% of its whole
area, it could be manually repaired and used;
c) When tiller hole and rudder stock become loosely engaged, build-up welding or spraying may be
adopted to repair the tiller hole. No cracking that runs vertical to the loading direction is allowed on
tiller;
d) When key way of the journal and key is loosened, widen the key way and replace a fitted key, and
repair welding could be applied to repair the key way.
5.3.3.6 Quality control requirements for rudder stock crack repair are as below:
a) If the length of the crack in the journal is no more than 1/4 of the diameter of the journal, the depth is
no more than 1%, less than 3 cracks are found and longitudinal crack is not in the same direction,
then manual inserting or grinding could be applied as the repair. If the depth of the longitudinal
crack is no more than 5% of the diameter, removing the crack and then welding could be applied as
the repair;
b) For big crack (the depth is 5% bigger than that of journal diameter, or the length is 1/4 of journal
diameter, or more than 3 big cracks are found), then reasonable repairing documents shall be
submitted and approved by owner representative and surveyor before being carried out.
5.3.3.7 Quality control requirements for the repair of the rudder stock bending deformation are as below:
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GB/T XXXXX-XXXX
a) If the linearity of the rudder stock is less than 2 mm/m, cold straightening or hot straightening could
be applied;
b) After the rudder stock was straightened, cutting could be applied to eliminate any remaining
deformation.
5.3.3.8 Quality control requirements for the repair of rudder twisting are as below:
a) When the rudder stock twisting angle is less than 6°, widen the key way;
b) When the rudder stock twisting angle is between 6° and 10°, NDT shall be applied, then carrying out
machining on the key way and annealing before being used;
c) When the rudder stock twisting angle is more than 10°, NDT for the damaged part shall be carried
out, and full inspection and measuring shall be applied. Special repairing documents shall be
provided and approved by the owner representative and surveyor before being carried out, otherwise
the stock shall be replaced.
5.3.3.9 If the depth of corroded rudder blade is less than 35% of plate depth and area is less than 250 cm2,
repair welding could be applied. If the depth is bigger or area is larger, partial inserting and welding could be
applied.
5.3.3.10 The tight-fitting bolts with anti-loosen device shall be adopted for the rudder stock level
connecting flange. The contact surface of the flange shall be painted with anti-corrosion material before
installation.
5.3.3.11 Rudder pintle abrasion and corrosion shall be repaired by machining or repair welding.
5.3.3.12 In general repairing, there is no need to check the relative deflection between rudder central line
and base line of the ship and shafting central line. Only the deflection of the rudder bearings needs to be
measured.
5.3.3.13 If the deflection of the rudder central line exceeds the standard, machining of the rudder carrier
inner hole and replacing the rudder bearing could be carried out.
5.3.3.14 Quality control for the rudder repair.
a) Rudder components machining and fitting accuracy;
b) Temperature control of rudder stock and blade repair welding;
c) Rudder blade plate changing;
d) Rudder center line positioning;
e) Rudder stock deformation repairing;
f) Rudder centralising;
g) Tight test.
The inspection & test for acceptancefor the rudder are as below:
a) Check and record the machining and fitting accuracy of each rudder component;
b) Carry out a tight test, and report provided;
c) Carry out a rudder movement test, and report provided;
d) Carry out a sea trial after rudder overhaul, report provided.
5.4 Steering gear
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5.4.1 Key points of the survey:
The key points of the survey for the steering gear are as below:
a) Check if slow movement, one side or both sides no movement, excursion or empty rudder happens.
b) Check whether the fixture is loosened.
c) Check working temperature of each component.
d) Check noise and vibration.
e) Dismount and check steering gear.
f) Hydraulic pressure pump overhaul.
5.4.2.1 Quality requirements of reciprocating hydraulic steering gear repair are as below:
a) The sealing surface or the rudder cylinder sealing ring shall not be scratched, shall have good
elasticity, and shall have no deformation;
b) The increment of clearance between the slider and the guide shall be no more than 0.2 mm;
c) The clearance of the crosshead gudgeon bushing and gudgeon shall be no more than 0.004 of the
diameter of the gudgeon;
d) The clearance of the rudder tiller and the cross head bushing shall be no more than 0.004 of the
diameter of the rudder tiller, or shall meet 2 times of the installation guide requirement;
e) The concentricity of four opposed-cylinder central line shall be 0.04mm/m; the concentricity of two
opposed-cylinder central line shall be 0.12 mm;
f) The parallelism of the ram center and ram slider installation surface shall be 0.05mm/m;
g) The parallelism of the cylinder and the guide shall be 0.05 mm/m;
h) The stopper shall guarantee that the maximum rudder angel is no more than 37°;
i) The fitting clearance of the ram and the cylinder bushing shall be no more than 0.0015 of the
diameter of the ram.
5.4.2.2 Quality requirements for rotary hydraulic steering gear repair are as below:
a) The zero-point of oil feeding pumps shall be synchronized;
b) No scratching or aging crack should be found on the surface sealing of rotor and stator;
c) The rubber seal of the rotor and stator shall be no more than two years old;
d) The flatness of the surface of end cover sealing shall be 0.2mm;
e) After installation, the rudder shall move smoothly and with a good fit.
5.4.3.1 If the surface of the oil tray is abraded, grind the oil tray on 0 grade accuracy plating with M1
alumina then wash in coal oil and polish.
5.4.3.2 If the oil surface of the cylinder is seriously abraded, grind the surface, then polish. To avoid emery
embedded into the brass, it is not permitted to use emery as the grinding material.
5.4.3.3 For abrasion of the surface of the variable head and stopper plate, then refer to the oil surface of
cylinder for the repair requirements.
5.4.3.4 When the slide shoes are seriously abraded, spare parts need to be replaced; if slightly abraded,
polish before reuse.
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GB/T XXXXX-XXXX
5.4.3.5 If the chromium plating of the ram surface is partly flaked, corroded or spotted, then quick electric
plating could be applied to repair. If defect area is large, then remove chromium plating and replace.
5.4.3.6 The defect of the cylinder main body could be eliminated by repair welding or chromium plating.
Then a water tight test shall be carried out.
5.4.3.7 If the cross head gudgeon is abraded, repair welding or chromium plating could be applied to
repair.
5.4.3.8 When repairing the guide plate and slide plate, grind the inner slide plate, adding a washer, then
scrape with the guide plate.
5.4.3.9 The key points for the quality control of the steering gear repair are as below:
a) The parallelism between rudder, cylinder center and guide;
b) The clearance between the rudder tiller and crosshead bushing;
c) The clearance between the ram and cylinder bushing;
d) The sealing surface flatness of the rotary steering gear cover;
e) Rubber seal for the rotary steering gear, rotating vane rotor and stator.
The inspection & test for acceptance of the steering gear are as below:
a) Check and record the machining and fitting accuracy of each component;
b) Carry out a tight test, record the data;
c) Carry out a safety valve opening test, record the data;
d) Carry out an integrity inspection, running test, record the data;
e) Carry out a zero load running test, record the data.
5.5 Side thruster
The key points of the survey for the side thruster are as below:
a) Check the integrity of the anti-corrosion painting and anodic protection;
b) Check the corrosion condition of the piping tunnel and protection grating;
c) Check the corrosion and deformation condition of the propeller blade and shaft;
d) Check the sealing condition for the propeller and shafting;
e) Check the abrasion condition of the gear contacting surface;
f) Check the operation condition of the prime mover, gearing and control system.
5.5.2.1 There are no attachments on the shrouding inner plate, gear box surface and propeller blade, the
bolts of each component shall not be loosened.
5.5.2.2 If the anti-corrosion painting is damaged, it shall be repainted, and the anodic protection shall not
be loosened, also checking there is no crack or such defections to be found.
5.5.2.3 Rubber sealing should be without breaking, crack, aging or defection, and expired product shall not
be used.
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GB/T XXXXX-XXXX
5.5.2.4 The conical gear and shaft shall be fitted tightly and the conical gear pair shall run smoothly after
fitting; no impacting or excessive noise occurs. When carrying out a running test, the conical gear auxiliary
shaft axial displacement shall be less than 0.10 mm.
5.5.2.5 Gear with defections as below shall be replaced:
a) The surface of the pitch cone is seriously spot corroded, or hardened layer is flaked;
b) If the gear teeth are seriously abraded, addendum sharped, thickness of teeth are decreased by 1/10
of its original thickness;
c) Partly crack at gear root.
5.5.2.6 When the surface is slightly corroded or spotted, if the ball (roller) is almost in good condition, it
is possible to manually rotate the ball (roller) without being loosened, and no excessive noise occurred, then
after clean, the bearing shall be re-used. But the inner and outer ring should have no crack.
5.5.2.7 The foundation of the prime mover and gearing shall be strong enough, the clutch shall be carefully
inspected, and the deflection of central aligning is ±0.05 mm.
5.5.2.8 For the propeller repairing see Table 5.2.
5.5.2.9 The clearance between propeller blade tip and shrouding inner surface shall meet vender’s
requirement.
5.5.3 Quality control for the repair process
5.5.3.1 If the surface hardness of the gear and pinion is same, only the pinion needs to be replaced when
gear is in good condition.
5.5.3.2 The oil level in normal condition shall maintain for one day with no leakage is allowed, and the
input shaft seal needs to be greased.
5.5.3.3 Oil-resistant gaskets shall be provided in a sealing ring seat and shrouding box fitting surface.
Avoid deformation of the rubber ring when the cover is being fitted.
5.5.3.4 Outer circle of rolling bearing and inner hole separately transition fitted with seat hole and driving
journal, oil solute, a thermo-keeping box to heat and expand the bearing or shrink the journal shall be adopted.
5.5.3.5 Quality control for the repairing of the side thruster:
a) Anti-corrosion painting and anodic protection;
b) Propeller and shaft seal;
c) Gear working condition;
d) The clearance between the propeller blade tip and shrouding inner hole.
The inspection & test for acceptance for side thruster are as below:
a) Check and record;
b) Running test, record the data and provide record report;
c) Mooring test, check and record data.
6 MACHINERY
6.1 Main Engine
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GB/T XXXXX-XXXX
6.1.1 Cylinder Cover
6.1.1.1 The key points of the survey for cylinder cover are as below:
a) Visual inspection of combustion chamber: It should be free from crack, burnout and/or leakage.
NDT and hydraulic test may be required if necessary.
b) Inspection of the cooling water jacket: It should be free from crack and obvious corrosion.
Meanwhile, the condition of anodes inside is to be checked as well.
c) Inspection of the air valve conduits and seats: It should be free from loosen or leakage. The
condition of the contact surface between valves and their seats is to be checked as well.
6.1.1.2 The quality requirements of repairing are as below:
a) Surface roughness of the cylinder cover after machining shall be in compliance with the
Table 78 Roughness of machining surface of the cylinder cover Unit: μm
Location Roughness, Ra
Fitting surface between cylinder cover and cylinder block 3.2
Before lapping and cladding 1.6
Conical surface of air valve seat
After lapping and cladding 0.8
Bore of air valve seat with inlay
3.2
With inlay
Bore of air valve rod
Without inlay 1.6
Bore of air valve conduit 3.2
b) Flatness of the fitting surfaces between the cylinder cover and cylinder body / visor, shall be in
compliance with requirements in Table 79;
Table 79 Flatness of fitting surface of cylinder cover Unit: mm
Bore of cylinder cover Flatness of fitting surfaces with cylinder body Flatness of fitting surfaces with cylinder casing
≤600 0.05 0.10
600～1 000 0.10 0.15
＞1 000 0.15 0.20
c) Accuracy of the bore and the conical surface of air valve seat shall be in compliance with
Table 80 Accuracy of bore and conical surface of air valve seat Unit: mm
Item Requirement
Cylindricality of air valve seat bore 0.5 times of the diameter tolerance
Runout of air valve seat bore based on the surface of air valve conduit 0.10
Verticality of air valve seat bore 0.03
Runout of air valve seat conical surface based on the surface of air valve
0.05
conduit
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GB/T XXXXX-XXXX
d) Concentricity of the injector nozzle stepped hole is to be within 0.10 mm;

e) Verticality of the air valve conduit bore is to be within 0.10 mm/dm in respect to the bottom surface
of air valve seat.
6.1.1.3 The quality control requirements of the repairing process are as below:
a) If the combustion chamber surface is found burn-out it shall be repaired;
b) If the combustion chamber or inner wall of the cooling water chamber is found cracked, the crack is
to be removed and verified with the appropriate NDT. Once the crack is removed, it is to be repaired
by built-up welding and machining. Where cracks have occurred on an unheated surface, the
cylinder cover is to be repaired by built-up welding, engineering plastic gluing and steel doubling. If
the injector nozzle seat bore, conduit or valve seat are found to have defects such as loosening,
leakage and slight crack it shall be repaired by inlaying.
c) If the fitting surfaces of cylinder covers, liners or any additional fitting surfaces of the assembled
cylinder cover are found with defects that affecting air tightness, they are to be repaired by
machining or grinding. The severe corrosion and damage are to be repaired by welding and
machining;
d) The fouling found in the cooling water chamber is to be descaled by chemical cleaning;
e) The quality control points of cylinder cover repair are as below:
1) Roughness of the machining surface of the cylinder cover;
2) Flatness of the fitting surface of the cylinder cover;
3) Accuracy of the bore and Conical surface of air valve seat;
4) Concentricity of the stepped hole of injector nozzle;
5) Verticality of the air valve conduit bore based on the bottom surface of cylinder cover.
6.1.1.4 The inspection & testing for acceptance of the cylinder cover repair are as below:
a) Visual inspection, measurement and record of the machining accuracy of component parts;
b) Carry out NDT for the welding seam and submit the test report after repair of crack;
c) Carry out hydraulic testing and submit the test report.
6.1.2 Cylinder liner
6.1.2.1 The key points of survey for cylinder liner are as below:
a) Check the inner surface for evidence of any abnormal wear, corrosion, crack and other mechanical
damage;
b) Check the inner chrome layer of cylinder liner for peeling, scraping and scarring;
c) Inspect the lubrication arrangement, check if there is any blockage of the hole or oil groove of
lubricator;
d) Inspect the sealing surface of oil filling pipe joint and screw thread, check if there is any damage
present;
e) Inspect the condition of cooling water chamber and sealing ring groove, check the amount of
diminution in corroded areas and verify there is no crack ;
f) Inspect the end faces and root of cylinder liner support shoulder, check there is any corrosion, crack,
scarring through sealing surfaces;
g) Inspect between cylinder liner and cover, check there is any defects such as crack or scarring which
may affect the seal between fitted surfaces;
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GB/T XXXXX-XXXX
h) Inspect the cylinder liner dimensional continuity, check the inner diameter, circularity and the
cylindricity of the liner;
i) In two-stroke diesel engines heightened attention is to be placed at scavenging ports, check if there is
any crack or other potential defects which may reduce the integrity of the liner.
a) The cylinder liner bore wear limit shall be in accordance with the requirements specified by the
manufacturer, if it is not specified, the maximum allowable value shall comply with the requirements
in Table 81;
b) The circularity and cylindricity of cylinder liner bore after machining shall comply with the
Table 81 Inner diameter increment, circularity and cylindricity of cylinder liner Unit: mm
Allowable limit of inner Circularity and Cylindricity

Cylinder bore, D9
diameter increment Standard range Allowable limit
>85～200 0.60 0.015 0.10
200～300 1.00 0.15
0.020
300～400 1.50 0.23
400～500 2.00 0.025 0.28
500～600 3.00 0.35
0.030
600～700 4.00 0.45
700～800 5.00 0.035 0.60
800～900 5.70 0.040 0.65
900～1 000 6.40 0.045 0.70
1 000～1 100 6.80 0.050 0.75
c) The run-out of the external surface of the cylinder liner and upper and lower planes of the upper
shoulder to the centerline of the cylinder liner shall be in accordance with the requirements in Table
82;
Table 82 Full runout of the external surface of cylinder liner and shoulder end face Unit: mm
Full end runout of upper and

Cylinder bore, D10 Full radial runout of excircle
lower plane of upper shoulder
>85～200 0.04
0.03
200～300 0.05
300～400 0.06
0.04
400～500 0.07
500～600 0.08
0.05
600～700 0.09
700～800 0.10
0.06
800～900 0.11
900～1 000 0.12
0.07
1 000～1 100 0.13
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d) The surface roughness of the cylinder liner after machining shall comply with the requirements in
Table 83;
Table 83 Surface roughness of cylinder liner Unit: μm
Machining surface Roughness, Ra

High-speed diesel engine 0.8
Surface of cylinder liner bore Medium-speed diesel engine 1.6
Low-speed diesel engine 3.2
Fitting external surface of cylinder liner and cylinder block 6.3
Upper and lower planes of cylinder liner upper shoulder 3.2
e) The thickness of the chrome layer (unilateral) shall comply with the requirements in Table 84;
Table 84 Thickness of chrome layer Unit: mm
Requirement
Item Cylinder bore, D11
≤100 100～200 200～300 ＞300
Speed of diesel engine＞500/(r/min) 0.10～0.15 0.15～0.20 0.20～0.25 0.25～0.30
Speed of diesel engine≤500/(r/min) — 0.18～0.23 0.23～0.26 0.26～0.30
f) The fitting surface between upper shoulder and cylinder block should be smooth and flat without any
defects such as crack, corrosion, deformations which may affect sealing property;
g) The fitting surface (groove) between cylinder liner and cover shall be smooth and flat without any
defect of crack and scarring through sealing surface.
a) The longitudinal scuffing on the bore surface of the cylinder liner can be removed by polishing when
cases remain within: Width is less than 0.2% times of the cylinder bore; Depth is less than 0.05%
times of the cylinder bore; Total number of scuffing defects is to be less than 3; Spacing is greater
than 50 mm between each scuffing case;
b) Cases outside the permissible longitudinal scuffing allowance shall be repaired by machining, the
cylinder bore shall be machined in cases where circularity and cylindricity exceed the limit due to
uneven wearing. Other defects in the liner bore may be repaired by local inlaying, if the inlay
material is compatible with the liner and the strength of the liner is to remain effective;
c) The cooling water chamber and associated systems shall be descaled and cleaned; Upon completion,
means of corrosion protection shall be renewed. Corrosion protection should be the same or
equivalent to the original means of protection and shall not reduce the heat transfer rate of the
cooling system;
d) Cracks shall be repaired in accordance with the approved procedures by the assigning authority;
e) Cases of crack in unpressurized areas of the cylinder liner should be repaired by built-up welding or
metal cladding;
f) The bore surface of the cylinder liner shall retain it designed material properties, where defects are
found which may be considered to affect these surface proprieties, the liner shall be repaired by
chromium-plating;
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GB/T XXXXX-XXXX
g) The quality control points of cylinder liner repair are as below:

1) Inner diameter increment of the bore;
2) Circularity and cylindricity of the bore;
3) Runout of the cylinder liner external surface and shoulder end face;
4) Surface roughness of the cylinder liner;
5) Thickness of the chrome layer.
6.1.2.4 The inspection & test for acceptance are as below:
a) Submit the measurement report of cylinder liner;
b) Carry out the NDT for the welding seam and submit the test report after repair of crack;
c) Carry out the hydraulic test of cooling water chamber and submit the test report.
6.1.3 Piston
6.1.3.1 The key points of survey for piston are as below:

a) Inspect the piston head, lifting ring screw, piston ring groove and piston skirt, check for evidence of
defects such as crack, burnout, scuffing, deformation and discontinuities;
b) Inspect the connection bolts and pins of piston assembly, check the condition of security of
components. Disassembly maybe required to check bolt holes and fitting surfaces for defects such as
mechanical damage, corrosion and crack if necessary. Inspect the piston inner wall, check if there is
any crack or corrosion and if condition of piston is in doubt hydraulic tests are to be carried out;
c) Inspect the sealing arrangements of the piston, check if there is any crack or loosen on the wearing
ring. Measure the outer diameter of each piston ring and find out the maximum value;
d) Measure the outer diameter of the piston head, piston middle and piston skirt, calculate the
circularity and cylindricity of the piston;
e) Measure the dimension of the piston pin and pin bearing, verify the wearing condition;
f) Measure the width of the piston ring groove and height of the piston ring.
a) The circularity and cylindricity of the piston skirt shall be in accordance with the requirements in
Table 85;
Table 85 Circularity and cylindricity of piston skirt Unit: mm
Circularity and Cylindricity

Cylinder bore, D12
Trunk pistion skirt Crosshead piston skirt
≤100 0.10
100～150 —
0.12
150～200
200～350 0.15
0.30
350～400 0.20
400～500 0.25 0.38
500～550 0.30 0.45
550～600 — 0.50
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Table 85 (continued) Unit: mm
Circularity and Cylindricity

Cylinder bore, D12
Trunk pistion skirt Crosshead piston skirt
600～650 0.60
650～700 0.65
700～750 0.75
750～800 0.85
800～850 0.95
—
850～900 1.05
900～950 1.15
950～1 000 1.25
1 000～1 050 1.35
1 050～1 100 1.40
b) The critical clearance between piston and cylinder liner shall comply with the requirements in Table
86;
Table 86 Critical clearance between piston and cylinder liner Unit: mm
Critical clearance of four-stroke trunk piston Critical clearance of Critical clearance of

Cylinder bore, D13
Cast iron piston Aluminum piston two-stroke trunk piston skirt crosshead piston skirt
≤100 0.35 0.40 —
100～150 0.55 0.60 0.75
150～200 0.72 0.80 1.00
200～250 0.88 1.00 1.10 —
250～300 1.04 1.20 1.20
300～350 1.20 1.40 1.30
350～400 1.35 1.40
400～450 1.50 1.60 2.10
450～500 1.80 2.30
500～550 — 1.90 2.50
550～600 — 2.70
600～650 2.90
650～700 3.20
700～750 3.40
750～800 3.80
800～850 — 4.00
850～900 4.20
— —
900～950 4.50
950～1 000 4.70
1 000～1 050 4.80
1 050～1 100 5.00
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GB/T XXXXX-XXXX
c) The clearance between ring groove and piston ring shall comply with the requirements in Table 87;
Table 87 Clearance between ring groove and piston ring Unit: mm
Clearance of gastight piston ring Clearance of piston scraper ring

Two-stroke Four-stroke
Cylinder bore, D14 Two-stroke Four-stroke
Two pcs on top others Two pcs on top others
Ass. Limit Ass. Limit Ass. Limit Ass. Limit Ass. Limit Ass. Limit
Trunk ≤150 0.15 0.25 0.10 0.25 0.10 0.20 0.08 0.20 0.05 0.25 0.035 0.20
piston 150～225 0.30 0.35 0.15 0.35 0.15 0.30 0.12 0.30 0.06 0.35 0.050 0.30
diesel 225～300 0.35 0.40 0.30 0.40 0.20 0.35 0.16 0.35 0.08 0.40 0.065 0.35
engine ＞300 0.40 0.50 0.35 0.50 0.25 0.45 0.20 0.45 0.09 0.50 0.075 0.45
>400～
Cross-h 0.20 0.40 0.14 0.40
550
ead
550～700 0.27 0.60 0.17 0.50 —
diesel
700～850 0.34 0.70 0.30 0.70
engine
＞850 0.45 0.90 0.40 0.90
d) The clearance between piston pin and pinhole shall comply with the requirements in Table 88;
Table 88 Fitting clearance between piston pin and pinhole Unit: mm
Critical clearance Critical clearance Critical clearance between floating piston pin
between floating between fixed and pinhole
Diameter of pinhole, d31
piston pin and pinhole piston pin and
Cast iron piston Aluminum piston
bushing pinhole bushing
≤50 0.13 0.02 0.04
50～75 0.18 0.03 0.06
0.010
75～100 0.25 0.04
0.07
100～125 0.30 0.05
125～150 0.36 0.06
0.08
150～175 0.40 0.015 0.07
175～200 0.48
—
200～225 0.54
225～250 0.60
0.020
250～275 0.65 —
275～300 0.70
e) The machining accuracy of the pinhole after repair, shall comply with the requirements in Table 89;
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GB/T XXXXX-XXXX
Table 89 Machining accuracy of pinhole Unit: mm
Circularity Inner surface roughness of

Diameter Verticality of the True position of the Concentricity of
and pinhole without bushing
of piston, centerline of centerline of the center line
cylindricity of Steel or cast iron Aluminu
d32 pinhole and piston pinhole and piston pinhole
pinhole piston m piston
≤200 0.10 Grade 6
0.025 mm/dm 0.015 3.2µm 1.6µm
＞200 0.20 tolerance
f) The dimension of the piston pins is to be set in accordance with the new or altered dimensions of the
pinhole. Fitting clearances are to be accordance with the operation manual after the repair of
pinholes, if this information is not available requirements in Table 90 are to be applied.
Table 90 Fitting clearance between piston pin and pin bearing Unit: mm
Fitting clearance between piston Fitting

Fit of floating piston pin and pinhole
pin and bushing clearance
Diameter of between Interference of
piston pin, d33 Tin-base floating piston Fitting clearance of Interference of fixed piston pin
Kelmet
bearing alloy pin and cast iron piston aluminum piston
bushing
≤50 0.050～0.065 0.04～0.05 0.000～0.010 0.010～0.020 0.000～0.010
50～75 0.065～0.095 0.05～0.08 0.010～0.015 0.020～0.030
—
75～100 0.095～0.130 0.08～0.10 0.015～0.020 0.010～0.015
0.020～0.035
100～125 0.130～0.150 0.10～0.12 0.020～0.025
125～150 0.150～0.180 0.12～0.15 0.12～0.15 0.025～0.030
0.025～0.040 0.015～0.020
150～175 0.180～0.210 0.15～0.18 0.15～0.17 0.030～0.035
175～200 0.210～0.240 0.18～0.21 0.17～0.19
200～225 0.240～0.270 0.21～0.24 0.19～0.21
225～250 0.270～0.300 0.24～0.27 0.21～0.23 — 0.020～0.030
250～275 0.300～0.330 0.27～0.30 0.23～0.25
275～300 0.330～0.360 0.30～0.33 0.25～0.27
6.1.3.3 The quality control requirements for the repairing process are as below:
a) If the circularity and cylindricity of piston skirt exceed the limit due to wearing, it shall be repaired
by machining or build up welding;
b) If slight wear of the piston ring and ring groove is found it shall be repaired by machining. In case of
serious wear this shall be repaired by chromium-plating, iron-plating or ring inlaying;
c) If significant wearing, loosening or scuffing of the abrasion ring is found it shall be renewed;
d) If defects and wear of the piston pinhole are found it shall be repaired by boring or reaming;
e) If defects found on the piston head such as crack, burnout, corrosion etc. are found, removal of
defects are to be by hand grinding. In cases where the condition of the piston head fail to meet the
requirements of the operation, manual repairs shall be by build-up welding to restore material to
required thickness;
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GB/T XXXXX-XXXX
f) The quality control points of piston repairs are as below:

1) Circularity and cylindricity of the piston;
2) Tolerance clearance between ring groove and piston ring;
3) Tolerance clearance between piston pin and piston pinhole;
4) Machining accuracy of the piston pinhole;
5) Tolerance clearance between piston pin and pin bearing.
6.1.3.4 The inspection & test for acceptance of piston repairing are as below:
a) Submit the dimension measurement report after piston repair;
b) Submit the measurement report after installation and alignment of piston;
c) Visual check and submit the NDT report;
d) Carry out the hydraulic testing and submit the test report after repair of the combined piston.
6.1.4 Inlet and exhaust valve gear
6.1.4.1 The key points of the survey for inlet and exhaust valve gear are as below:
a) Inspect the air valve rod, valve disc and valve seat, check if there is any defect such as crack, pitting,
sticking and scuffing on the surface. NDT is to be carried out, if necessary;
b) Inspect the air valve disc and valve seat, check for uniform contact and width of sealing face (sealing
line) between contact surfaces;
c) Inspect the air valve rod, check dimension tolerance such as circularity and cylindricity;
d) Inspect the valve rod and conduit, check the tolerance clearance between two components;
e) Inspect the valve seats and cylinder cover or valve casing and conduit, check there is no evidence of
loosening between connection;
f) Inspect the cooling water chamber of valve casing, check for evidence of leakage and where the
condition of components is in doubt carry out hydraulic testing;
g) Inspect the valve springs, check if there are any defects such as crack, corrosive pitting or abnormal
marks of sticking. In addition determine if there is any variation in length of valve springs, carry out
NDT and measure the dimension if necessary.
a) Inspect the end faces of valve rods, checking for concavity on the surface. Inspect the conical surface
of valve rod, check if there is any defect such as longitudinally continuous hard spots, corrosion and
over burning marks;
b) Inspect the end face, rod and conical surface of the air valve rod, check if there is any crack. In cases
where the diameter of the valve rod is more than 20 mm, hair line cracks less than 20 mm in length
are permitted provided there is no more than 2 defects on the same longitudinal direction of valve
rod;
c) Inspect the conical surface of valve seat, check if there is any defect such as longitudinally
continuous hard spots, corrosion and over burning marks. In addition embedded valve seats shall
match with the valve casing securely. In cases where cracks have been found between external and
conical surface of valve seats, cracks in the longitudinal direction are not permitted and no more than
2 transverse hair line cracks are permitted on the same longitudinal direction.
d) After repair the sealing arrangement of the valve shall be verified. Inspect the contact area between
the air valve and conical surface of valve seat shall verify it is not less than 1/3 of the original
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GB/T XXXXX-XXXX
designed fit area and that the width of valve line shall also comply with the requirements in Table
91;
Table 91 Width of valve line Unit: mm
Requirement
Item End face diameter of valve disc, d34
≤50 50～75 75～125 125～175 175～250 ＞250
Width of valve
2.0 2.5 3.0 3.5 4.0 4.0～6.0
line
e) Inspect of the circularity and cylindricity of the valve rod shall be in accordance with the
Table 92 Circularity and cylindricity of valve rod Unit: mm
Revolution of diesel engine, Cylindricity Circularity

r/min Standard range Allowable limit Standard range Allowable limit
≤250 0.040 0.080 0.030 0.060
250～750 0.030 0.060 0.025 0.040
＞750 0.015 0.030 0.015 0.030
f) Inspect the tolerance clearance between valve rod and conduit or guide bushing, verify its
compliance with the requirement of the operation manual. In case where reference information is not
available, the installation clearance shall be in accordance with tolerance H8/c6 and the clearance
limit shall be increased by 2 to 2.5 times of the tolerance H8/c6;
g) Inspect the air valve spring section diameter, verify the deduction is less than 0.07d35(d35 is nominal
diameter of spring). The limit of deduction of the end contact section between the available coils and
support coils is 0.8d35;
h) Inspect the air valve spring at free height, check it remain in the acceptable limits of deviation H6
is±0.025H6. The mean value of all spring (at least 6) shall be used as reference value in case the
nominal dimension of free height is not available.
a) Concavity on valve rod end should be repaired by built-up welding, if any;
b) If wearing of the valve rod is found it shall be repaired by chromium-plating, iron-plating or spray
welding;
c) If defects on the valve disc conical surface are found such as deformation, hard spots, corrosion and
over burning it shall be repaired by machining and the surface renewed built-up welding or spray
welding;
d) If defects on the valve seat conical surface are found it shall be repaired by either machining or
reaming;
e) If the valve seat conical surface is made of cast steel, it shall be repaired by machining or spray
welding. In cases where cast iron material is used instead, seats shall be repaired by spray welding;
f) If defects on integral valve seat are found it shall be repaired by inlaying new seat after turning the
damaged section;
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g) If a leakage of the valve casing is found it shall be repaired by welding or inlaying, after repairing a
hydraulic test shall be carried out to verify repair is effective;
h) If defects on surface of valve spring are found it shall be removed by grinding, after repairs NDT
shall be carried to verify the repair is effective;
i) The quality control points of inlet and exhaust valve gear repair are as below:
1) Tolerance of sealing width of the valve line;
2) Circularity and cylindricity of the valve rod;
3) Tolerance clearance between valve rod and conduit;
4) Section diameter and free height of the valve spring.
a) Visual check, measure and recording the repair accuracy;
b) Facing-up the air valve with valve seat and verify the tightness;
c) Carry out hydraulic test on the integral valve seat of the cooling water chamber and submit the test
report.
6.1.5 Main bearing and connecting rod bearing
6.1.5.1 The key points of survey for main bearing and connecting rod bearing are as below:
a) Inspect the bearing alloy, check if there is any defect such as of shucking, crack, peeling, over
wearing, serious sticking, scuffing and overheating. In addition check if there is any defect of serious
scuffing, burnout and corrosion on the working surface of bearing shell;
b) Inspect the bearing and journal, check the contact area and uniformity between the two contact
surfaces;
c) Inspect the bearing and journal, check the clearance between the two surfaces and verify the
thickness of bearing alloy.
6.1.5.2 The quality requirements of the repairing are as below:
a) Inspect the main bearing and crankpin bearing, check radial fitting clearance and limit clearance
between surfaces to comply with the requirements in Table 93;
b) Inspect the crosshead pin and bearing, check the total axial fitting clearance between surfaces is 0.40
mm～0.60 mm. In addition radial fitting clearance shall comply with the requirements in Table 94;
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GB/T XXXXX-XXXX
Table 93 Fitting clearance between main bearing and crankpin bearing Unit: mm
Trunk piston diesel engine

Crosshead diesel engine
Revelation ≤500 r/min Revelation >500 r/min
Diameter of
Tin-base bearing alloy Kelmet
journal, d36 Standard Allowable Standard Allowable
Standard Allowab Standard Allowab
range limit range limit
range le limit range le limit
≤100 0.06～0.08 0.20 0.08～0.10 0.20
100～125 — 0.08～0.11 0.25 0.10～0.12 0.25
125～150 — 0.11～0.15 0.30 0.13～0.16 0.30
150～200 0.14～0.18 0.30 0.16～0.20 0.40 0.17～0.23 0.40
200～250 0.18～0.22 0.40 0.20～0.24 0.50 0.24～0.28 0.50
250～300 0.17～0.21 0.40 0.22～0.26 0.50 0.24～0.28 0.60
300～350 0.21～0.25 0.50 0.26～0.30 0.60
350～400 0.25～0.30 0.60 0.30～0.34 0.70
—
400～450 0.30～0.35 0.70 0.34～0.38 0.80 —
450～500 0.35～0.40 0.80
—
500～550 0.40～0.45 0.90
550～600 0.45～0.50 1.00
600～650 0.50～0.55 1.10
— — —
650～700 0.55～0.60 1.20
＞700 0.60～0.65 1.30
Table 94 Fitting clearance of crosshead pin bearing Unit: mm
Diameter of crosshead pin,d37 Standard range Allowable limit

≤175 0.10～0.12 0.24
175～200 0.12～0.14 0.28
200～225 0.14～0.16 0.32
225～250 0.16～0.18 0.36
250～275 0.18～0.19 0.38
275～300 0.19～0.21 0.40
300～325 0.21～0.23 0.44
325～350 0.23～0.25 0.48
350～400 0.25～0.28 0.52
400～450 0.28～0.32 0.56
450～500 0.32～0.36 0.60
500～550 0.36～0.40 0.64
550～600 0.40～0.45 0.70
＞600 0.45～0.50 0.76
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c) Inspect the wall thickness dependent on the use of thick or thin-wall bearing shell alloy layers, verify
thick-walls are between 3 mm～6 mm and the thickness of thin-walls comply with the requirements
in Table 95;
Table 95 Thickness of thin-wall bearing shell alloy layer Unit: mm
Diameter of Thickness of thin-wall bearing shell alloy layer

bearing shell, D15 Tin-base bearing alloy Copper-lead alloy Aluminum alloy
≤50 0.40～0.45 0.50～0.60 0.40～0.45
50～100 0.45～0.50 0.60～0.65 0.45～0.50
100～150 0.50～0.55 0.65～0.70 0.50～0.55
150～200 0.55～0.60 0.70～0.75 0.55～0.60
200～250 0.60～0.65 0.75～0.80 0.60～0.65
d) Inspect the thickness of anti-friction layer, check thin-wall bearing shell comply with the
Table 96 Thickness of anti-friction layer of thin-wall bearing shell Unit: mm
Material of anti-friction layer Thickness of anti-friction layer

Tin-base and lead-base bearing alloy 0.25～0.50
0.40～0.80 (Sintering)
Copper-base bearing alloy 0.40～0.80 (Continuous casting)
0.40～1.00 (Centrifugal casting)
Aluminum-base bearing alloy 0.30～0.90
e) Inspect the anti-friction wall thickness deviation which is dependent on the use of thick or thin -wall
bearing shell alloy layers, thick-wall bearing shell is to be 0.5mm, and thin-wall bearing shell is to
comply with the requirements in Table 97;
Table 97 Thickness deviation of anti-friction layer of thin-wall bearing shell Unit: mm
Material of anti-friction layer Thickness of bearing wall Deviation
Tin-base bearing alloy ≤3.0 ±0.10

Lead-base bearing alloy ＞3.0 ±0.15
±0.25 (Sintering and continuous casting)
Aluminum alloy —
±0.30 (Centrifugal casting)
＞2.5～3.0 ±0.14
＞3.0～3.5 ±0.16
Aluminum-base bearing alloy ＞3.5～7.0 ±0.25
＞7.0～9.0 ±0.30
＞9.0～11.0 ±0.30
f) Inspect the thickness deviation of bearing shell, verify after machining it complies with the
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Table 98 Thickness deviation of bearing shell Unit: mm
Nominal outside diameter of requirement

bearing shell, D16 Without running-in layer With running-in layer
≤100 ±0.010 ±0.015
100～200 ±0.015 ±0.022
200～300 ±0.020 ±0.030
300～400 ±0.025 ±0.035
400～500 ±0.030 ±0.040
g) Inspect the thinning height and amount of the bearing shell, check it is in accordance with the
requirements in Table 99 and verify transitions from reduction area to the internal working surface
are to be made smooth;
Table 99 Thinning height and amount of bearing shell Unit: mm
Nominal outside diameter of

Height reduction Amount of reduction
bearing shell, D17
≤110 4 0.015～0.030
110～200 5 0.020～0.040
200～340 6 0.030～0.055
340～500 8 0.040～0.070
h) Inspect the width tolerance, verify after machining to compliance with h11;
i) Inspect the bearing shell surface geometric tolerance, verify under the specified hold-down condition,
the parallelism between the two-semi-section surfaces of the bearing shell and the generating line of
the external circle shall not exceed 0.02 mm/dm;
j) Inspect the thrust bearing shell geometric tolerance, verify verticality between the internal and
external side of the flanged plate thrust bearing shell and the generating line of the external circle
shall not exceed 0.04 mm;
k) Inner and outer diameter tolerance of the thin-wall bearing shell shall be in compliance with H7 and
k6. Inner and outer side width tolerance of two flanging of flan fed thrust bearing shell shall be in
compliance with H8 and h11. Inner and outer diameter accuracy tolerance of thick-wall bearing shell
shall be in compliance with H8 and h8, the others shall be same with tolerance requirement of
thin-wall bearing shell;
l) Inspect the bearing shell surface roughness, verify the surface roughness is Ra 0.80 µm of inner and
outer circle of bearing shell is Ra 3.2 µm of the fitting surface of two-semi-section.
a) If thin walled alloy bearing shell is found to be damaged it shall be renewed;
b) If the working surface of the bearing shell is found to have defects such as partial scuffing, corrosion,
eccentric wear, slight and small crack on it shall be repaired by scraping and trimming;
c) If the bearing shell is found to have defects such as small spalling, partial shelling or small crack and
deformation it shall be repaired by built-up welding;
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GB/T XXXXX-XXXX
d) If the bearing shell back is found to have any defects it shall be repaired by tin-plating or copper
plating;
e) If there is any defect on bearing shell surface such as large areas of shelling or spalling, over
wearing, closed cracks, burnt-out and serious corrosion, it shall be renewed or the bearing alloy
surface is to be recast with equivalent materials;
f) If the clearance of the bearing exceeds the prescribed allowable limits it shall be renewed or the
bearing alloy surface recast;
g) The quality control points of main bearing and connecting rod bearing repair are as below:
1) Assembly clearance between main bearing and crank pin bearing;
2) Assembly clearance of the crosshead pin bearing;
3) Thickness of the bearing shell alloy layer;
4) Thickness of the anti-friction layer of thin-wall bearing shell;
5) Thickness of the bearing shell;
6) Thinning height and amount of bearing shell.
a) Visual check, measure and record thickness of the alloy layer, thickness of the anti-friction layer,
bore relief and thinning height;
b) Measure and record the installation clearance between main bearing and connecting rod bearing and
summit the report;
c) Carry out the NDT and submit the test report.
6.2 Prime mover of diesel generator 1)
6.2.1.1 The key points of the survey are as below:

a) Inspect the crankshaft journal, verify there is no evidence of defects such as scuffing, corrosion pits,
mechanical damage and ensuring wear condition;
b) Inspect the main bearing along with upper and lower ends of connecting rod bearing, verify there is
no evidence of defects such as crack shucking, overheating, burning, scuffing, splintering and
ensuring wear condition;
c) Inspect the connecting rod of surfaces, verify where surfaces are machined there are no defects such
as crack, pitting, burrs and scuffing. In addition where surfaces are non-machined verify there are no
defects such as crack, deformation, enfoldment and over burning;
d) Inspect the connecting rod bolt hole of end face, verify there are no defects such as crack, pitting,
burr and scuffing;
e) Inspect the piston working surface, verify there are no defects such as crack, scuffing, pitting and
burr. In addition verify there is no deformation of the piston pin or any oxidation of the pin hole
surface;
f) Inspect the piston head, lifting ring screw, piston ring groove, piston pin bore and piston skirt, verify
there are no defects such as crack, burnout, scuffing on the and ensuring wear condition;
g) Inspect the working surface of cylinder liner, verify there are no defects such as scuffing, mark of
sticking, dimension of the inner diameter and ensuring wear condition of cylinder liner;
1) The quality requirements of other purposed diesel engine can also take a reference.
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GB/T XXXXX-XXXX
h) Inspect the cooling water chamber of cylinder liner, verify the scale rate and corrosion condition;
i) Inspect the cylinder cover combustion chamber surface, verify there are no defects such as crack,
erosion and irregularity; Inspect the grooves between fitting surface of the cylinder liner and cover,
verify there are no defects such as crack, erosion and irregularity;
j) Inspect the springs of air valve, starting valve and safety valve, verify there are no defects such as
plastic deformation, distortion and crack. Inspect geometric tolerance, verify the flatness of spring
mounting face and verticality of spring shaft line. Inspect the adjacent circle and end circle verify
there are no defects such as concave-convex deformation, drum deformation, waist shape
deformation and looseness. Inspect the rolling ball and groove of the rotary valve lifter of air valve,
verify there are no deformation and sinking.
k) Inspect the injection pump surface, verify matching parts are free of defects such as crack, grinding
crack, breach, damage, pitting and burring;
l) Inspect the injector nozzle wear condition.
6.2.2.1 The radial runout of the crankshaft main journal is not more than 50% of the total installation
clearance of main journal.
6.2.2.2 The circularity and cylindricity of the crankshaft journal shall comply with the requirements in
Table 100.
Table 100 Circularity and cylindricality of crankshaft journal Unit: mm
After repair Speed of crankshaft ≤500 r/min Speed of crankshaft＞500 r/min

Diameter
Main journal Crankpin journal Main journal Crankpin journal Main journal Crankpin journal
of journal
Circularity Circul cylind Circul cylindr
Circularity and Circul cylind Circul cylind
d38 and
cylindricity arity ricity arity ricity arity ricity arity icity
cylindricity
≤75 0.010 —
75～100 0.015 0.020
— 0.035
100～125 0.040
0.020 0.025
125～150 0.040
150～175 0.050 0.050 0.050
0.050 0.050
175～200 0.060 0.070 0.060 0.070 0.060 0.060
0.025 0.030
200～225 0.070 0.080 0.070 0.080 0.060 0.070 0.060 0.070
225～250 0.080 0.090 0.070
0.080 0.090 0.070 0.080 0.080
250～275 0.080
0.030 0.040 0.090 0.100
275～300 0.090 0.100 0.080 0.090
6.2.2.3 The radial runout of the main journal to crankshaft centerline shall comply with the requirements in
Table 101.
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GB/T XXXXX-XXXX
Table 101 Radial runout of main journal Unit: mm
Number of Number of Diameter of main journal，d39

journal support crankpin ≤75 75～100 100～150 150～250 250～350
1 1～3 0.015 0.020 0.025 0.030 0.040
2～3 4 0.020 0.025 0.030 0.040 0.050
3～4 5～8 0.025 0.030 0.035 0.050 0.060
5～6 9～12 — 0.040 0.055 0.065
6.2.2.4 The radial fitting clearance between main journal and main bearing shall comply with requirement
in Table 102.
Table 102 Radial fitting clearance of main journal Unit: mm
Speed of crankshaft＞500 r/min

Speed of crankshaft≤500 r/min
Diameter of White metal Copper alloy
journal,d40 Allowable Standard Allowable Allowable
Standard range Standard range
limits range limits limits
>75～100 0.06～0.08 0.20 0.08～0.10 0.20
100～125 — 0.08～0.11 0.25 0.10～0.12 0.25
125～150 0.11～0.15 0.30 0.13～0.16 0.30
150～200 0.14～0.18 0.30 0.16～0.20 0.40 0.17～0.23 0.40
200～250 0.18～0.22 0.40 0.20～0.24 0.50 0.24～0.28 0.50
250～300 0.22～0.26 0.50 0.24～0.28 0.60 — —
6.2.2.5 The parallelism of the crankpin center line to main journal center line is to be within 0.015 mm/dm.
6.2.2.6 The roughness of journal surface including transition arc area is to be Ra1.6 µm.
6.2.2.7 The transition arc area of the journal shall be checked by a sampler, and the clearance shall be not
more than 0.30 mm between transition arc area and sampler.
The main journal and main bearing shall be evenly contacted with the contact angle of 40°～60°. The crankpin
bearing and piston pin bearing shall be evenly contacted with the contact angle of 90°～120°. The Distribution
density of evenly contact area is 60％～70％. The contact area of the back bearing shell shall be greater than
75％.
6.2.2.8 The fitting clearance and limit clearance between lower end bearing of the connecting rod and
journal shall comply with the requirements in Table 102, the fitting clearance and limit clearance between
upper end bearing of the connecting rod and piston pin shall comply with the requirements in Table 103.
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GB/T XXXXX-XXXX
Table 103 Fitting clearance of piston pin Unit: mm
Diameter of piston pin,d41 Standard range Allowable limit

>25～50 0.03～0.04 0.08
50～75 0.04～0.05 0.10
75～100 0.05～0.06 0.14
100～125 0.06～0.08 0.16
125～150 0.08～0.10 0.20
150～175 0.10～0.12 0.24
175～200 0.12～0.14 0.28
6.2.2.9 The fitting interference of connecting rod bush and piston pin bush with mounting holes shall
comply with the requirements in Table 104.
Table 104 Fitting interference of bush Unit: mm
Outer diameter of bush,D18 Interference

≤50 0.015～0.025
50～75 0.020～0.030
75～125 0.025～0.040
125～175 0.030～0.050
175～250 0.040～0.060
＞250 0.060～0.080
6.2.2.10 The center line accuracy of the connecting rod upper and lower end after repair shall comply with
Table 105 Accuracy of center line of the upper and lower ends for connecting rod Unit: mm
Requirements
Items
Parallelism Grandient Verticality Position
Fore-and-aft direction 0.02 mm/dm —
—
Left-to-right direction of axis 0.05 mm /dm
Upper and lower end of hole axis line and connecting rod axis — 0.015 mm /dm 0.05
Two side of the lower end to lower end of hole axis line — 0.03 mm /dm
—
Lower connection plane and big end hole axis line 0.015 mm /dm —
6.2.2.11 The circularity and cylindricity of the piston pin shall comply with the requirements in Table 106,
the interference and fitting clearance of the piston pin shall comply with the requirements in Table 107.
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Table 106 Circularity and cylindricity of piston pin Unit: mm
Diameter of piston pin, d42 Circularity and cylindricity

≤50 0.03
50～75
0.04
75～100
100～125
0.05
125～150
150～175
0.06
175～200
200～250 0.07
＞250 0.08
Table 107 Interference and fitting clearance of piston pin Unit: mm
Fitting clearance of piston pin Interference of floating piston pin

Diameter of Fitting clearance of
and bush and pin hole Interference of
piston pin, floating piston pin
Aluminum fixed piston pin
d43 Kelmet White metal and pin hole bush Cast iron piston
piston
≤50 0.050～0.065 0.040～0.050 0～0.010 0.010～0.020 0～0.010
50～75 0.065～0.095 0.050～0.080 0.010～0.015 0.020～0.030
—
75～100 0.095～0.130 0.080～0.100 0.015～0.020 0.010～0.015
0.020～0.035
100～125 0.130～0.150 0.100～0.120 0.020～0.025
125～150 0.150～0.180 0.120～0.150 0.120～0.150 0.025～0.030
0.025～0.040 0.015～0.020
150～175 0.180～0.210 0.150～0.180 0.150～0.170 0.030～0.035
175～200 0.210～0.240 0.180～0.210 0.170～0.190 — 0.020～0.030
6.2.2.12 There shall be no transversal crack on the working surface of the piston pin. Individual
longitudinal cracks are allowable where the number of defects is less than 5, and if defects are found in the
same piston pin cross it is to be less than 2.
6.2.2.13 The piston pin and bush shall be evenly mated with the contact angle of 60°～90°.
6.2.2.14 The coaxiality of the piston pin center line is to be 0.02 mm. The verticality of piston pin center
line in relationship to the piston center line is to be 0.015 mm/dm.
6.2.2.15 After the piston replaced, the fitting clearance between the piston and cylinder liner shall comply
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GB/T XXXXX-XXXX
Table 108 Fitting clearance between piston and cylinder liner Unit: mm
Clearance between cast iron

Piston skirt
crown and aluminum alloy crown
Cylinder bore,
Cast iron piston Aluminum piston
D19 Top with Top without
Allowable Allowable
cooling cooling Standard range Standard range
limits limits
>75～100 0.50～0.64 0.60～0.80 0.09～0.12 0.35 0.18～0.22 —
100～125 0.64～0.80 0.80～1.00 0.12～0.15 0.45 0.22～0.26 0.50
125～150 0.80～1.00 1.00～1.20 0.15～0.18 0.55 0.26～0.32 0.60
150～175 1.00～1.16 1.20～1.40 0.18～0.21 0.65 0.32～0.38 0.70
175～200 1.16～1.32 1.40～1.60 0.21～0.24 0.72 0.38～0.44 0.80
200～225 1.32～1.48 1.60～1.80 0.24～0.27 0.80 0.44～0.50 0.90
225～250 1.48～1.64 1.80～2.00 0.27～0.30 0.88 0.50～0.56 1.00
250～275 1.64～1.80 2.00～2.20 0.30～0.33 0.96 0.56～0.62 1.10
275～300 1.80～1.96 2.20～2.40 0.33～0.36 1.04 0.62～0.68 1.20
300～325 1.96～2.12 2.40～2.60 0.36～0.39 1.12 0.68～0.76 1.30
325～350 2.12～2.28 2.60～2.80 0.39～0.42 1.20 0.76～0.82 1.40
6.2.2.16 The flatness of fitted face between the cylinder cover and cylinder liner is to be 0.15 mm, and the
surface roughness is to be Ra 3.2 µm.
6.2.2.17 The height of ring groove shall be not more than 30% of original height after trimming and
machining.
6.2.3 Quality control of the repairing process
6.2.3.1 The abrasion of the crankshaft main journal shall be repaired by chromium-plating or iron-plating.
6.2.3.2 The deformation of the connecting rod shall be straightened under cold or hot conditions. The
heating temperature shall be not more than the metallic transition temperature and NDT shall be carried out
after straightening.
6.2.3.3 The abrasion of the piston pin shall be repaired by chromium-plating or low temperature
iron-plating.
6.2.3.4 Piston and piston ring:
a) Defects such as crack, corrosion and burnout of the piston head ring groove shall be repaired by
built-up welding;
b) Abrasion on upper and lower end faces of the piston ring groove shall be machined and replaced
with a thickened piston ring.
6.2.3.5 Hydraulic testing of the cylinder liner shall be carried out after assembly.
6.2.3.6 The quality requirements of the cylinder cover and valve repair are as below:
a) Leakage of the air valve conduit and seat bore shall be repaired by inlaying;
b) Abrasion of the sealing surface on air valve seat shall be repaired by machining or inlaying;
c) Abrasion of the working surface on air valve seat shall be repaired by built-up welding;
d) Cracks in the cylinder cover shall be repaired by welding, polymer bonding or tie inserting , if the
strength is beyond of problem;
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GB/T XXXXX-XXXX
e) Grooves between the fitting surface of the cylinder liner and cover shall be removed by machining;
f) The air valve rod shall be replaced or repaired by chromium-plating in cases of abrasion. The valve
rod straightness is to be greater than 50% of installation clearance between valve rod and conduit;
g) The abrasion of the air valve working surface shall be repaired by built-up welding;
h) The scuffing, pitting and abrasion on sealing surface of the air valve, valve seat or the safety valve
shall be repaired by smoothly grinding.
6.2.3.7 The quality requirements for repair of fuel injector fitted parts are as below:
a) The defects such as mechanical damage, pitting, burring and minor deformation in the delivery valve
of the injection pump shall be removed by smoothly grinding;
b) The sealing surface of fitted coupled parts shall be smoothly grinded. The sliding fitting test is to be
carried out after grinding;
c) The excessive fitting clearance between injector needle and valve seat shall be repaired matching
couples and by smoothly grinding. The sliding fitting test is to be carried out after grinding.
6.2.3.8 The quality control points of prime mover of diesel generator repairing are as below:
a) Circularity and cylindricity of the crankshaft journal;
b) Radial runout of the main journal;
c) Radial fitting clearance of the main journal;
d) Fitting clearance of the piston pin;
e) Fitting interference of the bush;
f) Accuracy of the center line of upper and lower ends for connecting rod;
g) Wearing limit of the piston pin;
h) Interference and fitting clearance of the piston pin;
i) Fitting clearance between piston and cylinder liner.
Inspection & Test for acceptance of prime mover of diesel generator repairing as below:
a) Carry out the load test after overhaul;
b) Carry out the hydraulic test and submit the test report after cylinder cover repaired;
c) Carry out the correction and submit the report after safety valve repaired;
d) Carry out the oil discharge balance test and submit the test report after combined oil pump repaired;
e) Carry out the function test, sealing test and spray teat and submit the test report after oil injector
needle valve couple repaired.
6.3 Marine boiler
6.3.1 Boiler body
6.3.1.1 The key points of the survey for boiler body are as below:
a) Inspect the boiler shell plate, verify if there is any corrosion, deformation or crack;
b) Inspect the boiler furnace, verify if there is any deformation;
c) Inspect the boiler tube plate, verify if there is any deformation and crack;
d) Inspect the fire-proof coating, verify if there is any crazing, inclining or prolapsing of boiler fire
retardant tiles;
e) Inspect the fixed bolts, verify if there is any burnout of tiling.
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GB/T XXXXX-XXXX

a) Material of the renewed boiler plate shall be in compliance with the requirements of section 2.1;
b) Sample test of the boiler plate shall be carried out in case where the original information of the boiler
is not available. The tensile strength of new boiler plate shall be not less than 350 MPa. The average
value of impact test samples (3 pcs) should be no less than 27J;
c) Thickness diminution of boiler plate should not exceed 10%. Strength analysis of the boiler plate
shall be carried out in case where the corrosion depth exceed the permissible limit;
d) Boiler plate local corrosion is not to exceed more than 20% thickness of the original boiler plate and
the rectilinear length of the corrosion area in any direction is comply with the requirements in Table
109;
Table 109 Rectilinear length of boiler plate corrosion area Unit: mm
Thickness of boiler plate, δ10 Rectilinear length of local corrosion

≤12 ＜8δ10
＞12 ＜7δ10
e) Depth of deformation of the boiler tube plate shall not exceed the original designed thickness of the
tube plate;
f) Local deformation at the top combustion chamber plate around any 4 pieces of stay tube shall
comply with the requirements in Table110;
Table 110 Local deformation of combustion chamber top plate Unit: mm
Diameter of boiler, D20 Deformation

≤1 000 ≤6
＞1 000 ≤8
g) Deformation of boiler tube plate after rectification and welding stay tubes shall comply with the
requirements in Table111;
Table 111 Boiler tube plate deformation Unit: mm
Position Water side flame side

Deformation ≤6 ≤3
h) Circularity of boiler furnace shall comply with the requirements in Table 112;
Table 112 Circularity of boiler furnace Unit: mm
Type Circularity
Plain furnace 0.010D21
Corrugated furnace 0.015D21
Note: D21 ——inner diameter of the boiler furnace
i) Boiler fire retardant tiles are to be provided with manufacturer certification and the exterior shall be
smooth with no defects and crazing;
j) Verticality of the boiler fire retardant tile is 1 mm/m.
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6.3.1.3 The quality control of the repairing are as below:

a) The local corrosion of the boiler plate shall be repaired by built-up welding in case excessive
corrosion;
b) The individual corrosion pit of the boiler furnace is to be repaired by built-up welding in case where
the diameter of pit is less than 3 times of the plate thickness;
c) Repair welding area of more than 2500 cm2 shall be divided into sections, each of the welding
sequence in sections is to be with symmetric manner, and the layers of built-up welding should be
not more than 3 mm height;
d) The crack on the boiler furnace neck shall be removed and repaired by built-up;
e) The boiler tube plate shall be straightened in case excessive deformation;
f) The combustion chamber top plate shall be straightened in case excessive deformation, it shall be
partially cropped and renewed in cases there is any leakage from the stay tube joint;
g) The boiler fire retardant tiles and fire-proof coating shall be repaired in case where defects such as
crazing, inclining and prolapsing are found;
h) The quality control points of boiler plate repair are as below:
1) Material of the boiler plate;
2) Rectilinear length of the boiler plate corrosion area;
3) Local deformation of the combustion chamber top plate;
4) Circularity of the boiler furnace;
5) Verticality of the boiler fire retardant tile;
6) Welding material;
7) Welding quality;
8) Preheat and heat preservation;
9) Tightness test.
6.3.1.4 Inspection & test for acceptance
The inspection & test for acceptance of boiler plate repairing are as below:
a) Carry out NDT for the welding seams of important parts as per the requirement of assigning
authority and owner’s representative and submit the test report;
b) Carry out the tightness test and submit the test report;
c) Carry out the function test and submit the test report.
6.3.2 Boiler tube
6.3.2.1 The key points of the survey are as below:

a) Inspect the boiler smoke tube, verify if there is any defect such as corrosion, leakage, deformation,
crack and thickness gauging of tube ends;
b) Inspect the boiler water tube, verify if there is any defect such as corrosion, leakage and deformation
and thickness gauging water tube;
c) Inspect the boiler tube stay, verify the wear limit and taking measurement of the tube diameter.
a) The material of new boiler smoke tube, water tube and stay tube shall be in compliance with the
requirements of section 3.1;
b) The new boiler tube shall be sampled before inspection and hydraulic tested before fabrication;
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c) There are to be no defects such as crack, scuffing, corrugation and deformation on the surface of the
boiler tube. In addition thinning thicknesses in the bend area shall be less than 15% of the original
designed thickness;
d) The correctness of the bend tube shape shall be checked by sampler in according with figure 2. The
shape tolerance of bead tube shall comply with the requirements in Table 113;
Figure 2 Sample checking schematic
Table 113 Shape deviation of bend tube Unit: mm
Item Requirement
Deviation of pipe end, A0 ≤1
Deviation of pipe body, B2 ≤3
Deviation of pipe ends in horizontal direction, C ±2
Deviation of pipe ends in vertical direction, D22 -2～5
Straightness of sraight tube 3
e) The flaring and necking of boiler tube ends shall be finished under the temperatures greater than
800℃, the dimension deviation of boiler tube end shall comply with the requirements in Table 114;
Table 114 Dimension deviation of boiler tube end
Item Requirement
Length deviationof flaring or necking tube end ＞The sum of tube plate thickness and welding seam height
Diameterdeviation of flaring or necking tube end ≤0.01 times of boiler tube diameter
Positional deviation of flaring or necking tube end center ≤0.02 times of boiler tube diameter, but≤2 mm
Thinning amount of transitional region which between tube Less than 20% of original designed thickness.
end expansion or necking point and boiler tube Transitional region shall be away from tube plate 2mm~5 mm
f) One butt joint is permitted every 5m～7m along the length of the tube or along the whole length of
the tube where tubes are coiled. The requirement of butt joints shall comply with the requirements in
Table 115;
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GB/T XXXXX-XXXX
Table 115 Requirement of butt joint
Item Requirement
Welding groove and
Groove angle is 60 degree, root gap of welding seam is 2 mm, weld reinforcement is 2 mm.
welding seam
The groove shall be aligning and the offset not more than 10% of pipe thickness. The center line
Butt joint
perpendiculars to the end of pipe.
NDT to be carried out and exterior shall smooth and no crack, welding scars, pit and pore.
Inspection of welding seam
The undercut depth not more than 0.5 mm.
g) The tube search of the boiler shall be carried out after butt jointing or bending. The diameter of steel
ball shall comply with the requirements in Table 116;
Table 116 Diameter of steel ball Unit: mm
Tube bending radius of tube, R5 Requirement

≤2d44(d44＜25) 0.75d45
＜3d44 0.85d45
≥3d44 0.90d45
Note: d44 ——outer diameter of tube, d45 —— inner diameter of tube.
h) Annealing of the flaring tube end shall be carried out before tube assembly, with the temperature of
600℃ to 650℃. The length of annealed flaring tube end shall not be less than 100 mm and the time
of heat soak shall not be less than 12 min;
i) The surface of flaring tube end shall be smoothly polished, the length of polishing section shall be
more than 1.5 times of tube thickness;
j) The expanding tube shall be matched with the tube hole, and the fitting clearance between tube hole
and tube wall shall comply with the requirements in Table 117;
Table 117 Fitting clearance of expanding tube Unit: mm
Diameter of tube, D23 Requirement

＜38 0.5～0.8
≥38 0.6～1.0
k) The expanding tube end shall extend 6mm～8mm out of the tube plate. The transitional expansion
region shall be smooth.The length of expansion part shall be beyond the expansion connection, but
less than 5 mm;
l) Fitting of the tube in heating surface shall comply with the requirements in Table 118;
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GB/T XXXXX-XXXX
Table 118 Fitting requirement of boiler tube Unit: mm
Item Requirement
Space tolerance of closed-pitched water wall tubes ±0.5
Flatness of water wall tube banks 2.5
Space tolerance of convection heating surface tubes
±2.0
Space tolerance of convection heating surface tube banks
Flatness of convection heating surface tube banks 2.5
Center distance tolerance of water wall side tubes ≤2.0
Center distance tolerance of convection heating surface side tubes ≤3.0
m) The stay may remain unchanged where diameter reduction is not greater than 10% due to corrosion
or greater than 15% with an amount of less than 5% of the total stays, furthermore, which does not
concentrate at one place;
n) Circularity of stay tube after repair is to be within 0.5 mm;
o) Diameter deviation of stay tube shall comply with the requirements in Table 119.
Table 119 Diameter deviation of stay tube Unit: mm
Requirement
Item Stay tube diameter, d46
＜25 25～50 50～60 60～75 ≥75
+0.4 +0.4 +0.4 +0.5 +0.5
Deviation, △d46
-0.5 -0.7 -1.0 -1.1 -1.2
6.3.2.3 The quality control requirements of the repairing are as below:

a) The tube material shall be bent with uniform heating and at temperatures greater than 700℃. After
bending the interior and exterior of tube surfaces shall be cleaned;
b) Grease, dirt and oxides shall be cleaned before the boiler tube, stay and tube plate are to be installed;
c) The quality control points of boiler tube repair are as below:
1) Material of the boiler tube;
2) Shape deviation of the bend tube;
3) Dimension deviation of the boiler tube end;
4) Tube search of the boiler;
5) Requirement of the butt joint for coil tube;
6) Fitting clearance of the expanding tube;
7) Fitting requirement of the boiler tube;
8) Diameter deviation of the stay tube;
9) Hydraulic test.
6.3.2.4 The inspection and test for acceptance are as below:
a) The tube search of the boiler shall be carried out after butt jointing or the tubes bending;
b) Carry out strength testing and submit the test report after the new tubes are installed;
c) Carry out tightness testing and submit the test report after the new tubes are installed;
d) NDT is to be carried out on the welding seams of the critical parts and test reports are to be submit;
e) Carry out the hydraulic testing and submit the test report.
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GB/T XXXXX-XXXX
6.4 Marine pumps
6.4.1.1 The key points of the survey before dismantling are as below:
a) Check the starting current, working current, voltage and steady rotating speed;
b) Check the pressure at outlet and inlet when the discharge valve is fully closed, half open and fully
open respectively;
c) Check the temperature rising of bearing and running component, check the leakage at the shaft seal;
d) Monitor if there is any abnormal sound, noise or vibration during running;
e) Check the opening and closing pressure of the safety valve, check if there is any vibration and
leakage.
6.4.1.2 The key points of the survey after dismantling are as below:
a) Check the pump body, pump cover (side plate) if there is any defect such as scuffing, scratching,
crack, deformation, wearing and mechanical damage;
b) Check the interior surface of the sliding bearing if there is any defect such as scuffing, scratching,
damage, shelling, flaking and crack;
c) Check the interior and exterior circles for the roll bearing if there is any defect such as loosen, burnt
streaks, abrasion and chipping;
d) Measure the circularity and cylindricity of the pump shaft and check if there is any bend deformation
and wearing;
e) Check the matching condition of the key and key groove, if there is any defect of binding or torsion
crack of the key groove;
f) Check the sealing if there is any defect such as crack, damage, aging and deformation;
g) Check the matching condition of the shaft coupling, the aging and damage condition of the flexible
rubber ring;
h) Check the axis and radial clearances between gears and pump body of gear pump;
i) Check if there is any defect such as wearing, scuffing, scratching, breaking or crack on the gears;
j) Check the radial clearance between seal ring and impeller of centrifugal pump;
k) Check the cavitation and wearing of the centrifugal pump components;
l) Check the runout of the centrifugal pump impeller;
m) Check if there is any defect such as wearing, crack, air hole / scuffing on the cylinder liner or piston
of the reciprocating pump;
n) Check if there is any serious scuffing or rust scar on the surface of the piston rod, measure the
circularity and cylindricity of piston rod;
o) Check the interior and exterior surface of the crosshead and guide plate or crosshead pin and link rod
shaft sleeve if there is any serious scuffing and wearing, and measure the circularity and cylindricity;
p) Check the surface of the crank shaft main shaft neck and crank pin neck if there are any defects such
as the serious wearing, pulling and crack etc., and measure the circularity and cylindricity;
q) Check the matching clearance of the screw and pump body bush, screw shaft and bearing or the
drive gear of the screw pump;
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GB/T XXXXX-XXXX
r) Check the screw clearance, gear mesh clearance and driven screw axes thrust clearance;
s) Check the wearing condition of the machinery seal and thrust block;
t) Check the axes clearance of the vane pump rotor and thrust plate;
u) Check the clearance of the vane and vane groove or the slide condition of the vane in the groove;
v) Check the stator interior surface, end working surface of thrust plate , rotor both end surface, vane
groove wearing surface, vane working surface or if there are any defects such as the wearing of the
driven shaft, crack hollow and burn.
6.4.2.1 The quality requirements of gear pump repairing are as below:

a) The deviation of centre distance for bearing bore of the pump cover or side plate shall comply with
the requirements in Table 120;
Table 120 Deviation of centre distance for bearing bore of the pump cover or side plate Unit: mm
Requirements
Item Centre distance
＞50～80 80～120 120～180 180～250 250～315
Deviation of
±0.023 ±0.027 ±0.032 ±0.036 ±0.045
centre distance
b) The coaxiality, circularity and cylindricity of gear shaft shall comply with the requirements in Table
121;
Table 121 Coaxiality, circularity and cylindricity of gear shaft Unit: mm
Working journal of gear shaft, d47 Coaxiality Circularity and cylindricity

≤50 0.020 0.011
＞50 0.025 0.013
c) The radial assembly clearance of the sliding bearing shall comply with the requirements in Table
122;
Table 122 Radial assembly clearance of the sliding bearing Unit: mm
Diameter of shaft, d48 Assembly clearance Limit clearance

≤30 0.030～0.050 0.100
30～50 0.030～0.060 0.120
50～80 0.040～0.080 0.140
d) The assembly clearance and limit clearance of the gear and pump body shall comply with the
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Table 123 Assembly clearance and limit clearance between the gear and pump body Unit: mm
Tip diameter Standard scope Allowable limit

Remark
(pitch diameter) Radial Axial(total) Radial Axial
≤50 0.040～0.095 0.04～0.25 0.18
50～90 0.040～0.095 0.10～0.25 0.18 — 2CY type
90～126 0.10～0.24 0.10～0.35 0.38
≤50 0.13～0.20 0.025～0.040 0.31 0.05
CB-B type
50～75 0.17～0.26 0.035～0.045 0.34 0.07
e) The backlash of the gear set is 0.10 mm～0.20 mm;

f) The machining accuracy of the gear shall comply with the requirements in Table 124.
Table 124 Machining accuracy of gear
Item Requirement
Thickness deviation of the gear set ≤0.20mm
Radial runout of the gear tip circle to the gear shaft hole
0.020 mm
centre line
End runout of the gear face to the gear shaft hole centre line 0.020 mm
Cylindricity of the gear tip circle and shaft hole 0.010 mm
Surface roughness of the gear end faces, Ra 0.8 µm
Tooth flank of the gear Surface roughness, Ra 1.6 µm
set Engagement surface ＞70％
6.4.2.2 The quality requirements of centrifugal pump repairing are as below:

a) The machining accuracy of the pump shaft shall comply with the requirements in Table 125;
Table 125 Machining accuracy of the pump shaft Unit: mm
Item Radial runout Symmetry

Working shaft journal to the public axial line of two support journals 0.04
Fitting end face of sealing shaft liner and rolling bearing to the public axial —
0.03
line of two support journals
Key groove to the axial line — 0.05
b) The machining accuracy of the impeller shall comply with the requirements in Table 126;
Table 126 Machining accuracy of the impeller Unit: mm
Item Radial runout Symmetry

Seal ring edge to the axial line of shaft
0.060
hole
—
End face of wheel to the end face of
0.025
axial line
Key groove to the axial line of shaft hole — 0.050
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c) The assembly accuracy between the impeller or coupling and shaft shall comply with the
Table 127 Assembly accuracy between impeller or coupling and shaft
Type of shaft hole Assembly accuracy

Straight hole H7/k6
Tapered hole Contact area ＞70％
d) The assembly accuracy between the impeller shaft and shaft liner shall be grade H9/s6;
e) The radial runout of the impeller shaft journal shall be 0.05mm;
f) The assembly clearance between bearing and shaft shall comply with the requirements in Table 128;
Table 128 Assembly clearance of bearing
Item Requirement
Alloy bearing 0.001 5d49～0.002 5d49
Lignum-vitae bearing, laminate bearing, oily nylon bearing 0.005d49～0.007d49
Side contact angle between shaft and bearing centre 50°～60°
Note: d49——diameter of shaft journal.
g) The static balancing test of a new impeller shall be carried out, the limit deviation of weight at the
max. diameter of impeller shall comply with the requirements in Table 129;
Table 129 Deviation of weight for impeller static balancing
Outer diameter of impeller /mm Deviation of weight /g

≤200 ≤3
200～300 ≤5
300～400 ≤8
400～500 ≤10
500～700 ≤15
700～900 ≤20
h) The clearance of the fitting surface shall not be more than 0.05mm if directly fitted with the pump
body;
i) The assembly accuracy of the seal ring with pump body shall be grade H9/s6;
j) The runout of end face with impeller to end face of axial line shall be not more than 0.05mm;
k) The radial runout of installation inner edge of sealing ring to the axial line shall be not more than
0.05mm;
l) The assembly accuracy of the impeller for a two-stage pump or multistage pump with a shaft shall be
grade H7/j6;
m) The assembly accuracy of a multistage pump bearing (sliding) with a shaft shall comply with the
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GB/T XXXXX-XXXX
Table 130 Assembly accuracy of a multistage pump bearing with shaft
Type of bearing Assembly accuracy

Double-pivot grease lubricated bearing H7/e6 or E7/h6
The bearing with rotating speed over 1 800 r/min or the
H7/d6 or D7/h6
bearing with over 3 pivots or water lubricated bearing
n) The fitting clearance between the water seal ring of filling seals and shaft shall be 0.4mm～0.50mm,
the fitting clearance between the liner or cover and shaft shall be 0.40 mm～0.50mm;
o) The requirement for the alignment of the shaft coupling shall comply with the requirements in Table
131.
Table 131 Requirement for the alignment of shaft coupling
Type of shaft coupling Deflection /（mm/m） Offset /mm

Rigid ≤0.15 ≤0.10
Jaw-type ≤0.30 ≤0.12
Elastic ≤0.75 ≤0.15
6.4.2.3 The quality requirements for reciprocating pump repairing are as below:
a) The fitting clearance, circularity and cylindricity of cylinder liner and the increment of cylinder bore
shall comply with the requirements in Table 132;
Table 132 Fitting clearance, circularity, and cylindricity
of cylinder and increment of cylinder bore Unit: mm
Cylinder bore, D24 Fitting clearance Circularity and cylindricity Increment of cylinder bore
≤75 0.25～0.75 0.35
≤2.00
75～100 0.30～0.90 0.40
100～125 0.35～1.05 0.45
≤2.50
125～150 0.40～1.20 0.50
150～200 0.45～1.35 0.60 ≤3.00
200～250 0.50～1.50 0.65
≤4.00
250～300 0.55～1.65 0.70
＞300 0.60～1.95 0.80 ≤5.00
b) The axial clearance and gap clearance of the piston ring shall comply with the requirements in Table
133;
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GB/T XXXXX-XXXX
Table 133 Axial clearance and gap clearance of piston ring Unit: mm
Cylinder bore, D25 Gap clearance Axial clearance

≤100 1.40～3.50 0.15～0.30
100～150 1.70～4.25 0.20～0.40
150～200 2.00～5.00 0.25～0.50
200～250 2.25～5.62 0.30～0.60
250～300 2.50～6.00 0.40～0.80

＞300 3.00～7.50 0.45～0.90
c) The circularity and cylindricity of cylinder rod is not more than 0.002D26 (D26 is the diameter of
the cylinder rod, in mm);
d) The fitting clearance, circularity and cylindricity of crosshead and guide bushing shall comply with
the value given in Table 134;
Table 134 Fitting clearance, circularity and cylindricity of the crosshead and guide bushing Unit: mm
Nominal dimension of
Standard range Allowable limit Circularity and cylindricity
crosshead, d50
≤100 0.10～0.15 0.30 0.05
100～150 0.15～0.20 0.35 0.07
150～200 0.20～0.25 0.40 0.10
200～250 0.25～0.35 0.50 0.14
＞250 0.35～0.45 0.60 0.20
e) The fitting clearance, circularity and cylindricity of the crosshead pin and the bushing of the
connecting rod small end shall comply with the requirements in Table 135;
Table 135 Fitting clearance, circularity and cylindricity
of the crosshead pin and bushing of connecting rod small end Unit: mm
Diameter of crosshead pin, d51 Standard range Allowable limit Circularity and cylindricity
≤35 0.03～0.05 0.12 0.05
35～50 0.05～0.08 0.18 0.07
50～70 0.08～0.12 0.25 0.10
70～100 0.12～0.20 0.30 0.12
＞100 0.20～0.25 0.40 0.15
f) The Alignment between holes of small and big ends of connecting rod shall be 0.15mm/m;
g) The fitting clearance of sliding bearing shall comply with the requirements in Table 136;
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GB/T XXXXX-XXXX
Table 136 Fitting clearance of sliding bearings Unit: mm
Diameter of main journal, d52 Standard range Allowable limit

≤80 0.08～0.12 0.20
80～110 0.10～0.12 0.25
110～140 0.12～0.15 0.28
140～170 0.15～0.18 0.35
170～200 0.18～0.25 0.40
200～250 0.25～0.30 0.50
＞250 0.30～0.45 0.60
h) The circularity and cylindricity of the main journal and crank pin journal shall comply with the
Table 137 Circularity and cylindricity of main journal and crank pin journal Unit: mm
Diameter of main journal, d53 Circularity and cylindricity

≤80 0.05
80～110 0.06
100～140 0.08
140～170 0.09
170～200 0.10
200～250 0.12
＞250 0.15
i) The machining accuracy of the main components of a reciprocating pump shall comply with the
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GB/T XXXXX-XXXX
Table 138 Machining accuracy of main components of reciprocating pump
Item Requirement
Alignment between crank pin axis line and main journal axis line 0.02 mm
Crankshaft
Surface roughness, Ra 0.40 µm
Alignment between small end hole and big end hole 0.02 mm
Surface roughness of end holes, Ra 1.60 µm
Connecting rod
Coaxiality of liner bore of small end to the external edge 0.02 mm
Surface roughness of internal and external edges, Ra 1.60 µm
Coaxiality of external fitting surface to the axial bore line
Main bearing and connecting 0.02 mm
Verticality of lateral edge to the axial line of bore
rod big end bearing
Surface roughness of bore surface and external fitting surface, Ra 1.6 µm
Verticality of axial line to the external edge
Coaxiality of piston rod bore to the crosshead external edge
0.02 mm
Crosshead pinhole Runout of piston rod to internal and external edges of crosshead pressing
surface
Circularity and cylindricity 0.02 mm
Piston rod Runout of conical surface to outer diameter of piston rod 0.03 mm
Coaxiality of internal and external edges
0.03 mm
Cylinder liner Verticality of pressing surface to the external edge
Surface roughness of internal and external edges, Ra 1.6 µm
Runout of pressed surface to taper hole 0.02 mm
Coaxiality of external surface to taper hole 0.03 mm
Piston
Surface roughness of external edge and taper hole, Ra 1.6 µm
Axial surface roughness of groove, Ra 3.2 µm
Inlet and outlet valves and Verticality of inner hole to valve port plane 0.03 mm
guide liner of valve seat Surface roughness of sealing face of valve and valve seat, Ra 0.4 µm
6.4.2.4 The quality requirements of screw pump repairing are as below:

a) The installation clearance of the main components of a two-screw pump shall comply with the
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GB/T XXXXX-XXXX
Table 139 Installation clearance of main components of a two-screw pump Unit: mm
Item Diameter of screw Installation value Limit value Remark

66 0.200～0.243 0.360
Clearance between
104 0.325～0.380 0.580
screw and pump liner
150 0.200～0.250 0.380 For ZLB type pump
66 0.070～0.100 0.150
Meshing backlash of
104 0.250～0.700 1.000
screw and scerw thread
150 0.350～0.400 0.600 For ZLB type pump
Clearance between 46 0.089～0.115 0.220
scerw and bearing liner 70 0.175～0.208 0.350
b) The Machining accuracy and installation clearance of a three-screw pump shall be in accordance
with the requirements in Table 140;
Table 140 Machining accuracy and installation clearance of a three-screw pump Unit: mm
Item Nominal diameter of screw Standard range Allowable limit

Radial runout of the outer
0.025 0.060
diameter of screw
—
Circularity and cylindricity of
0.006 0.030
support journal of the screw
≤30 0.007 0.030
Circularity and cylindricity of
30～50 0.009 0.040
external edge of the screw
50～80 0.010 0.040
≤30 0.020～0.063 0.150
Clearance between the screw and 30～50 0.025～0.077 0.180
the bearing liner 50～80 0.030～0.090 0.200
80～120 0.040～0.110 0.250
≤50 0.070～0.130 0.200
50～80 0.080～0.140 0.220
Clearance between the screw and
80～120 0.140～0.220 0.340
the pump liner
120～180 0.180～0.280 0.420
180～200 0.220～0.310 0.460
c) The runout of the working surface of thrust bearing shall be not more than 0.01 mm;
d) The radial runout of the mechanical seal shaft liner (or shaft) shall comply with the requirements in
Table 141;
Table 141 Radial runout of mechanical seal shaft liner Unit: mm
Diameter of shaft ≤30 30～60 60～80 80～100

Radial runout 0.06 0.08 0.10 0.12
e) The surface roughness Ra of processed dynamic and static rings shall be 0.2 µm.
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6.4.2.5 The quality requirements of vane pump repairing are as below：

a) The wearing of interior surface of a stator shall be not more than 0.15 mm;
b) The axial clearance between the rotor and the distributor shall comply with the requirements in Table
142;
Table 142 Axial clearance of rotor Unit: mm
Diameter of rotor, d54 Standard range Allowable limit

≤50 0.015～0.036
0.07
50～63 0.020～0.042
63～80 0.025～0.042
0.08
80～100 0.025～0.049
c) The installation clearance between the vane and the vane groove shall comply with the requirements
in Table 143;
Table 143 Installation clearance of the vane Unit: mm
Diameter of rotor, d55 Standard range Allowable limit

≤63 0.015～0.025 0.040
63～80 0.015～0.030 0.050
80～100 0.015～0.035 0.060
d) The transition curve of the interior surface of the stator shall be continuous and smooth without any
defects such as break angle or edge surface. The machining accuracy shall comply with the
Table 144 Machining accuracy of the stator
Item Requirement
Radial runout & Coaxiality to the centerline of

Round arc at the interior of stator Grade 8 as in GB/T 1184—1996
external edge
Verticality to the axial line of external edge 0.015 mm

Two end faces of the stator
Roughness of the internal and external surface, Ra 0.8 µm
e) The machining accuracy of the rotor shall comply with the requirements in Table 145;
Table 145 Machining accuracy of the rotor
Item Requirement
Two end faces of the Verticality to axial line 0.015 mm
rotor Surface roughness, Ra 1.6 µm
Increment of the width of the groove ≤0.40 mm
f) The machining accuracy of the vane shall comply with the requirements in Table 146;
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Table 146 Machining accuracy of vane
Item Requirement
Verticality of top plane of contact surface between vane and stator to two side faces 0.01 mm
Contact surface between vane and vane groove
Alignment 0.01 mm
Contact surface between vane and distributor
Alignment 0.01 mm
0.005 mm～0.010 mm less than the
Width of the vane
width of rotor
g) The machining accuracy of the distributor shall comply with the requirements in Table 147;
Table 147 Machining accuracy of the distributor
Item Requirement
Alignment of the fitting surface with the rotor (only depression to the center is allowed, no bulging is
0.015 mm
permitted.)
Alignment of the fitting surface with rotor 0.020 mm
Fitting surface with pump body
Verticality of bore centerline to the rotor fitting surface 0.020 mm
Left distributor
Verticality of external edge to the rotor fitting surface 0.020 mm
Right distributor
Surface roughness of end face, Ra 3.2 µm
Coaxiality to bore 0.030 mm
External edge
Surface roughness of bore, Ra 1.6 µm
Note 1: The left distributor means that the external edge is not installed in the pump seat hole.
Note 2: The right distributor means that the external edge is installed in the pump seat hole.
h) The machining accuracy of the drive shaft shall comply with the requirements in Table 148;
Table 148 Machining accuracy of the drive shaft
Item Requirement
Surface roughness of working journal, Ra 0.8 µm
Coaxiality of external edge to the common axial line of two working journals 0.02 mm
Spline
Surface roughness of journal at external edge, Ra 1.6 µm
Journal fitted with Coaxiality to the common axial line of two working journals 0.02 mm
sealing ring Surface roughness of journal surface, Ra 1.6 µm
i) The machining accuracy of the pump body shall comply with the requirements in Table 149;
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Table 149 Machining accuracy of pump body
Item Requirement
Coaxiality to the centerline of bore of installation hole 0.025 mm
Bore of distributor in right pump body Verticality to the fitting surface of pump body 0.025 mm
Verticality of the centerline of bore of installation hole 0.025 mm
End face of distributor in right pump body
Verticality to the fitting surface of pump body 0.025 mm
Bore of distributor in left pump body
Surface roughness, Ra
3.2 µm
Surface roughness of end face of distributor in left pump body, Ra
Note 1: The right pump body means that with bearing hole and distributor seat hole.
Note 2: The left pump body means that without distributor seat hole.
j) The wearing limit for the internal surface of stator discharge port (fluid opening) shall be 0.15 mm;
k) The width increment of the vane groove shall be not more than 0.40 mm.
6.4.3 The quality control requirements of pump repairing are as below:
6.4.3.1 The main components of pumps shall be repaired by spray plating, chromium-plating, electro-brush
plating, built-up welding, bonding, grinding, tie insert or machining while the defects such as scuffing,
scratching, pitting, dent, abrasion, corrosion, crack or deformation are slight. The components shall be replaced
when the defects are severe or have an effect on the structural integrity of the pump.
6.4.3.2 The pump shaft shall be replaced in case of severe wearing and deformation.
6.4.3.3 The impeller shall be replaced in case of severe wearing and cavitation.
6.4.3.4 The seals such as “O” rings and sealing gaskets of stuffing shall be replaced after dismantling.
6.4.3.5 The technician carrying out the repair of the marine pumps shall comply with the requirements of
the pump’s specification manual if available.
6.4.3.6 The quality control points of marine pumps repairing are as below:
a) Material of the replaced main components;
b) Machining accuracy of main components;
c) Fitting accuracy of main components.
The inspection & test requirements of marine pumps repairing are as below:
a) Measure and record the machining accuracy and installation accuracy of main components;
b) Carry out hydraulic test and submit the test report after repairing the pump body;
c) Carry out function test and submit the test report.
6.5 Heat Exchanger
The key points of the survey for the heat exchanger are as below:
a) Check the condition of crack or corrosion on each seam of the casing;
b) Check the condition of corrosion, mechanical damage, crack and dent on the tube bundles;
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c) Check the condition of corrosion or mechanical damage on the tube fins;

d) Check the condition of corrosion and mechanical damage on the tube bundle baffles and supporting
lever;
e) Check the condition of corrosion and crack in water chamber and water chamber end cover, and if
the sealing width is throughout;
f) Check the corrosion condition of spreader plate and zinc anode;
g) Check the condition of the plate heat exchanger plate for corrosion, and sealing element for damage.
6.5.2.1 The wall thickness diminution of the casing and expansion joint shall not exceed 20% of the
original design.
6.5.2.2 The diminution of the wall thickness due to corrosion shall not exceed 20% of the original design,
and damage on the thread shall not exceed 20% of the original designed thread length.
6.5.2.3 The amount of damaged tube fins shall not exceed 7% of the total number.
6.5.2.4 The thickness diminution of the diversion plate shall not exceed 50% of the original design, the
radial clearance between baffle plate and internal diameter of casing shall not exceed of the former clearance
by 2 mm ~ 3 mm, the clearance between the bore and the outside diameter of the pipe shall not exceed of 1
mm.
6.5.2.5 The corrosion of the tube bundle supporting lever shall not exceed 20% of the original design, the
former tube wall thickness corrosion shall not exceed 50% of the original design.
6.5.2.6 The diminution of wall thickness of the tube jointed with tube sheet shall not exceed 12% of the
original design, and the length of the tube and the tube sheet shall not exceed 90% of the tube sheet thickness.
6.5.2.7 The mouthpiece shall be flush after expansion joint of the tube and the tube sheet; the tube length
extending from the tube sheet shall be not more than 1.5 mm. The flanged diameter (D27) of the tube hole shall
be less than d56+2.5 mm (see figure 3).
Figure 3 expanded tube schematic
6.5.2.8 The diminution of the wall thickness of the water chamber, water chamber end cover and spreader
plate shall not exceed 25% of the original design.
6.5.2.9 The end face flange shall be provided with an effective sealing width above 8 mm, the effective
sealing width of the flange plane of the pipe joint shall not be less than 6 mm.
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6.5.2.10 The thickness reduction of the pad of the plate heat exchanger due to partial corrosion shall not
exceed 20% of original design.
6.5.2.11 Compress the press plates in fixing and unfixed end with bolts, the distance between two pressing
plates on both ends shall be in accordance with the requirement in the drawing.
6.5.3.1 The local corrosion inside the casing may be repaired by welding or bonding, when the casing
internal surface is excessively corroded and exceeds the requirements, it shall be replaced.
6.5.3.2 The crack on each welding seam of the casing shall be recovered through grinding out the crack
and built-up welding.
6.5.3.3 For the crack repair on the connecting seam between the expansion joint and the casing, remove the
original weld and do re-welding.
6.5.3.4 If the number of damaged tubes is not more than 10% of the total number, maintain the usage
through blocking.
6.5.3.5 When the tubes develop crack, extensive deformation, corrosion or tubes thread damage that
exceeds the requirements, they shall be renewed.
6.5.3.6 When the damage condition of the tube fins and the corrosion of spreader plate exceeds the
requirements, it shall be renewed.
6.5.3.7 When the corrosion of tube bundle supporting lever and former tube exceeds the requirements, it
shall be renewed.
6.5.3.8 When crack or corrosion on water chamber, water chamber end cover and spreader plate exceeds
the requirements, it shall be replaced, high-polymer paint or other methods to be used when it is partly
corroded.
6.5.3.9 When the zinc anode is seriously corroded, it shall be renewed.
6.5.3.10 When partial corrosion of plate heat exchanger plate exceeds the requirements or severe
scratching, it shall be renewed. The sealing component shall be renewed entirely after disassembling.
6.5.3.11 The quality control points of heat exchanger repairing are as below:
a) Welding materials and welding quality;
b) Tube materials and machining accuracy;
c) Materials of cooling plate;
d) Tightness test.
Carry out tightness test and submit the test report after repairs.
6.6 Marine sewage treatment plant
The key points of the survey for the marine sewage treatment plant are as below：
a) Check if the surface of the casing has any damage, corrosion or crack of welding seam;
b) Check if the inner partition walls have any corrosion, pit, damage or crack of welding seam;
c) Check if the connection pipe on the casing has any corrosion, damage or crack welding seam;
d) Check if the sealing surface of the flange of the connection pipe has any scratching or pit corrosion;
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GB/T XXXXX-XXXX
e) Check if the wall of the vent pipe has any corrosion; check if there is any crack on the welded
connection; check if the flame screen has any damage;
f) Check if the filter screen in the exposure chamber has any corrosion or damage.
6.6.2 Quality requirement of the repairing
6.6.2.1 The material of the renewed part shall have the same properties and size as that of the original part
and shall have mill sheet.
6.6.2.2 The diminution of the casing wall thickness shall not exceed 20% of original design.
6.6.2.3 The contact sealing surface of the flanges on each chamber, tank and casing shall be flat and
smooth with good sealing performance and without through scratching.
6.6.2.4 The diminution of the wall thickness of short connection pipes on the casing shall not exceed 20%
of original design.
6.6.3.1 The partial corrosion, pit, and damage on the internal surface of the casing can be repaired by
built-up welding or bonding. Where there is excessive diminution on wall thickness, it shall be renewed.
6.6.3.2 The crack on each welding seam of the casing shall be repaired through grinding out the defect and
built-up welding.
6.6.3.3 When the crack, corrosion and severe deformation on the short connection pipe on the casing
exceed the requirements, it shall be replaced.
6.6.3.4 The valve seat and core can be repaired by grinding in case they are found to have defect such as
corrosion, pit, scratching or damage.
6.6.3.5 Metallic flame screen on vent pipe shall be renewed in case it is damaged.
6.6.3.6 The quality control points of marine sewage treatment plant repairing are as below:
a) Quality of materials;
b) Welding materials and welding quality;
c) Tightness test for valves;
d) Hydraulic test of casing.
The inspection & test requirements of marine sewage treatment plant repairing are as below:
a) Submit the copy of marine product certificate or type approval certificate of the replaced material as
per the requirement of the assigning authority;
b) Carry out hydraulic test of casing or valve and submit the test report after repairing;
6.7 Marine oil pollution prevention plant
The key point of the survey for marine oil pollution prevention plant are as below：
a) Check the condition of damage, corrosion and welding seam crack of the internal and external
surface of the casing;
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b) Check the condition of damage and welding seam crack of the sloping plate, tube, coarse particle
aggregates and sand filter;
c) Check the usage of coarse particle components and adsorbent material;
d) Check if the connecting pipe of the casing has any damage, corrosion and welding seam crack;
e) Check if the sealing surface of the pipe connection flange has any scratching or penetration;
f) Check if the oil discharge valve, inlet and outlet valves and three-way outlet valve have any
corrosion, spots, damage, cuts and crack;
g) Check if the rod of the safety valve and the spring have any deformation, bend and crack; check if
the seat has any defects such as spots and cuts;
h) Check if the oil pump body, shaft, bearings and plunger have any defects such as corrosion, damage
wear or other type of damage, and measure the fitting clearance between the moving parts.
6.7.2 Quality requirements for repairs
6.7.2.1 For the renewed material of the parts, its performance and specifications shall be consistent with the
original design requirements, and also with the material certificate.
6.7.2.2 The diminution of the wall thickness of the casing shall not exceed 20% of the thickness of the
original design.
6.7.2.3 The diminution of the wall thickness of the short connection pipes on the casing shall not exceed
20% of the wall thickness of the original design.
6.7.2.4 The contact sealing surface of the flanges on the casing shall be smooth, the seal wire intact and
free of cuts throughout.
6.7.2.5 The coarse particle components and adsorbent material shall be renewed in case of exceeding the
requirements in Table 150 after washing.
Table 150 Renewal qualification of coarse particle components and adsorbent material
Material type Renewal qualification

4016 polypropylene Diameter of particle＞4 mm
Nylon fibers Inelastic or aging
6.7.3.1 The damage, corrosion and weld crack on the surface of the casing can be repaired by built-up
welding.
6.7.3.2 When the connecting pipe has crack, serious corrosion and damage, it shall be renewed.
6.7.3.3 The notch on the sealing surface of the pipe connecting flange can be repaired by hand or
machining.
6.7.3.4 The erosion or damage of the oil discharge valve, inlet and outlet valves, valve seat and other
pieces shall be repaired with grinding, or with machining for critical parts.
6.7.3.5 The quality control points of marine oil pollution prevention plant repairing are as below:
a) Quality of material;
b) Welding material and welding quality;
c) Tightness test of valves;
d) Hydraulic test of casing.
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The inspection & test requirements of marine oil pollution prevention plant repairing are as below:
a) Submit the copy of marine product certificate or type approval certificate for the replaced material in
accordance with the requirement of assigning authority;
b) Carry out hydraulic test of casing or valve and submit the test report after repairing;
6.8 Piston-type air compressor
The key point of the survey for piston-type air compressor are as below：
a) Check if there is any defect such as deformation, corrosion, abrasion, mechanical damage and cracks
and others on the following items cylinder, cylinder cover, pistons, piston pins, piston rings,
connecting rod, connecting rod bolts, crankshaft, each bearing and intake and exhaust manifolds;
b) Check if there is crack on the body and crankcase;
c) Check if there is crack on crankshaft, piston pin and connecting rod bolts, Do NDT if necessary;
d) Measure fitting clearance between the cylinder and the piston, piston rings, cylinder cover and the
bearing.
6.8.2.1 The circularity and cylindricity of cylinder and piston shall comply with the requirements in Table
151.
Table 151 Circularity and cylindricity of the piston and cylinder Unit: mm
Inner diameter of cylinder liner，D28 Standard range Allowable limit

≤50 0.008 0.025
50～120 0.010 0.050
120～260 0.015 0.080
6.8.2.2 If unable to identify the specified value, the fitting clearance between the piston and the cylinder
shall comply with the requirements in Table 152.
Table 152 Fitting clearance between the piston and the cylinder Unit: mm
Inner diameter of cylinder liner，D29 Standard range Allowable limit

≤60 0.08～0.15 0.3
60～120 0.15～0.25 0.5
120～180 0.25～0.35 0.7
＞180 0.35～0.50 1.0
6.8.2.3 If unable to identify the specified value, the fitting clearance between the piston ring slot and the
axis shall comply with the requirements in Table 153.
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Table 153 Fitting clearance of the piston ring Unit: mm
Gap clearance Axial clearance Radial clearance

Inner diameter of
Allowable
cylinder liner，D30 Standard range Standard range Allowable limit Standard range
limit
≤60 0.2～0.3 0.5 0.02～0.05 0.50
0.10
60～120 0.3～0.5 1.0 0.02～0.06 0.50～0.75
120～180 0.5～0.8 0.03～0.09 0.75
1.5 0.12
＞180 0.8～1.0 0.03～0.10 1.00
6.8.2.4 The corrosion depth of the water chamber for cylinder liner shall not exceed 20% of the wall
thickness of the original design.
6.8.2.5 The axial incremental of the piston ring grooves shall not exceed 10% of the size of the original
design.
6.8.2.6 After machine repairing, the reduction of the main journal of the crankshaft or crank pin diameter
shall not exceed 2% of the original design.
6.8.2.7 If unable to identify the specified value, the fitting clearance between the crank pin and connecting
rod bearing shall comply with the requirements in Table 154.
Table 154 Fitting clearance between the crank pin and the connecting rod bearing Unit: mm
Radial clearance Axial clearance

Diameter of crankpin,d57
Standard range Allowable limit Standard range Allowable limit
≤50 0.045～0.077 0.12 0.2～0.30 0.50
50～80 0.055～0.090 0.15 0.3～0.50 0.75
80～100 0.060～0.110 0.18 0.5～0.75 1.00
6.8.2.8 The fillet and groove of the journal shall not have cracks, the surface of main journal and crank pin
shall not have transverse cracks, longitudinal crack lines with an angle of less than 30 ° with the axis are only
allowed, if there are 3 or less crack lines on one journal, not more than 2 on one cross-section, and the length
shall not exceed 20mm.
6.8.2.9 If unable to identify the specified value, the fitting clearance between the piston pin and connecting
rod bush shall comply with the requirements in Table 155.
Table 155 Fitting clearance between the piston pin and the connecting rod bush Unit: mm
Diameter of piston pin, d58 Standard range Allowable limit

≤30 0.040～0.064 0.09
30～50 0.050～0.077 0.12
50～80 0.060～0.090 0.15
6.8.2.10 Alignment of axes of bearing holes in big and small ends of connecting rod is 0.03 mm /dm in
vertical direction, 0.06 mm / dm in the horizontal direction.
6.8.2.11 If unable to identify the specified value, the positive clearance between the piston and the cylinder
cover shall comply with the requirements in Table 156.
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Table 156 Positive clearance of the cylinder Unit: mm
Inner diameter of cylinder liner，D31 Requirement

≤55 0.35～0.50
55～90 0.40～0.55
90～120 0.50～0.65
120～150 0.60～0.76
150～200 0.70～1.00
6.8.2.12 The circularity and cylindricity of the crankshaft main journal and crank shall comply with the
Table 157 Circularity and cylindricity of the main journal and crankpin Unit: mm
Diameterd of journal, d59 Standard range Allowable limit

≤50 0.005 0.020
50～120 0.006 0.025
120～260 0.008 0.030
6.8.2.13 The circularity and cylindricity of the piston pin shall comply with the requirements in Table 158.
Table 158 Circularity and cylindricity of piston pin Unit: mm
Diameter of piston pin, d60 Standard range Allowable limit

≤30 0.003 0.010
30～50 0.005 0.015
50～80 0.008 0.020
6.8.3.1 The cracks in the body and crankcase can be repaired by welding, double plate insert, metal
clapping or bonding.
6.8.3.2 Cylinder, piston and piston ring:
a) The slight wearing, corrosion, scuffing and scratches on cylinder or piston can be repaired by hand;
b) The severe galling, scratches and wearing that exceed requirements on the cylinder working surface
can be repaired by machining, if the diameter increment of the cylinder bore is more than 1% of the
original value, strength test shall be carried out;
c) If the fitting clearance between the piston and the cylinder exceeds the requirements, the piston or
cylinder liner or both shall be replaced;
d) The cylinder shall be renewed in case cracks or severe flaws are found;
e) Minor corrosion pitting and pits on water cylinder chamber is allowed, if the pitting depth exceeds
the requirements and corrosion area is substantial, the water cylinder chamber shall be renewed;
f) If the piston ring groove is worn out, it can be repaired by machining.
6.8.3.3 Crankshaft:
a) If the working surface on the main journal or crank pin have minor galling, worn out and damaged, it
can be repaired by hand. in case of substantial defects, they can be repaired by machining;
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b) When the wear on the main journal and crank pin exceeds requirements, it can be machined,
low-temperature iron plating, electrical brush-plating, chrome plating and others.
6.8.3.4 Bearing of main and connecting rod:
a) Defects such as minor scuffing and wearing on the bush can be repaired by slight wiping;
b) In case the surface of the bush has serious scuffing, laminating and peeling off alloy layer, it shall be
renewed;
c) If the bearing undergoes severe overheating, corrosion, crack and flaking, it shall be renewed;
d) The surface wear on the shell hole of the axis bush can be repaired by low-temperature iron plating,
electroplating or electrical brushing- plating.
6.8.3.5 Piston pin and connecting rod:
a) The minor corrosion spots on the piston pin is allowed, if any transverse crack or serious scuffing is
found, it shall be renewed;
b) The deformation of the connecting rod can be rectified on cold and hot condition. In case the heating
temperature exceeds the limit of metallographic change, annealing shall be done after rectification.
6.8.3.6 The quality control points of piston-type air compressor repairing are as below:
a) Circularity and cylindricity of piston and cylinder;
b) Fitting clearance of piston and cylinder;
c) Fitting clearance of piston ring;
d) Mounting clearance between crank pin and connecting rod bearing;
e) Fitting clearance between piston pin and connecting rod bearing;
f) Cylinder clearance;
g) Circularity and cylindricity of main journal and crank pin;
h) Circularity and cylindricity of piston pin.
The inspection & test requirements of the piston-type air compressor repairing are as below:
a) Measure and record the accuracy of the main components;
b) Carry out the function test and submit the test report.
7 DECK MACHINERY
7.1 Windlass
The key points of the survey for this are as below:

a) Check the reliability and flexibility of windlass, if there is any abnormal noise and vibration during
operation;
b) Check if the cable chain lifter has any slipping and jumping;
c) Check if the surfaces of chain lifter, mooring drum and warping head are excessively worn out;
d) Check if any abrasion, rusting, crack and scuffing is present on the working surfaces of the clutches,
and check the working condition of the clutches;
e) Check if any abrasion and corrosion is present on the brake lining, brake band, joint pin, brake vane,
brake screw and brake nut;
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f) Check if any corrosion and damage is present on the shaft supports, foundation, foundation holding
bolts and stoppers;
g) Check if any excessive abrasion, bite mark, crack, bending deformation is present on the axle journal
and if there is a blockage of the grease nipple;
h) Check the clearance between the shaft journal and the bearing or bushing;
i) Check if any excessive abrasion and crack of the open-type gears is present;
j) Check if any excessive abrasion, pit mark, hollow, crack, corrosion and looseness of drum bearing is
present;
k) Check if any abrasion on pitch circle of worm wheel and worm of reduction worm gearbox (if have)
is present.
7.1.2 Quality requirements of repairing
7.1.2.1 The installation clearance between the shaft journal and the bearing or bushing shall comply with
Table 159 Installation clearance between the shaft journal and the bearing or bushing Unit: mm
Radial clearance
Item Axial clearance
Standard range Allowable limit
Shaft journal and bearing 0.001 5d61+0.10 0.004d61 0.5～1.0
Shaft journal and bushing 0.001 5d61 0.004d61 0.5～1.0
Note: d61——Shaft journal diameter.
7.1.2.2 After manually trimming the contact surface between the bearing seat and the split type slide
bearing bush, the back of the bearing bush shall be evenly colored up to at least 80% of the total surface area,
the working surface between the bearing bush and the shaft journal shall be evenly colored up to at least 60%
of the working surface within the range of 30°～45°from the radial centre line of the bearing bush, and at least
80% of the working surface of the full axial working surface.
7.1.2.3 The contact area between the jaw and the socket of the clutch shall be more than 50% of jaw area,
and the central angle of the socket shall be 1°～2°bigger than the central angle of jaw.
7.1.2.4 The abrasion of the brake lining shall not more than 25％ of the original designed thickness, the
abrasion of the brake vane and the brake screw shall be not more than 20％ of the original designed
dimension.
7.1.2.5 The abrasion on the pitch circle: for open-type gears it shall be not more than 15% of the original
designed of the gear thickness, for closed-gears it shall be not more than 10% of the original designed gear
thickness.
7.1.2.6 The gear side clearance: for open-type gear shall be 24A11/2，µm, for closed-gear shall be 12A11/2，
µm (A1- gear pair center distance, in mm).
7.1.2.7 The contact area of the open-type gear shall be at least 30% of tooth height and 40% of gear width.
7.1.2.8 The abrasion on the pitch circle of the worm wheel and the reduction worm gearbox shall be not
more than 15% of the original designed gear thickness.
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7.1.3.1 The defects such as abrasion, rusting, sticking and crack on the working surface of the shaft
journals of chain lifter, mooring drum, warping head and clutch shall be manually trimmed and polished. The
critical defects shall be repaired by built-up welding to an acceptable strength condition; otherwise the shaft
journal shall be replaced.
7.1.3.2 The severe abrasion on the working surface of the chain lifter shall be repaired by built-up welding,
and NDT shall be carried out after repairing if necessary.
7.1.3.3 The defects such as abrasion, rusting and crack on the working surfaces of the mooring drum and
warping head shall be repaired by built-up welding.
7.1.3.4 Defects such as crack, abrasion, deformation and damage on the working surfaces of the jaw clutch
shall be repaired by built-up welding, and the crack is not allowed after repaired.
7.1.3.5 The brake lining, brake band, joint pin, brake vane, brake screw and brake nut of the braking device
shall be replaced in case abrasion and corrosion exceed the specified requirement.
7.1.3.6 The poor contact surface of open-type driving gear shall be manually trimmed. The gear shall be
replaced in case the tooth surface is grooved and worn out seriously.
7.1.3.7 Windlass repair quality control key points are as below:
a) Accuracy of assembly;
b) Welding material and welding quality.
The inspection & test requirements of windlass repairing are as below:

a) Measure and record the shaft journal installation clearance;
b) Carry out braking test and submit the test report;
c) Carry out anchoring test and record the speed of anchor heaving and the parameters of motor.
7.2 Mooring winch
The repair requirements of the mooring winch shall be in compliance with the requirements of chapter 7
section 7.1.
7.3 Marine cargo winch
7.3.1 Key points of survey
The key points of survey for this are as below:

a) Check each bearing if there is any abnormal temperature，noise and vibration when the marine cargo
winch is running;
b) Check the working reliability and flexibility of braking device, especially the reliability of automatic
braking under load due to voltage loss, power loss and stopping;
c) Check if there is any obvious deformation, crack and abrasion of the cable drum and warping drum;
d) Check if there is any crack scuffing, rusting, dent, bruising and pitting of the warping drum shaft;
e) Check if there is any looseness of the contact surface between rolling bearing and shaft journal or
bearing saddle bore, check if there is any defect such as over wear, overheating and discoloring of
roller (ball) external groove, peeling off, rusting, crack and damage of roller (ball) of the rolling
bearing;
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f) Check if there is any damage, pitting, peeling off, agglutination, deformation, indentation and crack
on tooth surface of driving gear, check if any buckling of the gear rim and any crack on gear hub and
spoke;
g) Check if there is any serious abrasion on the bull wheel and driving pinion of the slewing gear.
7.3.2.1 The cylindricity of drum shaft journal shall be 0.002d62 (d62—diameter of shaft journal).
7.3.2.2 The clearance between the slide bearing or drum lining and shaft journal shall be not more than
0.004 d62, and it shall be 0.0015 d62 after repaired.
7.3.2.3 The flatness of bedplate contact surface shall be 0.1 mm.
7.3.2.4 The radial run out of drum shaft journal shall be half of installation clearance.
7.3.2.5 External surface of shaft journal to be connected well with bearing saddle bore, inspect and confirm
the contact area shall be 75% at least by dyeing test, and distribution to be evenly, the clearance between the
contact surfaces shall be not inset by 0.05mm feeler.
7.3.2.6 The drum shaft journal shall be contact evenly with sliding bearing within 30°～40°on both sides of
bearing centerline.
7.3.2.7 The contact area of gear pair shall be at least 30% of the tooth height and 40% of gear width.
7.3.3.1 The slight crack on the bedplate shall be built-up welding after removing the crack. The bedplate
shall be renewed partially in case of the crack is serious. NDT shall be carried out after repairing.
7.3.3.2 The uneven contact surfaces between bedplate and foundation leading to leaking shall be repaired
by brushing and polishing.
7.3.3.3 The deformed or dislocated bearing saddle bore shall be repaired by boring and bushing.
7.3.3.4 The looseness of rolling bearing and bearing saddle bore shall be repaired by electro-brush plating.
7.3.3.5 The cracks on gear hub and spoke shall be repaired by built-up welding after removing the cracks.
NDT shall be carried out after repairing.
7.3.3.6 The minor abrasion and scuffing on the working surface of the shaft journal shall be manually
trimmed and polished. The shaft journal shall be repaired by chrome plating, iron plating at low temperature or
built-up welding if the defect is significant but in the allowable strength condition.
7.3.3.7 The slight abrasion and scuffing on the working surface of the drum shaft journal which is in
contact with the slide bearing shall be manually trimmed and polished. The shaft journal shall be repaired by
chrome plating, iron plating at low temperature or built-up welding after machined and re-machined if the
defect is significant but in the allowable strength condition.
7.3.3.8 The defects such as crack and abrasion on the cable drum and warping drum shall be repaired by
built-up welding.
7.3.3.9 The bearing bush shall be replaced if the clearance is exceeds the allowable limits or the working
surface is damaged significantly.
7.3.3.10 Marine cargo winch repairing quality control key points are as below:
a) Machining accuracy of the component parts;
b) Accuracy of the assembly;
c) Function test;
d) Load test.
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The inspection & test requirements of marine cargo winch repairing are as below:
a) Measure and record the machining accuracy and fitting clearance of the component parts;
b) Carry out function test and submit the test report;
c) Carry out load test and submit the test report.
7.4 Life boat davit
The key points of survey for this are as below:

a) Check if there are any defects such as rusting, abrasion and deformation of the davit structure
(including the davit beam, davit base, slipway frame and fixed spare part of the free fall launching
life boat);
b) Check if there are any defects such as rusting, abrasion and deformation of the launching and
recovery arrangement (including hanging chain, lifting hook, davit hook, link, release hook, pulley,
hoisting pad, fastener, boat fall, remote control wire, winch components and other components);
c) Carry out the launching & recovery test and falling test, and check the dependability and stability;
d) Check the welding seam between the deck and the davit foundation or slipway frame;
e) Check the wear condition of the pulley shaft pin and the concealed winched components.
7.4.2 Quality requirements of repair
7.4.2.1 The rusting or abrasion of davit frame shall be not more than 10％ of the original designed
thickness.
7.4.2.2 There shall be no crack or deformation on the davit frame.
7.4.2.3 The material and size of the renewed boat hoisting riggings and accessories shall be in accordance
with the requirements of original design drawing.
7.4.2.4 The dimensional deviation of the davit frame installation shall comply with the requirements in
table 160.
Table 160 Dimensional deviation of davit frame installation Unit: mm
Item Requirement
Forward & Backward ≤15
Center line of lifting hook
Leftward & Rightward ≤10
Alignment of freefall type davit 10
Alignment of slipway frames’ center palnes 8
Slipway type davit Distance of the diagonal intersection of two corresponding
≤10
point in the working length of two slipwayc
Alignment of slipway central plane relatived to theoretical
10
Freefall type davit central plane
Alignment of two slipways 5
Theoretical position clearance of the lifeboat fixed support andthesteel support of davit 50～100
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7.4.2.5 The tolerance for launching and recovery arrangement repairs shall be in compliance with the
requirements as below:
a) The fit tolerance of all the component parts of pulley such as sheave, shaft pin, bearing, shaft sleeve,
stopper, bolt, cotter pin and grease nipple for the launching and recovery arrangement shall be in
compliance with their machining standards;
b) The material and size of the boat fall shall be in accordance with the requirements of original design
drawing. In the condition of heeling and trimming with the ship in its lightest seagoing condition, the
length of the boat fall shall be long enough to remain 3 rounds on the winch barrel when the lifeboat
is lowered to the sea surface;
c) When the boat is recovered to its fixed position on the davit, the wire rope shall be evenly coiled on
the winch drum by a maximum of 3 layers, and the wire rope on the outermost layer shall be less
than 2/3 the drum length. The drum flange shall be higher than the outermost layer of the cable by
1.5 times the wire rope diameter;
d) The boat falls and winch shall work together to ensure synchronization and safety of the boat bow
and stern during launching & recovery and falling.
7.4.3.1 The quality control requirements of the davit frame repair process are as below:
a) The davit frame shall be cropped and renewed partially in case of rust or abrasion is over the
allowable limit;
b) The slight crack of the davit frame shall be repaired by built-up welding after removing the crack.
The davit frame shall be cropped and renewed partially in case the crack is significant;
c) The partial deformation of the davit frame shall be repaired by hot straightening together with water
cooling and mechanical force straightening. The davit frame shall be cut and renewed partially in
case the deformation can not be straightened.
7.4.3.2 The quality control requirements of launch and recovery arrangement repair process are as below:
a) The pulley, sheave and shaft pin shall be replaced in case the abrasion, deformation and damage is
above the allowable limit;
b) The pulley, sheave and shaft pin shall be replaced if there cracks have developed;
c) The stopper, bolts, cotter pin and grease nipple shall be replaced in case cracks and damaged has
occurred;
d) The boat hoisting riggings and accessories shall be replaced if deformed or broken
e) If the hydrostatic release unit failed, it shall be repaired or replaced.
7.4.3.3 Lifeboat davit repair quality control key points are as below:
a) Material of renewed section of davit frame;
b) Welding material and quality;
c) Deformation straightened;
d) Assembly accuracy of davit frame;
e) Repairing quality of launching and recovery arrangement;
f) Strength test;
g) Lifting and falling test of life boat.
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The inspection & test requirements of lifeboat davit repairing are as below:
a) Measure and record the assembly accuracy of davit frame;
b) Carry out strength test and submit the test report;
c) Carry out lifting and falling test and submit the test report.
8 OUTFITTING
8.1 Cargo hold hatch cover
The key points of survey for hatch cover are as below:

a) Corrosion, crack, deformation and damage of hatch cover's top plate, side plate, end plate and
stiffener shall be inspected;
b) Hatch cover’s opening, closing, locking and fastening devices shall be inspected;
c) Shift device (wheel, hinge, towing chain and pulley) shall be inspected;
d) Functional test for hatch cover shall be carried out and the test results shall be recorded;
e) Weather-tight device (packing slot, sealing rubber and cleat) shall be inspected;
f) Tightness test for hatch cover shall be carried out and the test results shall be recorded.
8.1.2.1 Dimension deviation of hatch cover is to be in accordance with the requirements in Table 161.
Table 161 Dimension deviation of the hatch cover Unit: mm
Difference of Difference of height at the

Length of hatch Length of Length of whole
Breadth Height diagonal length of diagonal intersection point
cover single panel cover
single/whole cover of single panel
≤4 000 ±5 ≤9 ≤10
4 000～8 000 ±8 ≤10 ≤12
±5
8 000～12 000 ±12 ≤12 ≤16
＞12 000 ±15 ≤15 ≤18
8.1.2.2 Deflection deviation of hatch cover is to be in accordance with the requirements in Table 162.
Table 162 Deflection deviation of the Hatch cover Unit: mm
Items Allowable limits

Deflection of long edge along vertical direction ≤L7/1 000
Deflection of long edge along horizontal direction ≤10
Deflection of short edge along vertical direction ≤L7/1 000
Deflection of short edge along horizontal direction ≤6
Note: L7 is the length of long/short edge of a single cover panel.
8.1.2.3 Installation deviation of the hatch cover is to be in accordance with the requirements in Table 163.
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Table 163 Installation deviation of the hatch cover Unit: mm

At joint of two cover panels, along height direction of hatch cover’s top plate ≤7
Alignment of side plates, along thickness direction: ≤4
Gap between side plates
≤10
Gap between top plates
8.1.2.4 Installation deviation for the wheel of hatch cover is to be in accordance with the requirements in
Table 164.
Table 164 Wheel installation tolerance Unit: mm
Distance between the

Type of Hatch Taper of Distance between wheel plane Distance between axle center
lowest edge of wheel and
cover axle and longitudinal vertical datum and transverse vertical datum
horizontal datum
Folding type ±2 ±3 ±5
Distance between axle center Distance between wheel
Sliding type 3 mm/m ±4 and longitudinal vertical datum plane and transverse vertical
plane is ±8 datum is ±5
Rolling type ±6 ±8 ±10
8.1.2.5 Installation deviation for the hinge of folding type hatch cover is to be in accordance with the
Table 165 Installation tolerance of the hinge and wheel Unit: mm

Distance between centerline of the end wheel and horizontal datum plane ±2
Distance between centerline of the end wheel and axis of the middle hinge
±5
Distance between centerline of the end wheel and axis of the end hinge
Distance between centerline of the middle hinge and horizontal datum plane
Distance between centerlines of the middle and the end hinge ±2
Distance between centerlines of the end hinge and horizontal datum plane
Distance between centerline of the end hinge and molded line of hatch opening ±3
Distance between centerline of end wheel, middle/end hinge and theoretic centerline of hatch cover ±2
Taper of center axis of eye plate’s hole and theoretic reference axis 5 mm/m
Assembly clearance of hinge shaft and hole ≤1
Coaxial degree between all hinges 4
8.1.2.6 Installation tolerance of the pontoon type hatch cover is ±2 mm.

8.1.2.7 Installation tolerance of the rolling type hatch cover’s connecting plate is ±5 mm.
8.1.2.8 When hatch cover is installed and locked, the Installation tolerance of the seal rubber shall be in
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Table 166 Installation tolerance of the sealing rubber Unit: mm

△A2——Deviation of center of compression bar and rubber； ΔA2
Dimensions ≤7
L8——Compression of rubber；
32×71
△L8——Deviation of compression ΔL8
L8 =8 ±2
ΔA2
≤7
8
Dimensions
40×71
8
2
ΔL8
L8=10 ±3
ΔA2
Dimensions ≤9
Rectangular
50×93
rubber with ΔL8
2
8 8 L8=13 ±4
foamed core
ΔA2
≤12
Dimensions
8
50×120
ΔL8
8
L8 =13 ±4
L9——Compression of rubber； Hollow

△L9——Deviation of compression 67×72 ±8
L9=12
Hollow
9 9 60×98 ±7
L9=11
Sliding
ΔL9
rubber
Solid
57×72 ±3
9 9
L9=7
8.1.2.9 Fabrication and installation of the packing slot shall be in accordance with the requirements in
Table 167.
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Table 167 Requirements of the fabrication and installation of the packing slot Unit: mm
Items Limits
Deviation of packing slot’s breadth and height
±2
Installation deviation of the packing slot
Butt weld of the packing slot The salient part shall be ground
Welding leg of the fillet weld in packing slot ≤Sealing rubber’s chamfer size
8.1.2.10 Installation of hatch cover’s compression bar shall be in accordance with the requirements in
Table 168.
Table 168 Requirements for the installation of hatch cover's batten Unit: mm
Items Limits
Deviation of compression bar’s breadth and height ±2
Installation flatness of the top surface of compression bar 4
Allowable deviation for the installation of the compression bar ±4
8.1.3.1 The original relative position and clearance between hatch cover panels and between hatch cover
and hatch coaming shall be marked as approval criteria after repairing.
8.1.3.2 Hatch cover shall be put on flat and hard floor in order to carry out the repairs; the suitable jigs
shall be prepared for the steel structure cropping and renewal work.
8.1.3.3 When hatch cover’s steel structure needs to be cropped and renewed on a large scale due to
corrosion, deformation and damage, the workmanship and procedure shall be provided.
8.1.3.4 Small corrosion and damage can be handled by Grinding, local crack can be repaired by chiseling
and welding. The local structure shall be cropped and renewed if the crack extends to a large scale.
8.1.3.5 For small-scale and serious corrosion, damage and deformation, the hatch cover can be repaired by
locally crop and renew.
8.1.3.6 For large-scale and serious corrosion, damage and deformation, the hatch cover shall be entirely
renewed as per original design.
8.1.3.7 For pontoon type hatch cover repairs, the welding, correcting, grinding, painting and cleaning shall
be finished before closing the bottom plate.
8.1.3.8 The hatch cover deformation shall be straightened by flame, alternative methods include water
cooling, gravity and mechanical fixation.
8.1.3.9 The key points of quality control of hatch cover repairing are as below:
a) Jig accuracy;
b) Assembly accuracy;
c) Weld quality;
d) Welding deformation;
e) Hatch cover’s installation accuracy;
f) Relative position between seal rubber and compression bar;
g) Tightness test;
h) Functional test.
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The inspection & test acceptance of hatch cover are as below:

a) Accuracy measure record shall be provided;
b) Tightness test shall be carried out and test report shall be provided;
c) Functional test shall be carried out and recorded.
8.2 Fixed steel ladder
The key points of survey for fixed steel ladder are as below:
a) Corrosion, crack, deformation and damage on ladder’s frame, step, rail and eye plate shall be
inspected;
b) Connecting structure between ladder and the main hull shall be inspected.
8.2.2.1 Dimension deviation of the frame and the step for indoor type, outdoor type and A-type inclined
ladder shall be in accordance with the requirements in Table 169.
Table 169 The tolerance of A-type cargo hold inclined ladder’s frame and step Unit: mm
Items Limits
Width of ladder frame ±5
Flatness and straightness of ladder frame 4
Torsion of ladder frame（distance between two centers of diagonal lines） 5
Distance between two adjacent steps ±2
Cumulative distance of steps ±5
Flatness of steel step 4
Perpendicularity of ladder frame 2 mm/m
Inclination of inclined ladder 4
8.2.2.2 Dimension deviation of the frame and the step of B-type cargo hold inclined ladder shall be in
Table 170 The tolerance of B-type cargo hold inclined ladder’s frame and step Unit: mm
Items Limits
Straightness of ladder frame 5
Installation perpendicularity of ladder frame 1 mm/m, maximum 10
Coaxial degree of the joint of ladder frame 2
Width of ladder frame ±5
Distance between two adjacent steps ±2
Cumulative distance of steps ±5
Flatness of steel step 4
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8.2.2.3 Dimension deviation of the handrail of the inclined ladder shall be in accordance with the
Table 171 Ladder’s handrail tolerance Unit: mm
Items Limits
Straightness of steel pipe 5
Distance between two side handrails ±5
Perpendicularity of handrail 10
Height of handrail’s stanchion ±5
Perpendicularity of handrail’s stanchion 10
Concentricity of the joint of handrail’s pipes 1
8.2.2.4 Dimension deviation of the vertical ladder shall be in accordance with the requirements in table
172.
Table 172 The tolerance of vertical ladder Unit: mm
Items Limits
Straightness of ladder frame 5
Torsion of ladder frame（distance between two centers of frame diagonal lines） 4
Perpendicularity of installation 2 mm/m
Distance between two adjacent square steel steps ±3
Levelness of square steel step 4
8.2.2.5 Flatness of platform is 6 mm.

8.2.2.6 Any burr, sharp corner, crack and other defects on the surface of steel members shall be removed.
8.2.2.7 Damage, crack and burr are not allowed to exist on hardwood and plastic handrails of indoor
inclined ladder.
8.2.2.8 The surface anticorrosive treatment shall be carried out as per ship owner’s requirements for all the
metal members of fixed steel ladder.
8.2.3.1 Small corrosion and damage can be handled by grinding, the local crack can be repaired by
chipping and welding.
8.2.3.2 For small-scale and serious corrosion, damage and deformation, the steel ladder can be repaired by
locally cropping and renewing.
8.2.3.3 For arge-scale and serious corrosion, damage and deformation, the steel ladder shall be entirely
8.2.3.4 The deformation of steel ladder shall be corrected by heating, alternative methods include water
8.2.3.5 The damaged galvanized coating of the steel ladder can be repaired with zinc rich paint.
8.2.3.6 The key points of quality control of fixed steel ladder repairing are as below:
a) Assembly accuracy;
b) Weld quality;
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c) Welding deformation.
Accuracy measurement record shall be provided after repairing.
8.3 Steel door
The key points of survey for steel door are as below:

a) Corrosion, crack, deformation and damage of door plate, door frame and seal slot shall be inspected;
b) Opening & closing test and locking test for the steel door shall be carried out and the test data shall
be recorded;
c) Weather-tight members (sealing rubber, packing slot, handle and hasp) shall be inspected;
d) Tightness test for the steel door is to be carried out if necessary and test data shall be recorded.
8.3.2.1 Dimension deviation of steel door plate and door frame shall be in accordance with the
Table 173 The tolerance of the steel door plate and the door frame Unit: mm
Allowable limits
Items
Height Breadth Straightness Flatness torsion
Door plate
±5 3 4
Door frame
Note: Torsion is the distance between two centers of frame diagonal lines
8.3.2.2 Dimension deviation of the wall opening for the steel door shall be in accordance with the
Table 174 Tolerance of the steel door’s wall opening Unit: mm
Allowable limits
Items Height of Perpendicularity of Centerline of wall opening
Height Breadth Flatness Torsion
door sill centerline and door frame
Wall +30 Horizontal centerline：±5
±6 ±6 4 2 mm/m 4
opening -10 Vertical centerline：±3
8.3.2.3 Installation of the steel door’s compression bar and sealing rubber shall be in accordance with the
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Table 175 The tolerance of steel door’s compression bar and sealing rubber Unit: mm
Items limits
Deviation between center of compression bar and sealing rubber ±2
Compression of sealing rubber 2～5
Contact Width between compression bar and sealing rubber ≥50％Compression bar’s thickness
8.3.2.4 Opening and closing of steel door shall be easy and smooth after the handle, hasp and hinge are
repaired.
8.3.2.5 Any burr, sharp corner, crack and other defects shall be removed from the surface of metal
structures and the members of steel door.
8.3.2.6 Anticorrosive Surface treatment shall be carried out as per ship owner’s requirements for all metal
members of the steel door.
8.3.3.1 The sealing rubber, handle, hasp and hinge shall be repaired or renewed as per original design
drawings.
8.3.3.2 For minor corrosion and damage can be repaired by grinding, localised crack can be repaired by
chipping and welding.
8.3.3.3 For small-scale and serious corrosion, damage and deformation, the steel door can be repaired by
8.3.3.4 To large-scale and serious corrosion, damage and deformation, the steel door shall be entirely
8.3.3.5 Deformation of steel door shall be corrected by flame, the method of water cooler, gravity and
mechanical fixation could also be used.
8.3.3.6 Key points of quality control for the steel door repair:
b) Weld quality;
c) Welding deformation;
d) Relative position between sealing rubber and compression bar;
e) Tightness, opening and closing tests.
The inspection & test acceptance of steel door are as below:

a) Accuracy measurement record shall be provided;
b) Tightness test is to be carried out and test report shall be provided;
c) Opening & closing test and locking test are to be carried out and test report shall be provided.
8.4 Side scuttle
The key points of survey for side scuttle are as below:
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a) Corrosion, crack, deformation and damage shall be inspected for side scuttle’s body, frame and
deadlight;
b) Opening & closing test for side scuttle shall be carried out, and the butterfly nut shall be operatedto
inspect the flexibility and effectiveness of the hinge, nut and bolt;
c) The tightness test for the side scuttle shall be carried out if necessary and test data shall be recorded.
8.4.2.1 Dimension deviation of the side scuttle’s body and frame shall be in accordance with the
Table 176 Tolerance of side scuttle’s body and frame Unit: mm
Limits
Items
Height Breadth Straightness Flatness Torsion
Body
±2 1 mm/m 2
Frame
Note: Torsion of side scuttle is the maximum distance between any two diameters in centers which are perpendicular to each
other
8.4.2.2 Dimension deviation of the side scuttle’s wall opening shall be in accordance with the requirements
in Table 177.
Table 177 Tolerance of side scuttle’s wall opening Unit: mm
Limits
Items Perpendicularity of Deviation between centerlines of
Height Width Flatness Torsion
centerline opening and frame
Wall Horizontal centerline：±2
±3 2 1 mm/m 2
opening Vertical centerline：±2
8.4.2.3 Installation of the compression bar and the sealing rubber of the side scuttle frame shall be in
Table 178 Installation deviation of the compression bar and the sealing rubber Unit: mm
Items Limits
Deviation between centers of compression bar and sealing rubber ±2
Compression of sealing rubber 1～3
Contact width between compression bar and sealing rubber ≥50％Thickness of compression bar
8.4.2.4 Opening and closing of side scuttle shall be easy and smooth after hinge, butterfly nut and bolt are
renewed, the clearance deviation between pin and hole shall be in accordance with the production
requirements.
structures and members of the side scuttle.
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8.4.2.6 Anticorrosive surface treatment shall be carried out as per ship owner’s requirements for all metal
members of the side scuttle.
8.4.3.1 Sealing rubber and glass holder which lose effectiveness due to damage and ageing shall be
renewed.
8.4.3.2 If hinge, butterfly nut and bolt can't be rotated smoothly due to light corrosion, these members shall
be disassembled, cleaned and lubricated.
8.4.3.3 Small corrosion and damage can be repaired by grinding, local crack can be repaired by chipping
and welding.
8.4.3.4 For small-scale and serious corrosion, damage and deformation, the side scuttle can be repaired by
8.4.3.5 For large-scale and serious corrosion, damage and deformation, the side scuttle shall be entirely
8.4.3.6 The damaged galvanized coating of the side scuttle can be repaired with zinc rich paint.
8.4.3.7 The key points of quality control of side scuttle repairing are as below:
b) Weld quality;
c) Relative position between sealing rubber and compression bar;
d) Tightness test;
e) Opening & closing test.
The inspection & test acceptance of side scuttle are as below:

c) Opening & closing test and locking test are to be carried out and recorded.
8.5 Small hatch
The key points of survey foe small hatch are as below:

a) Corrosion, crack, deformation and damage shall be inspected for small hatch cover and hatch
coaming;
b) Opening & closing test for the small hatch shall be carried out to inspect the flexibility and
effectiveness of opening device, hinge and fastener device (center fastener, fast-type clip and screw
clip);
c) Tightness test for the small hatch shall be carried out if necessary and the test results shall be
recorded.
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8.5.2.1 Dimension deviation of small hatch cover and hatch coaming shall be in accordance with the
Table 179 Tolerance of the small hatch cover and the hatch coaming Unit: mm
Limits
Items
Height Length or breadth Straigthness Flateness Torsion
Hatch cover ─
±5 2 mm/m 3
Hatch coaming 0～20
Note: For small circular hatch, length or breadth in the Table is the deviation of diameters.
8.5.2.2 Tolerance of deck plate opening for the small hatch shall be in accordance with the requirements in
Table 180.
Table 180 Tolerance of the deck plate opening Unit: mm
Limits
Items
Length Breadth Opening positioning Flatness
Deck plate opening ±5 4
Note: For small circular hatch，opening positioning is positioning deviation of circle centers
8.5.2.3 Installation of compression bar and sealing rubber for small hatch shall be in accordance with the
Table 181 Installation deviation of compression bar and sealing rubber for small hatch Unit: mm
Items Limits
Deviation between center of compression bar and sealing rubber ±2
compression of sealing rubber 2～4
Breadth of compression print ≥50％Thickness of compression bar
8.5.2.4 Opening and closing of the small hatch shall be easy and smooth after fastener and hinge are
repaired and renewed.
structures and members.
members of the small hatch.
8.5.3.1 Minor corrosion and damage can be repaired by grinding, local crack can be repaired by chipping
and welding.
8.5.3.2 For small-scale and serious corrosion, damage and deformation, the small hatch can be repaired by
local cropping and renewing.
8.5.3.3 For large-scale and serious corrosion, damage and deformation, the small hatch shall be entirely
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8.5.3.4 Sealing rubber, fastener and hinge which lose effectiveness due to damage shall be repaired or
renewed as per original specification.
8.5.3.5 Deformation of small hatch shall be corrected by heating, ,alternative methods include water
8.5.3.6 The key points of quality control of small hatch repairing are as below:
b) Weld quality;
d) Relative position between sealing rubber and compression bar;
e) Tightness test;
f) Opening & closing test.
The inspection & test acceptance of small hatch are as below:

c) Opening & closing test and locking test are to be carried out and recorded.
8.6 Accommodation ladder
The key points of survey for accommodation ladder are as below:

a) Accommodation ladder members such as frame, step, step driving bar, top platform, bottom platform,
handrail, protection wood, side roller, bottom roller, pin and shaft, shall be inspected, and the
corrosion, crack, deformation and damage shall be marked and recorded;
b) Functional test shall be carried out for the device used for lowering, hoisting, turning over and
fastening, the ladder structure, sling, roller, hanger arm, foundation, pad eye, pin and shaft, shackle
and hook shall be inspected and the corrosion, crack, deformation and damage shall be marked and
recorded;
c) The parts that can’t be inspected in site shall be disassembled and transported to manufacture factory
for inspection, inspection record for parts that are hidden are required.
8.6.2.1 Dimension deviation of the accommodation ladder shall be in accordance with the requirements in
Table 182.
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Table 182 Dimension deviation of accommodation ladder Unit: mm
Items Limits
Distance between intersection points of diagonal lines ≤3.0L10/10 000
Ladder frame hogging ≤1.5L10/1 000
Ladder frame sagging
≤L10/1 000
Ladder length
Ladder breadth
Ladder height ±2
Distance between two adjacent steps
Note: L10is the length of accommodation ladder
8.6.2.2 Installation of the lowering, hoisting, turn over and fastening device for accommodation ladder
Table 183 Installation deviation of the lowering, hoisting, turn over and fastening devices Unit: mm
Items Limits
Levelness of top platform 20
Distance between shaft center of top platform and side shell 0～5
Levelness of hanger arm 20
Perpendicularity between top platform and hanger 15
Coaxial degree between pad eye on deck, pad eye on hanger arm and shaft hole of 2L11/10 000
driving pipe
Note: L11is the length of the whole driving pipe
structures and members.
members of the accommodation ladder.
8.6.3.1 Accommodation ladder shall be put on a flat and hard floor when disassembled and transported to
workshop for repairing.
8.6.3.2 Minor corrosion and damage can be repaired by grinding, local crack can be repaired by chipping
and welding.
8.6.3.3 For small-scale and serious corrosion, damage and deformation, the accommodation ladder can be
repaired by local cropping and renewal.
8.6.3.4 For large-scale and significant corrosion, damage and deformation, the small hatch shall be entirely
8.6.3.5 Deformation of steel accommodation ladder shall be corrected by heating, alternative methods to be
used include water cooling, gravity and mechanical fixation
8.6.3.6 Deformation of the aluminum accommodation ladder structure shall be corrected by mechanical
method.
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8.6.3.7 Non-flame cropping method shall be applied for cropping and repairing aluminum accommodation
ladder, argon-arc welding shall be applied and welding consumables shall be in accordance with base metals.
8.6.3.8 The key points of quality control of accommodation ladder repairing are as below:
b) Weld quality;
d) Load test;
e) Functional test.
The inspection & test acceptance of accommodation ladder are as below:

b) Load test is to be carried out and test report shall be provided;
c) Functional test and locking test are to be carried out and recorded.
9 PIPING SYSTEM REPAIRING
9.1 Pipe
The key points of the survey for piping are as below:

a) The medium in piping system shall be identified before inspection; for the oil pipeline, the mark is
required and explosion-proof treatment is to be done;
b) Check if the pipe has developed any corrosion, crack, breakage, depression, deformation and others;
c) Check if the pipe has any bulge due to reduced strength; check if the vacuum pipe has any
depression, deformation and other defects;
d) Check if the piping insulation is complete, missing or breaking off etc.;
e) Check the condition of corrosion, crack and welding seam quality of the piping penetration piece;
f) Check the condition of corrosion and breaking off of anti-corrosive coating of the piping;
g) Check if the sealing surface of the flange has any spots, burr, scratches, perforation and other defects
affecting the seal;
h) Check if the thread joint and pipe joints have any crack, thread breakage and other defects;
i) Check if the body and welding seam of bellow pipe has any crack, corrosion and other defects;
j) Check if the rubber compensation pipe has any crack, bulge and other defects;
k) Check if the pipe support has any deformation, crack, corrosion and other defects.

a) For steel pipe and copper pipe, the diminution of thickness due to corrosion shall be less than 20% of
the original design thickness;
b) The pipe shall not have intergranular corrosion and transgranular corrosion;
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c) The pipe shall not have any scuffing due to sharp object or depression due to the crashing;
d) The ovality of the piping shall be less than 10% of the piping diameter;
e) Zinc layer of hot dip galvanized pipes shall not have any corrosion and breaking off;
f) Pipe insulation layer shall be complete without any missing and breaking off;
g) The concentricity of two connecting pipe shall be in accordance with the requirements in Table 184;
Table 184 The coaxiality of the piping connection Unit：mm
Thickness ≤2 2～3 3～5 5～9 9～15 ＞15

Coaxiality 0.3 0.6 1.0 1.5 2.5 3.0
h) The gap and groove angle of the butt welding pipes shall be in accordance with the requirements of
Table 185:
Table 185 Butt welding requirements of piping Unit：mm
Thickness of pipe Requirements

Gap ＞1.0～3.0
≤3
Groove angle —
Gap ＞1.5～3.0
3～6
Groove angle ＞30°～40°
Gap ＞2.0～4.0
＞6
Groove angle ≥50°～60°
i) NDT of the butt welding for pipes shall be in accordance with the requirements in Table 186:
Table 186 Requirements of NDT for butt welding pipes Unit：mm
Piping Class Size Requirement

OD≥76 100％ Ray inspection
Class I
OD＜76
10％ Sampling ray inspection
Class II OD≥102
9.1.2.2 The quality requirements of flange repairing are as below :

a) The flange sealing surface shall be smooth without any spots, burr, and other defects affecting
sealing;
b) The deflection angle between the flange sealing surface and the axial lead shall be less than 0.5︒ ;
c) In case of two flange connected, the alignment of the two sealing surface shall be in accordance with
the requirements in Table 187;
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Table 187 Alignment of Sealing surface between two connected flanges Unit：mm
Alignment
Nominal diameter
PN＜3 MPa PN≥3 MPa
≤50 ≤2 ≤1.5
65～100 ≤3 ≤2.0
125～200 ≤4 ≤3.0
225～350 ≤6
—
400～500 ≤8
d) The surface of flange inner edge shall be smooth, the fitting clearance with the pipe outside surface
Table 188 The fitting clearance between surfaces
of the flange inner edge and the pipe outer edge Unit：mm
Nominal diameter Average fitting clearance

＜25 ＜0.5
25～80 ≥0.6～1.0
100～200 ≥1.1～2.0
225～350 ≥2.1～3.0
≥350 ＜3.5
9.1.2.3 The quality control requirements of the threaded joint repair are as below:
a) The height reduction of the thread tooth caused by wearing shall be less than 20% of the original
tooth design;
b) The sealing parts with threaded joints shall form an evenly and uniform ring line after tightening.
9.1.2.4 The quality requirement of the bellow repairing are as below:
a) The surface of the longitudinal welding seam on the bellows shall be free of crack, pores, undercuts
and misalignment; the pits, collapse and welding reinforcement shall be less than 10% of the bellows
thickness;
b) The bellows surface shall be free of any crack or other defects such as scratches and collapse the
depth of which shall not exceed the lower deviation of the plate thickness;
c) The limit deviation of curvature radius at peak and valley of the U type bellows shall be ±15％;
d) The mean radius limit deviation and roundness deviation of the Ω type bellows shall be ±15％;
e) The verticality between both ends of the bellows and axes shall be 1% of the nominal diameter of the
bellows.
9.1.2.5 The fabrication and installation of piping supports shall be in accordance with the requirements of
the original vessel.
9.1.2.6 The penetration piece shall be without any corrosion and crack. The size of welding seam shall be
uniform, the welding seam transited to the base material shall be smooth without any visible sharp corners.
9.1.2.7 In general the distance between the insulated piping surface and the adjacent pipe, accessories and
the hull components shall be higher than 20 mm , and only on special cases higher than 10 mm.
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9.1.3 Quality control requirement of the repairing process
9.1.3.1 Minor defects on the surface of the pipe shall be removed, however, if the reduction of thickness
after polishing is less than the minimum requirements of repairing quality, the pipe shall be renewed.
9.1.3.2 To prevent welding deformation, the branch and elbow are to be welded firstly and then assemble
flanges.
9.1.3.3 In case the double-sided welding or single welding can not to be used for welding of oil pipe, the
gas protection shall be used as root welding.
9.1.3.4 Argon arc welding shall be used for copper nickel alloy pipe.
9.1.3.5 , If there is some minor damage on the welding of a galvanized plated steel pipe, it shall be applied
with zinc rich paint. If there is any damage in a large area, it is to be galvanized again. Any parts than do not
require galvanizing shall be protected (such as flange sealing surface).
9.1.3.6 For the ordinary piping, the compressed air shall be used to removing the internal rust, sand and oil
and any other debris; the oil piping shall be chemically cleaned first and checked by the pressure test before
installation on board.
9.1.3.7 All steam pipes, exhaust pipes and other pipes with high surface temperature shall be coated with
rust proof or heat resistant paint and then wrapped with heat insulation material.
9.1.3.8 The outer piping insulation layer which experiences high temperature shall be wrapped with
galvanized iron sheet.
9.1.3.9 White tape sealing material shall be used for pipe taper threads connections, cylindrical pipe thread
connection shall be lubricated with graphite grease.
9.1.3.10 For high temperature piping, a sliding hoop U-bolt or elastic support shall be used on the
expansion part. Rigid support is not suitable for the above use..
9.1.3.11 The pipe support shall be directly connected with the main hull structure, and not directly welded
on the shell.
9.1.3.12 For the oil piping system, the sliding pad shall be added between the pipe and the support.
9.1.3.13 The key points of quality control for piping repairs are as below:
a) The cleaning of the piping end connection surface and piping inside;
b) Sealing material of piping connection;
c) Surface quality of piping accessories;
d) The quality of pipe coating and hot galvanized;
e) Protection and plugging of the pipe after surface treatment;
f) The form and spacing of the pipe support; support welding;
g) The form of pipe support for non-ferrous metal pipe;
h) Integrity and accuracy of piping installation;
i) The medium, method and cleanliness of pipe flushing;
j) Internal cleaning and maintenance for the lubricating oil and hydraulic oil piping system;
k) Piping Tightness test.
The inspection & test for acceptance are as below:

a) Check and record the Integrity and accuracy of piping installation;
b) Piping non-destructive testing report;
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c) Piping pressure testing report.
9.2 Valve
The key points of the survey for valves are as below:

a) Check if the valve body and cover have any defects such as corrosion, damage, crack etc.;
b) Check the sealing condition of the connected surface between valve cover and body, valve body and
pipe flange;
c) Check the wear conditions of the valve disk, valve seat, wedge plate and plug core of gate valve,
check the sealing surface for defects such as spots, depression and damage ;
d) Check if the valve stem, lift rod, guide sleeve, adjustment bolt and locknut, etc. have any defects
such as deformation, rustiness, abrasion and damage, etc.;
e) Check if the safety valve spring and spring seat have any defects such as deformation, crack and
rustiness etc.;
f) If necessary, the pressure test on the valve body shall be carried out before repairing, in order to
check the sealing condition of the valve body.
9.2.2.1 The quality requirements of common valves repairing are as below:

a) No burr and shape and corner edges on the surface of the valve; no metal debris and rusty scale etc.
inside the valve;
b) Operation of the valves shall be smooth and without blocking;
c) Valve stem, valve seat and valve disc shall be concentric;
d) After repairing defects such as crack, flange warping and end face corrosion etc., the reduction of
thickness shall be less than 20% of the original design thickness;
e) The uniform corrosion depth of the valve body shall be less than 30% of the original design
thickness;
f) The surface of the valve seat shall be free of crack, and the sealing parts of valve body shall be free
of corrosion;
g) The thickness reduction of the valve seat due to wear shall not be less than 50% of the original
design thickness;
h) The assembly of the valve seat and valve body shall not be loose and leaking;
i) For valves with nominal pressure of PN≥1.6 MPa and DN≥80 mm, the thickness reduction of the
sealing surface due to wear shall be less than 65% of the original design thickness;
j) The valve disc shall be free of cracks and corrosion;
k) The sealing down deflection of gate valve core shall not exceed 1/3 of the sealing width;
l) The sealing surface height of valve core shall be higher than the sealing surface of the valve seat, and
shall be not higher than 1/2～2/3 of the height of valve seat sealing surface;
m) The reducing of flow area, which is caused by shrinkage of the plug core shall be less than 10% of
the flow area;
n) For gate valves and cock valves with PN≤0.6 MPa, after the valve disc sealing surface is grinded,
repaired and the tightness test are passed, holes less than 1mm deep and gaps higher than 25 times of
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the maximum diameter are allowed, however, the total number and diameter of holes shall be in
accordance with the requirements of Table 189;
Table 189 The grinding requirements for valve disc of gate valves and cock valves
Item Nominal diameter/mm Maximum diameter of holes/mm Total number of holes

≤150 0.5 ≤3
Gate valve 200～350 1.0 ≤5
400～500 1.5 ≤7
≤40 1.0 ≤3
Cock valve
＞40 2.0 ≤5
o) The thickness reducing of the thread tooth of valve stem caused by wearing shall be less than 20% of
the original tooth height, in case the valve nominal pressure is PN≥4.0 MPa, the thickness reduction
of the thread tooth shall be less than 15%;
p) The increasing gap between stuffing gland and valve stem caused by wear shall be less than 25％ of
the maximum installation gap;
q) After compacting the stuffing of the valves, the length of stuffing gland pressed into the stuffing box
shall be 10% ~ 25% of the length of the stuffing box;
r) In case the check valve and stop check valve lift steam rises, valves shall be closed automatically at
16 degrees tilt.
9.2.2.2 The quality requirements of safety valve repair are as below:
a) The upper and lower end face of safety valve spring shall be keep in parallel, the dimensional
deviation of the spring diameter shall be less than 0.1 mm per each of 100 mm, the roughness of the
smooth end faces of the spring shall be 6.3μm;
b) The supporting plane of two ends of the spring shall be higher than 3/4 ring;
c) The guide sleeve shall be without crack and severe scratching;
d) The drain hole of the safety valve shall be kept clear;
e) The assembly gap between the main parts of the safety valve shall be in accordance with the
requirements of Table 190;
Table 190 Assembly gap between the main parts of the safety valve Unit：mm
Item Requirements
Gap between valve stem and hole of adjusting bolt 1.00～1.20
Gap between shoulder of valve cover and valve body 0.08～0.12
Gap between outside diameter of guide sleeve and valve 0.06～0.08
f) The gap between outside of valve disc and the guide sleeve shall be in accordance with the
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Table 191 The gap between the outside of the valve disc and the guide sleeve Unit：mm
Outside diameter of valve disc Requirement

≥75～100 0.25～0.30
100～125 0.30～0.35
125～150 0.35～0.40
g) The testing shall be carried out in the workshop, valve resetting shall be smooth, no blocking
resistance, stable and reliable.
9.2.3.1 The quality control requirement of valve body repairing are as below:
a) If cracks or leakage during the pressure test are found on the body of the ductile iron valve( with
nominal pressure PN≤1.6 MPa and nominal diameter DN≥80 mm), steel valve and copper valve, ,
they shall be repaired by built-up welding according to the repairing procedure. In case either of the
following three defects are found, the valves shall be replaced:
In case of the uniform corrosion depth of the valves reach to 30% of the original thickness;
The valve flange is found with crack, warpage and end face corrosion and can’t be repaired;
If leaking is found in the valve body by pressure test following the repair.
b) The defects on the valve flange such as crack, warpage and end face corrosion shall be repaired by
methods such as grinding, scraping and cropping etc., The gray cast iron valves shall be renewed;
c) Annealing treatment shall be done for valves of which the valve body was repaired by welding.
9.2.3.2 The quality control of valve seat repairing are as below:
a) The defects of crack, cyclic corrosion on the surface of the ductile iron valve (nominal pressure
PN≤1.6 MPa and nominal diameter DN≥80 mm), steel valve and copper valve shall be repaired by
welding and grinding;
b) In case the wearing depth of valve seat exceed the requirements, the valve shall be renewed;
c) After finish turning and grinding, if the assembly parts between the valve seat and valve body are
still loosing or leaking, the valve shall be renewed.
9.2.3.3 The quality control requirements of valve disc repairing are as below:
a) The abrasion of valve disc sealing surface can be repaired by turning and grinding; if the wearing
depth exceed the requirements, the valve shall be replaced;
b) The grey cast iron or ductile iron valve limited in PN≥1.6 MPa and DN≤80 mm with crack or cyclic
corrosion shall be replaced; if the sinkage of gate valve exceed 1/3 of the sealing width, it shall
repaired by caulk-welding and then grinding, otherwise, it shall be replaced if the repairing does not
reach requirement;
c) If the reducing of flow area caused by sinkage of plug core exceed 10% of flow area; the plug core
shall be replaced;
d) No defects on the valve disc sealing surface after grinding and repairing; the defects can be allowed
on the gate valve and cock valve limited in nominal pressure PN≤0.6 MPa, but which shall be in
accordance with the requirements of ( 9.2.2.1 n ) above-mentioned.
9.2.3.4 The quality control requirements of valve stem repairing are as below:
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a) In case the valve stem is bending, it shall be corrected; the minor corrosion on the valve stem shall
be repaired by turning; it shall be replaced in case the wearing of thread on valve stem exceeds
requirements;
b) If the gap between valve stem and seal bushing is too big, the corrosion of valve stem is affecting
sealing, or the valve stem has severe bending so that it can’t be corrected, the valve stem shall be
replaced.
9.2.3.5 The key points of quality control of valve repairing are as below:
a) Repairing and assembly accuracy of main components;
b) Safety valve taking off test;
c) Pressure test.
The inspection & test for acceptance of valves are as below:

a) Measure and record the repairing accuracy of main components;
b) Carry out valve pressure test and issue report;
c) Carry out safety valves taking off test and issue report;
d) Function test to be carried out including valves and piping and issue report.
10 ELECTRICAL ENGINEERING
10.1 Cable
The key points of survey for cable are as below:

a) Check that the cable’s metal sheath is complete and intact;
b) Check that the insulation of the cable shield and cable core has not dried-up, burst, become tacky or
been damaged;
c) Check the cable conductor situations(e.g. short-circuit and broken-circuit) to measure the insulation
resistance between core-core and insulation resistance between core-ground (shielding layer) with an
ohm meter. Keep a record of the measurement.
10.1.2 Requirements of repairing
10.1.2.1 Provide a clear and durable mark for the tubing at the end of each cable core. The mark shall be
consistent with the wiring diagram inside the related connection box.
10.1.2.2 The minimum bending radius of renewed cable shall be in accordance with the requirements in
table 192.
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Table 192 Bending radius of renewal cable Unit: mm
Cable structure
Outside diameter of cable D32 Minimum bending radius
Insulating External protective layer
Metallic sheath or armour Any 6D32
Thermoplastic & elastomer ≤25 4D32
Non-armour or non-wired
＞25
6D32
Mineral Hard metal sheathing Any
10.1.2.3 The minimum bending radius of renewed radio-frequency cable shall be in accordance with the
requirements in table 193.
Table 193 Bending radius of renewal radio-frequency cable Unit: cm
Minimum bending radius

Model and size
Indoor installation Outdoor installation
50-7-2 5 10
50-7-6 6 12
50-7-8 5 10
50-12-1 7 14
50-17-2 11 22
50-17-3 12 24
75-4-1 3 6
75-4-2 4 8
75-7-2 5 10
75-7-3 6 12
75-7-11 5 10
75-17-2 11 22
10.1.2.4 The cross-sectional area of the conductor used for common grounding shall be in accordance with
the cross-sectional area of the maximum current-carrying conductor values given in Table 194.
Table 194 Grounding for metallic protective layer of cable Unit: mm2
Cross-sectional area of current-carrying conductor Cross-sectional area of grounding conductor

≤25 ≥1.5
＞25 ≥4.0
10.1.2.5 For a cable butt repair refer to the diagram in Figure 4. Requirements for the indentation height
and position are given in Table 195.
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A
b9
b9 A-A
h7
A
Figure 4 Cable butt repairing
Table 195 Cable butt repairing indentation height and position
Connector size/mm2 b9/mm h7/mm

10 4 4.5
16 4.7
25 5.2
35 6 6.2
50 6.7
70 8.2
95 9.7
120 10.7
8
150 12.2
185 13.7
240 15.7
300 10 17.5
400 19.2
10.1.2.6 The insulation resistance of repaired cable shall not be less than the original value.
10.1.2.7 For renewed cable, the core-core insulation resistance and core-ground (shielding layer) insulation
resistance shall not be less than 1 MΩ measured with a 500 V Mega-ohmmeter.
10.1.3.1 The cable shall be renewed in cases where any of the following defects exist:
a) All or most of the cable outer metal sheath and armour are rusted, damaged or difficult to repair;
b) All or most of the insulation of the cable outer sheath and cable core sheath are dried-up, burst, tacky
or damaged;
c) The cable conductor is short-circuited or broken-circuit, and the location of short or broken points
can not be confirmed, and the cable is without spare cores;
d) The radio-frequency cable conductor has a broken-circuit or the insulation is damaged;
e) The insulation resistance of core-core or core-ground（shielding layer) is less than 1MΩ and even
with the implementation of end insulation treatment cannot be improved;
f) Cable armor is damaged and within Zone 1 Hazardous areas.
10.1.3.2 The core structure and sheath structure of the renewal cable shall be equal to original cable or
comply with Class rules as a minimum.
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10.1.3.3 The renewal cable shall be the same model and standard as the original cable. If the model and
standard are not the same, the cross-sectional area of the renewal cable and the electrical characteristic shall be
no less than the original cable; the structure of the core and sheath shall be equal to the original cable.
10.1.3.4 The cable tying strip shall be selected depending on the area; plastic coated stainless steel cable
ties shall be used for Class A machinery spaces, fireproof cabins, weather areas and moist cabins. Plastic
coated steel or nylon cable ties shall be used for accommodation spaces and other areas. In cases where
non-metallic tying strip is used to fasten the cable laying above horizontal guide plates or brackets, additional
metallic tying strip shall be used to fasten the cableat1 meter intervals to prevent the cable loosening in the
event of a fire.
10.1.3.5 The renewal cable shall be laid as the original cable route, however, should a new cable route be
required, it is shall be done under the approval of the owners representatives and in compliance with Class
rules.
10.1.3.6 Cable grounding:
a) All metallic protective layers of cable shall be electrically connected to the metallic hull at both ends.
For final branch power cable, only the power side is to be connected. For control and instrument
signal cable, only the single end at the device is to be connected;
b) The surface of the ground conductor connection points on the hull structure shall be processed to
ensure the contact resistance is zero.
10.1.3.7 Repairing cable by heat-shrink or adding a connection box is applicable in cases of partial cable
defects or a shortening of cable length, the material and process should be approved by Classification Society.
10.1.3.8 After a cable butt repair, a tensile test is to be carried out by specific force if necessary. For the
method of tensile test, refer to figure 5.
loading direction loading direction
Figure 5 Cable tensile test
10.1.3.9 Butt of multi-core cable shall ensure basically consistent length of core wire and stagger
arrangement of connecting pipe of adjacent core wire.
10.1.3.10 For cable core that has a cross-sectional area within the range of1 mm2 to 6 mm2,sealed
connecting pipe with heat-shrinkable tubing is to be used and press-in connected by a special tool. For cable
core that has a cross-sectional area greater than6 mm2, it shall be press-in connected with hexagonal
connecting pipe.
10.1.3.11 Key points of quality control of cable repairing are as below:
a) Cable type selection;
b) Cable laying and fixing;
c) Cable butt repairing and testing;
d) Cable grounding.
Inspection & testing for acceptance of cable repairing are as below:

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a) Measure and record the cable insulation resistance;

b) Measure and record the continuity of repaired cable;
c) Execute the tensile test of the butt repaired cable and issue report;
d) Check the cable temperature during equipment function test;
e) For high-voltage cables perform a withstand voltage test and issue a report;
f) Provide qualification certificate of watertight compartments and cable fire resistance;
g) Provide product certification in accordance with requirements of Classification Society.
10.2 Electric motor
The key points of survey for electric motors are as below:

a) Check if there is any damage(broken or loose)on the motor shell, machine base, end cover,
indication plate of winding, indication of rotation direction, shaft coupling, belt pulley, air blade,
protective cover, mesh enclosures, observation window cover and junction box. Check if the rotation
of the rotor is flexible and if the shaft is bent.
b) After motor overhaul, check the gap between stator and rotor, check if the rotor balance weight is
loose or not and if the capacitor has been damaged or not.
c) Check if there are any burn marks on the surface (windings of stator, rotor, armature, shunt or series
excitation and reversing start), insulating layer carbonation, crack or burning smell, oxidation and
discoloration of conductive material caused by overheating. Measure the insulation of the windings
between the windings and ground using an ohmmeter;
d) Check the surface color and wear of commutator and collector ring, the tightness of commutator and
if there are any breakouts on the mica insulation chip;
e) Check the integrity and wear of the brake.
10.2.2.1 The cold state insulation resistance of the motor shall be above 2 MΩ after repair at a workshop.
10.2.2.2 The requirements of motor insulation after repair on site are as below.
a) For non re-winding motors, the winding insulation resistance shall be no less than 0.5 MΩ;
b) For re-winding motors, the winding insulation shall be no less than 1 MΩ;
10.2.2.3 Commutator and collector ring:
a) The surface roughness of commutator cylindrical shall be Ra=1.6 µm, the concentricity of
commutator cylindrical shall be in accordance with requirements in Table 196;
Table 196 The limit concentricity of commutator cylindrical Unit: mm
Diameter of commutator D33 Requirement

≤250 0.02
＞250 0.03
b) After commutator machining, carve the micasegment groove. The groove depth from the
commutator surface shall be in accordance with the requirements given in Table197;
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Table 197 Micasegment groove depth Unit: mm
Diameter of commutator D34 Requirement

≤50 0.5
50～150 0.8
150～300 1.2
＞300 1.5
c) Collecting ring outer roundness shall be 0.1 mm.

10.2.2.4 Electrical brush:
a) The fitting clearance of electrical brush and brush holder shall be in accordance with the
requirements given in Table 198;
Table 198 Fitting clearance of electrical brush and brush holder Unit: mm
Clearance along breadth direction Clearance along length direction

Category
Min Max Min Max
Electrical brush
cross-sectional area below 0.02 0.17 0.05 0.25
8×8
General motor 0.30 0.15 0.45
0.05
Reversible motor 0.20 0.10 0.40
b) The tolerance of spring elastic force between electrical brushes shall not exceed 10% of the mean
value, distance between brush and commutator shall be adjusted to 2 mm～5 mm;
c) The electrical brush shall be uniformly distributed around the commutator and the tolerance in space
shall be no more than 0.5mm;
d) The contact area of brush and commutator shall be more than 3/4 of the cross-sectional area of
electrical brush.
10.2.2.5 Electrical motor assembling:
a) The limit tolerance of shaft coupling hole diameter and rotating shaft diameter shall be in accordance
Table 199 Limit tolerance between shaft coupling and rotating shaft Unit: um
Shaft nominal diameter Limit tolerance of shaft Limit tolerance of shaft hole
d63/mm Upper deviation Lower deviation Upper deviation Lower deviation
≤18 -12 +5 -14
18～30 -14 +6 -17
30～50 -17 +7 -20
50～80 -20 +8 -23
0
80～120 -23 +9 -26
120～180 -27 +10 -30
180～260 -30 +11 -35
260～360 -35 +12 -40
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b) The limit tolerance of the bearing hole of the motor end cover and bearing shall be in accordance
with the requirements in table 200.
Table 200 Bearing hole of motor end cover and bearing Unit: um
Shaft nominal diameter Limit tolerance of bearing outside diameter Limit tolerance of end cover bore
≤18 -8 +5 -14
18～30 -9 +6 -17
30～50 -11 +7 -20
50～80 -13 +8 -23
80～120 -15 +9 -26
120～150 -18
0 +10 -30
150～180 -25
180～250 -30
+11 -35
250～260
-35
260～315
+12 -40
315～360
-40
360～400 +15 -45
c) The limit tolerance of the rotating shaft and bearing shall be in accordance with the requirements in
table 201;
Table 201 Limit tolerance of rotating shaft and bearing Unit: um
Shaft nominal diameter Limit tolerance of bearing inner ring diameter Limit tolerance of shaft diameter
≤6 +9 +1
6～10 +12
-10
10～18 +14 +2
18～30 +17
30～50 -12 +20
50～80 -15 +23 +3
80～120 0 -20 +26
120～180 -25 +30
180～250 -30
+35
250～260 +4
-35
260～315
+40
315～360
-40
360～400 +45 +5
10.2.3.1 The components of the motor shall be measured and marked during the overhauling period.
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10.2.3.2 Use compressed air to blow off the dust inside the motor, clean the winding and components with
chemical cleaning agents. The insulation resistance of the motor winding can be improved by drying and
varnishing. If repeated washing and drying does not achieve the required insulation values, the windings are to
be renewed.
10.2.3.3 The grade and specification of materials for repairing motor windings shall not be lower than the
original.
10.2.3.4 Partial repairing is allowed by means of local refitting, wrapping, drying or painting immersion in
order to renovate the winding to fix a partial short-circuit, broken circuit or earthed circuit where the location
is convenient for repairing.
10.2.3.5 If the insulation inside the winding groove is damaged, short-circuited, broken circuit, earthed,
or damaged part outside of the groove is hard to repair, the winding shall be re-winding.
10.2.3.6 During commutator or collecting ring machining, cooling liquid and soap water are not allowed to
be used in order to prevent the intrusion of chips and copper powder into the inside the motor.
10.2.3.7 The brush-holder shall be repaired or replaced if the insulation seat is broken and may affect
insulating property.
10.2.3.8 Renew the rusted spring of brush-holder with original size.
10.2.3.9 In cases of tight fitting, motor components shall be scraped. In cases of loose fitting motor
components, machining and welding shall be used.
10.2.3.10 Key points of electrical motor repairing quality control are as below:
a) Electric motor cleaning;
b) Electric motor drying;
c) Selection of winding material;
d) Precision of machining parts;
e) Assembly precision;
f) Testing of electric motor.
10.2.4.1 Inspection & test for acceptance of electrical motor repairing are as below:
a) Measure and record the insulation of electrical motor;
b) The electrical motor with a winding repair shall undergo a withstand voltage test inspection;
c) No-load test inspection and record;
d) DC motor shall undergo high-voltage and low-voltage test, check and record the spark rating data;
e) After winding repair, a DC motor shall undergo overload、over speed, overvoltage and an insulating
dielectric strength test and record. This data; to be recorded.
f) After winding repair, an AC motor shall undergo an insulating dielectric strength test and the data
should be recorded;
g) Execute electrical motor running with load test and issue report;
h) If necessary, execute the rotor balance test and issue report;
i) Electrical motor with brake shall undergo brake function test and issue report.
10.2.4.2 Generator repairing inspection requirements are as below:
a) For the re-winding generator, a load test is to be carried out in accordance with the prime drive diesel
engine actual output power and the data recorded;
b) After generator repair, an alarm test is to be carried out and the result recorded;
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c) After generator load test completion, measure and record each part of the motor temperature rise and
hot state insulation resistance;
d) According to the actual situation of the generator, load test shall be 100% overload test;
e) For generator re-winding or replacement and AVR repair or replacement, a voltage characteristic
experiment shall be performed and recorded;
f) Where a prime drive diesel engine or speed governor is replaced, or an AVR is repaired or re-wound,
a parallel load test shall be carried out. Prior to the parallel running test, individual load tests shall be
done.
10.3 Main switch board and emergency switch board
The key points of survey for switch boards are as below:

a) Check if the panel is rusted or distorted. The movement of door locks and hinges is flexible;
b) Check if the bus bar is distorted or the painting/ coating has changed or dropped;
c) Check if there are any sign of lamination, burns or ageing in the insulating part. Check the
connecting wire insulation is not tacky or aging;
d) Check if the anti-corrosion layer of fasteners and terminals is damaged and that the grounding is in
good condition;
e) Check if the switch and circuit breaker operation is flexible and reliable, the draw-out mechanism of
the draw-out breaker shall function flexibly, and position correctly;
f) Check if the relay and contactor coil contact point has burned out, that the arc chute is intact and the
armature movement is flexible;
g) Check if the transformer coils, mutual inductor coils and trip coils are not broken or burned;
h) Check that the fuse is intact, the support component is not broken or missing and the conductive
component of the contact is in good condition;
i) The button and indicating lamp shall function reliably.
10.3.2.1 Requirements of switch board structure are as below:

a) The panel and door shall be reliable and operate smoothly after repair;
b) After the door hinge repair, make sure the closing and opening of the door is flexible operates
smoothly, the opening angle is not less than 90° and it is not loose after closing;
c) The repaired fastener shall have sufficient strength, corrosion resistant and anti-loose measures;
d) Special grounding bases shall be provided for panel with electric components. A structural bar
durable grounding mark is to be attached at the grounding position.
10.3.2.2 Paint coating should be uniform and smooth; wrinkles and sagging are not allowed.
10.3.2.3 Requirements of main circuit breaker are as below:
a) The operation mechanism shall be flexible and the releasing mechanism shall act reliably;
b) The draw-out mechanism of the draw-out breaker shall be flexible, and position correctly and
reliably;
c) The surface of the contactor shall be smooth and well contacted. Different phases (pole) of the main
contactor shall be contacted at the same time;
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d) The shunt release and drop-voltage release device shall work correctly and reliably.
10.3.2.4 The electric clearance and creepage distance (excluding the conductor between main bus bar and
leading-out wire) between non-coating main bus bar of different phase and grounding metal part shall be in
accordance with the requirements given in Table 202.
Table 202 Electric clearance and creepage distance
between non-coating bus bar and grounding metal part Unit: mm
Rated voltage between poles or phase/V Electric clearance Creepage distance

≤250 ≥15 ≥20
250～660 ≥20 ≥25
＞660~1000 ≥25 ≥35
10.3.2.5 After repairing, the insulation resistance shall comply with the following requirement:
a) For at-site repairing, insulation resistance ≥0.5 MΩ;
b) For workshop repairing, insulation resistance ≥1 MΩ.
10.3.2.6 Reset the protecting unit of repaired generator shall be in accordance with requirement in
Table203.
Table 203 Setting value of generator protecting unit
Type Setting value

Long-delay overcurrent release Release after 15 S-30 S delay at 125%-135% the rated current of generator
Short-delay overcurrent release Release after max.0.6 S delay at pickup of 200%-250% the rated current of the generator
According to switching characteristics, release at 10 times to 20 times of the rated current, at
Instantaneous release low current limitation off-time should be less than 0.1 S, the upper limit of operating current
off time should be less than 0.1 S
Under-voltage protection Release after the delay(more than 0.6 S) at70%-35% the rated voltage
Reverse-power( Diesel driven Release after 3 S-10 S delay at 8%-15% the rated active power of generator
current)protecti Steam-turbine
Release after 3 S-10 S delay at 2%-6% the rated active power of generator
on driven
Set according to original design, release after the delay less than 15 S at 100% to 110% the
Overload preference trip device
rated current of the generator
10.3.3.1 In general the renewal components and materials should be same as the original models. In the
event of an impossible situation, the products with similar features and performance are allowed to be used
under the approval from ship-owner’s representative.
10.3.3.2 The main circuit breaker of the generator and the trip device shall be reset in accordance with the
original design requirements after repair. Any modifications should comply with Class rules.
10.3.3.3 The metal parts shall be galvanized passivation if it is requested for surface protection.
10.3.3.4 The replacement of the damaged electronic components for the integrated electrical device shall
be consistent with the original models and specifications.
10.3.3.5 Key points of switch board repairing quality control are as below:
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a) Repairing of structural components;

b) Selection of components;
c) Repairing and setting of circuit breaker;
d) Power-on test.
Inspections& test for acceptance of switch boards are as below:

a) Check the integrity and repairing quality and make a record;
b) Switchboard dielectric strength test and record the data if necessary;
c) Measure and record the insulation resistance;
d) Energized operation test and issue report;
e) Protection device test and issue report;
f) Instrument calibration and issue report;
g) Electrical interlock test and record;
h) Functional test record;
i) Circuit breaker on-off test and ensure consecutive switch on-off operation properly for 3 times;
j) For emergency switch board, auto-start test of emergency generator should be carrying out.
10.4 Distribution box and control box
Key points of survey for distribution box and control box shall be referred to key points of survey in
10.3.1.
10.4.2.1 All nameplates and symbols shall be correct, clear and durable.
10.4.2.2 The cabinet body shall be flat and smooth, well connection device to ground, reliable securing
device.
10.4.2.3 The movement of door lock, hinge etc, shall be flexible and the opening angle of the door shall be
greater than 90°.
10.4.2.4 Well connections should be same as wiring diagram.
10.4.2.5 Voltage, current and breaking capacity of circuit breakers and fuses should meet the original
design requirements.
10.4.2.6 After repair, distribution boxes should be consistent with the original design requirements. If not
contact and discuss with the ship owner representative to achieve agreement.
10.4.2.7 Paint coatings should be uniform and smooth, wrinkles and sagging are not allowed.
10.4.2.8 After repairs, the insulation resistance shall meet the following requirements:
a) For on-site repairs, insulation resistance ≥0.5 MΩ;
b) For workshop repairs, insulation resistance ≥1 MΩ.
10.4.3.1 In general the renewal parts or materials should be same as the original types; if similar products
to be used, owner's agreement should be achieved in advance.
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10.4.3.2 The original protection grade of box shall be kept after repairing.
10.4.3.3 Key points of repairing quality control of measuring instruments are as following:
a) After repair, the meter shall be calibrated by a Class II national calibration agency or qualified
agency. The calibration certificates should be issued.
b) If measuring instrument is unable to be calibrated, it shall be replaced with equal range and accuracy
as original one.
10.4.3.4 Quality control of repairing process of contactor:
a) After being checked and repaired, the open distance, contact pressure and over travel distance of the
contactor shall be adjusted in accordance with the technical requirements. The contact point shall be
kept in good condition.
b) Check the arc extinguishing system; if the arc chute is wet, dry it before use. If the arc blower coil is
short-circuited, the short shall be repaired; if the arc chute is broken, adhere it or replace it.
c) If the insulation of electromagnetic coil becomes poor, the coil shall be cleaned, dried and immersion
painted to improve the insulation. If the coil is burnt, it shall be re-winded in accordance with the
original design, and insulated.
10.4.3.5 Quality control of repairing process of auxiliary relay:
a) All component surfaces shall be cleaned;
b) The low insulation resistance coil shall be cleaned, dried and immersion painted to improve the
insulation. If burnt, rewind as original design and insulate the coil.
c) The over-current relay, over-voltage relay and time delay relay shall be reset to an accurate value in
accordance with original design value.
10.4.3.6 The control transformer and current mutual inductor in low insulation shall be painted with
insulated paint or recover the insulation layer. If burnt, rewind the coil to the original design value.
10.4.3.7 Key points of distribution box and control box repairing quality control are as below:
a) Selection of components;
b) Setting of protection device;
c) Energized function test.
Inspections of distribution box and control box requirements are as below:

a) Check and record integrity and repair quality;
b) Dielectric strength test and record the data if necessary;
c) Measure and record the insulation resistance;
d) Energized operation test and issue report;
e) Low voltage alarm and function test for charging and discharging panel, battery.
11 AIR CONDITIONING UNIT, REFRIGERATION PLANT AND VENTILATION DEVICE
11.1 Air conditioning unit and refrigeration plant
The key points of the survey for air conditioning units and refrigeration plants are as below:
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a) Running tests shall be carried out if possible, and the inlet/outlet air pressure and oil pressure of
compressor shall be recorded;
b) Check if there is any defect, serious deformation or crack in the components with bearing on main
force such as crankshaft, piston, connecting rod, piston pin and connecting rod bolts etc. NDT is to
be performed on the components such as crankshaft and connection rod bolts etc. bearing on key
force if possible;
c) Check the condition of the cooling water chamber and its relative parts etc. for any leaking;
d) Check if there is any fouling on the side of cooling water and air in the condenser and evaporator;
e) Check if there is any defect of corrosion, crack, rupture, pitting and deformation etc. on the coolant
pipe.
11.1.2.1 The quality requirements of piston type Freon compressor repairs are as below;
a) Clearance between each part of the Piston Freon type compressor shall be in accordance with its
technical specification;
b) If no relative technical specification can be found for the clearance of each part of the Piston Freon
compressor with cylinder bore less than or equal to 150 mm, the requirement in Table 204 shall be
complied with after repairs;
Table 204 Clearance between the parts Unit: mm
Items Requirements
Aluminum piston and cylinder Cylinder bore x 1.5‰～2.0‰
Cast iron piston and cylinder Cylinder bore x 0.3‰～0.5‰
Small end bearing and piston pin Piston pin diameter x 1.0‰～1.5‰
Big end bearing and crank pin Crank pin diameter x 1.5‰～2.0‰
Main bearing and main journal Shaft neck diameter x 1.5‰～2.0‰
Joint of piston ring for compressor (Revolution> 600 r/min) Cylinder bore x 4.0‰～6.0‰
Joint of piston ring for compressor (Revolution≤ 600 r/min) Cylinder bore x 2.0‰～3.0‰
c) After working surface machining, pressure tests is to be carried out in case that the cylinder bore was
increased by more than 0.5% in nominal diameter. However, the above increment of the diameter
shall be not more than 1% of the nominal diameter;
d) The Increment of the axial dimension of the piston ring groove shall be not more than 10% in
nominal diameter;
e) The exhaust residual gap of the refrigeration compressor and the air conditioning compressor shall
be in accordance with requirements in Table 205;
Table 205 Exhaust residual gap
Items Requirements
Refrigeration compressor Cylinder bore x 0.75％～1.00％
Air conditioning compressor Cylinder bore x 0.75％～1.00％
f) The decrease of the cylinder bore shall not exceed 0.2% of the cylinder diameter after worn;
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g) Under working condition, the refitted shaft seal of the compressor shall be in accordance with the
requirements in Table 206
Table 206 Shaft seal of the compressor
Items Requirements
The shaft seal of the compressor with Refrigeration Capacity The minimal oil penetration with no oil droplet is allowed
≤35 kW
The shaft seal of the compressor with Refrigeration Capacity The rate of oil droplet at shaft seal shall not exceed 0.5 mL/h.
＞35 kW
11.1.2.2 The repair quality requirements of refrigeration heat exchanger are as below:
a) The number of blocked pipes shall not exceed 10% of the total number of pipes in the unidirectional
water flow
b) The fouling shall not exist in cooling water tubes or air side of the condenser and evaporator;.
c) No leakage in the condenser and evaporator.
11.1.2.3 The repair quality requirements of refrigerating piping system are as below::
a) The piping line with fluorine shall be clean and dry without any residue impurities
b) The low pressure return line containing fluorine between the expansion valve and the compressor
cylinder shall be covered by insulation. The condensation should not exist on this piping line at
normal working temperature
11.1.3.1 The quality requirements in the process of repair for piston type Freon compressor are as below.
a) In case that little wear, slight galling and scratch, etc. on working surfaces of cylinder or piston have
been rectified by manual, the cylinder or piston could be continued to use;
b) In case serious galling and scratch, etc. on working surfaces of cylinder or piston, the defects should
be rectified by mechanical processing measures.
c) In case piston ring groove worn, it shall be machined and fabricated a new piston ring.
d) In case that little wear, slight galling and scratch, etc. on working surfaces of main journal or crank
pin have been rectified by manual, the main journal or crank pin could be continued to use;
e) In case serious galling and scratch, etc. on working surfaces of main journal or crank pin, the defects
should be rectified by mechanical processing measures;
f) In case slight galling and scratch, etc. on working surfaces of bear bush, the defects should be
scraped and trimmed by manual
g) In case serious galling and scratch or alloy layer flaked off on working surfaces of bear bush, the
bearing bush should be renewed
h) In case serious worn or damaged to the friction ring of crank shaft seal, the friction ring should be
renewed. In case the sealing ring has been worn or deteriorated.
11.1.3.2 The quality requirements in the process of repair for refrigeration heat exchanger are as below:
a) The fouling in cooling water tubes or air side of condenser and evaporator may be cleaned by
manual or chemical cleaning;
b) In case the water leakage was in the condenser or evaporator, it may be rectified by pipe expanding,
welding, local blocking or renewal;
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c) In case impossible to repair, the leaking pipe should be blocked.

11.1.3.3 When repairing of the piping line for refrigeration, the connection of piping line with fluorine
should avoid using the flange and pipe joint and should adopt welding form as far as possible
11.1.3.4 The key points of quality control for air conditioning and refrigeration plant are as below:
a) Clearance between the parts of piston type Freon compressor;
b) Air tightness test of compressor;
c) Running test of refrigeration and heat exchanger;
d) Air tightness test of the system;
e) Vacuum test of the system;
f) Function test of the system;
g) The pressure controller and the settings of the safety valves
The inspection & test requirements for air conditioning and refrigeration plant are as below:
a) Measure and record the clearance between main parts
b) Air tightness test for the compressor, and to issue test report
c) Air tightness test for the refrigeration heat exchanger, and to issue test report;
d) Air tightness test, vacuum test and function test for air conditioning and refrigeration system, and to
issue test report.
11.2 Ventilation device
Key points of the survey for the ventilation device are as below:
a) Check if the fan is running smoothly and has any interference and if the fan has any deformation,
crack, damage and other defects;
b) Check if the bearing temperature of the fan is normal;
c) Check if there is any corrosion, perforation and deformation in the ventilation duct;
d) Check if there is any deformation, crack, corrosion othersor other defect on the welding seam of the
duct hanger and its support frame;
e) Check if there is any blocking of the throttle, fire dampers, ventilation grate and rotary air outlet
switching operation;
f) Check if there is any corrosion, damage and other defect on the drain plug;
g) Check if any rust, perforation, deformation or other defect exists on the weather tight close device;
check if the switch operation is flexible.
11.2.2.1 The quality requirements of ventilation fan reparing are as below:

a) The parts repaired or replaced part shall be in accordance with the technical requirements of
ventilation fan technical specification;
b) The machining accuracy of the fan transmission shaft and the bearing seat shall be in accordance
Table 207 Machining accuracy of transmission shaft and bearing seat Unit: mm
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Items Requirements
Roundness and cylindricity of the working shaft neck
0.03
Radial runout to shaft line of the working bearing
Axis symmetric to shaft line of the keyway 0.05
The amount of interference of shaft and bearing inner ring
The amount of interference of the bearing seat hole and the 0.01～0.02
bearing outer ring
c) The assembly clearance of the fan air resistance ring shall be in accordance with the technical
specification requirements.
11.2.2.2 The noise and vibration levels of fans shall be in accordance with the requirements of ship design.
11.2.2.3 The quality requirements of ventilation duct repairs are as below:
a) The repair of the vent duct and accessories penetrating the fire division shall comply with the Class
Rules and the relevant Convention;
b) The deviation of center line of ducting after installation shall be in accordance with the requirements
in Table 208.
Table 208 Deviation of the ducting center line Unit: mm
Duct Length Requirements

≤2 000 ≤10
＞2 000 ≤15
c) The insertion depth of accessories in the spiral duct shall not be less than 40 mm. The insulation
layer of accessories shall be close to the end of vent duct;
d) Both connection ends of the spiral duct and accessories shall be covered with adhesive tape, the
width of which shall not be less than 20 mm. Tape corrugation shall be avoided.
11.2.2.4 The quality requirements of ventilator repairs are as below:
a) The bolted ring on the flange conection of the ventilator and fan duct shall be a locking ring;
b) Cowl-head ventilaor, mushroom ventilator and jet type ventilators shall run flexibly. The seal used
between the gooseneck and mushroom ventilator shall not leak.
11.2.2.5 The quality requirements of vent duct flange repairs are as below:
a) Flange sealing surface shall be smooth, with no scarring, burrs or other defects which would impair
it sealing property;
b) Flange connection shall not leak and the gasket shall meet the fire protection rating requirements of
the vent duct;
c) The flange fixing bolts shall be of the same type and the bolt extending from the nut shall be about
1.5 to 2.5 times of the screw pitch after tightening.
11.2.2.6 The quality requirements of hanger repairs are as below:
a) The hanger shall be installed perpendicularly to the duct and shall not be directly welded to the shell
plate;
b) A liner shall be added between the spiral duct hanger collar and the duct, which should not be loose;
c) Spacing, number and location of the hanger shall be same as the original design.
11.2.2.7 The quality requirements of damper repairs are as below:
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a) Operation of the switch and the rotating parts shall be flexible and reliable;
b) The thread part shall be greased.
11.2.3.1 The fan parts can be repaired by correction, welding, bushing and the scraped grinding method.
11.2.3.2 The replacement of rolling bearings or the bearing seat of the fan shall be the same type and
specifications as original if possible.
11.2.3.3 The duct shall be repaired as per the original design if there is corrosion, perforation, deformation
or any other damage. If seriously damaged it is to be renewed.
11.2.3.4 The connection between the spiral duct and the assessories shall be fixed by tapping screws first,
then wrapped with sealing tape.
11.2.3.5 The ventilator shall be repaired as per original if there is corrosion, perforation damage etc. If
damaged seriously it is to be renewed.
11.2.3.6 The key points of quality control for the ventilation device are as below:
a) Maching of fan transmission shaft and the bearing seat;
b) Clearance of fan choke ring assembly and deviation of duct center line;
c) Fan running test;
d) Function test of ventilation system.
The inspection & test for acceptance for the ventilation device are as below:
a) Measure and record the accuracy of the machining and repairing;
b) Running test for fan and submit test report:
c) Function test for ventilation system and test report.
12 FIRE-EXTINGUISHING ENGINEERING
12.1 Water fire-extinguishing systems
The key points of the survey for water fire-extinguishing systems are as below:
a) Check that the signs for the main fire pump and emergency pump are clear and that all of the pump
body, pressure gauge and other accessories are in good condition. Check that starting up is in the
normal condition;
b) Check that the fuel supply is adequate for the emergency fire pump and the heating system is in the
normal condition;
c) Check that the pressure and flow capacity at the outlet of fire pumps is satisfactory;
d) Check that the settings of all relief valves in fire pump are correct;
e) Check that all filters/strainers are free of debris and contamination;
f) Check that the firefighting hose boxes are fixed tightly; check that the box body is not rusted and the
door opens/closes smoothly;
g) Check if the firefighting pipes and hoses have any leaks, if the valve components and switches are in
good condition and if the component’s surface has any corrosion;
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h) Check if the operation for closing and switchover for the fire gun is in good condition;
i) Check if the firefighting hoses have any leaks; check if the firefighting hose joints have any
deformation and check the sealing washer for signs of ageing or desquamation;
j) Check if the international shore connections have any corrosion and that the fitting is complete.
12.1.2.1 All kinds of signs and marks are clear.

12.1.2.2 The fittings are complete without corrosion and ageing.
12.1.2.3 All system devices are working correctly.
12.1.2.4 Starting up and stopping of pumps is in normal condition.
12.1.2.5 The fire pumps shall supply adequate flow and steady pressure, the pressures value at fire
hydrants shall be in accordance with requirements in Table 209.
Table 209 Pressures at fire hydrants
Items Requirement/MPa
>1 000～4 000 ≥0.30
Passenger ship gross tonnage
>4 000 ≥0.40
>500～1 000 ≥0.25
cargo ship gross tonnage >1 000～6 000 ≥0.25
>6 000 ≥0.27
12.1.2.6 Pipelines and connectors have no leaks.
12.1.3.1 The hydrants with leaks shall be replaced.

12.1.3.2 Any rust shall be removed from the water fire-extinguishing piping system and be repaired where
necessary. Any pipes and fittings with serious corrosion or holing shall be replaced.
12.1.3.3 The key points of quality control for water fire-extinguishing systems are as below:
a) The pressure value for function test;
b) Setting value for relief valves pressure.
The inspection & test for acceptance of the water fire-extinguishing system are as below:
a) Measure and record the accuracy of repairs;
b) Function test and submit test report.
12.2 Fixed fire detection and fire alarm systems
The key points of the survey for fixed fire detection and fire alarm systems are as below:
a) Check if the voltage of the alarm power and the emergency power is in normal condition, check if
the function of switchover is in normal condition;
b) Check the functions of electric control parts for fixed fire detection and fire alarm systems;
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c) Check if the fire detector is hindered;

d) Perform the simulation test of fire detection system to confirm the functions in normal condition if
necessary.
12.2.2.1 The alarm setting of temperature sensing detectors shall be 54 ℃～78 ℃，it shall be 130 ℃～
140 ℃ in high temperature environments.
12.2.2.2 Smoke detectors can be checked with smoke generator, the alarm sensing point shall be actuated
in 2%～12.5% of light attenuation rate per meter.
12.2.2.3 Extraction smoke detector shall alarm when the light attenuation rate is more than 6.65%.
12.2.2.4 Fault self-test function shall be in normal condition.
12.2.3.1 Carry out the system functions test and faults test, verify the fault position and repair.
12.2.3.2 Carry out the driving function test of fire-extinguishing automatic release system without
extinguishing medium released.
12.2.3.3 Clean and test fire alarm detectors and ensure the correctness of identify function for regional
address.
12.2.3.4 Repair or replace faulty detectors.
12.2.3.5 The faults of printed circuit board or circuitry shall be repaired or renewed with the related
procedures.
12.2.3.6 The key points of quality control for fixed fire detection and fire alarm systems repairs:
a) Actuating temperature of thermal detector;
b) Actuating value of light attenuation rate of smoke detector;
c) Alarm value of light attenuation rate of extraction smoke detection system.
The inspection & test for acceptance of fixed fire detection and fire alarm systems are as below:
a) Carry out simulation fire test for fire detectors in relevant regions and record the data;
b) Carry out loading or loading capability simulation test for source of power supply and record the
data;
c) Submit the function test report.
12.3 Fixed gas fire-extinguishing systems
The key points of the survey for fixed gas fire-extinguishing systems are as below:
a) Check if all of the ventilation equipment and thermometers in the gas cylinder storage space are in
normal condition;
b) Check if the communication facilities between the gas cylinder storage space and the bridge are in
normal condition;
c) Check if the gas bottles have any damage or corrosion and check if the bottle pressure is in the
proper range;
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d) Check that the gas bottle hydrostatic test date is valid;

e) Check that all control/section valves are in the correct position;
f) Check for the correct tightness of control pipes;
g) Test and confirm the normal function operation for all fuel shut-off control facilities connected to
fire-protection systems;
h) Check if the discharge pipes are free when release.
12.3.2 Quality requirement for the repairing
12.3.2.1 The pressure of fire-extinguishing agent and pilot cylinders is acceptable.

12.3.2.2 All of the alarm and communication facilities are all in good condition.
12.3.2.3 CO2 release delay time shall meet the original design requirement. System agent and pilot
cylinders and pipes shall be without any defects, damage and leakage.
12.3.2.4 Flexible hoses shall be without damage or ageing.
12.3.2.5 Discharge pipes and nozzles shall not be blocked and corroded.
12.3.2.6 The containing of extinguishing cylinder shall be above or equal to 95% of the nominal charge.
12.3.3.1 Carry out rust removal and coating works for rusted pipes. Or shall be renewed and then marked
with signs if heavily rusted.
12.3.3.2 Carry out necessary adjusting and renovating for control cable driving system.
12.3.3.3 If the cylinder containing does not meet the requirement, the cylinder shall be refilled with the
medium provided from manufacturer according to filling guidance; if the extinguishing cylinder and pilot
cylinders are not qualified, it is to be renewed.
12.3.3.4 The discharge pipes and nozzles shall be blown with dry compressed air or nitrogen or in another
way to confirm the clearance of any obstructions.
12.3.3.5 The key points of quality control for fixed gas fire-extinguishing systems repairs are as below:
a) Blow out test;
b) Release delay time after CO2 alarm actuated;
c) Gas bottle working pressure.
The inspection & test for acceptance of fixed gas fire-extinguishing systems are as below:
a) After the cylinders have been refilled, submit test certification;
b) After the blowing through test for pipelines of gas fire-extinguishing system, submit test report.
12.4 Foam fire-extinguishing systems
The key points of survey for foam fire-extinguishing systems are as below:
a) Check the integrity of foam fire-extinguishing systems;
b) Check that all control/section valves are in the correct open/close position;
c) Check if the remaining quantity of foam concentrate in the foam system storage tank can meet the
related requirement;
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d) The function test for all water supply pumps and foam pumps is to be performed to verify the
pressure and flow capacity if necessary;
e) Verify the setting point for relief valves of pump;
f) Check all filters/strainers to verify that they are free from debris and contamination;
g) Test all fuel shut-off device to verify the system is in the normal operating condition;
h) Check control valves do not have any damage;
i) Test the foam proportional device or other foam mixing devices to confirm that the mixing ratio is
correct.
12.4.2.1 Valves open/close position and pressure indication shall be correct.

12.4.2.2 The remaining quantity of foam concentrate shall meet the design requirements.
12.4.2.3 Flow test pressure and flow capacity shall be in accordance with the requirement of the
equipment.
12.4.2.4 Water supply source switch off valve shall be normally operated without problem.
12.4.2.5 The pressure setting points of safety valves / pressure relief valves shall be in accordance with the
requirements of the equipment;
12.4.2.6 Filters/strainers should be free of blockages.
12.4.2.7 Pipes and nozzles shall be free of leakage and blockage.
12.4.2.8 Fresh water flushing pressure shall be greater than or equal to 0.48MPa, the fresh water shall be
completely discharged after flushing.
12.4.2.9 The dry air pressure shall be 0.5MPa~0.7MPa for blowing through of discharge pipes.
12.4.2.10 The deviation of the foam mixing ratio is to be within -10 ~ +30% of the nominal mixing ratio.
12.4.3.1 Adjusting mixing ratio of foam generator.

12.4.3.2 Foam release test is to be carried out, if necessary. The time lasted is not to exceed 1 minute.
12.4.3.3 Function test of the audible and visual alarms for the fixed system.
12.4.3.4 Flushing pipes by fresh water after flowing test.
12.4.3.5 Blowing through of discharge pipes by dry compressed air, nitrogen or another method to confirm
the working pipes and nozzles are free of any obstructions.
12.4.3.6 The key points of quality control of repairs for foam fire-extinguishing systems are as below:
a) Pump pressure and flow capacity during flow test;
b) Pressure setting points of safety valves / pressure relief valves;
c) Pipe and nozzle cleaning;
d) Foam’s mixing ratio.
The inspection & test for acceptance of foam fire-extinguishing systems repairing are as below:
a) Foam mixing ratio reports to be submitted after foam generating and mixing device repaired;
b) The pump is to be running tested to verify matching characters after repair;
c) System function test is to be submitted.
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12.5 Water mist, water spray and automatic sprinkler systems
The key points of the survey for water mist, water spray and automatic sprinkler systems are as below:
a) Test the open/close agility of valves in system;
b) Check for any damage or corrosion of automatic sprinkler system pressure tanks and other devices,
verify the water level is in normal position;
c) Check if the function of automatic starting device on the pumps is in normal condition;
d) Check if the pressure indication of the gauges are within the proper ranges;
e) Check if section valves are in normal working condition;
f) Verify the proper operation of water mist, water-spray and automatic sprinkler systems;
g) Check if there is any damage or corrosion of the high pressure cylinders;
h) Verify the pressure and flow capacity of the pumps are proper ;
i) Check if there is adequate freezing protection for anti-freeze systems;
j) Check if the system connection devices with other sources of water supply are in normal condition;
k) Verify the settings of safety valves and pressure relief valves of the pump are correct;
l) Check that all filters/strainers are free of debris and contamination.
12.5.2.1 Pipes and accessories tightness is good and free of any obstructions.
12.5.2.2 When the discharge pipes are blown through, the pressure of dry compressed air or nitrogen shall
be generally controlled at 0.5MPa~0.7MPa.
12.5.2.3 The function of Nozzles shall be in normal condition and no obstructions.
12.5.2.4 The actuating temperature & color signs of sprinkler actuating shall be in accordance with Table
210.
Table 210 Sprinkler actuating temperature and color signs Unit: ℃
Glass ball Sprinkler Fusible component sprinkler

Actuating temperature Working liquid color signs Actuating temperature Yoke arm color signs
57 Orange 57～77 Original color
68 Red 80～107 White
79 Yellow 121～149 Blue
93 Green __
141 Blue
12.5.2.5 The setting point of safety valves / pressure relief valves should be correct.
12.5.2.6 Carry out hydrostatic test with 1.25 times of working pressure for pipes and pressure tank.
12.5.3.1 The valves and accessories which are unconformable to requirements shall be repaired or
renewed .
12.5.3.2 Centering, adjusting, fastening or renovating to be carried out for the fire pump electromotor fan,
coupling, wiring terminal, overload relay and control box.
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12.5.3.3 Repair or renew the pumps and electromotor which are unconformable to requirements.
12.5.3.4 Repair or renew the pipes, accessories or sealing devices which are unconformable to
requirements.
12.5.3.5 Repair or renew the (water mist) nozzles which are unconformable to requirements.
12.5.3.6 Blow through test by dry compressed air or nitrogen to be carried out for discharging pipes and
nozzles. Or any other equivalent way to confirm the discharging pipes and nozzles are unimpeded.
12.5.3.7 The water supply system shall be open-up checked and repaired in case the pressure of water
pressure tank is low.
12.5.3.8 The key points of quality control for water mist, water spray and automatic sprinkler system
repairs are as below:
a) Hydrostatic test of pressure vessel;
b) Hydrostatic test of water pressure tank;
c) Cleaning of pipes and nozzles;
d) Confirm the starting up temperature of automatic sprinkler.
The inspection & test for acceptance for water mist, water spray and automatic sprinkler systems are as
below:
a) Submit test report of pressure vessel and water pressure tank;
b) Carry out function test for water mist, water spray and automatic sprinkler systems and submit test
report.
12.6 Fixed dry chemical powder systems
12.6.1 Key points for the survey
The key points of the survey for fixed dry chemical powder system:
a) Confirm the open/close valves are agile;
b) Confirm the pressure regulators are in normal condition;
c) Confirm the control device and section valves are in normal working condition;
d) Confirm the quantity of starting air comply with requirements;
e) Confirm the moisture content of dry chemical powder comply with requirements;
f) Check if the powder vessel, safety valve and discharge flexible hose have any leaks.
a) Nozzles are unimpeded;

b) Filling quantity of propellant gas cylinder meets design requirement;
c) Dry chemical powder is non-water and non-caking;
d) Powder vessel, safety valve and discharge flexible hose without any leakage.
12.6.3.1 If the pressure regulator’s calibration is overdue, re-calibrate it.

12.6.3.2 Clean up and dredge the working pipes and nozzles blocks.
12.6.3.3 Fill the propellant gas cylinder to the design pressure in case the pressure is low.
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12.6.3.4 Adjust or repair the control device in case it is abnormal.

12.6.3.5 Repair or renew the powder vessel, safety valve or discharge hose in case it failed in the pressure
test.
12.6.3.6 Blow through test by dry compressed air or nitrogen to be carried out for discharging pipes and
nozzles to confirm they are unimpeded.
12.6.3.7 Carry out hydro-test or non-destructive testing for all powder vessels if necessary.
12.6.3.8 The driven object shall be isolated in simulation testing for control device.
12.6.3.9 The key points of quality control for fixed dry chemical powder systems are as below:
a) Confirm the quantities of propellant gas cylinder;
b) Hydrostatic test or non-destructive examination for powder vessel.
The inspction & test for acceptance for fixed dry chemical powder systems are as below:
a) Carry out hydro-test or non-destructive examination for powder vessel and submit report;
b) Carry out function test or simulating test and submit test report.
13 PAINTING
13.1 Steel surface preparation
The key points of survey for steel surface preparation are as below:
a) The rust, organisms, scrape, grease and original coating conditions shall be inspected , and take
photos;
b) The adhesion, salinity and other contaminants shall be inspected.
13.1.2.1 Steel surface preparation shall be in accordance with the requirements in Table 211.
Table 211 Requirements of Steel surface preparation
standard ranges
Items remarks
— PSPC
Cleanness Sa2.5 Sa2.5 —
Thickness of steel plate t≥6 mm
Shot blasting Roughness Medium class 30-75μm GB/T 13288.2—2011
Cleanness Sa2.5 Sa2.5 —
Length of steel profile L≥3 m
Roughness Medium class 30-75μm GB/T 13288.2—2011
Pickling, hand Thickness of steel plate t＜6 mm No scale,
tool and power Length of steel profile L＜3 m Cleanness No rust, St3 —
tool cleaning Steel outfitting No grease
13.1.2.2 Shop primer shall be in accordance with the requirements in Table 212.
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Table 212 Requirements of application of shop primer Unit: micron
Items standard ranges allowable limits remarks

Type of paint Zinc primer
— —
Zincless primer
Coating film ≥12 Comply with painting marker product
Zinc primer 15～20
thickness ≤30 specification
≥18
Zincless primer 20～25
≤40
13.1.2.3 Secondary derusting shall be in accordance with the requirements in Table 213.
Table 213 Requirements of secondary derusting
standard ranges
Items remarks
— PSPC
Secondary derusting Cleanness Sa2 Sa2.5 GB/T 8923.1—2011
Abrasive blasting
of new steel plate, Roughness Medium class 30-75μm GB/T 13288.2—2011
profile and outfitting. Hand tool or Power tool St2 St3 GB/T 8923.1—2011
Rust distribution
Hand tool or Power tool PSt2 PSt3 GB/T 8923.2—2008
ration≤20％
Cleanness
Rust distribution High-pressure water
GB/T8923.4—2013;
ration＞20％ jetting or abrasive WJ-3；PSa2
GB/T 8923.2—2008
Shell blasting
13.1.2.4 Surface cleaning before painting shall be performed in accordance with the requirements in Table
214.
Table 214 Requirements of steel surface cleaning before painting
Items standard ranges allowable limits remarks

Water
Invisible to naked eye — —
Soluble salt
Soluble salt, equivalent to NaCl ≤50 mg/m2 NaCl PSPC
Grease With trace remained
Zinc salt Remove
With slight trace remained
Dust of gas cutting and welding
—
Chalk marking Basically cleaned
Paint marking No need to remove —
Mucilage, weed fouling Remove
Steel surface defects, weld defects P1 GB/T 8923.3—2009
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13.1.3.1 The machinery and equipment in the work site should be protected.
13.1.3.2 Correct any steel plate deformation and remove weld defects before painting.
13.1.3.3 Overlap zones of repair areas boundary should be lightly swept or ground to a good smooth
surface.
13.1.3.4 The repair process of water ballast tank (PSPC) is as follows: remove the sludge, the scale, grease
and other contaminants by high pressure water, dry the water ballast tank, perform the steel surface preparation
(the applied method shall be subject to the old coating status and ship service life).
13.1.3.5 Key points of quality control for steel surface preparation are as below:
a) Roughness and cleanliness of steel surface;
b) Shop primer paint system quality;
c) Steel surface cleaning before painting .
The inspection & test for acceptance of steel surface preparations are as below:
a) Roughness and cleanliness shall be measured and recorded;
b) Dry film thickness of shop primer shall be measured and recorded.
13.2 Coating system
13.2.1.1 The appearance quality of coating shall be in accordance with the requirements in Table 215.
Table 215 Requirements of appearance quality of coating
Items standard ranges allowable limits

External surface of Holiday, pinhole, crack None —
superstructure, wheelhouse, Sagging, brush mark, wrinkling, Not obvious Slight
accommodation cabins and prematurely dried particle
interior passage Color Natural deviation shall be Not reduce the paint
accepted system quality
Surface of shell, exposed Holiday, pinhole, crack None —
deck, engine room, stores, Sagging, wrinkling Not obvious Slight
cargo hold, cargo tank, void Color Natural deviation shall be Not reduce the paint
space and cofferdam etc. accepted system quality
13.2.1.2 The coating film thickness shall be in accordance with the requirements in Table 216.
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Table 216 Requirements of coating film thickness
Items Distribution of coating film thickness Standard ranges Remarks

Working and living Film thickness of over 80% measured points Up to required thickness As per painting
space (engine room Film thickness of remaining measured points Up to 80% required thickness marker’s
and superstructure recommendation
etc.) or painting
Except above areas Film thickness of over 85% measured points Up to required thickness product’s
Film thickness of remaining measured points Up to 85% required thickness specification
PSPC Film thickness of over 90% measured points Up to required thickness
Film thickness of remaining measured points Up to 90% required thickness
13.2.2.1 The painting ambient condition (such as temperature and humidity) shall be in accordance with
the requirements of the paint manufacturer.
13.2.2.2 The wet film thickness shall be regularly measured and inspected during the painting process.
13.2.2.3 The dry film thickness shall be measured after drying, unqualified areas shall be repainted.
13.2.2.4 Pre-coating and stripping shall be carried out for the areas where the coating film thickness is
difficult to achieve with spray.
13.2.2.5 The ventilation conditions shall be in accordance with the requirements of manufacturer’s
instructions during the painting process.
13.2.2.6 The coating system defects should be removed and repaired.
13.2.2.7 Key points of quality control of painting are as below:
a) Ambient condition;
b) Wet film thickness and dry film thickness.
Approval points of the coating system:

a) The appearance quality and dry film thickness of the coating shall be inspected and recorded;
b) The coating log shall be recorded and be included in the Coating Technical File (CTF) for PSPC
requirements.
14 SPECIAL EQUIPMENT
14.1 Stainless steel cargo tanks
The key points of survey for stainless steel cargo tank are as below:
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a) Check the locations of stress concentration, e.g. corners of transverse section of cargo tanks, the
upper& lower ends of central longitudinal bulkhead and toe ends of strong deck beams, etc. for any
deformation, corrosion or cracks;
b) Check the welds of cargo tank bulkheads for any leaks or cracks;
c) Check the validity of seals for penetrations in cargo tank bulkheads;
d) Thickness measurements of tank internals or double bottom;
e) Check the tank liners for any corrosion or fall off.
14.1.2.1 The structural corrosion shall not exceed 75% of the permitted corrosion value.
14.1.2.2 The welding materials used for repair should match the base metal.
14.1.2.3 Repair area and welding should be smooth.
14.1.2.4 The welding seams should be formed evenly with no defects such as cracks, pores, under fill or
undercut on the surface.
14.1.2.5 Temperature between welding layers of stainless steel shouldn’t exceed 100℃; the highest one
shouldn’t exceed 150℃. Temperature between manual arc welding layers should be lower than 60℃.
14.1.2.6 100% PT damage detection should be done in boundary weld seams of stainless steel cargo tanks
(including erection butt welds); 10% PT damage detection should be done in angle welding seams of stainless
steel with carbon steel and heterogeneous steel; and 20% RT and 10% PT damage detection should be done in
joints of stainless steel with heterogeneous steel.
14.1.3.1 Ordinary oily pen or paint is not permitted to the materials in blanking of stainless steel, and no
punching or steel seal is allowed;
14.1.3.2 Surface protection means such as adhesive film shall be provided for stainless steel after it is
polished.
14.1.3.3 To avoid carburetion to weld seam, plasma air arc gouging and sand grinder are often used for
back gouging and clamp removal.
14.1.3.4 Dedicated scaffolds are to be used for construction of stainless steel cargo tank, e.g. wood or
bamboo scaffolds.
14.1.3.5 During construction, try to avoid damage of passive film by scratch, arc attack, collision, etc.
14.1.3.6 No hull plate/flame distortion rectification is applied to rectify the deformation of stainless steel
material.
14.1.3.7 Defects in welds shall be cleared by mechanical means, and then welding repair.
14.1.3.8 After the repair is completed, the tank should be treated by pickling and passivation.
14.1.3.9 Quality control points of stainless steel tank repair:
a) Welding material selection;
b) Rectification of stainless steel;
c) Temperature between layers of stainless steel welding;
d) Welding quality;
e) Passive film of stainless steel;
f) Pickling and passivation treatment of cargo tank.
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14.1.4 Inspection & Test for acceptance
Inspection & Test for acceptance of stainless steel cargo tanks repairing are as below:
a) Submit NDT report;
b) Tank tightness shall be tested, and test report submitted.
14.2 Inert Gas System
The key points of survey for inert gas systems are as below:
a) Examining whether any leakage of the inert gas generators;
b) Examining whether any leakage of the scrubbers, whether the nozzles and impingement plates are
stuck, whether the scrubbers and valves are seriously corroded; Examining the operating condition of
the inert gas generators and scrubbers, as well as whether the generated inert gas is within the scope
of the technical specifications.
c) Examining the damage of the components of the inert gas blower;
d) Examining the function of the inert gas distribution and regulating valves and points of corrosion or
leakage.
e) Examining corrosion of pipelines, flange and welding area, and examining obstruction of the
pipeline valve.
f) Examining the corrosion damage of Cooling pumps and pipelines;
g) Examining internal coating of deck water seal;
h) The pressure vessels storing the inert gas should be checked as follow:
1) Whether the pressure is in the range of use;
2) Whether any pitting, dents, flake pitting or grooving corrosion on the container due to corrosion,
Thickness measurement shall be carried out if obvious corrosion.
3) Whether the securing devices are fastened.
14.2.2.1 The gage pressure in cargo tanks shall be maintained by the inert gas system to be between 0.007
MPa and the setting pressure of the dump valve.
14.2.2.2 No defects such as burrs, lacerations or deformations are allowed on the impellers of the inert gas
fans. The axiality between the choma and the case is 0.05mm, and the axiality between the choma and axle
hole is 0.03 mm.
14.2.2.3 The impellers shall be renewed if the wear of the trochal disk of the inert gas blower exceeds 1/3
of the original thickness, or if the wear of the impellers exceeds 1/2 of the original thickness.
14.2.3.1 If the ebonite lining of the scrubbers is found aged, dropped or seriously lost, it shall be repaired
by professional organizations. The impingement plates and valves shall be renewed if corrosion and wear are
found.
14.2.3.2 The impellers and cases of the inert gas fans shall be renewed if cracks, deformations, corrosion or
excessive wear are found. The shaft shall be renewed if cracks or damages are found.
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14.2.3.3 If the PT detection result of the impeller seams is unsatisfactory, the seams shall be polished,
washed , preheated and patch welded.
14.2.3.4 Any pipe shall be renewed if it is found to be seriously corroded. The anti-corrosion coating,
material and wall thickness shall be identical with original.
14.2.3.5 The pressure container for storing inert gas shall be renewed if any pittings, dokes, flake pittings
or grooving corrosion exist on the surface.
14.2.3.6 The inert gas distribution valves and adjusting valves shall be renewed if corroded, leakingor
poorly effective.
14.2.3.7 Static balance check shall be carried out for the inert gas blower impellers before the reassembling
with main shaft.
14.2.3.8 Quality control of repair of the inert gas system:
a) Deformation and corrosion of impellers and cases of inert gas fans;
b) Corrosion or leakage of the inert gas distribution valves and adjusting valves;
c) Corrosion or damage of pipe flanges and valves;
d) Quality of pressure container surfaces.
Inspection & Test for acceptance of Inert gas system repairing are as below:
a) Simulation test of inert gas blower;
b) Utility test of scrubber ventilation system;
c) Simulation test of alarm and safety equipment in inert gas system when necessary and test report
submitted;
d) Tightness test should be done, and test report submitted;
e) Utility test shall be carried out after the inert gas system is repaired, and test report submitted.
14.3 Dredger pump apparatus
The key points of survey for dredger pump apparatus are as below:
a) Dredger pump casing:
1) Check dredger pump casing for any cracks and leaks;
2) Check dredger pump casing and pump tongue for any abrasion;
3) Check inner wall of dual-casing dredger pump for any serious cracks, gas corrosion and wear
through.
b) Pump cover:
1) Check dredger pump cover for any cracks and leaks;
2) Check dredger pump cover for any wear, gas corrosion and leakage.
c) Impeller:
1) Verify wear condition of suction and blade of impeller;
2) Verify gas corrosion and corrosion condition on impeller.
d) Impeller shaft:
1) Check interval between shaft and bearing;
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2) Check impeller shaft on junction plane thread and adjust washer if there is any rust and it is
loose.
e) Liner:
1) Check liner if there are any cracks;
2) Check liner if there is any wear and corrosion.
f) Anti-wear ring:
1) Verify wear, gas corrosion and corrosion condition on inner surface and end face of suction
anti-wear ring;
2) Check rubber leak-proof ring for any ageing and wear.
14.3.2.1 Dredger pump casing:

a) After repair of partial gas corrosion, wear and corrosion, no obvious outside defect exists on runner
surface and bead should be smoothly polished;
b) Welding repair can be done to defects such as cracks and shrinkage on inner or out-surface of pump
casing, and infiltration flaw detection for them necessarily;
c) Wear on pump casing shouldn’t be over 1/3 of the wall thickness;
d) Interval between pump tongue and impeller cannot be 4 times wider than original design request.
e) When iron basal self-fluxing alloy powders are used for spray welding, non-penetrating mini-cracks
are allowed at welding layers with length less than 10 mm, amount less than 20 and space of crevices
more than 100 mm.
14.3.2.2 Dredger pump cover:
a) After repair, plane degree at pump cover end face should be 0.1 mm;
b) Cracks, sand holes, stoma, shrinkage and slag are not allowed in steel casting's surface, and
non-destructive examination should be carried out;
c) Error at pump cover's casting size should be according to requests in GB/T 6414 and CT12;
d) Processing accuracy at inner diameter of front cover suction is H8, roundness and cylindrical degree
should be according to GB/T 1184(Class 8);
e) Processing accuracy at inner hole for feeder of back cover should be according to GB/T 1184(Class
8).
14.3.2.3 Impeller:
a) Assembling crevice between impeller and front/back pump cover(liner) is 2.5 mm;
b) Static equilibrium test should be done to the impeller;
c) For repair of front/back wall board, anti-deformation should be adopted.
d) The biggest crevice between impeller shaft and bearing shouldn't be over 2 times of installation
crevice.
14.3.2.4 Liner:
a) After surfacing or spray welding, liner should be leveled with plane degree 0.2 mm;
b) When nickel basal powder is used for spray welding on surface, cracks are not allowed. When iron
basal powder is used for spray welding, non-penetrating, intermittent cracks are allowed with less
than 10 cracks, crevice more than 100 mm & depth less than 1/20 of liner thickness;
c) Scattered stomas are allowed on spray welding surface with less than 10, depth less than 3 mm,
diameter less than 10 mm & crevice more than 200 mm;
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d) Liner periphery is spray welded to be over slope with slope angle less than 45°；
e) Overlap is not allowed on surface of spray welding or surfaces with plane degree 0.5 mm.
14.3.2.5 Anti-wear ring:
a) Obvious crack, shelling and stripping shouldn’t exist on surface when nickel basal self-fluxing alloy
powder is used with over slope at edge surface & without a sharp angle;
b) Intermittent cracks are allowed on surface when iron basal self-fluxing alloy powder is used with
less than 5 & crevice more than 200 mm;
c) Roughness of anti-wear ring surface shouldn’t be lower than 3.2 mm.
14.3.3.1 Dredger pump casing:

a) Clean and polish the parts with serious gas corrosion, wear and corrosion, surfacing will be done
with CO2 protection welding and wear-resistant electrodes, flatting smoothly;
b) For the runner with large area of wear & depth more than 15mm, surfacing primer should be adopted
with wear-resistant electrodes or CO2 protection welding, leaving 5mm of surface; forming by spray
welding with self-fluxing alloy powder;
c) For the inter-runner of casing with serious wear or over 1/3 thickness of runner casing, pasting repair
is better used for casting pieces;
d) After repair of surface cracks, non-destructive examination should be carried out;
e) After repair, a tightness test should be carried out;
f) When a large area of serious wear exists in a pump casing, measures will be adopted to prevent the
pump port from deformation during the repair;
g) Pump casing repairs quality control key points:
1) Welding quality;
2) Tightness test.
14.3.3.2 Dredger pump cover:
a) Clean and polish the parts with gas corrosion, wear and corrosion, surfacing will be done with CO2
protection welding and wear-resistant electrodes, flatting smoothly;
b) During the course of repair welding, measures should be adopted for controlling any deformation;
c) Machine dressing will be done after welding;
d) Annealing should be carried out when necessary;
e) Pump casing repair quality control key points:
1) Welding quality;
2) Casting quality;
3) Welding deformation.
14.3.3.3 Impeller:
a) Surfacing or spray welding can be carried out with wear-resistant electrodes for the parts with
serious corrosion and wear, such as front/back walls, suction and both working faces of impeller;
b) If the corrosion and wear parts on front/back walls, suction and both working faces are over 1/2 of
the original thickness, cast-iron alloy insert welding can be adopted;
c) Impeller quality control key points:
1) Welding quality;
2) Welding deformation.
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14.3.3.4 Impeller shaft:

a) CO2 protection welding or nickel basal self-fluxing alloy powder spray welding will be used on the
working face of impeller shaft where there is wear and corrosion;
b) Over slope should be at the edge conjoining spray welding layers and matrix;
c) Impeller shaft quality control key points:
1) Welding quality;
2) Conjoining strength of welding layer and matrix;
3) Hardness.
14.3.3.5 Liner:
a) If depth of wear and corrosion isn’t over 1/3 of liner’s total thickness & defective parts cover less
than 1/3 of liner surface area, repair it. Plasma spray welding or oxygen-acetylene flame spray will
be used with nickel basal powder or iron basal self-fluxing alloy powder to the left 5mm layer based
on rust-removal, polishing and surfacing with CO2 if the piece is seriously worn;
b) Liner repair quality control key points:
1) Welding quality;
2) Crack size;
3) Surface stoma.
14.3.3.6 Anti-wear ring:
a) If depth of wear and corrosion is over 1/3 of the total thickness & defect parts cover more than 1/2 of
total area, repair it;
b) If gas corrosion and wear on main ring of suction and anti-wear ring of impeller are within the
allowed range for deformation, try to carry out surfacing primer with CO2 protection welding, then
plasma or oxygen acetylene flame welding used for surfaces layer with iron-base or nickel-base
self-fluxing alloy powder;
c) Disassemble and renew the rubber seal ring when wear and cavitation damage exist in the surface;
d) Key points of quality control for Anti-wear ring is welding quality control.
Inspection & test for acceptance of pump apparatus are as below:

a) An installation record should be provided for disassembled and repaired dredger pump apparatus;
b) After repair of pump apparatus, performance test should be done according to the requirement and a
repair report should be submitted.
14.4 Dredge reamer
The key points of survey for Dredge reamer are as below:

a) Check the welding reamer blade and activating gear seat without any crack or serious wear;
b) Check riveting reamer blade to confirm rivet without any wear, rust or loose;
c) Thickness measurement for the reamer blade;
d) Clearance measurement between reamer neck and reamer ring;
e) Check reamer neck hub to confirm without any cracks or serious wear;
f) Check reamer key groove to confirm without any rust or key rolle.
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14.4.2.1 Penetrated crack are not allowed to exist in the head of reamer hub area.
14.4.2.2 Annealing should be carried out after welding for the complete reamer head connecting
end(reamer arm, hub and big ring);
14.4.2.3 The weight balance should be kept for each reamer arm during repair.
14.4.2.4 The installation dimension between the reamer body and arched girder should meet to the design
requirement.
14.4.2.5 The wear down of reamer blade should be not more than 1/3 of original thickness; and thickness
in way of blade edge area should be more than 10 mm.
14.4.2.6 The gap between the reamer neck and ring area should be not more than 2.5 times of the initial
assembling clearance.
14.4.3.1 Reamer repair process quality control should be according to the requirements in Table 217.
Table 217 Reamer repair process quality control
Reamer type Defect Quality control

High Manganese steel Serious wear on Cut off the serious wear area and prepare new welding
Zigzag reamer cutting tooth groove, then the high manganese cast steel or formed forging
butt joint with remaining part of the reamer by welding.
Welding or detachable Serious wear of Renew reamer tooth as original material or build up /spray
wear-resistant steel knife reamer tooth welding on the reamer cutting surface with anti-wear layer
tooth
Formed blade of cast Serious wear of Renew opening/closing detachable reamer blade or build up
steel or cast iron blade /spray welding on cutting or insert with alloy-cast iron by
proper welding
Below the medium Fit clearance Inner diameter≥40 mm; The build up welding or spray
carbon cast steel reamer exceeded welding should be carried out ,and surface dealt by proper
ring seriously machining.
between the Or insert one new alloy-cast iron by proper welding and
reamer neck and surface machining.
ring
14.4.3.2 Key points of quality control of reamer repairing are as below:
a) Welding quality;
b) Installation accuracy.
Inspection & test for acceptance of dredger reamer are as below:
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a) Record of reamer installation accuracy;

b) Reamer performance test and record.
14.5 Dredger mud bucket
The key points of survey for dredger mud bucket are as below:
a) Check the wear condition of the bucket body, pin hole and bucket lip.
b) Check the distance between bucket bottom and pin hole center;
c) Check the bucket bottom pin seat without cracks.
14.5.2.1 The wear or diminution of bucket body should be ≤40% of original plate thickness;
14.5.2.2 When the build up carried out for buck body, there should be no defects such as crack, porosity,
slag inclusion which exist in the surface of welding layer.
14.5.2.3 Reducing of distance between bucket bottom and pin hole centre should be≤7mm; the difference
of wear condition of two bottom plates should be ≤5mm.
14.5.2.4 Bucket pin hold roundness is 0.015mm.
14.5.3.1 Bucket repair process quality control should be according to requirements in Table 218.
Table 218 Mud bucket repair process quality control
Position Defect Process quality control

Oxygen acetylene welding, plasma spray
Bucket lip, edge
welding, deposition welding
Bucket body wear Insert with cast steel plate
Sliding working face of bucket Repair welding, release welding stress by
bushing hammering method
14.5.3.2 Key points of quality control of dredger bucket repairing are as below:
a) Welding quality;
b) Repair accuracy.
Inspection & Test for acceptance of dredger mud bucket are as below:
a) Bucket installation accuracy record;
b) Bucket performance check and acceptance record.
14.6 Ramp of a RO-RO ship
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The key points of survey for ramp are as below:

a) Check the ramp open and closed positions to ensure it is in working order;
b) Check the working condition of the hydraulic system;
c) Check the working condition of the winch;
d) Check for deformation of the structure; check the amount of wear of the moving parts such as the
hinge; check the working condition of the pusher and locking device;
e) Check whether the wire rope is in good condition and lubrication conditions.
14.6.2.1 When local structure of the ramp need renewing, it should meet the requirements of the relevant
chapter 3 hull part.
14.6.2.2 The two diagonal length tolerances should not be more than 12 mm, the flatness of corners should
be 10 mm.
14.6.2.3 After repair, the hydraulic system should satisfy the standard of hydraulic equipment quality
inspection GB 3766—2001。
14.6.2.4 For winch repair technical requirements, refer to the related requirements of the anchor winch in
deck machinery part.
14.6.2.5 Wire rope and pulley：
a) If the steel wire rope has been crushed, broken or has excessive wear or corrosion, compared to the
original size, it shall be renewed；
b) If one side of pulley has mild wear, it can be repaired. But for serious wear, the pulley shall be
renewed;
c) If the clearance of pulley and pin exceeds 0.5 mm, the bushing should be replaced. After being
replaced and new installation of the bushing, the gap between the liner with pin should be 0.15 mm
to 0.2 mm;
d) If pulley seat corrosion is serious, it shall remedied by an insert plate or be completely renewed.
14.6.2.6 The structure flatness of rubber compression zone is 6 mm.
14.6.2.7 The gap between the wedge of the locking device with the stopper should be no more than 3 mm.
14.6.2.8 After corrosion and wear and tear, hinge eye plate thickness shall be not less than 0.9 times of the
original thickness; aperture should be no greater than 1.1 times the original aperture.
14.6.2.9 If the clearance of the shaft and the hinge of the spherical bearing is more than 0.5 mm, the
spherical bearing should be replaced. After replacement of the spherical bearing, the clearance between the
spherical bearing and shaft pin should be 0.15 mm ~ 0.20 mm.
14.6.2.10 The new thickness of the chrome plating layer on the hydraulic oil cylinder should not be less
than 0.02 mm, surface hardness shall be not less than 800 HV.
14.6.3.1 Ramp structure:

a) When repairing the folding ramp, the section should be dismantled and should be properly fixed to
the ramp to ensure safety;
b) Deformation should hot straightening, and also can assist by the water cooling, mechanical force,
gravity method etc..
14.6.3.2 Hydraulic pushing locking hydraulic cylinder:
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a) For minor scratches on the hydraulic cylinder, an oil stone can be used to polish, if more serious it
should be polished round then chromed. If necessary, it is to be renewed;
b) After repair, the hydraulic oil cylinder parts should be cleaned and dried, after refitting the hydraulic
oil and seal can be applied;
c) Hydraulic pipelines should be cleaned before the hydraulic oil cylinder is installed. After installation
the hydraulic oil cylinder should be fully deflated;
d) Every pipe joint can not leak when the hydraulic oil cylinder device and each moving part of the oil
is in order.
14.6.3.3 Hinge:
a) If hinge seat is deformation to rotate jammed, should be fixed the ramp, and then hot straightening or
dismantled to renew. Should be under the protection of crane
b) Rubber seals that are damaged or aged, shall be renewed.
14.6.3.4 Ramp repair quality control points:
a) Structural repair precision;
b) repair quality of the hydraulic oil cylinder;
c) The assembly precision of the hinge.
Inspection & Test for acceptance of the ramp are as below:

a) Measure and record the repair precision of structure;
b) Function test and record;
c) Load test and issue a report;
d) Hose test and issue a report.
14.7 Pilot door of container vessel
The key points of survey for a pilot door are as below:

a) Check whether the open and closed position of the pilot door is normal or not;
b) Check the sealing situation of rubber seals;
c) Check the structure of pilot door including plate and section for any corrosion and deformation;
d) Check the hinge of pilot door, check the clearance/gap between pin and eyes plate;
e) Check the hinge pin, if there is any damage such as biting, crack, deformation etc;
f) Check the operating condition of hydraulic pump unit including noise, vibration and temperature
situation;
g) Check the hydraulic pipe system, if there is any corrosion, vibration and leakage;
h) Check the setting pressure of safety valve;
i) Check the hydraulic cylinder and piston rod, if the surface is smooth or if there is scuffing;
j) Check of the seal ring of hydraulic cylinder, if there is any abrasion or ageing;
k) Check the guide pulley block of wire, if there is any corrosion and deformation;
l) Check the limit switch and indicator light of pilot door, whether the working condition is normal or
not.

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14.7.2.1 The flatness of door body structure is10 mm. The length tolerance of diagonals shall be less than
12 mm. The deformation of the side plate, end plate, seal groove and pressing flat shall be less than 5 mm/m.
14.7.2.2 The corrosion allowance of hinge plate shall not be more than 10% of the original designed
thickness. The abrasion allowance of the pin hole shall not be more than 10% of the original designed pinhole
diameter.
14.7.2.3 The dimensional deviation of renewed seals and locking devices shall not be more than 2 mm. The
positional deviation of the installation shall not be more than 2 mm.
14.7.2.4 The steel wire shall be not flattened, broken or corroded.
14.7.2.5 The clearance between sheave and hinge pin shall not be more than 0.5 mm. The installation
clearance between the bush and shaft pin shall be 0.15 mm ～ 0.20 mm.
14.7.3.1 The quality control requirements of the pilot door structure repair process is given below:
a） The local deformation of the door structure shall be repaired by hot straightening. Where this cannot
be repaired by hot straightening, the door structure shall be partially cut and renewed;
b） The hinge plate shall be renewed in cases where the corrosion and abrasion is over the limits;
c） For slight abrasion, scuffing and crack of the shaft pin, it shall be repaired by machining, but if more
serious, the shaft pin shall be replaced;
d） The watertight rubber shall be replaced if it is aged or deformed.
14.7.3.2 The quality control requirements of hydraulic jacking and locking cylinder repairs are as below:
a) Slight scuffing of the piston rod of the hydraulic cylinder shall be manually trimmed and polished.
The piston rod of hydraulic cylinder shall be renewed or re-chrome-plated after grinding if it is
damaged seriously;
b) The rubber seals shall be renewed if damaged or aged;
c) The hydraulic pipe shall be renewed .if it is leaking or serious corroded. Additional pipe supports
shall be added if vibration is serious.
14.7.3.3 Pilot door repairing quality control key points are as below:
a) Welding material and quality;
b) Assembly accuracy;
c) Tightness test.
Inspection & Test for acceptance of pilot door repairing are as below:
a) Measure and record the repair accuracy;
b) Carry out the tightness test after hydraulic pipe repairs and submit the test report;
c) Carry out the function test and submit the test report;
d) Carry out the hose test and submit the test report.
14.8 Lashing bridge and container socket of container vessel
The key points of survey for lashing bridges and container sockets are as below:
a) Check the corrosion and deformation of the lashing bridge structure;
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GB/T XXXXX-XXXX
b) Check the deformation of the lashing bridge railing, handrail and grating;
c) Check the deformation and corrosion of the cell guide;
d) Check the deformation and corrosion of the container socket.
14.8.2.1 Normally, the material of renewed part shall be same as original. In cases where a substitute
material has been used, ensure the strength is not reduced. After agreement and confirmation by owner’s
representative it shall be substituted by equally or higher grade material.
14.8.2.2 After repair, the installation accuracy of container sockets shall comply with the values given in
Table 219.
Table 219 Installation accuracy of container sockets unit: mm
Items Allowable range

The distance between two container sockets center in ±5
longitudinal direction
The distance between two container sockets center in ±3
transverse direction
The diagonal length of container sockets center ≤10
The flatness of one set container socket 4
14.8.2.3 The verticality of single cell guide shall comply with the value given in Table 220.
Table 220 Verticality of single cell guide unit: mm
Items Standard range Allowable limits

Verticality 3 4
14.8.3.1 Slight corrosion of structure shall require de-rusting, re-welding, grinding and touching up. For
serious corrosion, the structure shall be renewed.
14.8.3.2 Slight deformation of structure shall require hot straightening. For serious deformations, the
structure shall be renewed.
14.8.3.3 Slight corrosion of the container sockets shall require de-rusting, re-welding, grinding and touch
up. The container sockets shall be renewed in cases of serious corrosion.
14.8.3.4 Lashing bridge and container sockets repair quality control key points are as below:
a) Material and size of renewed component and container socket;
b) Welding material and quality;
c) Assembly and positional accuracy;
d) Container test.
Inspection & Test for acceptance of lashing bridge and container socket repairing are as below:
a) Measure and record the installation accuracy of the cell guide and container sockets.
b) Carry out the container test and record the test result.
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REFERENCE
[1] CB 3364-1991 Technical requirements for repairing of prime motor of diesel generator set for ships
[2] CB 3369-1991 Technical requirements for repairing of ship-used variable pitch screw
[3] CB 3378-1992 Technical requirements for repairing of refrigeration and air conditioning refrigeration
equipment for ships
[4] CB/T 3379-1991 Technical requirements for repair of marine Z-shaped propelling plants
[5] CB/T 3416-1992 Technical requirements for repair and inspection of marine shaft
[6] CB/T 3417-1992 Technical requirements for repair of stern shafts, jack shafts, thrust shafts and
couplings of ships
[7] CB/T 3418-1992 Technical requirements for repair of marine shaft bearings, stern shafts and pipelines
[8] CB/T 3419-1992 Technical requirements for repair of marine shaft sealing devices
[9] CB/T 3420-1992 Technical requirements for marine shafting repair and assembling
[10] CB/T 3421-1992 Requirements for repair and acceptance on marine shafts and their submitted
documents
[11] CB/T 3422-1992 Technical requirements for repair of marine propellers
[12] CB/T 3423-1992 Inspection and submitted documents for repair of marine propellers
[13] CB/T 3424-2013 Repairing and installing technical requirements for ship rudder bearing
[14] CB/T 3425-2013 Ship rudder system and tiller repairing technical requirements
[15] CB/T 3426-2013 Repairing technical requirements for ship rudder blade
[16] CB/T 3427-2013 Repairing and installing technical requirements for ship rudder parts
[17] CB/T 3428-2013 Technical requirements for center line orientation and calibration of ship rudder
repair
[18] CB/T 3429-2013 Acceptable requirements and submissions of ship rudder repair
[19] CB/T 3473-1993 Technical requirements for cylinder cover repair for marine diesel engines
[20] CB/T 3498-2013 Trial technical requirement after diesel main engine repaired
[21] CB/T 3502-1992 Technical requirements for repair of cylinder jacket for marine diesel engines
[22] CB/T 3503-1993 Technical requirements for repair of marine diesel engines air valve
[23] CB/T 3504-1993 Technical requirements for repair of marine diesel engines spiral spring
[24] CB/T 3505-1993 Technical requirements for repair of fuel injection equipment precision matching
part for ship diesel engines
[25] CB/T 3533-1994 Technical requirements for repair and installation of marine diesel engines
[26] CB/T 3539-1994 Technical requirements for repair of connecting sleeve & piston pinning sleeve for
marine diesel engines
[27] CB/T 3540-1994 Technical requirements for repair of piston ring repair for marine diesel engines
[28] CB/T 3543-1994 Repairing technical requirements for piston of marine diesel engine
[29] CB/T 3574-1994 Technical requirements for ship switch board repair
[30] CB/T 3575-1994 Technical requirements for ship distribution box repair
[31] CB/T 3577-1994 Technical requirements for ship cable repair
[32] CB/T 3580-1994 Technical requirements for repair and thickness measurement of hull plates and
members
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GB/T XXXXX-XXXX
[33] CB/T 3583-1994 Repairing technical requirements for ship hatch cover
[34] CB/T 3584-1994 Repairing technical requirements for ship bulkhead, surround wall and deck
structure.
[35] CB/T 3586-1994 Technical requirements for local remedial by insert plate and large scale cutting
and repairing for shell plate.
[36] CB/T 3587-1994 Repairing technical requirement for hull
[37] CB/T 3636-1994 Technical requirements for marine boiler repair and inspection
[38] CB/T 3637-1994 Technical requirements for marine boiler pipe fittings repair
[39] CB/T 3638-1994 Technical requirements for marine boiler plates repair
[40] CB/T 3641-1994 Technical specifications for marine boiler repair and acceptance
[41] CB/T 3679-1995 Technical requirements for marine to-and-fro hydraulic steering gear repair
[42] CB/T 3680-1995 Technical requirements for repair of marine rotary vane hydraulic steering gear
[43] CB/T 3682-1995 Technical requirements for marine cargo crane repair
[44] CB/T 3685-1995 Technical requirements for marine heat exchanger repair
[45] CB/T 3687-1995 Technical requirements for marine mooring winch and capstan repair
[46] CB/T 3688-1995 Technical requirements for marine anchor windlass and anchor capstan repair
[47] CB/T 3689-1995 Technical requirements for marine cane pump repair
[48] CB/T 3701-1995 Technical requirements for marine gear pump repair
[49] CB/T 3705-1995 Technical requirements for marine reciprocating pump repair
[50] CB/T 3706-1995 Technical requirements for marine centrifugal pump repair
[51] CB/T 3708-1995 Technical requirements for marine screw pump repair
[52] CB/T 3709-1995 Technical requirements for marine piston air compressor repair
[53] CB/T 3711-2013 Welding repairing technical requirements for marine diesel engine parts
[54] CB/T 3733-2013 Technical requirement for repairing mud-pump in a dredger
[55] CB/T 3739-1995 Test method on special equipment repair for cutter suction dredger
[56] CB/T 3743-1995 Test method on dredging equipment repair for bucket ladder dredger
[57] CB/T 3744-1995 Technical requirements for dredge repair for grab dredger
[58] CB/T 3931-1999 Repairing items of delivery and acceptance for commercial steel
sea-going ship
[59] CB/T 3937-1999 Repairing specification of marine electrical machine
[60] CB/T 4162-2011 Technical requirements of repairing for steel door on ship
[61] CB*/Z 158-1979 Technical specifications for ship pipeline repair
[62] CB*/Z 324-1982 Technical specifications for repair of ship pipeline fittings
_________________________________
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CONTENT

This standard is drafted according to the requirements of GB/T1.1 - 2009.

CHINA SHIP REPAIRING QUALITY STANDARD

3.1 Materials for ship repairing

3.1.1 General requirements of materials

General requirements of materials are as below:

3.1.2 Material substitution principles for steel plate

3.1.3 Material substitution principles for profile

The principles of material substitution for profiles is as below:

3.1.4 Material substitution principles for pipe

The principles of material substitution for pipes is as below:

3.1.5 Material substitution principles for paints

The principles of material substitution for paint is as below:

3.1.6 Equipment renewal principles

The principles of equipment renewal is as below:

3.2 Documents for approval

3.3 Main inspection list for ship common repairing

Table 1 Inspection list for hull

No. Items Content Stage Surveyor Owner

4 (e.g. generator, hydraulic cylinder After

3.3.3 Dock repairing

Table 2 Inspection list for the dock repairs

No. Items Content Stage Surveyor Owner

No. Items Content Stage Surveyor Owner

Clearance of intermediate shaft bearing

Intermediate bearing load test

Tightness test after stern tube seal installation

Propeller shaft and stern tube bearing wear down

N.D.T. for root of taper part and keyway of stern shaft

Operational test of shafting After

Rudder construction centre verification and zero During

position confirmation fabricating

3.3.4 Machinery engineering

Table 3 Inspection list of machinery engineering

No. Items Content Stage Surveyor Owner

Piston re-assembly and alignment inspection

Cylinder cover and piston Tightness test √

Governor operation test

3 Heat exchanger Heater and cooler cleaning and Tightness test ─

Crane (disassemble, Steel wire renew and installation

No. Items Content Stage Surveyor Owner

11 Ship side pipe Fit, welding, Tightness test welding/After

12 remote control After

No. Items Content Stage Surveyor Owner

3.3.5 Deck machinery and outfitting

Table 4 Inspection list of deck machinery and outfitting

No. Items Content Stage Surveyor Owner

No. Items Content Stage Surveyor Owner

8 Hoisting equipment Welded seam N.D.T.

Steel wire renew and installation

No. Items Content Stage Surveyor Owner

3.3.6 Electrical engineering

Table 5 Inspection list for electrical engineering part

No. Items Contents Stage Surveyor Owner

Check all cable penetrations installation √

No. Items Contents Stage Surveyor Owner

Electromotor, alternator and hot state insulation of electromotor &

No. Items Contents Stage Surveyor Owner

Emergency stop system for the oil