planned maintainece system for ships

7/30/2019 Planned Maintainece System for Ships

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PLANNED

MAINTENANCE

SYSTEM


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Introduction on Planned Maintenance

The concept and basic understanding of Planned Maintenance isessential,

it is NOT a cure for all your equipment problems but a structured and effective Planned Maintenance system can

guarantee you

that the machine is expected to perform on its optimumcondition,

and damages in cost savings on repair and maintenance wouldthus be reduced.

Planned Maintenance

is a long term solution for your daily day to day problems.

We need to put a stop on fire fighting practices, an accumulationof such practice will - hurt your plant financially,

- shorten the life of your equipment,

- delayed deliveries to customers,

- high costs on spares.


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Maintenance is expensive and it is tempting to

put off until tomorrow in order to save money

today. But this may lead to increased costs

later on, not only for repairs but also may be

of loss in hire, pollution claims, extra port stay,

etc.

Thus a balance must be achieved betweencosts of repair and probable losses.


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Preventive maintenance involves opening of

machinery for checks, adjustments and

replacements of parts if required. Selection of theproper interval between inspections is important.

Frequent inspections will reduce availability of

equipments, increase workload of the crew,

leading to negligence of other equipment and

increase the danger of erroneous reassembly,

causing malfunction.

Only judgement and experience can help indeciding the proper interval between

inspections.


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Very few components used on ship have got a

specific fixed lifetime after which they have to

be replaced. With most components the

reliability decreases with age.

For economic reasons such parts cannot be

replaced at specific intervals but their

condition must be monitored regularly andcorrective action taken before failures occur.


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Planned maintenance by itself cannot be carried outto such an extent that no incidental maintenancewill be required.

Imagine maintaining and checking each and everypart of the ship.

The costs would be astronomical and the ship willhave to be placed off-hire frequently just to carry

out this maintenance. Since it is not possible to ensure that each and every

part of the ship is 100% safe, a balance must bereached between planned, incidental and corrective

maintenance. This will result in a balance between maintenance

costs and losses due to breakdowns. (See figure)


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Objectives of Maintenance

The management of marine fleet is a critical challenge that directly affectssuccess of the overall company. A company that wants to survive withtheir competition and an economic slowdown must focus on a rigid

framework on their maintenance structure and strategy they must adoptfor the Planned Maintenance System.

The ship has to comply with the safety and pollution preventionregulations issued by the Flag State, the Port State Authorities and theIMO.

In operation, the ship must be periodically surveyed for maintenance of

class and the class certificate. Additionally, as required by the ISM code, the maintenance management

of the ship is the primary responsibilities of the ship owner and shipmanagement company.

To preserve capital by prolonging the economic life of the ship and

enhancing its resale value. To preserve the ships performance as a cargo carrier by reducing cargo

losses and off-hire times.

To preserve operational efficiency so that excessive repair bills do not eatinto profits.


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Procedures for developing and improving PlannedMaintenance System

The company should also take into account thefollowing when developing and improvingmaintenance procedures: -

The maintenance recommendations andspecifications of the equipment manufacturer

The history of the equipment, including failures,defects and damage, and the corresponding remedialaction

The results of third-party inspections

The age of the ship

The identified critical equipment or systems

The consequences of the failure of the equipment onthe safe operation of the ship.


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A systematic approach to the PMS will include:

Establishing maintenance intervals

Defining inspection methods & frequency

Specifying inspection type, measuring equipmentand required accuracy

Establishing appropriate acceptance criteria

Assigning responsibility for inspection activities toappropriately qualified personnel

Assigning responsibility for maintenance activities toappropriately qualified personnel

Defining requirements and mechanisms for reporting


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The PMS is to include the following:

The description and documentation of the Planned Maintenance systemare to be in the English language.

Reports in Planned Maintenance system should be in English, except

when not suitable for the crew. In that case a brief English summary isrequired.

Planned Maintenance program must include equipment manufacturerrequirements.

Inventory content, i.e. items/systems have to be included in the

maintenance program. Maintenance time intervals, i.e. time intervals at which the maintenance

jobs are to take place.

Maintenance instructions, i.e. maintenance procedures to be followed.

Maintenance documentation and history, i.e. documents specifyingmaintenance jobs carried out and their results.

Reference documentation, i.e. performance results and measurementstaken at certain intervals for trend investigations from delivery stage.

Document flow chart, i.e. chart showing flow and filling of maintenancedocuments as planning cards, job cards etc.

Signing instructions, i.e. who signs documents for verification of

maintenance work carried out.


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Special, survey arrangements are made for shipsthat use an approved maintenance systemwhich must contain: A list of all systems, equipment and components used

in the plan.

Specified intervals for maintenance .

Maintenance instructions for the equipment.

A record of maintenance carried out.

Reference data from new building plans

After verifying that the system is actually beingused on board, the annual survey can be reducedto a general survey of the engine-room, testing ofimportant systems and verification of thereporting in the planned maintenance system.

Pl i d t l it l t f l d


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Planning and control are vital aspects of a plannedmaintenance system so that

Ships officers can plan and manage better, improve shipsperformance and meet the objectives of the company.

Work can be carried out systematically so that no itemsare overlooked.

Continuously can be maintained and new officers joiningare aware of the maintenance schedule.

It provides feedback to the office so that support services

can be arranged or if required the planned maintenanceschedule and procedures may have to be modified.

A filing, coding and labelling system, spare parts,inventory, plans, technical information, etc. will be

necessary.


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Computerised Planned Maintenance Systems for usein shipping industry

The development of computerised PMS was boostedby computer development, especially the developmentof Windows.

A variety of PMS programs for shipboard use appeared,

and gradually they become more and moresophisticated and complex.

Producers recognized shipping needs and most of theprograms today have several (semi)independentmodules and the customer (shipping company) canchoose what package they want to use.

Programs today do not contain only maintenance, theyoffer almost all what is needed on board the ship.


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Most common modules in modern PMS system include:

Maintenance (main and essential part of program')

Stock ordering and purchase

Stock control (inventory)

Safety management Quality management

Crewing and staff

Self assessment

Modules can vary between different programs, butthey are all based and built around main module,Maintenance.


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Maintenance

This module should meet requirements listed in ISM(International Safety Management Code), chapter 5,

section 10. The database should be constructed according to the

manufacturer's recommendations, and goodseamanship practice.

The database should include all shipboard vitalequipment, and all equipment should have a clearlydefined maintenance plan.

Performed tasks should be kept in the system as well asnotes from crew members performing the task.

Access to various aspects in the system must beselective and programs must have ability to individuallyrecognize users (login ID and password). Best exampleof this practice is Class requirement that only ChiefEngineer have access to jobs linked with Surveys.
http://en.wikipedia.org/wiki/International_Safety_Management_Codehttp://en.wikipedia.org/wiki/International_Safety_Management_Codehttp://en.wikipedia.org/wiki/Chief_Engineerhttp://en.wikipedia.org/wiki/Chief_Engineerhttp://en.wikipedia.org/wiki/Marine_surveyorhttp://en.wikipedia.org/wiki/Marine_surveyorhttp://en.wikipedia.org/wiki/Chief_Engineerhttp://en.wikipedia.org/wiki/Chief_Engineerhttp://en.wikipedia.org/wiki/Marine_surveyorhttp://en.wikipedia.org/wiki/Marine_surveyorhttp://en.wikipedia.org/wiki/Chief_Engineerhttp://en.wikipedia.org/wiki/Chief_Engineerhttp://en.wikipedia.org/wiki/International_Safety_Management_Code


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Class societies allow special status to ships with well implementedPMS.

Survey of various machinery components is performed usuallywith regular Class surveyor inspection, and it is based on schedulegiven in Continous Machinery Survey.

Surveyor comes to ship several times per year and inspects variousmachinery components, determining their condition.

Inspection is scheduled every five years and the system is intended

to assure good functionality of ship's machinery and thereforesafety of the ship.

As PMS is increasing overall safety and reliability of the ship, Classsocieties allow another form of Survey to be performed on theships with well established PMS.

Most of CSM inspections (all except steering gear and pressurevessels) is carried out by Chief Engineer, based on regular PMS

jobs, and Class surveyor is coming on board the ship only once ayear to inspect items Chief Engineer is not entitled to and to check

what items were inspected since last Class inspection.
http://en.wikipedia.org/w/index.php?title=Continous_Machinery_Survey&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Continous_Machinery_Survey&action=edit&redlink=1http://en.wikipedia.org/wiki/Shiphttp://en.wikipedia.org/wiki/Shiphttp://en.wikipedia.org/w/index.php?title=Continous_Machinery_Survey&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Continous_Machinery_Survey&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Continous_Machinery_Survey&action=edit&redlink=1


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The older type of planned maintenance systemconsisted of a card file system.

Each card pertained to the maintenance of one

equipment. It had all the information required to the maintenance

printed on it.

These cards were filed in groups according to theperiod of maintenance.

Thus cards for items which required to be maintainedevery week were in one group, the cards for itemsrequiring to be maintained every month in anothergroup and so on.

When the equipment was maintained the card wasplaced at the bottom of the file.

Thus the cards for items which needed to be donecurrently were on top and the officer could see at aglance which item needed to maintained with priority.


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Today with computers the maintenance carried out is entered intothe computer where it is transferred to the company by E-mail.

Action such as replenishment of spares is undertaken by thecompany. If any maintenance is not carried out on time, it flashes on

screen. A list of items pending or due for maintenance at any particular

time can be printed out.

Planned Maintenance System (PMS) applied for the Class approval

The ship owner/manager can make a formal request to class forsystem/type approval. The system approval is valid for all shipsmanaged by the ship owner/manager, having this PMSimplemented on board.

The 2nd step is the implementation survey on the PMS on board asbasis for granting this survey arrangement to each ship.

The 3rd step is the PMS final vessel approval, upon confirmationfrom the attending surveyor that a successful implementationsurvey has been carried out.

planned maintainece system for ships

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