A.B.S. Guidelines
American Bureau of Shipping
Incorporated by the Legislature of
the State of New York 1862
American Bureau of Shipping
Two World Trade Center, 106th Floor
New York, NY 10048 U.S.A.

Section
Intro Mission
Intro Quality Policy
Intro Foreword
1.0 General
2.0 Initial Conditions
3.0 Submission Requirements
4.0 Onboard Documentation
5.0 Special Conditions
6.0 Alternative Techniques
7.0 Overhauls and Damage Repairs
8.0 Annual Confirmation Survey of Preventative Maintenance Program
9.0 Fees
10.0 Information
Appendix A


MISSION
The mission of the American Bureau of Shipping is to serve the public interest as well as the needs of our clients by promoting the security of life, property and the natural environment primarily through the development and verification of standards for the design, construction and operational maintenance of marine-related facilities.
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QUALITY POLICY
It is the policy of the American Bureau of Shipping to provide quality services in support of our mission and to be responsive to the individual and collective needs of our clients as well as those of the public at large. All of our client commitments, supporting actions, and services delivered must be recognized as expressions of quality. We pledge to monitor our performance as an on-going activity and to strive for continuous improvement.
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FOREWORD
In Recent years there has been an increasing reliance by owners on shore-based personnel for repair and maintenance of machinery on board vessels and offshore structures. Since 1978, ABS has cooperated with Owners on developing and implementing preventative maintenance programs. This guide is based upon this experience.

Planned Maintenance and Condition-based Maintenance are the two techniques discussed in this guide that are used to assist Owners in maintaining machinery. Often these techniques are used concurrently.

Planned maintenance involves the setting of formal schedules for maintenance and overhaul of machinery. Running time or calendar time may be used for establishing a schedule. Such schedules are generally established by the machinery manufacturer and include lubrication servicing; filter, bearing, and seal replacements; as well as major overhaul.

Condition-based maintenance involves the use of diagnostic technologies to monitor machine conditions. This process involves establishing a baseline and operating parameters, then periodically monitoring the machine and comparing any changes in operating conditions to the baseline. Repairs or replacements are carried out based upon the detection and fault diagnosis of the machine towards a condition of failure. Common tools used in condition monitoring are vibration analysis, oil analysis, ferrography, thermography, electric current wave form analysis, and borescopic examination. Supplemental technologies such as demodulation, ultra-sonic analysis, shock-pulse, spike-energy, HFD, etc. for roller bearing element condition monitoring, may be used in addition to vibration analysis. Measurements are taken at periodic intervals.

This guide has been updated and supersedes the 1987 edition. As the field of condition monitoring technology is progressing rapidly modifications to these guidelines may be necessary in the future. ABS is at all times ready to consider alternative methods to those outlined in this Guide to meet the overall intent of promoting safe operation and continued effective maintenance of machinery.
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1.0 GENERAL
The following are procedures and conditions under which a properly conducted preventative maintenance plan may be credited as satisfying the requirements of Special Continuous Survey of Machinery. Consideration will be given to extending overhauls (opening out) beyond the five-year cycle where Planned Maintenance and Condition Monitoring programs are in effect.

No preventative maintenance plan supersedes the judgment of an ABS Surveyor.

These programs do not waive ABS Surveyor attendance for damage, representative overhaul of main engines, generator engines, steering gear, general insulation condition and resistance tests, electrical devices functional tests, reduction gear teeth examinations, hydrostatic tests of pressure vessels, tests and verification of safety devices such as relief valves, overspeed trips, emergency shut-offs, low-oil pressure trips, etc. as required by the ABS Rules for Building and Classing Steel Vessels.

The reference to an ABS Recognized Condition Monitoring Company refers to those companies whom ABS has identified as an External Specialist. Please refer to section 10.0 of this Guide.
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2.0 INITIAL CONDITIONS
Before considering applications for a preventative maintenance program in lieu of a conventional Special Continuous Survey of Machinery, the following conditions are to be met:
  • 2.1 Age of Vessel
    There is no limit on the age of a vessel when entered into the program, however vessels over 15 years of age will be subject to special consideration. This special consideration involves a review of the vessels records to ascertain the historical performance of the machinery which could affect the Preventative Maintenance Program. Provided there is no historical problems related to the maintenance of machinery the vessel will be considered eligible.

  • 2.2 Surveys
    Surveys related to the vessel are to be up-to-date, without overdue outstanding recommendations which would effect the Preventative Maintenance Program. The machinery in the program is to be on a Special Continuous Survey of Machinery (CMS) cycle.

  • 2.3 Damages
    There is to be no record of unrepaired damage to the vessel or its machinery which would effect the vessels ability to participate in the Preventative Maintenance Program.
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3.0 SUBMISSION REQUIREMENTS
  • 3.1 Program Description
    A comprehensive preventative maintenance program is to be submitted to the responsible ABS Technical Office (as listed in Appendix A) for approval. Only machinery subject to Special Continuous Survey of Machinery is to be included in the program. This program is to include the following:
    • 3.1.1 For items covered by Planned Maintenance Program
      a
      A list and description of the machinery.
      b
      Schedule of servicing and overhaul.
      c
      Description of the work to be performed at each interval. This schedule is to meet at least the servicing and overhaul intervals specified by the manufacturer and a statement to this effect is to accompany the plan.
      d
      Machinery identification method and record keeping procedures.
      e
      Where the servicing and overhaul intervals exceed those specified by the manufacturer, the basis of the extended schedule along with supporting data is to be submitted together with the manufacturer's servicing specifications.
    • 3.1.2 For Items covered by Condition Monitoring Program
      a
      A list and description of the machinery covered including:
      • method of data collection and analysis tools.
      • nominal rpm
      • horsepower
      • location and orientation of sensor attachments, which are to be permanently marked on machinery.
      • sampling procedures for oil analysis.
      b
      Schedule of data collection.
      c
      Type and model of data collection instrument, including sensor and attachment method, and calibration schedule.
      d
      Acceptance criteria of data.
      e
      Baseline data - Initial or baseline data are to be recorded in the presence of an ABS Surveyor and/or a representative specialist of an ABS Recognized Condition Monitoring Company. All machinery that does not meet acceptance criteria is to be corrected and rechecked prior to acceptance into the Preventative Maintenance Program.
    • 3.2 Owner's Annual Preventative Maintenance Report
      The vessel's Owner or qualified representative is to submit to the responsible ABS Technical Office (as listed in Appendix A) an Annual Preventative Maintenance Report containing the following information. Any reports submitted without the following information will be returned without action to the submitter.
      • 3.2.1 Planned Maintenance Program Report - Annual
        a
        A summary list of all machinery covered under the Planned Maintenance Program including a complete description of work completed on each machine since the last submitted report.
        b
        Exceptions, notes, and comments noted during work.
        c
        Modifications and justifications to the schedule, such as might be recommended by a machinery manufacturers technical bulletin.
        d
        Summary and analysis of machines that failed prior to scheduled maintenance or servicing.
      • 3.2.2 Condition Monitoring Program Report - Annual
        a
        A summary list of all machinery covered under the Condition Monitoring Program clearly stating the overall condition of the machinery based on the most recent vibration measurement data (i.e. Satisfactory, Marginal, Suspect, Unacceptable, etc.). Data for the report must have been collected within three months of the submission date of the report by an ABS Recognized Condition Monitoring Company.
        b
        Vibration spectral data must be reviewed by a representative specialist of an ABS Recognized Condition Monitoring Company.
        c
        For machines with identified faults, spectral data must be included, as well as alarm criteria, and historical trending data.
        d
        Relevant operational data during data recording, such as sea state, machine temperature, other equipment affecting the data, etc. should be included.
        e
        Quarterly overall vibration meter readings recorded by vessel personnel. The type of recording device, method of data collection, and calibration of the data collector must be provided.

    If the machinery included in the Planned Maintenance or Condition Monitoring Program has changed this is to be stated. Any machinery to be added to the system is subject to the requirements of 3.1
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4.0 ONBOARD DOCUMENTATION
  • Planned Maintenance Program
    a
    The latest up-to-date information required in 3.1.1
    b
    A copy of the manufacturers service manuals.
    c
    All records showing compliance with the program are to be made available for review by the ABS Surveyor at the Annual Survey of Machinery.
  • Condition Monitoring Program
    a
    For vessels with onboard vibration meters or FFT vibration analyzers, manuals supplied by manufacturers for use of data collectors and computer programs, as well as guidance for machine operating and diagnosis of machine faults.
    b
    Records of lube oil analysis, rotor positioning readings, interstage bleed system pressures, and vibration readings are to be recorded by the vessels personnel at least on a quarterly basis and retained onboard for review annually by the attending ABS Surveyor.
    c
    Complete vibration data as specified in 3.1 are to be taken at least annually, or more frequently when warranted by abnormal conditions and operational parameters, reviewed by a representative specialist of an ABS Recognized Condition Monitoring Company and retained onboard for review annually by the attending ABS Surveyor.
    d
    If the vessel includes internal combustion engines in the program, the data outlined in 5.2 must be retained onboard for review annually by the attending ABS Surveyor.
    e
    Calibration date of equipment. Calibration is to be in accordance with the manufacturer's recommendations or annually, whichever is more frequent.
    f
    Any repairs or changes to any machines must be reported, and a summation and analysis of all unscheduled maintenance and/or breakdowns of monitored equipment.
    g
    All records showing compliance with the program, including a copy of the most recent owners annual report are to be made available for review by the ABS Surveyor at the Annual Survey of Machinery.
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5.0 SPECIAL CONDITIONS
  • 5.1 Steam Turbines
    For main propulsion steam turbines, checking the turbine journal, thrust bearings, flexible couplings, and low pressure turbine via the exhaust trunk, or other means of assessing the turbine internal condition including borescope examination of the ahead turbine, may be acceptable in lieu of opening the turbine casing at the second and alternate Special Surveys thereafter provided that the Preventative Maintenance Program is satisfactorily maintained and all onboard documentation per section 4.0 is available for review.
  • 5.2 Internal Combustion Engines
    Machine condition monitoring of internal combustion engines must provide detailed engine analysis as well as information provided in 3.1. The following data must be recorded at least monthly:
    a
    Operating time (running hours)
    b
    Power Output
    c
    rpm
    d
    Cylinder pressure as function of crank angle
    e
    Injection pressure as function of crank angle
    f
    Cylinder liner and piston ring wear (on basis of compression/firing pressures or proximity readings)
    g
    Scavenging air pressures and temperatures
    h
    Lubricating oil and cylinder oil consumption
    i
    Bearing temperatures
    j
    Cylinder exhaust temperatures
    k
    Turbocharger vibration
    l
    Lubricating oil analysis (quarterly)

    Variable or abnormal readings are to be recorded by the vessels personnel more frequently as appropriate to properly monitor the performance range or establish the trend.
  • 5.3 Electrical Switch Gear and Power Distribution Panels
    Condition monitoring plans for electrical equipment are to include examination of panels, switchboards, transformers, and other essential electrical apparatus by infrared photographic thermography during each five-year survey cycle while the circuit is energized and under normal work loads. A report describing the results of the survey, as well as periodic insulation resistance records must be retained onboard for review by the attending ABS Surveyor.
  • 5.4 Permanently Installed Monitoring Equipment
    Permanently installed electronic analyzing equipment used for the Preventative Maintenance Program is to comply with the requirements of section 4/11.39 of the ABS Rules for Building and Classing Steel Vessels, regarding testing and certification of automatic and remote control systems for use onboard ship.
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6.0 ALTERNATIVE TECHNIQUES
Application of techniques of condition monitoring other than those mentioned above will be specially considered.
  • 6.1 Semi-Annual Alternative
    Condition monitoring based on semi-annual signatures is acceptable as an alternative technique for rotating machinery in lieu of quarterly overall vibration meter readings supplemented by an annual signature as required in item 3.2.2. The semi-annual signatures are to be taken and reviewed by a representative specialist of an ABS Recognized Condition Monitoring Company. External checks such as lube oil analysis, shaft position indicating, and bearing temperatures are not effected and are to continue to be monitored by the crew at least on a quarterly basis.

    The annual owners report is to clearly indicate that this alternative is being utilized and must include both semi-annual signatures for all of the monitored equipment. In addition, a summation and analysis of all unscheduled maintenance and/or breakdowns of the monitored equipment which were not identified by the semi-annual signatures must be included. Any reports submitted without the required statement of maintenance and/or summation will be returned without action to the submitter.

  • 6.2 Remote Access/Computer Disk Alternative
    Owners may opt to submit their annual reports on either a 3 1/2", 1.44 mB DOS compatible floppy disk or make arrangements to allow access via a modem to review the reports. These reports must contain at least the information required in 3.2. These programs will be evaluated on a case by case basis by the Responsible ABS Technical Office responsible for the submittal. In addition, the Owners must submit annually in hard copy the following:
    a
    A letter of intent stating that the annual report is contained at either a remote location available for access via a modem or that the report is on a 3 1/2" , 1.44 mB DOS compatible floppy disk.
    b
    A summation and analysis of the annual vibration signatures.
    c
    A summation and analysis of all unscheduled maintenance and/or breakdowns of the monitored equipment.
    d
    Directions how to access the information remotely or to retrieve the report from the 3 1/2", 1.44 mB DOS compatible floppy disk.

    This alternative applies to annual submittals only. Initial submittals are to be submitted in hard copy.
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7.0 OVERHAULS AND DAMAGE REPAIRS
  • 7.1 Overhauls
    An ABS Surveyor is to attend and report on representative overhauls of the main parts of the main engines, generator engines, and steering gear at least once during each five year cycle. This would include overhaul of pistons, crossheads, crankpin bearings, main bearings, and steering gear pumps and controls. Following overhauls, new baseline data is to be recorded in the presence of the Surveyor and/or a representative specialist of an ABS Recognized Condition Monitoring Company within six months of the overhaul and included in the Annual Report.
  • 7.2 Damage Repairs
    An ABS Surveyor is to attend all damage surveys. Damaged machinery will be tested when service is restored and machine conditions are to be checked against historical data for variances.
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8.0 ANNUAL CONFIRMATION SURVEY OF PREVENTATIVE MAINTENANVE PROGRAMS
Simultaneously with each Annual Survey of Machinery, for vessels on a Preventative Maintenance program, the attending Surveyor is to survey and report on any machinery opened out at the time of his visit, generally examine all machinery, witness functional tests as appropriate, review the vessel's periodical condition monitoring data and/or records of maintenance and repairs. The Surveyor may credit to the CMS any machines that were overhauled and tested in the presence of and to the satisfaction of the attending Surveyor.

Additionally, any machinery that has been overhauled in accordance with the Planned Maintenance schedule may be credited to the CMS by the attending Surveyor after a satisfactory operational test.

Any machinery that has acceptable machine conditions as per the Condition Monitoring Program may be credited to the CMS by the attending Surveyor after a satisfactory operational test. Special consideration is given for the opening of main propulsion steam turbines in accordance with section 5.1 of this Guide and applicable ABS Steel Vessel Rules.

The Surveyor is also to report on the continued effectiveness of the Preventative Maintenance Program, subject to review of the Owners Annual Preventative Maintenance Report and accompanying condition monitoring data and/or records of maintenance and repairs by the respective Responsible ABS Technical Office.
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9.0 FEES
For fees relating to this program contact:

Fee Coordination Department
American Bureau of Shipping
Two World Trade Center: 106th Floor
New York, NY 10048
Telephone:
(212) 839-5297
Fax:
(212) 839-5130
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INFORMATION
For information on becoming an ABS External Specialist please contact:

American Bureau of Shipping
16855 Northchase Drive
Houston, TX 77060-6008
Attn.:
Coordinator of ABS Programs
Phone:
(713) 874-6483
Fax:
(713) 874-6398
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Appendix A
ABS Technical Offices Responsible for Preventative Maintenance

ABS Americas
American Bureau of Shipping
16855 Northchase Drive
Houston, TX 77060-6008


Attn.: Coordinator of ABS Programs

ABS Europe
American Bureau of Shipping
No.1 Frying Pan Alley
London E1 7HR, England

Attn.: Director of Engineering

ABS Pacific
American Bureau of Shipping
Kiyoken Building, Yokohama Just
5th Floor
12-6 Takashima 2-chome Nishi-ku
Yokohama 220, Japan

Attn.: Director of Engineering
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