Rules and Regulations

for the
Construction and Classification
of Steel Ships

Part 4
Main and Auxiliary Machinery
January 2011
Indian Register of Shipping

Part 4

Main and Auxiliary Machinery

Contents

Chapter 1 General Requirements for the Design and

Construction of Machinery

Chapter 2 Piping Design Requirements

Chapter 3 Pumping and Piping

Chapter 4 Prime Movers and Propulsion Shafting

Systems

Chapter 5 Boilers and Pressure Vessels

Chapter 6 Steering Gear

Chapter 7 Control Engineering

Chapter 8 Electrical Installations

Chapter 9 Deleted

Chapter 10 Requirements for Fusion Welding

Chapter 11 Spare Gear

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Contents

Chapter 1 : General Requirements for the Design and

Construction of Machinery

Section 1 : General
2.3 Fire protection
1.1 Scope
2.4 Ventilation
1.2 Machinery to be constructed under survey
2.5 Communications
1.3 Extent of survey
2.6 Machinery controls
1.4 Departures from the rules

1.5 Plans and particulars Section 3 : Trials

1.6 Availability of machinery for operation 3.1 General

1.7 Environmental conditions 3.2 Sea Trials

1.8 Power ratings

Section 4 : Certification of Machinery and
1.9 Units Components Based upon Quality
Management Systems
1.10 Astern power
4.1 General
1.11 Fuel
4.2 Requirements for approval
1.12 Materials
4.3 Information required for approval
1.13 Alternative design and arrangements
4.4 Approval and maintenance of approval

Section 2 : Machinery Room Arrangements 4.5 Certification of products

2.1 General 4.6 Certification of diesel engines

2.2 Accessibility

Chapter 2 : Piping Design Requirements

Section 1 : General
1.8 Flanges
1.1 Scope
1.9 Materials
1.2 Classes of pipes

1.3 Design pressure Section 2 : Carbon and Low Alloy Steel Pipes
and Fittings
1.4 Design temperature
2.1 Materials
1.5 Design symbols
2.2 Minimum thickness of steel pipes and bends
1.6 Heat treatment
2.3 Types of connection
1.7 Minimum thickness of pipes and bends

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2.4 Flange connections 5.5 Impact resistance

2.5 Threaded sleeve joints 5.6 Temperature

2.6 Welding, non-destructive examination and 5.7 Requirements for pipes/piping systems
post-weld heat treatment of welded pipes depending on service and/or locations

2.7 Mechanical joints 5.8 Material approval and quality control during
manufacture

Section 3 : Copper and Copper Alloy Pipes 5.9 Installation

and Fittings
5.10 Test specification for plastic pipes
3.1 Materials

3.2 Minimum thickness of pipes Section 6 : Flexible Hoses

3.3 Heat treatment 6.1 Definition

6.2 Scope
Section 4 : Cast Iron Pipes and Fittings
6.3 Design and construction
4.1 Spheroidal or nodular graphite cast iron
6.4 Installation
4.2 Grey cast iron
6.5 Tests

Section 5 : Plastic Pipes and Fittings 6.6 Marking

5.1 General
Section 7 : Hydraulic Tests on Pipes and
5.2 Terms and definitions Fittings

5.3 Strength 7.1 Hydraulic tests before installation on board

5.4 Axial strength 7.2 Testing after assembly on board

Chapter 3 : Pumping and Piping

Section 1 : General 2.2 Drainage of cargo holds

1.1 Scope 2.3 Drainage from refrigerated cargo spaces

1.2 Plans 2.4 Drainage from fore and aft peaks

1.3 Materials 2.5 Drainage from tanks, cofferdams and void

spaces
1.4 Valves and cocks
2.6 Drainage from spaces above fore and after
1.5 Shipside fittings (other than sanitary peaks, chain lockers and above machinery
discharges and scuppers) spaces

1.6 Piping installation 2.7 Drainage from machinery spaces

2.8 Drainage from tunnel

Section 2 : Bilge and Ballast Piping Systems
2.9 Sizes of bilge suctions
2.1 General
2.10 Bilge pumps and ejectors

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Section 5 : Steam Piping and Condensate
2.11 Pump types Piping Systems

2.12 Bilge piping arrangements and fittings 5.1 Expansion and drainage

2.13 Additional requirements for passenger 5.2 Steam pipes in way of holds, shaft and pipe
ships tunnels

2.14 Drainage arrangements on vessels not 5.3 Relief valves

fitted with propelling machinery
5.4 Steam supply to auxiliaries
2.15 Ballast system
5.5 Steam for fire extinguishing in cargo holds

Section 3 : Vents, Sounding, Overflow and 5.6 Condensate pumps

Scuppers and Discharges Piping Systems

3.1 General Section 6 : Boiler Feed Piping Systems

3.2 Vent pipes 6.1 Feed water piping

3.3 Overflow pipes 6.2 Feed pumps

3.4 Sounding arrangements 6.3 Valves, cocks and fittings

3.5 Scuppers and discharges 6.4 Fresh-water connections

3.6 Water level detectors on single hold cargo 6.5 Feed water tanks
ships other than bulk carriers
6.6 Evaporators

Section 4 : Fuel Oil Systems

Section 7 : Engine Cooling Water Systems
4.1 General
7.1 General
4.2 Oil fuel tanks
7.2 Cooling water main supply
4.3 Oil fuel piping
7.3 Cooling water standby supply
4.4 Arrangement of valves, cocks, pumps and
fittings 7.4 Relief valves on cooling water pumps

4.5 Heating arrangements 7.5 Sea inlets for cooling water pumps

4.6 Temperature indication

Section 8 : Lubricating Oil Piping Systems
4.7 Filling arrangements
8.1 General
4.8 Alternate carriage of oil fuel and water
ballast 8.2 Pumps

4.9 Deep tanks for the alternative carriage of oil, 8.3 Control of pumps and alarms
water ballast or dry cargo
8.4 Emergency supply for propulsion turbines
4.10 Oil fuel burning arrangements and propulsion turbogenerators

4.11 Remote stop of oil fuel pumps and fans 8.5 Filters

8.6 Valves and cocks on lubricating oil tanks

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Chapter 4 : Prime Movers and Propulsion Shafting Systems

Section 1 : General 3.2 Plans and particulars

1.1 Scope 3.3 Materials

1.2 Materials 3.4 Design and construction

1.3 Turning gear 3.5 Welded components

1.4 Power ratings 3.6 Vibration

1.5 Overload capacity 3.7 Containment

1.6 Certification of machinery 3.8 Inlet and exhaust systems

1.7 Type approval program 3.9 Fuel and salt deposits

Section 2 : Steam Turbines 3.10 Indication of temperature

2.1 Scope 3.11 External influences

2.2 Plan and particulars 3.12 Overhaul life

2.3 Materials 3.13 Safety arrangements

2.4 Design and construction 3.14 Starting arrangements

2.5 Vibration 3.15 Tests

2.6 External influences 3.16 Shop trials

2.7 Steam supply and water system 3.17 Electric starting

2.8 Turning gear 3.18 Type testing of gas turbine

2.9 Safety arrangement

Section 4 : Oil Engines
2.10 Bled steam connections
4.1 Scope
2.11 Steam strainers
4.2 Plans and particulars
2.12 Emergency arrangements
4.3 Materials and material testing
2.13 Tests and equipment
4.4 Hydraulic tests
2.14 Balancing
4.5 Crankshaft design
2.15 Hydraulic tests
4.6 Design and construction
2.16 Indicators for movement
4.7 Crankcase ventilation
2.17 Weardown gauges
4.8 Safety devices

Section 3 : Gas Turbines 4.9 Governing

3.1 Scope 4.10 Oil fuel, lubricating oil, cooling water and
exhaust gas systems

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4.11 Engine starting arrangements 6.14 Tailshaft liners

4.12 Type testing of oil engines 6.15 Keys and keyways for propeller
connections
4.13 Work's trials (acceptance test)
6.16 Stern tube and bearings
4.14 Shipboard trials
6.17 Roller element bearings
4.15 Dual fuel diesel engines
6.18 Shaft bearing materials

Section 5 : Gearing 6.19 Glass Reinforced Plastic coating

5.1 Scope
Section 7 : Propellers
5.2 Plans and particulars
7.1 Scope
5.3 Materials
7.2 Plans and particulars
5.4 Design and construction
7.3 Materials
5.5 Accuracy of gear cutting and alignment
7.4 Design
5.6 Balancing of gear pinions and wheels
7.5 Fitting of propellers
5.7 Gearcases

5.8 Type tests and sea trials Section 8 : Vibrations and Alignment

5.9 Alignment and weardown gauges 8.1 Scope

5.10 Trials 8.2 Basic system requirements

8.3 Resilient mountings

Section 6 : Main Propulsion Shafting
8.4 Torsional vibration
6.1 Scope
8.5 Axial vibrations
6.2 Alternative calculation methods
8.6 Lateral vibrations
6.3 Plans and particulars
8.7 Shaft alignment
6.4 Materials for shafting

6.5 Intermediate and thrust shafts Section 9 : Thrusters

6.6 Tailshafts and stern tube shafts 9.1 Scope

6.7 Hollow shafts 9.2 Plans and particulars

6.8 Integral couplings 9.3 Materials

6.9 Demountable couplings 9.4 Design and construction

6.10 Tooth couplings 9.5 Piping systems

6.11 Flexible couplings 9.6 Control and monitoring

6.12 Interference fit assemblies 9.7 Electrical systems

6.13 Coupling bolts 9.8 Tests

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10.5 Installation of turbochargers

Section 10 : Turbochargers
10.6 Testing, inspection and certification of
10.1 Scope turbochargers

10.2 Plans and particulars 10.7 Certification of turbochargers

10.3 Design 10.8 Engine and shipboard trials

10.4 Piping systems for turbocharger

Chapter 5 : Boilers and Pressure Vessels

Section 1 : General
2.6 Standpipe and branches

1.1 Scope 2.7 Particular design requirements for boilers,

superheaters, economizers, steam receivers
1.2 Design pressure and similar vessels

1.3 Metal temperature 2.8 Access arrangements

1.4 Plans and particulars 2.9 Shell type exhaust gas heated economizers
that may be isolated from the steam plant
1.5 Classification of pressure vessels system

1.6 Definition of symbols

Section 3 : Fittings and Mountings
1.7 Materials
3.1 General
1.8 Allowable stress
3.2 Safety valves
1.9 Joint factors
3.3 Stop valves
1.10 Pressure parts of irregular shape
3.4 Water level indicators
1.11 Adverse working conditions
3.5 Low water level fuel shut-off and alarm
1.12 Minimum shell thickness
3.6 Feed check valves
1.13 Heat treatment, non-destructive examina-
tion and routine tests 3.7 Pressure gauges

3.8 Blow-down and scum valves

Section 2 : Design Requirements
3.9 Salinometer valve or cock
2.1 Cylindrical shells and drums subject to
internal pressure
Section 4 : Hydraulic Tests
2.2 Spherical shells subject to pressure on the
concave side 4.1 Boilers (fired and exhaust gas heated),
economizers, superheaters, reheaters, steam
2.3 Dished ends subject to pressure on concave receivers, steam heated generators and similar
side vessels

2.4 Conical ends subject to internal pressure 4.2 Other pressure vessels

2.5 Unstayed flat end plates

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Chapter 6 : Steering Gear

Section 1 : General
5.2 Electric control circuits
1.1 Scope
5.3 Monitoring and alarms
1.2 Definitions

1.3 Installation Section 6 : Emergency Power

1.4 Steering gear compartment 6.1 General

1.5 Plans
Section 7 : Testing and Trials
1.6 Materials
7.1 Testing
1.7 Rudder, rudder stock, vanes, tiller and
quadrant 7.2 Trials

1.8 Mechanical steering gear

Section 8 : Additional Requirements

Section 2 : Performance 8.1 For tankers, chemical tankers or gas carriers

of 10,000 tons gross and upwards and every
2.1 General ship of 70,000 tons gross and upwards

2.2 Rudder angle limiters 8.2 For tankers, chemical tankers or gas carriers
of 10,000 tons gross and upwards

Section 3 : Construction and Design 8.3 For tankers, chemical tankers or gas carriers
of 10,000 tons gross and upwards but of less
3.1 General than 100,000 tonnes deadweight

3.2 Components
Section 9 : Guidelines for the Acceptance of
3.3 Valve and relief valve arrangement Non-duplicated Rudder Actuators for Tanker,
Chemical Tankers or Gas Carriers of 10,000
3.4 Flexible hoses tons gross and upwards but of less than
100,000 tonnes Deadweight

Section 4 : Steering Control Systems 9.1 Materials

9.2 Design
4.1 General
9.3 Construction details

Section 5 : Electric Power Circuits, Electric 9.4 Non-destructive testing

Control Circuits, Monitoring and Alarms
9.5 Testing
5.1 Electric power circuits

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Chapter 7 : Control Engineering

Section 1 : General 3.1 Boilers

1.1 Scope 3.2 Propulsion machinery

1.2 Remote control systems capability 3.3 Emergency diesel engines

1.3 Plans and particulars

Section 4 : Tests and Trials
1.4 Operational guidance manual
4.1 Individual components
1.5 Location of control stations
4.2 Shop testing
1.6 Main control station
4.3 Trials on board
1.7 Secondary control stations

1.8 Control console construction Section 5 : Machinery Operated from a

Centralised Control Station – ‘CCS’ Notation
1.9 Instrumentation
5.1 General requirements
1.10 Displays, indications and alarms
5.2 Centralised control station for machinery
1.11 Safety systems

Section 6 : Programmable Electronic

Section 2 : Control - System Characteristics systems

2.1 Power supply 6.1 Scope

2.2 Electrical and electronic devices 6.2 General

2.3 Hydraulic controls 6.3 Additional requirements for programmable

electronic systems used for essential services
2.4 Pneumatic controls and safety critical systems

2.5 Ship motion effects 6.4 System categories

2.6 Bridge control for main propulsion machinery 6.5 Data communication links

2.7 Valve control system 6.6 Protection against modification

6.7 Documents to be submitted

Section 3 : Requirements for various
Machinery Installations 6.8 Tests and conformance

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Chapter 8 : Electrical Installations

Section 1 : General Requirements

2.8 Emergency source of power
1.1 Scope
2.9 Requirements for uninterrupted power
1.2 Definitions system (UPS) units as alternative and/or
transitional source of power
1.3 Surveys
2.10 Essential services
1.4 Plans
2.11 Diversity factor
1.5 Essential and other services
2.12 Lighting circuits
1.6 Ambient reference conditions
2.13 Motor circuits
1.7 Vibrations, accelerations
2.14 Motor controls
1.8 Voltage and frequency variations
2.15 Remote stops for ventilation fans and
1.9 Location and construction pumps

1.10 Design and construction 2.16 Fire detection and extinguishing systems

1.11 Voltages 2.17 Lift circuits

1.12 Electrical equipment for use in explosive 2.18 Heating and cooking equipment
gas atmospheres
2.19 Temporary external supply / shore
1.13 Enclosures connection

1.14 Creepage and clearance 2.20 Permanent external supply

1.15 Earthing of non-current carrying parts 2.21 Protection

1.16 Bonding for the control of static electricity

Section 3 : Cables and Busbar Trunking
1.17 Operation under fire conditions Systems

1.18 Additions and alterations 3.1 General

3.2 Conductors
Section 2 : System Design
3.3 Insulating materials
2.1 General
3.4 Construction
2.2 Supply and distribution systems
3.5 Testing
2.3 Voltage and frequency variations
3.6 Voltage rating
2.4 Earth indication
3.7 Choice of insulating material
2.5 Number, arrangement and capacity of
generators 3.8 Choice of protective covering

2.6 Prime movers for generators 3.9 Current rating

2.7 Number and capacity of transformers or 3.10 Correction factors for current rating
power convertors

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3.11 Installation of cables Section 7 : Miscellaneous Equipment

3.12 Mechanical protection of cables 7.1 Accumulator batteries

3.13 Earthing of metal coverings 7.2 Luminaries - construction and testing

3.14 Securing of cables 7.3 Accessories - Construction and testing

3.15 Penetration of bulkheads and decks by 7.4 Heating and cooking equipment
cables
7.5 Lightning conductors
3.16 Installation of cables in pipes and conduits

3.17 Installation of cables in refrigerated spaces Section 8 : Electric Propulsion Systems

3.18 Cables for alternating current 8.1 General

3.19 Cable ends 8.2 Excitation

3.20 Busbar trunking systems 8.3 Maneuvering controls

8.4 Cables
Section 4 : Switchgear and Control Gear
Assemblies 8.5 Overload and short circuit protection

4.1 Main and emergency switchboards 8.6 Earth leakage detection

4.2 Distribution switchboards 8.7 Discharge protection

4.3 Navigation lights 8.8 Safety devices

4.4 Control gear 8.9 Electro-magnetic couplings

4.5 Testing 8.10 Alarms

8.11 Identification
Section 5 : Rotating Machines - Construction
and Testing
Section 9 : Fire Safety Systems
5.1 General
9.1 Fire detection and alarm systems
5.2 Rating
9.2 Automatic sprinkler system
5.3 Temperature rise
9.3 Fire pumps
5.4 Generator control
9.4 Fire safety stops
5.5 Overloads
9.5 Installation of electrical and electronic
5.6 Brushgear equipment in engine rooms protected by fixed
water-based local application fire-fighting
5.7 Inspection and testing systems (FWBLAFFS)

Section 6 : Converting Equipment Section 10 : Crew and Passenger Emergency

Safety Systems
6.1 Transformers
10.1 Emergency lighting
6.2 Semiconductor equipment
10.2 General emergency alarm system

10.3 Public address system

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12.13 Requirements of electrical equipment
allowed in paint stores and in the enclosed
Section 11 : Ship Safety Systems spaces leading to paint stores

11.1 Watertight doors

Section 13 : High Voltage Systems
11.2 Shell doors, loading doors and other
closing appliances 13.1 Scope

13.2 High voltage and low-voltage segregation

Section 12 : Electrical Equipment for use in
Explosive Gas / Combustible Dust 13.3 System design
Atmospheres
13.4 Degrees of protection
12.1 General
13.5 Air clearances
12.2 Selection of equipment
13.6 Creepage distances
12.3 Installation of electrical equipment and
cabling 13.7 Protection

12.4 Dangerous zones and spaces 13.8 Rotating machinery

12.5 Semi-enclosed spaces 13.9 Power Transformers

12.6 Ventilation 13.10 Cables

12.7 Pressurisation 13.11 Switchgear and controlgear assemblies

12.8 Cable and cable installation 13.12 Auxiliary systems

12.9 Requirements for tankers intended for the 13.13 Installation

carriage in bulk of oil cargoes having a flash
point not exceeding 60°C (closed cup test)
Section 14 : Trials
12.10 Requirements for ships for the carriage of
liquefied gases in bulk 14.1 General

12.11 Requirements for ships intended for the 14.2 Insulation resistance measurement
carriage in bulk of other flammable liquid
cargoes 14.3 Earth continuity

12.12 Special requirements for ships with 14.4 Performance

spaces for carrying vehicles with fuel in their
tanks, for their own propulsion 14.5 Voltage drop

Chapter 9 : Deleted

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Chapter 10 : Requirements for Fusion Welding

Section 1 : General 2.6 Routine tests for Class 3 fusion welded

pressure vessels
1.1. Scope
2.7 Construction and workmanship
1.2. General requirements for welding plant and
welding quality 2.8 Non-destructive examination of fusion
welded pressure vessels

Section 2 : Fusion Welded Pressure Vessels 2.9 Repairs to welded seams on fusion welded
pressure vessels
2.1 Manufacture of Class 1 and Class 2 fusion
welded pressure vessels 2.10 Post-weld heat treatment of pressure
vessels
2.2 Manufacture of Class 3 fusion welded
pressure vessels
Section 3 : Welded Pressure Pipes
2.3 Preliminary tests for Class 1 and Class 2
fusion welded pressure vessels 3.1 General

2.4 Preliminary tests for Class 3 fusion welded 3.2 Non-destructive examination of welded
pressure vessels pipes

2.5 Routine tests for Class 1 and Class 2 fusion 3.3 Post-weld heat treatment
welded pressure vessels
3.4 Heat treatment after forming of pipes

Chapter 11 : Spare Gear

Section 1 : General Requirements Section 2 : Spare Parts Recommended for

Main and Auxiliary Machinery Installations
1.1 General
2.1 List of minimum required spare parts

End of Chapter

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Chapter 1

General Requirements for the Design and Construction of Machinery

Contents
Section

1 General
2 Machinery Room Arrangements
3 Trials
4 Certification of Machinery and Components Based upon
Quality Management Systems

Section 1

General

1.1 Scope - Auxiliary engines which are the source of

power for services essential for safety or for
1.1.1 The Chapters of this Part cover the the operation of the ship at sea;
construction and installation of main propulsion
and auxiliary machinery systems, together with - Steering machinery;
their associated equipment, boilers, pressure
vessels and pumping and piping arrangements - Athwartship thrust units, their prime movers
fitted in vessels classed or intended to be and control mechanisms;
classed with IRS.
- All pumps necessary for the operation of
1.2 Machinery to be constructed under vessel, main propulsion and essential
survey machinery, e.g. boiler feed, cooling water
circulating, condensate extraction, oil fuel,
1.2.1 In ships intended to be built under Special lubricating oil, etc.;
Survey, all important units of equipment are to
be surveyed at the manufacturer's works. The - All heat exchangers necessary for the
workmanship is to be to the Surveyor's operation of main propulsion and essential
satisfaction and the Surveyor is to be satisfied machinery, e.g. air, water and lubricating oil
that the components are suitable for the coolers, oil fuel and water heaters, de-
intended purpose and duty. Examples of such aerators and condensers, evaporators and
units are : distiller units;

- Main propulsion engines, including their - Air compressors, air receivers and other
associated gearing, flexible couplings, pressure vessels necessary for the
scavenge blowers and superchargers; operation of main propulsion and essential
machinery. Any other unfired pressure
- Boilers supplying steam for propulsion or for vessels for which plans are required to be
services essential for the safety or the submitted for approval in accordance with
operation of the ship at sea, including the requirements of Ch.5;
superheaters, economisers, desuper-
heaters, steam receivers. All other boilers - Alarm and control equipment as detailed in
having working pressures exceeding 0.34 Ch.7;
[N/mm2], and having heating surfaces
greater than 4.65 [m2]; - Electrical equipment and electrical
propelling machinery as detailed in Ch.8.

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Page 2 of 8 General Requirements for the Design and Construction of Machinery

- All pumps essential for safety of the ship, in operation and in restoring the propulsion, no
e.g. fire, bilge and ballast pumps; and stored energy for starting and operating the
propulsion plant, the main source of electrical
- Valves and other components detailed in power and other essential auxiliaries is assumed
Ch.2. to be available. In order to restore operation
from the "dead ship" condition, an emergency
1.3 Extent of survey generator complying with the requirements of
Pt.4, Ch.8, Cl.2.8 may be used provided that the
1.3.1 The Surveyors are to examine and test the emergency power supply from it is available at
materials and workmanship from the all times. It is assumed that means are available
commencement of work until the final test of the to start the emergency generator at all times.
machinery under full power working conditions.
Any defects, etc., are to be indicated as early as 1.6.2 "Blackout" is a sudden loss of electric
possible. power in the main distribution system. All means
of starting by stored energy are available.
1.3.2 Where items of machinery are
manufactured as individual or series produced 1.7 Environmental conditions
units, IRS would be prepared to give
consideration to the adoption of a survey 1.7.1 All components and systems covered by
procedure based upon quality assurance the Rules are to be designed to operate under
concepts as detailed in Sec.4. the following environmental conditions if not
otherwise specified in the detailed requirements
1.4 Departures from the rules for the component or system:

1.4.1 Where it is proposed to depart from the - ambient air temperature in the machinery
requirements of the Rules, IRS will be prepared space between 0°C and 55°C;
to give due consideration to the circumstances
of any special case. - relative humidity of air in the machinery
space up to 96 per cent;
1.4.2 Any novelty in the construction of the
machinery, boilers or pressure vessels is to be - sea water temperature up to 32°C; and
reported to IRS.
- list, rolling, trim and pitch in accordance with
1.5 Plans and particulars Table 1.7.1.

1.5.1 Before the work is commenced, plans in 1.7.2 Where the Rules have requirements for
triplicate of all machinery items, as detailed in capacity or effect of machinery, these are to be
relevant Chapters of this Part giving the based on a total barometric pressure of 1 bar,
requirements for individual systems, are to be an engine room ambient temperature or suction
submitted for approval. The particulars of the air temperature of 45°C, a relative humidity of 60
machinery, including power ratings and design per cent and a sea water temperature or where
calculations, where applicable, necessary to applicable the temperature of the charge air
verify the design, are also to be submitted. Any coolant at inlet of 32°C. The engine
subsequent modifications are subject to manufacturer is not expected to provide
approval before being put in to operation. simulated ambient reference conditions at test
bed.
1.5.2 The strength requirements for rotating
parts of the machinery, as specified in relevant 1.7.3 In the case of ships to be classed for
Chapters of this Part, are based upon strength restricted service, the rating is to be suitable for
consideration only and their application does not the temperature conditions associated with the
relieve the manufacturer from the responsibility geographical limits of the restricted service.
for the presence of dangerous vibrations in the
installation at speeds within the operating range. 1.7.4 Where electrical equipment is installed
within environmentally controlled spaces the
1.6 Availability of machinery for operation ambient temperature for which the equipment is
suitable may be reduced from 45°C to a value
1.6.1 Ship's machinery is to be so arranged that not less than 35°C provided:
it can be brought in to operation from the "dead
ship" condition using only the facilities available - The equipment is not for use for emergency
on board. "Dead ship" condition is understood to services.
mean a condition under which the main
propulsion plant, boilers and auxiliaries are not

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Table 1.7.1 : Machinery inclinations

Angle of inclination 1
Installations/Components Athwartships Fore and aft
Static Dynamic Static Dynamic

Main and auxiliary machinery 15° 22.5° 5°4 7.5°

Safety equipment
e.g. emergency power installations,
emergency fire pumps and their devices 22.5°3 22.5°3 10° 10°
Switch gear, electric and electronic
appliances2 and remote control systems

Notes

1 Athwartships and fore and aft inclinations occur simultaneously.

2 Switches and controls are to remain in their last set position. Upto an angle of inclination of 45° no
undesired switching operations or operational changes may occur.

3 In ships for the carriage of liquefied gases and of chemicals the emergency power supply must also
remain operable with the ship flooded to a final athwartships inclination upto maximum of 30°.

4 For ships where Rule length (L) exceeds 100 [m], the fore and aft static angle of inclination can be
taken as 500/L degrees.

5 Any deviations from these angles of inclination taking into consideration the size and service
conditions of the ship will be specially considered.

1.8 Power ratings

- Temperature control is achieved by at least
two cooling units so arranged that in the 1.8.1 In the following Chapters, where the
event of loss of one cooling unit, for any dimensions of any particular component are
reason, the remaining unit(s) is capable of determined from shaft power, P in kW, and
satisfactorily maintaining the design revolutions per minute, R, the values to be used
temperature. are to be derived from the following:

- The equipment is able to be initially set to - For main propulsion machinery, the
work safely within a 45°C ambient maximum shaft power and corresponding
temperature until such a time that the lesser revolutions per minute giving the maximum
ambient temperature may be achieved. The torque for which the machinery is to be
cooling equipment is to be rated for a 45°C classed; and
ambient temperature.
- For auxiliary machinery, the maximum
- Audible and visual alarms are provided, at a continuous shaft power and corresponding
continually manned control station, to revolutions per minute which will be used in
indicate any malfunction of the cooling units. service.

- It is to be ensured that electrical cables for 1.9 Units

their entire length are adequately rated for
the maximum ambient temperature to which 1.9.1 Units and formulae included in the Rules
they are exposed along their length. are shown in SI units.

- The equipment used for cooling and 1.9.2 Where the metric version of shaft power,
maintaining the lesser ambient temperature i.e. (shp), appears in the Rules, 1 shp is
is to be classified as a secondary essential equivalent to 75 [kgf] [m/sec] or 0.735 [kW].
service, as defined in Ch.8, sec.1.
1.9.3 Pressure gauges may be calibrated in bar

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where, 1.11.2 For emergency generator engines, fuel

having a flash point (closed cup test) of not less
1 bar = 0.1 [N/mm2] = 1.02 [kgf/cm2]. than 43°C may be used.

1.10 Astern power 1.11.3 Fuels with flash points lower than 60°C,
but not less than 43°C unless specially
1.10.1 In order to maintain sufficient approved, may be used in ships intended for
maneuverability and secure control of the ship in service restricted to geographical limits where it
all normal conditions, the main propulsion can be ensured that the temperature of the
machinery is to be capable of reversing the machinery and boiler spaces will always be
direction of thrust so as to bring the ship to rest 10°C below the flash point of fuel. In such
from the maximum service speed. The main cases, safety precautions and the arrangements
propulsion machinery is to be capable of for storage and pumping will be specially
maintaining in free route astern at least 70% of considered. (Also refer Pt.6, Ch.2, 1.2.1).
the ahead revolutions.
1.11.4 The use of fuels having a lower flash
1.10.2 Where steam turbines are used for main point than specified in 1.11.1 to 1.11.3 as
propulsion, they are to be capable of applicable may be permitted provided that such
maintaining in free route astern at least 70% of fuel is not stored in any machinery space and
the ahead revolutions for a period of at least 15 arrangements for the complete installation are
minutes. The astern trial is to be limited to 30 specially approved.
minutes or in accordance with manufacturer’s
recommendation to avoid overheating of the 1.11.5 For engines operating on "boil-off"
turbine due to the effects of “windage” and vapours from the cargo, the arrangements will
friction. be specially considered.
1.10.3 For main propulsion systems with 1.12 Materials
reversing gears, controllable pitch propeller or
electric propeller drive, running astern is not to 1.12.1 The materials used in the construction
lead to overload of the propulsion machinery. are to be manufactured and tested in
accordance with the requirements of Pt.2 of the
1.10.4 The ahead revolutions as mentioned Rules. Materials for which provision is not made
above are understood as those corresponding to therein may be accepted, provided that they
the maximum continuous ahead power for which comply with an approved specification and such
the vessel is classed. tests as may be considered necessary.
1.10.5 The reversing characteristics of the 1.12.2 Installation of material which contain
propulsion plant are to be demonstrated and asbestos is prohibited.
recorded during trials.
1.13 Alternative design and arrangements
1.11 Fuel
1.13.1 The Rules generally cover the
1.11.1 The flash point (closed cup test) of oil fuel requirements of SOLAS Ch.II-1, Parts C, D and
for use in ships classed for unrestricted service, E. Design and arrangements alternative to these
in general, is not to be less than 60°C. requirements may be accepted based on
SOLAS Reg. II-1/55 and MSC.1/Circ. 1212.

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Section 2

Machinery Room Arrangements

2.1 General silencers or other equipment required to be

insulated and electrical equipment, as far as
2.1.1 The machinery is to be so designed, practicable. In particular, oil fuel filters under
installed and protected that risks of fire, pressure for diesel engines are to be
explosions, accidental pollution, leakages and located such that in the event of leakage, oil
accidents thereof, and accidents to personnel cannot be sprayed on to the exhaust
working in machinery spaces will be minimised. manifold.

2.1.2 The design and arrangement of machinery c) Oil filters fitted in parallel for the purpose of
foundations, shaft connections, piping and enabling cleaning without disturbing oil
ducting is to take into account the effects of supply to engines (e.g. duplex filters) are to
thermal expansion, vibrations, mis-alignment be provided with arrangements that will
and hull interaction to ensure operation within minimise the possibility of a filter under
safe limits. pressure being opened by mistake.
Filter/filter chambers are to be provided with
Bolts and nuts exposed to dynamic forces and suitable means for :
vibrations are to be properly secured.
- venting when put in to operation; and
2.2 Accessibility
- depressurizing before being opened.
2.2.1 Accessibility, for attendance and
maintenance purposes, is to be provided for Valves or cocks with drain pipes led to a
machinery plants. safe location are to be used for this
purpose.
2.3 Fire protection
d) Hydraulic units with working pressure above
2.3.1 All surfaces of machinery where the 15 bar are preferably to be placed in
surface temperature may exceed 220°C, e.g., separate spaces. If it is impracticable to
steam and exhaust gas lines, silencers, boilers, locate such units in separate space,
exhaust gas boilers, turbo blowers, etc. are to adequate shielding is to be provided.
be effectively shielded to prevent ignition of
combustible materials coming in to contact with 2.3.4 Flammable or oil absorbing materials are
them. Where insulation covering these surfaces not to be used in floors, gratings, etc. in boiler
is oil absorbing or may permit penetration of oil, and engine rooms, shaft tunnels or in
the insulation is to be encased in steel or its compartments where settling tanks are installed.
equivalent.
2.3.5 Segregation of oil fuel purifiers
2.3.2 The insulation is to be of a type and so
supported that it will not crack or deteriorate a) Oil fuel purifiers for heated oil are to be in
when subjected to vibration. separate room enclosed by steel bulkheads
extending from deck to deck and provided
2.3.3 Oil spillages coming into contact with hot with self-closing steel doors.
surfaces, electrical installations or other sources
of ignition. b) The room is to be provided with :

a) Precautions (e.g. shielding) are to be taken - independent mechanical ventilation or a

to prevent oil that may escape under ventilation arrangement which can be
pressure from any pump, filter or heater or isolated from the machinery space
piping from coming into contact with sources ventilation;
of ignition.
- fire detecting system; and
b) Oil tanks, pipes, filters, heaters, etc. are not
to be located immediately above or near - fixed fire extinguishing installation.
units of high temperature including boilers,
steam pipe lines, exhaust manifolds,
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The extinguishing installation is to be 2.5 Communications

capable of being activated from outside the
room. Closing of ventilation openings is to 2.5.1 At least two independent means of
be effected from a position close to where communication are to be provided between the
the extinguishing system is activated. The bridge and engine room control station from
extinguishing system is to be separate for which the engines are normally controlled.
the room, but may be part of the main fire
extinguishing system for the machinery One of these means is to visually indicate the
spaces. order and response, both at the engine room
control station and on the bridge.
c) If it is impracticable to locate the oil fuel
purifiers in a separate space, IRS will give 2.5.2 At least one means of communication is to
special consideration with regard to location, be provided between the bridge and any other
containment of possible leakages, shielding control position(s) from which the propulsion
and ventilation. A local fixed fire machinery may be controlled.
extinguishing system is to be provided
which is to be capable of being activated 2.5.3 Propulsion machinery orders from the
manually from the machinery control navigation bridge are to be indicated in the main
position or from other suitable location. If machinery control room and at the manoeuvring
automatic release is provided, additional platform.
manual release is to be arranged.
2.6 Machinery controls
2.4 Ventilation
2.6.1 Main and auxiliary machinery essential for
2.4.1 All spaces, including engine and cargo the propulsion, control and safety of ship are to
pump spaces, where flammable or toxic gases be provided with effective means for its
or vapours may accumulate, are to be provided operation and control. All control systems
with adequate ventilation under all conditions. essential for the propulsion, control and safety of
the ship are to be independent or designed such
2.4.2 Machinery spaces in particular are to be that failure of one system will not affect the
adequately ventilated so that a sufficient supply performance of the other system.
of air is maintained for operation of the
machinery, when machinery or boilers are 2.6.2 Where remote control of propulsion
operating at full power in all weather conditions machinery from the navigating bridge is
including heavy weather. provided, the control is to be performed by a
single control device for each independent
The openings on deck through which the air is propeller, with automatic control of all
supplied to machinery space should be suitably associated services, including, where
protected, in such a way that they can supply air necessary, means of preventing overload of the
in all weather conditions. propulsion machinery.

Section 3

Trials

3.1 General to demonstrate that any vibration which may

occur within the operating speed range is
3.1.1 Tests of components and trials of acceptable.
machinery, as detailed in the Chapters giving
the requirements for individual systems are to 3.2.2 The trials are to include demonstrations of
be carried out to the satisfaction of the the following :
Surveyors.
- The adequacy of the starting arrangements
3.2 Sea trials to provide the required number of starts of
the main engines;
3.2.1 For all types of installations, the sea trials
are to be of sufficient duration, and carried out - The ability of the machinery to reverse the
under normal maneuvering conditions, to prove direction of thrust of the propeller in
the machinery under power. The trials are also sufficient time, under normal maneuvering

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conditions, and so bring the ship to rest from The marking is to indicate freedom from hard
maximum ahead rated speed; and bearing, particularly towards the end of the
teeth, including both ends of each helix where
- In turbine installations, the ability to permit applicable.
astern running at 70 per cent of the full
power ahead revolutions without adverse 3.2.5 The stopping times, ship headings and
effects. The astern trial need not be of more distances recorded on trials, together with the
than 30 minutes duration. results of trials to determine the ability of ships
having multiple propellers to navigate and
3.2.3 Where controllable pitch propellers are maneuver with one or more propellers
fitted, the free route astern trial is to be carried inoperative, are to be available on board for the
out with the propeller blades set in full pitch use of the master or designated personnel.
astern position. Where emergency manual pitch
setting facilities are provided, their operation is 3.2.6 Where the ship is provided with
to be demonstrated to the satisfaction of the supplementary means for maneuvering or
Surveyors. stopping, the effectiveness of such means is to
be demonstrated and recorded as referred to in
3.2.4 In geared installations, prior to full power 3.2.5.
sea trials, the gear teeth are to be suitably
coated to demonstrate the contact markings, 3.2.7 All trials are to be to Surveyor's
and on conclusion of sea trials all gears are to satisfaction.
be opened up sufficiently to permit the
Surveyors to make an inspection of the teeth.

Section 4

Certification of Machinery and Components Based upon

Quality Management Systems

4.1 General
4.1.5 Approval by another organization will not
4.1.1 This certification scheme is applicable to normally be acceptable as sufficient evidence
works where the employment of quality control that a manufacturer's arrangements comply with
procedures is well established. IRS will have to IRS requirements.
be satisfied that the practices employed will
ensure that the quality of finished products is to 4.2 Requirements for approval
the standards which would be demanded when
using traditional survey procedures. 4.2.1 The manufacturer is required to have
adequate equipment and facilities for those
4.1.2 IRS will consider proposed designs for operations appropriate to the level of design,
compliance with the Rules, or other appropriate development and manufacture being
requirements, and the extent to which the undertaken.
manufacturing processes and control
procedures ensure conformity of the product to 4.2.2 The manufacturer shall demonstrate that
the design. A comprehensive survey will be the firm has experience consistent with
made by the Surveyors of the actual operation technology and complexity of the product for
of the quality control programme and of the which approval is sought and that firm's
adequacy and competence of the staff to products have been of a consistently high
implement it. standard.

4.1.3 Where IRS considers that the 4.2.3 The manufacturer should have
requirements of 4.1.2 can be satisfactorily implemented quality management systems
complied with, the manufacturers will, in generally in accordance with the ISO 9000
general, be approved and authorized to inspect series of standards.
and certify their products.
4.2.4 The manufacturer shall establish and
4.1.4 The procedures and practices of maintain procedures and controls to ensure that
manufacturers which have been granted IRS requirements for certification of materials
approval will be kept under continuous review.

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and components at sub-contractors's works are 4.4.3 An extension of approval in respect of

complied with to the satisfaction of IRS. product type may be given at the discretion of
IRS without any additional assessment.
4.3 Information required for approval
4.4.4 The certificate will be valid for 3 years
4.3.1 Manufacturers applying for approval under subject to surveillance assessments being
this scheme are to submit the following carried out every 6 months.
information :
4.4.5 When significant faults or deficiencies are
- Description of the products for which found during surveillance assessments or
certification is required including, where surveillance assessments are not carried out,
applicable, model or type number; the certificate of approval may be
withdrawn/suspended at the discretion of IRS.
- Applicable plans and details of materials
used; 4.5 Certification of products

- An outline description of all important 4.5.1 After issue of the Quality Assurance
manufacturing plant and equipment; Approval Certificate, the manufacturer would be
authorized to issue certificate for products on
- A summary of equipment used for behalf of IRS subject to the certificates being
measuring and testing during manufacturing countersigned by IRS Surveyors. Arrangements
and completion; for this will be specially advised by IRS.

- The quality manual; 4.6 Certification of diesel engines

- The system used for identification and 4.6.1 Certification of diesel engines based on
traceability; Quality Management Systems described in this
section can be considered only for diesel
- Number and qualification of personnel engines which have been type approved in
engaged in quality control and quality accordance with the IRS “Type approval
assurance; and certification scheme for machinery
manufactured by mass production system”.
- A list of suppliers of materials and Further, the requirements given in 4.6.2 and
components and proposed arrangements to 4.6.3 below are to be complied with in respect of
ensure compliance with IRS requirements certification of individual components of diesel
for certification. engines.

4.4 Approval and maintenance of approval 4.6.2 The following components are to be
manufactured under survey :
4.4.1 After receipt and appraisal of the
information required by 4.3, an assessment of a) Crank shaft
the Works would be carried out by the b) Connecting rods and Connecting rod bolts
Surveyors to ensure compliance with the quality c) Attached pumps and heat exchangers
manual.
4.6.3 For the following components, certificates
4.4.2 If the initial assessment of the Works submitted by the manufacturer may be accepted
confirms that the implementation of the quality
management systems is satisfactory, IRS will a) Camshaft
issue to the manufacturer a Quality Assurance b) Cylinder block
Approval Certificate which will include details of c) Cylinder liners
the products for which approval has been given. d) Pistons
e) Cylinder heads.

End of Chapter

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Chapter 2

Piping Design Requirements

Contents
Section

1 General
2 Carbon and Low Alloy Steel Pipes and Fittings
3 Copper and Copper Alloy Pipes and Fittings
4 Cast Iron Pipes and Fittings
5 Plastic Pipes and Fittings
6 Flexible Hoses
7 Hydraulic Tests on Pipes and Fittings

Section 1

General

1.1 Scope 1.2 Classes of pipes

1.1.1 The requirements of this Chapter apply to 1.2.1 For the purpose of testing, type of joints to
the design and construction of piping systems, be adopted, heat treatment and welding
including pipe fittings and valves forming parts procedure, piping systems are divided into three
of such systems for the following services: classes, as given in Table 1.2.1.

Air, vapour, gas (excluding liquefied gas cargo 1.3 Design pressure
and process piping), water, lubricating oil, fuel
oil, hydraulic fluid systems for steering gear, 1.3.1 The design pressure, P, is the maximum
toxic gas and liquids, cargo oil and tank cleaning permissible working pressure and is to be not
piping and open ended lines such as drains, less than the highest set pressure of the safety
overflows, vents and boiler escape pipes. valve or relief valve. For oil fuel pipes the design
pressure is to be taken in accordance with Table
1.1.2 The requirements of this Chapter do not 1.3.1. For gaseous fuel, the design pressure will
cover the following: be specially considered.

Exhaust pipes from internal combustion engines 1.3.2 In water tube boiler installations, the
and gas turbines, and pipes forming integral part design pressure for steam piping between the
of a boiler. boiler and integral superheater outlet is to be
taken as the design pressure of the boiler, i.e.
1.1.3 Hydraulic fluid systems other than those not less than the highest set pressure of any
for steering gear will be specially considered. safety valve on the boiler drum. For piping
leading from the superheater outlet, the design
1.1.4 For requirements pertaining to piping pressure is to be taken as the highest set
systems for liquefied gases (cargo and process) pressure of the superheater safety valves.
and cargo piping systems of ships carrying
chemicals in bulk reference should be made to
applicable Chapters of Pt.5 of the Rules.

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1.3.3 The design pressure of feed piping and restrict the pressure to a lower value than the
other piping on the discharge from pumps is to shut valve load, the design pressure is to be the
be taken as the pump pressure at full rated highest set pressure of the protective device.
speed against a shut valve. Where a safety
valve or other protective device is fitted to

Table 1.2.1 : Classes of piping systems 3,4

Piping system Class I Class II Class III

Without special
Toxic or corrosive media Not to be used Not to be used
safeguards
a) Flammable media
heated above flash
point2
b) Flammable media Without special
With special safeguards1 Not to be used
having flash point safeguards
2
below 60°C
c) Liquefied gas

Steam P > 16 or T > 300 16 ≥ P > 7 and 300 ≥ T > 170 P ≤ 7 and T ≤ 170
Thermal Oil P > 16 or T > 300 16 ≥ P > 7 and 300 ≥ T > 150 P ≤ 7 and T ≤ 150
Fuel oil + Lubricating oil +
P > 16 or T > 150 16 ≥ P > 7 and 150 ≥ T > 60 P ≤ 7 and T ≤ 60
Flammable hydraulic oil
Other media5 including
water, air, gases, non- P > 40 or T > 300 40 ≥ P > 16 and 300 ≥ T > 200 P ≤ 16 and T ≤ 200
flammable hydraulic oil

Notes:

1 Safeguards for reducing leakage possibility and limiting its consequences will be specially
considered e.g. leading pipes in positions where leakage of internal fluids will not cause a potential
hazard or damage to surrounding areas or by the usage of pipe ducts, shielding, screening etc.
2 Cargo oil pipes belong to Class III piping systems.
3 P = Design pressure in bar as defined in 1.3
4 T = Design temperature in °C as defined in 1.4.
5 For open ended pipes (drains, overflow, vents, exhaust gas lines, boiler escape lines, etc.)
irrespective of the temperature, Class III pipes may be used.

Table 1.3.1 : Definition of the design pressure for fuel oil systems

Working T ≤ 60°C T > 60°C

temperature

Working
Pressure (WP)
WP ≤ 7 bar 3 bar or max. working pressure, 3 bar or max. working pressure,
whichever is greater whichever is greater
WP > 7 bar Max. working pressure 14 bar or max. working pressure,
whichever is greater

1.4 Design temperature special cases the design temperature will be

specially considered.
1.4.1 The design temperature is to be taken as
the maximum temperature of the internal fluid, 1.4.2 In the case of pipes for superheated
but in no case is it to be less than 50°C. For steam, the temperature is to be taken as the

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designed operating steam temperature for the pipes which are considered to be equivalent to
pipeline, provided that the temperature at the seamless pipes. Where other methods of pipe
superheater outlet is closely controlled. Where manufacture are proposed, the value of e will be
temperature fluctuations exceeding 15°C above specially considered.
the designed temperature are to be expected in
normal service, the steam temperature to be 1.6 Heat treatment
used for determining the allowable stress is to
be increased by the amount of this excess. 1.6.1 Method of heat treatment and means of
temperature control and recording are to be to
1.5 Design symbols the satisfaction of Surveyors.

1.5.1 The symbols used in this Chapter are 1.7 Minimum thickness of pipes and bends
defined as follows:
1.7.1 The minimum thickness, t, of straight pipes
a = percentage negative manufacturing is to be determined by the following formula
tolerance on thickness; when ratio of outside-diameter to inside-
diameter does not exceed the value 1.7:-
b = bending allowance [mm];
⎛ PD ⎞ 100
c = corrosion allowance [mm]; t =⎜ + c⎟ [mm]
⎝ 20Ke + P ⎠ 100 − a
D = outside diameter of pipe [mm] (see 1.5.2);
where,
d = inside diameter of pipe [mm] (see 1.5.3);
P, D, e and a are defined in 1.5.1.
e = weld efficiency factor (see 1.5.4);
The maximum permissible design stress, K, is to
P = design pressure, in bar; be taken as the lowest of the following values:-

Pt = hydraulic test pressure, in bar; Et R S

K= or 20 or R or σ 1 / 100,000 / 1
R = radius of curvature of a pipe bend at the 1.6 2.7 1.6
centreline of the pipe [mm];
where,
T = design temperature, in °C;
σ1/100,000/1 = average stress [N/mm2] to produce
t = the minimum thickness of a straight pipe 1% creep in 100,000 hrs at the design
[mm], including corrosion allowance and temperature.
negative tolerance, where applicable;
Et = specified minimum lower yield or 0.2 per
tb = the minimum thickness of a straight pipe to cent proof stress at the design temperature
be used for a pipe bend [mm]; including bending
allowance, corrosion allowance and negative R20 = specified minimum tensile strength at
tolerance, where applicable; ambient temperature

K = maximum permissible design stress SR = average stress to produce rupture in

[N/mm2]. 100,000 hours at the design temperature.

1.5.2 The outside diameter, D, is subject to Value of K may be obtained from Sec.2, Table
manufacturing tolerance, but these are not to be 2.1.1 and Table 2.1.2 for carbon and low alloy
used in the evaluation of formulae. steel pipes and fittings or from Sec.3, Table
3.2.1 for copper and copper alloys pipes and
1.5.3 The inside diameter, d, is not to be fittings.
confused with nominal size, which is an
accepted designation associated with outside c is obtained from Sec.2, Table 2.2.1 for carbon
diameters of standard rolling sizes. and low alloy steel pipes and fittings or from
Sec.3, Table 3.2.3 for copper and copper alloys
1.5.4 The weld efficiency factor, e, is to be taken pipes and fittings.
as 1.0 for seamless and electric resistance and
induction welded steel pipes delivered by 1.7.2 Where it is proposed to use, for high
manufacturers approved for making welded temperature service, alloy steels other than
those detailed in Sec.2, particulars of the tube

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sizes, design conditions and appropriate with recognised national/international standards.

national or proprietary material specifications For special applications, the dimensions of the
are to be submitted for consideration. flanges and related bolts, will be specially
considered.
1.7.3 The minimum thickness, tb, of a straight
steel pipe to be used for a pipe bend is to be 1.8.2 Gaskets are to be suitable for the medium
determined by the following formula, except being conveyed under design pressure and
where it can be demonstrated that the use of a temperature conditions and their dimensions
thickness less than tb would not reduce the and configurations are to be in accordance with
thickness below 't' at any point after bending:- a recognized standard and for the intended
service.
⎛ PD ⎞ 100
tb = ⎜ + b + c⎟ [mm] 1.9 Materials
⎝ 20Ke + P ⎠ 100 − a
1.9.1 Materials for ferrous castings and forgings
where, of Class I and Class II piping systems are to be
produced at Works approved by IRS and are in
P, D, R, e, b and a are defined in 1.5.1; general to be tested in accordance with the
requirements of Pt.2 of the Rules.
K and c are defined in 1.7.1;
1.9.2 The manufacturer's test certificate for
D ⎛ PD ⎞ materials of valves and fittings will be accepted
b= ⎜ ⎟ [mm] in lieu of the IRS certificate provided the
2.5R ⎝ 20Ke + P ⎠ maximum conditions are less than given in
Table 1.9.1.
In general, R, is to be not less than 3D.
1.9.3 Pipes and bodies of valves, intended to be
1.7.4 Notwithstanding the requirements of 1.7.1 fitted on ship's side and bottom or on collision
and 1.7.3, the minimum thickness of pipes is not bulkhead, are to comply with the requirements
to be less than that indicated in Sec.2 or 3, as of Class II piping systems.
applicable. For threaded pipes, where permitted,
the minimum thickness is to be measured at the 1.9.4 Materials for Class III piping systems may
bottom of the thread. be manufactured and tested in accordance with
the requirements of an acceptable national/
1.8 Flanges international standard.

1.8.1 The dimensions of flanges and related

bolts, gaskets are to be chosen in accordance

Table 1.9.1 : Maximum conditions for valves and fittings for which manufacturer's test
certificate is acceptable

DN = Nominal Diameter [mm]

Material Working temp.°C
Pw = Working Pressure in bar
Carbon and low alloy steel
DN < 50 or
Spheroidal or nodular cast < 300
Pw x DN < 2500
iron
DN < 50 or
Copper alloy < 200
Pw x DN < 1500

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Section 2

Carbon and Low Alloy Steel Pipes and Fittings

2.1 Materials
2.2 Minimum thickness of steel pipes and
2.1.1 Pipes having forge butt welded longitudinal bends
seams are not to be used for oil fuel systems,
for heating coils in oil tanks, or for pressures 2.2.1 The minimum thickness of steel pipes and
exceeding 4.0 bar. bends is to be higher of that calculated by
Sec.1, Cl.1.7 and that indicated in Table 2.2.2,
2.1.2 Steel pipes, valves and fittings may be Table 2.2.3 or Table 2.2.4 as applicable.
used within the temperature limits indicated in
Table 2.1.1 and Table 2.1.2. Where rimming 2.2.2 The value of 'c' to be used in Sec.1, Cl.1.7
steel is used for pipes manufactured by electric is to be in accordance with Table 2.2.1
resistance or induction welding processes, the
design temperature is limited to 400°C.

Table 2.1.1 : Carbon and carbon-manganese steel pipes

Specified 2
Maximum permissible stress [N/mm ]
min.
tensile Maximum design temperature °C
strength
[N/mm ]
2 50 100 150 200 250 300 350 400 410 420 430 440 450
320 107 105 99 92 78 62 57 55 55 54 54 54 49
360 120 117 110 103 91 76 69 68 68 68 64 56 49
410 136 131 124 117 106 93 86 84 79 71 64 56 49
460 151 146 139 132 122 111 101 99 98 85 73 62 53
490 160 156 148 141 131 121 111 109 98 85 73 62 53

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Table 2.1.2 : Alloy steel pipes

2
Specified Minimum permissible stress [N/mm ]
min. tensile
Type of steel strength Maximum design temperature °C
2
[N/mm ] 50 100 200 300 350 400 440 450 460 470
1 Cr 1/2 Mo 440 159 150 137 114 106 102 101 101 100 99
2 1/4 Cr 1 Mo
410 76 67 57 50 47 45 44 43 43 42
annealed
2 1/4 Cr 1 Mo
normalised and 490 167 163 153 144 140 136 130 128 127 116
tempered (Note 1)
2 1/4 Cr 1 Mo
normalised and 490 167 163 153 144 140 136 130 122 114 105
tempered (Note 2)
1/2 Cr 1/2 Mo 1/4 V 460 166 162 147 120 115 111 106 105 103 102
Maximum design temperature °C
480 490 500 510 520 530 540 550 560 570
1 Cr 1/2 Mo 440 98 97 91 76 62 51 42 34 27 22
2 1/4 Cr 1 Mo
410 42 42 41 41 41 40 40 40 37 32
annealed
2 1/4 Cr 1 Mo
normalised and 490 106 96 86 76 67 58 49 43 37 32
tempered (Note 1)
2 1/4 Cr 1 Mo
normalised and 490 96 88 79 72 64 56 49 43 37 32
tempered (Note 2)
1/2 Cr 1/2 Mo 1/4 V 460 101 99 97 94 82 72 62 53 45 37

Notes:

1 Maximum permissible stress values applicable when the tempering temperature does not exceed 750°C.

2 Maximum permissible stress values applicable when the tempering temperature exceeds 750°C.

Table 2.2.1 : Values of 'c' for steel pipes

Piping service c [mm] (See Notes 1,2, 3)

Superheated steam systems 0.3
Saturated steam systems 0.8
Steam coil systems in cargo tanks 2.0
Feed water for boilers in open circuit systems 1.5
Feed water for boilers in closed circuit systems 0.5
Blow down (for boilers) systems 1.5
Compressed air systems 1.0
Hydraulic/lubricating oil systems 0.3
Fuel oil systems 1.0
Cargo oil systems 2.0
Refrigerating plants 0.3
Fresh water systems 0.8
Sea water systems, in general 3.0

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Table 2.2.1 (Contd.)

Notes:

1 For pipes passing through tanks an additional corrosion allowance is to be considered according to
the figures given in Table and depending upon the external medium in order to account for the
external corrosion.
2 The corrosion allowance may be reduced where pipes and any integral pipe joints are protected
against corrosion by means of coating, lining etc., however, the reduction is not to be more than 50
percent in any case.
3 In the case of use of special alloy steel with sufficient corrosion resistance, the corrosion allowance
may be reduced to zero.

Table 2.2.2 : Minimum wall thickness for steel pipes 11 [All dimension in mm]

Nominal External Pipes in Venting Bilge ballast Bilge, air, overflow

size diameter D general 3, 4, overflow and and general and sounding pipes
6, 8, 9, 10
sounding sea water passing through
pipes for pipes 1, 3-8 ballast and fuel tanks,
structural ballast lines through
tanks 1-4, 6, 8 fuel tanks and fuel
lines through ballast
1-8
tanks
6 10.2 1.6
12 1.6
8 13.5 1.8
10 17.2 1.8
19.3 1.8
20 2
15 21.3 2 3.2
25 2 3.2
20 26.9 2 3.2
25 33.7 2 3.2
38 2 4.5 3.6 6.3
32 42.4 2 4.5 3.6 6.3
44.5 2 4.5 3.6 6.3
40 48.3 2.3 4.5 3.6 6.3
51 2.3 4.5 4 6.3
50 60.3 2.3 4.5 4 6.3
63.5 2.3 4.5 4 6.3
70 2.6 4.5 4 6.3
65 76.1 2.6 4.5 4.5 6.3
82.5 2.6 4.5 4.5 6.3
80 88.9 2.9 4.5 4.5 7.1
90 101.6 2.9 4.5 4.5 7.1
108 2.9 4.5 4.5 7.1
100 114.3 3.2 4.5 4.5 8
127 3.2 4.5 4.5 8
133 3.6 4.5 4.5 8
125 139.7 3.6 4.5 4.5 8
152.4 4 4.5 4.5 8.8
150 168.3 4 4.5 4.5 8.8
177.8 4.5 5 5 8.8
175 193.7 4.5 5.4 5.4 8.8
200 219.1 4.5 5.9 5.9 8.8
225 244.5 5 6.3 6.3 8.8

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Table 2.2.2 (Contd.)

Nominal External Pipes in Venting Bilge ballast Bilge, air, overflow

size diameter D general 3, 4, overflow and and general and sounding pipes
6, 8, 9, 10
sounding sea water passing through
pipes for pipes 1, 3-8 ballast and fuel tanks,
structural ballast lines through
1-4, 6, 8
tanks fuel tanks and fuel
lines through ballast
tanks 1-8
250 273 5 6.3 6.3 8.8
298.5 5.6 6.3 6.3 8.8
300 323.9 5.6 6.3 6.3 8.8
350 355.6 5.6 6.3 6.3 8.8
368 5.6 6.3 6.3 8.8
400 406.4 6.3 6.3 6.3 8.8
450 457.2 6.3 6.3 6.3 8.8
Notes:
1 IRS may accept reduction in thickness of pipes by an amount not exceeding 1 mm for pipes
efficiently protected against corrosion.
2 For sounding pipes, except for those for cargo tanks with cargo having a flash point less than 60°C,
the minimum wall thickness is to apply to the part outside the tank.
3 For threaded pipes, where permitted, the minimum wall thickness is to measured at the bottom of
the thread.
4 The external diameters and thicknesses have been selected from ISO recommendations R 336 for
welded and seamless steel pipes. For pipes covered by other standards, slightly less thicknesses
may be accepted.
5 The minimum wall thickness for bilge lines and ballast lines through deep tanks will be specially
considered. See Pt.5 for thickness of ballast lines passing through oil cargo tanks.
6 The minimum wall thickness for pipes larger than 450 [mm] nominal size is to be in accordance with
a national or international standard and in any case not less than the minimum wall thickness
indicated for 450 [mm] pipe size.
7 The minimum internal diameter for bilge, sounding, air and overflow pipes shall be 50 [mm], 32 [mm]
and 50 [mm] respectively.
8 In general the minimum thickness given in this table is the nominal wall thickness and no allowance
need be made for negative tolerance and reduction in thickness due to bending.
9 Minimum wall thickness of exhaust gas pipes will be specially considered.
10 Minimum wall thickness for cargo oil lines will be specially considered.
11 This table is not applicable to air pipes above weather deck, scuppers and discharges which are
covered by loadline convention and also to pipes covered by Table 2.2.3.

Table 2.2.3 : Minimum wall thickness for steel pipes for CO2 fire extinguishing

From bottles to distribution From distribution station to

External diameter D [mm]
station nozzles
21.3 - 26.9 3.2 2.6
30 - 48.3 4 3.2
51 - 60.3 4.5 3.6
63.5 - 76.1 5 3.6
82.5 - 88.9 5.6 4
101.6 6.3 4
108 - 114.3 7.1 4.5
127 8 4.5
133 - 139.7 8 5
152.4 - 168.3 8.8 5.6

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Table 2.2.3 (Contd.)

Notes:

1 Pipes are to be galvanised at least internally, except those fitted in the engine room where
galvanising may be dispensed with.
2 For threaded pipes, where allowed, the minimum wall thickness is to be measured at the bottom of
the thread.
3 The external diameters and thicknesses have been selected from ISO recommendations R 336 for
smooth welded and seamless steel pipes. For pipes covered by other standards, slightly less
thickness may be accepted.
4 For larger diameters, the minimum wall thickness will be specially considered.
5 In general, the minimum thickness is the nominal wall thickness and no allowance need be made for
negative tolerance and reduction in wall thickness due to bending.

Table 2.2.4 : Minimum wall thickness for austenitic stainless steel pipes

External diameter D Minimum wall External diameter D Minimum wall

[mm] thickness [mm] [mm] thickness [mm]
10.2 to 17.2 1.0 219.1 2.6
21.3 to 48.3 1.6 273.0 2.9
60.3 to 88.9 2.0 323.9 to 406.4 3.6
114.3 to 168.3 2.3 Over 406.4 4.0
Note : Diameters and thicknesses according to national or international standard may be accepted.

2.3 Types of connection attached to the branches by screwing and

expanding or by welding. Alternative methods of
2.3.1 Pipe lengths may be joined by flange attachment may be accepted provided
details are submitted for consideration.
- screwed-on or welded on bolted flanges
- Butt welds between pipes or between pipes 2.4.3. Examples of accepted flanged
and valve chests or other fittings connections and their uses are given in Fig.2.4.1
- Socket weld joints and Table 2.4.1 respectively.
- Threaded sleeve joints
- Mechanical joints. 2.4.4 Where flanges are secured by screwing,
as indicated in Fig.2.4.1, the pipe and flange are
and are to be to a recognized standard or of a to be screwed with a vanishing thread and the
design proven to be suitable for the intended diameter of the screwed position of pipe over
purpose. the thread is not to be appreciably less than the
outside diameters of the unscrewed pipe. After
2.4 Flange connections the flange has been screwed hard home, the
pipe is to be expanded into the flange.
2.4.1 Flange attachments are to be in
accordance with recognized national or The vanishing thread on a pipe is to be not less
international standards applicable to piping than three pitches in length, and the diameter at
system keeping in view the boundary fluids, the root of the thread is to increase uniformly
design pressure and temperature conditions, from the standard root diameter to the diameter
external or cyclic loading and location. at the top of the thread. This may be produced
by suitably grinding the dies, and the flange
2.4.2 Flanges may be cut from plates or may be should be tapered out to the same formation.
forged or cast. The material is to be suitable for
the design temperature. Flanges may be

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Table 2.4.1 : Type of flange connections

Lub. and fuel

Steam Other media
Class of oil
t°C
piping Typical flange Typical flange Typical flange
application application application
I 1) > 400 A A-B A
≤ 400 A - B2 A-B
II > 250 A-B-C A-B-C A-B-C
≤ 250 A-B-C-D-E A-B-C-D-E
III A-B-C-D-E A - B -C - E A-B-C-D-E
1 For Class I only one condition is sufficient.

2 Type B for outer diameter < 150 [mm] only.

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2.5 Threaded sleeve joints
a) Class I piping having outside diameter not
2.5.1 Threaded sleeve joints requiring pressure- more than 33.7 [mm].
tight joints, having parallel or tapered threads in
accordance with national or other established b) Class II and Class III piping having outside
standards, may be used with carbon steel pipes diameter not more than 60.3 [mm].
within the limits given in Table 2.5.1 and for
services other than pipe systems conveying Threaded joints with parallel threads are to be
combustible or toxic fluids or services where allowed for Class III piping having outside
fatigue, severe erosion or crevice corrosion is diameter not more than 60.3 [mm].
expected to occur.
In particular cases, sizes in excess of those
Threaded joints in CO2 systems shall be allowed mentioned above may be accepted by IRS if in
only inside protected spaces and in CO2 cylinder compliance with a recognized national and/or
rooms. international standard.

Threaded joints for direct connections of pipe

lengths with tapered threads are to be allowed
for

Table 2.5.1 : Limiting design conditions for threaded sleeve joints

Nominal bore [mm] Maximum pressure in bar Maximum temp.°C

≤ 25 12 260
> 25 ≤ 40 10 260
> 40 ≤ 80 8.5 260
> 80 ≤ 100 7 260

2.6 Welding, non-destructive examination 2.7.4 Where the application of mechanical joints
and post-weld heat treatment of welded results in reduction in pipe wall thickness due to
pipes the use of bite type rings or other structural
elements, this is to be taken into account in
2.6.1 Requirements regarding welding determining the minimum wall thickness of the
procedures, non-destructive examination of pipe to withstand the design pressure.
welds and post-weld heat treatment are given in
Ch.10. The materials used in construction of
mechanical joints is to be compatible with the
2.7 Mechanical joints piping material and internal and external media.
In general the mechanical joints are to be of fire
2.7.1 Mechanical joints means devices intended resistant type as required by Table 2.7.1.
for direct connection of pipe lengths other than
by flanges, threaded joints or welding as 2.7.5 The pressure pulsation, piping vibration,
described in 2.4, 2.5 and 2.6. temperature variation and any other similar
adverse effects occurring during operation on
2.7.2 The requirements given here are board is not to result in failure of joint integrity or
applicable to pipe unions, compression its tightness.
couplings, slip-on joints as shown in Fig.2.7.
Similar joints complying with these requirements 2.7.6 Mechanical joints, which in the event of
may be acceptable. damage could cause fire or flooding, are not to
be used in piping sections directly connected to
2.7.3 Mechanical joints including pipe unions, the sea openings or tanks containing flammable
compression couplings, slip-on joints and similar fluids.
joints are to be of approved type for the
pressure ratings, service conditions and the 2.7.7 The mechanical joints are to be designed
intended application. The construction and type to withstand internal and external pressure as
are to conform to the examples shown in Fig.2.7 applicable and where used in suction lines are
and are to be in accordance with Table 2.7.1 to be capable of operating under vacuum.
and Table 2.7.2 for their classification and
application. (For approval refer “Type Approval 2.7.8 The number of mechanical joints in oil
of Mechanical Joints used in Piping”). systems is to be kept to a minimum. In general,

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flanged joints conforming to recognised accepted if in compliance with a recognised

standards are to be used. national and/or international standard.

2.7.9 Piping in which a mechanical joint is fitted 2.7.14 Mechanical joints are to be subjected to
is to be adequately adjusted, aligned and the following tests:
supported Supports or hangers are not to be
used to force alignment of piping at the point of .1 leakage test
connection. .2 vacuum test
.3 vibration (fatigue) test
2.7.10 Slip-on joints are normally not to be used .4 fire endurance test
in pipelines in cargo holds, tanks and other .5 burst pressure test at 4 times the design
spaces which are not easily accessible, unless pressure (for design pressures above 200 bar,
approved in each case. the burst pressure will be specially considered
by IRS)
2.7.11 Application of mechanical joints inside .6 pressure pulsation test
tanks may be permitted only for the same media .7 assembly test
that is in the tanks. .8 pull out test.

2.7.12 Unrestrained slip-on joints are to be used NOTE : For details of tests refer classification
only in cases where compensation of lateral notes, “Type Approval of Mechanical Joints
pipe deformation is necessary. Usage of these used in Piping”.
joints as the main means of pipe connection is
not permitted. 2.7.15 The installation of mechanical joints is to
be in accordance with the manufacturer’s
2.7.13 In particular cases, sizes in excess of assembly instructions and using special tools
those mentioned in Table 2.7.2 may be and gauges as required.

Table 2.7.1 : Application of mechanical joints

Kind of connections
Systems Pipe unions Compression Slip-on joints
couplings 6)
Flammable Fluids (Flash point ≤ 60°)
1 Cargo oil lines + + +5)
2 Crude oil washing lines + + +5)
3 Vent lines + + +3)
Inert Gas
4 Water seal effluent lines + + +
5 Scrubber effluent lines + + +
6 Main lines + + +2) 5)
7 Distributions lines + + +5)
Flammable Fluids (Flash point > 60°)
8 Cargo oil lines + + +5)
9 Fuel oil lines + + +3) 2)
10 Lubricating oil lines + + +2) 3)
11 Hydraulic oil + + +2) 3)
12 Thermal oil + + +2) 3)
Sea Water
13 Bilge lines + + +1)
14 Fire main and water spray + + +3)
15 Foam system + + +3)
16 Sprinkler system + + +3)
17 Ballast system + + +1)
Sea Water (contd.)
18 Cooling water system + + +1)
19 Tank cleaning services + + +
20 Non-essential systems + + +
Fresh Water
21 Cooling water system + + +1)

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Table 2.7.1 (Contd.)

Kind of connections
Systems Pipe unions Compression Slip-on joints
couplings 6)
Sounding / Vent
Sanitary / Drains / Scuppers
22 Condensate return + + +1)
23 Non-essential system + + +
24 Deck Drains (Internal) + + +4)
25 Sanitary Drains + + +
26 Scuppers and Discharge + + -
(Overboard)
27 Water tanks / Dry spaces + + +
28 Oil tanks (f.p > 60°C) + + +2) 3)
Miscellaneous
29 Starting / Control air 1) + + -
30 Service air (non-essential) + + +
31 Brine + + +
32 CO2 system 1) + + -
33 Steam + + + 7)

Abbreviations

+ Application is allowed
- Application is not allowed

Footnotes:

1) Inside machinery spaces of category A – only approved fire resistant types.

2) Not inside machinery spaces of category A or accommodation spaces. May be accepted in other
machinery spaces provided the joints are located in easily visible and accessible positions.
3) Approved fire resistant types
4) Above free board deck only.
5) In pump rooms and open decks – only approved fire resistant types.
6) If compression couplings include any components which readily deteriorate in case of fire, they are
to be of approved fire resistant type as required for slip-on joints.
7) Slip type joints as shown in Fig.2.7 may be used for pipes on deck with a design pressure of 10 bar
or less provided that they are restrained on the pipes (i.e. free axial moment of joint with respect to
pipe is prevented).

Table 2.7.2 : Application of mechanical joints depending upon the class of piping

Classes of piping systems

Types of joints
Class I Class II Class III
Pipe Unions
Welded and brazed + (OD ≤ 60.3 mm) + (OD ≤ 60.3 mm) +
type
Compression Couplings
Swage type + + +
Bite type + (OD ≤ 60.3 mm) + (OD ≤ 60.3 mm) +
Flared type + (OD ≤ 60.3 mm) + (OD ≤ 60.3 mm) +
Press type - - +

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Table 2.7.2 : (Contd.)

Classes of piping systems

Types of joints
Class I Class II Class III
Slip-on joints
Machine grooved type + + +
Grip type - + +
Slip type - + +

Abbreviations:

+ Application is allowed
- Application is not allowed

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Section 3

Copper and Copper Alloy Pipes and Fittings

3.1 Materials
3.2 Minimum thickness of pipes
3.1.1 Pipes are to be seamless and branches
are to be provided by cast or stamped fittings, 3.2.1 The minimum thickness of copper and
pipe pressings or other approved fabrications. copper alloy pipes and bends is to be higher of
Copper pipes for class I and II are to be that calculated by Sec.1, Cl.1.7 and that
seamless. indicated in Table 3.2.2.

3.1.2 Brazing and welding materials are to be 3.2.2 The value of 'c' to be used in Sec.1, Cl.1.7
suitable for the operating temperature and for is to be in accordance with Table 3.2.3.
the medium being carried. All brazing and
welding are to be carried out to the satisfaction 3.3 Heat treatment
of the Surveyors.
3.3.1 Pipes which have been hardened by cold
3.1.3 In general, the maximum permissible bending are to be suitably heat treated on
service temperature of copper and copper alloy completion of fabrication and prior to being
pipes, valves and fittings is not to exceed 200°C tested by hydraulic pressure. Copper pipes are
for copper and aluminium brass, and 300°C for to be annealed and copper alloy pipes are to be
copper nickel. Cast bronze valves and fittings either annealed or stress relief heat treated.
complying with the requirements of Pt.2 Ch.8
may be accepted up to 260°C.

Table 3.2.1 : Copper and copper alloy pipes

Specified Permissible stress [N/mm2]

min.
Condition of Maximum design temperature °C
Pipe material tensile
supply
strength
50 75 100 125 150 175
[N/mm2]
Copper Annealed 220 41.2 41.2 40.2 40.2 34.3 27.5
Aluminium brass Annealed 320 78.5 78.5 78.5 78.5 78.5 78.5
95/5 90/10 copper
Annealed 270 68.6 68.6 67.7 65.7 63.7 61.8
nickel-iron
70/30 copper nickel Annealed 360 81.4 79.4 77.5 75.5 73.5 71.6
Maximum design temperature °C
200 225 250 275 300
Copper Annealed 220 18.6 - - - -
Aluminium brass Annealed 320 24.5 - - - -
95/5 90/10 copper
Annealed 270 58.8 55.9 52.0 48.1 44.1
nickel-iron
70/30 copper nickel Annealed 360 69.6 67.7 65.7 63.7 61.8

Notes :

1. Intermediate values may be determined by linear interpolation.

2. For materials not included in the Table, the permissible stress shall be specially considered by IRS.

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Table 3.2.2 : Minimum thickness for copper and copper alloy pipes

Standard pipe sizes (outside Minimum overriding nominal thickness [mm]

diameter[mm]) Copper Copper alloy
8 to 10 1.0 0.8
12 to 20 1.2 1.0
25 to 44.5 1.5 1.2
50 to 76.1 2.0 1.5
88.9 to 108 2.5 2.0
133 to 159 3.0 2.5
193.7 to 267 3.5 3.0
273 to 457.2 4.0 3.5
508 4.5 4.0

Table 3.2.3 : Corrosion allowance 'c' for copper and copper alloy pipes

Piping Material c [mm]

Copper, brass and similar alloys, copper-tin alloys except those with
lead contents
0.8
Copper-nickel alloys (with Ni ≥ 10%)
0.5
Note:

For media without corrosive action in respect of the material employed and in case of special alloys
with sufficient corrosion resistance, the corrosion allowance may be reduced to zero.

Section 4

Cast Iron Pipes and Fittings

4.1 Spheroidal or nodular graphite cast iron general, to be subject to the same limitations as
grey cast iron.
4.1.1 Spheroidal or nodular graphite iron
castings for pipes, valves and fittings in Class II 4.2 Grey cast iron
and III piping systems are to be made in a grade
having a specified minimum elongation not less 4.2.1 Grey cast iron pipes, valves and fittings
than 12 per cent on gauge length of 5.65√So, will, in general, be accepted in Class III piping
where So is the actual cross-sectional area of systems except as stated in 4.2.2. Grey cast
the test piece. iron valves and fittings may be accepted in the
Class II steam systems, but the design pressure
4.1.2 Proposals for the use of this material in or temperature is not to exceed 13 bar or 220°C
Class I piping systems will be specially respectively.
considered, but in no case is the material to be
used in systems where the design temperature 4.2.2 Grey cast iron is not to be used for the
exceeds 350°C. following:

4.1.3 Where the elongation is less than the a) Pipes for steam systems and fire
minimum required by 4.1.1, the material is, in extinguishing systems;

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b) Pipes, valves and fittings for boiler blow e) Clean ballast lines through cargo oil tanks
down systems and other piping systems to forward ballast tanks;
subject to shock or vibration;
f) Bilge lines in tanks;
c) Ship-side valves and fittings;
g) Outlet valves of fuel and lubricating oil
d) Valves fitted on collision bulkhead; tanks with static head.

Section 5

Plastic Pipes and Fittings

5.1 General reinforcement, such as PVC and fibre reinforced

plastics - FRP.
5.1.1 Proposals to use plastics material in
shipboard piping systems will be considered in 5.2.2 "Pipes/piping systems" means those made
relation to the properties of the materials, the of plastic(s) and include the pipes, fittings,
operating conditions of temperature and system joints, method of joining and any internal
pressure, and the intended service. Any or external liners, coverings and coatings
proposed service for plastics pipes not required to comply with the performance criteria.
mentioned in these Rules is to be submitted for
special consideration. 5.2.3 "Joint" means joining pipes by adhesive
bonding, laminating, welding, etc.
5.1.2 Attention is also drawn to the Guidelines
for the Application of Plastic Pipes on Ships 5.2.4 "Fittings" means bends, elbows, fabricated
contained in IMO Resolution A.753(18). branch pieces etc. of plastic materials.

5.1.3 Plastic pipes and fittings will, in general, be 5.2.5 "Nominal pressure" means the maximum
accepted in Class III piping systems. Proposals permissible working pressure which should be
for the use of plastics in Class I and Class II determined in accordance with the requirements
piping systems will be specially considered. in 5.3.3.

5.1.4 These requirements are not applicable to 5.2.6 "Fire endurance" means the capability of
flexible pipes and hoses and mechanical piping to maintain its strength and integrity (i.e.
couplings used in metallic piping systems. capable of performing its intended function) for
some predetermined period of time while
5.1.5 Piping systems made of thermoplastic exposed to fire.
materials, such as polyethylene (PE),
polypropylene (PP), polybutylene (PB) and 5.3 Strength
intended for non-essential services are to meet
the requirements of recognized standards and 5.3.1 The strength of the pipes is to be
that of 5.8 and 5.9. However the safety aspects determined by hydrostatic pressure tests to
due to fire will require to be considered. failure on representative sizes of the pipe.

5.1.6 The use of plastics may be restricted by 5.3.2 The strength of fittings and joints is to be
statutory requirements of the National Authority not less than that of the pipes.
of the country in which the ship is to be
registered. 5.3.3 The nominal pressure is to be determined
from the following conditions :
5.1.7 The specification of piping is to be in
accordance with a recognized national or a) Internal Pressure
international standard acceptable to IRS. In
addition, requirements given in 5.3 to 5.6 are to For an internal pressure the nominal pressure,
be complied with. Pn, is to be lesser of the following :

5.2 Terms and definitions Psth

Pn Int ≤
5.2.1 "Plastic(s)" means both thermoplastic and 4
thermosetting plastic materials with or without

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or where,

Plth Pcol = pipe collapse pressure.

Pn Int ≤
2.5 5.3.4 In no case is the collapse pressure to be
less than 3 bar.
where,
5.3.5 The maximum working external pressure
Psth = short-term hydrostatic test failure is a sum of the vacuum inside the pipe and a
pressure; head of liquid acting on the outside of the pipe.
Plth = long-term hydrostatic test failure 5.3.6 The maximum permissible working
pressure (> 100,000 h) pressure is to be specified with due regard for
maximum possible working temperatures in
b) For an external pressure the nominal accordance with Manufacturer's recommen-
pressure, Pn, is to be as under : dations.

Pcol 5.3.7 The thickness of pipes is in no case to be

Pn ext ≤ less than that specified in Table 5.3.1.
3

Table 5.3.1 : Minimum wall thickness for plastic pipes

External diameter D Minimum wall thickness External diameter Minimum wall thickness
[mm] [mm] D [mm] [mm]
10.2 to 17.2 1.0 219.1 2.6
21.3 to 48.3 1.6 273.0 2.9
60.3 to 88.9 2.0 323.9 to 406.4 3.6
114.3 to 168.3 2.3 Over 406.4 4.0
Note : The external diameters and thicknesses have been selected from ISO 1127 : 1980. For pipes
covered by other standards, slightly less thicknesses may be accepted.

5.4 Axial strength 5.6 Temperature

5.4.1 The sum of the longitudinal stresses due 5.6.1 The permissible working temperature
to pressure, weight and other loads is not to depending on the working pressure is to be in
exceed the allowable stress in the longitudinal accordance with Manufacturer's recommen-
direction. dations, but in each case it is to be at least 20°C
lower than the minimum heat distortion
5.4.2 In the case of fibre reinforced plastic pipes, temperature of the pipe material, determined
the sum of the longitudinal stresses is not to according to ISO 75 method A, or equivalent.
exceed half of the nominal circumferential stress
derived from the nominal internal pressure 5.6.2 The minimum heat distortion temperature
condition (See 5.3.3). is to be not less than 80°C.

5.5 Impact resistance 5.7 Requirements for pipes/piping systems

depending on service and/or locations
5.5.1 Plastic pipes and joints are to have a
minimum resistance to impact in accordance 5.7.1 Fire endurance
with recognised national or international
standards such as ASTM D.2444 or equivalent. 5.7.1.1 Pipes and their associated fittings whose
5.5.2 After the test the specimen is to be integrity is essential to the safety of ships are
subjected to hydrostatic pressure equal to 2.5 required to meet the minimum fire endurance
times the design pressure for at least 1 hour. requirements of Appendix 1 or 2, as applicable,
of IMO Res A.753(18).

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5.7.1.2 Depending on the capability of a piping 5.7.2.2 Surface flame spread characteristics are
system to maintain its strength and integrity, to be determined using the procedure given in
there exist three different levels of fire IMO Res. A.653(16) with regard to the
endurance for piping systems. modifications due to the curvilinear pipe
surfaces as listed in Appendix 3 of IMO Res.
a) Level 1. Piping having passed the fire A.753(18).
endurance test specified in Appendix 1 of
IMO Res A.753(18) for a duration of a 5.7.3 Fire protection coatings
minimum of one hour without loss of
integrity in the dry condition is considered to 5.7.3.1 Where a fire protective coating of pipes
meet level 1 fire endurance standard (L1). and fittings is necessary for achieving the fire
endurance level required, it is to meet the
b) Level 2. Piping having passed the fire following requirements:
endurance test specified in Appendix 1 of
IMO Res A.753(18) for a duration of a a) The pipes are generally to be delivered from
minimum of 30 minutes in the dry condition the manufacturer with the protective coating
is considered to meet level 2 fire endurance on.
standard (L2).
b) The fire protection properties of the coating
c) Level 3. Piping having passed the fire are not to be diminished when exposed to
endurance test specified in Appendix 2 of salt water, oil or bilge slops. It is to be
IMO Res A.753(18) for a duration of a demonstrated that the coating is resistant to
minimum of 30 minutes in the wet condition products likely to come into contact with the
is considered to meet level 3 fire endurance piping.
standard (L3).
c) In considering fire protection coatings, such
5.7.1.3 Permitted use of piping depending on characteristics as thermal expansion,
fire endurance, location and piping system is resistance against vibrations and elasticity
given in Table 5.7.1 "Fire Endurance are to be taken into account.
Requirements Matrix".
d) The fire protection coatings are to have
5.7.2 Flame spread sufficient resistance to impact to retain their
integrity.
5.7.2.1 All pipes, except those fitted on open
decks and within tanks, cofferdams, pipe tunnels 5.7.4 Electrical conductivity
and ducts are to have low surface flame spread
characteristics not exceeding average values Where electrical conductivity is to be ensured,
listed in IMO Res. A.653(16). the resistance of the pipes and fittings is not to
exceed 1 x 105 Ohm/m.

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Table 5.7.1 : Fire endurance requirements matrix

Sr.
Piping Systems Location
No.
A B C D E F G H I J K

Fuel oil tanks

Accommoda-
Ballast water
pump rooms

Ro/Ro cargo
Cargo pump

Cargo tanks

void spaces

Open decks
cargo holds

tion service
Cofferdams

and control
pipe tunnel
Category A

machinery
Machinery

and ducts
spaces of

Other dry
spaces &

spaces
rooms

holds
Other

tanks
1 2 3 4 5 6 7 8 9 10 11 12 13
CARGO (FLAMMABLE CARGOES f.p. ≤ 60°C
10 2
1. Cargo lines NA NA L1 NA NA O NA O O NA L1
Crude oil 10 2
2. NA NA L1 NA NA O NA O O NA L1
washing lines
10
3. Vent lines NA NA NA NA NA O NA O O NA X
INERT GAS
Water seal
4. NA NA O1 NA NA O1 O1 O1 O1 NA O
effluent line
Scrubber 1 1 1 1
5. O O NA NA NA NA NA O O NA O
effluent line
6
6. Main line O O L1 NA NA NA NA NA O NA L1
7. Distribution lines NA NA L1 NA NA O NA NA O NA L12
FLAMMABLE LIQUIDS (f.p. > 60°C)
3 10
8. Cargo lines X X L1 X X NA O O O NA L1
3
9. Fuel oil X X L1 X X NA O O O L1 L1
10. Lubricating X X L1 X X NA NA NA O L1 L1
11. Hydraulic oil X X L1 X X O O O O L1 L1
1
SEAWATER
Bilge main & 7 7
12. L1 L1 L1 X X NA O O O NA L1
branches
Fire main &
13. L1 L1 L1 X NA NA NA O O X L1
water spray
14. Foam system L1 L1 L1 NA NA NA NA NA O L1 L1
15. Sprinkler system L1 L1 L3 X NA NA NA O O L3 L3
10
16. Ballast L3 L1 L3 L3 X O O O O L2 L2
Cooling water,
17. essential L3 L3 NA NA NA NA NA O O NA L2
services
Tank cleaning
18. services fixed NA NA L3 NA NA O NA O O NA L32
machines
Non-essential
19. O O O O O NA O O O O O
systems
FRESH WATER
Cooling water
20. L3 L3 NA NA NA NA O O O L3 L3
essential
Condensate
21. L3 L3 L3 O O NA NA NA O O O
return
Non-essential
22. O O O O O NA O O O O O
systems

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Table 5.7.1 : Fire endurance requirements matrix (Contd.)

Sr.
Piping Systems Location
No.
A B C D E F G H I J K

Fuel oil tanks

Accommoda-
Ballast water
pump rooms

Ro/Ro cargo
Cargo pump

Cargo tanks

void spaces

Open decks
cargo holds

tion service
Cofferdams

and control
pipe tunnel
Category A

machinery
Machinery

and ducts
spaces of

Other dry
spaces &

spaces
rooms

holds
Other

tanks
1 2 3 4 5 6 7 8 9 10 11 12 13
SANITARY/DRAINS/SCUPPERS
Deck drains 4 4 4
23. L1 L1 NA L1 O NA O O O O O
(internal)
Sanitary drains
24. O O NA O O NA O O O O O
(internal)
Scuppers and
1,8 1,8 1,8 1,8 1,8 1,8
25. discharges O O O O O O O O O O O
(overboard)
SOUNDING/AIR
Water tanks/dry 10
26. O O O O O O O O O O O
spaces
Oil tanks (f.p. > 3 10
27. X X X X X X O O O X X
60°C)
MISCELLANEOUS
5 5 5 5 5 5 5
28. Control air L1 L1 L1 L1 L1 NA O O O L1 L1
Service air (non-
29. O O O O O NA O O O O O
essential)
30. Brine O O NA O O NA NA NA O O O
Auxiliary low
31. pressure steam L2 L2 O9 O9 O9 O O O O O9 O9
(≤ 7 bar)

Abbreviations:

L1 : Fire endurance test (appendix 1) in dry conditions, 60 min

L2 : Fire endurance test (appendix 1) in dry conditions, 30 min
L3 : Fire endurance test (appendix 2) in wet conditions, 30 min
O : No fire endurance test required
NA : Not applicable
X : Metallic materials having a melting point greater than 925°C

Footnotes:

1 Where non-metallic piping is use, remotely controlled valves to be provided at ship's side (valve
is to be controlled from outside space).

2 Remote closing valves to be provided at the cargo tanks.

3 When cargo tanks contain flammable liquids with f.p. > 60°C, "O" may replace "NA" or "X".

4 For drains serving only the space concerned, "O" may replace "L1".

5 When controlling functions are not required by statutory requirements or guidelines, "O" may
replace "L1".

6 For pipe between machinery space and deck water seal, "O" may replace "L1".

7 For passenger vessels, "X" is to replace "L1".

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8 Scuppers serving open decks in positions 1 and 2, as defined in Regulation 13 of the

International Convention on Load Lines, 1966 should be "X" throughout unless fitted at the upper
end with the means of closing capable of being operated from a position above the freeboard
deck in order to prevent downflooding.

9 For essential services, such as fuel oil tank heating and ship's whistle, "X" is to replace "O".

10 For tankers where compliance with paragraph 3 (f) of Regulation 13F of Annex I of MARPOL
73/78 is required, "NA" is to replace "O".

Location Definitions:

A Machinery spaces of Machinery spaces of Category A as defined in SOLAS* Regulation II-

Category A 2/3.19.
B Other machinery spaces Spaces, other than Category A machinery spaces and cargo pump
and pump rooms rooms, containing propulsion machinery, boilers, steam and internal
combustion engines, generators and major electrical machinery,
pumps, oil filling stations, refrigerating, stabilising, ventilation and air-
conditioning machinery and similar spaces and trunks to such
spaces.
C Cargo pump rooms Spaces containing cargo pumps and entrances and trunks to such
spaces.
D Ro-ro cargo holds Ro-ro cargo holds are ro-ro cargo spaces and special category
spaces as defined in SOLAS* Regulation II-2/3.14 and 3.18.
E Other dry cargo holds All spaces other than ro-ro cargo holds used for non-liquid cargo and
trunks to such spaces.
F Cargo tanks All spaces used for liquid cargo and trunks to such spaces.
G Fuel oil tanks All spaces used for fuel oil (excluding cargo tanks) and trunks to such
spaces.
H Ballast water tanks All spaces used for ballast water and trunks to such spaces.
I Cofferdams, voids, etc. Cofferdams and voids are those empty spaces between two
bulkheads separating two adjacent compartments.
J Accommodation, service Accommodation spaces, service spaces and control stations as
defined in SOLAS* Regulation II-2/3.10, 3.12, 3.22.
K Open decks Open deck spaces as defined in SOLAS* Regulation II-2/26.2.2(5).
* SOLAS 74 as amended by the 1978 SOLAS Protocol and the 1981 and 1983 amendments
(consolidated text).

5.8 Material approval and quality control fittings are produced with consistent and uniform
during manufacture mechanical and physical properties.

5.8.1 Prototypes of pipes and fittings are to be 5.8.4 Each pipe and fitting made by hand lay up
tested to determine short-term and long-term technique, is to be tested by the Manufacturer at
design strength, fire endurance and low surface a hydrostatic pressure not less than 1.5 times
flame spread characteristics, electrical the nominal pressure. For other pipes and
resistance (for electrically conductive pipes), fittings, manufactured in accordance with the
impact resistance in accordance with this recognized standards by machined processes
Section. (e.g. ‘Continuous extruding’, ‘Filament wound
and centrifugally cast’) the hydrostatic pressure
5.8.2 For prototype testing representative test may be carried out in accordance with
samples of pipes and fittings are to be selected requirements stipulated in the relevant standard
to the satisfaction of the Classification Society. to which the pipe or fittings are manufactured,
provided that there is an effective quality system
5.8.3 The Manufacturer is to have quality in place at manufacturer’s works.
system that meets ISO 9000 series standards or
equivalent. The quality system is to consist of 5.8.5 Piping and fittings are to be permanently
elements necessary to ensure that pipes and marked with identification. Identification is to
include pressure ratings, the design standards

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that the pipe or fitting is manufactured in
accordance with and the material of which the 5.9.3 External loads
pipe or fitting is made.
5.9.3.1 When installing the piping, allowance is
5.8.6 In case the Manufacturer does not have an to be made for temporary point loads, where
approved quality system complying with ISO applicable. Such allowances are to include at
9000 series or equivalent, pipes and fittings are least the force exerted by a load (person) of 100
to be tested in accordance with this Section to kg at mid-span on any pipe of more than 100
the satisfaction of the attending surveyors for mm nominal outside diameter.
every batch of pipes.
5.9.3.2 Besides for providing adequate
5.8.7 Depending upon the intended application, robustness for all piping including open-ended
IRS may require, pressure testing of each pipe piping a minimum wall thickness, complying with
and/or fitting. 5.3.7 may require to be increased taking into
account the conditions encountered during
5.9 Installation service on board ships.

5.9.1 Supports 5.9.3.3 Pipes are to be protected from

mechanical damage where necessary.
5.9.1.1 Selection and spacing of pipe supports
in shipboard systems are to be determined as a 5.9.4 Strength of connections
function of allowable stresses and maximum
deflection criteria. Support spacing is not to be 5.9.4.1 The strength of connections is to be not
greater than the pipe Manufacturer's recommen- less than that of the piping system in which they
ded spacing. The selection and spacing of pipe are installed.
supports are to take into account pipe
dimensions, mechanical and physical properties 5.9.4.2 Pipes may be assembled using
of the pipe material, mass of pipe and contained adhesive-bonded, welded, flanged or other
fluid, external pressure, operating temperature, joints.
thermal expansion effects, loads due to external
forces, thrust forces, water hammer, vibrations, 5.9.4.3 Adhesive, when used for joint assembly,
maximum accelerations to which the system are to be suitable for providing a permanent seal
may be subjected. Combination of loads is to be between the pipes and fittings throughout the
considered. temperature and pressure range of the intended
application.
5.9.1.2 Each support is to evenly distribute the
load of the pipe and its contents over the full 5.9.4.4 Tightening of joints is to be performed in
width of the support. Measures are to be taken accordance with Manufacturers' instructions.
to minimise wear of the pipes where they
contact the supports. 5.9.5 Installation of conductive pipes

5.9.1.3 Heavy components in the piping system 5.9.5.1 In piping systems for fluids with
such as valves and expansion joints are to be conductivity less than 1000 pico siemens per
independently supported. metre (pS/m) such as refined products and
distillates use is to be made of conductive pipes.
5.9.2 Expansion
5.9.5.2 Regardless of the fluid being conveyed,
5.9.2.1 Suitable provision is to be made in each plastic piping is to be electrically conductive if
pipeline to allow for relative movement between the piping passes through a hazardous area.
pipes made of plastic and the steel structure, The resistance to earth from any point in the
having due regard to: piping system is not to exceed 1 x 106 Ohm. It is
preferred that pipes and fittings be
i) the difference in the coefficients of thermal homogeneously conductive. Pipes and fittings
expansion; having conductive layers are to be protected
against a possibility of spark damage to the pipe
ii) deformations of the ship's hull and its wall. Satisfactory earthing is to be provided.
structure.
5.9.5.3 After completion of the installation, the
5.9.2.2 When calculating the thermal resistance to earth is to be verified. Earthing
expansions, account is to be taken of the wires are to be accessible for inspection.
system working temperature and the
temperature at which assembly is performed.

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5.9.6 Application of fire protection coatings

v) dimensional requirements and tolerances,
5.9.6.1 Fire protection coatings are to be applied and
on the joints, where necessary for meeting the
required fire endurance for 5.7.3, after vi) tests acceptance criteria upon completion of
performing hydrostatic pressure tests of the the assembly.
piping system.
5.9.8.6 Any change in the bonding procedure
5.9.6.2 The fire protection coatings are to be which will affect the physical and mechanical
applied in accordance with Manufacturer's properties of the joint is to require the procedure
recommendations, using a procedure approved to be requalified.
in each particular case.
5.9.9 Bonding procedure quality testing
5.9.7 Penetration of divisions
5.9.9.1 A test assembly is to be fabricated in
5.9.7.1 Where plastic pipes pass through "A" or accordance with the procedure to be qualified
"B" class divisions, arrangements are to be and it is to consist of at least one pipe-to-pipe
made to ensure that the fire endurance is not joint and one pipe-to-fitting joint.
impaired. These arrangements are to be tested
in accordance with Recommendations for fire 5.9.9.2 When the test assembly has been cured,
test procedures for "A", "B" and "F" bulkheads it is to be subjected to a hydrostatic test
(Resolution A.754(18) as amended). pressure at a safety factor 2.5 times the design
pressure of the test assembly, for not less than
5.9.7.2 When plastic pipes pass through one hour. No leakage or separation of joints is
watertight bulkheads or decks, the watertight allowed. The test is to be conducted so that the
integrity of the bulkhead or deck is to be joint is loaded in both longitudinal and
maintained. circumferential directions.

5.9.7.3 If the bulkhead or deck is also a fire 5.9.9.3 Selection of the pipes used for test
division and destruction by fire of plastic pipes assembly, is to be in accordance with the
may cause the inflow of liquid from tanks, a following:
metallic shut-off valve operable from above the
freeboard deck should be fitted at the bulkhead a) When the largest size to be joined is 200
or deck. mm nominal outside diameter, or smaller,
the test assembly is to be the largest piping
5.9.8 Control during installation size to be joined.

5.9.8.1 Installation is to be in accordance with b) When the largest size to be joined is greater
the Manufacturer's guidelines. than 200 mm nominal outside diameter, the
size of the test assembly is to be either 200
5.9.8.2 Prior to commencing the work, joining mm or 25% of the largest piping size to be
techniques are to be approved by the joined, whichever is greater.
Classification Society.
5.9.9.4 When conducting performance
5.9.8.3 The tests and examinations specified in qualifications, each bonder and each bonding
this Section are to be completed before operator are to make up test assemblies, the
shipboard piping installation commences. size and number of which are to be as required
above.
5.9.8.4 The personnel performing this work are
to be properly qualified and certified to the 5.9.10 Testing after installation on board
satisfaction of the Classification Society.
5.9.10.1 Piping systems for essential services
5.9.8.5 The procedure of making bonds is to are to be subjected to a test pressure not less
include: than 1.5 times the design pressure or 4 bar
whichever is greater.
i) materials used,
5.9.10.2 Piping systems for non-essential
ii) tools and fixtures, services are to be checked for leakage under
operational conditions.
iii) joint preparation requirements,

iv) cure temperature,

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5.9.10.3 For piping required to be electrically 3) All relevant design drawings, catalogues,
conductive, earthing is to be checked and data sheets, calculations and functional
random resistance testing is to be conducted. descriptions.
4) Fully detailed section assembly drawings
5.10 Test specification for plastic pipes showing pipe, fittings and pipe
connections.
5.10.1 Scope
III. Materials
Section 5.10 contains requirements for the Type
Approval of plastic pipes. It is applicable to rigid 1) The resin used for the construction of
pipes, pipe joints and fittings. plastic pipes and fittings.
2) Catalyst and accelerator types and
5.10.2 Documentation concentration employed in the case of
reinforced polyester resin pipes or
The following information for the plastic pipes, hardeners where epoxide resins are
fittings and joints is to be submitted for employed.
consideration and approval: 3) A statement of all reinforcements
employed where the reference number
I. General information does not identify the mass per unit area or
the text number of a roving used in a
1) Pipe and fitting dimensions filament winding process, these are to be
2) Maximum internal and external working detailed.
pressure 4) Full information regarding the type of gel-
3) Working temperature range coat or thermoplastic liner employed during
4) Intended services and installation construction, as appropriate.
locations 5) Cure/post-cure conditions. The cure and
5) The level of fire endurance post-cure temperatures and time required
6) If electrically conductive and resin/reinforcement ratio.
7) Fluids Intended to be carried 6) Winding angle and orientation.
8) Limits on flow rates
9) Serviceable life 5.10.3 Testing
10) Installation instructions
11) Details of marking. Testing is to demonstrate that pipes, fittings and
joints for which Type Approval is sought comply
II. Drawings and supporting documentation: with requirement of Section 5.

1) Certificates and reports for relevant tests The standards to be used for testing of pipes,
previously carried out. joints and fittings are given in Table 5.10.1 and
2) Details of relevant standards. Table 5.10.2.

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Table 5.10.1 : Typical standards for general requirements for all systems

Test Rule clause no. / Remarks

Typical Standard
1 Internal pressure (1) 5.3.3a) Top, Middle, Bottom (of
ASTM D 1599 range)
ASTM D 2992 Tests are to be carried out on
ISO 15493 or equivalent pipe spools made of different
pipe sizes, fittings and pipe
connections
2 External pressure (1) 5.3.3b) As above, for straight pipes
ISO 15493 or equivalent only
3 Axial strength 5.4 As above
4 Load deformation ASTM D2412 or equivalent Top, Middle Bottom (of each
pressure range)
5 Temperature limitations ISO 75 Method A GRP piping Each type of resin
system: HDT test on each type
of resin acc. To ISO 75 method
A
Thermoplastic piping systems:
ISO 75 Method A; ISO 306
Plastics – Thermoplastic
materials – Determination of
Vicat softening temperature
(VST) VICAT test according to
ISO 2507

Polyesters with an HDT below

80°C should not be used.
6 Impact resistance ISO 9854:1994, ISO 9653:1991 Representative sample of
ISO 15493 each type of construction
ASTM D2444 or equivalent
7 Ageing Manufacturer’s standard Each type of construction
ISO 9142:1990
8 Fatigue Manufacturer’s standard or Each type of construction
service experience
9 Fluid absorption ISO 8361:1991
10 Material compatibility (2) ASTM C581
Manufacturer’s standard

Notes:
(1) Test to be witnessed by IRS Surveyor.
(2) If applicable.

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Table 5.10.2 : Typical standards for additional requirements depending on service

and/or locations of piping

Test Rule clause no. / Remarks

Typical Standard
1 Fire endurance (1) (2) IMO Res. A753(18), Appendix Representative samples of
1,2 each type of construction and
type of pipe connection
2 Flame spread (1) (2) 5.7.2 Representative samples of
each type of construction
3 Smoke generation (2) IMO Fire Test Procedures Code Representative samples of
each type of construction
4 Toxicity (2) IMO Fire Test Procedures Code Representative samples of
each type of construction
5 Electrical conductivity (1) (2) ASTM F1173-95 or ASTM Representative samples of
D257, NS6126 para 11.2 or each type of construction
equivalent

Notes:
(1) Test to be witnessed by IRS Surveyor.
(2) If applicable.

Tests 1, 2 and 5 of above table are optional. However, if carried out, the range of approved applications
for the pipes will be limited accordingly (See Table 5.7.1).

Section 6

Flexible Hoses

6.1 Definition not accepted in high pressure fuel oil injection

systems.
6.1.1 Flexible hose assembly is defined as short
length of integral metallic or non-metallic hose 6.2.3 These requirements for flexible hose
with prefabricated end fittings ready for assemblies are not applicable to hoses intended
installation. to be used in fixed fire extinguishing systems.

6.2 Scope 6.3 Design and construction

6.2.1 The requirements of 6.3 to 6.6 apply to 6.3.1 Flexible hoses are to be designed and
flexible hoses of metallic or non-metallic material constructed in accordance with recognized
intended for a permanent connection between a National or International Standards. Flexible
fixed piping system and items of machinery hoses constructed of rubber or plastics materials
where necessary to accommodate relative and intended for use in bilge, ballast,
movement between the machinery and the fixed compressed air, oil fuel, lubricating, hydraulic
piping system. The requirements may also be and thermal oil systems are to incorporate a
applied to temporarily connected flexible hoses single double or more closely woven integral
or hoses of portable equipment. wire braid or other suitable material for
reinforcement.
6.2.2 Flexible hose assemblies as defined in
6.1.1 may be accepted for use in oil fuel, Flexible hoses of plastics materials such as
lubricating, hydraulic and thermal oil systems, Teflon or Nylon, (which are used for the
fresh water and sea water cooling systems, purposes mentioned above), where
compressed air systems, bilge and ballast reinforcement is not possible by incorporating
systems and Class III steam systems where closely woven integral wire braid are to have
they comply with 6.3 to 6.6. Flexible hoses are

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suitable reinforcing material as far as 6.4 Installation

practicable.
6.4.1 In general, flexible hoses are to be limited
Where rubber or plastic material hoses are to be to a length necessary to provide for relative
used in oil supply lines to burners, the hoses are movement between fixed and flexibly mounted
to have external wire braid protection in addition items of machinery / equipment or systems.
to the reinforcement mentioned above which is
provided during manufacturing. Flexible hoses 6.4.2 Flexible hose assemblies are not to be
for use in steam systems are to be of metallic installed where they may be subjected to
construction. torsional deformation (twisting) under normal
operating conditions.
6.3.2 Flexible hoses are to be complete with
approved end fittings in accordance with 6.4.3 The number of flexible hoses, in piping
manufacturer’s specification. The end systems mentioned in 6.2.2 is to be kept to
connections that do not have a flange are to minimum and to be limited for the purpose
comply with 2.7 as applicable and each type of stated in 6.2.1.
hose/fitting combination is to be subject to
prototype testing to the same standard as that 6.4.4 Where flexible hoses are intended to be
required by the hose with particular reference to used in piping systems conveying flammable
pressure and impulse tests. Refer Pt.4, Ch.4, fluids that are in close proximity of heated
4.8.5.2. surfaces the risk of ignition due to failure of the
hose assembly and subsequent release of fluids
6.3.3 The use of hose clamps and similar types is to be mitigated as far as practicable by the
of end attachments is not acceptable for flexible use of screens or other similar protection to the
hoses in piping systems for steam, flammable satisfaction of the Surveyor.
media, starting air systems or for sea water
systems where failure may result in flooding. In 6.4.5 Flexible hoses are to be installed in clearly
other piping systems, the use of hose clamps visible and readily accessible locations.
may be accepted where the working pressure is
less than 5 bar and provided there are double 6.4.6 The installation of flexible hose assemblies
clamps at each end connection. is to be in accordance with the manufacturer’s
instructions and use limitations with particular
6.3.4 Flexible hose assemblies intended for attention to the following, if any:
installation in piping systems where pressure
pulses and/or high levels of vibration are - Orientation
expected to occur in service, are to be designed - End connection support (where necessary)
for the maximum expected impulse peak - Avoidance of hose contact that could cause
pressure and forces due to vibration. The tests rubbing and abrasion
required by 6.5 are to take into consideration the - Minimum bend radii.
maximum anticipated in-service pressures,
vibration frequencies and forces due to 6.5 Tests
installation.
6.5.1 Acceptance of flexible hose assemblies is
6.3.5 Flexible hose assemblies constructed of subject to satisfactory prototype testing.
non-metallic materials intended for installation in Prototype test programmes for flexible hose
piping systems for flammable media and sea assemblies are to be submitted to IRS by the
water systems where failure may result in manufacturer and are to be sufficiently detailed
flooding, are to be of fire-resistant type. Fire to demonstrate performance in accordance with
resistance is to be demonstrated by testing to the specified standards given in 6.5.2 and 6.5.3.
ISO 15540 and ISO 15541.
6.5.2 The tests are, as applicable, to be carried
6.3.6 Flexible hose assemblies are to be out on different nominal diameters of hose type
selected for the intended location and complete with end fittings for pressure, burst,
application taking into consideration ambient impulse resistance and fire resistance in
conditions, compatibility with fluids under accordance with the requirements of the
working pressure and temperature conditions relevant standard. The following standards are
consistent with the manufacturer’s instructions to be used as applicable:
and any requirements given elsewhere in the
Rules. (Refer Pt.4, Ch.3, 4.3.5; Pt.4, Ch.6, 3.4; - ISO 6802 – Rubber and plastics hoses and
Pt.5, Ch.26, 2.6.10; Pt.5, Ch.29, 2.1.2). hose assemblies – Hydraulic pressure
impulse test without flexing.

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- ISO 6803 – Rubber and plastics hoses and Note : * The international standards, e.g. EN or
hose assemblies – Hydraulic pressure SAE for burst testing of non-metallic hoses,
impulse test with flexing. require the pressure to be increased until burst
without any holding period at 4 x MWP.
- ISO 15540 – Ships and marine technology –
Fire resistance of hose assemblies – Test 6.6 Marking
methods.
6.6.1 Flexible hoses are to be permanently
- ISO 15541 – Ships and marine technology – marked by the manufacturer with the following
Fire resistance of hose assemblies – details:
Requirements for test bench.
- Hose manufacturer’s name or trademark.
- ISO 10380 – Pipe work – Corrugated metal - Date of manufacture (month/year).
hoses and hose assemblies. Other - Designation type reference.
standards may be accepted where agreed - Nominal diameter.
by IRS. - Pressure rating.
- Temperature rating.
6.5.3 All flexible hose assemblies are to be
satisfactorily prototype burst tested to an Where a flexible hose assembly is made up of
international standard* to demonstrate they are items from different manufacturers, the
able to withstand a pressure not less than four components are to be clearly identified and
times its design pressure without indication of traceable to evidence of prototype testing.
failure or leakage.

Section 7

Hydraulic Tests on Pipes and Fittings

7.1 Hydraulic tests before installation on Pt and P are defined in Sec.1, Cl.1.5.1
board
K100 = allowable stress for 100°C [N/mm2]
7.1.1 All Class I and II pipes and their
associated fittings are to be tested by hydraulic Kt = allowable stress for the design temperature
pressure to the Surveyor's satisfaction. Further, [N/mm2].
all steam, feed, compressed air and fuel oil
pipes, together with their fittings, are to be 7.1.4 In no case is the membrane stress to
similarly tested where the design pressure is exceed 90 per cent of the yield stress at the
greater than 3.5 bar. The test is to be carried out testing temperature.
after completion of manufacture and before
installation on board and, where applicable, 7.1.5 All valves and fittings are to be tested in
before insulating and coating. accordance with recognized standards, but not
less than 1.5 times the nominal pressure rating
7.1.2 Where the design temperature does not at ambient temperature. Valves, cocks and
exceed 300°C, the test pressure is to be 1.5 distance pieces intended to be fitted on the ship
times the design pressure. side below the load waterline are to be
hydraulically tested to a pressure not less than 5
7.1.3 For steel pipes and integral fittings for use bar.
in systems where the design temperature
exceeds 300°C, the test pressure is to be as 7.1.6 When, for technical reasons, it is not
follows but need not exceed twice the design possible to carry out complete hydrotesting
pressure: before assembly on board for all sections of
piping, proposals for testing the remaining/
K 100 closing lengths of piping, particularly in respect
Pt = 1.5 P bar of the closing seams, are to be submitted for
Kt approval.

where, 7.1.7 Pressure testing of small bore pipes (less

than 15 mm) may be waived at the discretion of
IRS depending on the application.
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7.2.3 The hydraulic test required by 7.2.2 may

7.2 Testing after assembly on board be omitted provided non- destructive tests by
ultrasonic or radiographic methods are carried
7.2.1 Heating coils in tanks and liquid or gas fuel out on the entire circumference of all butt welds
oil piping are to be tested by hydraulic pressure, with satisfactory results. Where ultrasonic test
after installation on board, to 1.5 times the has been carried out, the manufacturer is to
design pressure but in no case to less than 4 provide the Surveyor with a signed statement
bar. confirming that ultrasonic examination has been
carried out by an approved operator and that
7.2.2 Where pipes specified in 7.1.1 are butt there were no indications of defects which could
welded together during assembly on board, they be expected to have prejudicial effect on the
are to be tested by hydraulic pressure in service performance of the piping.
accordance with the requirements of 7.1 after
welding. The pipe lengths may be insulated, 7.2.4 Where bilge pipes are accepted in way of
except in way of the joints made during double bottom tanks or deep tanks, the pipes
installation and before hydraulic test is carried after fitting are to be tested by hydraulic
out. pressure to the same pressure as the tanks
through which they pass.

End of Chapter

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Chapter 3

Pumping and Piping

Contents
Section

1 General
2 Bilge and Ballast Piping Systems
3 Vents, Sounding, Overflow and Scuppers and Discharges Piping Systems
4 Fuel Oil Systems
5 Steam Piping and Condensate Piping Systems
6 Boiler Feed Piping Systems
7 Engine Cooling Water Systems
8 Lubricating Oil Piping Systems

Section 1

General

1.1 Scope c) Boiler feed piping systems;

1.1.1 The requirements of this Chapter are d) Steam piping and condensate piping
applicable to all ships but may be modified for systems;
ships classed for restricted services or for
special services. e) Bilge and ballast piping systems;

1.1.2 Whilst these requirements are considered f) Lubricating-oil piping systems;

to satisfy the relevant requirements of the
International Convention for the Safety of Life at g) Liquid cargo pumping systems;
Sea, 1974, and applicable amendments,
attention should be given to any relevant h) Hydraulic power piping systems for
statutory requirements of the National Authority essential services;
of the country in which the ship is to be
registered. i) Compressed air piping systems;

1.1.3 Consideration will be given to special j) Steering gear piping systems;

cases or to arrangements which are considered
equivalent to those required by Rules. k) Sea water and fresh water service piping
systems;
1.2 Plans
l) Vents, sounding and overflow piping
1.2.1 The following plans in diagrammatic form systems;
are to be submitted for consideration before
proceeding with the work: m) Sanitary piping systems;

a) General arrangement of pumps and piping n) Fire main and fire extinguishing piping
systems; systems.

b) Oil-fuel filling, transfer and service piping 1.2.2 The plans are to include the information
systems; like size, wall thickness, maximum working
pressure, temperature and material of all pipes,

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and type, size and material of the valves and a) directly on the shell plating;
fittings.
b) to the plating of fabricated steel water boxes
1.3 Materials of rigid construction integral with the ship's
plating;
1.3.1 The materials to be used in piping systems
are to be suitable for the service intended. In c) to short, rigid distance pieces welded to the
general, except where otherwise stated, pipes, shell plating.
valves and fittings are to be made of steel, cast
iron, copper, copper alloy or other approved 1.5.2 All valves and cocks fitted directly to the
material. See Ch.2 also. shell plating are to have spigots extending
through the plating. These spigot on valves may
Materials for pipes carrying corrosive fluids are however be omitted, if valves are fitted on pads
to be compatible with the fluids being handled which themselves form spigots in way of plating.
and are to be specially considered.
1.5.3 Boiler blow-down valves or cocks are to
1.3.2 Materials sensitive to heat such as have a protection ring fitted on the outside of the
aluminium, lead or plastics, are not to be used in shell plating. The spigot of the valve or the cock
systems essential to the safe operation of the is to be flush with the outer surface of the
ship. protection ring.

1.4 Valves and cocks 1.5.4 Valves and cocks are to be attached to the
shell plating by bolts tapped into the plating and
1.4.1 All the valves and cocks are to be so fitted with countersunk heads, or by studs
designed and constructed so that the valve screwed into heavy steel pads fitted to the
covers or glands will not slacken up when the plating. The stud holes are not to penetrate the
valves are operated. pad plating.

1.4.2 All the valves are to be designed to close 1.5.5 Ship side valves and fittings, if made of
with right hand (clockwise when facing the end steel or material with low corrosion resistance,
of the stem) motion of the wheel of the valve. are to be suitably protected against wastage.

1.4.3 All the valves and cocks are to be fitted in 1.5.6 Gratings are to be fitted at all openings in
places where they are easily accessible at all ship's side for inlet of seawater. The net area
times and are to be fitted with legible through the gratings is to be at least twice the
nameplates indicating their function in the area of the valves connected to the opening.
system and their installation is to be such that it Provision is to be made to clear the gratings by
can be readily observed that they are open or low pressure steam or compressed air.
closed.
1.5.7 The scantlings of valves and valve stools
1.4.4 All the valves and cocks fitted with remote fitted with steam, or compressed air clearing
control are to be provided with local manual connections are to be suitable for the maximum
control independent of the remote operating pressure to which the valves and stools may be
mechanism. The operation of the local control is subjected.
not to render the remote control system
inoperable. 1.6 Piping installation

1.4.5 The valves, cocks and other fittings which 1.6.1 Heavy pipes and valves are to be so
are attached directly to plating, which is required supported that their weight is not taken up by
to be of watertight construction, are to be connected pumps and fittings.
secured to the plating by means of studs
screwed into the plating and not by bolts 1.6.2 Support of the pipes is to be such that
passing through clearance holes. Alternatively detrimental vibrations do not arise in the system.
the studs may be welded to the plating.
1.6.3 Where pipes are carried through watertight
1.5 Shipside fittings (other than sanitary bulkheads or tank tops, means are to be made
discharges and scuppers) to ensure the integrity of the watertightness of
the compartment.
1.5.1 All sea inlet and overboard discharge
valves are to be fitted in either of the following 1.6.4 As far as possible, installation of pipes for
ways : water, oil, exhaust gases from oil engines or
steam, is to be avoided near electric

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switchboards. If this is impracticable, all the damaged mechanically, are to be suitably
joints in pipe line and valves are to be at a safe protected.
distance from the switchboards and shielded to
prevent damage to switchboard. 1.6.9 All pipes which pass through chambers
intended for the carriage or storage of
1.6.5 Provision is to be made to take care of refrigerated cargo are to be well insulated. In
expansion or contraction stresses in pipes due case the temperature of the chamber is below
to temperature stresses or working of the hull. 0°C the pipes are to be insulated from the ship's
structure also, except at positions where the
1.6.6 Expansion pieces of approved type, made temperature of the ship's structure is always
of oil resistant re-inforced rubber or other above 0°C and is controlled by outside
approved material may be used in circulating temperature.
water systems in machinery spaces.
Air refreshing pipes leading to and from
1.6.7 All piping systems, where a pressure refrigerated chambers need not be insulated
greater than the designed pressure could be from the ship's structure.
developed, are to be protected by suitable relief
valves. 1.6.10 Deck wash pipes and discharge pipes
from the pumps to domestic water tanks are not
1.6.8 All pipes, situated in cargo spaces, fish to pass through cargo holds.
holds or other spaces, where they can be

Section 2

Bilge and Ballast Piping Systems

2.1 General suction at the after end situated as near the

centerline as practicable may be accepted.
2.1.1 All ships are to be provided with necessary
pumps, suction and discharge piping and means In ships where the bilge water cannot be entirely
of drainage so arranged that any compartment drained by suctions as provided above due to
can be pumped out effectively, when the ship is the fitting of watertight floors or keelsons,
on an even keel and/or designed trim and is additional suctions may be required. Recesses
either upright or has a list of not more than 5 and cementing/composition are to be so
degrees, through at least one suction, except for arranged that water in any part of the hold may
machinery spaces where at least two suctions find its way to the suction pipes easily.
are required, one of which is to be a branch
bilge suction and the other is to be a direct bilge 2.2.2 In the holds of ships with double bottom,
suction. Wing suctions will, generally, be bilge suctions are to be provided on each side at
necessary for this purpose, except for short the after end of the holds. Where the tanktop
narrow compartments, where a single suction extends to the shipside, bilge suctions are to be
may be sufficient. led from bilge wells of at least 0.15 [m3] capacity
each, situated at the after end at each side of
2.1.2 All passenger ships are to be provided the hold. Where the tanktop has inverse
with an efficient bilge pumping plant capable of camber, an additional bilge suction from a well
pumping from and draining any watertight situated near the centerline is also to be
compartment which is neither a permanent oil provided. Bilge wells of smaller size may be
compartment nor a permanent water considered depending on the size of the vessel
compartment under all practicable conditions, and the size of the compartment.
after a casualty, whether the ship is upright or
listed. If the tanktop is of a design having
discontinuities or depressions, the number and
2.2 Drainage of cargo holds position of bilge suctions will be given special
consideration.
2.2.1 In ships without a double bottom one bilge
suction is normally to be provided on each side 2.2.3 Ships with one cargo hold, are to have
of the cargo hold, at the after ends. However, if suctions in the fore and after ends of the hold. In
the rise of floor exceeds 5 degrees, one bilge ships having two or more holds, bilge suctions

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are to be fitted in suitable positions in the fore means of a self closing cock situated in a well
and after ends of holds over 30 [m] in length. lighted and accessible position, and draining into
engine room or tunnel.
2.3 Drainage from refrigerated cargo spaces
2.4.3 The collision bulkhead is not to be pierced
2.3.1 Provision is to be made for the continuous below the bulkhead deck by more than one pipe
drainage of the inside of all insulated chambers for dealing with the contents inside the fore peak
and cooler trays. tank. Where the forepeak is divided into two
compartments for carrying two different kinds of
2.3.2 Drains which are led from lower holds and liquids, the collision bulkhead may be pierced by
cooler trays situated on the tank top are to be two pipes, i.e. one for each compartment
fitted with liquid sealed traps and non-return provided that there is no practical alternative to
bilge valves. piercing by such a second pipe and that having
regard to the additional subdivision provided in
2.3.3 Drains from 'tween deck chambers and the forepeak, the safety of the ship is
from cooler trays which are situated well above maintained.
the tank top are to be fitted with liquid sealed
traps. 2.4.4 The pipe/pipes piercing the collision
bulkhead is/are to be provided with screwdown
2.3.4 Where drains from separate chambers join valve/s capable of being operated from above
a common main, the branch pipes are each to the bulkhead deck/freeboard deck and the chest
be provided with a liquid sealed trap. of the valve is to be secured to the collision
bulkhead inside the forepeak tank except as
2.3.5 The liquid sealed traps are to be of permitted by 2.4.5. An indicator is to be provided
adequate depth and are to have a pressure to indicate whether the valve is open or shut.
head of at least 100 [mm] when connected to air
ducts and 50 [mm] otherwise and arrangements 2.4.5 Any valve required by 2.4.4 may be fitted
are to be made for ready access to the traps for on the after side of the collision bulkhead,
cleaning and refilling with brine. provided the valve is readily accessible at all
times and the space in which it is located is not
2.3.6 Sluices, scuppers or drain pipes, which a cargo space.
would permit drainage from compartments
outside the insulated chambers into the bilges of 2.4.6 In ships other than passenger ships, the
the latter, are not to be fitted. valve required by 2.4.3 may be fitted on the after
side of the collision bulkhead, provided the valve
2.3.7 Screwed plugs or other means for blanking is readily accessible at all times and is not
off scuppers draining insulating chambers and subject to mechanical damage.
cooler trays are not to be fitted. If, however, it is
especially desired to provide means for 2.5 Drainage from tanks, cofferdams and
temporarily closing these scuppers, they may be void spaces
fitted with shutoff valves controlled from readily
accessible positions on a deck above the load 2.5.1 All the tanks except self-draining tanks,
waterline. An indicator is to be provided to whether for water ballast, oil fuel, liquid cargoes
indicate whether the valve is open or shut. etc. are to be provided with suction pipes led to
suitable power pumps. The pumping plant is to
2.4 Drainage from fore and aft peaks be so arranged that any water or liquid within
any compartment of the ship can be pumped out
2.4.1 Where the peaks are used as tanks, a through atleast one suction, when the ship is on
power pump suction is to be led to each tank, an even keel and/or designed trim and is either
except in case of small tanks (generally not upright or has a list of not more than 5 degrees.
exceeding 2 [m3] used for the carriage of
domestic fresh water where hand pumps may 2.5.2 Where the length of the ballast tank
be used. exceeds 30 [m], an additional suction is to be
provided at the forward end of the tank. Where
2.4.2 The peaks may be drained by hand pumps the width of the tank is unusually large, suctions
provided the peaks are not used as tanks and near the centerline in addition to wing suctions
they are not connected to bilge main. The may be required.
suction lift is to be well within the capacity of the
hand pumps and is not to exceed 7.3 [m]. 2.5.3 Suction pipes from the cofferdams and
void spaces are to be led to the main bilge line.
In case of vessels of length 24 [m] or less and
fishing vessels, after peak may be drained by

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2.5.4 In ships where deep tanks may be used near the center-line as possible. Bilge suctions
for either water ballast or dry cargo, provision is at wings will be required in all ships having rise
to be made for blanking the water ballast suction of floor less than 5 degrees.
and filling when the tank is being used for
carrying cargo and for blanking the bilge line 2.7.3 General requirements for machinery
when the tank is being used for carriage of spaces:
water ballast.
a) In ships where machinery is situated at the
2.6 Drainage from spaces above fore and after end, it will generally be necessary to
after peaks, chain lockers and above provide suctions at the forward wings in
machinery spaces addition to the suctions at the after end of
the machinery space;
2.6.1 Provision is to be made for the drainage of
chain locker and watertight compartments above b) Special means are to be provided to prevent
the fore peak tank by hand or power pump accumulation of bilge water under main
suctions. propulsion generators and motors;

2.6.2 Steering gear compartments or other small c) Where the machinery space is divided into
enclosed spaces situated above the after peak watertight compartments, the drainage
tank are to be provided with suitable means of system for all compartments except for main
drainage, either by hand or power bilge engine room is to be same as for cargo
suctions. holds except that one direct bilge suction
from each watertight compartment would
2.6.3 If the compartments referred to in 2.6.2 are also be required;
adequately isolated from the adjacent 'tween
decks, they may be drained by scuppers of not d) The direct bilge suctions in machinery
less than 38 [mm] bore, discharging into the space(s) are to be led to independent power
tunnel (or machinery spaces in case of ships pump(s), and the arrangements are to be
with machinery aft) and fitted with self-closing such that these direct suctions can be used
cocks situated in well lighted and visible independently of the main bilge line
positions. These arrangements are not suctions.
applicable to passenger ships unless they are
specially approved in relation to subdivision 2.7.4 Emergency bilge suction :
considerations.
a) An emergency bilge suction is to be fitted to
2.7 Drainage from machinery spaces the largest independent power pump, the
capacity of which is at least equal to the
2.7.1 Machinery spaces with double bottom: bilge pump. The suction is to be led to a
suitable low position in the machinery space
a) Where the inner bottom extends the full fitted with a screw-down non-return valve
length of the engine room forming bilges at having the spindle so extended that the
the wings, one branch bilge suction and one hand wheel is at least 450 [mm] above the
direct bilge suction will be required at each engine room floor plates. The valve name
side. Where the inner bottom extends the plate is to be clearly marked -
full length and breadth of machinery space, 'EMERGENCY BILGE SUCTION';
one branch and one direct bilge suctions are
to be led to each of the two bilge wells, b) In motorships, the emergency bilge suction
situated one at each side; is to be led to the main cooling water pump.
The suction is to be the same size as that of
b) The capacity of the bilge wells is to be at the cooling water pump;
least 0.15 [m3];
c) In steamships, the main sea water
c) If the inner bottom has inverse camber or circulating pump is to be fitted with an
discontinuity or depressions formed due to emergency bilge suction. This suction is to
crankpins or other recesses, additional have diameter of at least two third of the
suctions are to be provided. pump suction;

2.7.2 Machinery spaces without double bottom: d) If two or more cooling water pumps are
provided for main engine(s), each capable
In ships without inner bottom, where the rise of of supplying sufficient cooling water for
floor is 5 degrees or more, one branch and one normal power, only one pump need be fitted
direct bilge suctions are to be led to positions as with an emergency bilge suction;

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less than 50 [mm] and the diameter of the main

e) Where the main circulating pump is not bilge line is not be less than that of the branch
suitable for emergency bilge suction, the bilge line.
emergency bilge suction is to be led to the
largest available independent power pump, 2.9.3 The internal diameter of the direct bilge
which is not fitted with a direct bilge suction suction is not to be less than the main bilge line.
and is situated in the same compartment;
2.9.4 In oil tankers and similar ships, where the
f) If the pump to which emergency bilge is engine room pumps do not deal with bilge
connected is of self priming type, then the drainage outside the machinery spaces, the rule
direct bilge suction on the same side as the diameter of the bilge main may be reduced
emergency bilge suction may be omitted provided the proposed cross-sectional area of
except in passenger ships. the bilge main is not less than twice that
required for the branch bilge suction in
2.8 Drainage from tunnel machinery spaces.

2.8.1 A bilge suction, connected to the main 2.9.5 The area of each branch pipe connecting
bilge line is to be provided for draining the tunnel the bilge main to a distribution chest is to be not
well. This tunnel well may extend to the outer less than the sum of the areas required by the
bottom. If the shaft tunnel slopes from aft to rules for the two largest branch bilge suction
forward end, an additional bilge suction at pipes connected to that chest, but need not be
forward end is to be provided. greater than that required for the main bilge line.

2.8.2 Internal diameter of the tunnel bilge 2.10 Bilge pumps and ejectors
suction pipe is not to be less than 65 [mm]
except for vessels of length less than 60 [m], 2.10.1 All ships, other than passenger ships, are
where tunnel bilge suction pipes of 50 [mm] bore to be provided with at least two independent
are acceptable. power bilge pumps. For ships of length 91.5 [m]
and below, one of these pumps may be main
2.8.3 Where the length of the tunnel is more engine driven. See 2.13 for requirements
than 30 [m], bilge suctions are to be provided at regarding passenger ships.
both the forward and aft ends.
2.10.2 The capacity of each bilge pump is to be
2.9 Sizes of bilge suctions sufficient enough to give the water a speed of at
least 122 [metres/minute] through the rule size
2.9.1 The internal diameter of the bilge pipes is of the main bilge line under normal working
not to be less than that found by the following conditions.
formula to the nearest 5 [mm] commercial size
available: The capacity of the bilge pump may be found by
the following formula :
dm = 1.68 L (B + D) + 25 [mm]
Q = 5.75 x 10-3 x d2 [m3/hour]

db = 2.15 C (B + D) + 25 [mm] where,

3
Q = Capacity of pump [m /hour];
where,
d = rule diameter of bilge main [mm].
dm = internal diameter of bilge main [mm];
2.10.3 In ships, other than passenger ships,
db = internal diameter of branch bilge [mm];
where one bilge pump is of slightly less than rule
capacity, the deficiency may be made good by
L = Rule length of ship [m];
an excess capacity of the other pump. In
general this deficiency is to be limited to 30 per
B = Moulded breadth of ship [m];
cent.
C = Length of the compartment [m];
2.10.4 An ejector in conjunction with a sea water
pump may be accepted as a substitute for
D = Moulded depth to bulkhead deck [m].
independent power bilge pump. This, however,
is not acceptable on passenger ships.
2.9.2 In any case, bilge main suction line and
branch bilge suction line diameters are not to be

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2.10.5 Pumps required for essential services are
not to be connected to a common suction or 2.12.4 The intactness of the machinery spaces,
discharge chest or pipe unless the bulkheads and of tunnel plating is not to be
arrangements are such that the working of any impaired by fitting of scuppers discharging into
pumps so connected is unaffected by the other machinery spaces or tunnel from adjacent
pumps being in operation at the same time. compartments which are situated below the
bulkhead deck. These scuppers may, however,
2.10.6 General service pumps and ballast be led into a strongly built scupper drain tank
pumps may be accepted as independent power situated in the machinery space or tunnel but
bilge pumps, provided : closed to these spaces and drained by means of
a suction of appropriate size led from the main
a) Their capacity is adequate and in bilge line through a screw-down non-return
accordance with 2.10.2. valve.

b) These pumps, together with the pipelines to a) The scupper tank air pipe is to be led above
which they are connected, are fitted with the bulkhead deck and provision is to be
necessary devices to ensure that there is no made for ascertaining the level of the water
risk of entry of water or oil fuel in the holds in the tank;
or machinery spaces.
b) Where one tank is used for the drainage of
c) The arrangements are such that at least one several watertight compartments, the
of these pumps is immediately available for scupper pipes are to be provided with
bilge duty, when required, even when the screw-down non- return valves.
remaining pumps are in use for other
essential duties such as fire fighting. 2.12.5 No drain valve or cock is to be fitted to
the collision bulkhead. Drain valves or cocks are
2.10.7 For bilge pump capacity for ships having not to be fitted to other watertight bulkheads if
closed vehicle and ro-ro spaces and special alternative means of drainage are practicable.
category spaces, refer Pt.6, Ch.7, Cl. 3.6.1.4 These arrangements are not permissible in
and 3.6.1.5. passenger ships.

2.11 Pump types 2.12.6 Where drain valves or cocks are fitted to
bulkheads other than collision bulkhead, as
2.11.1 The bilge pumps required by the rules permitted by 2.12.5, the drain valves or cocks
are to be of self-priming type, unless an are to be at all times readily accessible and are
approved priming system is provided for these to be capable of being shut off from positions
ships. above the bulkhead deck. Indicators are to be
provided to show whether the drains are open or
2.12 Bilge piping arrangements and fittings shut.

2.12.1 Bilge pipes are not, as far as possible, to 2.12.7 Bilge pipes which are required for
pass through double bottom tanks. If draining cargo or machinery spaces are to be
unavoidable, such bilge pipes are to be provided entirely distinct from sea inlet pipes or from
with welded joints or heavy flanged joints and pipes which may be used for filling or emptying
are to be tested after fitting to the same spaces where water or oil is carried. This does
pressure as the tanks through which they pass. not, however, exclude a bilge ejection
connection, a connecting pipe from a pump to its
2.12.2 The parts of bilge pipes passing through suction valve chest, or a deep tank suction pipe
deep tanks, intended to carry water ballast, suitably connected through a change-over
fresh water, liquid cargo or fuel oil are normally device to bilge, ballast or oil line.
to be contained in a pipe tunnel, but where this
is not done, the pipes are to be of heavy gauge 2.12.8 The arrangement of pumps, valves and
with welded or heavy flanged joints. The open piping is to be such that any pump could be
ends of such pipes are to be fitted with non- opened up for overhaul and repairs without
return valves. The pipes are to be tested, after affecting the operation of the other pumps.
fitting, to a pressure of not less than the
maximum head to which the tanks may be 2.12.9 The arrangement of valves, pumps,
subjected. cocks and their pipe connections is to be such
as to prevent the possibility of placing one
2.12.3 Expansion bends, not glands, are to be watertight compartment in communication with
fitted to pipes passing through double bottom another, or of cargo spaces, machinery spaces
tanks or deep tanks. or other dry spaces coming in communication

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with the sea or the tanks. For this purpose the 2.12.17 Where non-return valves are fitted to the
bilge suction pipe of any pump also having sea open ends of bilge suction pipes in cargo holds
suction is to be fitted with a non-return valve in order to decrease the risk of flooding, they are
which cannot permit communication between to be of an approved type which does not offer
the bilges and the sea or the compartments in undue obstruction to the flow of water.
use as tanks.
2.13 Additional requirements for passenger
2.12.10 Screw-down non-return valves are to be ships
provided in the following fittings :
2.13.1 All passenger ships are to have at least
a) Bilge distribution chest valves; three power bilge pumps connected to the bilge
main, one of which may be attached to the
b) Direct bilge suction and bilge pump propelling unit. Where the bilge pump numeral is
connection to main line; 30 or more, one additional independent power
pump is to be provided. Sanitary, ballast and
c) Bilge suction hose connections on the general service pumps may be accepted as
pumps or on the main line; independent power bilge pumps if fitted with
necessary connections to the bilge pumping
d) Emergency bilge suctions. system.

2.12.11 Bilge suction pipes from machinery The bilge pump numeral is to be calculated as
spaces and shaft tunnel, except emergency follows:
bilge suction, are to be led from easily
accessible mud boxes fitted with straight tail When P1 is greater than P : bilge pump numeral
pipes to the bilges. The open ends of the tail
pipes are not to be fitted with strum boxes. The ⎡ M + 2P1 ⎤
mud boxes are to be provided with covers which = 72 ⎢ ⎥
can be easily opened and closed for cleaning ⎣ V + P1 − P ⎦
purposes.
in other cases: bilge pump numeral
2.12.12 Strum boxes are to be fitted to the open
ends of bilge suction pipes from the cargo holds.
⎡ M + 2P ⎤
The diameter of holes from these strum boxes is = 72 ⎢ ⎥
not to be more than 10 [mm] and the total area ⎣ V ⎦
of the holes is not to be less than twice the area
of the pipes. where,
2.12.13 Where access manholes to bilge wells LL = the load line length of the ship (metres), as
are necessary, they are to be fitted as near to defined in Pt.3, Ch.1, Cl.2.1.9;
the suction strums as practicable.
M = the volume of the machinery space (cubic
2.12.14 Adequate distance is to be provided metres), as defined in Pt.6, Ch.1, Sec.3 that is
between the open ends of suction pipes and below the bulkhead deck; with the addition
bilge well bottom to permit adequate and easy thereto of the volume of any permanent oil fuel
flow of water and to facilitate cleaning. bunkers which may be situated above the inner
bottom and forward of, or abaft, the machinery
2.12.15 All the valves, cocks and mud boxes are space;
to be located in easily accessible positions
above or at the same level as the floor plates. P = the whole volume of the passenger and
Where this is unavoidable, they may be fitted crew spaces below the bulkhead deck (cubic
immediately below the floor plates provided the metres) which are provided for the
floor plates are capable of being opened and accommodation and use of passengers and
closed easily and suitable name plates are fitted crew, excluding baggage, store, provision and
indicating the fittings below. mail rooms;
2.12.16 Where relief valves are fitted to pumps V = the whole volume of the ship below the
having sea connections, these valves are to be bulkhead deck (cubic metres);
fitted in readily visible positions above the
platform. The arrangement is to be such that P1 = KN,
any discharge from the relief valves will also be
readily visible. where,

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return valve is to be fitted to the pipe in the
N = the number of passengers for which the compartment containing the open end.
ship is to be certified, and
For the purpose of 2.13.5 and 2.13.6, 'breadth'
K = 0.056LL means the maximum moulded breadth of the
ship at or below the deepest sub-division
However, where the value of KN is greater than loadline.
the sum of P and the whole volume of the actual
passenger spaces above the bulkhead deck, P1 2.13.6 All the distribution boxes, cocks and
is to be taken as the above sum (i.e. the sum of valves in connection with the bilge pumping
P and the whole volume of the actual passenger arrangements are to be in positions which are
spaces above the bulkhead deck) or two-thirds accessible at all times under ordinary
KN, whichever is the greater. circumstances. They are to be so arranged that,
in the event of flooding, one of the bilge pumps
2.13.2 Where practicable, the power bilge may be operative on any compartment, in
pumps are to be placed in watertight addition, damage to a pump or its pipe
compartments so arranged or situated that connecting to the bilge main outboard of a line
these compartments will not readily be flooded drawn at one-fifth of the breadth of the ship
by the same damage. If the engines and boilers (measured as per 2.13.5) is not to put the bilge
are in two or more watertight compartments, the system out of action. If there is only one system
pumps available for bilge service are to be of pipes common to all the pumps, the
distributed throughout these compartments as necessary cocks or valves for controlling the
far as is possible. bilge suctions must be capable of being
operated from above the bulkhead deck. Where
2.13.3 On ships 91.5 [m] or more in length or in addition to the main bilge pumping system an
having a bilge pump numeral of 30 or more, the emergency bilge pumping system is provided, it
arrangements are to be such that at least one is to be independent of the main system and so
power pump is available for use in all ordinary arranged that a pump is capable of operating on
circumstances in which a ship may be flooded at any compartment under flooding conditions, in
sea. This requirement will be satisfied if: that case only the cocks and valves necessary
for the operation of the emergency system need
a) One of the required pumps is an emergency be capable of being operated from above the
pump of reliable submersible type having a bulkhead deck.
source of power situated above the
bulkhead deck; or 2.13.7 All valves and cocks mentioned in 2.13.6
which can be operated from above the bulkhead
b) The pumps and their sources of power are deck shall have their controls at their place of
so disposed throughout the length of the operation clearly marked and provided with
ship that under any condition of flooding means to indicate whether they are open or
which the ship is required to withstand, at closed.
least one pump in undamaged compartment
will be available. 2.13.8 Where it is necessary to correct large
angles of heel, in case of damage, the means
2.13.4 In passenger ships, independent power adopted, are where practicable, to be self
bilge pumps situated in machinery spaces are to acting, but in any case where controls to cross
have direct suctions from these spaces, except flooding fittings are provided, they are to be
that not more than two such suctions are operable from above the bulkhead deck.
required in any one space, where two or more
such suctions are provided there is to be at least 2.13.9 Bilge wells constructed in the double
one on the port side and one on the starboard bottom in connection with drainage
side. arrangements of holds, etc. are not to extend
downwards more than necessary. The depth of
2.13.5 Provision is to be made to prevent the the well is in no case to be more than the depth
compartment served by any bilge suction pipe less 457 [mm] (18 inches) of the double bottom
being flooded in the event of the pipe being at the center line nor is the well to extend below
severed, or otherwise damaged by collision or the horizontal plane passing through the point of
grounding in any other compartment. For this intersection with the frame line amidships of a
purpose where the pipe is at any part situated transverse diagonal line inclined at 25 degrees
nearer the side of the ship than one-fifth the to the base line and cutting it at a point one half
breadth of the ship (measured at right angles to the ship's moulded breadth from the middle line.
the centerline at the level of the deepest A well extending to the outer bottom is,
subdivision loadline), or in a duct keel, a non-

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however, permitted at the after end of the shaft 2.15 Ballast system
tunnel.
2.15.1 Provision is to be made for ballasting and
2.14 Drainage arrangements on vessels not deballasting all the ballast tanks by pipe lines
fitted with propelling machinery which are entirely separate and distinct from
pipe lines used for bilging.
2.14.1 Vessels not fitted with propelling
machinery are to be provided effective hand 2.15.2 Where the length of the ballast tanks
pumps which can be operated from above the exceeds 30 [m], an additional suction is to be
bulkhead deck or the highest convenient level provided at the forward end of the tanks. Where
which is always available. There is to be one the width of the tank is unusually large, suction
pump for each compartment or two pumps near the centerline in addition to wing suctions
connected to a bilge main having at least one may be required.
branch to each compartment.

Section 3

Vents, Sounding, Overflow and Scuppers and

Discharges Piping Systems

3.1 General 3.2.4 Vent pipes to double bottom tanks, deep

tanks extending to the shell plating or tanks
3.1.1 Reference to oil in this Section is to be which can be run up from the sea and sea
taken to mean oil which has a flash point of chests are to be led above the bulkhead deck.
60°C or above (closed cup test).
3.2.5 Air pipes for sea chests are to be fitted
3.1.2 The portions of vent, overflow and with shut off valve directly on sea chest.
sounding pipes fitted above the weather deck
are to be of steel. 3.2.6 Vent pipes to oil fuel and cargo oil tanks,
cofferdams, all tanks which can be pumped up,
3.1.3 Name plates are to be affixed to the upper shaft tunnels and pipe tunnels are to be led
ends of all vent and sounding pipes. above the bulkhead deck and to open air.

3.1.4 For vent pipes and sounding pipes passing 3.2.7 Vent pipes from lubricating oil storage
through refrigerated spaces, see Pt.5. tanks may terminate in the machinery spaces,
provided that the open ends are so situated that
3.1.5 For design and test heads of tanks see issuing oil cannot come into contact with
Pt.3. electrical equipment or heated surfaces.

3.2 Vent pipes 3.2.8 The open ends of vent pipes to oil fuel and
cargo oil tanks are to be situated where no
3.2.1 Vent pipes are to be fitted to all tanks, danger will be incurred from issuing oil or vapour
cofferdams, tunnels, sea chests and other when the tank is being filled.
compartments which are not fitted with
alternative ventilation arrangements. 3.2.9 For details regarding height and closing
devices for vent pipes see Pt.3.
3.2.2 The vent pipes are to be fitted at the
opposite end of the tank to which the filling pipes 3.2.10 The open ends of vent pipes to oil fuel,
are placed and/or at the highest part of the tank. cargo oil and ballast tanks fitted with anodes for
Where the tank top is of unusual or irregular cathodic protection, are to be fitted with a wire
profile, special consideration will be given to the gauze diaphragm of incorrodible material which
number and positions of the vent pipes. can be readily removed for cleaning. The clear
area through the wire gauze is to be at least
3.2.3 Tanks provided with anodes for cathodic equal to the area of the vent pipe. Location and
protection, are to be provided with vent pipes at arrangement of vent pipes for fuel oil service,
forward and aft ends. settling and lubricating oil tanks is to be such
that a broken vent pipe will not directly lead to

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the risk of ingress of seawater splashes or 3.3.4 Overflow pipes from tanks, other than oil
rainwater. fuel, cargo oil and lubricating oil tanks, are to be
led to the open or to suitable overflow tanks
3.2.11 In the case of all tanks which can be arranged as in 3.3.3.
pumped up either by ship's pumps or by shore
pumps through a filling main, the total cross- 3.3.5 Where overflow from tanks, which are
sectional area of the vent pipes to each tank, or used for the alternative carriage of oil and water
of the overflow pipes where an overflow system ballast, are connected to an overflow system,
is provided, is to be not less than 25 per cent arrangements are to be made to prevent water
greater than the effective area of the respective ballast overflowing in to tanks containing oil.
filling pipes.
3.3.6 The arrangement of the vent and/or
3.2.12 Where tanks are fitted with cross flooding overflow system is to be such that in the event
connections, the vent pipes are to be of of any one of the tanks being bilged, tanks
adequate area for these connections. situated in other watertight compartments of the
ship cannot be flooded through combined vent
3.2.13 Vent pipes are not to be less than 50 pipes or the overflow main. In the case of
[mm] bore. vessels of 24 [m] length and less, fishing
vessels and trawlers the arrangement is to be
3.2.14 Shaft tunnels and pipe tunnels are to be such that in the event of any one of the tanks
fitted with vent pipes with an internal diameter of being bilged, the other tanks cannot be flooded
not less than 75 [mm]. from the sea through combined vent pipes or the
overflow main.
3.2.15 Vent pipes are to be self-draining under
normal conditions of trim. 3.3.7 Overflow pipes are to be self-draining
under normal conditions of trim.
3.2.16 The thickness of the exposed portion of
the vent pipes are to be as required in Pt.3, 3.3.8 For size of overflow pipes, see 3.2.11.
Ch.13, 3.2.5.
3.4 Sounding arrangements (Also refer Pt.6,
3.3 Overflow pipes Ch.2, 1.2.2.3.5)

3.3.1 All tanks which can be pumped up are to 3.4.1 All tanks, cofferdams and pipe tunnels are
be fitted with overflow pipes when the pressure to be provided with sounding pipes or other
head corresponding to the height of vent pipe is approved means for ascertaining the level of
greater than that for which the tanks are suitable liquid in the tanks. Means of ascertaining the
or when the sectional area of the vent pipes is level of liquid in oil fuel tanks is to be of safe
less than that required by 3.2.11. type. Level switches may be used provided they
are contained in steel enclosure or other
3.3.2 Oil fuel and lubricating oil tanks which can enclosures not destroyed by fire. Bilges of
be pumped up and which have openings for compartments which are not, at all times, readily
fittings, for example - for a float sounding accessible are to be provided with sounding
system, are to be fitted with overflow pipes. The pipes. The soundings are to be taken as near
tank openings, for such fittings, are to be the suction pipes as practicable.
situated above the highest point of the overflow
piping. 3.4.2 Oil level gauges may be used for tanks
containing lubricating oil, oil fuel or other
3.3.3 In the case of oil fuel and lubricating oil flammable liquid in place of sounding pipes,
tanks, the overflow pipe is to be led to an subject to the following conditions:
overflow tank of adequate capacity or to a
storage tank having space reserved for overflow - In passenger ships such gauges should not
purposes and be in readily visible position. A require penetration below the top of the tank
sight glass is to be provided in the overflow pipe and their failure or overfilling of the tanks will
to indicate when the tanks are overflowing. Such not allow release of their contents; and
sight glasses are to be placed only in the vertical
portion of the pipes and be located in a readily - In cargo ships, the failure of level gauges or
visible position. Alternatively, an alarm device is overfilling of the tank will not allow release
to be provided to give warning either when the of their contents into the space. The use of
tanks are overflowing or when the oil reaches a cylindrical gauge glasses is not acceptable.
predetermined level in the tanks. Flat type glasses may be accepted provided
they are of heat resisting quality, adequately
supported, protected from mechanical

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damage and fitted with self closing valves coming into contact with source of ignition.
between the gauges and the tanks. The short sounding pipes are to be
arranged in such a way that overflow or oil
3.4.3 Except as permitted by 3.4.4 sounding spray will not reach any of machinery
pipes are to be led to positions above the components mentioned above.
bulkhead deck which are at all times accessible.
In the case of oil fuel tanks, cargo oil tanks and - The short sounding pipes for fuel oil and
lubricating oil tanks, the sounding pipes are to flammable oil tanks are to be fitted with self-
be led to safe positions on the open deck. The closing cocks having cylindrical plugs with
sounding pipes should not terminate in any weight loaded levers permanently attached
space where the risk of ignition from spillage and with pedals for opening or other
from sounding pipe exists. Sounding pipes are approved arrangements. The sounding
not to terminate in passenger or crew spaces. pipes are to be provided with small diameter
self closing control cock located below
3.4.4 Where it is impracticable to comply with cylindrical self closing cocks for the purpose
3.4.3 above, short sounding pipes may be fitted of ascertaining the presence of oil in the
in readily accessible positions as indicated in the pipe before sounding pipe is opened.
following: Provision must be made so as to ensure
that any spillage of oil through the control
a) Passenger ships: cock involves no ignition hazard.

- Only to double bottom tanks and 3.4.6 Elbow sounding pipes are not to be used
cofferdams in machinery spaces. for deep tanks unless the elbows and pipes are
situated within closed cofferdams or within tanks
- All short sounding pipes are to be containing similar liquids. They may, however,
provided with self closing cocks as be fitted to other tanks and may be used for
described in 3.4.5. sounding bilges, provided that it is not
practicable to lead them direct to the tanks or
b) Cargo ships: compartments.

- Only to tanks and cofferdams in a) The elbows are to be of heavy construction

machinery spaces and shaft tunnels. and adequately supported;

- Short sounding pipes to fuel oil and b) In passenger ships, elbow sounding pipes
flammable oil tanks are to be provided are not permissible.
with self closing cocks as described in
3.4.5. Short sounding pipes to other 3.4.7 Striking plates of adequate thickness and
types of tanks and cofferdams may be size are to be fitted under open ended sounding
fitted with screw caps attached by chain pipes. Where slotted pipes having closed ends
to the pipe or with shut-off cocks. are employed, the closing plugs are to be of
substantial construction.
3.4.5 If short sounding pipes are fitted to oil
tanks in machinery spaces, all the following 3.4.8 All sounding pipes are to be not less than
requirements are to be met: 32 [mm] bore. All sounding pipes, whether for
compartments or tanks, which pass through
- For fuel oil and flammable oil tanks an oil refrigerated spaces or the insulation thereof, in
level gauge complying with requirements of which the temperatures contemplated are 0°C or
3.4.2 is to be provided in addition. below, are to be not less than 65 [mm] bore.
(However, in case of fuel and flammable
liquid tanks other than double bottom tanks 3.4.9 The upper ends of all sounding pipes are
and fitted with overflow arrangement, this to be provided with efficient closing devices. The
level gauge need not be fitted). sounding pipes are to be arranged as straight as
practicable, and if curved, the curvature is to be
- Short sounding pipes to oil fuel tanks, large enough to permit easy passage of
flammable oil tanks and lubricating oil tanks sounding rod/chain.
are not to be placed in the vicinity of boilers,
preheaters, heated surfaces, electric 3.5 Scuppers and discharges (Also refer Pt.3,
generators or motors with commutator or Ch.13)
collector rings or electric appliances which
are not totally enclosed, unless precautions 3.5.1 Scupper and discharge pipes which are
are taken such as the fitting of effective not required to be of substantial thickness in
screens to prevent the oil spillage from accordance with Pt.3 are to be at least 4.5 [mm]
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thick for pipes of 155 [mm] external diameter having a single cargo hold below the freeboard
and less; and 6.0 [mm] for pipes of external deck or cargo holds below the freeboard deck
diameter of 230 [mm] and more, intermediate which are not separated by at least one full
sizes are to be determined by linear watertight bulkhead, are to be fitted with water
interpolation. level detectors in such cargo hold/s, unless
exempted by 3.6.3.
3.5.2 Scupper and discharge pipes which are
required to be of substantial thickness in 3.6.2 The water level detectors are to:
accordance with Pt.3 are to be at least of
following thickness: i) give an audible and visual alarm at the
navigation bridge when the water level
- 7 [mm] thick for pipes of external diameter above the inner bottom in the cargo hold
of equal to or less than 80 [mm]; reaches a height of not less than 0.3 [m]
and another when such level reaches
- 10 [mm] thick for pipes of external diameter not more than 15% of the mean depth of
equal to 180 [mm]; the cargo hold; and

- 12.5 [mm] thick for pipes of external ii) be fitted at the aft end of the hold, or
diameter equal to or more than 220 [mm]; above its lowest part where the inner
bottom is not parallel to the design
Intermediate sizes are to be determined by waterline. Where webs or partial
linear interpolation. watertight bulkheads are fitted above
the inner bottom, fitting of additional
3.5.3 Overboard discharges are to be so located detectors may be required.
as to prevent any discharge of water into the life
boats. 3.6.3 The water level detectors required in 3.6.1
need not be fitted in ships having watertight side
3.6 Water level detectors on single hold compartments each side of the cargo hold
cargo ships other than bulk carriers length extending vertically at least from inner
bottom to freeboard deck.
3.6.1 Ships of load line length LLL (see Pt.3,
Ch.1 for definition of LLL) less than 80 [m] and

Section 4

Fuel Oil Systems

4.1 General in 4.5.3 Where water tube boilers are installed,

there is to be a space of at least 760 [mm]
4.1.1 Reference to oil in this Section is to be between the tanktop and the underside of the
taken to mean oil which has a flash point of pans forming the bottom of the combustion
60°C (closed cup test) or above. spaces. The boilers are to be adequately
lagged.
4.2 Oil fuel tanks
4.2.3 Oil fuel tanks are not to be located directly
4.2.1 Oil fuel tanks are to be separated from above the boilers or other highly heated
fresh water and lubricating oil tanks by means of surfaces.
cofferdams. For requirements in respect of
protective location of fuel oil tanks, see Pt.3, 4.2.4 Minimum two fuel oil service tanks for
Ch.1, Sec.1.6. each type of fuel used on board necessary for
propulsion and vital systems or equivalent
4.2.2 The clearance spaces between the boilers arrangements (See Fig. 4.2.4 for equivalent
and tops of the double bottom tanks, and arrangement) are to be provided with a capacity
between the boilers and the sides of the storage of at least 8 hours at maximum continuous
tanks in which oil fuel and cargo oil is carried, rating of the propulsion plant and normal
are to be adequate for the free circulation of the operating load of the generating plant.
air necessary to keep the temperature of the
stored oil sufficiently below it's flash point except
in the case of tanks complying with arrangement

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Fig.4.2.4 : ‘Equivalent arrangement’ for F.O. service tanks (Refer Clause 4.2.4)

A) Main and auxiliary engines and boilers operating on heavy fuel (one fuel ship)

Rule requirements

HFO Serv Tank HFO Serv Tank MDO Tank

Capacity for at least 8.h each Capacity for at least 8.h each For initial cold starting or
Main Eng + Main Eng + repair work of engines/Boiler
Aux. Eng + Aux. Eng +
Aux Boiler Aux Boiler

Equivalent arrangements

HFO Serv Tank MDO Serv Tank

Capacity for at least 8.h each Capacity for at least 8.h each
Main Eng + Main Eng +
Aux. Eng + Aux. Eng +
Aux Boiler Aux Boiler

The above arrangement only applies where main and auxiliary engines can operate with heavy fuel oil
under all load conditions and, in the case of main engines, during manoeuvring.

For pilot burners of auxiliary boilers if provided, an additional MDO tank for 8 h operation may be
necessary.

B) Main engines and boilers on HFO and aux. Engines on MDO (two fuel ship)

Rule requirement

HFO Serv Tank HFO Serv Tank MDO Serv MDO Serv Tank
Capacity for at least Capacity for at least Tank Capacity for at least 8.h
8.h each 8.h each Capacity for at each Aux. Eng
Main Eng + Main Eng + least 8.h each
Aux Boiler Aux Boiler Aux. Eng

Equivalent arrangement

HFO Serv Tank MDO Serv Tank

Capacity for at least Capacity for at least MDO Serv Tank
8.h each the highest of : Capacity for at least
Main Eng + 8h each Aux. Eng the highest of :
Aux Boiler + Aux. Boiler or 8h each Aux. Eng +
4h each Main Eng + Aux Boiler or
Aux. Eng + 4h each Main Eng +
Aux Boiler Aux. Eng +
Aux Boiler

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Fig.4.2.4 : (Contd.)

Notes:

1. The arrangements in A) and B) above apply, provided the propulsion and vital systems which use two
types of fuel, support rapid fuel change over and are capable of operating in all normal operating
conditions at sea with both types of fuel (MDO and HFO)

2. Service tank is a fuel oil tank which contains only fuel of a quality ready for use, i.e. fuel of a grade and
quality that meets the specification required by the equipment manufacturer. A service tank is to be
declared as such and not to be used for any other purpose.

3. Use of a settling tank with or without purifiers alone and one service tank is not acceptable as an
“equivalent arrangement” to two service tanks.

4. The equivalent arrangements described above are the interpretations followed by IRS, unless the flag
administration has provided a different interpretation.

4.3 Oil fuel piping 4.3.7 Pipes for tanks storing fresh water are to
be separate and distinct from any pipes which
4.3.1 Oil fuel pressure pipes are to be led, may be used for oil or oily water, and are not to
where practicable, remote from heated surfaces be led through tanks which contain oil, nor are
and electrical appliances, but where this is oil pipes to be led through fresh water tanks.
impracticable the pipes are to have a minimum
number of joints and are to be led in well lighted 4.3.8 Pipes conveying vegetable oils or similar
and readily visible positions. cargo oils are not to be led through oil fuel
tanks, nor are oil fuel pipes to be led through
4.3.2 Pipes conveying oil heated above 60°C tanks containing such cargoes.
are to be of seamless steel or other approved
material having flanged or welded joints. 4.3.9 In passenger ships, provision is to be
made for the transfer of oil fuel from any oil fuel
4.3.3 The flanges are to be machined, and the storage or settling tank to any other oil fuel
jointing material, which is to be impervious to oil storage tank.
heated to 150°C, is to be the thinnest possible,
so that the flanges are practically metal to metal. 4.3.10 Where IRS may permit the conveying of
The scantlings of the pipes and their flanges are oil and combustible liquids through accommo-
to be suitable for a pressure of at least 14 bar or dation and service spaces, the pipes conveying
for the design pressure, whichever is the oil or combustible liquids are to be of a material
greater. approved by IRS having regard to the risk of fire.

4.3.4 The short joining lengths of pipes to the 4.4 Arrangement of valves, cocks, pumps
burners from the control valves at the boiler may and fittings
have cone unions, provided these are of
specially robust construction. 4.4.1 The oil fuel pumping arrangements are to
be distinct from other pumping systems as far as
4.3.5 Flexible hoses of approved material and practicable and the means provided for
design may be used for the burner pipes, preventing dangerous interconnection in service
provided that spare length complete with are to be thoroughly effective.
couplings, are carried on board.
4.3.6 Transfer, suction and other low pressure 4.4.2 All valves and cocks forming part of the oil
oil pipes and all pipes passing through oil fuel installation are to be capable of being
storage tanks are to be made of cast iron or controlled from readily accessible positions
steel, having flanged joints suitable for a working which, in the engine room and boiler spaces are
pressure of not less than 7 bar. The flanges are to be above the working platform.
to be machined and the jointing material is to be
impervious to oil. Where the pipes are of 25 4.4.3 Every oil fuel suction pipe from a double
[mm] bore or less, they may be seamless bottom tank is to be fitted with a valve or a cock.
copper or copper alloy, except those which pass
through storage tanks. 4.4.4 For oil fuel tanks which are situated above
the double bottom tanks, the inlet and outlet,
pipes which are connected to the tank at a point

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lower than the outlet of the overflow pipe or

below the top of the tanks without an overflow 4.4.11 Relief valves are to be fitted on the oil
pipe, are to be fitted with shut off valves located side of the heaters and are to be adjusted to
on the tank itself. operate at a pressure of 3.5 bar above that of
the supply pump relief valves. The discharge
4.4.5 In the engine and boiler spaces, valves, from the relief valves is to be led to a safe
mentioned in 4.4.4, are to be capable of being position.
closed locally and from positions outside these
spaces which will always be accessible in the 4.4.12 Drip trays are to be fitted at location
event of fire occurring in these spaces. where frequent leakage is expected, oil burners
Instructions for closing the valves are to be at furnace mouths, drain and valves under daily
indicated at the valves and at the remote control service tanks, filter and all other oil fuel
positions. The controls for remote operation of appliances which are required to be opened up
the quick closing valve for the emergency frequently for cleaning or adjustment. Where
generator fuel tank are to be in a separate drain pipes are provided from collected
location from other quick closing valves for tanks leakages, they shall be led to a suitable oil drain
in the engine room. tank not forming part of an overflow system.

4.4.6 Every oil fuel suction pipe which is led into 4.4.13 Where MARPOL Regulation I/12A for
the engine and boiler spaces, from a tank protective location of fuel oil tanks applies (see
situated above the double bottom, outside these Pt.3, Ch.1, Sec.1.6), the fuel oil lines, suction
spaces (including shaft tunnel, pipe tunnel or wells and valves are to satisfy the requirements
similar spaces), is to be fitted in the machinery of paragraph 9 and 10 of the above MARPOL
space with a valve controlled as in 4.4.5, except Regulation.
where the valve on the tank is already capable
of being closed from an accessible position Valves for such fuel oil tanks are to be located
above the bulkhead deck. above the bottom at distances not less than that
required for suction wells` in paragraph 10 of
4.4.7 Settling tanks are to be provided with MARPOL Regulation I/12A. Plan showing the
means for draining water from the bottom of the location of tanks, suction wells and valves,
tanks. If the settling tanks are not provided, the indicating the distances are to be submitted for
oil fuel bunkers or daily service tanks are to be approval.
fitted with water drains.
The requirements for locations of oil fuel lines do
Open drains for removing water from oil tanks not apply to fuel oil air escapes and overflow
are to be fitted with valves or cocks of self- pipes.
closing type, and suitable provision is to be
made for collecting the oily discharge. 4.5 Heating arrangements

4.4.8 Where a power driven pump is necessary 4.5.1 Steam heating installation
for transferring oil fuel, a stand by pump is to be
provided and connected ready for use, or, 4.5.1.1 Where steam is used for heating oil fuel,
alternatively, emergency connections may be cargo oil or lubricating oil, in bunkers, tanks,
made to another suitable power driven pump. heaters or separators, the exhaust drains are to
discharge the condensate into an observation
4.4.9 All pumps which are capable of developing tank in a well lighted and accessible position
a pressure exceeding the design pressure of the where it can be readily seen whether or not it is
system are to be provided with relief valves. free from oil.
Each relief valve is to be in close circuit, i.e.
arranged to discharge back to the suction side 4.5.2 Thermal oil installations
of the pump and to effectively limit the pump
discharge pressure to the design pressure of the 4.5.2.1 The inlet and outlet valves of oil-fired
system. Pressure relief valves need not be fitted thermal oil heaters and exhaust-fired thermal oil
when the system is secured only by centrifugal heaters is to be controllable from outside the
pumps so designed that the pressure delivered compartment where they are situated.
cannot exceed that for which the piping is Alternatively an arrangement for quick gravity
designed. drainage of the thermal oil contained in the
system into a collecting tank is acceptable.
4.4.10 Valves or cocks are to be interposed
between the pumps on the suction and 4.5.2.2 Heating of liquid cargoes with flash
discharge pipes in order that any pump may be points below 60°C shall be arranged by means
shut off for opening up and overhaul.

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of a separate secondary system, located 4.5.3 Oil fuel in storage tanks is not to be heated
completely within the cargo area. to a temperature within 10°C below the flash
point of the oil. Where oil fuel in service tanks,
A single circuit system is acceptable on the settling tanks and any other tanks in the supply
following conditions: system is heated following arrangements are to
be provided:
- system is so arranged that a positive
pressure in the coil shall be at least 3 [m] - The length of the vent pipes from such tanks
water column above the static head of the and/or a cooling device is sufficient for
cargo when circulating pump is not in cooling the vapours to below 60°C;
operation, otherwise the outlet of the vent pipes is to
be located at least 3 m away from a source
- the thermal oil system expansion tank shall of ignition;
be fitted with high and low level alarms,
- There are no openings from the vapour
- means to be provided in the thermal oil space of the fuel tanks in to machinery
system expansion tank for detection of spaces (bolted manholes are acceptable);
flammable cargo vapours. Portable
equipment is accepted, - Any enclosed spaces are not to be located
directly above such oil fuel tanks, except for
- valves for the individual heating coils is to vented cofferdams; and
be provided with locking arrangement to
ensure that the coils are under static - Electrical equipment is not to be fitted in the
pressure at all times. vapour space of the tanks, unless they are
certified intrinsically safe.
4.5.2.3 The thermal oil circulating pumps is to be
arranged for emergency stopping from a 4.6 Temperature indication
position outside the space where they are
situated. 4.6.1 Tanks and heaters in which oil is heated
are to be provided with suitable means for
4.5.2.4 Vents from expansion tanks and thermal ascertaining the temperature of the oil.
oil storage tanks of thermal oil heating plants is
to be led to open deck. 4.7 Filling arrangements

4.5.2.5 Exhaust-fired thermal oil heaters 4.7.1 The bunkering of the ship is to be carried
out through a permanently fitted pipeline,
− The heater is to be so designed and provided with the required fittings and ensuring
installed that all tubes are easily and readily fuel delivery to all storage tanks. The open end
be inspected for signs of corrosion and of the filling pipe is to be led to the tank bottom.
leakage.
In passenger ships fuel bunkering stations are to
− Visual inspection and tightness testing of be isolated from other spaces and are to be
the heater tubes is to be not less than the efficiently drained and ventilated.
working pressure and is to be carried out
annually. Hydraulic testing is to be carried 4.7.2 Provision is to be made against over-
out bi-annually. pressure in the filling pipes, served by pumps on
board, and any relief valve fitted for this purpose
− The heater is to be fitted with temperature is to discharge into an overflow tank or other
sensor(s) and an alarm for fire detection. safe position.

− A fixed fire extinguishing and cooling system 4.8 Alternate carriage of oil fuel and water
is to be fitted. A drenching system providing ballast
copious amounts of water is acceptable.
The exhaust ducting below the exhaust 4.8.1 Where it is intended to carry oil fuel and
boiler is to be arranged for adequate water ballast in the same tanks alternatively, the
collection and drainage, to prevent water valves or cocks connecting the suction pipes of
flowing into the diesel engine. The drain is these tanks with the ballast pump and those
to be led to a suitable location. connecting them with the oil fuel transfer pump
are to be so arranged that the oil may be
pumped from one tank by the oil fuel pump at

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the same time as the ballast pump is being used arranged that one filter can be opened up when
on any other tank. the other is in use.

Where settling or service tanks are fitted, each 4.10.1.4 Where steam is required to bring the
having a capacity sufficient to permit 12 hour boiler plant into operation, starting up oil fuel
normal service without replenishment, the above unit, including an auxiliary heater and hand
requirement may be dispensed with. pump, or other suitable starting up device, which
does not require power from shore, is to be
4.8.2 Attention is drawn to the statutory provided.
requirements issued by the National Authorities
in connection with International Convention for 4.10.1.5 Where burners are provided with steam
the Prevention of Pollution of the Sea by Oil, purging and/or atomizing connections, the
1973/78. arrangements are to be such that oil fuel cannot
find its way into steam system in the event of
4.9 Deep tanks for the alternative carriage of valve leakage.
oil, water ballast or dry cargo
4.10.1.6 The burner arrangements are to be
4.9.1 In the case of deep tanks which can be such that a burner cannot be withdrawn unless
used for the carriage of oil fuel, cargo oil, water the oil fuel supply to that burner is shut off and
ballast or dry cargo, provision is to be made for that oil cannot be turned on unless the burner
blank flanging the oil and water ballast filling and has been correctly coupled to the supply line.
suction pipes, also the steam coils if retained in
place, when the tank is used for dry cargo, and 4.10.1.7 A quick-closing master valve is to be
for blank flanging the bilge suction pipes when fitted to the oil supply to each boiler manifold,
the tanks are used for oil or water ballast. suitably located so that the valve can be readily
operated in an emergency, either directly or by
4.9.2 If the deep tanks are connected to an means of remote control, having regard to the
overflow system, the arrangements are to be machinery arrangements and location of
such that liquid or vapour from other tanks controls.
cannot enter the deep tanks when dry cargo is
carried in them. 4.10.1.8 In the case of top-fired boilers, means
are to be provided so that, in the event of flame
4.10 Oil fuel burning arrangements failure, oil fuel supply to the burners is shut off
automatically, and audible and visual warnings
4.10.1 For boilers are given.

4.10.1.1 Where steam is required for the main 4.10.1.9 Provision is to be made, by suitable
propelling engines, for auxiliary machinery for non-return arrangements, to prevent oil from
essential services, or for heating of heavy fuel spill systems being returned to the burners when
oil and is generated by burning oil fuel under oil supply to these burners has been shut off.
pressure, there are to be not less than two oil
burning units, each unit comprising a pressure 4.10.1.10 For alternatively fired furnaces of the
pump, suction and discharge filters and a boilers using exhaust gases and oil fuel, the
heater. For auxiliary boilers, a single oil burning exhaust gas inlet pipe is to be provided with an
unit may be accepted, provided that alternative isolating device and interlocking arrangements
means, such as an exhaust gas boiler or whereby oil fuel can only be supplied to the
composite boiler, are available for supplying burners when the isolating device is closed to
steam for essential services. the boiler.

4.10.1.2 In two unit installations, each unit is to 4.10.2 For internal combustion engines
be capable of supplying fuel for generating all
the steam required for essential services. In 4.10.2.1 Filters are to be fitted in the supply lines
installations of three or more units, the to the main and auxiliary machinery. For non-
capacities and arrangements of the units are to redundant units for essential services, it must be
be such that all the steam required for essential possible to clean the filters without stopping the
services can be maintained with any one unit unit or reducing the supply of filtered oil to the
out of action. unit.

4.10.1.3 In systems where oil is fed to the For auxiliary engines one single oil fuel filter for
burners by gravity, duplex filters are to be fitted each engine may be accepted.
in the supply pipeline to the burners and so

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4.10.2.2 Where an oil fuel booster pump is fitted, accessible in the event of a fire occurring in the
which is essential to the operation of the main galley.
engine(s), a standby pump is to be provided.
The standby pump is to be connected ready for 4.10.3.2 The galley is to be well ventilated.
immediate use but where two or more main
engines are fitted, each with its own pump, a 4.11 Remote stop of oil fuel pumps and fans
complete spare pump may be accepted
provided that it is readily accessible and can be 4.11.1 Emergency stop of power supply to the
easily installed. following pumps and fans is to be arranged from
a central place outside the engine and boiler
4.10.2.3 Where pumps are provided for fuel room:
valve cooling, the arrangements are to be as in
4.10.2.2. - oil fuel transfer pump;

4.10.2.4 In multi-engine installations which are - oil fuel booster pump;

supplied from the same fuel source, means of
isolating the fuel supply and spill piping to - nozzle cooling pumps when oil fuel is
individual engines, shall be provided. The used as coolant;
means of isolation shall not affect the operation
of the other engines and shall be operable from - oil fuel purifiers;
a position not rendered inaccessible by a fire on
any of the engines. - pumps for oil-burning installations;

4.10.3 Oil fired galleys - fans for forced draught to boilers;

4.10.3.1 The fuel supply to the burners is to be - fans for ventilation of engine and boiler
controlled from a position which will always be rooms.

Section 5

Steam Piping and Condensate Piping Systems

5.1 Expansion and drainage such arrangements are to be submitted for

consideration.
5.1.1 In all steam piping systems, ample
provision is to be made for expansion and 5.2.2 Where the steam pipes pass through shaft
contraction to take place without unduly tunnels and pipe tunnels, these are to be
straining the pipes. efficiently secured and insulated in such a way
that the lagging surface temperature does not
5.1.2 The slope of the pipes and the number exceed 60°C.
and position of the drain valves or cocks are to
be such that water can be efficiently drained 5.3 Relief valves
from any portion of the steam piping system,
when the ship is on even keel and/or designed 5.3.1 Auxiliary steam lines not designed to
trim and is either upright or has a list of not more withstand boiler pressure are to be fitted with
than 5 degrees. relief valves, installed on the low pressure side,
immediately after pressure reducing valve,
5.1.3 Drain valves or cocks are to be readily having sufficient discharge capacity to protect
accessible. the piping against excessive pressure.

5.2 Steam pipes in way of holds, shaft and 5.4 Steam supply to auxiliaries
pipe tunnels
5.4.1 The steam supply to steering gear and
5.2.1 In general, steam pipes are not to be led essential auxiliaries is to be so arranged that it is
through spaces which may be used for carrying not affected in the event of main steam supply to
cargo. But where it is impracticable to avoid propulsion machinery or cargo oil pumps being
steam pipes passing through cargo spaces, the shut off.
pipes are to be efficiently insulated, secured and
protected against mechanical damage. Plans for

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5.5 Steam for fire extinguishing in cargo the main and auxiliary condensers, at least one
holds of which is to be independently driven. Where
one of the independent feed pumps is fitted with
5.5.1 Where steam is used for fire extinguishing direct suctions from the condensers and a
in cargo holds, provision is to be made to discharge to the feed tank, it may be accepted
prevent damage to cargo by leakage of steam or as an independently driven extraction pump.
drip. Details of proposed precautionary measu-
res are to be submitted for approval. 5.6.2 Condensate pumps are to be provided
with valves or cocks, interposed between the
5.6 Condensate pumps pumps and the suctions and the discharge
pipes, so that any pump may be opened up for
5.6.1 Two or more extraction pumps are to be overhaul while the others continue in operation.
provided for dealing with the condensate from

Section 6

Boiler Feed Piping Systems

6.1 Feed water piping

6.3 Valves, cocks and fittings
6.1.1 Two separate means of feed are to be
provided for all main and auxiliary boilers, which 6.3.1 Independent feed pumps, required for
are required for essential services, with the feeding the main boilers, are to be fitted with
exception of boilers in which steam is generated automatic regulators for controlling their output.
exclusively by exhaust gases or steam, where
one means of feed will be accepted provided an 6.3.2 The valves on the suction pipes from
alternative steam supply is available. hotwell or condenser and the feed drain tanks or
filter are to be of the non-return type.
IR6.1.1 Where a steam generating system
consists of two or more adequately sized 6.3.3 Feed pumps are to be provided with
boilers, one independent feed water supply pipe valves or cocks, interposed between the pumps
to each boiler from two feed pumps is and the suction and the discharge pipes, so that
considered acceptable. any pump may be opened up for overhaul while
the others continue in operation.
6.2 Feed pumps
6.4 Fresh-water connections
6.2.1 Two or more feed pumps are to be
provided of sufficient capacity to supply the 6.4.1 Feed pumps for water-tube boilers are to
boilers under full load conditions with any one have fresh-water connections only.
pump out of action. At least one of these pumps
is to be independently driven. 6.5 Feed water tanks

6.2.2 In multiple screw ships in which there is 6.5.1 All ships fitted with boilers are to be
only one independently driven feed pump, each provided with storage space for reserve feed
main engine is to be provided with a feed pump. water. Capacity of these tanks is to be at least
twice the hourly evaporation rate of the boilers.
6.2.3 Where only one independent feed pump
has been provided, a harbour feed pump or an 6.5.2 Feed water tanks are to be separated from
injector is to be fitted to provide second means oil tanks by cofferdam.
of feed to the boilers which are in use when the
main engines are not working. 6.6 Evaporators

6.2.4 The harbour feed pump, as required by 6.6.1 For main boilers, one or more evaporators,
6.2.3, may be used as general service pump, of adequate capacity, are to be provided.
provided that it is not connected to tanks
containing oil, or to tanks, cofferdams and bilges
which may contain oily water.

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Section 7

Engine Cooling Water Systems

7.1 General of cooling need not be fitted if there are

suitable emergency connections from a salt
7.1.1 Centrifugal cooling water pumps are to be water system;
installed as low as possible in the ship.
e) Where each auxiliary is fitted with a cooling
7.2 Cooling water main supply water pump, standby means of cooling need
not be provided for auxiliaries. Where,
7.2.1 Provision is to be made for an adequate however a group of auxiliaries is supplied
supply of cooling water to the main propelling with cooling water from a common system, a
machinery and essential auxiliary engines, also standby cooling water pump is to be
to lubricating oil and fresh water coolers and air provided for this system. This pump is to be
coolers for electric propelling machinery, where connected ready for immediate use and
these coolers are fitted. The cooling water may be a suitable general service pump.
pump(s) may be worked from the engines or be
driven independently. 7.3.3 When selecting a pump for standby
purposes, consideration is to be given to the
7.3 Cooling water standby supply maximum pressure which it can develop if the
overboard discharge valve is partly or fully
7.3.1 Provision is also to be made for a separate closed and, when necessary, condenser doors,
supply of cooling water from a suitable water boxes, etc. are to be protected by an
independent pump of adequate capacity. approved device against inadvertent over
pressure.
7.3.2 The following arrangements are accepta-
ble, depending on the purpose for which the 7.4 Relief valves on cooling water pumps
cooling water is intended:
7.4.1 Where cooling water pumps can develop a
a) Where only one main engine is fitted, the pressure head greater than the design pressure
standby pump is to be connected ready for of the system, they are to be provided with relief
immediate use; valves on the pump discharge to effectively limit
the pump discharge pressure to the design
b) Where more than one main engine is fitted, pressure of the system.
each with its own pump, a complete spare
pump of each type may be accepted; 7.5 Sea inlets for cooling water pumps

c) Where a sea inlet scoop arrangement is 7.5.1 Sea-water cooling systems for main and
fitted, and there is only one independent auxiliary machinery are to be connected to at
condenser circulating pump, a further pump, least two cooling water inlets, preferably on
or a connection to the largest available opposite sides of the ship.
pump suitable for circulation duties, is to be
fitted to provide the second means of 7.5.2 Where sea water is used for the direct
circulation when the ship is maneuvering. cooling of main engines and auxiliaries, the sea
The pump is to be connected ready for water suction pipes are to be provided with
immediate use; strainers which can be cleaned without
interrupting the cooling water supply.
d) Where fresh water cooling is employed for
main/or auxiliary engines, a standby means

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Section 8

Lubricating Oil Piping Systems

8.1 General reduction gearing, oil operated couplings and

controllable pitch propellers, unless approved
8.1.1 The lubricating systems are to be so alternative arrangements are provided. Where
arranged that they will remain efficient with the the oil glands for stern tubes are provided with
ship inclined from the normal to any angle up to oil circulating pump, and the continuous running
15° transversely and when pitching 10° of this pump is necessary during normal
longitudinally and when rolling up to 22.5° from operation, then a standby pump for this purpose
the vertical. is to be provided.

8.1.2 Lubricating oil systems are to be entirely 8.2.4 Independently driven rotary type pumps
separated from other systems. This are to be fitted with non- return valves on the
requirement, however, does not apply to discharge side of the pumps.
hydraulic governing and maneuvering systems
for main and auxiliary engines. 8.2.5 A relief valve in close circuit is to be fitted
on the pump discharge if the pump is capable of
8.1.3 Lubricating oil tanks are to be separated developing a pressure exceeding the design
from other tanks containing water, fuel oil or pressure of the system, the relief valve is to
cargo oil, by means of cofferdams. effectively limit the pump discharge pressure to
the design pressure of the system.
8.1.4 For fire protection requirements also refer
Pt.6, Ch.2, 1.2.3. 8.3 Control of pumps and alarms

8.2 Pumps 8.3.1 The power supply, to all independently

driven lubricating oil service pumps is to be
8.2.1 Where lubricating oil for the main capable of being stopped from a position outside
engine(s) is circulated under pressure, a the space which will always be accessible in the
standby lubricating oil pump is to be provided event of fire occurring in the compartment in
where the following conditions apply: which they are situated, as well as from the
compartment itself.
a) The lubricating oil pump is independently
driven and the total output of the main 8.3.2 All main and auxiliary engines and turbines
engine(s) exceeds 370 [kW]; intended for essential services are to be
provided with means of indicating the lubricating
b) One main engine with its own pump is fitted oil pressure supply to them. Alarms for reduction
and the output of the engine exceeds 370 in pressure of the lubricating oil supply are to be
[kW]; actuated from the outlet side of any restrictions
such as filters, coolers etc. For main and
c) More than one main engine each with its auxiliary internal combustion engines, above 37
own lubricating oil pump is fitted and the [kW] an alarm device with audible and visual
output of each engine exceeds 370 [kW]. signal for failure of lubricating system is to be
provided.
8.2.2 The standby pump is to be of sufficient
capacity to maintain the supply of oil for normal 8.4 Emergency supply for propulsion
conditions with any one pump out of action. The turbines and propulsion turbogenerators
pump is to be fitted and connected ready for
immediate use, except that where the conditions 8.4.1 A suitable emergency supply of lubricating
referred to in 8.2.1(c) apply, a complete spare oil is to be arranged to come automatically into
pump may be accepted. In all cases satisfactory use in the event of low oil pressure.
lubrication of the engines is to be ensured while
starting and maneuvering. The emergency source of supply is to be
independent of power from main switchboard.
8.2.3 Similar provisions to those of 8.2.1 and
8.2.2 are to be made where separate lubricating 8.4.2 The emergency supply may be obtained
oil systems are employed for piston cooling, from a gravity tank containing sufficient oil to
maintain adequate lubrication for not less than 6

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minutes, and, in case of propulsion turbo- 8.6 Valves and cocks on lubricating oil tanks
generators, until the unloaded turbine comes to
rest from its maximum rated running speed. 8.6.1 The provisions of 4.4.4, 4.4.5 and 4.4.6
are also to apply to lubricating oil tanks except
8.5 Filters those having a capacity less than 500 litres,
storage tanks on which valves are closed during
8.5.1 In systems, where lubricating oil is the normal operation mode of the ship, or where
circulated under pressure, provision is to be it is determined that an unintended operation of
made for efficient filtration of the oil. For non- a quick closing valve on the oil lubricating tank
redundant units, for essential services, it must would endanger the safe operation of the main
be possible to clean the filters without stopping propulsion and essential auxiliary machinery.
the unit or reducing the supply of filtered oil to
the units. 8.6.2 Where an engine lubricating oil drain tank
extends to the bottom shell plating in ships that
8.5.2 In the case of propulsion turbines and their are required to be provided with a double
gears, arrangements are to be made for bottom, a shutoff valve is to be fitted in the drain
lubricating oil to pass through magnetic strainers pipe between the engine crank case and the
and fine filters. double bottom lubricating oil tank. This valve is
to be capable of being closed from an
accessible position above the level of the lower
platform (floor plates).

End of Chapter

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Chapter 4

Prime Movers and Propulsion Shafting Systems

Contents
Section

1 General
2 Steam Turbines
3 Gas Turbines
4 Oil Engines
5 Gearing
6 Main Propulsion Shafting
7 Propellers
8 Vibrations and Alignment
9 Thrusters
10 Turbochargers

Section 1

General

1.1 Scope 1.3 Turning gear

1.1.1 The requirements of this Chapter are 1.3.1 Arrangements are to be provided to turn
applicable to all ships but may be modified for the prime movers of main propulsion systems,
ships classed for restricted services or for reduction gears and auxiliary drives. Suitable
special services. interlocks are to be provided.

1.1.2 Prime movers of less than 100 [kW] 1.4 Power ratings
capacity may be accepted based upon
manufacturer's certificate provided the prime 1.4.1 Where requirements to dimensions in this
movers are of an approved type. Chapter are based on power and revolutions per
minute, the values to be applied are maximum
1.1.3 Attention is drawn to any relevant statutory continuous power measured on engine output
requirements of the country in which the ship is shaft and corresponding revolutions per minute.
to be registered.
1.4.2 The maximum continuous power for which
1.1.4 Prime movers and power transmission the engine is to be approved is defined in ISO
systems not specified in this Chapter will be 3046/I for oil engines and ISO 3977 for gas
specially considered by IRS. turbines.

1.2 Materials 1.4.3 For plants where overload is used

frequently, the scantling criteria may have to be
1.2.1 Materials intended for the main parts of the based on over load due to accumulated fatigue.
prime movers and power transmission systems
are to be manufactured and tested in 1.5 Overload capacity
accordance with the requirements of Pt.2.
1.5.1 Prime movers of electric generators are to
be capable of developing 10 per cent overload

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for a short period of time (15 minutes). The specification may be type approved in
overload power refers to the power of the accordance with “IRS certification scheme for
generator set. type approval of products”.

1.6 Certification of machinery 1.7.2 For non mass-produced engines the

requirements given in subsection 4.12 of this
1.6.1 The certification of machinery is to be in chapter are applicable for type approval.
accordance with requirements given in Chapter
1, Section 4 of this part. 1.7.3 For mass-produced machinery, “Type
approval certification scheme for machinery
1.7 Type approval program manufactured by mass production system” is to
be referred to.
1.7.1 Products that can be consistently
manufactured to the same design and

Section 2

Steam Turbines

2.1 Scope If required, the following information is also to be

submitted:
2.1.1 The requirements of this Section are
applicable to steam turbines for main propulsion - Vibration calculation of rotors and/or
and to those for essential auxiliary services. blades;

2.2 Plan and particulars - Performance characteristics with

functional description;
2.2.1 The following plans are to be submitted for
consideration, together with particulars of - Specification of reliability and
materials, maximum shaft powers and availability; and
revolutions per minute. The pressures and
temperatures applicable at maximum shaft - Analysis proving the specified reliability
power and under the emergency conditions are and availability.
to be stated or indicated on the plans.
2.2.2 Full particulars of the means proposed for
- General technical specifications; emergency propulsion are to be submitted.

- General arrangement; 2.2.3 Where rotors and castings are of welded

construction, details of the welded joints are also
- Sections showing rotors, bearings and to be submitted for consideration.
casings;
2.3 Materials
- Sections showing typical blades and
blade fastenings; 2.3.1 In the selection of materials, consideration
is to be given to their creep strength, corrosion
- Integrated steam and drain piping; resistance and scaling properties at working
temperatures to ensure satisfactory perfor-
- Foundation and fastening; mance and long life under service condition.

- Block diagram with functional 2.3.2 Grey cast iron is not to be used for
description of control and monitoring temperatures exceeding 260°C.
system;
2.3.3 Turbine rotors and discs are to be of
- Lubricating oil system; forged steel. For carbon and carbon-manganese
steel forgings, the specified minimum tensile
- Operating instructions manual; and strength is to be selected within the limits of 400
and 600 [N/mm2]. For alloy steel rotor forgings,
- Test programmes. the specified minimum tensile strength is to be
selected within the limits of 500 and 800
[N/mm2]. For discs and other alloy steel
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forgings, the specified minimum tensile strength 2.4.7 Joints in rotors and major joints in
is to be selected within the limits of 500 and cylinders are to be designed as full-strength
1000 [N/mm2]. welds and for complete fusion of the joint.

2.3.4 For alloy steels, details of the proposed 2.4.8 Adequate preheating is to be employed for
chemical composition, heat treatment and mild steel cylinders and components and where
mechanical properties are to be submitted for the metal thickness exceeds 44 [mm], and for all
approval. low alloy steel cylinders and components and for
any part where necessitated by joint restraint.
2.3.5 When it is proposed to use material of
higher tensile strength, full details are to be 2.4.9 Stress relief heat treatment is to be applied
submitted for approval. to all cylinders and associated components on
completion of the welding of all joints and
2.4 Design and construction attached structures. For details of stress relief
procedures, temperature and duration, See
2.4.1 In the design and arrangement of turbine Ch.10.
machinery, adequate provision is to be made for
the relative thermal expansion of the various 2.4.10 Surveyors are to be satisfied that the
turbine parts, and special attention is to be given desired quality of welding is attainable with the
to minimizing casing and rotor distortion under proposed welding equipment and procedure,
all operating conditions. and for this purpose test specimens
representative of the welded joints are to be
2.4.2 Turbine bearings are to be so disposed provided for radiographic examination and
and supported that lubrication is not adversely mechanical tests.
affected by heat flow from adjacent hot parts of
the turbine. Effective means are to be provided 2.4.11 Smooth fillets are to be provided at
for intercepting oil leakage and preventing oil abrupt changes of section of rotors, spindles,
from reaching high temperature glands and discs, blade roots and tensions. The rivet holes
casings and steam pipes pockets are to be in blade shrouds are to be rounded and
sufficiently large to prevent excessive radiused on top and bottom surfaces, and
accumulation and leakage of oil. tenons are to be radiused at their junction with
blade tips. Balancing holes in discs are to be
2.4.3 The design analysis, if required, is to well rounded and polished.
include a full vibration analysis with
measurements as necessary, covering vibration 2.4.12 Surveyors are to be satisfied as to the
of the rotor as well as blade vibrations. workmanship and riveting of blades to shroud
bands, and that the blade tenons are free from
2.4.4 Turbine rotors, cylinders and associated cracks, particularly with high strength blade
components fabricated by means of welding will material. Test samples are to be sectioned and
be considered for acceptance if constructed by examined, and pull-off tests made if considered
firms whose works are properly equipped to necessary by Surveyors.
undertake welding to equivalent standards, for
rotors and cylinders respectively, to those 2.4.13 Main turbine rotor discs fitted by shrinking
required by the Rules for Class 1 welded are to be secured with keys, dowels or other
pressure vessels, See Ch.10. approved means.

2.4.5 Before work is commenced, manufacturers 2.5 Vibration

are to submit for consideration details of
proposed welding procedures and their 2.5.1 Care is to be taken in the design and
proposals for routine examination of joints by manufacture of turbine rotors, rotor discs and
non-destructive means. blades to ensure freedom from undue vibration
within the operating speed range. Consideration
2.4.6 Where it is proposed to construct rotors of blade vibration should include the effect of
from two or more forged components joined by centrifugal force, blade root fixing, metal
welding, full details of the chemical composition, temperature and disc flexibility where
mechanical properties and heat treatment of the appropriate.
materials, together with particulars of the
welding consumables, an outline of the welding 2.6 External influences
procedure, method of fabrication and heat
treatment, are to be submitted for consideration. 2.6.1 Pipes and ducts connected to turbine
casings are to be so designed that no excessive
thrust loads or moments are applied by them to

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the turbines. Grating and any fittings in way of

sliding feet or flexible-plate supports are to be so b) Auxiliary turbines intended for driving
arranged that casing expansion is not restricted. electric generators are to be fitted with
Where main turbine seatings incorporate a tank speed governors which, with fixed setting,
structure, consideration is to be given to the are to control the speed within 10 per cent
temperature variation of the tanks in service to momentary variation and five per cent
ensure that turbine alignment will not be permanent variation when full load is
adversely affected. suddenly taken off or put on. The permanent
speed variations of alternating current
2.7 Steam supply and water system machines intended for parallel operations
are to equal within a tolerance of ± 0.5 per
2.7.1 In the arrangement of the gland sealing cent.
system, the pipes are to be made self-draining
and every precaution is to be taken against the 2.9.3 Low vacuum and over pressure protective
possibility of condensed steam entering the device
glands and turbines. The steam supply to the
gland sealing system is to be fitted with an a) Sentinel relief valves are to be provided at
effective drain trap. In the air ejector re- the exhaust ends of all turbines, to provide a
circulating water system, the connection to the warning to personnel of allowable pressure
condenser is to be so located that water cannot being exceeded. The valve discharge
impinge on the L.P. rotor or casing. outlets are to be visible and suitably
guarded if necessary to avoid injury to
2.8 Turning gear personnel. Where a low vacuum cut-out
device is provided, the sentinel relief valve
2.8.1 The turning gear for all propulsion turbines at the L.P. exhaust may be omitted.
is to be power-driven and if electric, is to be
continuously rated. b) Sentinel relief valves are to be provided at
the exhaust ends of all auxiliary turbines
2.9 Safety arrangement and the valve discharge outlets are to be
visible and suitably guarded if necessary.
2.9.1 Overspeed protective devices Low vacuum or over pressure cut-out
devices, as appropriate, are also to be
a) An overspeed protective device is to be provided for auxiliary turbines not installed
provided for main and auxiliary turbines to with their own condensers.
shut off the steam automatically and prevent
the maximum designed speed being c) When for auxiliary turbines, the inlet steam
exceeded by more than 15 per cent. pressure exceeds the pressure for which the
exhaust casing and associated piping up to
b) Where two or more turbines of a compound exhaust valve are designed, means to
main turbine installation are separately relieve the pressure are to be provided.
coupled to the same main gear wheel, and
one over-speed protective device is 2.10 Bled steam connections
provided, this is to be fitted to the L.P.
ahead turbine. Hand trip gear for shutting off 2.10.1 Non-return or other means, which will
the steam in an emergency is to be provided prevent steam and water returning to the
at the maneuvering platform. turbines, are to be fitted in bled steam
connections.
c) Where exhaust steam from auxiliary
systems is led to the main turbine, activation 2.11 Steam strainers
of the over-speed protective device is to cut
off this steam supply to the main turbine. 2.11.1 Efficient steam strainers are to be
provided close to the inlets to ahead and astern
2.9.2 Speed governors high pressure turbines, or alternatively at the
inlets to the maneuvering valves.
a) Where a turbine installation incorporates a
reverse gear, electric transmission or 2.12 Emergency arrangements
reversible propeller, a speed governor in
addition to, or in combination with, the 2.12.1 Lubricating oil failure
overspeed protective device is to be fitted,
and is to be capable of controlling the speed a) Arrangements are to be made for the steam
of the unloaded turbine without bringing the to the ahead propulsion turbines to be
overspeed protective device into action. automatically shut off in the event of failure
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of the lubricating oil pressure; however, 2.12.3 Single main boiler
steam is to be made available at the astern
turbine for braking purposes in such an a) Ships intended for unrestricted service,
emergency. fitted with steam turbines and having a
single main boiler, are to be provided with
b) Auxiliary turbine arrangements are to be means to ensure emergency propulsion in
such that steam supply is automatically shut the event of failure of the main boiler.
off in the event of failure of the lubricating oil
pressure. 2.13 Tests and equipment

c) Main turbines are to be provided with a 2.13.1 Stability testing of turbine rotors
satisfactory emergency supply of lubricating
oil which will come into use automatically in a) All solid forged H.P. turbine rotors intended
case of lubricating oil pressure falling below for main propulsion service where the inlet
a predetermined value. The emergency steam temperature exceeds 400°C are to be
supply may be obtained from a gravity tank subjected to at least one thermal stability
containing sufficient oil to maintain adequate test. This requirement is also applicable to
lubrication until the turbine is brought to rest rotors constructed from two or more forged
or by equivalent means. If emergency components joined by welding. The test
pumps are used these are to be so may be carried out at the forge or turbine
arranged that their operation is not affected builders' works (a) after heat treatment and
by failure of the power supply. Suitable rough machining of the forging or (b) after
arrangements for cooling the bearings after final machining, or (c) after final machining
stopping may also be required. and blading of the rotor. The stabilizing test
temperature is to be not less than 28°C
2.12.2 Single screw ships above the maximum steam temperature to
which the rotor will be exposed and not
a) In single screw ships fitted with cross more than the tempering temperature of the
compound steam turbine installations in rotor material.
which two or more turbines are separately
coupled to the same main gear wheel, the b) Where main turbine rotors are subjected to
arrangements are to be such as to enable thermal stability tests at both forge and
safe navigation, when the steam supply to turbine builders' works the foregoing
any one of the turbines is required to be requirements are applicable to both tests. It
isolated. For this emergency operation is not required that auxiliary turbine rotors
purpose, the steam may be led direct to the be tested for thermal stability, but if such
L.P. turbine and either the H.P. or I.P. tests are carried out, the requirements for
turbine can exhaust direct to the condenser. main turbine rotors will be generally
Adequate arrangements and controls are to applicable.
be provided for these operating conditions
to ensure that the pressure and temperature 2.14 Balancing
of the steam will not exceed those which the
turbines and condenser can safely 2.14.1 All rotors as finished-bladed and
withstand. complete with half-coupling are to be
dynamically balanced to the Surveyor's
b) The necessary pipes and valves for these satisfaction, in a machine of sensitivity
arrangements are to be readily available appropriate to the size of rotor.
and properly marked. A fit up test of all
combinations of pipes and valves is to be 2.15 Hydraulic tests
performed prior to the first sea trials.
2.15.1 Maneuvering valves are to be tested to
c) The permissible power/speeds when twice the working pressure. The nozzle boxes of
operating without one of the turbines (all impulse turbines are to be tested to 1.5 times
combinations) is to be specified and the working pressure.
information provided on board.
2.15.2 The cylinders of all turbines are to be
d) The operation of the turbines under tested to 1.5 times the working pressure in the
emergency conditions is to be assessed for casing, or to 2.0 bar whichever is greater.
the potential influence on shaft alignment
and gear teeth loading conditions.

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2.15.3 For test purposes, the cylinders may be 2.16 Indicators for movement
subdivided with temporary diaphragms for
distribution of test pressures. 2.16.1 Indicators for determining the axial
position of rotors relative to their casings, and
2.15.4 Condensers are to be tested in the steam for showing the longitudinal expansion of
space to 1.0 bar. The water space is to be casings at the sliding feet, if fitted, are to be
tested to the maximum pressure which the provided for main turbines. The latter indicators
pump can develop at ship's full draught with the should be fitted at both sides and be readily
discharge valve closed plus 0.7 bar with a visible.
minimum test pressure of 2.0 bar. Where the
operating conditions are not known, the test 2.17 Weardown gauges
pressure is to be not less than 3.4 bar.
2.17.1 Main and auxiliary turbines are to be
provided with bridge weardown gauges for
testing the alignment of the rotors.

Section 3

Gas Turbines

3.1 Scope
- Casings;
3.1.1 The requirements of this Section are
applicable to gas turbines for main propulsion - Combustion chambers and heat
and to those for essential auxiliary services. exchangers;
These requirements do not apply to exhaust gas
turbo-blowers. - Gasifiers;

3.1.2 The spare gear for gas turbines has not - Regenerators or recuperators;
been indicated in view of the variation in turbine
design and service conditions. In the - Rotors (turbine and compressor),
circumstances, a list of proposed spare gear is including discs, blades, bearings
to be submitted for consideration. couplings, and clutches;

3.2 Plans and particulars - Sections showing blades, blade

fastenings and sealings;
3.2.1 Following data is to be submitted:
- Oil fuel and lubricating oil systems
- Rated power; including controls and safety devices;
- Rated speed;
- Maximum turbine entry temperature at - Governor arrangements;
which rated power can be achieved;
- Mass and velocity of rotating elements; - Enclosure configurations (where
- Balancing data; applicable);
- Type test schedule, measurements and
data; - Starting arrangements;
- Manufacturer’s shop test schedule.
- Air intake and exhaust system;
3.2.2 The following plans are to be submitted for
consideration together with particulars of - Control systems, safety systems and
materials. devices and associated failure mode
and effect analysis;
- General technical specifications
including effect of inlet temperature on - Details of proposed automatic safety
power; devices to safeguard against hazardous
conditions arising in the event of
- General arrangement; malfunctions in the gas turbine
installation together with failure mode
- Sectional assembly; and effect analysis;

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3.4.3 Design basis
- Vibration monitoring systems; and
a) Calculations of the steady stresses,
- All other critical systems such as fire including the effect of stress raisers, etc., in
fighting arrangements for enclosures, the turbine and compressor rotors and
ventilation, lighting, smoke detector etc. blading at the maximum speed and
temperature in service, are to be submitted
3.2.3 Where applicable, plans are to indicate the for consideration. Such calculations should
most onerous pressures and temperatures to indicate the designed service life and be
which each component is subject. accompanied, where possible, by test
results substantiating the limiting criteria.
3.2.4 Details are to be submitted, where
applicable, of high temperature characteristics of b) Details of calculations and tests to establish
the materials, including (at the working the service life of other stressed parts,
temperatures) the associated creep rate and including gearing (where applicable),
rupture strength for the designed service life, bearings, seals, etc., are to be submitted. All
fatigue strength, corrosion resistance and calculations and tests should take account
scaling properties. Particulars of heat treatment, of all relevant environmental factors
including stress relief, where applicable, are to including particular type of service and fuels
be submitted. intended to be used.

3.3 Materials 3.5 Welded components

3.3.1 Rotors and discs are to be of forged steel. 3.5.1 Components fabricated by means of
For carbon and carbon- manganese steel welding will be considered for acceptance if
forgings, the specified minimum tensile strength constructed by firms whose works are properly
is to be selected within the limits of 400 and 600 equipped to undertake welding of the standards
[N/mm2]. For alloy steel rotor forgings, the appropriate to the components according to the
specified minimum tensile strength is to be relevant requirements of Ch.10.
selected within the limits of 500 and 800
[N/mm2]. For discs and other alloy steel 3.5.2 Before work is commenced, manufacturers
forgings, the specified minimum tensile strength are to submit for consideration details of
is to be selected within the limits of 500 to 1000 proposed welding procedures and their
[N/mm2]. proposals for routine examination of joints by
non-destructive means.
3.3.2 For alloy steels, specifications giving the
proposed chemical composition and heat 3.5.3 Major joints are to be designed as full-
treatment are to be submitted for approval. strength welds and for complete fusion of the
joint.
3.3.3 When it is proposed to use a material of
higher tensile strength, full details are to be 3.5.4 Stress relief treatment is to be applied to
submitted for approval. all cylinders, rotors and associated components
on completion of the welding of all joints and
3.4 Design and construction attached structures. For details of stress relief
procedure, temperature and duration, See
3.4.1 All parts of turbines, compressors, etc., are Ch.10.
to have clearances and fits consistent with
adequate provision for the relative thermal 3.5.5 Surveyors are to be satisfied that the
expansion of the various components. Special desired quality of welding is attainable with the
attention is to be given to minimizing casing and proposed welding equipment and procedure,
rotor distortion under all operating conditions. and for this purpose test specimens
representative of the welded joints are to be
3.4.2 Turbine bearings are to be so disposed provided for radiographic examination and
and supported that lubrication is not adversely mechanical tests as required for steam turbines.
affected by heat flow from adjacent hot parts.
Effective means are to be provided for 3.6 Vibration
intercepting oil leakage and preventing oil from
reaching high temperature glands and casings. 3.6.1 Care is to be taken in the design and
manufacture of turbine and compressor rotors,
rotor discs and rotor blades to ensure freedom
from undue vibration within the operating speed
range. Calculations of the critical speeds giving

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full details of the basic assumptions are to be variation of the tank in service to ensure that
submitted for consideration. Where critical turbine alignment will not be adversely affected.
speeds are found by calculation to occur within
the operating speed range, vibration tests may 3.11.4 Where the turbine is provided with an
be requested in order to verify the calculations. acoustic enclosure, this is to act as shield to
prevent contamination of machinery spaces
3.7 Containment from external hazards and contain the heat
emission from the gas generator. The enclosure
3.7.1 Consideration should be given to the need is to be structurally sound and is to be a self-
for containment, with a view to minimizing and contained unit with arrangements for ventilation,
localizing damage, in the event of rotor blade lighting and noise attenuation. The drainage
failure. arrangements in the enclosure are to be
provided to prevent build up of liquids. A self
3.8 Inlet and exhaust systems contained and independent fire fighting system
is to be provided for such enclosure. One or
3.8.1 The air-inlet system is to be designed to more observation window/s is/are to be provided
minimize the entrance of harmful foreign matter. for visual inspection of critical components such
as auxiliary gearbox and burner manifold.
3.8.2 The arrangement of the turbine exhaust
system is to be such as to prevent exhaust 3.12 Overhaul life
gases being drawn into the compressors.
3.12.1 The overhaul schedule recommended by
3.9 Fuel and salt deposits the manufacturer is to be submitted for
consideration.
3.9.1 When it is intended to burn non-distillate
fuels forming harmful deposits, adequate 3.13 Safety arrangements
provision should be made for periodic removal
of the deposits. 3.13.1 Overspeed protective devices

3.9.2 Means for preventing the accumulation of a) An overspeed protective device is to be

salt deposits in the compressors and turbines provided for each shaft of main and auxiliary
are to be provided. turbines to shut off the fuel automatically,
near the burners, to prevent a dangerous
3.9.3 Flow path cleaning or washing system is to overspeed condition of the shaft, except
be provided, where required by the gas turbine where it can be established that such a
manufacturer. Provision is to be made for condition cannot arise.
periodical cleaning / washing by inhibiting
liquids, steam or any other cleaning medium. b) The overspeed device should normally be
The details of the arrangements and the set to operate when the speed of the line
associated system are to be submitted for exceeds the rated maximum speed by 15
approval. per cent.

3.10 Indication of temperature 3.13.2 Speed governors

3.10.1 Means are to be provided for indicating a) Where a main propulsion installation
the temperature of the power turbine exhaust incorporates a reverse gear, electric
gases. transmission or controllable (reversible)
pitch propeller, a speed governor,
3.11 External influences independent of the overspeed protective
device, is to be fitted and is to be capable of
3.11.1 Pipes and ducting connected to casings controlling the speed of the unloaded power
are to be so designed that no excessive thrust turbine without bringing the overspeed
loads or moments are applied by them to the protective device into action.
compressors and turbines.
b) Where an auxiliary turbine is intended for
3.11.2 Platform gratings and fittings in way of driving an electric generator, a speed
the supports are to be so arranged that casing governor, independent of the overspeed
expansion is not restricted. protective device, is to be fitted which, with
fixed setting, is to control the speed within
3.11.3 Where main turbine seatings incorpo- 10 per cent momentary variation and 5 per
rating a tank structure are proposed, cent permanent variation when full load is
consideration is to be given to the temperature suddenly taken off or put on. The

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permanent speed variation of a.c. machines 3.13.7 Inlet and exhaust silencers are to be
intended for parallel operations are to be fitted to limit the sound power level at one meter
equal within a tolerance of 0.5 per cent. from the gas turbine system to 110 dB for
unmanned machinery spaces or to 90 dB for
3.13.3 The following turbine services are to be manned machinery spaces.
provided with automatic temperature controls so
as to maintain steady state conditions 3.14 Starting arrangements
throughout the normal operating range of the
main turbine: 3.14.1 Means are to be provided, preferably
- lubricating oil system; automatic or interlocked, to clear all parts of the
- oil fuel supply (or automatic control of oil gas turbine of the accumulation of liquid fuel, or
fuel viscosity as an alternative); and for purging gaseous fuel, before ignition
- exhaust gas. commences on starting, or recommences after
failure to start.
3.13.4 Alarms and automatic shutdown devices
are to be provided in accordance with Table 3.14.2 The starting arrangements can be
3.13.1. pneumatic, hydraulic or electric. The starting air
pipes system, safety fittings and number of
3.13.5 Hand trip gear for shutting off the fuel in starts are to comply with the requirements for oil
an emergency is to be provided locally at the engines as given in Section 4.11.
turbine control platform and where applicable, at
the centralized control station. 3.14.3 Starting devices are to be so arranged
that firing operation is discontinued and main
3.13.6 All non-mobile gas turbines are to be fuel valve is closed within pre-determined time in
provided with independent, self contained case of ignition failure.
suitable foam or CO2 or water mist fire fighting
system with detection ability to give warning 3.14.4 Where the gas turbine is arranged for air
automatically at local and remote control starting, the total air receiver capacity is to be
positions when activated. This system is to be sufficient to provide, without replenishment, not
distinctly separate from the fire fighting less than six consecutive starts. At least two air
arrangements in the machinery space. The receivers of equal capacity are to be provided.
arrangements together with calculations For details of air receivers, see Chapter 5. For
showing the capacities of the cylinders is to be multi engine installations three consecutive
submitted for approval. starts per engine are required.

Table 3.13.1 : List of alarms and shutdown

Monitoring parameter Alarm Shutdown

Turbines speed High value Yes
Lubricating oil pressure Low value Yes
Lubricating oil pressure of reduction gear Low value Yes
Differential pressure across lubricating oil filter High value
Lubricating oil temperature High value
Oil fuel supply pressure Low value
Oil fuel temperature High value
Cooling medium temperature High value
Bearing temperature High value
Flame and ignition failure Activated Yes
Automatic starting failure Activated
Vibration High value Yes
Axial displacement of rotor High value Yes
Exhaust gas temperature High value Yes
Vacuum pressure at the compressor inlet High value Yes
Loss of control system Activated

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3.15 Tests 3.17.3 The combined capacity of the batteries

for starting the auxiliary turbines is to be
3.15.1 Balancing sufficient for at least three starts for each
turbine.
a) The rotors as finished-bladed and complete
with half-coupling are to be dynamically 3.17.4 The requirements for battery installations
balanced to the Surveyor's satisfaction, in a are given in Pt.4, Ch.8.
machine of sensitivity appropriate to the size
of rotor. 3.18 Type testing of gas turbine

3.15.2 Hydraulic tests 3.18.1 Type tests are to be carried out in

accordance with the agreed test programme on
a) All casings are to be tested to a hydraulic a representative machine comprising gas
pressure equal to 1.5 times the highest generator and power turbine and are to be
pressure in the casing during normal witnessed by IRS surveyor. It may be carried out
operation or 1.5 times the pressure during at the manufacturer’s works or at any
starting, whichever is the higher. For test establishment having suitable facilities
purposes if necessary, the casings may be acceptable to IRS.
subdivided with temporary diaphragms for
distribution of test pressure. 3.18.2 Where the gas turbine unit can be
separated conveniently into a gas generator and
b) Where hydraulic tests cannot be carried out, a power turbine, the type test is to include an
the manufacturers are to submit, for initial test of the gas generator to ascertain that
approval, alternative proposals for the fuel consumption and gas horse power are
determining the soundness of the within ±2.5% of design maximum conditions at
component. rated speed.

c) Inter coolers and heat exchangers are to be 3.18.3 After completion of the initial test of the
tested to 1.5 times the maximum working gas generator, the gas generator and power
pressure on each side separately. turbine are to be assembled together and
prepared for the gas turbine type test.
3.16 Shop trials
3.18.4 On the over speed test, a propulsion gas
3.16.1 Upon completion of fabrication and generator is to be run at not less than 10% in
assembly, each gas turbine is to be subjected to excess of gas generator speed corresponding to
a shop trial in accordance with the specified full power of the gas turbine engine for
manufacturer’s test schedule, which is to be not less than 10 minutes continuously and the
submitted for review before the trial. During the power turbine disconnected from the
trial, the turbine is to be brought up to its over dynamometer is to be run at not less than 15%
speed limit to enable testing of the overspeed in excess of the maximum designed speed for
protective device. not less than 10 minutes continuously.

3.17 Electric starting 3.18.5 Where it is impracticable to overspeed

the complete installation, each rotor, completely
3.17.1 Where main turbines are fitted with bladed and with all relevant parts such as half-
electric starters, two batteries are to be fitted. couplings, shall be overspeed tested individually
Each battery is to be capable of starting the at the appropriate speed.
turbines when cold and the combined capacity is
to be sufficient without recharging to provide the 3.18.6 During the type tests at specified full
number of starts of the main turbines as power the pressure and temperature of the gas
required by 3.14.4. at outlet from the gas generator is to be
recorded and the gas mass flow is to be
3.17.2 Electric starting arrangements for assessed from air flow and fuel flow
auxiliary turbines are to have two separate measurements.
batteries or be supplied by separate circuits
from the main turbine batteries when such are 3.18.7 During the type tests the following
provided. Where one of the auxiliary turbines features are to be demonstrated:
only is fitted with an electric starter one battery
will be acceptable. i) Freedom from air and gas leaks.
ii) Operation of starting arrangements.
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iii) Effectiveness of interlocks, if fitted.
iv) Satisfactory lubricating oil and fuel oil system - A cold start is defined as a start after 2
characteristics. hours or more of natural cooling with the
v) Wet and dry motoring. engine at rest.
vi Engine start following a failure to start.
vii) Operation of engine cleaning system. - A warm start is defined as a start within 15
viii) Reliability of operation at minimum idling minutes of shutting down after the engine
speed. has been running for not less than two
hours.
3.18.8 Starting tests are to be carried out to
determine: - An intentional failure to start is defined as
the performance of a normal starting
i) Time to light from cold. sequence with the ignition system
ii) Time to reach idling speed from cold. deliberately rendered inoperative.
iii) Time to reach full output from idling speed.
iv) That the required number of starts can be Note : i), ii), iii) and iv) are to be average of four
obtained from the specified starting air bottle readings.
capacity.
v) The minimum pressure to ensure a cold start
is to be established.

Section 4

Oil Engines

4.1 Scope k) Details regarding engine driven machinery;

4.1.1 The requirements of this Section apply to l) Material specifications.

conventional type of internal combustion
engines used as prime movers for main 4.2.2 The following plans are to be submitted,
propulsion and for essential auxiliary machinery. for each type of engine, in triplicate:

4.2 Plans and particulars a) Engine transverse section;

4.2.1 The particulars to be submitted for all b) Engine longitudinal section;

engines are to include the following:
c) Bedplate and crankcase, cast or welded
a) The type of engine; with welding details and instructions;

b) Number of cylinders, bore and stroke; d) Thrust bearing assembly;

c) Particulars of engine cycle; e) Thrust bearing bedplate, together with

details of manufacture/fabrication;
d) Vee angle, if applicable;
f) Frame box, cast or welded with welding
e) Firing order; details and instructions;

f) Proposed shaft power and corresponding g) Tie rod;

revolutions per minute;
h) Cylinder head assembly;
g) Weight of reciprocating parts;
i) Cylinder liner;
h) Weight and diameter of flywheel or flywheel
effect for the engine; j) Crankshaft and crankshaft assembly;

i) Maximum and mean indicated pressures; k) Thrust shaft or intermediate shaft (if integral
with engine), coupling bolts;
j) Details regarding scavenge pumps/blowers,
turbochargers, etc., as applicable; l) Counterweights (if not integral with
crankshaft) including fastening;

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4.3 Materials and material testing

m) Connecting rod, assembly;
4.3.1 Materials used for the construction of oil
n) Crosshead assembly; engines are to comply with the requirements of
Pt.2 in so far as applicable. Other materials will
o) Piston rod, assembly; be specially considered.

p) Piston, assembly; 4.3.2 The specified minimum tensile strength of

castings and forgings for crankshafts is to be
q) Camshaft drive assembly; selected within the following general limits:

r) Arrangement of foundation (for main a) Carbon and carbon-manganese steel

engines only); castings 400 - 550 [N/mm2];

s) Details of fuel oil system; * b) Carbon and carbon manganese steel

forgings (normalized and tempered) : 400 -
t) Details of air starting system; * 600 [N/mm2];

u) Details of lubricating oil system; * c) Carbon and carbon-manganese steel

forgings (quenched and tempered) : not
v) Details of engine cooling system; * exceeding 700 [N/mm2];

w) Details of shielding and insulation of d) Alloy steel castings : not exceeding 700
exhaust pipes; [N/mm2];

x) Shielding of high pressure fuel pipes (when e) Alloy steel-forgings : not exceeding 1000
required); [N/mm2];

y) Arrangement of crankcase explosion relief f) Spheroidal or nodular graphite iron

devices (when required); castings: 370 - 800 [N/mm2].

z) Operation and service manuals. 4.3.3 Where it is proposed to use alloy steel
castings, forgings or iron castings for
aa) Schematic layout or other equivalent crankshafts, details of the chemical composition,
documents of hydraulic system (for valve lift) heat treatment and mechanical properties are to
on the engine. be submitted for approval.

bb) Governor arrangements. * 4.3.4 Components of engines are to be tested

as listed in Table 4.3.1 in accordance with the
cc) Engine control and safety system. * requirements of Pt.2.

dd) Vibration damper assembly. 4.3.5 Pipes and accessories for starting air
systems and other high pressure systems,
ee) Details of engine driven pumps. which are part of the engine, are to be tested in
accordance with the requirements of Pt.4, Ch.2.
* Where engines incorporate electronic control
system, a failure mode and effects analysis 4.4 Hydraulic tests
(FMEA) is to be submitted for information to
demonstrate that failure of an electronic control 4.4.1 In general, various components of the
system will not result in the loss of essential engine are to be hydraulically tested to
services for the operation of the engine and that pressures as indicated in Table 4.4.1.
operation of the engine will not be lost or
degraded beyond an acceptable performance 4.4.2 Where design features are such that
criteria of the engine. modifications to the test requirements shown in
Table 4.4.1 are necessary, alternative proposals
for hydraulic tests are to be submitted for special
consideration.

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Table 4.3.1 : Components of engines for which material and non-destructive tests are required
Non-destructive tests
Material tests Magnetic particle
Components Ultrasonic
or liquid penetrant
Cylinder dia. of Cylinder dia. of Cylinder dia. of
engines engines engines
1 Crankshaft All All All
2 Crankshaft coupling flange (non-integral) for main
Above 400 mm - -
propulsion engines
3 Crankshaft coupling bolts Above 400 mm - -
4 Steel piston crowns Above 400 mm All Above 400 mm
5 Piston rods Above 400 mm Above 400 mm Above 400 mm
6 Connecting rods and bearing caps All Above 400 mm All
7 Crossheads Above 400 mm - -
8 Cylinder liner - steel parts Above 300 mm - -
9 Cylinder cover - cast steel Above 300 mm All Above 400 mm
10 Steel castings for welded bedplates All All All
11 Steel forgings for welded bedplates All - -
12 Plates for welded bedplates, frames, crankcases
All - -
and entablatures
13 Tie rods All - Above 400 mm
14 Supercharger shaft and rotor, including blades
(supercharger means turbochargers and engine
driven compressor including "Root Blower"). Above 300 mm - -
Auxiliary blowers are not considered as
supercharger
15 Bolts and studs for cylinder covers, crossheads,
Above 300 mm - Above 400 mm
main bearings, connecting rod bearings
16 Steel gear wheels for camshaft drives Above 400 mm - Above 400 mm

Table 4.4.1 : Hydraulic test pressures

Components Test pressure (p is the maximum
working pressure of the component
concerned)
1 Fuel injection system (pressure side of pump body, injection
The lesser of 1.5p or p + 300 bar
valve, injection pipe)
2 Cylinder cover, cooling space2) 7.0 bar
3 Cylinder liner, over whole length of cooling space "
4 Piston crown, cooling space (where piston rod seals cooling
"
space, test after assembly)2)
5 Cylinder jacket cooling space The greater of 1.5p or 4.0 bar
6 Exhaust valve cooling space "
7 Turbo-blower cooling water space "
8 Exhaust pipe cooling space "
1)
9 Coolers each side "
10 Engine driven pumps (oil, water fuel, bilge) "
11 Engine driven air compressor, including cylinders, covers, Air side - 1.5p water side greater of 4.0 bar
intercoolers and aftercoolers or 1.5p
12 Scavenge pump cylinder 4.0 bar
13 Hydraulic system (piping, pump actuator etc. for hydraulic drive
1.5p
of valves)
Notes:
1) Charge air coolers need only be tested on water side.
2) For forged steel cylinder covers and forged steel piston crowns test methods other than pressure testing may
be accepted. e.g. suitable non-destructive examination and dimensional control properly recorded.

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4.5 Crankshaft design minimize the in rush of air after crankcase

explosion.
4.5.1 Detailed analysis to prove the design of
the crankshaft is to be submitted for 4.7.3 To avoid interconnection between
consideration. Classification Notes on design of crankcases and the possible spread of fire
crankshafts may be followed in this regard. following an explosion, crankcase ventilation
Manufacturers may also be required to submit pipes and oil drain pipes for each engine are to
detailed analysis for special design features, be independent of each other.
e.g. serrations in connecting rods and bearing
caps. 4.8 Safety devices

4.6 Design and construction 4.8.1 For crankcase:

4.6.1 The design and construction is to be such 4.8.1.1 Crankcases are to be provided with light
as to enable the oil engine to meet the general weight spring-loaded valves or other quick-
requirements with regard to environmental acting and self closing devices, of an approved
conditions, functional capability and reliability. type, to relieve the crankcases of pressure in the
event of an internal explosion and to prevent
4.6.2 Cylinders, cylinder liners, cylinder covers, any inrush of air thereafter. The valves are to be
pistons and other parts subject to high designed to open at a pressure not greater than
temperature or pressure are to be of material 0.2 bar.
suitable for the stress and temperature to which
they are exposed. 4.8.1.2 The valve lids are to be made of ductile
material capable of withstanding the shock of
4.6.3 The engine bedplate or crankcase is to be contact with stoppers at the full open position.
of rigid and oil-tight construction. The bedplate is The discharge from the valves is to be shielded
to be provided with sufficient number of holding by flame guard or flame trap to minimise the
down bolts to effectively secure it to the engine possibility of danger and damage arising from
seatings. the emission of flame.

4.6.4 Transverse girders, cylinder blocks and 4.8.1.3 Crankcase explosion relief valves are to
columns, when of fabricated construction, are be type tested in a configuration that represents
normally to be stress-relieved after welding. the installation arrangements that will be used
on an engine, in accordance with IRS
4.6.5 Crankcases and their doors are to be of Classification Notes on “Guidance for Type
robust construction and the doors are to be Testing of Crankcase Explosion Relief Valves”.
securely fastened so that they will not be readily
displaced by an explosion taking into account 4.8.1.4 Where crankcase relief valves are
the installation of explosion relief valve as provided with arrangements for shielding
required by 4.8. emissions from the valve following an explosion,
the valve is to be type tested to demonstrate
4.6.6 Piston rod glands, which are subjected to that the shielding does not adversely affect the
pressure from scavenging air, are to be of a operational effectiveness of the valve.
design ensuring that air will not leak into the
crankcase. 4.8.1.5 Crankcase explosion relief valves are to
be provided with a copy of manufacturer’s
4.7 Crankcase ventilation installation and maintenance manual that is
specific to the size and type of valve being
4.7.1 Ventilation of crankcase and any supplied for installation on a particular engine.
arrangement which could produce a flow of The manual is to contain the following
external air within the crankcase, is in general information:
not permitted except for dual fuel engines where
crankcase ventilation is to be provided in - Description of valve with details of
accordance with 4.15.1.3. If forced extraction of function and design limits.
the gases from crankcase is provided (e.g. for - Copy of type test certificate.
smoke-detection purposes), the vacuum in the - Installation instructions.
crankcase is not to exceed 25 [mm] of water - Instructions for testing and renewal of
column. any sealing arrangements.
- Actions required after a crankcase
4.7.2 Crankcase ventilation pipes where explosion.
provided are to be as small as practicable to

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4.8.1.6 A copy of the installation and at the engine room control location. This
maintenance manual required by 4.8.1.5 is to be warning notice is to specify that whenever
provided on board ship. overheating is suspected in the crankcase, the
crankcase doors or sight holes are not to be
4.8.1.7 Plans showing details and arrangements opened until a reasonable time has elapsed
of crankcase explosion relief valves are to be after stopping the engine, sufficient to permit
submitted for approval in accordance with 4.2.2. adequate cooling within the crankcase.

4.8.1.8 Valves are to be provided with suitable 4.8.1.16 Where crankcase oil mist detection
markings that include the following information: arrangements are to be fitted to engines (as per
Pt.4, Ch.7 and Pt.5, Ch.22) they are to be of a
- Name and address of manufacturer type approved by IRS and tested in accordance
- Designation and size with Note 1) and comply with 4.8.1.17 to
- Month / Year of manufacture 4.8.1.28. Engine bearing temperature monitors
- Approved installation orientation. or equivalent devices used as safety devices are
to be type approved by IRS for such purposes.
4.8.1.9 In engines having cylinders not
exceeding 200 [mm] bore and having a Note 1) : Classification Notes – “Type approval
crankcase gross volume not exceeding 0.6 [m3], of crankcase oil mist detection and alarm
relief valves may be omitted. equipment”.

4.8.1.10 In engines having cylinders exceeding 4.8.1.17 The oil mist detection system and
200 [mm] bore, but not exceeding 250 [mm] arrangements are to be installed in accordance
bore, at least two relief valves are to be fitted, with the manufacturer’s and engine designer’s
each valve is to be located at or near the ends instructions / recommendations. The following
of the crankcase. Where the engine has more particulars are to be included in the instructions:
than 8 crank throws an additional valve is to be
fitted near the center of the engine. - Schematic layout of engine oil mist
detection and alarm system showing
4.8.1.11 Engines, with cylinder bores exceeding location of engine crankcase sample points
250 [mm], but not exceeding 300 [mm], are to and piping or cable arrangements together
have at least one relief valve in way of each with dimensions of the pipe to the detector.
alternate crank throw, with a minimum of two
relief valves. - Evidence of study to justify the selected
location of sample points and sample
4.8.1.12 In engines having cylinders exceeding extraction rate (if applicable) in
300 [mm] bore, at least one relief valve is to be consideration of the crankcase
fitted in way of each main crank throw. arrangements and geometry and the
predicted, crankcase atmosphere where oil
4.8.1.13 Additional relief valves are to be fitted mist can accumulate.
for separate spaces on the crankcase, such as
gear or chain cases for camshaft or similar - The manufacturer’s maintenance and test
drives, when the gross volume of such spaces manual.
exceeds 0.6 [m3].
- Information relating to type or in-service
4.8.1.14 The free area of each crankcase relief testing of the engine with engine protection
valve is not to be less than 45 [cm2]. The system test arrangements having approved
combined free area of the relief valves fitted on types of oil mist detection equipment.
2 3
the engine is not to be less than 115 [cm /m ] of
the crankcase volume. 4.8.1.18 A copy of the oil mist detection
equipment maintenance and test manual
The free area of the relief valve is the minimum required by 4.8.1.17 is to be provided on board
flow area at any section through the valve, when ship.
the valve is fully open.
4.8.1.19 Oil mist detection and alarm information
When calculating the gross volume of the is to be capable of being read from a safe
crankcase, the volume of stationary parts within location away from the engine.
the crankcase may be deducted.
4.8.1.20 Each engine is to be provided with its
4.8.1.15 A warning notice is to be fitted in a own independent oil mist detection arrangement
prominent position, preferably on a crankcase and a dedicated alarm.
door on each side of the engine, or alternatively

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4.8.1.21 Oil mist detection and alarm systems crankcase pressure monitoring, recirculation
are to be capable of being tested on the test bed arrangements.
and onboard under engine at standstill and
engine running at normal operating conditions in - Evidence to demonstrate that the
accordance with test procedures that are arrangements are effective in preventing the
acceptable to IRS. build up of potentially explosive conditions
together with details of in-service
4.8.1.22 Alarms and shutdowns for the oil mist experience.
detection system are to be in accordance with
Pt.5, Ch.22, Sec.3 and the system - Operating instructions and the maintenance
arrangements are to comply with Pt.5, Ch.22, and test instructions.
Sec.2.
4.8.1.30 Where it is proposed to use the
4.8.1.23 The oil mist detection arrangements are introduction of inert gas into crankcase to
to provide an alarm indication in the event of a minimize a potential crankcase explosion,
foreseeable functional failure in the equipment details of the arrangements are to be submitted
and installation arrangements. to IRS for consideration.

4.8.1.24 The oil mist detection system is to 4.8.2 Scavenge spaces:

provide an indication when any lenses fitted in
the equipment and used in determination of the 4.8.2.1 Scavenge spaces in open connection to
oil mist level have been partially obscured to a the cylinders are to be fitted with relief valves.
degree that will affect the reliability of the The valves are to open quickly in case of an
information and alarm indication. explosion.

4.8.1.25 Where oil mist detection equipment 4.8.2.2 For crosshead type engines, scavenge
includes the use of programmable electronic spaces in open connection to the cylinders are
systems, the arrangements are to be in to be provided with an approved fire
accordance with the rule requirements for such extinguishing system, which is to be entirely
systems. separate from the fire extinguishing system of
the engine room.
4.8.1.26 Plans of showing details and
arrangements of oil mist detection and alarm 4.8.3 Cylinders:
arrangements are to be submitted for approval
in accordance with Pt.4, Ch.7. 4.8.3.1 Cylinder relief valves are to be fitted to
engines having cylinders over 230 [mm] bore.
4.8.1.27 The equipment together with detectors The valves are to open at a pressure not
is to be tested when installed on the test bed exceeding 40 per cent above the designed
and on board ship to demonstrate that the maximum pressure and are to discharge where
detection and alarm system functionally no damage can occur. Consideration will be
operates. The testing arrangements are to be to given to any other alternative relief arrangement.
the satisfaction of IRS.
4.8.3.2 In the case of auxiliary engines,
4.8.1.28 Where sequential oil mist detection consideration will be given to the replacement of
arrangements are provided the sampling the relief valve by an efficient warning device of
frequency and time is to be as short as over pressure in the cylinders.
reasonably practicable.
4.8.4 Lubrication system:
4.8.1.29 Where alternative methods are
provided for the prevention of the build-up of oil 4.8.4.1 The lubricating oil drain pipes from the
mist that may lead to a potentially explosive engine sump to drain tank are to be taken down
condition within the crankcase details are to be as low as possible, to ensure that their outlet
submitted for consideration. The following ends are submerged at all times. Where two or
information is to be included in the details: more engines are installed, vent pipes, if fitted,
and lubricating oil drain pipes are to be installed
- Engine particulars – type, power, speed, independently of each other to prevent
stroke, bore and crankcase volume. intercommunication between crankcases.

- Details of arrangements to prevent the build 4.8.5 Fuel systems:

up of potentially explosive conditions within
the crankcase, e.g. bearing temperature 4.8.5.1 All external high-pressure fuel delivery
monitoring, oil splash temperature, lines between the high-pressure fuel pumps and

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fuel injectors are to be protected with a jacketed per cent for main engines and 15 per cent for
piping system capable of containing fuel from a auxiliary engines.
high-pressure line failure. A jacketed pipe
incorporates an outer pipe into which the high- 4.9 Governing
pressure fuel pipe is placed, forming a
permanent assembly. The jacketed piping 4.9.1 For main propulsion engines:
system is to include means for collection of
leakages and arrangements provided for an An efficient governor is to be fitted to each main
alarm to be given of a fuel line failure. However, engine and so adjusted that the speed of the
this requirement need not be applied for engines engine does not exceed that for which the
intended to be fitted on board non-passenger engine is to be classed by more than 15 per
vessels of less than 500 GT. cent.

4.8.5.2 Components of a diesel engine fuel When electronic speed governors of main
system is to be designed considering the engines form part of a remote control system,
maximum peak pressure which will be they are to comply with the following:
experienced in service, including any high
pressure pulses which are generated and a) if lack of power to the governor may cause
transmitted back into the fuel supply and spill major and sudden changes in the preset
lines by the action of fuel injection pumps. speed and direction of the thrust of the
Connections within the fuel supply and spill lines propeller, back up power supply is to be
are to be constructed having regard to their provided;
ability to prevent pressurized oil fuel leaks while
in service and after maintenance. b) local control of engines is always to be
possible;
4.8.6 Starting air:
c) electronic speed governor and its actuators
4.8.6.1 In order to protect air main against are to be type tested as per IRS
explosion arising from improper functioning of Classification Notes “Type Approval of
starting valves, the following are to be fitted: Electrical Equipment used for Control,
Protection, Safety and Internal
a) an isolating non-return valve or equivalent at Communication in Marine Environment”,
the starting air supply connection to each and
engine;
d) Also refer Cl.4.12.4.1c).
b) a bursting disc or flame arrestor in way of
the starting valve of each cylinder for direct 4.9.2 For auxiliary engines:
reversing engines having a main starting
manifold or at the supply inlet to the starting Governors on diesel engines driving main or
air manifold for non-reversing engines. emergency electric generators are to be capable
of automatically maintaining the speeds within
4.8.6.2 Bursting disc or flame arrestor may be following limits:
omitted for engines having a bore not exceeding
230 [mm], or where the power of the engine is a) Momentary variations of 10 per cent of the
less than 1100 [kW]. maximum rated speed when the rated load
of the generator is suddenly thrown off;
4.8.7 Overspeed protective devices:
b) Momentary variations of 10 per cent of the
4.8.7.1 Each main engine developing 220 [kW] maximum rated speed when 50 per cent of
or over, which can be declutched or which the rated load is suddenly thrown on
drives a controllable pitch propeller, also each followed by the remaining 50 per cent load
auxiliary engine developing 220 [kW] and over after an interval sufficient to restore the
for driving an electric generator, is to be fitted speed to steady state. Steady state
with an approved overspeed protective device. conditions should be achieved in not more
than 5 seconds;
4.8.7.2 The overspeed protective device,
including its driving mechanism is to be Note : Steady state conditions are those at
independent of the governor required by 4.9 and which the envelope of speed variation does to
is to be so adjusted that the speed does not exceed +1% of the declared speed at the new
exceed that for which the engine and its driven power.
machinery are to be classed by more than 20

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c) At all loads between no load and rated load - the power distribution system is
the permanent speed variation is not to be designed such that the declared
more than 5 per cent of the maximum rated maximum step loading is not exceeded
speed;
- the compliance of time delays and
d) For generating sets operating in parallel, the loading sequence with the above is to
governing characteristics of the engine are be demonstrated at the time of ship’s
to be such that within the limits of 20 per trials.
cent and 100 per cent of total load, the load
on any generating set does not normally 4.10 Oil fuel, lubricating oil, cooling water
differ from its proportionate share of the total and exhaust gas systems
load by more than
4.10.1 Oil fuel, lubricating oil and cooling water
i) 15 per cent of the rated output of piping systems are to comply with the
the largest machine; or requirements of Ch.3 in so far as these are
applicable.
ii) 25 per cent of the rated output of
the individual machine in question, 4.10.2 Exhaust pipes which are led overboard
whichever is less; near the waterline are to be protected against
the possibility of water finding its way inboard.
e) For generating sets intended to operate in Where the exhaust is cooled by water spray, the
parallel, it is to be possible to adjust the exhaust pipes are to be self-draining overboard.
governor so that the load is kept within 5 per
cent of the rated load at normal frequency; 4.10.3 Exhaust pipes of two or more engines are
not to be connected together, but are to be led
f) For alternating current installations, the separately to the atmosphere unless arranged to
permanent speed variation of the machines prevent the return of gases to an idle engine.
intended for parallel operations are to be
equal within a tolerance of ± 0.5 per cent. 4.11 Engine starting arrangements

g) Application of electrical load in more than 2 4.11.1 First start arrangement:

load steps (See Fig.4.9.2) can only be
permitted on the condition that 4.11.1.1 Equipments for starting the main and
auxiliary engines are to be provided so that the
- the design of the ship's electrical system necessary initial charge of starting air or initial
enables the use of such generator sets electric power can be developed on board ship
without external aid. If for this purpose an
- such a provision is made in the design emergency air compressor or electric generator
stage and same is approved while is required, these units are to be power driven
scrutinising the drawings by hand starting oil engines or steam engines,
except in the case of small installations where a
- the safety of the ship's electrical system hand operated compressor of approved capacity
in the event of parallel operation and may be accepted. Alternatively, other devices of
failure of a generator is to be approved type may be accepted as a means of
demonstrated at ship's trials. providing the initial start.

4.9.3 Emergency generator sets must satisfy the 4.11.2 Compressed air starting systems:
above governor conditions even when :
4.11.2.1 Two or more starting and maneuvering
a) their total consumer load is applied air compressors of sufficient total capacity for
suddenly, or the requirements of the main engines are to be
fitted. At least one of the compressors is to be
b) their total consumer load is applied in steps, driven independent of the main propulsion unit
subject to following: and is to have a capacity not less than 50 per
cent of the total required capacity. The total
- the total load is supplied within 45 capacity of air compressors is to be sufficient to
seconds since power failure of the main supply within one hour the quantity of air needed
switchboard to satisfy the requirement of 4.11.2.9 by
charging the receivers from atmospheric
- the maximum step load is declared and pressure. The main air compressors are to be of
demonstrated approximately the same size.

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4.11.2.2 The compressors are to be so designed is to be fitted in the discharge pipe between
that the temperature of the air discharged to the compressors and receivers.
starting air receivers will not substantially
exceed 93°C in service. A small fusible plug or 4.11.2.7 The starting air pipe system from air
an alarm device operating at 121°C is to be receivers to main and auxiliary engines is to be
provided on each compressor to give warning of entirely separate from the compressor discharge
excessive air temperature. The emergency air system. Stop valves on the air receivers are to
compressor need not comply with these permit slow opening to avoid sudden pressure
requirements. rises in the piping system. Valve chests and
fittings in the piping systems are to be of ductile
4.11.2.3 Each compressor is to be fitted with a material.
safety valve so proportioned and adjusted that
accumulation of pressure, with the outlet valve 4.11.2.8 Drain valves for removing
closed, will not exceed 10 per cent of the accumulations of oil and water are to be fitted on
maximum working pressure. compressors, separators, filters and air
receivers. In the case of any low-level pipelines,
4.11.2.4 The castings of the cooling water drain valves are to be fitted to suitably located
spaces are to be fitted with a safety valve or drain pots or separators.
bursting disc so that ample relief will be provided
in the event of the bursting of an air cooler tube. 4.11.2.9 The total air receiver capacity is to be
sufficient to provide, without replenishment,
4.11.2.5 Air compressor inlets are to be located number of starts as per Table 4.11.1.
in an atmosphere reasonably free from oil
vapour or, alternatively, an air duct from outside a) If starting system serves two or more of the
the machinery space is to be led to the above specified purposes, the capacity of
compressors. the system is to be the sum of the capacity
required.
4.11.2.6 The air discharge pipe from the
compressors is to be led direct to the starting air b) At least two air receivers of about equal
receivers. Provision is to be made for capacity are to be provided.
intercepting and draining oil and water in the air
discharge for which purpose a separator or filter
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Page 20 of 52 Prime Movers and Propulsion Shafting Systems

Table 4.11.1 : Number of starts of engines

Duty of engine No. of starts

Propulsion engines – reversible 12 consecutive starts alternating between Ahead
and Astern of each engine
Propulsion engines - non-reversible, connected to
a controllable pitch propeller or other device 6 starts for
enabling the start without opposite torque each engine

Engines for driving electric generators and

3 starts for
emergency generators and engines for other
each engine
purposes
Propulsion engine - reversible 12 starts
Propulsion engine - non-reversible 6 starts
Engines for driving electric generators and
emergency generators and engines for other 3 starts each
purposes

4.11.3 Electric starting

4.12.1.3
4.11.3.1 Where main engines are fitted with
electric starters, two batteries are to be fitted. .1 Engines are of the same type if they do not
The arrangement is to be such that batteries vary in any detail included in the definition in .2.
cannot be connected in parallel. When two engines are to be considered of the
same type it is assumed that they do not
4.11.3.2 Each battery is to be capable of starting substantially differ in design and their design
the engines when in cold and ready to start details, crankshaft, etc. and the materials used
conditions. The combined capacity is to be meet Rule requirements and are approved by
sufficient without recharging to provide within 30 IRS.
minutes the number of starts of the main
engines as required by 4.11.2.9. .2 Definition

4.11.3.3 The electric starting arrangements for The type of internal combustion engine
auxiliary engines are to have two separate expressed by the Engine Builder’s designation is
batteries or may be supplied by separate circuits defined by:
from main engine batteries when such are
provided. In case of a single auxiliary engine, - the bore,
only one battery is required. - the stroke,
- the method of injection (direct or indirect
4.11.3.4 The starting batteries are to be used for injection),
starting and engine's own monitoring purposes - the kind of fuel (liquid, dual-fuel,
only. Provision is to be made to maintain gaseous),
continuously the stored energy at all times. - the working cycle (4-stroke, 2-stroke),
- the gas exchange (naturally aspirated or
4.12 Type testing of oil engines supercharged),
- the maximum continuous power per
4.12.1 General cylinder at maximum continuous speed
and/or maximum continuous brake
4.12.1.1 The requirements of 4.12.1 to 4.12.5 mean effective pressure,1
apply to type testing of non-mass produced - the method of pressure charging
engines only. For mass produced engines, refer (pulsating system, constant, pressure
to "Type approval certification scheme for system),
machinery manufactured by mass production - the charging air cooling system (with or
system". without intercooler, number of stages),
- cylinder arrangement (in-line, vee).2
4.12.1.2 Upon finalization of the engine design
for production of every new engine type
intended for the installation on board ships, one
engine shall be presented for type testing.

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Notes: 4.12.1.5 Engines which are subjected to type

testing are to be tested in accordance to the
1. After a large number of engines has been scope as specified herein.
proved successfully by service experience, an
increase in power upto maximum 10% may be 4.12.1.6 It is assumed that"
permitted, without any further type test, provided
approval for such power is given. - the engine is optimised as required for
the condition of the type;
2. One type test suffices for the whole range of
engines having different numbers of cylinders. - the investigations and measurements
required for reliable engine operation
.3 If an electronically controlled diesel engine have been carried out during internal
has been type tested as a conventional engine tests by the engine manufacturer; and
IRS may waive tests required by 4.12 provided
the results of the individual tests are expected to - the design approval has been obtained
be similar. for the engine type in question on the
basis of documentation specified in this
4.12.1.4 A type test carried out for a particular Section and IRS has been informed
type of engine at any place, at any manufacturer about the nature and extent of
will be accepted for all engines of the same type investigations carried out during the pre-
built by licensees and licensers. production stages.

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4.12.1.7 The type test is subdivided into three - At constant speed for engines intended
stages, namely: for generating sets;

- State A - Internal tests - The limit points of the permissible

Functional tests and collection of operation operating range. These limit points are
values including test hours during the to be defined by the engine
internal tests, the relevant results of which manufacturer.
are to be presented to the Surveyors during
the type test. 4.12.3 Emergency operation situations
Testing hours of components which are
inspected shall be stated. 4.12.3.1 For turbocharged engines the
achievable continuous output is to be
- Stage B - Type approval test determined in the case of turbocharger damage
Type approval test in the presence of the as under:
Surveyors.
- engines with one turbocharger, when
rotor is blocked or removed;
- Stage C - Component inspection
Components inspections by the Surveyors - engines with two or more turbochargers,
after completion of the test programme. when damaged turbocharger is shut off.
The engine manufacturer will have to
complete all results and measurements for 4.12.4 Stage B - Type approval test
the engine tested during the test report,
which will have to be handed over to the 4.12.4.1 During the type test the tests listed
Surveyors. below are to be carried out in the presence of
the Surveyors and the results achieved are to be
4.12.2 Stage A - Internal tests recorded. Deviations from this programme, if
any, are to be agreed between the engine
4.12.2.1 Function tests and collection of manufacturer and the Surveyors.
operating data during the internal tests.
a) Load points
a) During the internal tests the engine is to be
operated at the load points important for the - Load points at which the engine is to be
engine manufacturer and the pertaining operated according to the power/speed
operating values are recorded. The load diagram (See Fig.4.12.1). The data to be
points may be selected according to the measured and recorded when testing the
range of application. engine at various load points are to include
all necessary parameters for the engine
b) If an engine can be satisfactorily operated at operation.
all load points without using mechanically
driven cylinder lubricators this is to be - The operating time per load point depends
verified. on the engine size ( achievement of steady
stage condition) and on the time for
c) For engines which may operate on heavy collection of the operating values. Normally,
fuel oil, the suitability for this will have to be an operating time of 0.5 hour can be
proved in an appropriate form, at assumed per load point.
Manufacturer's (Licenser or Licensee)
tested in general, but where not possible, - Rated power, i.e. 100% output at 100%
latest on board for the first engine to be put torque and 100% speed corresponding to
into service. load point 1. Operating time of two hours is
required at this load point and two sets of
4.12.2.2 Normal case readings are to be taken at approximately 1
hour interval.
- The normal case includes:
- 100% power at maximum permissible speed
- The load points 25%, 50%, 75%, 100% corresponding to load point 2.
and 110% of the maximum rated power;
- Maximum permissible torque (normally
- Along the nominal (theoretical) propeller 110%) at 100% speed corresponding to
curve and at constant speed for load point 3 or maximum permissible power
propulsion engines; (normally 110%) and speed according to

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nominal propeller curve corresponding to - Crank bearing and main bearing,
load point 3a. dismantled;

- Minimum permissible speed at 100% torque

corresponding to load point 4. - Cylinder liner in the installed condition;

- Minimum permissible speed at 90% torque - Cylinder head, valves dismantled;

corresponding to load point 5.
- Control gear, camshaft and crankcase with
- Part loads, e.g. 75%, 50%, 25% of rated opened covers.
power and speed according to nominal
propeller curve corresponding to points 6, 7 NOTE:
and 8 and at rated speed with constant If deemed necessary by the Surveyors further
governor setting corresponding to points 9, dismantling of the engine may be required.
10 and 11.
4.13 Work's trials (acceptance test)
b) Emergency operation
4.13.1 Engines are, in general, to be shop-
- Maximum achievable power when operating tested at the Maker's Works under the
along the nominal propeller curve and when supervision and to the satisfaction of Surveyors.
operating with constant governor setting for In general following tests are to be carried out:
rated speed as per 4.12.3.
4.13.1.1 For Main Engines Driving Propellers
c) Functional tests
a) At 100 per cent load at maximum
- Lowest engine speed according to nominal continuous power P in [kW] at
propeller curve. corresponding RPM, R : at least 60 minutes
after having reached steady conditions;
- Starting tests, for non-reversible engines
and/or starting and reversing tests, for b) At 110 per cent load at 1.032R : for 45
reversible engines. minutes after having reached steady
conditions;
- Governor test.
c) 90% (or normal continuous cruise power),
- Testing the safety system, particularly for 75%, 50% and 25% power in accordance
overspeed and low lubricating oil pressure. with the nominal propeller curve for a
duration to the satisfaction of the attending
- Integration Tests : For electronically Surveyor;
controlled diesel engines integration tests
are to verify that the response of the d) Determination of the lowest working speed,
complete mechanical, hydraulic and if possible, with engine loaded according to
electronic system is as identified from FMEA the propeller curve;
study carried out. (Refer 4.2.2).
e) Starting, reversing and governing tests, and
NOTE: proving of safety cutouts, such as
For engines, intended to be used for emergency overspeed, shutdown device, etc.
service supplementary tests according to the
regulations of administration may be required. 4.13.1.2 For Main Engines Driving Generators
For Propulsion
4.12.5 Stage C - Component inspection
a) At 100 per cent load at maximum
4.12.5.1 Immediately after the test run the continuous power P in [kW] at
components of one cylinder for in-line engines corresponding RPM, R : at least 60 minutes
and two cylinders for V-engines are presented after having reached steady conditions;
for inspection. The following components are
concerned: b) At 110 per cent load : for 45 minutes after
having reached steady conditions;
- Piston removed and dismantled;
c) 75 per cent, 50 per cent, 25 per cent load
- Crosshead bearing, dismantled; and idle run;

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d) Starting and governor tests and proving of

safety cutouts such as overspeed, shutdown 4.14 Shipboard trials
device, etc.
4.14.1 After the conclusion of the running-in
NOTES: programme, prescribed by the engine
manufacturer, engines are to undergo the trials
1. For all stages, the engine is going to be as specified below:
tested, the pertaining operation values are
to be measured and recorded by the engine 4.14.1.1 Scope of trials
manufacturer. All results are to be compiled
in an acceptance protocol to be issued by a) Main propulsion engines driving fixed
the engine manufacturer. propellers

2. In each case all measurements conducted i) At rated engine speed R : at least 4

at various load points are to carried out at hours; and at engine speed
steady operating conditions. The readings corresponding to normal continuous
for 100% power (rated power at rated cruise power: at least 2 hours
speed) are to be taken twice at an interval of
at least 30 minutes. ii) At engine speed R1 = 1.032 R : 30
minutes (where the engine
3. After running on test bed, the fuel delivery adjustment permits). See 4.13.1.1(b)
system of engines driving generators must
be adjusted such that overload (110 per iii) At minimum on-load speed
cent) power can be given in service after
installation on board, so that the governing iv) Starting and reversing manoeuvres
characteristics including the activation of
generator protective devices can be fulfilled v) In reverse direction of propeller
at all times. For engines driving propellers rotation at a minimum engine speed
the fuel delivery system must be adjusted so of R2 = 0.7 R for 10 minutes
that engines can be loaded to 100% of the
power. vi) Monitoring, alarm and safety
systems.
4.13.1.3 For Auxiliary Engines
b) Main propulsion engines driving controllable
Tests to be performed in accordance with pitch propellers or reversing gears 4.14.1.1
4.13.1.2. applies as appropriate.

NOTE: Controllable pitch propellers are to be tested

After running on test bed, the fuel delivery with various propeller pitches.
system of engines driving generators must be
adjusted such that overload (110 per cent) c) Single main engines driving generators for
power can be given in service after installation propulsion. The tests to be performed at
on board, so that the governing characteristics rated speed with a constant governor
including the activation of generator protective setting under conditions of:
devices can be fulfilled at all times.
i) 100% power (rated propulsion power)
4.13.2 The data to be measured and recorded, at least 4 hours; and at normal
when testing the engine at various load points is continuous cruise propulsion power at
to include all necessary parameters for the least 2 hours
engine operation. The crankshaft deflection is to ii) 110% power (rated propulsion power)
be checked when this check is required by the : 30 minutes
manufacturer during operating life of the engine. iii) In reverse direction of propeller
rotation during the dock or sea trials
4.13.3 The scope of the trials may be expanded at a minimum speed of 70% of the
depending on the engine application. nominal propeller speed: 10 minutes
iv) Starting manoeuvres
4.13.4 Integration Tests : For electronically v) Monitoring, alarm and safety
controlled diesel engines integration tests are to systems;
verify that the response of the complete
mechanical, hydraulic and electronic system is Note : Tests are to be based on the rated
as identified from FMEA study carried out. electrical powers of the electric propulsion
(Refer 4.2.2). motors.

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d) Engines driving auxiliaries 4.15.1.3 Protection of crankcase

i) Engines driving generators or a) Crankcase relief valves are to be fitted in

important auxiliaries are to be way of each crankthrow. The construction
subjected to an operational test for at and operating pressure of the relief valves
least 4 hours. During the test, the set are to be determined considering explosions
concerned is required to operate at its due to gas leaks.
rated power for an extended period.
b) If a trunk piston type engine is used as DFD
ii) It is to be demonstrated that the engine, the crankcase is to be protected by
engine is capable of supplying 100% the following measures:
of its rated power and in the case of
shipboard generating sets account i) Ventilation is to be provided to prevent the
shall be taken of the times needed to accumulation of leaked gas, the outlet for
actuate the generator's overload which is to be led to a safe location in the
protection system. open space through flame arrester.

e) The suitability of engine burning residual or ii) Gas detecting or equivalent equipment. (It
other special fuels is to be demonstrated, if is recommended that means for automatic
machinery installation is arranged to burn injection of inert gas are to be provided).
such fuels.
iii) Oil mist detector.
4.14.1.2 In addition the scope of the trials may
be expanded in consideration of the special c) If a cross-head type engine is used as DFD,
operating conditions, such as towing, trawling the crankcase is to be protected by oil mist
etc. detector or bearing temperature detector.

4.15 Dual fuel diesel engines 4.15.1.4 Protection for piston underside
space of cross-head type engine
4.15.1 Control and safety systems for Dual
Fuel Diesel (DFD) engines a) Gas detecting or equivalent equipment is to
be provided for piston underside space of
4.15.1.1 Application cross-head type engine.

a) The following requirements are applicable to 4.15.1.5 Engine exhaust system

dual-fuel diesel engines utilising high
pressure Methane gas (NG: Natural Gas) as a) Explosion relief valves or other appropriate
fuel. These requirements are in addition to protection system against explosion are to
those given in Pt.4, Ch.4 for oil fired diesel be provided in the exhaust, scavenge and
engines and Pt.5, Ch.4, Sec.5, 16 of the air inlet manifolds.
'Rules and Regulations for the Construction b) The exhaust gas pipes from DFD engines
and Classification of Steel Ships'. are not to be connected to the exhaust
pipes of other engines or systems.
4.15.1.2 Operation mode
4.15.1.6 Starting air line
a) DFD engines are to be of the dual-fuel type
employing pilot fuel ignition and to be a) Starting air branch pipes to each cylinder
capable of immediate change-over to oil fuel are to be provided with effective flame
only. arresters.

b) Oil fuel only is to be used when starting the 4.15.1.7 Combustion monitoring
engine.
a) A failure mode and effect analysis (FMEA)
c) Oil fuel only, in principle, is to be used when examining all possible faults affecting the
the operation of an engine is unstable combustion process is to be submitted for
and/or during manoeuvring and port approval.
operations.
Details of required monitoring will be
d) In case of shut-off of the gas fuel supply, the considered based on the outcome of the
engines are to be capable of continuous analysis. The following table may serve as
operation by oil fuel only. guidance:

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Automatic shut-off of the

Faulty condition Alarm
interlocked valves*
Function of gas fuel injection valves and pilot oil fuel injection
X X
valves
Exhaust gas temperature at each cylinder outlet and
X X
deviation from average
Cylinder pressure or ignition failure of each cylinder X X
* It is recommended that the gas master valve is also closed.

4.15.1.8 Gas fuel supply to engine (however, an interlocked gas valve

connected to vent outlet is to be
a) Flame arresters are to be provided at the opened).
inlet to the gas supply manifold for the
engine. 2) Construction and strength of the
outer pipes are to comply with the
b) Arrangements are to be made so that the requirements of Pt.5, Ch.4, Sec.5,
gas supply to the engine can be shut-off Cl.5.2 of the 'Rules and Regulations
manually from manoeuvring platform or any for the Construction and
other control position. Classification of Steel Ships'.

c) The arrangement and installation of the gas 3) It is to be so arranged that the inside
piping are to provide the necessary flexibility of the gas fuel supply piping system
for the gas supply piping to accommodate between the master gas valve and
the oscillating movements of DFD engine, the DFD engine is to be
without risk of fatigue failure. automatically purged with inert gas,
when the master gas valve is closed;
d) The connections of gas line and protection or
pipes or ducts required in 4.15.1.9(a) to the
gas fuel injection valves are to provide ii) The system when complying with
complete coverage by the protection pipe or Cl. 16.3.1.2 of Pt.5, Ch.4, Sec.16 of the
ducts. 'Rules and Regulations for the
construction and Classification of Steel
4.15.1.9 Gas fuel supply piping systems Ships' and in addition, with 1) through 4)
given below:
a) Gas fuel piping may pass through or extend
into machinery spaces or gas-safe spaces 1) Materials, construction and strength
other than accommodation spaces, service of protection pipes or ducts and
spaces and control locations provided that mechanical ventilation systems are
they fulfill one of the following: to be sufficiently durable against
bursting and rapid expansion of high
i) The system when complying with pressure gas in the event of gas
16.3.1.1 of Pt.5, Ch.4, Sec.16 of the pipe burst.
'Rules and Regulations for the
Construction and Classification of Steel 2) The capacity of mechanical
Ships' and in addition, with 1), 2) and 3) ventilating system is to be
given below: determined considering the flow rate
of gas fuel and construction and
1) The pressure in the space between arrangement of protective pipes or
concentric pipes is monitored ducts, as deemed appropriate by the
continuously. Alarm is to be issued Rules of IRS.
and automatic valves specified in Cl.
16.3.6 of Pt.5, Ch.4, Sec.16 of the 3) The air intakes of mechanical
'Rules and Regulations for the ventilating systems are to be
Construction and Classification of provided with non-return devices
Steel Ships' and the master gas fuel effective for gas fuel leaks. However,
valves specified in Cl.16.3.7 of Pt.5, if a gas detector is fitted at the air
Ch.4, Sec.16 of the 'Rules and intakes, these requirements may be
Regulations for the construction and dispensed with.
Classification of Steel Ships' are to
be closed before the pressure drops
to below the inner pipe pressure

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4) The number of flange joints of
protective pipes or ducts is to be iii) Abnormally specified in 4.15.1.9(a)(i).
minimised; or
b) In addition to the causes specified in Pt.5,
iii) Alternative arrangements to those given Ch.4, Sec.16, Cl.16.3.7 of the 'Rules and
in paragraph 4.15.1.9(i) and 4.15.1.9(ii) will Regulations for the construction and
be specially considered based upon an Classification of Steel Ships', the master gas
equivalent level of safety. valve is to be closed in case of any of the
following:
b) High pressure gas piping system are to be
ensured to have sufficient constructive i) Oil mist detector or bearing temperature
strength by carrying out stress analysis detector specified in 4.15.1.3(b)(iii) and (c)
taking into account the stresses due to the detects abnormality.
weight of the piping system including
acceleration load when significant, internal ii) Any kind of gas fuel leakage is detected
pressure and loads induced by hog and sag
of the ships. iii) Abnormality specified in 4.15.1.9

c) All valves and expansion joints used in high iv) Abnormality specified in 4.15.1.11(a).
pressure gas fuel supply lines are to be of
an approved type. c) The master gas valve is to close
automatically upon activation of the
d) Joints on entire length of the gas fuel supply interlocked gas valves.
lines are to be butt-welded joints with full
penetration and to be fully radiographed, 4.15.1.11 Emergency stop of the DFD
except where specially approved by IRS. engines

e) Pipe joints other than welded joints at the a) DFD engine is to stopped before the gas
locations specially approved by IRS are to concentration detected by the gas detectors
comply with the appropriate National or specified in Pt.5, Ch.4, Sec.16, Cl.16.2.2 of
International standards or those whose the 'Rules and Regulations for the
structural strength has been verified through Construction and Classification of Steel
tests and analysis as deemed appropriate Ships', reaches 60% of lower flammable
by IRS. limit.

f) For all butt-welded joints of high pressure 4.15.1.12 Gas fuel make-up plant and related
gas fuel supply lines, post-weld heat storage tanks
treatment are to be performed depending on
the kind of material. a) Construction, control and safety system of
high pressure gas compressors, pressure
4.15.1.10 Shut-off of gas fuel supply vessels and heat exchangers constituting a
gas fuel make-up plant are to be arranged
a) In addition to the causes specified in Pt.5, to the satisfaction of IRS.
Ch.4, Sec.16, Cl. 16.3.6 of the 'Rules and
Regulations for the construction and b) The possibility for fatigue failure of the high
Classification of Steel Ships' supply of gas pressure gas piping due to vibration is to be
fuel to DFD engines is to be shut off by the considered.
interlocked gas valves in case following
abnormality occurs: c) The possibility for pulsation of gas fuel
supply pressure caused by the high
i) Abnormality specified in 4.15.1.7 pressure gas compressor is to be
considered.
ii) DFD engine stops from any cause

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Section 5

Gearing

5.1 Scope 5.2.3 At least the following particulars of the

gearing are to be submitted along with the
5.1.1 The requirements of this Section cover the plans:
construction, material and inspection of
reduction gears for main propelling purposes a) Shaft power and revolutions for each pinion;
and for driving electric generators.
b) Number of teeth in each gear;
5.1.2 Design of bevel gears will be specially
considered. c) Generating pitch diameters;

5.1.3 For torsional vibration requirements, See d) Helix angles at generating pitch diameters;
Sec.8.
e) Normal pitches of teeth at generating pitch
5.1.4 Rated power of gear is the maximum diameters;
transmitted power at which the gear is designed
to operate continuously at its rated speed. f) Tip diameters;

5.1.5 The rated torque is defined by the rated g) Root diameters;

power and speed and is the torque used in the
gear rating calculations. h) Face widths and gaps, where applicable;

5.1.6 The gear rating is the rating for which the i) Pressure angles of teeth (normal or
gear is designed to transmit it’s rated torque. transverse) at generating pitch diameters;

5.2 Plans and particulars j) Minimum backlash;

5.2.1 The following plans, in triplicate, of the k) Centre distance;

reduction gearing are to be submitted:
l) Basic rack tooth form;
For Approval
m) Details of tooth flank corrections, if adopted;
a) Pinion(s) and wheel(s);
n) Details of post hobbing process, if any;
b) Shafts;
o) Case depth for surface-hardened teeth;
c) Hub(s);
p) Shrinkage allowance for shrunk-on rims and
d) Other power transmitting parts; hubs;

For information only q) Type of coupling proposed for oil engine

applications.
e) Longitudinal and transverse sections of the
gear box; 5.2.4 Gears with Multiple Prime Mover Inputs

f) Clutch(es) and/or coupling(s); 5.2.4.1 For single helical gears with

arrangements utilizing multiple prime mover
g) Gear casing including propeller thrust inputs, and single or multiple outputs, the
bearing housing, if applicable. following analyses for all operating modes are to
be conducted:
5.2.2 The plans are to show clearly all
dimensions, details of all fillets and stress - All bearing reactions
raisers, and material of all the parts. - Tooth modifications
- Load distributions on the gear teeth
- Contact and tooth root bending stresses

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A summary of the results of these analyses for 5.4.3 Where castings are used for wheel
each operating mode is to be submitted for centres, any radial slots in the periphery are to
review. be fitted with permanent chocks before
shrinking-on the rim.
5.3 Materials
5.4.4 Where bolts are used to secure side plates
5.3.1 Specifications for materials of pinions, to rim and hub, the bolts should be tight fit with
pinion sleeves, wheel rims, gear wheels and the holes and the nuts should be suitably locked
shafting giving chemical composition, heat by means other than welding.
treatment and mechanical properties are to be
submitted for approval with the plans of gearing 5.4.5 When welding is employed in the
and are to be in accordance with Pt.2. construction of wheels, the welding procedure is
to be approved by the Surveyors before work is
5.3.2 Where the teeth of a pinion or gear wheel commenced. For this purpose, welding
are to be surface hardened, the proposed procedure approval tests are to be carried out
specification and details of the procedure are to with satisfactory results. Such tests are to be
be submitted for approval. representative of the joint configuration and
materials. Wheels are to be stress relieved after
5.3.3 In the selection of materials for pinions and welding. All welds are to have a satisfactory
wheels consideration should be given to their surface finish and contour. Magnetic particle or
compatibility in operation. In general, for gears liquid penetrant examination of all important
of through hardened steels, except in the case welding joints is to be carried out to the
of low reduction ratios, provision should also be satisfaction of the Surveyors.
made for a hardness differential between pinion
teeth and wheel teeth. For this purpose the 5.4.6 In general arrangements are to be made
specified minimum tensile strength of the wheel so that the interior structure of the wheel may be
materials should not be more than 85 per cent of examined. Alternative proposals will be specially
that of the pinion. considered.

5.3.4 Subject to 5.3.3, the specified minimum 5.5 Accuracy of gear cutting and alignment
tensile strength of steel gear forgings is to be
selected within the following limits: 5.5.1 Gears are to be cut only on machines
which are maintained at a high standard of
- Pinions and pinion sleeves - 550-1050 accuracy. Hobbing machines used in the
[N/mm2]; production of large gears are to be operated
under conditions of temperature control with a
- Gear wheels and rims - 400-850 total temperature variations not exceeding 2°C
[N/mm2]. for the finishing cut. The blank should be
allowed sufficient time to stabilize to the
A tensile strength range is also to be specified machine temperature before cutting
and is not to exceed 120 [N/mm2] when the commences.
specified minimum tensile strength is 600
2
[N/mm ] or less. For higher strength steels, the 5.5.2 The accuracy of gear-cutting of pinions
range is not to exceed 150 [N/mm2]. and wheels is to be demonstrated to the
satisfaction of the Surveyors. For this purpose,
5.3.5 Unless otherwise agreed, the specified records of measurements of pitch error,
minimum tensile strength of the core is to be undulations, axial pitch errors, tooth thickness
800 [N/mm2] for induction-hardened or nitrided and backlash should be available for review by
2
gearing and 750 [N/mm ] for carburized gearing. Surveyors on request.

5.4 Design and construction 5.5.3 The alignment is to be demonstrated in the

workshop by meshing in the gearbox without oil
5.4.1 The design and construction is to be such clearance in the bearings, or in the meshing
as to enable the gearing to meet the general frame without oil clearance in the bearings or on
requirements with respect to functional rollers. Meshing is to be carried out with the
capability and reliability. gears locating in their load positions, and a load
sufficient to overcome pinion weight and axial
5.4.2 Detailed analysis to prove the design of movement is to be imposed.
the gearing is to be submitted for consideration.
In this regard, Classification Notes on the design 5.5.4 A permanent record is to be made of the
of gearing may be followed. meshing contact for the purpose of re-checking
the alignment when installed on board ship. The
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meshing contact on each helix is not to be less construction they are to be stress-relieved on
than following: completion.

a) For through-hardened gears, 5.7.2 Inspection openings should be provided at

the peripherals of gearcases to enable the teeth
- 40 per cent of the working depth for 35 of pinions and wheels to be readily examined.
per cent of the length; and When the construction of gearcases is such that
sections of the structure cannot readily be
- 20 per cent of the working depth for moved for inspection purposes, access
further 35 per cent of the length; openings of adequate size are to be also
provided at the ends of the gearcases to permit
b) For through-hardened gears and for all examination of the structure of the wheels. Their
surface hardened gears, attachment to the shafts should be capable of
being examined by removal of bearing caps or
- 40 per cent of the working depth for 50 by equivalent means.
per cent of length; and
5.8 Type tests and sea trials
- 20 per cent of the working depth for a
further 40 per cent of the length. 5.8.1 Upon completion of fabrication and
assembly, reduction gear unit is to be subjected
5.6 Balancing of gear pinions and wheels to type testing in accordance with the agreed
test programme which is to be submitted by the
5.6.1 All pinions, gear wheels and flexible manufacturer for approval. Type tests are to be
couplings or sleeves whose maximum designed witnessed by the Surveyor.
speed of rotation exceeds 1000 revolutions per
minute are to be dynamically balanced, where 5.8.2 Reduction gearing units, in general, are to
the speed of rotation is 1000 revolutions per be type tested at maker’s works and test load
minute or less, these components are to be and duration of testing is to be agreed upon in
statically or, alternatively, dynamically balanced. each case.
Parts of couplings, etc., which are to be fixed to
the gear in service are normally to be attached 5.8.3 Tests are to include demonstration of
before balancing. satisfactory operation of clutches and couplings,
if fitted.
5.6.2 For static balancing the final out of balance
of each assembly at the balancing planes is not 5.8.4 After completion of type tests, all gear
to exceed 2200 [N mm/tonne] of gears whose elements are to be examined for tooth contact
maximum design speed is less than 300 marking and alignment. All gear tooth contact is
revolutions per minute and 680 [N mm/tonnes] to conform to the requirements given in Cl.
for gears whose maximum design speed is 5.5.5.
between 300 and 1000 revolutions per minute.
For dynamic balancing the final out of balance is 5.8.5 The gear lub.oil system is to be provided
not to exceed 190,000/N1 [N mm/tonne], where with means of indicating the lub.oil pressure
N1 = revolutions per minute appropriate to the supply to them. Alarms are to be provided to
assembly. indicate low lub.oil pressure, low clutch oil/air
pressure and high lub.oil temperature in
5.6.3 Balancing may, however, be omitted for accordance with Part 4, Chapter 7, Table 1.9.1.
turbine secondary pinions and for oil engines
gearing, provided that the rotating components 5.9 Alignment and weardown gauges
are of solid forged construction or have a solid
forged centre with shrunk-on rim and in both 5.9.1 Reduction gears with sleeve bearings for
cases are machined to give a concentric and main and auxiliary turbines and oil engines, are
uniform cross-section. to be provided with weardown gauges or
micrometers for testing the internal alignment of
5.7 Gearcases the various elements in the gearcases. In certain
gears, e.g. gears of the dual tandem type, the
5.7.1 Gearcases and their supports are to be direction of loading on the bearings of a gear
designed sufficiently stiff such that misalignment element may be such that an accurate indication
at the mesh due to movements of the external of its alignment under operating conditions
foundations and the thermal effects under all cannot be obtained using weardown gauges. In
conditions of service do not disturb the overall these instances, suitable alternatives such as
tooth contact. If welding is employed in their crown thickness micrometer are to be provided.

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5.9.2 Approved means are to be provided by the
gear manufacturer to enable the Surveyors to 5.10.2 In the case of through-hardened gears,
verify that no distortion of the gearcase has not less than 70 per cent contact across
taken place, when chocked and secured to its effective face width should be indicated. When
seating on board ship. the teeth of such gears are finished by an
approved post hobbing process or profile
5.10 Trials ground, not less than 90 per cent contact across
the effective face width is to be indicated.
5.10.1 The sea trials should be of sufficient
duration to prove the gears. After these trials, 5.10.3 For surface hardened gears, the contact
the marking revealed by inspection should across the effective face width is also to be not
indicate freedom from hard bearings, particularly less than 90 per cent.
towards both ends of each helix.

Section 6

Main Propulsion Shafting

6.1 Scope 6.2 Alternative calculation methods

6.1.1 The requirements of this Section apply to 6.2.1 Alternative calculation methods will be
shafting for main propulsion of straight forged considered provided these calculations take into
design and which are driven by rotating account all relevant loads in the complete
machines such as diesel engines, turbines or dynamic shafting system under all permissible
electric motors. The requirements for couplings, operating conditions giving due consideration to
coupling bolts, keys, keyways, sternbushes and the dimensions and arrangements of all shafting
associated components are also included. The connections. The alternative calculation method
diameter of shafting as calculated may require is to also take into account design criteria for
to be modified as a result of alignment continuous and transient operating loads for
considerations and vibration characteristics (See dimensional adequacy for fatigue strength and
Sec.8) or the inclusion of stress raisers, other peak operating loads for yield strength. Refer
than those contained in this section. 6.2.2 to 6.2.5 as guidance for alternative
calculations.
The requirements given in this section do not
cover shafts intended for following application. 6.2.2 The two important considerations that are
essential for the design of propulsion shafting
- gearing shafts are:
- electric motor shafts
- generator rotor shafts a) Fatigue
- turbine rotor shafts. b) Stress concentration and notch
sensitivity.
6.1.2 The scantlings of shafts that are integral to
equipment, such as for gear boxes, podded Fatigue : The deterioration of the properties of
drives, electrical motors and/or generators, material which takes place under conditions
thrusters, turbines and which in general involving fluctuating stresses. Fatigue failures
incorporate particular design features are to be generally occur at loads, which if applied
determined taking into account appropriate statically would be below the elastic limit. The
additional criteria including that for stiffness, fatigue limit of a material is the stress which will
high temperature application etc. The not produce failure, even if many fluctuations of
requirements given in this section may be it are imposed.
applied if such shafts are subjected mainly to
torsion and are having traditional design Stress concentration in shafts : Basic stress
features. analysis calculations assume that the
components are smooth, have a uniform section
6.1.3 For additional strengthening for shafts in and have no irregularities. In practice virtually all
ships classed for navigation in waters with ice engineering components have to have changes
condition, refer Pt.5, Ch.21 and for diesel engine in section and/or shape. Common examples are
crankshaft refer IRS Classification Note shoulders on shafts, oil holes, key ways and
“Crankshaft for Internal Combustion Engines”. screw threads. Any discontinuity changes the
stress distribution in the vicinity of the

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discontinuity, so that the basic stress analysis b) High cycle fatigue criterion (typically > 107),
equations no longer apply. Such ‘discontinuities’ i.e. torsional vibration stresses permitted for
or ‘stress raisers’ cause local increase of stress continuous operation as well as reverse
referred to as ‘stress concentration’. bending stresses.
The limits for torsional vibration stresses are
For static loading the theoretical or geometric given in 8.4.2.
stress concentration factors Kt or Kts relate to
actual maximum stress at the discontinuity to c) The accumulated fatigue due to torsional
the nominal stress as follows: vibration when passing through a barred
speed range or any other transient condition
Kt = maximum direct stress/nominal direct stress with associated stresses beyond those
Kts = maximum shear stress/nominal shear permitted for continuous operation is
stress. addressed by the criterion for transient
stresses in 8.4.2.
The subscript ‘t’ denotes that the stress
concentration value is a theoretical calculation 6.2.4 The factors k (for low cycle fatigue) and ck
based only on the geometry of the component (for high cycle fatigue) as given in Table 6.5.1
and discontinuity. and Table 8.4.2 respectively take into account
the influence of:
Some materials are not as sensitive to notches
as implied by the theoretical stress - The stress concentration factors (scf)
concentration factor. For these materials a relative to the stress concentration for a
reduced value of stress concentration factor Kf flange with fillet radius of 0.08do (geometric
may be used where the maximum stress = Kf x stress concentration of approximately 1.45).
nominal stress. The value of Kf which depends
on notch sensitivity ‘q’ is to be determined using x
1.45 ⎡ scf ⎤
the following equation: ck ≈ and k ≈ ⎢ ⎥
scf ⎣1.45 ⎦
q = (Kf - 1) / (Kt - 1) where q is between 0 and 1.
where the exponent x considers low cycle notch
If q = 0, then Kf = 1 as the material has no sensitivity.
sensitivity to notches. If q = 1, then Kf = Kt and
the material is fully notch sensitive. - The chosen values of the notch sensitivity
are mainly representative for soft steels (σB
When designing, usual practice is to first find Kt < 600), while the influence of steep stress
from the geometry of the component, then gradient s in combination with high strength
specify the material and determine the notch steels may be underestimated.
sensitivity, q from the chart for the notch radius.
- The size factor CD being a function of
For cyclic loading, the theoretical stress diameter only does not purely represent a
concentration factor is to be defined as statistical size influence, but rather a
combination of this statistical influence and
endurance limit without stress concentration the notch sensitivity.
K t1 =
endurance limit with stress concentration
6.2.5 The stress concentration factor (scf) at the
end of slots can be determined by means of the
Using the notch sensitivity factor ‘q’ in cyclic following empirical formulae:
loading of shaft, fatigue stress concentration
factor Kf is calculated as : (l − e)/d
scf = α t(hole) + 0.57.
Kf = 1 + q (Kt1 – 1) ⎛ di ⎞ e
⎜1 − ⎟ .
6.2.3 The alternative calculation methods are to ⎝ d⎠ d
take into account following fatigue related issues
as have been considered in rule formulations: where,

a) Low cycle fatigue criterion (typically < 104), e = slot width

i.e. the primary cycles represented by zero l = length of the slot
to full load and back to zero, including do = outer diameter
reversing torque if applicable. di = inner diameter (Refer figure given under
Table 6.5.1).

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This formula applies to: 6.4 Materials for shafting

- slots at 120 or 180 or 360 degrees apart. 6.4.1 The materials are to comply with the
relevant requirements of Pt.2, Ch.5. The
- slots with semicircular ends. (Though multi- specified minimum tensile strength of forgings is
radii slot end can reduce the local stresses, to be selected within the following general limits:
this is not included in this empirical formula).
a) Carbon and carbon-manganese steel 500-
- slots with no edge rounding (except 600 [N/mm2]; However, shaft material
chamfering), as any edge rounding having specified minimum tensile strength of
increases the scf slightly. 400 [N/mm2] may be used if calculations are
submitted to show that vibratory stresses
α t(hole) = factor representing the stress occurring in the shafts are lower than the
permissible stresses even in the transient
concentration of radial hole of diameter e: operation.
2 2 2
e ⎛e⎞ ⎛e⎞ ⎛d ⎞ b) Alloy steels - 500-800 [N/mm2].
= 2.3 − 3 . + 15 . ⎜ ⎟ + 10 . ⎜ ⎟ . ⎜ i ⎟
d ⎝d⎠ ⎝d⎠ ⎝ d ⎠ 6.4.2 If materials with greater specified or actual
tensile strength than the limitations given in
6.3 Plans and particulars 6.4.1 are used, no consideration will be given for
reduction of shaft diameter or acceptance of
6.3.1 The following plans, in triplicate, together higher permissible vibratory stresses, than those
with the necessary particulars of the machinery, stated in 6.4 to 6.6.
including the maximum power and revolutions
per minute, are to be submitted for approval 6.4.3 Ultrasonic tests are required on shaft
before the work is commenced. forgings where the diameter is 250 [mm] or
greater.
- Power take-off arrangement if any (e.g.
shaft generator), propulsion boosters or 6.5 Intermediate and thrust shafts
similar equipment rated for 100 [kW] and
above; 6.5.1 The diameter, d, of the shaft is to be not
- Final gear shaft; less than determined by the following formula:
- Thrust shaft;
- Intermediate shafting, shaft bearings;
P ⎛ 560 ⎞
- Tube shaft, where applicable; d = Fk 3 ⎜ ⎟ [mm]
- Tail shaft; n ⎝ σB + 160 ⎠
- Stern tube, shaft seals and Stern bush;
- Stern tube lubrication system; where,
- Couplings (integral, demountable, keyed or
shrink-fit), coupling bolts and keys; F = 95 for turbine installations, electric
- Flexible coupling including constructional propulsion installations and oil engine
details, static and dynamic torsional installations with slip type couplings;
stiffness, damping characteristic, rated
power, torque and RPM, allowable vibratory = 100 for other oil engine installations;
torque for continuous and transient
operation and allowable misalignment for k = shaft design factors as given in Table 6.5.1;
continuous operations;
- Cardan shafts, if fitted. σB = specified minimum tensile strength of the
material [N/mm2]. For calculation purposes, this
6.3.2 The specified minimum tensile strength of value is not be taken greater than 800 [N/mm2];
each shaft is to be stated.
P = maximum shaft power, in [kW];
6.3.3 A shafting arrangement plan indicating the
relative position of the main engines, flywheel, n = Revolutions per minutes corresponding to
flexible coupling, gearing, thrust block, line maximum shaft power giving maximum torque.
shafting and bearings, stern tube, 'A' brackets
and propeller, as applicable, is to be submitted 6.5.2 For shafts with design features other than
for information. stated in Table 6.5.1, the value of k will be
specially considered.

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Table 6.5.1 : Shaft design factors k for line shafts and thrust shafts

Intermediate shaft with Thrust shafts external to

engine
Integral Shrink fit Key-ways Radial Longitudi On both In way of axial Straight
Factor coupling coupling cylindrical holes, nal slots sides of bearings where a sections
flange 1) 2)
and transverse 6)
thrust roller bearing is
tapered 3), holes 5) collars 1) used for taking
4)
up thrust
k 1.0 1.0 1.1 1.1 1.2 1.1 1.1 1.0
Notes:

1) Fillet radius is not to be less than 0.08d.

2) k refers to the plain shaft section only. Where shafts may experience vibratory stresses close to
the permissible stresses for continuous operation, an increase in diameter to the shrink fit
diameter is to be provided, e.g. a diameter increase of 1 to 2% and a blending radius nearly
equal to the change in diameter are to be provided.

3) At a distance of not less than 0.2d from the end of the keyway the shaft diameter may be
reduced to the diameter calculated with k = 1.0. Fillet radii in the transverse section of the
bottom of the key way are not to be less than 0.0125d.
4) It is recommended that keyways are in general not to be used in installations with a slow speed
crosshead or 2-stroke engines with a barred speed range.

5) Diameter of radial bore (dh) not to exceed 0.3do.

The intersection between a radial and an eccentric (rec) axial bore (see below) the value will be
determined on the basis of data submitted in each case.

6) Subject to following limitations being complied with -

i) slot length (I)/outside diameter < 0.8 and

ii) inner diameter (di )/outside diameter do < 0.8 and
iii) slot width (e)/outside diameter do > 0.10.
The end rounding of the slot is not to be less than e/2. An edge rounding should
preferably be avoided as this increases the stress concentration slightly. The k
value is valid for 1, 2 and 3 slots and they are to be arranged 360, 180 or 120
degrees apart from each other respectively.

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6.6 Tailshafts and stern tube shafts value is not to be taken greater than 600
[N/mm2];
6.6.1 The diameter, dp, of the tailshaft
immediately forward of the forward face of the P and n are defined in 6.5.
propeller boss or, if applicable, the forward face
of the tailshaft flange, is to be not less than 6.6.2 The diameter, dp of the tailshaft
determined by the following formula: determined in accordance with the formula in
6.6.1 is to extend over a length not less than
that to the forward edge of the bearing
P ⎛ 560 ⎞
d p = 100 k 3 ⎜ ⎟ [mm] immediately forward of the propeller or 2.5 dp
n ⎝ σB + 160 ⎠ whichever is the greater.

where, 6.6.3 The diameter of the portion of the tailshaft

and tubeshaft forward of the length required by
k = shaft design factors as given in Table 6.6.1; 6.6.2 to the forward end of the forward sterntube
seal is to be determined in accordance with the
σB = specified minimum tensile strength of the formula in 6.6.1 except that:
2
material [N/mm ]. For calculation purposes, this

Table 6.6.1 : Shaft design factors k for tailshafts 1) and stern tube shafts

Factor Propulsion Stern tube configuration Tailshafts : propeller attachment Stern

drive method tube
Keyed Key less Flanged shafts
attachment
by shrink fit
All Oil lubricating bearings and 1.26 1.22 1.22 1.15
provided with an approved
type of oil seating gland
All Water lubricated bearings : 1.26 1.22 1.22 1.15
k
continuous shaft liners or
equivalent
All Water lubricated bearings : 1.29 1.25 1.25 1.18
non-continuous shaft liners

Note : 1) Fillet radii in the transverse section at the bottom of the keyway are not to be less than
0.0125dp

k = 1.15, where k = 1.22 or 1.26 as required by 6.7 Hollow shafts

6.6.1 (shafts fitted with continuous liner or oil
lubricated); 6.7.1 For hollow shafts where the bore exceeds
40 per cent of the outside diameter the minimum
k = 1.18, where k = 1.25 or 1.29 as required by shaft diameter is not to be less than that given
6.5.1 (shafts with water lubricated bearings). by the following equation:

The change of diameter from that required by

1
6.6.1 to that required by this clause should be do = d 4
[mm]
gradual. 3 ⎛d ⎞
1 − ⎜⎜ i ⎟⎟
6.6.4 Tailshafts which run in sterntubes and tube ⎝ do ⎠
shafts may have the diameter forward of the
forward stern tube seal gradually reduced to the where,
diameter of the intermediate shaft. Abrupt
changes in shaft section at the do = outside diameter [mm];
tailshaft/tubeshaft to intermediate shaft
couplings are to be avoided. d = Rule size diameter of shaft [mm], calculated
in accordance with 6.5 or 6.6;

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6.10 Tooth couplings

di = diameter of central hole [mm].
6.10.1 The contact stress, σc, at the flanks of
6.7.2 Where the diameter of central hole does mating teeth of a gear coupling is not to exceed
not exceed 0.4 times the outside diameter, no that given in Table below, where:
increase over Rule size need be provided.
24x10 6 P
6.8 Integral couplings σc = [ N/mm 2 ]
nd p bhz
6.8.1 The thickness of coupling flanges is not to
be less than the minimum required diameter of P and n are defined in 6.4.1.
the coupling bolts calculated as in para 6.9, with
tensile strength of the bolt material being taken dp = pitch circle diameter of coupling teeth [mm]
as the tensile strength of the corresponding
shaft material or 0.2 times the rule diameter of b = tooth facewidth [mm]
the shaft under consideration, whichever is
greater. Special consideration will be given by h = tooth height [mm]
IRS for flanges having non-parallel faces;
however, in such cases the thickness of the z = number of teeth (per coupling half).
flanges is not be less than the coupling bolt
diameter.
Allowable σc values
6.8.2 The fillet radius at the base of the coupling Tooth material Allowable σc
flange is to be not less than 0.08 of the diameter surface value [N/mm2]
of the shaft at the coupling. The fillets are to treatment
have a smooth finish and are not to be recessed Surface 19
in way of nuts and bolt heads. The fillet may be hardened teeth
formed of multiradii in such a way that the stress
concentration factor will not be greater than for a Through 11
circular fillet with radius 0.08 times the actual hardened teeth
shaft diameter.
6.10.2 Where experience has shown that under
6.8.3 Where the propeller is attached by means similar operating and alignment conditions, a
of a flange, the thickness of the flange is to be higher tooth loading can be accommodated full
not less than 0.25 times the actual diameter of details are to be submitted for consideration.
the adjacent part of the tailshaft. The fillet radius
at the base of the coupling flange is to be not 6.11 Flexible couplings
less than 0.125 times the diameter of the shaft
at the coupling. 6.11.1 Details of flexible couplings are to be
submitted together with the manufacturers'
6.9 Demountable couplings rating capacity, for the designed operating
conditions including short term high power
6.9.1 Couplings are to be made of steel or other operation. Verification of coupling characteristics
approved ductile material. The strength of will be required.
demountable couplings and keys is to be
equivalent to that of the shaft. Couplings are to 6.11.2 In determining the allowable mean,
be accurately fitted to the shaft. maximum and vibratory torque ratings,
consideration of the mechanical properties of
6.9.2 Hydraulic and other shrink fit couplings will the selected elastic element type in
be specially considered upon submittal of compression, shear and fatigue loading together
detailed preloading and stress calculations and with heat absorption/generation is to be given.
fitting instructions. In general, the torsional
holding capacity is to be at least 2.8 times the 6.11.3 In determining the allowable torque
transmitted torque and preload stress is not to ratings of the steel spring couplings,
exceed 70 per cent of the yield strength. consideration of the material mechanical
properties to withstand fatigue loading and
6.9.3 Provision is to be made to resist astern overheating is to be given.
pull.

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6.12 Interference fit assemblies d = required diameter [mm], of the intermediate
shaft taking into account ice strengthening
6.12.1 The interference fit assembly is to have a requirements, if applicable;
capacity to transmit a torque Q without slippage.
T = specified minimum tensile strength of the
P shaft material [N/mm2];
Q = 9550 (1+C) . S [N-m]
n Tb = specified minimum tensile strength of the
bolt material [N/mm2];
Where,
= and also T ≤ Tb ≤ 1.7 T, but not higher than
P = power transmitted, kW 1000 [N/mm2]
n = RPM of the shaft i = number of bolts in the coupling;
C = coefficient as per Table 6.12.1 D = pitch circle diameter of bolt holes [mm].
S = 2.0 for assemblies accessible from within 6.13.2 The diameter of the non-fitted bolts will
the vessel be specially considered upon the submittal of
detailed preloading and stress calculations and
= 2.5 for assemblies not accessible from fitting instructions.
within the vessel.
6.14 Tailshaft liners
Table 6.12.1 : 'C' values for guidance 6.14.1 The thickness, t, of bronze or gunmetal
purposes liners fitted on tailshafts, in way of bearings, is
not to be less than given by following formula:
Coupling Location C
High Speed Shafting 168 + d p
0.3
- IC engine driven t= [mm]
High Speed Shafting 28
- Electric Motor or Turbine 0.1
driven where,
Low Speed Shafting
0.1
- Main or PTO stage gearing t = thickness of liner [mm];

6.12.2 The effect of any axial load acting on the dp = diameter of tailshaft under the liner [mm].
assembly is to be considered.
6.14.2 The thickness of the continuous liner
6.12.3 The resulting equivalent von Mises stress between the bearings is not be less than 0.75t.
in the assembly is not to be greater than the
yield strength of the component material. 6.14.3 Continuous liners are preferably to be
cast in one length. If made of several lengths,
6.12.4 Reference marks are to be provided on the joining of the separate pieces is to be made
the adjacent surfaces of parts secured by by welding through the whole thickness of liner
shrinkage alone. before shrinking. In general, the lead content of
the gunmetal of each length forming a butt
6.13 Coupling bolts welded liner is not to exceed 0.5 per cent. The
composition of the electrode or filler rods is to be
6.13.1 The diameter of the fitted bolts at the substantially lead free.
joining faces of the coupling is to be not less
than that given by the following formula: 6.14.4 The liners are to withstand a hydraulic
pressure of 2.0 bar after rough machining.
d 3 (T + 160)
d b = 0.65 6.14.5 The liners are to be carefully shrunk or
iD Tb forced upon the shaft by hydraulic pressure, and
they are not to be secured by pins.
where,
6.14.6 Effective means are to be provided for
preventing water from reaching the shaft at the
db = diameter of the fitted coupling bolts [mm];
part between the after end of the liner and the
propeller boss.

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b) For bearings which are white-metal lined, oil

6.14.7 If the liner does not fit the shaft tightly lubricated and provided with an approved
between the bearing portions in the stern tube, type of oil sealing gland; the length of the
the space between the shaft and the liner is to bearing is to be approximately twice the
be filled with a plastic insoluble non-corrosive diameter required for the tailshaft and is to
compound. be such that the nominal bearing pressure
will not exceed 0.8 [N/mm2]. The length of
6.15 Keys and keyways for propeller the bearing is to be not less than 1.5 times
connections its diameter;

6.15.1 Round ended or sled-runner ended keys c) For bearings of cast iron, bronze which are
are to be used, and the key ways in the oil lubricated and fitted with an approved oil
propeller boss and cone of the tailshaft are to be sealing gland; the length of the bearing is, in
provided with a smooth fillet at the bottom of the general, to be not less than 4 times the
keyways. The radius of the fillet is to be at least diameter required for tailshaft;
0.0125 of the diameter of the tailshaft at the top
of the cone. The sharp edges at the top of the d) For bearings which are grease lubricated,
keyways are to be removed. the length of bearing is to be not less than 4
times the diameter required for the tailshaft;
6.15.2 Two screwed pins are to be provided for
securing the key in the keyway, and the forward e) For water lubricated bearings lined with two
pin is to be placed at least one-third of the or more circumferentially spaced sectors of
length of the key from the end. The depth of the an approved plastics material, in which it
tapped holes for the screwed pins is not to can be shown that the sectors operate on
exceed the pin diameter and the edges of the hydrodynamic principles, the length of the
holes are to be slightly beveled. bearing is to be such that the nominal
bearing pressure will not exceed 0.55
6.15.3 The distance between the top of the cone [N/mm2]. The length of the bearing is not to
and the forward end of the keyway is to be not be less than twice its diameter;
less than 0.2 of the diameter of the tailshaft at
the top of the cone. f) For approved oil lubricated bearings of
synthetic rubber, reinforced resin or plastic
6.15.4 The effective sectional area of the key in materials, the length of the bearing is to be
d3 not less than 2.0 times the rule diameter of
shear, is to be not less than [mm2] the shaft in way of the bearing. The length
2.6 d 1 of the bearing may be reduced provided the
nominal pressure is not more than 6 bar as
where, determined by static bearing reaction
calculation taking into account shaft and
d = diameter [mm], required for the intermediate propeller weight which is deemed to be
shaft determined in accordance with 6.4, based exerted solely on the aft bearing divided by
on material having a specified minimum tensile the projected area of the shaft. In any case
strength of 400 [N/mm2]; the length is not to be less than 1.5 times
the actual diameter. Where the material has
d1 = diameter of shaft at mid-length of the key proven satisfactory testing and operating
[mm]. experience, consideration may be given to
an increased bearing pressure.
6.16 Stern tube and bearings
6.16.2 Forced water lubrication is to be provided
6.16.1 The length of the bearing in the for all bearings lined with rubber or plastics and
sternbush next to and supporting the propeller is for those bearings lined with lignum vitae where
to be as follows: the shaft diameter is 380 [mm] or over. The
supply water may come from a circulating pump
a) For water lubricated bearings which are or other pressure source. The water grooves in
lined with lignum vitae, rubber composition the bearings are to be of ample section and of a
or staves of approved plastic material; the shape which will be little affected by weardown,
length is to be not less than 4 times the particularly for bearings of the plastic type.
diameter required for the tailshaft under the
liner; 6.16.3 The shut off valve or cock controlling the
supply of water is to be fitted direct to the after
peak bulkhead, or to the sterntube where the

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water supply enters the sterntube forward of the - 30,000 hours for other bearings.
bulkhead.
Where L10h is the basic rating life in hours which
6.16.4 Where a tank supplying lubricating oil to 90% of a sufficiently large group of apparently
the sterntube is fitted, it is to be located above identical bearings is expected to attain.
the load water line and is to be provided with a
low level alarm device in the engine room. 6.18 Shaft bearing materials

6.16.5 Where sternbush bearings are oil 6.18.1 Shaft bearing fitted in stern bushes and
lubricated, provision is to be made for cooling shaft bossings in “A” and “P” brackets are to be
the oil by maintaining water in the after peak constructed from an approved material and
tank above the level of the sterntube or by other effectively secured to prevent rotational and
approved means. Means of ascertaining the axial movement in the stern tube(s) and stern
temperature of the oil in the sternbush are also bush(es)
to be provided.
For vessels with TAILSHAFT CONDITION 6.19 Glass Reinforced Plastic coating
MONITORING (TCM) notation, at least two
independent temperature sensors or other 6.19.1 The tail shaft may be protected by a
approved arrangements are to be provided for fiberglass reinforced plastic coating between
measuring the aft bearing temperature. liners in accordance with the following
procedure, which effectively prevents sea water
6.16.6 The oil sealing glands used for sterntube from contacting the steel shaft. In such cases,
bearings, which are oil lubricated, are to be of the tailshaft survey interval would be 5 years as
approved type. applicable for the tailshaft survey notation
TS(CL). The procedure is to be approved in
6.16.7 An arrangement for readily obtaining each case:
accurate oil samples is to be provided. The
sampling point is to be taken from the lowest a) Coatings are to consist of at least 4
point in the lub.oil system as far as practicable. plies of cross-woven glass tape
Also the arrangements are to be such as to impregnated with resin or equivalent
permit the effective removal of the contaminants process.
from the oil lubricating system.
b) The shaft is to be cleaned with solvent
6.16.8 Stern seals are to be of the axially direct or grit blasted.
face type. Soft packing glands are to be used c) Shaft is to be examined and 1st coat is
only if specified by Owners. to be given in presence of Surveyors.

6.16.9 Where bulkhead glands are fitted, a d) Shaft is to be subjected to spark test
watertight sealing arrangement is to be after coating. There should be freedom
provided. Bulkhead seals is not to be formed by from porosity.
a bulkhead mounted plummer bearing.
e) Effective means are to be provided to
6.16.10 Plummer bearings are to be either prevent water gaining access to the
bulkhead mounted or of pedestal type. metallic region of the shaft.
f) It is to be ensured that provision is
6.17 Roller element bearings made for overlapping and adequate
bonding of the coating.
6.17.1 Roller element bearings are to have
design life, L10h not less than: g) The end of the liner is to stepped and
tapered as required to protect the end of
- 40,000 hours for propeller thrust bearing; the wrapping.

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Section 7

Propellers

7.1 Scope 7.2.2 In case of controllable pitch propeller

following additional plans / data is to be
7.1.1 The requirements of this Section cover the submitted:
construction, materials and inspection of
propellers. - Hub and it’s attachments to tailshaft
flange with connecting bolts
7.2 Plans and particulars - Propeller blade flange and it’s
attachment bolts
7.2.1 A plan, in triplicate, of the propeller is to be - Internal control mechanisms
submitted for approval, together with the - Hydraulic piping control systems
following particulars: - Instrumentation and alarm systems
- Strength calculations for internal
a) Maximum shaft power, P, in [kW]; components

b) Revolutions per minute of the propeller at In case of highly skewed propellers with skew
maximum power, R; angle greater than 50 degree and controllable
pitch propeller skew angle greater than 25
c) Propeller diameter, D [m]; degrees, propeller load and stress analysis
proving adequacy of blade strength are to be
d) Pitch at 25 per cent radius (for solid submitted.
propellers only), P0.25 [m];
7.3 Materials
e) Pitch at 35 per cent radius (for controllable
pitch propellers only), P0.35 [m]; 7.3.1 Castings for propellers and propeller
blades are to comply with the requirement of
f) Pitch at 70 per cent radius, P0.7 [m]; Pt.2, Ch.8. The specified minimum tensile
strength is to be not less than stated in Table
g) Length of blade section of the expanded 7.4.1.
cylindrical section at 25 per cent radius (for
solid propeller only), L0.25 [mm]; 7.3.2 When it is proposed to use materials which
are not included in Table 7.4.1, details of the
h) Length of blade section of expanded chemical composition, mechanical properties
cylindrical section at 35 per cent radius (for and density are to be submitted for approval.
controllable pitch propellers only) L0.35 [mm];
7.4 Design
i) Rake at blade tip measured at shaft axis
(backward rake positive, forward rake 7.4.1 Minimum blade thickness
negative), K [mm];
7.4.1.1 Where the propeller blades are of
j) Number of blades, N; conventional design, the thickness, t, of the
propeller blades at 25 per cent radius for solid
k) Developed area ratio, a. propellers, at 35 per cent for controllable pitch
propellers, neglecting any increase due to fillets,
is to be not less than:

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Table 7.4.1 : Material constants

Materials Specified min. UTS [N/mm2] f w

Manganese bronze Grade Cu 1 440 20.6 8.3
Ni-Manganese bronze Grade Cu 2 440 20.9 8.0
Ni-Aluminium bronze Grade Cu 3 590 25.7 7.5
Mn-Aluminium bronze Grade Cu 4 630 23.25 7.5
Cast iron 250 11.77 7.2
Carbon and low alloy steels 400 14.0 7.9
Note : The value of f may be increased by 10 percent for twin screw and outboard propellers of triple
screw ships.

a) For fixed propellers

T = maximum thickness of the expanded
2.5BKC s cylindrical section as approved at 25 per cent or
AP
t 0.25 = 1055 + 35 per cent radius, as applicable [mm];
C n CRN C Cn
Cs = section area coefficient at 25 per cent
b) For controllable pitch propellers radius or 35 per cent radius as applicable;

1.6 BKC s as
AP =
t 0.35 = 847 + LT
C n CRN C Cn
as = area of the expanded cylindrical section at
where, 25 per cent radius or 35 per cent radius, as
applicable [mm2];
t0.25 = minimum blade thickness required at 25
per cent radius; f = material constant as per Table 7.4.1;
t0.35 = minimum blade thickness required at 35 w = material constant as per Table 7.4.1;
per radius;
a) For fixed-pitch propellers
Cn = section modulus coefficient at 25 per cent
radius or 35 per cent radius as applicable;
6.0 D 4.3 P0.25
A = 1.0 + +
lo P0.7 D
= and is not to be taken greater
Uf L T2
2 3
than 0.10; ⎛ 4300 w a ⎞ ⎛ R ⎞ ⎛D⎞
B=⎜ ⎟ ⎜ ⎟ ⎜ ⎟
⎝ N ⎠ ⎝ 100 ⎠ ⎝ 20 ⎠
lo = moment of inertia of the expanded
cylindrical section at 25 per cent radius or 35 per
⎛ 1.5P0.25 ⎞
⎟ (L 0.25 f − B)
cent radius, as applicable, about a straight line
passing through the center of gravity parallel to C = ⎜1 +
the pitch line or to the nose-tail line [mm4]; ⎝ D ⎠

Uf = maximum normal distance from the b) For controllable pitch propellers

moment of inertia axis to points on the face
boundary (tension side) of the section at 25 per 6.0 D 3.0 P0.35
cent radius or 35 per cent radius, as applicable A = 1.0 + +
[mm]; P0.7 D

L = length of the blade section of the expanded 2 3

⎛ 4900 w a ⎞ ⎛ R ⎞ ⎛D⎞
cylindrical section at 25 per cent radius or 35 per B=⎜ ⎟ ⎜ ⎟ ⎜ ⎟
cent radius, as applicable [mm]; ⎝ N ⎠ ⎝ 100 ⎠ ⎝ 20 ⎠

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7.5 Fitting of propellers

⎛ 0.6P0.25 ⎞
C = ⎜1 + ⎟ (L 0.35 f − B) 7.5.1 The propeller boss is to be a good fit on
⎝ D ⎠ the tailshaft cone. The forward edge of the bore
of the propeller boss is to be rounded to about 6
7.4.1.2 Propellers of unusual design or [mm] radius. In general the contact area
application will be subject to special between propeller hub and tailshaft taper is to
consideration upon submittal of detailed stress be not less than 70 per cent of the theoretical
calculations. contact area. On completion of final pull-up
propeller is to be secured.
7.4.1.3 Fillets at the root of the blades are not to
be considered in the determination of blade 7.5.2 The exposed part of the tailshaft is to be
thickness. protected from the action of water by filling all
spaces between propeller hub, cap and shaft
7.4.2 Keyless propellers with a suitable filling material. The propeller
assembly is to be sealed at the forward end with
7.4.2.1 Where propellers are fitted without keys, a well-fitted soft rubber packing ring. When the
detailed stress calculations and fitting rubber ring is fitted in an external gland, the hub
instructions are to be submitted for approval. counterbore is to be filled with suitable material,
and clearances between shaft liner and hub
7.4.3 Controllable pitch propellers counterbore are to be kept to a minimum. When
the rubber ring is fitted internally, ample
7.4.3.1 In the case of controllable - pitch clearance is to be provided between liner and
propellers, means are to be provided to lock the hub and the ring is to be sufficiently sized to
blades in ahead position in case of the failure of squeeze in to the clearance space when the
the pitch operating mechanism. propeller is driven up on the shaft, and, where
necessary, a filler piece is to be fitted in the
7.4.3.2 A propeller pitch indicator is to be fitted propeller - hub keyway to provide a flat
at each location from which it is possible to unbroken seating for the ring. The recess
control the pitch of the propeller. formed at the small end of the taper by the over
hanging propeller hub is to be packed with red
lead putty or rust-preventing compound before
the propeller nut is put on.

7.5.3 Effective means are to be provided to

prevent the slackening of the propeller nut.

Section 8

Vibrations and Alignment

8.1 Scope
8.1.2 Unless otherwise advised, it is the
8.1.1 The requirements of this Section are responsibility of the Shipbuilder as the main
applicable to the following systems: contractor to ensure, in co-operation with the
Engine builders, that the information required by
a) Main oil engine propulsion systems, except this Section is prepared and submitted.
in the case of ships classed for smooth
water service, when fitted with engines 8.2 Basic system requirements
having powers less than 200 [kW].
8.2.1 The systems are to be free from excessive
b) Auxiliary oil engine machinery systems used torsional, axial and lateral vibration, and are to
for essential services, where the power be aligned in accordance with tolerances agreed
developed by auxiliary engines is 200 [kW] with the respective manufacturers.
and over.
8.2.2 Where changes are subsequently made to
c) Main propulsion systems formed by turbines a dynamic system which has been approved,
or electric motors geared to the shafting and revised calculations are to be submitted for
situated aft. consideration.

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8.4.1.6 Where calculations indicate the
8.3 Resilient mountings possibility of excessive torsional vibration within
the range of working speeds, torsional vibration
8.3.1 Where the machinery is installed on measurements, using the appropriate
resilient mountings, linear vibration (steady state recognized techniques, may be required to be
and transient) is not to exceed the limiting taken from the machinery installation for the
values agreed with the manufacturers of the purpose of determining the need for restricted
machinery nor those of the resilient mountings. speed ranges.

8.3.2 Misalignment arising from such vibration is 8.4.2 Permissible limits of stresses due to
not to impose excessive loading on machinery torsional vibrations
components within the system.
8.4.2.1 Alternating torsional vibration stresses
8.4 Torsional vibration are stresses resulting from the alternating torque
which is superimposed on the mean torque.
8.4.1 General
8.4.2.2 In no part of the propulsion system may
8.4.1.1 Torsional vibration calculations, including the alternating torsional vibration stresses
an analysis of the vibratory torques and stresses exceed the values of τ1 for continuous operation
for the dynamic systems formed by the oil and τ2 for transient running.
engines, turbines, motors, generators, flexible
couplings, gearing, shafting and propeller, 8.4.2.3 For continuous operation the permissible
where applicable, including all branches, are to stresses due to alternating torsional vibrations
be submitted for approval together with the are not to exceed the following values:
associated plans.
σB + 160
8.4.1.2 Particulars of the division of power τ1 = ± C k C D (3 − 2λ 2 ) for λ < 0.9
developed throughout the speed range for 18
turbines or from all intended combinations of
operation in oil engine installations having more σB + 160
than one engine and/or with power take-off τ1 = ± 1.38 C k C D for 0.9 ≤ λ < 1.05
systems are to be submitted.
18
where,
8.4.1.3 Any special speed requirements for
prolonged periods in service are to be indicated,
e.g., range of trawling revolutions per minute, τ1 = permissible stress due to torsional
range of operation revolutions per minute with a vibrations for continuous operation [N/mm2];
controllable pitch propeller, idling speed, etc.
σB = tensile strength of shaft material [N/mm2];
8.4.1.4 The calculations and/or measurements
carried out on oil engine installations containing Ck = factor for different shaft design features as
transmission items sensitive to vibratory torque, given in Table 8.4.2;
e.g. gearing, flexible couplings, or generator
rotors and their drives, are to take into account CD = size factor = 0.35 + 0.93d-0.2;
the effects of engine malfunction commonly
experienced in service, such as cylinder(s) not do = shaft outside diameter under consideration
firing. [mm];

8.4.1.5 Restricted speed ranges will be imposed λ = speed ratio = n/no;

in regions of speed where stresses are
considered to be excessive for continuous n = speed in rpm under consideration at rated
running. Similar restrictions will be imposed, or power;
other protective measures required to be taken,
where vibratory torques are considered to be no = rated speed in rpm.
excessive for particular machinery items.

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Table 8.4.2 : ck factors for different design features

Intermediate shafts with Thrust shafts Tailshafts

external to engines

bearing and forward

Key fitted propellers
Keyway, cylindrical

Flange mounted or
keyless taper fitted
shrink fit couplings
flange and straight

In way of bearing
1

Between forward
Keyway, tapered
Integral coupling

On both sides of
Longitudinal slot

bearing is used

end of aft most

stern tube seal

when a roller
thrust collar
Radial hole
connection

connection

propellers
section

Ck = 1.0 1.0 0.60 0.45 0.50 0.30 2) 0.85 0.85 0.55 0.55 0.80

Note:
1) The ck value is valid for 1, 2 and 3 slots and they are to be arranged 360, 180 or 120 degrees
apart from each other respectively.
2) Ck = 0.3 is a safe approximation within the limitations given in note No.6 under Table 6.5.1). If the
slot dimensions are outside of the above limitations, or if the use of another ck is desired, the
actual stress concentration factor (scf) is to be documented or determined from para No.3 of
Appendix. In which case:
Ck = 1.45/scf
The scf is defined as the ratio between the maximum local principal stress and √3 times
the nominal torsional stress (determined for the bored shaft without slots).

8.4.2.4 Where a vessel, because of its type of vibrations are not, in any case, to exceed the
employment, is operated predominantly in the values given by the following formula:
lower speed range, special consideration may
be given to the permissible stresses for 1.7 τ 1
continuous operation. τ2 = for λ ≤ 0.8
Ck
8.4.2.5 Where the stresses exceed the limiting
values of τ1 for continuous operation, restricted where,
speed ranges are to be imposed which are only
allowed to be passed through rapidly. τ2 = permissible stress due to torsional
vibrations for transient running.
8.4.2.6 Restricted speed ranges are not
acceptable, in the speed range between 0.8 to 8.5 Axial vibrations
1.05 of the rated speed. The limits of the barred
speed range are to be calculated in accordance 8.5.1 For all main propulsion shafting systems,
with the following formula unless proved to be the Shipbuilders are to ensure that amplitudes
otherwise. due to axial vibrations are satisfactory
throughout the speed range, so far as
16 N c (18 − λ ) N c practicable. Where appropriate, amplitudes may
≤n≤ be reduced by the use of suitable vibration
18 − λ 16 dampers or phasing of propeller and engine, etc.
where,
8.5.2 Unless previous experience of similar
installation shows it to be unnecessary,
nc = critical speed in [rpm].
calculations of the shafting system are to be
carried out. These calculations are to include the
8.4.2.7 For transient running the permissible
effect of the thrust block seating and the
stresses due to the alternating torsional
surrounding hull structure taking part in the
vibration. The result of these calculations or the

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evidence of previous experience is to be
submitted for consideration. - Flexibility of engine and thrust bearing
foundations,
8.5.3 Where calculations indicate the possibility
of excessive axial vibration amplitudes within the - Engine induced vibrations, gear tooth
range of working speeds, measurements using loadings, flexible couplings,
an appropriate recognized technique may be
required to be taken from the shafting systems - Effect of power take-off,
for the purpose of determining the need for
restricted speed ranges. - Effect of hull deformations at all
conditions of ship loading and operation.
8.6 Lateral vibrations
Consideration is also to be given to any limits of
8.6.1 For all main propulsion shafting systems, vibrations and loadings specified by the
the Shipbuilders are to ensure that amplitudes equipment manufacturer. The Shipbuilder is to
due to lateral vibrations are satisfactory position the bearings and construct the bearing
throughout the speed range. seatings to minimize the effects of movements
under all operating conditions.
8.6.2 Unless previous experience of similar
installations shows it to be unnecessary, 8.7.2 For geared installations, where two or
calculations of lateral, or bending, vibration more pinions are driving the final reduction
characteristics of the shafting system are to be wheel, calculations are to be submitted to verify
carried out. These calculations, taking account that shaft alignment is such that proper bearing
of dynamic bearing stiffnesses, are to cover the reactions are maintained under all operating
frequencies giving rise to all critical speeds conditions.
which may result in significant amplitudes within
the speed range, and are to indicate relative 8.7.3 Shaft alignment calculations are to be
deflections and bending moments throughout submitted for the following alignment-sensitive
the shafting system. types of installations for review:

8.6.3 The results of these calculations, or the i) Propulsion shafting with power take-
evidence of previous experience, is to be off or with booster power
submitted for consideration. arrangements.
ii) Propulsion shafting for which the tail
8.6.4 Where calculations indicate the possibility shaft bearings are to be slope
of excessive lateral vibration amplitudes within bored.
the range of working speeds, measurements iii) Propulsion shaft having diameter
using an appropriate recognized technique may 300mm. and above in way of after
be required to be taken from the shafting system most stern tube bearing
for the purpose of determining the need for iv) Propulsion shafting arrangement
restricted speed ranges. requiring long shaft line.

8.7 Shaft alignment The alignment calculations are to include

bearing reactions, shear forces and bending
8.7.1 For main propulsion installations, the moments along the shafting.
shafting is to be aligned to give reasonable
bearing reactions, and bending moments, taking The alignment calculations are to be performed
into consideration following factors : for the following conditions, as applicable:

- Forces which may affect the reliability of - Theoretically aligned cold and hot
the propulsion shafting system including conditions of the shaft with specified
weight of the propeller and shafts, alignment tolerances.

- Hydrodynamic forces acting on the - Deviation from the theoretical aligned

propeller, conditions due to the forces exerted by
power take-off or booster power.
- Number of propeller blades in relation to
diesel engine cylinders, Calculations are to be performed for the
maximum allowable alignment tolerances and
- Misalignment forces, are to show that:

- Thermal expansion,

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- Bearing loads under all operating association with other stresses in the
conditions are within the acceptable shaft.
limits specified by the bearing
manufacturer. - Forces and moments on propulsion
equipment are within the limits specified
- Bearing reactions are always positive by the machinery manufacturers.
(i.e. supporting the shaft).
8.7.4 Shaft alignment is to be verified by
- Shear forces and bending moments on measurement.
the shaft are within acceptable limits in

Section 9

Thrusters

9.1 Scope 9.2.3 Calculations and specifications

9.1.1 The requirements of this section are a) Thruster prime mover type and operational
applicable to: power/speed envelop.

- fixed thruster for propulsion b) Rating and type of motor for the azimuthing
mechanism (e.g. type hydraulic or electric).
- steerable thruster units (azimuth
thrusters) for propulsion and steering c) Gearing calculations for the azimuthing and
propulsion mechanism which is to be
- tunnel thruster for transverse propulsion designed in accordance with classification
aid to manoeuvring. notes on the design of gearing. Calculation
for bevel gears is to be on the basis of a
9.2 Plans and particulars conversion to equivalent helical gear.

The following plans and information in triplicate d) Bearing specifications.

are to be submitted.
e) Details of control engineering aspects in
9.2.1 Fixed/azimuth propulsion thrusters accordance with Chapter 7.

a) A general arrangement sectional assembly f) Calculations indicating suitability of

plan showing all the connections of the components for short term high power
torque transmitting components from the operation, where applicable.
prime mover to the propeller, together with
the azimuthing mechanism and if a nozzle is g) Where design is carried out using fatigue
provided, the nozzle ring structure and analysis, a fatigue strength analysis of
nozzle support struts. components indicating a factor of safety of
1.5 at the design loads based on a suitable
b) Detailed and dimensional plans of the fatigue failure criteria is required to be
individual torque transmitting components. submitted for review.

c) Schematic plans for lubricating and 9.3 Materials

hydraulic systems, together with pipe
material, relief valves and working 9.3.1 The materials used on the construction are
pressures. to be manufactured and tested in accordance
with Part 2.
9.2.2 Tunnel thrusters
9.3.2 The grades for various components to be
In addition to applicable requirements of 9.2.1, analogous to relevant section of the Rules, Pt.4,
structural assembly plan including connections Ch.4, Sec.7 for propellers, Pt.4, Ch.4, Sec.6 for
to tunnel. shafting and Pt.4, Ch.4, Sec.5 for gearing.

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9.4 Design and construction be derived using load
measurements of similar units,
9.4.1 General where possible.

9.4.1.1 The arrangement of all types of thrusters ii) Under a static duty (< 103 load cycles)
is to be such that the craft can be manoeuvred steering torque. (for azimuth thruster with
in accordance with the design specifications. nozzle see 9.4.3.1).

9.4.1.2 The requirements associated with the iii) The following minimum factor of safety
structural and watertight integrity and the values are to be achieved:
installation arrangement are to be in accordance
with Pt.3. Surface stress SHmin = 1.2

9.4.1.3 In addition to the requirements of this Bending Stress SFmin = 1.55.

section reference is to be made to:
c) For hydraulic pressure retaining parts and
- Main transmission gearing (Pt.4, Ch.4, load bearing (See Chapter 5).
Sec.5). Bevel gears will be specially
considered on the basis of a conversion 9.4.3 Azimuth thrusters with a nozzle
to equivalent helical gears.
9.4.3.1 For steerable rudder propellers
- Main transmission shafting (Pt.4, Ch.4, contained within a nozzle, the design lateral
Sec.6). force Fr and the turning moment Qr is to be
calculated as follows:
- Propeller (Pt.4, Sec.7).
Fr = 376 . A . V2 [N]
- Torsional vibration (Pt.4, Ch.4, Sec.8 of
the 'Rules and Regulations for the Qr = Fr . r [N-m]
Construction and Classification of Steel
Ships'). where,

- Lateral vibration for shafting systems A = projected area of nozzle [M2]

which include cardan shafts (Pt.4, Ch.4,
Sec.8 of the 'Rules and Regulations for V = Maximum service speed [knots] with the
the Construction and Classification of ship on summer load waterline. When the speed
Steel Ships'). is less than 10 knots, V is to be replaced by the
expression Vmin = (V+20)/3
9.4.2 Azimuth thrusters
r = the horizontal distance from centre line of
9.4.2.1 The following requirements are to be stock to centre of pressure of nozzle, but not to
complied with: be taken less than 10% of the chord length of
the nozzle.
a) The azimuthing mechanism is to be capable
of a maximum rotational speed of not less The nozzle stock diameter in way of tiller, is to
than 1.5 rev/min. be not less than:

b) Gearing for the azimuthing mechanism is to d u = 4.2 3 Q r .K [mm]

be designed in accordance with
classification notes on the design of gearing.
Bevel gears will be specially considered on where,
the basis of a conversion to equivalent
helical gears. k = material factor for nozzle stock.

i) Under dynamic operating conditions, the 9.4.3.2 The scantlings of the nozzle stock or
gear is to be considered for: steering tube are to be such that the equivalent
stress, σ,does not exceed 118/k [N/mm2] i.e.
- Design maximum dynamic duty
steering torque. σ e = σ 2 + 3τ t2 ≤ 118 / k [N/mm 2 ]
- Variable loading, where applicable.
A spectrum (duty) factor may be where,
used. The load spectrum value is to

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σ is the bending stress [N/mm2] calculated using

the maximum bending moment, BM, on the a) Arrangements to maintain the cleanliness of
nozzle stock or steering tube. the hydraulic fluid, taking into consideration
the type and design of the hydraulic system.
For nozzles without bottom support :
b) A fixed storage tank having sufficient
capacity to recharge at least one azimuth
BM = F + T x a [Nm]
r
2 2
power actuating system including the
reservoir. The piping from the storage tank
T = Maximum thrust developed by the thruster is to be permanent and arranged in such a
[N] manner as to allow recharging from within
the thruster space.
Fr = design lateral force [N/mm2] as per 9.4.3.1
c) Where the lubricating oil for the azimuth
a = Vertical distance from centre line of nozzle thrusters is circulated under pressure,
to the section under consideration [m] (See provision is to be made for the efficient
Fig.9.4.3.2). filtration of the oil. The filters are to be
capable of being cleaned without stopping
τt is the torsional shear stress [N/mm2] the thruster or reducing the supply of filtered
calculated using the torque Qr as per 9.4.3.1. oil.

9.6 Control and monitoring

9.6.1 General

9.6.1.1 Except where indicated in this section

the control engineering systems are to be in
accordance with Pt.4, Ch.7.

9.6.1.2 Azimuthing control for azimuth

thruster(s) and propeller pitch control for
azimuth and/or tunnel thruster(s) are to be
provided from the navigating bridge, the main
machinery control location and locally.

9.6.1.3 Means are to be provided at the remote

control location(s) to stop each azimuth or
tunnel thruster unit.

9.6.2 Monitoring and alarms

9.6.2.1 Alarms and monitoring requirements are

9.5 Piping systems indicated in 9.6.2.2, 9.6.2.3 and Table 9.6.2.

9.5.1 General 9.6.2.2 An indication of the angular position of

the azimuth thruster(s) and the propeller pitch
The piping system for azimuth thrusters is to position for azimuth and/or tunnel thruster(s) are
comply with the general design requirements to be provided at each location from which it is
given in Pt.4, Ch.2. possible to control the direction of thrust or the
pitch.
The specific requirements for lubricating/
hydraulic oil systems and standby arrangements 9.6.2.3 All alarms associated with thruster unit
are given in Pt.4, Ch.3. faults are to be indicated individually on the
navigating bridge and in accordance with the
9.5.2 Azimuth thruster alarm system specified by Chapter 7.

The hydraulic power operating systems for each

azimuth thruster are to be provided with the
following:

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Table 9.6.2
Item Alarm Note
Thruster, azimuth or tunnel Indicators, see 9.6.2.2
Azimuthing motor Power failure, single Also running indication on bridge and at machinery
phase control location
Propeller pitch motor Power failure In case of failure the propeller pitch should be locked in
full ahead position. Also running indication on bridge
and at machinery control location
Electric propulsion motor Overload, power Also running indication on bridge and at machinery
failure control location
Control system Failure
Hydraulic oil supply tank level Low
Hydraulic oil system pressure Low
Hydraulic oil system High Where oil cooler is fitted
temperature
Hydraulic oil filters differential High Where oil filters are fitted
pressure
Lubricating oil supply Low If separate forced lubrication
pressure

9.7 Electrical systems transformers, converters, protective devices or

control circuits.
9.7.1 General
9.8 Tests
The electrical installation is to be designed,
constructed and installed in accordance with the 9.8.1 Azimuth thrusters
requirements of Pt.4, Ch.8.
9.8.1.1 The performance specified for the craft is
9.7.2 Emergency power for steering systems to be demonstrated.
and drives
9.8.1.2 The actual values of steering torque are
The arrangement to comply with Pt.4, Ch.6, to be verified during sea trials to confirm that the
Sec.6, Cl.6.1.1 design maximum dynamic duty torque has not
been exceeded.
9.7.3 Circuits
9.8.2 Tunnel thrusters
Azimuth thruster auxiliaries and controls are to
be served by individual circuits. Services that It is to be demonstrated that the thruster unit
are duplicated are to be separated throughout meets the specified performance.
their length as widely as is practicable and
without the use of common feeders,

Section 10

Turbochargers

10.1 Scope particulars such as materials, constructional

details and type test data. Acceptance of such
10.1.1 The requirements of this section are turbochargers will be subject to a satisfactory
applicable to turbochargers suitable for diesel performance test after installation conducted in
engines rated for 100 [kW] and above intended the presence of the Surveyor.
for propulsion and auxiliary services essential
for propulsion, maneuvering and safety of the 10.1.3 The term turbocharger refers also to
vessel. superchargers, turboblowers, scavenge blowers
or other similar equipment designed to charge
10.1.2 Turbocharger for diesel engines rated for the diesel engine cylinders.
less than 100 [kW] may be accepted based
upon manufacturers certificate and other
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10.2 Plans and particulars submitted for review. The manufacturer is to

specify the limits of speed and temperature.
10.2.1 The following plans are to be submitted
together with particulars of materials, maximum - Castings for turbochargers intended for
shaft power and RPM. engines with rating of 100 [kW] and above
are to be of a specification suitable for
- Sectional assembly stresses and temperatures to which they are
- Parts list designed to function. Cast iron may only be
- Casings considered for operating temperatures not
- Turbine rotors exceeding 232°C. Ductile cast iron designed
- Compressor rotors for high temperature service is acceptable
- Compressor and turbine discs subject to review of mechanical and
- Blading metallurgical properties at design
- Shafts temperatures. Cast steel may be considered
- Bearing arrangements for operating temperatures not exceeding
427°C. All castings are to be properly heat-
10.2.2 Turbocharger piping system treated to remove internal stresses.

- Lubrication system - Seals and drains: Casings are to be

- Cooling system provided with suitable seals. Drains are to
be fitted in places where water or oil is likely
10.2.3 Data – following data is to be submitted to collect.

- Operating speed and temperatures 10.3.2 Shafts, rotors and blades

- Speed and temperature limitations
- Balancing data - Rotors, bearings, discs, impellers and
- Type test data blades are to be designed in accordance
- Mass and velocity of rotating elements with sound engineering principles. Design
criteria along with engineering analyses
10.2.4 Materials – following details are to be substantiating the suitability of the design for
submitted the rated power and speed are to be
submitted for review.
- Material specifications, including density,
Poisson’s ratio, range of chemical 10.3.3 Type test data
composition, room-temperature physical
properties and, where material is subject - The manufacturer is to submit type test data
to temperatures exceeding 427°C, the in support of the design. The type test is
high-temperature strength characteristics preferably to be witnessed and certified by a
as well as creep rate and rupture Surveyor. The type test data are to contain
strength for the design service life. at least the test schedule, measurements
taken during the tests and test results.
- Forgings: compressor and turbine rotors Normally, the type test is to include
and shafts in accordance with Ch.5. following:

10.2.5 Calculation and analyses - at least one hour of hot running test at
maximum permissible speed and
- Design basis and design analyses for temperature,
turbine and compressor rotors and
blading including calculations and test - verification of performance tests specified in
results to substantiate the suitability and 10.6.6 and
strength of components for the intended
service. - opening the turbocharger for examination
after the test.
10.3 Design
10.4 Piping systems for turbocharger
10.3.1 Turbochargers intended for engines with
rating below 100 [kW] will be accepted on the 10.4.1 The lubricating oil and cooling water
basis of manufacturer’s type test data. The test piping systems of turbochargers are to be in
data are to be in accordance with 10.3.3. accordance with the provisions of Ch.3 Sec.7
Considerations will be given also to design and Sec.8 of this Part respectively.
criteria and engineering analyses being

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10.5 Installation of turbochargers 10.6.5 Dynamic balancing

10.5.1 Air inlet of turbocharger is to be fitted with Rotors are to be dynamically balanced at a
filter. speed equal to the natural period of the
balancing machine and rotor combined.
10.5.2 Hot surfaces likely to come into contact
with the crew are to be water-jacketed or 10.6.6 Shop trial
effectively insulated. Where the temperature of
hot surfaces is likely to exceed 220°C and Upon completion of fabrication and assembly,
where any leakage, under pressure or each turbocharger is to be subjected to a shop
otherwise, of fuel oil, lubricating oil or other trial, either on a test bed or on a test engine, in
flammable liquid is likely to come into contact accordance with the manufacturer’s test
with such surfaces, they are to be suitably schedule, which is to be submitted for review
insulated with non-combustible materials that before the trial. During the trial, the following
are impervious to such liquid. Insulation material tests are to be conducted:
not impervious to oil is to be encased in sheet
metal or an equivalent impervious sheath. - Impeller and inducer wheels are to be over
speed tested for 3 minutes either:
10.5.3 Pipe or duct connections to the
turbocharger casing are to be made in such a o On a test bed at 20% above the
way as to prevent the transmission of excessive maximum operating speed at
loads or moments to the turbochargers. ambient temperature, or
o On a test engine at 10% above the
10.6 Testing, inspection and certification of maximum operating speed at
turbochargers operating temperature.

10.6.1 Shop inspection and Tests - A mechanical running test for at least 20
minutes at maximum operating speed and
The following shop inspection and tests are to operating temperature, or a test run on the
be witnessed by a surveyor for turbochargers of engine for which the turbocharger is
engines with rating greater than 100 [kW] intended, for 20 minutes at 110% of the
engine’s rated output.
10.6.2 Material tests
10.7 Certification of turbochargers
The materials are to meet requirements given in
Part 2 of the Rules. Materials used in the 10.7.1 Each turbocharger required to be certified
construction of turbines are to be tested in the by 10.1 is:
presence of a Surveyor in accordance with the
provisions of 10.2.4. This requirement does not i) to have its design approved by IRS for
apply to independently driven auxiliary blowers which purpose, plans and data as
that are not required during continuous required by 10.2 are to be submitted to
operation of the engine. IRS for approval and a unit of the same
type is to be satisfactorily type tested
10.6.3 Welded fabrication (see 10.3.3).

All welded fabrication is to be conducted with ii) to be surveyed during its construction
qualified welding procedures, by qualified for compliance with the design
welders and with welding consumables approved, along with, but not limited to,
acceptable to the Surveyors. material tests, hydrostatic tests,
dynamic balancing, performance tests,
10.6.4 Hydrostatic tests etc. as indicated in 10.6, all to be carried
out to the satisfaction of the Surveyor.
The cooling spaces of each gas inlet and outlet
casing are to be hydrostatically tested to 1.5
times the working pressure but not to be less
than 4 bars.

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10.7.2 Approval under type approval program machinery manufactured by mass

production system”.
The manufacturer seeking certification under
above scheme will be given type approval 10.8 Engine and shipboard trials
certificate on completion of the following
requirements: Before final acceptance, each turbocharger,
after installation on the engine is to be operated
i) Design appraisal in accordance with in the presence of the Surveyor to demonstrate
10.7.1 i). its ability to function satisfactorily under
ii) Type test in accordance with 10.3.3 and operating conditions and its freedom from
4.12, Ch.4 as applicable. Test schedule harmful vibrations at speeds within the operating
is to be submitted for review. range. The test schedules are to be as indicated
iii) For mass produced turbochargers, refer in 4.13 for engine shop test and in 4.14 for
“Type approval certification scheme for shipboard trials.

End of Chapter

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Chapter 5

Boilers and Pressure Vessels

Contents
Section

1 General
2 Design Requirements
3 Fittings and Mountings
4 Hydraulic Tests

Section 1

General

1.1 Scope 1.2 Design pressure

1.1.1 The requirements of this Chapter are 1.2.1 The design pressure is the maximum
applicable to pressure vessels of seamless and permissible working pressure and is to be not
fusion welded construction, and their mountings less than the highest set pressure of any safety
and fittings, for the following uses : valve.

a) Fired boilers; 1.2.2 The calculations made to determine the

scantlings of the pressure parts are to be based
b) Exhaust gas heated boilers; on the design pressure, adjusted where
necessary to take account of pressure variations
c) Economizers, superheaters, reheaters and corresponding to the most severe operational
steam receivers for, and associated with (a) conditions.
and(b);
1.2.3 It is desirable that there should be a
d) Steam heated steam generators; margin between the normal pressure at which
the boiler or pressure vessel operates and the
e) Other pressure vessels containing: lowest pressure at which any safety valve is set
to lift, to prevent unnecessary lifting of the safety
- toxic fluids; valve.

- fluids with pressure above 40 bar; and 1.3 Metal temperature

- vapours or gases, e.g. air receivers, 1.3.1 The metal temperature, T, used to
hydrophore or similar vessels, CO2 evaluate the allowable stress, σ, is to be taken
containers, etc. and having pV ≥ 1.5, as the actual metal temperature expected under
where p is the design pressure in bar operating conditions for the pressure part
and V is the volume of the vessel [m3]. concerned, and is to be stated by the
manufacturer when plans of the pressure parts
1.1.2 Consideration will be given to are submitted for consideration.
arrangements or details of boilers, pressure
vessels and equipment which can be shown to 1.3.2 For boilers, the design metal temperature
comply with other recognized standards, is not to be taken less than the following values,
provided they are not less effective. unless justified by an exact calculation of the
temperature drop and is in no case to be taken
less than 250°C:

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a) For steam heated steam generators, gases, is to be protected by a shield of good

secondary drums of double evaporation refractory material or by other approved means.
boilers, steam receivers and pressure parts
of fired pressure vessels not heated by hot 1.3.4 Drums and headers of thickness greater
gases and adequately protected by than 30 [mm] are not to be exposed to
insulation, the metal temperature, T is to be combustion gases having an anticipated
taken as the maximum temperature of the temperature in excess of 650°C unless they are
internal fluid; efficiently cooled by closely arranged tubes.

b) For pressure parts heated by hot gases, T 1.4 Plans and particulars
is to be taken as not less than 25°C in
excess of the maximum temperature of the 1.4.1 The following plans, in triplicate, for boiler
internal fluid; and pressure vessels are to be submitted for
approval, in so far as applicable:
c) For combustion chambers of the type used
in horizontal wet-back boilers, T is to be a) General arrangement, including arrange-
taken as not less than 50°C in excess of the ment of valves and fittings;
maximum temperature of the internal fluid;
b) Sectional assembly;
d) For furnaces, fire boxes, rear-tube plates of
dry-back boilers and pressure parts subject c) Seating arrangements;
to similar rates of heat transfer, T is to be
taken as not less than 90°C in excess of the d) Steam, water drum and header details;
maximum temperature of the internal fluid;
e) Water wall details;
e) For boiler, superheater, reheater and
economizer tubes, the design temperature f) Steam and superheater tubing, including the
is to be taken as under : tube support arrangements;

i) For boiler tubes the design g) Economizer details;

temperature is to be taken as not
less than saturated steam h) Casing arrangement;
temperature plus 25°C for tubes
mainly subject to convection heat, i) Reheat section;
or plus 50°C for tubes mainly
subject to radiant heat; j) Fuel oil burning arrangement;

ii) For superheater and reheater k) Forced draft system;

tubes, the design temperature is to
be taken as not less than steam l) Boiler mountings including steam stop
temperature expected in the part valves, safety valves and their relieving
being considered, plus 35°C for capacities, feed water connections, blow-off
tubes mainly subject to convection arrangements, watergauges, test cocks, etc.
heat. For tubes mainly subject to
radiant heat the design temperature 1.4.2 The plans are to include the following
is to be taken as not less than the particulars, in so far as applicable :
steam temperature expected in the
part being considered, plus 50°C, a) Scantlings;
but the actual metal temperature
expected is to be stated when b) Materials;
submitting plans;
c) Weld details;
iii) The design temperature for
economizer tubes is to be taken as d) Design pressures and temperatures;
not less than 35°C in excess of the
e) Heating surface areas of boilers and
maximum temperature of the
superheaters;
internal fluid.
f) Estimated pressure drop through
1.3.3 In general, any part of boiler drums or
superheater;
headers not protected by tubes, and exposed to
radiation from the fire or to the impact of hot
g) Estimated evaporation rate;
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d = diameter of hole or opening [mm];
h) Proposed setting pressure of safety valves
on steam drum and superheater; Di = inside diameter [mm];

i) Pressure vessel class; Do = outside diameter [mm];

j) Details of heat treatment and testing of J = joint factor applicable to the welded seams
welds; or ligament efficiency between tube holes,
expressed as a fraction;
k) Calculations of thicknesses, when required;
p = design pressure, in bar;
l) Test pressures.
Ri = inside radius [mm];
1.5 Classification of pressure vessels
Ro = outside radius [mm];
1.5.1 For Rule purposes, boilers and pressure
vessels are graded as shown in Table 1.5.1. ro = outside knuckle radius [mm];

1.5.2 Pressure vessels which are constructed in ri = inside knuckle radius [mm];
accordance with the requirements of Class 2 or
Class 3 will, if manufactured in accordance with s = pitch [mm];
the requirements of a superior class, be
approved with the scantlings appropriate to that T = design temperature, °C;
class.
t = minimum thickness [mm];
1.5.3 In special circumstances relating to service
σ = allowable stress [N/mm ].
2
conditions, materials, operating temperature, the
carriage of dangerous gases and liquids, etc., it
may be required that certain pressure vessels 1.7 Materials
be manufactured in accordance with the
requirements of a superior class. 1.7.1 Materials used in the construction of Class
1 & 2 pressure vessels are to be manufactured
1.6 Definition of symbols and tested in accordance with the requirements
of Pt.2 under the supervision of IRS Surveyors.
1.6.1 The symbols used in the various formulae
in this Chapter are defined as follows and are Materials for Class 3 pressure vessels will be
applicable to the specific part of the pressure accepted with manufacturer's certificate.
under consideration :

Table 1.5.1 : Grading of pressure vessels

Steam-heated steam
Boilers Other pressure vessels
generators
15000
Class 1 p > 3.5 p > p > 50 or t > 38
Di + 1000
20000
15000 < p ≤ 50 or 16 < t ≤ 38 or
Class 2 p ≤ 3.5 p ≤ Di + 1000
Di + 1000
material temperature > 150°C
Pressure vessels not included in Class
Class 3
1 and 2

Note:

p = design pressure, in bar; Di = internal diameter [mm]; t = shell thickness [mm]

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Valves and fittings for pressure vessels are to

be manufactured and tested under the 1.7.7 Where a fusion welded pressure vessel is
supervision of IRS Surveyors in the following to be made of alloy steel and approval of the
cases: scantlings is required on the basis of the high
temperature properties of the material,
- cast steel and nodular cast iron valves particulars of the welding consumables to be
and fittings - when D > 50 [mm] and PD used, including typical mechanical properties
> 2000 and chemical composition of the deposited weld
metal, are to be submitted for approval.
- cast steel valves and fittings - when D >
50 [mm] and T > 400°C or T < -10°C 1.8 Allowable stress

- copper alloy valve and fittings - when D 1.8.1 The term "allowable stress",σ, is the stress
>50 [mm] and pD > 1000 to be used in the formulae for calculation of
scantlings of pressure parts.
- Where p is the design pressure in bar
and D is the nominal diameter in [mm]. 1.8.2 The allowable stress, σ, is to be the lowest
of the following values:
1.7.2 The specified minimum tensile strength of
carbon and carbon manganese steel plates, Et E R S
pipes, forgings and castings is to be within the = or 20 or 20 or R
following general limits : 1.6 1.8 2.7 1.6

a) For seamless and fusion welded pressure where,

vessels - 340 - 520 [N/mm2];
Et = specified minimum lower yield strength or
b) For boiler furnaces, combustion chambers 0.2 per cent proof stress at temperature T;
and flanged plates - 400 - 520 [N/mm2].
E20 = specified minimum lower yield strength or
1.7.3 The specified minimum tensile strength of 0.2 per cent proof stress at ambient
low alloy steel plates, pipes, forgings and temperature;
castings is to be within the general limits of 400 -
500 [N/mm2], and pressure vessels made in R20 = specified minimum tensile strength at
these steels are to be either seamless or Class room temperature;
1 fusion welded.
SR = average stress to produce rupture in
1.7.4 The specified minimum tensile strength of 100,000 hours at temperature T;
boiler and superheater tubes is to be within the
following general limits : T = metal temperature (see 1.6).

a) Carbon and carbon-manganese steels - 320 1.8.3 The allowable stress for steel castings is to
- 460 [N/mm2]; be taken as 80 per cent of the value determined
by the method indicated in 1.8.2, using the
b) Low alloy steels - 400 - 500 [N/mm2]. appropriate values for cast steel.

1.7.5 Semi-killed, fully killed and fine grain, 1.8.4 Where steel castings, which have been
normal strength structural steels complying with tested in accordance with Pt.2, are also
the requirements of Pt.2, Ch.3 will be accepted subjected to non-destructive tests, consideration
for following Class 3 pressure vessels when: will be given to increasing the allowable stress
using a factor up to 90 per cent in lieu of the 80
15000 per cent referred to in 1.8.3. Particulars of the
p < non-destructive test proposals are to be
D i + 2000 submitted for consideration.

1.7.6 Where it is proposed to use materials 1.9 Joint factors

other than those specified in Pt.2, details of the
chemical compositions, heat treatment and 1.9.1 The following joint factors are to be used in
mechanical properties are to be submitted for equations in this chapter, where applicable.
approval. In such cases the values of the Fusion welded pressure parts are to be made in
mechanical properties used for deriving the accordance with Ch.10 :
allowable stress are to be subject to agreement
by IRS.
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Pressure vessel Joint factor
Class 1 1.0 c) superimposed loads such as other pressure
Class 2 0.80 vessels, operating equipment, insulation,
Class 3 0.60 corrosion-resistant or erosion-resistant
linings and piping;
1.9.2 The longitudinal joints for all classes of
vessels are to be butt joints. Circumferential d) reactions of supporting lugs, rings, saddles
joints for Classes 1 and 2 vessels are also to be or other types of supports; or
butt joints.
e) the effect of temperature gradients on
1.10 Pressure parts of irregular shape maximum stress.

1.10.1 Where pressure parts are of such 1.12 Minimum shell thickness
irregular shape that it is impracticable to design
their scantlings by the application of formulae 1.12.1 Only plus tolerances are allowed on the
given in this Chapter, the suitability of their design shell thickness.
construction is to be determined by hydraulic
proof test of a prototype or by an agreed 1.12.2 The thickness after forming of any shell
alternative method. Di
or head is not to be less than 3 + [mm] for
1.11 Adverse working conditions
1500
carbon, carbon-manganese and low-alloy steels
or 3 [mm] for stainless steel and non-ferrous
1.11.1 Where working conditions are adverse,
materials. For pressure vessels, where the
special consideration may be required to be
cylindrical part is made of a pipe, a smaller
given to increasing the scantlings derived from
minimum thickness may be approved. See also
the formulae, e.g. by increasing the corrosion or
Sec.2 for minimum thicknesses of plates in case
other allowance at present shown in the
of boilers.
formulae, or by adopting a design pressure
higher than defined in 1.2, to offset the possible
1.13 Heat treatment, non-destructive
reduction of life in service caused by the
examination and routine tests
adverse conditions. In this connection, where
necessary, account should also be taken of any
1.13.1 Details regarding heat treatment, non-
excess of loading resulting from :
destructive examination and routine tests are to
be in accordance with the requirements of
a) impact loads, including rapidly fluctuating
Ch.10.
pressures;

b) weight of the vessel and normal contents

under operating and test conditions;

Section 2

Design Requirements

2.1 Cylindrical shells and drums subject to t, p, Ri and σ are defined in Sec.1;
internal pressure
J = efficiency of ligaments between tube holes
2.1.1 Minimum thickness or other openings in the shell or the joint factor
of the longitudinal joints (expressed as a
2.1.1.1 The minimum thickness, t, of a fraction), as defined in Sec.1, whichever applies.
cylindrical shell is to be determined by the In the case of seamless shells clear of tube
following formula: holes or other openings, J = 1.0.

pRi 2.1.1.2 The formula in 2.1.1.1 is applicable only

t= + 0.75 [mm] where the resulting thickness does not exceed
10 σ J - 0.5p half the internal radius, i.e. where Ro is not
greater than 1.5 Ri.
where,

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2.1.1.3 Irrespective of the thickness determined is to be taken as twice the circumferential

by 2.1.1.1, t is not to be less than: efficiency.

For Boilers (Fired and 6.0 [mm] for

exhaust gas heated), cylindrical shell
economizers, plates.
superheaters,
reheaters, steam For tube plates, such
receivers, steam- thickness as will give
heated steam a minimum parallel
generators and seat of 9.5 [mm], or
similar vessels such greater width as
may be necessary to
ensure tube
tightness.

2.1.2 Efficiency of ligaments between tube

holes

2.1.2.1 Where tube holes are drilled in a

cylindrical shell in a line or lines parallel to its
axis, the efficiency, J, of the ligaments is to be
determined as follows:

a) for regular drilling (See Fig.2.1.2.1)

s-d
J=
s
b) for irregular drilling (See Fig.2.1.2.2)

S1 + S 2 − 2 d
J=
S1 + S 2

where,

d = the mean effective diameter of the tube

holes, [mm], after allowing for any serrations,
counterboring of recessing, or the compensating
effect of tube stub, see 2.1.3 and 2.1.4;

s = pitch of tube holes [mm];

s1 = the shorter of any two adjacent pitches 2.1.2.4 Where tube holes are drilled in a
[mm]; cylindrical shell along a diagonal line with
respect to the longitudinal axis, the efficiency, J,
s2 = the longer of any two adjacent pitches of the ligament is to be determined as in 2.1.2.5
[mm]. to 2.1.2.8.

2.1.2.2 When applying the formula in 2.1.2.1, 2.1.2.5 For spacing of tube holes on a diagonal
the double pitch (s1 + s2) chosen is to be that line as shown in Fig.2.1.2.3, or in a regular saw-
which makes J a minimum, and in no case is s2 tooth pattern as shown in Fig.2.1.2.4, J is to be
to be taken as greater than twice s1. obtained from the series of curves given in Fig
2.1.2.6 where a and b, as shown in Fig.2.1.2.3
2.1.2.3 Where the circumferential pitch between and Fig.2.1.2.4, are measured, in millimeters, on
tube holes measured on the mean of the the median line of the plate , and d is as defined
external and internal drum or header diameters in 2.1.2.1.
is such that the ligament efficiency determined
by the formula in 2.1.2.1 is less than one- half of
the ligament efficiency of the longitudinal axis, J

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α = angle between centerline of cylinder and

centerline of diagonal holes.

2.1.2.7 For regularly staggered spacing of tube

holes as shown in Fig.2.1.2.5, the smallest value
of the efficiency, J, of all ligaments (longitudinal,
circumferential and diagonal) is obtained from
Fig.2.1.2.7, where a and b, as shown in
Fig.2.1.2.5 are measured, in millimeters, on the
median line of the plate, and d as defined in
2.1.2.1.

2.1.2.8 For irregularly spaced tube holes whose

centers do not lie on a straight line, the formula
'b' in 2.1.2.1 is to apply, except that an
equivalent longitudinal width is to be used. An
equivalent longitudinal width is that which gives,
using the formula 'a' in 2.1.2.1 the same
efficiency as would be obtained using
Fig.2.1.2.6 for the diagonal ligament in question.

2.1.2.9 The spacing of tube holes is to be such

that the minimum width, in [mm], of any ligament
between tube holes is not less than:

0.125 d + 12.5 [mm]

where,
2.1.2.6 The data for Fig.2.1.2.6 is based on the
following: d = diameter of tube holes [mm].

2 2.1.3 Compensating effect of tube stubs

J=
A + B + (A − B) 2 + 4C 2 2.1.3.1 Where a drum or header is drilled for
tube stubs fitted by strength welding, either in
where, line or in staggered formation, the effective
diameter of holes is to be taken as follows:
a (Cos 2 α + 1)
A= A
2 (a − d Cosα ) de = da −
t

⎛ d Cosα ⎞
B = 0.5 ⎜1 − (
⎟ Sin α + 1
2
) where,
⎝ a ⎠ de = the equivalent diameter of the hole [mm];

a Sinα Cosα da = the actual diameter of the hole [mm];

C=
2 (a − d Cosα ) A =the compensating area provided by each
tube stub and its welding fillets [mm2];
a
Cosα = t = thickness of the shell [mm].
a + b2
2

2.1.3.2 The compensating area, A, is to be

b measured in a plane through the axis of the tube
Sinα = stub parallel to the longitudinal axis of the drum
a2 + b2 or header and is to be calculated as follows
(See Fig.2.1.3.1 and Fig.2.1.3.2):

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2.1.3.4 No credit will be given for the additional

strength of tube stub material having an
allowable stress greater than that of the shell.

2.1.4 Unreinforced openings

2.1.4.1 Openings in a definite pattern such as

tube holes, may be designed in accordance with
the rules for ligaments in 2.1.2, provided that the
diameter of the largest hole in group does not
exceed that permitted by 2.1.4.2.

2.1.4.2 The maximum diameter, d, of any

isolated unreinforced openings is to be obtained
from the curves in Fig.2.1.4.1 and Fig.2.1.4.2.
The value of K to be used is calculated from the
following formula:

p Do
K=
18.2 σ t

where,

p, Do and σ are defined in Sec.1;

t = actual thickness of shell [mm].

2.1.4.3 For elliptical or oval holes, d refers to the

major axis when this lies longitudinally or to the
mean of the major and minor axes when minor
- The cross-sectional area of the stub, in axis lies longitudinally.
excess of that required by 2.7.1 for the
minimum tube thickness, from the interior 2.1.4.4 No unreinforced opening is to exceed
surface of the shell up to a distance b from 200 [mm] in diameter.
the outer surface of the shell;
2.1.4.5 Openings may be considered isolated if
- plus the cross-sectional area of the stub the center distance between two openings on
projecting inside the shell within a distance the longitudinal axis of the cylindrical shell is not
b from the inner surface of the shell; less than:

- plus the cross-sectional area of the shell

welding fillets inside and outside the shell; d+1.1 Dt with a minimum of 5d

where, where,

d = diameter of openings in shell (mean

b = da tb diameter if dissimilarly sized openings are
involved)
tb = actual thickness of tube stub [mm].
D = mean diameter of shell
2.1.3.3 Where the material of the tube stub has
an allowable stress lower than that of the shell, t = actual thickness of shell
the compensating cross-sectional area of the
stub is to be multiplied by the ratio:- Where the center distance is less than so
derived, the openings are to be fully
allowable stress of stub at design metal temperature compensated
.
allowable stress of shell at desgn metal temperature

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Where two openings are offset on a diagonal σ = the allowable stress of shell material at
line, the diagonal efficiency from Fig.2.1.2.7 may design temperature;
be used to derive an equivalent longitudinal σs
center distance for the purpose of this is to be taken as not greater than 1.
paragraph. σ
2.1.5 Reinforced openings

2.1.5.1 The following notations are used in

Fig.2.1.5.1(a),(b) and (c):

A = calculated thickness of shell without joint or

opening;

B = thickness calculated in accordance with

2.7.1;

C = 0.8 di t b

D= D i t a and is not to exceed 0.5 di;

ta = actual thickness of shell plate [mm];

tb = actual thickness of standpipe stem or

branch [mm];

tr = thickness of added reinforcement [mm] (tr

will be zero when there is no compensating
plate on the side of the shell under
consideration);

di = internal diameter of standpipe or branch

[mm];

Di = internal diameter of cylindrical shell [mm].

2.1.5.2 Openings larger than those permitted by

2.1.4 are to be reinforced by the method shown
in Fig.2.1.5.1. Compensation will be considered
adequate when:

σs
Y+Z ≥X
σ
where, 2.1.5.3 Area X is to be such that the
reinforcement is provided on all planes through
X = the area to be compensated and is indicated the center of the opening and normal to the shell
by X in Fig.2.1.5.1; surface, and is to be calculated as the product of
the radius of the hole cut in the shell and the
Y = the compensating area available in the shell thickness, A, that would be required for an
material and is indicated by Y in Fig.2.1.5.1; equivalent seamless unpierced shell.

Z = the compensating area available in the 2.1.5.4 Area Y is to be measured in the same
standpipe material and is indicated by Z in plane as area X, and is to be calculated as the
Fig.2.1.5.1; product of the difference between the actual
shell thickness and the equivalent unpierced
σs = the allowable stress of the standpipe shell thickness, A, and the dimension from the
material at design temperature; edge of the opening in shell to limit D.

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2.1.5.5 Area Z is to be measured in the same 2.3 Dished ends subject to pressure on
plane as area X, and is to be calculated as concave side
follows:
2.3 1 Minimum thickness
- For that part of standpipe which projects
outside the shell, calculate the full cross- 2.3.1.1 The thickness, t, of semi-ellipsoidal,
sectional area of the stem up to a distance torispherical and hemispherical unstayed ends,
C from the actual outer surface of the shell dished from plate, having pressure on the
plate, and deduct from it the cross-sectional concave side and satisfying the conditions listed
area which the stem would have if its below, is to be determined by the following
thickness was as calculated in accordance formula:
with 2.7.1;
p DoK
- plus, in the case of set- through nozzles t= + 0.75 [mm]
(see Fig.2.1.5.1 (a) and (b), the full cross- 20 σ J
sectional area of that part of the stem which
projects inside the shell up to a distance of where,
C, from the inside surface of the shell;
p, Do, σ and J are defined in Sec.1;
- plus, the cross-sectional area of all
K = a shape factor in accordance with 2.3.2 and
- appropriate fillet welds; Fig.2.3.1.1.

- plus, if additional reinforcement is fitted as 2.3.1.2 For semi-ellipsoidal ends:

illustrated in Fig.2.1.5.1(b), the cross-
sectional area of the reinforcement and the the external height, H ≥ 0.18 Do, where Do = the
sectional area of its fillet welds. external diameter of the parallel portion of the
end [mm].
2.1.5.6 The welds attaching standpipes and
reinforcing plates to the shell are to be of 2.3.1.3 For torispherical ends:
sufficient size to transmit the full strength of the
reinforcing areas and all other loadings to which the internal radius, Ri ≤ Do;
they may be subjected.
the internal knuckle radius, ri ≥ 0.1 Do;
2.2 Spherical shells subject to pressure on
the concave side the internal knuckle radius, ri ≥ 3t;
2.2.1 Minimum thickness the external height, H ≥ 0.18 Do, and is to be
determined as follows:
2.2.1.1 The minimum thickness of a spherical
shell is to be determined by the following
formula: H = Ro − (R o − 0.5 D o )(R o +0.5 D o − 2 ro )
pRi 2.3.1.4 In addition to the formula in 2.3.1.1, the
t= + 0.75 [mm] thickness, t, is to be not less than that
20 σ J − 0.5p determined by 2.2.

where, 2.3.1.5 In all cases, H is to be measured from

the commencement of curvature, see
p, Ri, σ, J and t are defined in Sec.1. Fig.2.3.1.2.(a),(b),(c) and (d).

2.2.1.2 The formula in 2.2.1.1 is applicable only 2.3.1.6 For boilers (fired and exhaust gas
where the resulting thickness does not exceed heated), economisers, superheaters, reheaters,
half the internal radius. steam receivers, steam heated steam
generators and similar vessels, the minimum
2.2.2 Openings thickness of the head, t, is to be not less than
9.5 [mm]. In special cases where it is proposed
2.2.2.1 Openings in spherical shells are to to use less than 9.5 [mm] thickness, the
comply with the relevant requirements of 2.3. proposals will be subject to special
consideration.

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2.3.1.7 For ends which are butt welded to the

drum shell, the thickness of the edge of the
flange for connection to the shell is to be not
less than the thickness of an unpierced
seamless or welded shell, whichever is
applicable, of the same diameter and material
and determined by 2.1.

2.3.2 Shape factors for dished ends

2.3.2.1 The shape factor, K, to be used in

2.3.1.1 is to be obtained from the curves in

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Fig.2.3.1.1, and depends upon the ratio of 2.3.4 Flanged openings in dished ends
height to diameter H/Do.
2.3.4.1 The requirements in 2.3.3 apply equally
2.3.2.2 The lowest curve in the series provides to flanged openings and to unflanged openings
the factor K for plain ends without openings or cut in the plate of an end. No reduction may be
with small openings not requiring reinforcement. made in the end plate thickness on account of
For lower values of H/Do, the shape factor, K, flanging.
depends on the ratio of thickness to diameter,
t/Do, as well as the ratio H/Do and a trial 2.3.4.2 Where openings are flanged, the radius,
calculation may be necessary to arrive at the rm, of the flanging is to be not less than 25 [mm],
correct value of K. See Fig.2.3.1.2(d). The thickness of the flanged
portion may be less than the calculated
2.3.3 Dished ends with unreinforced thickness.
openings
2.3.4.3 Unreinforced and flanged openings in
2.3.3.1 The openings in dished ends may be dished ends are to be so arranged that the
circular or approximately elliptical. distance from the edge of the hole to the outside
edge of the plate and the distance between
2.3.3.2 The upper curves in Fig.2.3.1.1 provide openings are not less than those shown in
values of K to be used in 2.3.1.1 for ends with Fig.2.3.1.3.
unreinforced openings. The selection of the
d 2.3.5 Dished ends with reinforced openings
correct curve depends on the value and
Do t 2.3.5.1 Where it is desired to use a large
a trial calculation is necessary to select the opening on a dished end of less thickness than
correct curve. would be required by 2.3.3, the end is to be
reinforced. This reinforcement may consist of a
where, ring or standpipe welded into the hole, or of
reinforcing plates welded to the outside and/or
d = the diameter of the largest opening in the inside of the end in the vicinity of the hole, or a
end plate [mm] (in the case of an elliptical combination of both methods, see Fig.2.3.1.4.
opening, the larger axis of the ellipse); Forged reinforcement may be used.

t = minimum thickness, after dishing [mm]; 2.3.5.2 Reinforcing material within the following
limits may be taken as effective reinforcement:
Do = outside diameter of dished end [mm].
a) The effective width l1, of reinforcement is not
2.3.3.3 The following requirements must in any to exceed 2 R i t or 0.5 do whichever is the
case be satisfied:
lesser;
t
≤ 0.1 b) The effective length l2 of a reinforcing ring is
Do not exceed do tb ;

d
≤ 0.7 where,
Do
Ri = The internal radius of the spherical part of a
torispherical end [mm]; or
2.3.3.4 From Fig.2.3.1.1 for any selected ratio
H/Do, the curve for unpierced ends gives a value
= the internal radius of the meridian of the
d ellipse at the center of the opening, of a semi-
for as well as for K. Openings giving a
Do t ellipsoidal end, [mm], and is given by the
following formula:
d
value of not greater than the value so
Do t [ a 4 − x 2 (a 2 − b 2 )]1.5
obtained may thus be pierced through an end a4 b
designed as unpierced without any increase in
thickness. where,

a, b and x are shown in Fig.2.3.1.2(c);

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tb = actual thickness of ring or standpipe [mm];

do = external diameter of ring or standpipe [mm]; p Do K
l1 and l2 are shown in Fig.2.3.1.4. t= + 0.75 [mm]
20 σ J
2.3.5.3 The shape factor, K, for a dished end
having a reinforced opening can be read from where,
Fig.2.3.1.1 using the value obtained from:
t, p, σ and J are defined in Sec.1;
d o − A/t d
instead of from Do = outside diameter, in [mm], of the conical
Do t (D o t ) section or end, see Fig.2.4.1.1(a),(b),(c) and (d);

where, K = a factor, taking in to account the stress in

the knuckle, see Table 2.4.1.1.
A = the effective cross-sectional area of
reinforcement and is to be twice the area shown 2.4.1.2 If the distance of a circumferential seam
shaded on Fig.2.3.1.4. from the knuckle or junction is not less than L,
then J is to be taken as 1.0, otherwise J is to be
A trial calculation is necessary to select the taken as the weld joint factor appropriate to the
correct curve. circumferential seam;

2.3.5.4 The area shown in Fig.2.3.1.4 is to be where,

obtained as follows:-
L = distance, in [mm], from knuckle or junction
- calculate the cross-sectional area of within which meridional stresses determine the
reinforcement both inside and outside the required thickness, see Fig.2.4.1.1;
end plate within the length l1;
Dot
- plus the full cross-sectional area of that part = 0.5
of the ring or standpipe which projects Cosψ
inside the end plate up to the distance l2;
ri = inside radius of transition knuckle, in [mm],
- plus the full cross-sectional area of that part which is to be taken as 0.01 Dc in case of
of the ring or standpipe which projects conical sections without knuckle transition.
outside the internal surface of the end plate
up to a distance l2; 2.4.1.3 The minimum thickness, t, of those parts
of conical sections not less than a distance L
- and deduct the sectional area which the from the junction with a cylinder or other conical
ring or standpipe would have if its thickness section is to be determined by the following
were as calculated in accordance with 2.7.1. formula:-

2.3.5.5 If the material of the ring or the p Dc

reinforcing plates has an allowable stress value t= + 0.75 [mm]
lower than that of the end plate, then the (20 σ J − p ) Cosα
effective cross-sectional area, A, is to be
multiplied by the ratio:- where,

allowable stress of reinforcing plate at design temperature Dc = inside diameter, in [mm], of conical section
or end at the position under consideration, see
allowable stress of end plate at design temperature
Fig.2.4.1.1;

2.4 Conical ends subject to internal pressure α1, α2, α3 = angle of slope of conical section (at
the point under consideration) to the vessel axis,
2.4.1 Minimum thickness see Fig.2.4.1.1.
2.4.1.1 The minimum thickness, t, of the 2.4.1.4 Conical ends may be constructed of
cylinder, knuckle and conical section at the several ring sections of decreasing thickness, as
junction and within the distance L from the determined by the corresponding decreasing
junction is to be determined by the following diameter.
formula, but in no case is to be less than the
thickness determined by 2.4.1.3:-

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Table 2.4.1.1 : Values of K as a function of ψ and ri/Do

Values of K for ri/Do ratios

ψ 0.01 0.02 0.03 0.04 0.06 0.08 0.10 0.15 0.20 0.30 0.40 0.50
10° 0.70 0.65 0.60 0.60 0.55 0.55 0.55 0.55 0.55 0.55 0.55 0.55
20° 1.00 0.90 0.85 0.80 0.70 0.65 0.60 0.55 0.55 0.55 0.55 0.55
30° 1.35 1.20 1.10 1.00 0.90 0.85 0.80 0.70 0.65 0.55 0.55 0.55
45° 2.05 1.85 1.65 1.50 1.30 1.20 1.10 0.95 0.90 0.70 0.55 0.55
60° 3.20 2.85 2.55 2.35 2.00 1.75 1.60 1.40 1.25 1.00 0.70 0.55
75° 6.80 5.85 5.35 4.75 3.85 3.50 3.15 2.70 2.40 1.55 1.00 0.55

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2.4.1.5 The thickness of conical sections having 2.7 Particular design requirements for
an angle of inclination to the vessel axis of more boilers, superheaters, economizers, steam
than 75 degrees is to be determined as for a flat receivers and similar vessels
plate.
2.7.1 Boiler tubes subject to internal
2.5 Unstayed flat end plates pressure

2.5.1 Minimum thickness 2.7.1.1 The minimum wall thickness of straight

tubes subject to internal pressure is to be
2.5.1.1 The thickness of an unstayed flat end determined by the following formula:
plate is to be determined in accordance with
2.7.3.3 or 2.8.1.7 or 2.8.1.8 as applicable. p Do
t= [mm]
2.6 Standpipe and branches 20 σ + p

2.6.1 Minimum thickness where,

2.6.1.1 The minimum wall thickness of t, p, Do and σ are as defined in Sec.1. The
standpipes and branches is to be not less than thickness is in no case to be less than that
that determined by 2.7.1. In determining the wall shown in Table 2.7.1.
thickness of branches, internal pressure in
addition to loads by connected piping and 2.7.1.2 If the tube is ordered with a minus
vibrations are to be taken into account. The tolerance, the minimum thickness according to
thickness, however, is not to be less than: the formula in 2.7.1.1 is to be increased by the
necessary amount. Where tubes are bent, the
t = 0.04 Do + 2.5 [mm] thickness of the thinnest part of the tube is not to
be less than the calculated thickness, unless it
where, can be demonstrated that the method of
bending results in no decrease in strength at the
t and Do are as defined in Sec.1. bend as compared with the straight tube. In
connection with any new method of bending, the
2.6.1.2 In no case need the wall thickness manufacturer is to prove that this condition is
exceed that of the shell. satisfied.

2.6.1.3 Where standpipe or branch is connected 2.7.1.3 For boiler, superheater and economizer
by screwing, the thickness is to be measured at tubes, the wall thickness required for the drum
the root of the threads. or header connection or tube stub is to be
calculated as part of the tube.

2.7.1.4 The minimum thickness of downcomer

tubes and pipes which form an integral part of
the boiler and which are not exposed to
combustion gases is to comply with the
requirements for steam pipes.

Table 2.7.1 : Minimum thickness of tubes

Nominal outside diameter of Minimum thickness [mm],
Minimum thickness [mm]
tube [mm] See Note
≤ 38 1.75 2.95
> 38 ≤ 50 2.16 2.95
> 50 ≤ 70 2.40 2.95
> 70 ≤ 75 2.67 3.28
> 75 ≤ 95 3.05 3.28
> 95 ≤ 100 3.28 3.28
> 100 ≤ 125 3.50 3.50
Note : Applicable to tubes subject to internal pressure and fitted in cylindrical boilers and also for the
tubes of low pressure water tube boilers having a design pressure of 1.72 [N/mm2] and under with
open feed system.

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2.7.2 Boiler tubes subject to external

pressure where,

2.7.2.1 The wall thickness of tubes with outside t, p, Do and σ are as defined in Sec.1;
diameter 100 [mm] and less is not to be less
than: The nominal thickness of plain boiler tubes is,
however, in no case to be less than given in
p Do Table 2.7.2.
t= [mm]
157 σ

Table 2.7.2 : Thickness of plain tubes under external pressure

Outside Nominal thickness of tube [mm]

diameter of
tube [mm] 2.9 3.2 3.6 4.0 4.5
2
Design pressure [N/mm ]
51 1.1 1.5 2.1
57 1.0 1.35 1.8 2.2
63.5 0.9 1.25 1.6 2.1
70 0.8 1.1 1.5 1.95
76.1 1.0 1.35 1.75 2.1
82.5 0.9 1.25 1.6 1.95
88.9 0.85 1.15 1.5 1.8

2.7.2.2 Regarding minus tolerance and d = diameter of tube hole [mm].

reduction in thickness due to bending, see
2.7.1.2. 2.7.3 Headers

2.7.2.3 Plain tubes may be seal welded at both 2.7.3.1 Circular headers
ends, seal welded at the inlet end and expanded
at the outlet end or expanded at both the ends. 2.7.3.1.1 The minimum thickness of circular
Where the tubes are seal welded, the tubes are section headers is to be calculated in
to be expanded into the tube plates in addition accordance with 2.1.
to welding.
2.7.3.2 Rectangular section headers
2.7.2.4 Where plain tubes are expanded only,
the process is to be carried out with roller 2.7.3.2.1 The thickness of flat surfaces of
expanders, and the expanded portion of the rectangular solid forged headers is to be not
tube is to be parallel through the full thickness of less than (t + 0.75) [mm], where t = the greatest
the tube plate. In addition to expanding, tubes basic thickness, in [mm], derived by the use of
may be bellmouthed or beaded at the inlet end. Fig.2.7.3.1.

2.7.2.5 Where the total number of tubes are 2.7.3.2.2 Fig.2.7.3.1 shows values of t/B
arranged in one nest and no stay tubes are corresponding to the values of term K, for
fitted, the ends of all tubes are to be welded or parameters of A/B;
expanded and beaded at the inlet end, and
welded or expanded at the outlet end. where,

2.7.2.6 The spacing of the tube holes is to be A = the distance, in [mm], between centerline of
such that the minimum width, in [mm], of any the openings and the limit of the effective width,
ligament between the tube holes is not less B, of the header. Where there is more than one
than: row of holes, A is the distance to the row
showing the lowest efficiency;
0.125 d + 12.5 [mm]
B = the effective width, in [mm], of the pierced
where, surface under consideration measured between
the supporting sides of the headers, minus one

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corner radius. The effective width is not to be 2.7.3.3.2 Ends attached by welding are to be
taken as less than 0.9 of the full distance designed as follows:-
between the sides;
a) Dished Ends: these are to be in accordance
10σ J with 2.3
K=
p b) Flat Ends: the minimum thickness of flat end
plates is to be determined by the following
where, formula:-

σ and p are as defined in Sec.1; pC

t = di
J = the efficiency of the ligaments as calculated 10 σ
in 2.1.2. Where there are several rows of tube
holes, the lowest calculated efficiency is to be where,
used.
p and σ are as defined in Sec.1;
2.7.3.2.3 Investigations of two stresses are
necessary: t = minimum thickness of end plate [mm];
- the stress at the corner of the header, where di = internal diameter of circular header or least
A/B = 0 and J = 1, see Fig.2.7.3.1; width between walls of rectangular header [mm];
- and the stress in the ligaments between C = a constant depending on method of end
tube holes or other openings piercing the attachment, see Fig.2.7.3.2
flat face of the header.
For end plates welded as shown in Fig.2.7.3.2
2.7.3.2.4 The corner radius is not to be less than (a):
6.5 [mm].
C = 0.19 for circular headers;
2.7.3.2.5 Where the header surfaces are
machined locally at hand holes, the total = 0.32 for rectangular headers;
thickness may be reduced by a maximum of 4
[mm]. For end plates welded as shown in Fig.2.7.3.2
(b) and (c):
2.7.3.2.6 Except for small areas not exceeding
325 [mm2], where a reduction of designed C = 0.28 for circular headers;
thickness up to 50 per cent may be permitted,
the thickness derived from the use of Fig.2.7.3.1 = 0.40 for rectangular headers.
is to be the minimum. Such minimum is in no
case to be less than 7.5 [mm] or where tube 2.7.3.3.3 Where flat end plates are bolted to
holes are drilled, to be less than:- flanges attached to the ends of headers, the
flanges and end plates are to be in accordance
t = 0.5 d + 6.35 [mm] with recognized pipe flange standards.

where, 2.7.4 Flat surfaces and flat tube plates

d = the diameter of the tube holes [mm]. 2.7.4.1 Stayed flat surfaces

2.7.3.3 Header ends 2.7.4.1.1 Where flat end plates are flanged for
connection to the shell, the inside radius of
2.7.3.3.1 The shape and thickness of ends flanging is to be not less than 1.75 times the
forged integrally with the bodies of headers are thickness of the plate, with a minimum of 38
to be the subject of special consideration. [mm].
Where sufficient experience of previous
satisfactory service of headers with integrally 2.7.4.1.2 Where combustion chamber of firebox
forged ends cannot be shown, the suitability of a plates are flanged for connection to the wrapper
proposed form of end is to be proved in plate, the inside radius of flanging is to be equal
accordance with 1.10. to the thickness of the plate, with a minimum of
25 [mm].

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where,

t and p are as defined in Sec.1;

σ1 = 0.85 σ, where σ is as defined in Sec.1;

d = A +B
2 2
where the stays are regularly
pitched

A = horizontal pitch of the stays

B = vertical pitch of the stays

where the tubes are irregularly pitched

d = diameter of the largest circle which can be

drawn through three points of support without
enclosing another point of support. Only two
points of support may lie on one side of any
diameter of the circle.

C = a constant, dependent on the method of

support as detailed in 2.7.4.1.7. Where various
forms of support are used, C is to be the mean
of the values for the respective methods
adopted.

2.7.4.1.7 All constants given in this paragraph

relate to plates which are stress relieved and not
Fig.2.7.4.1 : Attachment of unflanged end
exposed to flame. Where the plates are exposed
plate to shell
to flame the thickness of the plate is to be
increased by 10 per cent. The values of C in the
formula in 2.7.4.1.6 is to be as follows:-
2.7.4.1.3 Where unflanged flat plates are
connected to the shell by welding, the methods
a) Where plain bar stays are strength welded
of attachment are to be as shown in Fig.2.7.4.1.
in to the plates as shown in Fig.2.7.4.2.
Similar forms of attachment may be used where
unflanged combustion chamber or firebox plates
C = 0.39
are connected to the wrapper plate by welding.
b) Where plain bar stays pass through holes in
2.7.4.1.4 Where the flange curvature is a point
the plates and are fitted on the outside with
of support, this is to be taken at the
washers as shown in Fig.2.7.4.3.
commencement of curvature, or at a line distant
3.5 times the thickness of the plate from the
C = 0.35 where the diameter of the washer
outside of the plate, whichever is nearer to the
is 3.5 times the diameter of the stay.
flange.
C = 0.33 where the diameter of the washer
2.7.4.1.5 Where a flat plate is welded directly to
is 0.67 times the pitch of the stays.
a shell or wrapper plate, the point of support is
to be taken at the inside of the shell or wrapper
c) Where the flat plate is flanged for
plate.
attachment to the shell, flue, furnace or
wrapper or, alternatively, is welded directly
2.7.4.1.6 The thickness, t, of those portions of
to the shell, flue, furnace or wrapper.
flat plates supported by stays is to be
determined by the following formula:
C = 0.33

p d) where the support is a gusset or link stay

t = Cd + 0.75 [mm]
10 σ 1
C = 0.39

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2.7.4.1.8 Alternative methods of support will be 2.7.4.1.10 Where the flat top plates of
specially considered. combustion chambers are supported by welded-
on girders, the equation in 2.7.4.1.6 is to apply
2.7.4.1.9 Where a flat plate has a manhole or as follows:
sighthole and the opening is strengthened by
flanging, the total depth, H, of the flange, a) In the case of welded-on girders provided
measured from the outer surface of the plate, is with waterways;
to be not less than:
C = 0.42;
H= tW
d = X2 + Y2
where,
where,
H = depth of flange [mm];
X = width of waterway in the girder plus the
t = thickness of plate [mm]; thickness of the girder [mm];

W = minor axis of manhole or sight hole [mm]. Y = pitch of girder [mm];

b) In the case of the continuously welded-on

girders;

C = 0.51;

d = D;

where,

D = distance between inside faces of girders

[mm].

2.7.4.2 Flat tube plates within tube nests

2.7.4.2.1 Stay tubes are to be fitted:

a) Where the total number of tubes are

arranged in one nest, the area of which
2
exceeds 0.65 [m ] in the case of direct fired
boilers, and 2.0 [m2] in the case of waste
heat boilers;

b) In all cases where the total number is

arranged in more than one nest.

2.7.4.2.2 Where stay tubes are not fitted, the

ends of all tubes are to be welded or expanded
and beaded at the inlet end, and welded or
expanded at the outlet end. For details of seal
welding of plain tubes, see Fig.2.7.4.4.

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a) 12.5 [mm], where the diameter of the tube

hole does not exceed 50 [mm]; and

b) 14 [mm], where the diameter of the tube

hole is greater than 50 [mm].

2.7.4.3 Flat tube plates between wide water

spaces and around tube nests

2.7.4.3.1 The thickness of the tube plate in the

wide water space between tube nests is to be
determined by the following formula:

p
t = Cd + 0.75 [mm]
2.7.4.2.3 Where stay tubes are required to be 10σ 1
fitted, the thickness of those parts of the tube
plates within the tube nests is to be determined where,
by the following formula:
t = thickness of the tube plate [mm];
p
t = CM + 0.75 [mm] p = design pressure [N/mm2];
10σ 1
σ1 = 0.85 σ, where σ is as defined in Sec.1;
where,

t = thickness of tube plate [mm]; d = A 2 + B2

p = design pressure [N/mm2]; A = width [mm], of the wide water space

between the tube nests (measured from the
σ1 = 0.85 σ, where σ is as defined in Sec.1; centerline of the stay tubes);

M = mean pitch, in [mm], of the stay tubes B = pitch [mm], of the stay tubes in boundary
supporting any positions of the plate (being the rows of wide water space;
sum of the four sides of any quadrilateral divided
by 4); C = 0.42, if the plates are not exposed to flame;

C = 0.42 for plates not exposed to flame with = 0.46, if the plates are exposed to flame.
stay tube secured as shown in Fig.2.7.4.5;
2.7.4.3.2 The values of C and the method of
C = 0.46 for plates exposed to flame. securing the stay tubes are as indicated in
2.7.4.2.3.
2.7.4.2.4 Where the area of the tube nest does
not exceed 0.65 [m2] in the case of direct fired 2.7.4.3.3 Where stay tubes are irregularly
boilers, or 2.0 [m2] in the case of waste heat pitched, d is to be taken as the diameter of the
boilers, and stay tubes are not fitted, the largest circle which can be drawn through any
thickness of the plate is to be determined by the three points of support without enclosing
formula in 2.7.4.2.3; another point of support. Where various forms of
supports are used, the value of C is to be the
where, mean of the values for the respective methods
adopted.
M = Four times the mean pitch [mm], of the plain
tubes in the nest; 2.7.4.3.4 For the portions of the end plates
between the top rows of tubes and steam space
C = 0.45 for plates not exposed to flame; stays, the formula in 2.7.4.3.1 is to apply, B
being taken as the distance between the
= 0.49 for plates exposed to flame. centerline of the top row of tubes and the center
of the bar stays or other point of support, and A
2.7.4.2.5 The thickness, t, of any tube plate in A1 + A 2
being taken as where A1 is the
the tube area is to be not less than: 2
horizontal distance between the centers of bar

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stays or other methods of support, and A2 is the where,
horizontal distance between the center of one
stay tube and the center of next stay tube in the t and p are as defined in Sec.1;
top boundary row. Where no stay tubes are
fitted, A2 is to be taken as equal to four times the d = depth of girder [mm];
horizontal pitch of the plain tubes.
l = length of girder [mm], measured internally
2.7.4.3.5 Where no stay tubes are fitted, the from tube plate to back chamber plate;
support afforded by the plain tubes are not to be
taken to extend beyond the line enclosing the s = distance apart of the girders [mm];
outer surfaces of the tubes except that, between
the outside of the wing row of tubes and the R20 = specified minimum tensile strength of the
attachment of the end plate to shell, there may girder plate [N/mm2].
be an unsupported width equal to the flat plate
margin, as given by the formula in 2.7.4.6.1. 2.7.4.6 Flat plate margins

2.7.4.4 Combustion chamber tube plates 2.7.4.6.1 The width of margin, b, of a flat plate
under compression which may be regarded as being supported by
the shell, furnaces or flues to which the flat plate
2.7.4.4.1 The thickness of combustion chamber is attached is not to exceed that determined by
tube plates under compression due to the the following formula:
pressure on the top plate, based on a
compressive stress not exceeding 960 bar is to C(t − 0.75)
be determined by the following formula: b= [mm]
p
pWs
t= [mm] where,
1930(s − d)
t and p are as defined in Sec.1;
where,
b = width of margin [mm];
t and p are as defined in Sec.1;
C = 31.0 for plates not exposed to flame;
W = internal width of combustion chamber [mm],
measured from tube plate to back chamber = 28.8 for plates exposed to flame.
plate;
2.7.4.6.2 Where an unflanged flat plate is
s = pitch of tubes [mm], measured horizontally welded directly to shell, furnaces or flues and it
where tubes are chain pitched, or diagonally is not practicable to effect the full penetration
where the tubes are staggered pitched and the weld from both sides of the flat plate, the
diagonal pitch is less than the horizontal pitch; constant C used in formula in 2.7.4.6.1 is to be:

d = internal diameter of plain tubes. C = 23.6 for plates not exposed to flame;

2.7.4.5 Girders for combustion chamber top = 22.3 for plates exposed to flame.
plates
2.7.4.6.3 In the case of plates which are flanged,
2.7.4.5.1 The formula in 2.7.4.5.2 is applicable the margin is to be measured from the
to plate girders welded continuously to the top commencement of curvature of flanging, or from
combustion chamber plates by means of a full a line 3.5 times the thickness of the plate,
penetration weld. measured from the outside of the plate,
whichever is nearer to the flange.
2.7.4.5.2 The proportion of steel plate girders
supporting the tops of combustion chambers is 2.7.4.6.4 Where the flat plate is not flanged for
to be determined by the following formula: attachment to the shell, furnaces or flues, the
margin is to be measured from the inside of the
0.32 p l 2 s shell or the outside of the furnaces or flues,
t= [mm] whichever is applicable.
d 2 R 20

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2.7.4.6.5 In no case is the diameter, D, in [mm], 2.7.5 Flat plates and ends of vertical boilers
of the circle forming the boundary of the margin
supported by the uptake of a vertical boiler to be 2.7.5.1 Tube plates of vertical boilers
greater than determined by the following
formula: 2.7.5.1.1 Where vertical boilers have a nest or
nests of horizontal tubes, so that there is direct
tension on the tube plates due to the vertical
345
D= + d 2 [mm] load on the boiler ends or to their acting as
p horizontal ties across the shell, the thickness of
the tube plates in way of the outer rows of tubes
where, are to be determined by the following formula:

A = cross-sectional area of the uptake tube pD

[mm2];
t= + 0.75 [mm]
5JR 20
p = design pressure in bar;
where,
d = external diameter of uptake [mm].
t and p are as defined in Sec.1;

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D = twice the radial distance of the center of the p = design pressure, in bar;
outer row of tube holes from the axis of the shell
[mm]; t = thickness of the tube plate [mm].

R20 = specified minimum tensile strength of tube 2.7.5.2.2 For the combustion chamber tube
plate [N/mm2]; plate the minimum number of gussets are to be:

J = efficiency of ligaments between tube holes in - 1 gusset where C exceeds 255 000
the outer vertical rows (expressed as a fraction);
- 2 gussets where C exceeds 350 000
s−d
= - 3 gussets where C exceeds 420 000
s
2.7.5.2.3 For the smoke box tube plate the
where, minimum number of gussets are to be:
s = vertical pitch of tubes [mm]; - 1 gusset where C exceeds 255 000
d = diameter of tube holes [mm]. - 2 gussets where C exceeds 420 000
2.7.5.1.2 Each alternate tube in the outer 2.7.5.2.4 The shell plates to which the sides of
vertical rows of tubes is to be a stay tube. the tube plates are connected are to be not less
Further, the arrangement of stay tubes in the than 1.5 [mm] thicker than is required by the
nests is to be such that the thickness of the tube formula applicable to shell plates with
plates meets the requirements of 2.7.4.2. and continuous circularity; and where gussets or
2.7.4.3. other stays are not fitted to the shelves, the
strength of the parts of the circumferential
2.7.5.1.3 Where the vertical height of the tube seams at the top and bottom of these plates
plates between the top and bottom shelves from the outside of one tube plate to the outside
exceeds 0.65 times the internal diameter of the of the other, is to be sufficient to withstand the
boiler, the staying of the tube plates, and the whole load on the boiler end with a factor of
scantlings of the tube plates and shell plates to safety of not less than 4.5 related to R20 (where
which the sides of the tube plates are connected R20 is the specified minimum tensile strength
will require to be specially considered. It is of the shell plates [N/mm2].
recommended, however, that for this type of
boiler the vertical height of the tube plates 2.7.5.3 Dished and flanged ends for vertical
between the top and bottom shelves should not boilers
exceed 1.25 times the internal diameter of the
boiler. 2.7.5.3.1 The minimum thickness, t, of dished
and flanged ends for vertical boilers which are
2.7.5.2 Horizontal shelves of tube plates subject to pressure on the concave side and are
forming part of the shell supported by central uptakes is to be
determined by the following formula:
2.7.5.2.1 For vertical boilers of the type referred
to in2.7.5.1, in order to withstand the vertical
PRi
load due to pressure on the boiler ends, the t= + 0.75 [mm]
horizontal shelves of the tube plates are to be 10σ 2
supported by gussets in accordance with the
following formula: where,

A Di p t, p and Ri are as defined in Sec.1;

C=
t
σ2 = 1.3 σ, where σ is defined in 1.6.
where,
2.7.5.3.2 The inside radius of curvature, Ri, of
A = maximum horizontal dimension of the shelf the end plate is to be not greater than the
from the inside of the shell plate to the outside of external diameter of the cylinder to which it is
the tube plate [mm]; attached.

Di = inside diameter of the boiler [mm]; 2.7.5.3.3 The inside knuckle radius, ri, of the arc
joining the cylindrical flange to the spherical
surface of the end is to be not less than four
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times the thickness of the end plate, and in no are supported by central uptake, is to be
case less than 65 [mm]. determined by the following formula:

2.7.5.3.4 The inside radius of curvature of flange pRo

to uptake is to be not less than twice the t= + 0.75 [mm]
thickness of the end plate, and in no case less 10σ
than 25 [mm].
where,
2.7.5.3.5 If the dished end has a manhole, the
opening is to be strengthened by flanging. The t, p, Ro and σ are as defined in Sec.1.
total depth, H, of the flange, measured from the
outer surface of plate on the minor axis, is to be 2.7.5.5.2 The inside radius of dishing and
not less than: flanging are to be as required by 2.7.5.3.

2.7.5.6 Dished and flanged ends for

H= tW unsupported vertical boiler furnaces:

where, 2.7.5.6.1 The minimum thickness, t, of dished

and flanged ends for vertical boiler furnaces that
H = depth of flange [mm]; are subject to pressure on the convex side and
are without support from stays of any kind, is to
t = thickness of the plate [mm]; be determined by the following formula, but is in
no case to be less than the thickness of the
W = minor axis of manhole [mm]. firebox:

2.7.5.4 Flat crowns of vertical boilers C pRo

t= + 0.75 [mm]
2.7.5.4.1 The minimum thickness of flat crown 660
plates of vertical boilers is to be determined as
in 2.7.4; d and c are defined as follows: where,

a) Where the crown is supported by an uptake t and p are as defined in Sec.1;

only;
Ro = outside radius of the crown plate, in [mm],
d = diameter [mm], of the largest circle (in no case Ro/t to exceed 88);
which can be drawn between the
connections to the shell or fire box and 2x
uptake (see 2.7.4.1.1 to 2.7.4.1.5); C= or 0.85 whichever is greater
x +σ
c = 0.47, if the plates are not exposed to
flame; x = specified minimum 0.2 per cent proof stress
in [N/mm2], at a temperature 90°C above the
= 0.51, if the plates are exposed to flame; saturated steam temperature corresponding to
the design pressure for carbon and carbon-
b) Where bar stays are fitted in accordance manganese steel with a specified minimum
2
with 2.7.4.1.6 and 2.7.4.1.7; tensile strength of 400 [N/mm ];

d = diameter, in [mm], of the largest circle σ = specified minimum 0.2 per cent proof stress
which can be drawn through three points of in [N/mm2], at a temperature 90°C above the
support without enclosing another point of saturated steam temperature corresponding to
support; the design pressure for the steel actually used.

c = the mean of the values for the respective 2.7.5.6.2 The inside radius of curvature, Ri, see
points of support through which the circle Fig.2.3.1.2 (a), of the end plate is to be not
passes. greater than the external diameter of the
cylinder to which it is attached.
2.7.5.5 Dished and flanges ends for
supported vertical boiler furnaces 2.7.5.6.3 The inside knuckle radius, ri, see
Fig.2.3.1.2 (a), of the arc joining the cylindrical
2.7.5.5.1 The minimum thickness, t, of dished flange to the spherical surface of the end is to
and flanged ends for vertical boiler furnaces that be not less than four times the thickness of the
are subject to pressure on the convex side and end plate and in no case less than 65 [mm].

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p D o (L + 160)
2.7.6 Cylindrical furnaces subject to external t= + 0.75 [mm]
pressure 102400
2.7.6.1 Maximum thickness CpD o L
t= + + 0.75 [mm]
2.7.6.1.1 Furnaces, plain or corrugated, are not 1100 320
to exceed 22.5 [mm] in thickness.
where,
2.7.6.2 Corrugated furnaces
t and p are as defined in Sec.1;
2.7.6.2.1 The minimum thickness, t, of
corrugated furnaces is to be determined by the Do = external diameter of the furnace, flue or
following formula: combustion chamber [mm];

P Do L = length of section between the center of

t= + 0.75 [mm] points of substantial support [mm];
C
2x
where, C=
x +σ
p is as defined in Sec.1;
where,
Do = external diameter of the furnace measured
at the bottom of the corrugations [mm]; x and σ are as defined in 2.7.5.6.

t = thickness, of the furnace plate measured at 2.7.6.4 Plain furnaces of vertical boilers
the bottom of the corrugations [mm];
2.7.6.4.1 The thickness of plain furnaces not
C = 1060 for Fox, Morision and Deighton exceeding 1700 [mm] in external diameter is to
corrugations; be determined by the formulae given in
2.7.6.3.1, the greater of the two thicknesses
= 1130 for suspension and bulb corrugations. being taken;

2.7.6.3 Plain furnaces, flue sections and where,

combustion chamber bottoms
D = external diameter of the furnace, in [mm];
2.7.6.3.1 The minimum thickness, t, of plain where the furnace is tapered, the diameter is to
furnaces or furnaces strengthened by stiffening be the mean of that at the top and that at the
rings, of flue sections and of the cylindrical bottom where it meets substantial support from
bottoms of combustion chambers is to be flange, ring or row of stays;
determined by the following formulae, the
greater of two thicknesses being taken: L = effective length, in [mm], of the furnace
between the points of substantial support as
indicated in Fig.2.7.6.4.1.

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pressure on convex surface is to be determined

by the following formula:

CpR o
t= + 0.75 [mm]
608
where,

t and p are as defined in Sec.1;

Ro = outer radius of curvature of furnace [mm];

2x
C= or 0.85, whichever is greater
x +σ
where,

x and σare as defined in 2.7.5.6.

2.7.6.5.2 In no case is the minimum thickness to

Ro
exceed 22.5 mm, or the ratio to
(t − 0.75)
exceed 100.

2.7.6.6 Ogee rings

2.7.6.6.1 The minimum thickness, t, of the ogee

ring which connects the bottom of the furnace to
the shell of a vertical boiler and sustains the
whole vertical load on the furnace is to be
determined by the following formula:
2.7.6.4.2 For furnaces under 760 [mm] in
external diameter, the thickness is to be not less p D i (D i − D o )
than 8 mm, and for furnaces 760 [mm] in t= + 0.75 [mm]
external diameter and over, the thickness is to 9000
be not less than 9.5 [mm]. Furnaces exceeding
1700 [mm] in external diameter will be subject of where,
special consideration.
t and p are as defined in Sec.1;
2.7.6.4.3 A circumferential row of stays
connecting the furnace to the shell will be Di = inside diameter of boiler shell [mm];
considered to provide substantial support to the
furnace, provided that: Do = outside diameter of lower part of the
furnace where it joins the ogee ring [mm].
a) the diameter of the stay is not less than 22.5
[mm] or twice the thickness of the furnace, 2.7.6.7 Uptakes of vertical boiler
whichever is the greater. In case of screwed
stays the diameter is to be measured over 2.7.6.7.1 The minimum thickness, t, of internal
the threads; uptakes of vertical boiler is to be determined by
the following formulae, the greater of the two
b) the pitch of the stays at the furnace does not thicknesses being taken:
exceed 14 times the thickness of the
furnace. p D o (L + 610)
t= + 4 [mm]
2.7.6.5 Hemispherical furnaces 102400

2.7.6.5.1 The minimum thickness, t, of pD o L

unsupported hemispherical furnaces subject to t= + + 4 [mm]
1100 320

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2.7.7.3.2 For a stay tube or bar stay, the net
where, area to be supported is to be the area [mm2],
enclosed by the lines bisecting at right angles
t and p are as defined in Sec.1; the lines joining the stay and the adjacent points
of support, less the area of any tubes or stays
Do = external diameter of uptake [mm]; embraced. In the case of a stay tube or bar stay
in the boundary rows, the support afforded by
L = length of uptake between the centers of the flat plate margin, where applicable, should
points of substantial support [mm]. be taken into account.

2.7.7 Stay tubes and bar stays for cylindrical 2.7.7.3.3 Where there are no stay tubes in the
boilers tube nest, the area to be supported by a bar
stay is to extend to the tangential boundary of
2.7.7.1 Stay tubes the tube nest.

2.7.7.1.1 Each stay tube is to be designed to 2.8 Access arrangements

carry its due proportion of the load on the plates
which it supports. No stay tube is to be less than 2.8.1 General
5 [mm] thick at its thinnest part.
2.8.1.1 All pressure vessels are to be so made
2.7.7.1.2 The thickness of stay tubes welded to that the internal surfaces may be examined.
the tube plates is to be such that the maximum Wherever practicable, the openings for this
stress on the thinnest part of the tube does not purpose are to be sufficiently large for access
exceed 69 [N/mm2]. and for cleaning the inner surfaces.

2.7.7.1.3 Welded-in stay tubes are to be 2.8.1.2 Manholes in cylindrical shells should
expanded into tube plate in addition to welding. preferably have their shorter axes arranged
longitudinally, and are to be located clear of the
2.7.7.1.4 Stay tubes may be welded into the welded joints in the shell.
boiler after stress relief, provided they are not
adjacent in the same tube nest. 2.8.1.3 Doors for manholes and sightholes are
to be formed from steel plate or of other
2.7.7.2 Combustion chamber and longitu- approved construction, and all jointing surfaces
dinal bar stays. are to be machined.

2.7.7.2.1 The permissible stress in combustion 2.8.1.4 Doors of the internal type are to be
chamber and other similar bar stays, calculated provided with spigots which have a clearance of
on minimum sectional area, is not to exceed 62 not more than 1.5 [mm] all round, i.e. the axes of
[N/mm2]. the opening are not to exceed those of the door
by more than 3 [mm].
2.7.7.2.2 The diameter of any stay is to be not
less than 19 [mm]. 2.8.1.5 Doors of the internal type for openings
not larger than 230 x 180 [mm] need be fitted
2.7.7.2.3 The permissible stress in longitudinal with only one stud, which may be forged integral
stays, calculated on the minimum cross- with the door. Larger doors are to be provided
sectional area, is not to exceed: with two studs screwed through the door and
fitted with nuts on the inside. Alternatively, bolts
minimum specified tensile strength [N/mm 2 ] may be used, screwed through the door with the
heads inside. Other methods of attachment may
5.3 be accepted, provided that details are submitted
for consideration.
2.7.7.2.4 In no case is the diameter of the
longitudinal stays at any section to be less than 2.8.1.6 The crossbars or dogs for doors are to
25 [mm]. be of steel.

2.7.7.3 Loads on stay tubes and bar stays 2.8.1.7 Circular flat cover plates may be fitted to
raised circular manhole frames not exceeding
2.7.7.3.1 Stay tubes and bar stays are to be 400 [mm] diameter, and for an approved design
designed to carry the whole load due to pressure not exceeding 18 bar. Thickness of the
pressure on the area to be supported. frames are to be not less than 19 [mm] in all
parts. The circular cover plates and joint flanges
for such frames are to be not less than:-

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2.9 Shell type exhaust gas heated

a) 25 [mm] thick for an approved design economizers that may be isolated from the
pressure: ≤ 8.6 bar; steam plant system

b) 29 [mm] thick for an approved design 2.9.1 Scope

pressure: > 8.6 bar ≤ 14.5 bar;
2.9.1.1 This requirement is applicable to shell
c) 32 [mm] thick for an approved design type exhaust gas heated economizers that are
pressure: > 14.5 bar ≤ 18 bar. intended to be operated in a flooded condition
and that may be isolated from the steam plant
2.8.1.8 The cover plates are to be provided with system and intended to be fitted on board ships
spigots and are to be secured by at least 16 contracted for construction on or after 1 January
bolts not less than 25 [mm] diameter, so that the 2007.
stress in the bolts at the root of the thread due to
pressure does not exceed: 2.9.2 Design and construction

- 34 [N/mm2] for 25 [mm] diameter bolts 2.9.2.1 Design and construction of shell type
economizers are to pay particular attention to
- 41 [N/mm2] for 28 [mm] diameter bolts the welding, heat treatment and inspection
arrangements at the tube plate connection to the
- 45 [N/mm2] for 32 [mm] diameter bolts shell.

2.8.1.9 For the purpose of calculation, the 2.9.2.2 Every shell type economizer is to be
pressure may be assumed to act on the whole provided with a means of indicating the internal
area within the pitch circle of the bolts. pressure and to be located so that the pressure
can be easily read from a position from which
2.8.1.10 For smaller circular openings in the pressure may be controlled.
headers and similar fittings, an approved type of
plug may be used. 2.9.2.3 Every shell type economizer is to be
provided with removable lagging at the
2.8.2 Additional requirements for boilers, circumference of the tube end plates to enable
superheaters, economizers, and similar ultrasonic examination of the tube plate to shell
vessels connection.

2.8.2.1 In water tube boilers, manholes are to be 2.9.3 Feed water

provided in all drums of sufficient size to allow
access for internal examinations and cleaning 2.9.3.1 Every economizer is to be provided with
and for fitting and expanding the tubes. In the arrangements for pre-heating and de-aeration,
case of headers for water walls, superheaters or addition of water treatment or combination
economizers, and of drums which are too small thereof to control the quality of feed water to
to permit entry, sight holes or mudholes within the manufacturer’s recommendations.
sufficiently large and numerous for these
purposes are to be provided. 2.9.4 Operating instructions

2.8.2.2 Cylindrical boilers are to be provided, 2.9.4.1 The manufacturer is to provide operating
where possible, with means for ingress to permit instructions for each economizer and is to
examination and cleaning of the inner surfaces include reference to:
of plates and tubes exposed to flame. Where the
boilers are too small to permit this there are to - Feed water treatment and sampling
be sightholes and mudholes sufficiently large arrangements.
and numerous to allow the inside to be
satisfactorily cleaned. - Operating temperatures – exhaust gas and
feed water temperatures.
2.8.2.3 Where the cross tubes of vertical boilers
are large, there is to be a sight hole in the shell - Operating pressure.
opposite to one end of each tube sufficiently
large to allow the tube to be examined and - Inspection and cleaning procedures.
cleaned. These sight holes are to be in positions
accessible for that purpose. - Records of maintenance and inspection.

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- The need to maintain adequate water flow
through the economizer under all operating - Procedures for using the exhaust gas
conditions. economizer in the dry condition.

- Periodical operational checks of the safety - Procedures for maintenance and overhaul
devices to be carried out by the operating of safety valves.
personnel and to be documented
accordingly.

Section 3

Fittings and Mountings

3.1 General 3.2.1.2 The valves, spindles, springs and

compression screws are to be so encased and
3.1.1 All valves over 38 [mm] diameter are to be locked or sealed that the safety valves and pilot
fitted with outside screws, and the covers are to valves after setting to the working pressure,
be secured by bolts or studs. All valves are to be cannot be tampered with or overloaded in
arranged to shut with a right-hand (clockwise service. The spring casing of superheater safety
rotation) motion of the wheels. valves should be ventilated, or other
arrangements provided to protect the springs
3.1.2 Construction and arrangement of valves from excessive temperature.
and cocks are to be such that it can be seen
without difficulty whether they are open or shut, 3.2.1.3 Valves are to be so designed that in the
preferably by fitting a suitable indicator. event of fracture of springs they cannot lift out of
their seats.
3.1.3 Where boiler mountings are secured by
studs, the studs are to have a full thread holding 3.2.1.4 Easing gear is to be provided for lifting
in the plate for a length of at least one diameter. the safety valves and is to be operable by
If the stud hole penetrates the whole thickness mechanical means at a safe position from the
of the plate, the stud is to be screwed right boiler or engine room platforms.
through the plate and is to be fitted with a nut
inside the boiler. Where bolts are used for 3.2.1.5 Safety valves are to be made with
securing mountings, they are to be screwed working parts having adequate clearances to
right through the plate with their heads inside ensure complete freedom of movement.
the boiler.
3.2.1.6 Valve seats are to be effectively secured
3.1.4 Safety valve chests and other boiler and in position. Any adjusting devices which control
superheater mountings subject to pressures discharge capacity are to be positively secured
exceeding 10.3 bar or to steam temperatures so that the adjustment will not be affected when
exceeding 218°C, and boiler blow-down fittings, the safety valves are dismantled at surveys.
are to be made of steel or other approved
material. 3.2.1.7 All the safety valves of each boiler and
steam generator may be fitted in one chest,
3.1.5 Adequate arrangements are to be which is to be separate from any other valve
provided for draining and venting the separate chest and is to be connected directly to the shell
parts of each pressure vessel. by a strong and stiff neck, the passage through
which is to be of cross-sectional area not less
3.2 Safety valves than the aggregate area of the safety valves in
the chest in case of full lift valves, and one half
3.2.1 For boilers and steam generators of that area in case of other valves.

3.2.1.1 Boilers and steam generators are to be 3.2.1.8 Each safety valve chest is to be drained
fitted with not less than two safety valves, each by a pipe fitted to the lowest part and led with a
having a minimum internal diameter of 25 [mm], downward gradient to the bilges or to a tank,
but those having a total heating surface of less clear of the boilers. No valves or cocks are to be
than 50 [m2] may have one valve not less than fitted to these drain pipes. It is recommended
50 [mm] diameter. that the bore of the drain pipes be not less than
19 [mm].

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3.2.1.9
Where a superheater, reheater or economizer is
a) Where a shell type economizer is capable of fitted with a valve between one of these and the
being isolated from the steam plant system, it is boiler, the unit is to have appropriate safety
to be provided with at least one safety valve and valves. Such safety valves are not to be
when it has a total heating surface of 50 [m2] or regarded as safety valves for the boiler.
more, it is to be provided with at least two safety
valves. 3.2.1.13 Where it is impracticable to attach
safety valves directly to the superheater, the
b) Such safety valves for shell type exhaust gas valves are to be located as near as possible
heated economizers are to incorporate features thereto and fitted to a branch piece connected to
that will ensure pressure relief even with solid the superheater outlet pipe.
matter deposits on the valve and guide, or
features that will prevent the accumulation of 3.2.1.14 In high temperature installations the
solid matter in way of the valve and in the drains from safety valves are to be led to a tank
clearance between the valve spindle and guide. or other place where high temperature steam
can be safely discharged.
c) Alternatively a bursting disc discharging to
suitable waste steam pipe is to be fitted in 3.2.1.15 The designed discharge capacities of
addition to the valve. The alternative the safety valves on each boiler and steam
arrangements for ensuring pressure relief in the generators are to be found from the following
event of solid matter on the valve and guide are formulae :
to function at a pressure not exceeding 1.25
times the economizer approved design pressure Saturated steam safety valves
and are to have sufficient capacity to prevent
damage to the economizer when operating at its AC (p + 1.03)
design heat input level. Full particulars of the E=
proposed arrangements are to be submitted for 98.1
consideration.
Superheated steam safety valves
d) To avoid the accumulation of solid matter
deposits on the outlet side of safety valves and AC (p + 1.03) vs
bursting discs, the discharge pipes and safety E=
valve / bursting disc housings are to be fitted 98.1 vh
with drainage arrangements from the lowest part
and led with a downward gradient to the bilges where,
or to a tank, clear of the economizer, where it
will not pose threat to either personnel or E = the maker's specified peak load
machinery. evaporation, in [kg/hour] (including all
evaporation from waterwalls, integral, or
e) Where a steam receiver is fitted with safety steaming economizers and other heating
valves to relieve the steam output of the surfaces in direct communication with the
economizer and the economizer cannot be boiler). In no case is the designed evaporation
isolated from the receiver, the requirements of to be based on less than 29 [kg/m2] hour of
3.2.1.9 (b) & (c) may be waived. heating surface for fired boiler and 14.5 [kg/m2]
hour for exhaust gas heated boilers;
3.2.1.10 Full details of the proposed
arrangements to satisfy 3.2.1.9(a) to 3.2.1.9(e) A = for ordinary, high lift or improved high lift
2
are to be submitted for approval. safety valves, the aggregate area, in [mm ], of
the orifices through the seatings of the valves,
3.2.1.11 In case of watertube boilers, each neglecting the area of guides and other
saturated steam drum and each superheater are obstructions;
to be provided with at least one safety valve.
= for full lift safety valves, the net aggregate
2
3.2.1.12 When a boiler is fitted with an integral area, in [mm ], through the seats after deducting
superheater without any intervening stop valve, the area of the guides or other obstructions
the safety valve(s) on the superheater may be when fully lifted;
considered as boiler safety valve(s). The safety
valves are to be so proportioned and positioned C = 4.8 for valves of ordinary type, having a
that when relieving, sufficient steam is forced minimum lift of D/24;
through the superheater to prevent damage to
the heater.

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= 7.2 for valves of high lift type, having a valves to be set to a pressure higher than 3 per
minimum lift of D/16; cent above the design pressure of the boiler.

= 9.6 for valves of improved high lift type 3.2.1.19 Tests for accumulation of pressure are
having a minimum lift of D/12; to be carried out. The boiler pressure is not to
rise more than 10 per cent above the design
= 19.2 for valves of full lift type having a pressure, when the boiler stop valves are closed
minimum lift of D/4; under full firing conditions. The duration of the
accumulation test is to be 15 minutes for smoke-
D = bore of valve seat [mm]; tube boilers and 7 minutes for water-tube
boilers. During this test, no more feed water is to
p = design pressure, in bar; be supplied than is necessary to maintain a safe
working water level.
= specific volume of saturated steam [m3/kg];
3.2.1.20 For ordinary, high lift and improved high
Vh = specific volume of superheated steam lift type valves, the cross-sectional area of the
[m3/kg]. waste steam pipe and passages leading to it is
to be at least 10 per cent greater than the
3.2.1.16 When the discharge capacity of a aggregate area of the safety valves as used in
safety valve of approved design has been the formulae in 3.2.1.15. For full lift and other
established by type tests, carried out in the approved valves of high discharge capacity, the
presence of the Surveyors or by an independent cross-sectional area of the waste steam pipe
authority recognized by IRS, on valves and passages is to be not less than 0.1C times
representative of the range of sizes and the aggregate valve area.
pressures intended for marine application,
consideration will be given to the use of a 3.2.1.21 The cross-sectional area of the main
constant higher than C=19.2, based on 90 per waste steam pipe is to be not less than the
cent of the measured capacity up to a maximum combined cross-sectional areas of the branch
of C = 45 for full lift safety valves. waste steam pipes leading thereto from the
boiler safety valves. In case of water tube
3.2.1.17 Where boilers are not fitted with boilers, each boiler should have a separate
superheater, the safety valves are to be set to waste steam system to atmosphere.
open at a pressure of not more than 3 per cent
above the approved design pressure, and in no 3.2.1.22 Waste steam pipes are to be led to the
case at a pressure higher than : atmosphere and are to be adequately supported
and provided with suitable expansion joints,
a) the design pressure of the steam piping; or bends or other means to relieve the safety valve
chests of undue loading.
b) the least sum of the design pressure of the
machinery connected to the boiler and the 3.2.1.23 The scantlings of waste steam pipes
pressure drop in the piping between this and silencers are to be suitable for the
machinery and the boiler. maximum pressure to which the pipes may be
subjected in service, and in any case not less
3.2.1.18 Where boilers are fitted with than 10.0 bar.
superheaters, the safety valves on the
superheaters are to be set to a pressure not 3.2.1.24 Silencers fitted to waste steam pipes
higher than : are to be so designed that the clear area
through the baffle plates is not less than that
a) the design pressure of the steam piping; or required for pipes.

b) the least sum of the design pressure of the 3.2.1.25 The safety valves of each exhaust gas
machinery connected to the boiler and the heated economizer/and each exhaust gas
pressure drop in the piping between this heated boiler which may be used as an
machinery and the boiler. economizer are to be provided with entirely
separate waste steam pipes.
The safety valves on the boiler drum are to be
set to a pressure not less than the superheater 3.2.1.26 External drains and exhaust steam
valve setting plus 0.35 bar plus the pressure vents to atmosphere are not to be led to waste
drop through the superheater, when the boiler steam pipes.
stop valves are closed and the superheater
safety valves are relieving at their rated
capacity. In no case, however, are the safety

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3.2.1.27 It is recommended that a scale trap and discharge from safety valves or fusion plugs on
means for cleaning be provided at the base of air receivers is to be led to open deck outside
each waste steam pipe. machinery spaces, alternatively, the quantity of
gas for fire fighting purposes is to be increased
3.2.1.28 In installations operating with a high to such an extent that the efficiency of the fire
degree of superheat, consideration is to be extinguishing installation is not affected.
given to the high temperatures which waste
steam pipes, silencers and surrounding spaces 3.3 Stop valves
will attain when the superheater safety valves
are blowing during accumulation tests and in 3.3.1 Boilers and steam generators
service. Adequate protection against heat
effects is to be provided to Surveyor's 3.3.1.1 One main stop valve is to be fitted to
satisfaction. each boiler and located as near the boiler as
practicable. There are to be as few auxiliary stop
3.2.1.29 Waste steam pipes are to be led well valves as possible so as to avoid piercing the
clear of electric cables and any parts or boiler shell than is absolutely necessary.
structures sensitive to heat or likely to distort,
the pipes are to be insulated where necessary. 3.3.1.2 Where two or more boilers are
connected together :
3.2.2 For pressure vessels other than boilers
and steam generators a) the steam connections for each boiler are to
be provided with two stop valves with a
3.2.2.1 Each pressure vessel system or each drain connection between them. The valve
pressure vessel which can be isolated, is to be nearest to the boiler is to be a non-return
provided with arrangements to prevent valve;
overpressure.
b) essential services are to be capable of
3.2.2.2 Pressure vessels intended to operate being supplied from at least two boilers.
completely filled with liquid are to have a liquid
relief valve unless otherwise protected against 3.3.2 Pressure vessels other than boilers and
overpressure. steam generators

3.2.2.3 Where a pressure vessel is fitted with 3.3.2.1 Each pressure vessel or system is to be
heating coils, and fracture in the coils may fitted with a stop valve situated as close as
increase the normal pressure of fluid in the possible to the shell.
pressure vessel, the relieving capacity of the
safety device is to be sufficient to take into 3.4 Water level indicators
account the fracture of one tube.
3.4.1 Every boiler and steam-heated steam
3.2.2.4 The total capacity of the safety valves, generator is to be fitted with at least two
fitted to any pressure vessel or system of independent means of indicating the water level
pressure vessels, is to be sufficient to discharge in it, one of which is to be a gauge glass. The
the maximum quantity of fluid (liquid or gaseous) other means is to be either an additional gauge
that can be generated or supplied without glass or an approved equivalent device.
causing a rise in the pressure of more than 10
per cent above the design pressure. 3.4.2 Where a steam and water drum exceeding
4 [m] in length is fitted athwartships, two gauge
3.2.2.5 The safety valves are to be set to open glasses are to be fitted in suitable positions, one
at a pressure of not more than 3 per cent above near each end of the drum.
the design pressure.
3.4.3 The water gauges are to be readily
3.2.2.6 The use of bursting discs or a accessible and placed so that the water level is
combination of bursting discs and safety valves clearly visible. The lowest visible part of the
instead of safety valves is subject to special glass of the water gauge is to be situated at the
consideration in each case. lowest safe working water level.

3.2.2.7 The discharge from safety valves is to be a) In the case of water-tube boilers, the water
led to a place where no hazard will be created gauge glasses are to be located so that
by the contents being discharged. water is just showing when the water level in
the steam drum is just above the top row of
3.2.2.8 Where a gas is used for fire tubes when the boiler is cold (generally
extinguishing in the machinery spaces, the about 25 [mm] above).

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to the burners when the water level falls to a
b) In water-tube boilers, the tubes of which are predetermined low level.
not entirely drowned when cold, the water
gauge glasses are to be placed, to the 3.6 Feed check valves
Surveyor's satisfaction, in the positions
which have been found by experience to 3.6.1 Each main boiler or auxiliary boiler for
indicate satisfactorily that the water content essential services and each steam-heated
is sufficient for safety when the boiler is steam generator is to have two independent
worked under all service conditions. feed pipes; each feed pipe is to be provided with
two feed check valves. Boiler heated exclusively
c) The level of the highest part of the effective by exhaust gases may have only one feed pipe
heating surfaces, e.g. combustion chamber and with one feed check valve.
top of a horizontal boiler and the furnace
crown of a vertical boiler, is to be clearly 3.6.2 The feed check valves are to be attached,
marked in a position adjacent to the water wherever practicable, direct to the boiler, but
gauge glass. where the arrangements necessitate the use of
standpipes between the boiler and the check
3.4.4 The length of the water gauge glasses is valves, these pipes are to be of steel or other
to be sufficient for verifying the water levels in approved material. For boiler feed water
case of alarm and oil supply cut-off. systems, See Ch.3, Sec.6.

3.4.5 The cocks of all water gauges are to be 3.6.3 In boilers, where economizer forms an
operable from positions free from danger in the integral part of the boiler, and where the
event of the glass breaking. arrangements necessitate the use of a common
inlet pipe on the economizer for both main and
3.4.6 If the water gauges are not fitted directly to auxiliary feed systems, this pipe is to be as short
the shell of the boiler, but to stand pillars or as practicable, and the arrangement of check
columns, it is desirable that these pillars or valves is to be such that either feed line can be
columns should be bolted directly to the shell of effectively isolated without interruption of the
the boiler. If they are connected to the boiler by feed water supply to the boiler.
means of pipes, the pipes are to be fitted with
terminal cocks, not valves, secured direct to the 3.6.4 The feed check valves are to be fitted with
boiler shell. efficient gearing, whereby they can be
satisfactorily worked from the stokehold floor, or
a) For boilers exceeding 3 [m] in diameter, the other convenient position.
pillars are to be not less than 63 mm, and
the connecting pipes not less than 38 [mm] 3.6.5 Standpipes on boiler, for feed inlet, are to
internal diameter. For boilers exceeding 2.3 be designed with an internal pipe to prevent
[m] but not exceeding 3 [m] in diameter, the direct contact between the feed pipe and the
pillars are to be not less than 50 [mm] and boiler shell or end plates with the object of
the pipes not less than 32 [mm] internal minimizing thermal stresses in these plates.
diameter. Similar arrangements are to be provided for
desuperheater and other connections, where
b) The upper ends of the connecting pipes are significant temperature difference occur in
to be so arranged that there is no pocket or service.
bend where an accumulation of water from
the condensation of the steam can lodge. 3.7 Pressure gauges
They should not pass through the uptake if
they can be otherwise arranged. If, 3.7.1 Each boiler and superheater is to be
however, this condition cannot be complied provided with a steam-pressure gauge.
with, they may pass through it by means of
a passage at least 50 [mm] clear of the pipe 3.7.2 The pressure gauges are to be placed
all round, open for ventilation. where they are easily read. The highest
permissible working pressure is to be marked off
3.5 Low water level fuel shut-off and alarm on pressure gauge in red.

3.5.1 Each fired boiler is to be fitted with a 3.8 Blow-down and scum valves
system of water level detection which is to be
independent of any other mounting on the boiler 3.8.1 Each boiler is to be fitted with at least one
and which will operate audible and visible blow-down valve secured to the lower part of the
alarms and shut-off automatically the fuel supply boiler.

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3.8.2 Where it is not practicable to attach the down non- return valves fitted for each boiler to
blow-down valve direct to water-tube boilers, the prevent the possibility of the contents of one
valve may be placed immediately outside the boiler passing to another.
boiler casing with a steel pipe of substantial
thickness fitted between the boiler and valve. 3.8.5 The blow-down cock or valve on the ship's
The pipe and valve are to be suitably supported side is to be fitted in a readily accessible
and any pipe which may be exposed to direct position, above the level of the floor plates, and
heat from the furnace is to be adequately is to be arranged such that it can be readily
protected. seen whether it is open or shut. The cock handle
is not to be removable unless the cock is shut,
3.8.3 The blow-down valve and its connections and if a valve is fitted, the wheel is to be fixed to
to the sea need not be more than 38 [mm], and the spindle.
is to be not less than 19 [mm] internal diameter.
For cylindrical boilers the size of the valve may 3.9 Salinometer valve or cock
be generally 0.0085 times the diameter of the
boiler. 3.9.1 Each boiler is to be provided with a
salinometer valve or cock secured direct to the
3.8.4 Blow-down valves and scum valves boiler in a convenient position. The valve or
(where the latter are fitted) of two or more boiler cock is not to be on the water gauge standpipe.
may be connected to one common discharge,
but where thus arranged there are to be screw-

Section 4

Hydraulic Tests

4.1 Boilers (fired and exhaust gas heated), assembly is to be tested to 1.25 times the
economizers, superheaters, reheaters, steam design pressure.
receivers, steam heated generators and
similar vessels 4.1.2 Mountings

4.1.1 General 4.1.2.1 All boiler mountings are to be subjected

to a hydraulic test of twice the approved design
4.1.1.1 Boilers and pressure vessels, together pressure with the exception of feed check valves
with their components are to withstand the and other mountings connected to the main feed
following hydraulic tests without any sign of system which are to be tested to 2.5 times the
weakness or defect. approved boiler design pressure, or twice the
maximum pressure which can be developed in
4.1.1.2 Having regard to the variation in the the feed line in normal service, whichever is
types and design of boilers, the hydraulic test greater.
may be carried out by either of the methods
indicated below: 4.2 Other pressure vessels

a) Boilers are to be tested on completion to a 4.2.1 General

pressure 1.5 times the approved design
pressure; or 4.2.1.1 Pressure vessels are to be tested on
completion to a pressure, pt, determined by the
b) Where construction permits, all components following formula, without showing signs of
of the boiler are to be tested on completion weakness or defect :-
of the work including heat treatment to 1.5
times the design pressure. In the case of σ 50 t
components such as drums or headers, p t = 1.3 p
which are to be drilled for tube holes, the σT t − 0.75
test may be made before drilling the tube
holes, but is to be after the attachment of t
standpipes, stubs and similar fittings and but in no case is to exceed 1.5 p
t − 0.75
also after heat treatment has been carried
out. Where all the components have been
where,
tested as above, each completed boiler after

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pt = test pressure, in bar σT = allowable stress at design temperature
[N/mm2].
p = design pressure, in bar
4.2.2 Mountings
t = nominal thickness of shell as indicated on the
plan [mm] 4.2.2.1 Mountings are to be subjected to a
hydraulic test of twice the approved design
σ50 = allowable stress at 50°C [N/mm2] pressure.

End of Chapter

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Page 1 of 11
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Chapter 6

Steering Gear

Contents
Section

1 General
2 Performance
3 Construction and Design
4 Steering Control Systems
5 Electric Power Circuits, Electric Control Circuits, Monitoring and Alarms
6 Emergency Power
7 Testing and Trials
8 Additional Requirements
9 Guidelines for the Acceptance of Non-duplicated Rudder Actuators for Tanker,
Chemical Tankers or Gas Carriers of 10,000 tons gross and upwards but of less
than 100,000 tonnes Deadweight

Section 1

General

1.1 Scope 1.2.2 Main steering gear means the machinery,

rudder actuator(s), the steering gear power
1.1.1 The requirements of this Chapter apply to units, if any, and ancillary equipment and the
the design and construction of steering gear. means of applying torque to the rudder stock
(e.g. tiller or quadrant) necessary for effecting
1.1.2 Whilst the requirements of this Chapter are movement of the rudder for the purpose of
considered to meet the relevant regulations of steering the ship under normal service
the Safety of Life at Sea 1974 and applicable conditions.
amendments, attention should be given to any
relevant statutory requirements of the National 1.2.3 Steering gear power unit means :
Authority of the country in which the ship is to be
registered. a) in the case of electric steering gear, an
electric motor and its associated electrical
1.1.3 Consideration will be given to other cases, equipment;
or to other arrangements which are equivalent to
those required by the Rules. b) in the case of electrohydraulic steering gear,
an electric motor and its associated
1.2 Definitions electrical equipment and connected pump;

1.2.1 Steering gear control systems means c) in the case of other hydraulic steering gear,
the equipment by which orders are transmitted a driving engine and connected pump.
from the navigating bridge to the steering gear
power units. Steering gear control systems 1.2.4 Auxiliary steering gear means the
comprise transmitters, receivers, hydraulic equipment other than any part of the main
control pumps and their associated motors, steering gear necessary to steer the ship in the
motor controllers, piping and cables. event of failure of the main steering gear but not
including the tiller, quadrant or components
serving the same purpose.

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Chapter 6 Part 4
Page 2 of 11 Steering Gear

1.6 Materials
1.2.5 Power actuating system means the
hydraulic equipment provided for supplying 1.6.1 All the steering gear components and the
power to turn the rudder stock, comprising a rudder stock are to be of sound and reliable
steering gear power unit or units, together with construction to the Surveyor's satisfaction.
associated pipes and fittings, and a rudder
actuator. The power actuating systems may 1.6.2 All components transmitting mechanical
share common mechanical components, i.e. forces to the rudder stock are to be tested
tiller, quadrant and rudder stock, or components according to the requirements of Pt.2.
serving the same purpose.
1.6.3 Ram; cylinders; pressure housing of rotary
1.2.6 Maximum ahead service speed means vane type actuators; hydraulic power piping;
the greatest speed which the ship is designed to valves; flanges and fittings; and all steering gear
maintain in service at sea at her deepest components transmitting mechanical forces to
seagoing draught. the rudder stock (such as tillers, quadrants, or
similar components) are to be of steel or other
1.2.7 Rudder actuator means the compo- approved ductile material, duly tested in
nent(s) which converts directly hydraulic accordance with the requirements of Pt.2. In
pressure into mechanical action to move the general, such material is not to have an
rudder. elongation of less than 12 per cent nor a tensile
strength in excess of 650 [N/mm2]. The use of
1.2.8 Maximum working pressure means the ductile (nodular) iron castings will be acceptable
expected pressure in the system when steering provided the material has an elongation of not
gear is operated to comply with 2.1.2(b). less than 12 per cent.

1.3 Installation 1.7 Rudder, rudder stock, vanes, tiller and

quadrant
1.3.1 The steering gear is to be secured to the
seating by fitted bolts, and suitable chocking 1.7.1 For the requirements regarding rudder,
arrangements are to be provided. The seating is rudder stock, See Pt.3, Ch.14.
to be of substantial construction.
1.7.2 All components transmitting mechanical
1.4 Steering gear compartment forces to the rudder stock are to have a strength
of at least equivalent to the rudder stock in way
1.4.1 The steering gear compartment is to be : of the tiller. The resultant equivalent stress, σe,
caused by the transmission of rudder torque, Qr,
a) Readily accessible and, as far as in tillers, vanes and other power transmitting
2
practicable separated from machinery components is not to exceed 118/k [N/mm ], i.e.
spaces;

b) Provided with suitable arrangements to σ e = σ 2 + 3τ 2 ≤ 118 / k [N/mm 2 ]

ensure working access to steering gear
machinery and controls. These where,
arrangements are to include handrails and
gratings or other non-slip surfaces to ensure σe = The combined equivalent stress, [N/mm2]
suitable working conditions in the event of
hydraulic fluid leakage. σ = The bending stress, [N/mm2]

τ= The torsional shear stress, [N/mm ]

1.5 Plans 2

1.5.1 Before starting construction, all relevant k = Material factor for the component under
plans and specifications are to be submitted for consideration as defined in Pt.3, Ch.14, Sec.1;
approval in triplicate.
Qr = The rudder torque calculated as per Pt.3,
1.5.2 These plans should give details of Ch.14, Sec.3.2 [N-m].
scantlings and materials of the steering gear
together with proposed rated torque and all relief 1.7.3 The section modulus 'Z' [cm3] and the
valve settings. sectional area 'A' [cm2] of the tiller arms is not to
be less than the following:

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⎛ x⎞
Z = 0.012 Q r ⎜1 − ⎟ k [cm 3 ] n = Total number of joining bolts.
⎝ R⎠
k = Material factor for the bolts.
Q
A = 2.0 r k x 10 − 4 [cm 2 ] ks = Material factor for the rudder stock material.
R
1.7.7 The dimensions of the key are to comply
where, with the requirements of Pt.3, Ch.14, Sec.6.2.
R = The distance [m] from the point of 1.7.8 Where higher tensile bolts are used on
application of the effort on the tiller to the centre bolted tillers and quadrants, the yield and
of rudder stock; and ultimate tensile stresses of the bolt material are
to be stated on the plans submitted for approval,
x = The distance [m] from the section under together with full details of the methods to be
consideration to the centre of the rudder stock. adopted to obtain the required setting-up stress.
Where patent nuts or systems are used, the
1.7.4 The boss may be fitted on the rudder stock manufacturer's instructions for assembly should
by shrinking with/without key or may be of the be adhered to.
split type. The ratio between the mean of outer
and inner diameters of the boss is to be not less 1.7.9 In bow rudders having a vertical locking
than 1.75 and the height of the boss is not to be pin operated from the deck above, positive
less than the inner diameter of the boss. means are to be provided to ensure that the pin
can be lowered only when the rudder is exactly
1.7.5 Co-efficient of friction for shrink fitting is to central. In addition, an indicator is to be fitted at
be taken as specified in Pt.3, Ch.14, Sec.6.3. the deck to show when the rudder is exactly
central.
1.7.6 In case of split type boss, the total number
of joining bolts is to be at least 4. The distance 1.8 Mechanical steering gear
of the centre of the bolts from the centre of the
rudder stock is generally to be 1.15du and the 1.8.1 Steel-wire rope, chain and other
thickness of the coupling flange is to be at least mechanical systems, when these are used for
1.1 times the required bolt diameter. The rudder stock diameters of 120 [mm] and less but
thickness of shim to be fitted between two excluding allowance for strengthening in ice, will
halves before machining is to be 0.0015du. The be specially considered. In general the breaking
diameter of the coupling bolt, db is to be not less strength of rods/chains etc. is not to be less
than : than:

du k Qr
d b = 0.60 [mm] Breaking strength = 6 N
(nks) R

where, Where R is defined in 1.7.3.

du = The rudder stock diameter [mm] in way of

the tiller calculated in accordance with Pt.3,
Ch.14, Sec.5;

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Section 2

Performance

2.1 General deepest seagoing draught and running

ahead at one half of the maximum ahead
2.1.1 Unless the main steering gear comprises service speed or 7 knots, whichever is the
of two or more identical power units, in greater; and
accordance with 2.1.4 or 8.1.1, every ship is to
be provided with a main steering gear and an c) Operated by power where necessary to
auxiliary steering gear in accordance with the meet the requirements of (b) and in any
requirements of the Rules. The main steering case when the Rules, excluding
gear and the auxiliary steering gear are to be so strengthening for navigation in ice, require a
arranged that the failure of one of them will not rudder stock over 230 [mm] diameter in way
render the other one inoperative. of the tiller. (See 2.1.1).

The rudder stock diameters mentioned in 2.1.4 Where the main steering gear comprises
2.1.2c), 2.1.3c) and 6.1.1 are to be taken as two or more identical power units, an auxiliary
having been calculated for mild steel with yield steering gear need not be fitted, provided that :
strength of 235 [N/mm2].
a) In a passenger ship, the main steering gear
2.1.2 The main steering gear and rudder stock is capable of operating the rudder as
are to be : required by 2.1.2 (b) while any one of the
power units is out of operation;
a) Of adequate strength and capable of
steering the ship at maximum ahead speed b) In a cargo ship, the main steering gear is
which is to be demonstrated in accordance capable of operating the rudder as required
with 7.2; by 2.1.2 (b) while operating with all power
units;
b) Capable of putting the rudder over from 35°
on one side to 35° on the other side with the c) The main steering gear is arranged so that
ship at its deepest seagoing draught and after a single failure in its piping system or in
running ahead at maximum ahead service one of the power units the defect can be
speed and under the same conditions, from isolated so that steering capability is
35° on either side to 30° on the other side in regained.
not more than 28 seconds;
2.1.5 Main and auxiliary steering gear power
c) Operated by power where necessary to units are to be:
meet the requirements of (b) and in any
case when the Rules, excluding a) Arranged to re-start automatically when
strengthening for navigation in ice, require a power is restored after a power failure;
rudder stock over 120 [mm] diameter in way
of the tiller (See 2.1.1); and b) Capable of being brought into operation
from a position on the navigating bridge. In
d) So designed that they will not be damaged the event of a power failure to any one of
at maximum astern speed; however, this the steering gear power units, an audible
design requirement need not be proved by and visual alarm is to be given on the
trials at maximum astern speed and navigating bridge;
maximum rudder angle.
c) Arranged so that transfer between units can
2.1.3 The auxiliary steering gear is to be : be readily effected.

a) Of adequate strength and capable of 2.1.6 Where the steering gear is so arranged
steering the ship at navigable speed and of that more than one power system can be
being brought speedily into action in an simultaneously operated, the risk of hydraulic
emergency: locking caused by a single failure is to be
considered.
b) Capable of putting the rudder over from 15
on one side to 15 on the other side in not
more than 60 seconds with the ship at its

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2.1.7 A means of communication is to be an effort exceeding 16 [kgf] under normal
provided between the navigating bridge and the conditions.
steering gear compartment.
2.2 Rudder angle limiters
2.1.8 Steering gear, other than of the hydraulic
type, will be accepted provided the standards 2.2.1 Power-operated steering gears are to be
are considered equivalent to the requirements of provided with positive arrangements, such as
this Section. limit switches, for stopping the gear before the
rudder stops are reached. These arrangements
2.1.9 Manually operated gears are only are to be synchronized with the gear itself and
acceptable when the operation does not require not with the steering gear control.

Section 3

Construction and Design

3.1 General where,

3.1.1 Rudder actuators other than those covered σB = specified minimum tensile strength of
by 8.3 and Sec.9 are to be designed in material at ambient temperature
accordance with the relevant requirement of
Ch.5 for Class 1 pressure vessels σY = specified minimum yield stress or 0.2 per
(notwithstanding any exemptions for hydraulic cent proof stress of the material, at ambient
cylinders). temperature

3.1.2 Accumulators, if fitted, are to comply with A and B are given by the following table :
the requirements of Ch.5.

3.1.3 The welding details and welding Wrought Cast Nodular

procedures are to be approved. All welded joints Steel Steel Cast Iron
within the pressure boundary of a rudder A 3.5 4 5
actuator or connecting parts transmitting B 1.7 2 3
mechanical loads are to be full penetration type
or of equivalent strength. 3.2 Components
3.1.4 The construction is to be such as to 3.2.1 Special consideration is to be given to the
minimize local concentration of stress. suitability of any essential component which is
not duplicated. Any such essential component is
3.1.5 The design pressure for calculations to to, where appropriate, utilize anti-friction
determine the scantlings of piping and other bearings such as ball bearings, roller bearings
steering gear components subjected to internal or sleeve bearings which are to be permanently
hydraulic pressure is to be at least 1.25 times lubricated or provided with lubrication fittings.
the maximum working pressure to be expected
under the operational conditions specified in 3.2.2 All steering gear components transmitting
2.1.2 (b) taking into account any pressure which mechanical forces to the rudder stock, which are
may exist in the lower pressure side of the not protected against overload by structural
system. Fatigue criteria may be applied for the rudder stops or mechanical buffers, are to have
design of piping and components, taking into a strength at least equivalent to that of the
account pulsating pressures due to dynamic rudder stock in way of the tiller.
loads (See Sec.9).
3.2.3 Oil seals between non-moving parts,
3.1.6 The permissible primary general forming part of the external pressure boundary,
membrane stress is not to exceed the lower of should be of the metal type or of an equivalent
the following values type.

σB σy 3.2.4 Oil seals between moving parts, forming

or part of the external pressure boundary, are to be
A B
duplicated, so that the failure of one seal does

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not render the actuator inoperative. Alternative design pressure. The valves are to be of
arrangements providing equivalent protection adequate size and so arranged as to avoid an
against leakage may be accepted. undue rise in pressure above the design
pressure.
3.2.5 Piping, joints, valves, flanges and other
fittings are to comply with the requirements of 3.3.3 Relief valves, for protecting any part of the
Ch.2 for Class I piping systems components. hydraulic system which can be isolated, required
The design pressure is to be in accordance with by 3.3.2 are to comply with the following:
3.1.5.
a) The setting pressure is not to be less than
3.2.6 Hydraulic power operated steering gears 1.25 times the maximum working pressure.
are to be provided with the following :-
b) The minimum discharge capacity of the
a) Arrangements to maintain the cleanliness of relief valve(s) is not to be less than 110 per
the hydraulic fluid taking into consideration cent of the total capacity of the pumps which
the type and design of the hydraulic system; can deliver through it (them). Under such
conditions the rise in pressure is not to
b) A fixed storage tank having sufficient exceed 10 per cent of the setting pressure.
capacity to recharge at least one power In this regard, due consideration is to be
actuating system including the reservoir, given to extreme foreseen ambient
where the main steering gear is required to conditions in respect of oil viscosity.
be power operated. The storage tank is to
be permanently connected by piping in such 3.4 Flexible hoses
a manner that the hydraulic systems can be
readily recharged from a position within the 3.4.1 Hose assemblies approved by IRS may be
steering gear compartment and provided installed between two points where flexibility is
with a contents gauge. required but are not subjected to torsional
deflection (twisting) under normal operating
3.3 Valve and relief valve arrangement conditions. In general, the hose should be
limited to the length necessary to provide for
3.3.1 For all vessels with non-duplicated flexibility and for proper operation of machinery.
actuators, isolating valves are to be fitted at the (See also Ch.2).
connection of pipes to the actuators, and are to
be directly fitted to the actuator. Arrangements 3.4.2 Hoses should be high pressure hydraulic
for bleeding air from the hydraulic system are to hoses according to recognized standards and
be provided, where necessary. suitable for the fluids, pressures, temperatures
and ambient conditions in question.
3.3.2 Relief valves are to be fitted to any part of
the hydraulic system which can be isolated and 3.4.3 Burst pressure of hoses is not to be less
in which pressure can be generated from the than four times the design pressure.
power source or from external forces. The
setting of the relief valves is not to exceed the

Section 4

Steering Control Systems

4.1 General lever. Where the control system consists of

a hydraulic telemotor, a second independent
4.1.1 Steering gear control is to be provided: system need not be fitted, except in a
tanker, chemical tanker or gas carrier of
a) For the main steering gear, both on the 10,000 tons gross and upwards;
navigating bridge and in the steering gear
compartment; c) For the auxiliary steering gear, in the
steering gear compartment and, if power
b) Where the main steering gear is arranged operated, it is to be also operable from the
according to 2.1.4, by two independent navigating bridge and is to be independent
control systems, both operable from the of the control system for the main steering
navigating bridge. This does not require gear;
duplication of the steering wheel or steering

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d) Where the steering gear is so arranged that a) If the main steering gear is power operated,
more than one control system can be be indicated on the navigating bridge. The
simultaneously operated, the risk of hydraulic rudder angle indication is to be independent
locking caused by a single failure is to be of the steering gear control system.
considered.
b) Be recognizable in the steering gear
4.1.2 Any main and auxiliary steering gear compartment.
control system operable from the navigating
bridge is to comply with the following: 4.1.4 Appropriate operating instructions with a
block diagram showing the change-over
a) Means are to be provided in the steering procedures for steering gear control systems
gear compartment for disconnecting any and steering gear actuating systems are to be
control system operable from the navigating permanently displayed in the wheelhouse and in
bridge from the steering gear it serves; the steering gear compartment.

b) The system is to be capable of being 4.1.5 Where the system failure alarms for
brought into operation from a position on the hydraulic lock (See Ch.7) are provided,
navigating bridge. appropriate instructions are to be placed on the
navigating bridge to shut down the system at
4.1.3 The angular position of the rudder is to : fault.

Section 5

Electric Power Circuits, Electric Control Circuits,

Monitoring and Alarms

5.1 Electric power circuits emergency switchboard. An auxiliary electric or

electrohydraulic steering gear may be
5.1.1 Short circuit protection, an overload alarm connected to one of the circuits supplying the
and in the case of polyphase circuits, an alarm main steering gear. The circuits supplying an
to indicate single phasing is to be provided for electric or electrohydraulic steering gear are to
each main and auxiliary motor circuit. Protective have adequate rating for supplying all motors
devices are to operate at not less than twice the which can be simultaneously connected to them
full load current of the motor or circuit protected and may be required to operate simultaneously.
and are to allow excess current to pass during
the normal accelerating period of the motors. 5.1.5 The circuits, required by 5.1.4, are to be
separated throughout their length as widely as is
5.1.2 Circuits obtaining their power supply via an practicable.
electronic converter, e.g. for speed control and
which are limited to full load current for 5.1.6 In ships of less than 1600 tons gross, if an
continuous rating are exempt from the auxiliary steering gear is not electrically powered
requirement to provide protection against or is powered by an electric motor primarily
excess current of magnitude as given in 5.1.1. intended for other services, the main steering
The overload alarm is to be set to a value for gear may be fed by one circuit from the main
which the electronic converter is designed switchboard. Consideration would be given to
considering the most severe condition of other protective arrangements than described in
operation. 5.1.1, for such a motor primarily intended for
other services.
5.1.3 Indicators for running indication of each
main and auxiliary motor are to be installed on 5.2 Electric control circuits
the navigating bridge and at a suitable main
machinery control position. 5.2.1 Electric control systems are to be
independent and separated as far as is
5.1.4 Each electric or electrohydraulic steering practicable throughout their length.
gear comprising one or more power units is to
be served by at least two exclusive circuits fed 5.2.2 Each main and auxiliary electric control
directly from the main switchboard; however one system which is operable from the navigating
of the circuits may be supplied through the bridge is to comply with the following:-

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b) Each separate circuit is to be provided with

a) It is to be served with electric power by a short circuit protection only.
separate circuit supplied from the
associated steering gear power circuit, from 5.3 Monitoring and alarms
a point within the steering gear
compartment, or directly from the same 5.3.1 All alarms associated with steering gear
section of the switchboard busbars, main or faults are to be indicated on the navigating
emergency, to which the associated bridge and in accordance with the alarm system
steering gear power circuit is connected. specified in Ch.7, Table 1.9.1. The alarms are to
be both audible and visual.

Section 6

Emergency Power

6.1 General source of power is to be used only for this

purpose.
6.1.1 Where the rudder stock is required to be
over 230 [mm] diameter in way of the tiller (See 6.1.2 In every ship of 10,000 tons gross and
2.1.1), excluding strengthening for navigation in upwards, the alternative power supply is to have
ice, an alternative power supply, sufficient at a capacity for at least 30 minutes of continuous
least to supply the steering gear power unit operation and in any other ship for at least 10
which complies with the requirements of 2.1.3 minutes.
and also its associated control system and the
rudder angle indicator, is to be provided 6.1.3 Where the alternative power source is a
automatically, within 45 seconds, either from the generator, or an engine driven pump, starting
emergency source of electrical power or from an arrangements are to comply with the
independent source of power located in the requirements relating to the starting
steering gear compartment. This independent arrangements of the emergency generators.

Section 7

Testing and Trials

7.1 Testing whole test no abnormal heating, excessive

vibration or other irregularities are permitted.
7.1.1 The requirements of the Rules relating to After the test, the pump is to be opened out and
the testing of Class 1 pressure vessels, piping, inspected. Type tests may be waived for a
and related fittings including hydraulic testing power unit which has been proven to be reliable
apply. in marine service.

7.1.2 After installation on board the vessel the 7.2 Trials

steering gear is to be subjected to the required
hydrostatic and running tests. 7.2.1 The steering gear is to be tried out on the
trial trip in order to demonstrate to the
7.1.3 Each type of power unit pump is to be Surveyor's satisfaction that the requirements of
subjected to a type test. The type test is to be the Rules have been met. The trial is to include
for a duration of not less than 100 hours, the test the operation of the following :-
arrangements are to be such that the pump may
run in idling conditions, and at maximum i) The steering gear; including
delivery capacity at maximum working pressure. demonstration of the performances
During the test, idling periods are to be required by 2.1.2 (b) and 2.1.3 (b). If the
alternated with periods at maximum delivery vessel cannot be tested at the deepest
capacity at maximum working pressure. The draught, alternative trial conditions may
passage from one condition to another should be specially considered;
occur at least as quickly as on board. During the

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ii) The steering gear power units, including
transfer between steering gear power vii) The means of communication between
units; the steering gear compartment and
wheelhouse, also the engine room, if
iii) The isolation of one power actuating applicable;
system, checking the time for regaining
steering capability; viii) The alarm and indicators;

iv) The hydraulic fluid recharging system; ix) Where the steering gear is designed to
avoid hydraulic locking, this feature is to
v) The emergency power supply required by be demonstrated.
6.1.1;
Test of items (d), (g), (h) and (i) may be effected
vi) The steering gear controls, including at the dockside.
transfer of control and local control;

Section 8

Additional Requirements

8.1 For tankers, chemical tankers or gas of hydraulic power actuating systems
carriers of 10,000 tons gross and upwards is to be provided. Loss of hydraulic
and every ship of 70,000 tons gross and fluid from one system is to be capable
upwards of being detected and the defective
system automatically isolated so that
8.1.1 The main steering gear is to comprise two the other actuating system or systems
or more identical power units complying with the remain fully operational.
provisions of 2.1.4.
c) Steering gears other than of the hydraulic
8.2 For tankers, chemical tankers or gas type are to achieve equivalent standards.
carriers of 10,000 tons gross and upwards
8.3 For tankers, chemical tankers or gas
8.2.1 Subject to 8.3, the following are to be carriers of 10,000 tons gross and upwards
complied with : but of less than 100,000 tonnes deadweight

a) The main steering gear is to be so arranged 8.3.1 Solutions other than those set out in 8.2.1
that in the event of loss of steering capability which need not apply the single failure criterion
due to a single failure in any part of one of to the rudder actuator or actuators, may be
the power actuating systems of the main permitted provided that an equivalent safety
steering gear, excluding the tiller, quadrant standard is achieved and that:
or components serving the same purpose,
or seizure of rudder actuators, steering a) Following loss of steering capability due to a
capability is to be regained in not more than single failure of any part of the piping
45 seconds after the loss of one power system or in one of the power units, steering
actuating system. capability is regained within 45 seconds;
and
b) The main steering gear is to comprise
either; b) Where the steering gear includes only a
single rudder actuator special consideration
i) two independent and separate power is given to stress analysis for the design
actuating systems, each capable of including fatigue analysis and fracture
meeting the requirements of 2.1.2 (b); mechanics analysis, as appropriate, the
or material used, the installation of sealing
arrangements and the testing and
ii) at least two identical power actuating inspection and provision of effective
systems which, acting simultaneously maintenance. In consideration of the
in normal operation are capable of foregoing, regard will be given to the
meeting the requirements of 2.1.2(b). "GUIDELINES" in Sec.9.
Where necessary to comply with
these requirements, inter- connection

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8.3.2 Manufacturers of steering gear who intend the Sec.9 are to submit full details when plans
their product to, comply with the requirements of are forwarded for approval.

Section 9

Guidelines for the Acceptance of Non-duplicated Rudder Actuators

for Tanker, Chemical Tankers or Gas Carriers of 10,000 tons gross
and upwards but of less than 100,000 tonnes Deadweight

9.1 Materials 9.2.3 Dynamic loads for fatigue and fracture

mechanics analysis The assumptions for
9.1.1 Parts subject to internal hydraulic pressure dynamic loading for fatigue and fracture
or transmitting mechanical forces to the rudder- mechanics analysis where required by 3.1.5, 8.3
stock are to be made of duly tested ductile and 9.2.2 are to be submitted for appraisal. Both
materials complying with recognized standards. the cases of high cycle and cumulative fatigue
Materials for pressure retaining components are are to be considered.
to be in accordance with recognized pressure
vessel standards. These materials are not to 9.2.4 Allowable stresses For the purpose of
have an elongation less than 12 per cent nor a determining the general scantlings of parts of
tensile strength in excess of 650 [N/mm2]. rudder actuators subject to internal hydraulic
pressure the allowable stresses should not
9.2 Design exceed:

9.2.1 Design pressure The design pressure σm ≤ f

should be assumed to be at least equal to the
greater of the following :- σp ≤ 1.5 f

a) 1.25 times the maximum working pressure σb ≤ 1.5 f

to be expected under the operating
conditions required in 2.1.2(b). σp + σb ≤ 1.5 f
b) The relief valves(s) setting. σm + σb ≤ 1.5 f
9.2.2 Analysis In order to analyse the design where,
the following are required :
σm = equivalent primary general membrane
a) The manufacturers of rudder actuators stress
should submit detailed calculations showing
the suitability of the design for the intended
σp = equivalent primary local membrane stress
service.
σb = equivalent primary bending stress
b) A detailed stress analysis of the pressure
retaining parts of the actuator should be
carried out to determine the stresses at the σB σY
f = the lesser of or
design pressure. A B
c) Where considered necessary because of σB = specified minimum tensile strength of
the design complexity or manufacturing material at ambient temperature
procedures, a fatigue analysis and fracture
mechanics analysis may be required. In σY = specified minimum yield stress or 0.2
connection with these analyses, all foreseen percent proof stress of material at ambient
dynamic loads should be taken into account. temperature
Experimental stress analysis may be
required in addition to, or in lieu of, A and B are as follows :
theoretical calculations depending upon the
complexity of the design.

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Wrought Cast Nodular 9.3.4 Isolating valves Isolating valves are to be

Steel Steel Cast Iron fitted at the connection of the pipes to the
A 4 4.6 5.8 actuator, and should be directly mounted on the
B 2 2.3 3.5 actuator.

9.2.5 Burst test Pressure retaining parts not 9.3.5 Relief valves Relief valves for protecting
requiring fatigue analysis and fracture the rudder actuator against over-pressure as
mechanics analysis may be accepted on the required in 3.3.2 are to comply with the
basis of a certified burst test and the detailed following:
stress analysis required by 9.2.2 need not be
provided. The minimum bursting pressure a) The setting pressure is not to be less than
should be calculated as follows :- 1.25 times the maximum working pressure
expected under operating conditions
σB a required by 2.1.2(b).
Pb = P A
σB b) The minimum discharge capacity of the
relief valve(s) is to be not less than 110 per
where, cent of the total capacity of all pumps which
provide power for the actuator. Under such
Pb = minimum bursting pressure conditions the rise in pressure should not
exceed 10 per cent of the setting pressure.
P = design pressure as defined in 9.2.1 In this regard due consideration should be
given to extreme foreseen ambient
A = as defined in 9.2.4 conditions in respect of oil viscosity.

σBa = actual tensile strength 9.4 Non-destructive testing

σB = tensile strength as defined in 9.2.4. 9.4.1 The rudder actuator should be subjected
to suitable and complete non-destructive testing
9.3 Construction details to detect both surface flaws and volumetric
flaws. The procedure and acceptance criteria for
9.3.1 General The construction should be such non-destructive testing should be in accordance
as to minimize local concentration of stress. with requirements of recognized standards. If
found necessary, fracture mechanics analysis
9.3.2 Welds may be used for determining maximum
allowable flaw size.
a) The welding details and welding procedures
should be approved. 9.5 Testing

b) All welded joints within the pressure 9.5.1 Tests, including hydrostatic test, of all
boundary of a rudder actuator or connection pressure parts at 1.5 times the design pressure
parts transmitting mechanical loads should should be carried out.
be full penetration type or of equivalent
strength. 9.5.2 When installed on board the ship, the
rudder actuator should be subjected to a
9.3.3 Oil seals Oil seals forming part of the hydrostatic test and a running test.
external boundary are to comply with 3.2.3 and
3.2.4.

End of Chapter

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Chapter 7

Control Engineering

Contents
Section

1 General
2 Control - System Characteristics
3 Requirements for various Machinery Installations
4 Tests and Trials
5 Machinery Operated from a Centralised Control Station – ‘CCS’ Notation
6 Programmable Electronic Systems

Section 1

General

1.1 Scope 1.2 Remote control systems capability

1.1.1 The requirements of this Chapter are in 1.2.1 When it is desired to fit a centralized
general to be complied with for all machinery control system having one or more control
plants where instrumentation is required locations and embodying various degrees of
according to other Chapters of the Rules. In automatic and remote control of the propulsion
addition, the requirements apply to the following, plant or associated ship's service systems, the
when installed :- control and monitoring systems are to be
designed, assembled and installed in
a) remote control systems for propulsion accordance with the requirements given in
machinery, controllable pitch propeller, and Section 5, to assure operation as effective as
steering gear; could be obtained with the same systems
arranged for manual control and monitoring by
b) safety systems for propulsion plants and watchkeeping personnel.
electric power generating plants;
1.3 Plans and particulars
c) instrumentation equipment of boiler plants.
1.3.1 Plans and specifications for the control
d) Safety systems for emergency diesel systems, are to be submitted, in triplicate, for
engines. approval and are to at least include the following
information:
1.1.2 For vessels intended to operate with
unattended machinery spaces, refer to Pt.5. a) machinery arrangement plans showing
locations control in relation to controlled
1.1.3 Alarm systems are to satisfy the units;
environmental requirements of IRS
Classification Notes “Type Approval of Electrical b) arrangements and details of control
Equipment used for Control, Protection, Safety consoles including front views, installation
and Internal Communication in Marine arrangements together with schematic
Environment”. diagrams for all power, control and
monitoring systems including their functions;

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is to be taken to fit no flanges or joints over or

c) kind and size of all electrical cables and near the console unless provision is made to
wiring associated with the control systems prevent any leakage from injuring the
including voltage rating, service voltage and equipment.
currents together with overload and short
circuit protection; 1.5.5 Glass in a control room located within or
adjacent to the machinery space is to be of the
d) functional block diagrams of all control and shatter-resistant type.
monitoring systems;
1.5.6 When the main control for the propulsion
e) schematic plans of hydraulic and pneumatic plant is to be situated in a location remote from
control systems together with all inter- the propulsion machinery space, details of
connections, piping sizes and materials special arrangements are to be submitted to
including working pressures, relief valve show that the operation of the propulsion plant
settings, reducing valves, filters, would be as effective as with the main control
compressors and their type and located within or adjacent to the machinery
manufacturers; space.

f) description of all alarm and emergency 1.6 Main control location

tripping arrangements, functional sketches
or description of all special valves, 1.6.1 Controls
actuators, sensors and relays;
1.6.1.1 The main control location is to provide
g) schematic plans and supporting data of fire- control of the propulsion plant and associated
protection and extinguishing systems, ship's service system including starting,
including fire-detection and alarm systems, stopping, and for change over of vital pumps
bilge high level alarms; and motors, and is to provide effective means
for monitoring temperatures, pressures, the
h) control system fault analysis, test program electrical system, fluid and gas flows, liquid
for testing controls, monitoring and alarm levels and other variables which are essential
systems. for the propulsion plant operation.

1.4 Operational guidance manual 1.6.1.2 Effective means are to be provided for
monitoring and controlling direction of rotation or
1.4.1 An operational guidance manual is to be propeller pitch and speed of propeller for the
provided on board the vessel for reference and safe operation of the plant from standby
is to contain the necessary system technical condition at departure through normal operation
information and give operating instructions for to "finished with engines" at the end of the
normal and emergency operations. voyage.

1.5 Location of controls 1.6.1.3 The main control location is to be fitted

with alarms and emergency trips as required
1.5.1 Ship motion and anticipated structural together with indicators and is to have means for
vibrations are to be considered when selecting the assessment of the operational status of all
the locations of main and associated secondary machinery and systems vital to the propulsion of
control locations. the vessel. Control functions from the console
may be designed for either 'remote manual' or
1.5.2 The control locations are to be well 'automatic control'.
ventilated and air conditioning is to be provided
for the control consoles when required by the 1.6.2 Independent manual control
operational characteristics of the components
within the consoles. There is to be an alarm for 1.6.2.1 Means are to be provided for
failure of the console integral air conditioning. independent manual control, at or near the
machinery concerned, in the event of failure of a
1.5.3 Enclosed main control location located particular control in the centralized control
within the machinery spaces are to have two system. Necessary instrumentation is to be
means of access located as remote from each provided so that satisfactory operation of the
other as practicable. machinery under independent manual control
can be exercised for lengthy periods.
1.5.4 The leading of pipes in the vicinity of Independent manual control of propulsion
control console is to be avoided as far as machinery is to be demonstrated during the
possible. When such leads are necessary, care tests/trials to the satisfaction of the Surveyors.

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This is to include demonstration of independent 1.9 Instrumentation
manual control through the full maneuvering
range and transfer from automatic control. 1.9.1 Main control location

1.6.3 Order of control-location command 1.9.1.1 Instrumentation and alarms at the main
control location are to provide all information
1.6.3.1 When the propulsion machinery is necessary for monitoring the operation of the
arranged to be controlled from two or more propulsion, electrical and emergency systems,
locations, the main control location is to have generally in accordance with Table 1.9.1.
means for transferring control from a secondary
location to the main location at all times and 1.9.2 Secondary control location
blocking any unauthorized control from any
secondary location. Consideration will be given 1.9.2.1 Instrumentation and alarms for the
to special cases where it may be necessary for bridge control locations and other secondary
a secondary control location to have command control locations are to be generally in
over control transfers between control locations. accordance with Table 1.9.2.

1.6.4 Control transfer 1.10 Displays, indications and alarms

1.6.4.1 Transfer of control from one location to 1.10.1 The alarms and displays required by
another, except as required by 1.6.3.1, is to be Table 1.9.1 and Table 1.9.2 for essential
possible only with acknowledgement by the services are to be readily distinguishable from
receiving locations. The main control location other alarms (e.g. fire alarm) and are to be
and the secondary control location are to have grouped functionally in so far as practicable.
an indicator showing which location is in control. Alarms are to have individual visual presentation
with preferably a common audible signal.
1.7 Secondary control locations
1.10.2 In general, alarms and displays not
1.7.1 In general, secondary control locations for required by Table 1.9.1 and Table 1.9.2 or not
the control of propulsion machinery from the concerned with the management of the
bridge or other locations on board are to be kept propulsion machinery (non- essential alarms)
as simple as possible and provided with only are to be grouped separately from the essential
those indicators and controls necessary for the alarms. Audible signals for non-essential alarms,
effective control of speed and direction of the if provided, are to be of a character distinct from
propulsion engines, and of the controllable-pitch that for essential alarms.
propeller where fitted, for normal operation.
1.10.3 The number of colours used to indicate
1.7.2 Precautions are to be taken to ensure that status of plant operation is to be kept to a
the engine is not normally operated in a barred minimum. A uniform code is to be used so that
speed range. like colours indicate like functions or status of
operation in the controlled plant or system.
1.7.3 If the control system automatically shuts
down the main propulsion engine for any 1.10.4 Alarm systems are to be designed so that
reason, this is to be alarmed at the main control they cannot remain deactivated when the
location and each secondary control location. monitoring system has returned to the normal
Restoration of normal operating conditions is to running condition. Alarm systems are to provide
be possible only after manual reset. Automatic both audible and visual alarm upon each fault
restarting is not to be possible. condition. Alarms, due to fault condition in
machinery, are to remain active until
1.8 Control console construction acknowledged and if arrangements are made to
mute audible alarms they are not to extinguish
1.8.1 Control consoles are to be preferably self- visual alarms. Acknowledgement of visual
supported with the sides and backs suitably alarms is to be clearly indicated. Alarms are to
protected. Where necessary, protection is to be be of the self-monitoring type so that a circuit
provided for consoles which might be subject to failure will cause an alarm condition and are to
damage by leaks or falling objects. have provisions for testing all audible and visual
alarms and indicating lamps.

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1.10.5 Machinery, safety and control system

faults are to be indicated at the relevant control 1.10.12 The alarm system is to be capable of
locations to advise duty personnel of a fault being tested during normal machinery operation.
condition. The presence of unrectified faults is to
be clearly indicated at all times. 1.10.13 The alarm system is to be designed as
far as practicable to function independently of
1.10.6 Where the alarms are displayed as group control and safety systems such that a failure or
alarms provision is to be made to identify malfunction in these systems will not prevent the
individual alarms at the main control location (if alarm system from operating.
fitted) or alternatively at subsidiary control
locations. 1.10.14 Disconnection or manual overriding of
any part of the alarm system should be clearly
1.10.7 Acknowledgement of alarms at positions indicated.
outside a machinery space is not to silence the
audible alarm or extinguish the visual alarm in 1.10.15 When alarm systems are provided with
that machinery space. means to adjust their set point, the
arrangements are to be such that the final
1.10.8 If an alarm has been acknowledged and settings can be readily identified.
a second fault occurs prior to the first being
rectified, audible and visual alarms are again to 1.10.16 Where monitors are provided at the
operate. Where alarms are displayed at a local location in control and if fitted, in the duty
panel adjacent to the machinery and with engineer’s accommodation, they are to provide
arrangements to provide a group or common immediate display of new alarm information
fault alarm at the main control room alarm regardless of the information display page
display then the occurrence of a second fault currently selected. This may be achieved by
prior to the first alarm being rectified need only provision of a dedicated alarm monitor, a
be displayed at the local panel, however, the dedicated area of screen for alarms or other
group alarm is to be re-initiated. suitable means.
Unacknowledged alarms on monitors are to be
distinguished by either flashing text or a flashing 1.10.17 Alarms are to be displayed in the order
marker adjacent to the text. A change of colour in which they occur. Alarms requiring shutdown
will not in itself be sufficient to distinguish or slowdown action are to be given visual
between acknowledged and unacknowledged prominence.
alarms.
1.11 Safety systems
1.10.9 For the detection of transient faults which
are subsequently self-correcting, alarms are 1.11.1 Where safety systems are provided, the
required to lock in until accepted. requirements of Pt.5, Ch.22, 2.5.2 to 2.5.8 are to
be complied with.
1.10.10 The alarm system is to be arranged with
automatic changeover to a standby power 1.11.2 Where arrangements are provided for
supply in the event of a failure of the normal over-riding a safety system, they are to be such
power supply. Where an alarm system could be that in-advertent operation is prevented. Visual
adversely affected by an interruption in power indication is to be given at the relevant control
supply, changeover to the standby power supply location(s) when a safety over-ride is operated.
is to be achieved without a break. The consequences of over-riding a safety
system are to be established and documented.
1.10.11 Failure of any power supply to the alarm
system is to operate an audible and visual alarm
at the main control location.

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Table 1.9.1 : Displays, indications and alarms for main control location

Alarm
System Remote Display Remarks
activation
Main boilers
Main steam superheater Temperature
1 High -
outlet Pressure
Pressure Low
2 Fuel oil to burners -
Viscosity (temperature) High (low)
3 Master fuel oil cut-off valve - Closed -
4 Atomizing medium Pressure Outside limits -
5 Forced draft Pressure (water column) Failure -
6 Water level Level High, low
-
Low-low
7 Feed pump discharge Pressure -
8 Feed water salinity Salinity - -
Main turbine
1 Steam, ahead chest Pressure - -
2 Steam, astern chest Pressure - -
3 Steam, gland steam Pressure - -
L.O. to turbines and Temperature High
4 -
reduction gears Pressure Low
5 L.O. sump level - Low -
6 L.O. gravity tank Level Low -
Bearings, turbine, thrust and
7 Temperature High -
reduction gear (individual)
8 Main condensate pump Running Failure -
9 Main condenser Vacuum Low -
10 Main circulator Running Failure -
11 Condensate level - High -
12 Deaerator feed tank Level Low -
13 Astern guardian valve Position Failure to open -
14 Vibration - Excessive -
15 Rotor axial displacement - Excessive -
16 Shaft roll over - Stopped -
17 Scoop valve Position - -
Main circulator sea suction
18 Position - -
valve
Turbogenerator
L.O. to turbine and reduction Pressure Low
1 -
gear Temperature High
2 Bearings Temperature High -
3 Aux. Condenser Vacuum Low -
4 Aux. Condensate pump Running - -
5 Aux. Circulating pump running - -

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Table 1.9.1 : (Contd.)

Alarm
System Remote Display Remarks
activation
Main diesel engines
Pressure Low
1 L.O. to engine See Note 1
Temperature High
Differential pressure across
2 Pressure High -
L.O. discharge filter
3 L.O. to reduction gear Pressure Low -
4 L.O. at reduction gear Temperature High -
Oil mist concentration in
See Note 2,
5 crankcase or temperature of - High
17
bearings
6 L.O. drain tank level - Low-high See Note 3
7 Cylinder lubrication - Failure See Note 1
8 Cooling water to cylinders Pressure or flow Low See Note 10
9 Cylinder cooling water outlet Temperature High See Note 4
Level of cylinder cooling
10 - Low -
water in expansion tank
11 Piston coolant Pressure Low See Note 5
Flow of piston coolant
through each piston and
Flow, temperature (or Low-high
12 temperature in manifold (or See Note 5
temperature) (high)
temperature of coolant at
each piston outlet)
Level of piston coolant in
13 - Low See Note 5
expansion tank
Pressure Low
14 Fuel valve coolant -
Temperature High
Level of fuel valve coolant in
15 - Low -
expansion tank
16 Sea water coolant Pressure Low See Note 10
17 F.O. to injection pumps Pressure Low -
Low-high
18 F.O. to engine Temperature or viscosity See Note 8
(Low-high)
Level of F.O. in daily service
19 - Low-high See Note 6
tank
20 Charging air Temperature Low-high See Note 7
Deviation of each cylinder
from average and exhaust
21 Temperature High See Note 9
gas temperature of each
engine
Fire in scavenging belt, for
22 - Activated See Note 11
two stoke engines
23 Starting air Pressure Low -
24 Overspeed - Activated -

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Table 1.9.1 : (Contd.)

Alarm
System Remote Display Remarks
activation
Diesel generators
1 F.O. to engines Pressure Failure -
Pressure Low
2 L.O. to engines -
Temperature High
3 Starting air Pressure Low -
4 Exhaust gas Temperature - -
Temperature High
5 Cooling medium, outlet See Note 10
Pressure Low
Level in cooling water
6 expansion tank, if not - Low -
connected to main system
7 overspeed - Activated -
Steering gear
1 Rudder position Indication - See Note 13
2 Steering gear power units - Failure -
Running and stopped Overload and
3 Steering gear motors See Note 14
indication single phase
4 Control system power - Failure -
Steering gear hydraulic oil
5 - Low See Note 15
tank level
6 Auto pilot indication Running indication Failure -
7 Hydraulic lock - Fault See Note 16
Addition services as applicable
1 Control electric power available Failure -
2 Control air supply Pressure Low -
3 Hydraulic control system Pressure Low -
4 Control location in operation In command indication - -
5 Propeller pitch indicator Pitch - -
6 Propeller speed, direction RPM, direction - -
7 Stern tube L.O. tank level - Low -
8 F.O. service or settling tank - Low, high -
F.O. settling tank
9 - High -
temperature
Volts amperes Off limits
10 Generators, ship service -
Frequency High off limits
11 Fuel oil service pump Running - -
12 Console air conditioning - Failure -
13 Automatic shut down - Shut-down -
14 Turning gear Engaged - -
15 Fire main Pressure - -
16 Bilge pump Running - -
17 Bilge level - High -
18 Clutch air or oil pressure - Low -

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Table 1.9.1 : (Contd.)

Notes:

1 Individual alarms are required where separate lubricating oil systems (e.g. for camshaft, rocker
arms, turbocharger, etc.) are installed. For turbochargers with an integrated self-contained oil
lubrication system such alarm is not required.

2 Main bearings and thrust bearings of propulsion engines having a cylinder bore over 300 [mm] are
to be monitored for high temperature by individual sensors connected to a single alarm.

3 Where separate lubricating oil systems are installed, individual level alarms are required for the
tanks.

4 Where one common cooling space without individual stop valves is employed for all cylinder jackets,
one temperature alarm for the common cooling water outlet will be approved.

5 Only applicable for cross-head type engines.

6 High-level alarm is required only if suitable overflow arrangements are not provided.

7 Both the displays and alarms are not required if automatic temperature control is not necessary.
Low temperature alarm may be replaced by an alarm for water detection in the charging air duct.

8 Not required for distillate fuels.

9 Alarm for slow speed engines (under 300 RPM) and medium speed engines above 4000 bhp.

10 Not required for attached cooling pumps.

11 Not required for engines with bore 300 [mm], or under.

12 Alarms required for steering gear need to be fitted only on the bridge.

13 The rudder angle indication is to be on the navigation bridge and independent of the steering gear
control system.

14 Steering gear motors running indicators are to be fitted both on the bridge and main control location.

15 Each tank is to be monitored.

16 Where more than one system (either power or control) can be operated simultaneously each system
is to be monitored and the system at fault is to be identified.

17 If engine power is ≥ 2250 [kW] or cylinder bore > 300 [mm] following is to be provided:

- Slow down with alarm for low speed diesel engines

- Shut down with alarm for medium and high speed engines.

- IRS may permit overriding of auto shut off or slow down arrangements, provided consequences
of overriding auto shut off or slow down are established and documented.

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Table 1.9.2 : Displays, indications and alarms for secondary control location

System Display Alarm Remarks

1 Control location In command - -
2 Propeller speed and direction Ahead, astern, RPM - -
3 Propeller pitch Pitch - -
4 Starting air pressure - Low -
5 Propulsion unit - Abnormal -
6 Remote control power - Failure -
7 Shaft roll over - Stopped -
8 Bilge level - High -

Section 2

Control - System Characteristics

2.1 Power supply 2.1.5 Conductors for monitoring circuits which

carry low-level or information-level signals are to
2.1.1 The control systems are to be served by be installed in such a manner or provided with
two feeders from the main switchboard. One of shields so as to minimize the introduction of
the feeders may be from the emergency spurious signals from outside sources. Wiring
switchboard, if provided. Transfer may be by within consoles is to be arranged to provide
manual or automatic switch installed in or maximum accessibility and protection from
adjacent to the control console. The feeder from steam, water or oil piping.
the transfer switch to the control console may be
through a single cable. These feeders are not to 2.2 Electrical and electronic devices
supply power for any other machinery.
2.2.1 All electrical and electronic devices are to
2.1.2 The feeders supplying power to the control be suitable for use in marine atmosphere,
console are to be provided with short- circuit resistant to corrosion, not affected by shipboard
protection at the main switchboard and vibration and motion and are to be capable of
emergency switchboards, if provided. Where performing their intended functions at
circuits within the control consoles are protected compartment ambient temperature. Electrical
by fuses or circuit breakers, the control-system and electronic devices are to be applied on the
protection is to be subdivided and arranged so basis of 50°C ambient when located in
that failure of one set of fuses or circuit breakers machinery spaces or 40°C ambient when
will not cause maloperation or failure of another located in other spaces, including those cases
circuit or system and it is to be possible to when the component is located in an
isolate the defective system. airconditioned console.

2.1.3 The power for monitoring, alarms and 2.2.2 Semiconductor devices are to be selected
emergency action is to be supplied automatically on the basis of expected shipboard ambient air-
from an emergency source upon failure of ship's temperature ranges of 0°C-50°C for interior
service power supply. An audio / visual alarm is compartments and 0°C-60°C inside of consoles.
to be provided at the main control location to Silicon and selenium semiconductor devices are
indicate failure of power supply. to be used in preference to germanium which
may be used, where its characteristics are
2.1.4 Cables and console wiring for control and favoured for a circuit provided care is taken to
monitoring are to be of the flame-retarding type ensure satisfactory operation under shipboard
and are to be stranded except that solid conditions.
conductors may be used in low energy circuits,
where they are properly supported and not 2.2.3 Steady-state voltage variations of 10 per
subject to undue vibration or movements. cent and frequency variations of ± 5 per cent
from the nominal console feeder rating are not

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to affect the intended functioning of the 2.3 Hydraulic controls

electrically operated control and monitoring
devices. Where close tolerances on voltage and 2.3.1 Hydraulic pumps, actuators, motors and
frequency are required, special regulated accessories are to be suitable for the intended
supplies are to be provided. Voltage transients duty, compatible with the working fluid and are
are not to cause any dangerous malfunctioning to be designed to operate safely at full-power
or damage to the control and monitoring devices conditions. In general, the hydraulic fluid is to be
and the control equipment is to be fitted with non-flammable or have a flash point above
transient- voltage suppressors. 157°C.

2.2.4 The design and arrangement of all devices 2.3.2 All control piping is to be readily accessible
is to provide ready accessibility to parts and supported so as to protect the piping and
requiring inspection, adjustment or periodic associated accessories from mechanical
replacement. Where devices are parts of sub- damage, vibration and shock. The control piping
circuits assembled in physically-identical is to be suitably marked to indicate the character
modular units for easy mounting on and removal of its service.
from the console, suitable arrangements such
as matched plug-in modules with coded plugs 2.3.3 The hydraulic pumps are to be fitted in
are to be provided to facilitate correct duplicate and have pressure relief protection on
replacement of modules in the console. the discharge side. The pump suctions are to be
from a reservoir of sufficient capacity to contain
2.2.5 Built-in circuitry is to be provided for use in all the fluid when drained from the system,
the testing of module functions. maintain the fluid level at an effective working
height and allow air and foreign matter to
2.2.6 Consideration is to be given to minimize, separate out. The pump suctions are to be sized
as far as practicable, the probability that failure and positioned to prevent cavitation or starvation
of any one component or device in the control of a pump. A duplex filter which can be cleaned
circuitry will cause unsafe operation of the plant. without interrupting the oil supply is to be fitted
on the discharge side of the pumps.
2.2.7 Control levers or wheels are to be readily
identifiable as to function and position and are to 2.4 Pneumatic controls
be arranged for a logical sequence of
operations. Suitable interlocks are to be 2.4.1 Air compressors, actuators, motors and
provided to prevent incorrect operation. accessories are to be suitable for the intended
duty and have working and other parts which will
2.2.8 When logic circuits are used for sequential not be damaged or rendered ineffective by
start-up or for operating individual plant, corrosion.
components, indicators are to be provided at the
control console to show the successful 2.4.2 All control piping is to be readily accessible
completion of the sequence of operations by the and supported so as to protect the piping and
logic circuit and start-up and operation of the associated accessories from mechanical
component. If some particular step is not carried damage, vibration and shock. The control piping
out during the sequence, the sequence is to is to be suitably marked to indicate the character
stop at this point. Manual override is to be fitted of its service.
in vital functions to permit control in case of
failure of a logical circuit. 2.4.3 Compressed air for pneumatic control is to
be available from at least two air compressors.
2.2.9 Electrically-powered actuators for the The starting air system may be used as a
execution of control commands are to be source of control air. The air pressure to the
suitable for shipboard use, and have working pneumatic control system is to be automatically
and other parts which would not be damaged or maintained at the level required for the operation
rendered ineffective by corrosion. The windings of the installation and low air pressure is to set
are to be treated to resist oil and water and the off an alarm at the main control location. Means
enclosures are to be suitable for the location. are to be provided in the delivery from the
The ratings of coils is to be based on ambient air compressors to assure clean, dry and oil-free air
temperature of 50°C when located in the to the pneumatic controls.
machinery spaces and 40°C when located
outside such spaces. The power supply for 2.5 Ship motion effects
electrical actuators is to be from the same
source as the power to the control systems. 2.5.1 All control, actuating, monitoring and alarm
devices are to be able to operate successfully

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when inclined at an angle of 30° in any direction 2.6.6 Means of control, independent of the
from the vertical and when subjected to vibratory bridge control system, are to be provided on the
frequencies of 2 to 80 Hz, in conjunction with bridge to enable the propulsion machinery to be
peak to peak amplitudes of 2 [mm] for stopped in an emergency.
frequencies 2 to 13.2 Hz and an acceleration of
0.7 g for frequencies of 13.2 to 80 Hz. Care is to 2.6.7 Audible and visual alarms are to operate
be taken to ensure that mounting arrangements on the bridge and in the locations required by
for the components will not amplify shipboard Pt.5, Ch.22 if any power supply to the bridge
vibrations. control system fails. Where practicable the
preset speed and direction of thrust are to be
2.6 Bridge control for main propulsion maintained until corrective action is taken.
machinery
2.6.8 At least two means of communication are
2.6.1 Where a bridge control system for main to be provided between the bridge and the main
propulsion machinery is to be fitted, the control location in the machinery space. One of
requirements of 2.6.2 to 2.6.8 are to be these means may be the bridge control system;
complied with. the other is to be independent of the main
electrical power supply. See also Pt.4, Ch.1,
2.6.2 Means are to be provided to ensure Sec.2, Cl. 2.5.
satisfactory control of propulsion from the bridge
in both the ahead and astern directions. 2.7 Valve control system

2.6.3 Instrumentation to indicate the following is 2.7.1 Where bilge, ballast, oil fuel transfer and
to be fitted on the bridge: sea valves for engine services are operated by
remote or automatic control, the requirements of
a) Propeller speed. 2.7.2 to 2.7.5 are to be satisfied.
b) Direction of rotation of propeller for a
fixed pitch, propeller or pitch position for 2.7.2 Failure of actuator power is not to permit a
controllable pitch propeller. valve to move to an unsafe condition.
c) Clutch position where applicable.
d) Shaft brake position where applicable. 2.7.3 Positive indication is to be provided at the
e) Engine speed. remote control location for the service to show
the actual valve position or alternatively that the
2.6.4 The propeller speed, direction of rotation valve is fully open or closed.
and, if applicable, the propeller pitch are to be
controlled from the bridge under all normal sea 2.7.4 Equipment located in places which may be
going and manoeuvring conditions. flooded is to be capable of operating when
submerged.
2.6.5 Remote control of the propulsion
machinery is to be from one control location at 2.7.5 A secondary means of operating the
any one time. See also 1.6.3. Main propulsion valves, which may be by local manual control, is
control units on the navigating bridge may be to be provided.
interconnected. Means are to be provided at the
main machinery control location to ensure 2.7.6 For requirements applicable to closing
smooth transfer of control between the bridge appliances on scuppers and sanitary
and machinery control locations. discharges, see Pt.3, Ch.13.

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Section 3

Requirements for various Machinery Installations

3.1 Boilers burner within 6 seconds following flame failure.

In the case of the failure of the flame scanner,
3.1.1 General the fuel to the burner is to be shut off
automatically. On flame failure of all burners in
3.1.1.1 Where a boiler-control system is fitted for boilers fitted with an automatic ignition system,
the purpose of automatically controlling the the control system is to go to the automatic
combustion, feed water and firing functions, the boiler purge condition.
arrangements are to be capable of automatically
and safely satisfying the steam requirements 3.1.3.2 Where boilers are fitted with an
demanded from the boiler under normal automatic ignition system, a timed boiler purge
evaporation between minimum and maximum with all air registers open is required prior to
firing rates and be able to maintain complete ignition of the initial burner. The boiler purge
and stable combustion at the minimum rate of may be initiated manually or automatically. The
firing or during any sudden change in steam purge time is to be based on a minimum of four
demand. air changes of the combustion chamber and
furnace passes. It is to be proven that the forced
3.1.1.2 To prevent a build-up of excessive boiler draft fan is operating and the air registers and
steam which might occur when all burners are in dampers are open before the purge time
service and burners are at the minimum firing commences.
rate, one of the following arrangements or
equivalent is to be provided:- 3.1.3.3 Means provided to by-pass the flame-
scanner control system temporarily during a
a) Burners sequencing, which may require trial- for ignition period is to be limited to 15
automatic control of one or more, but not seconds from the time the fuel reaches the
necessarily all, burners in the boiler; burners. Except for this trial- for-ignition period
there is to be no means provided to by-pass one
b) an automatic steam dump system, or more of the burner flame scanner systems
unloading to a condenser of adequate size. unless the boiler is being manually fired.
For long-term operation at low loads, the
excess burner capacity may be secured. 3.1.3.4 Where boilers are fitted with an
automatic ignition system, and where residual
3.1.2 Fuel oil system fuel oil is used, means are to be provided for
lighting off the burners with igniters lighting
3.1.2.1 A master fuel oil cut-off valve is to be properly heated residual fuel oil. Alternatively,
provided in the fuel system to each boiler. The the burners may be lighted off with a light oil
valve is to be automatically closed upon flame used as a pilot to ignite residual fuel oil. If all
failure of all burners in the boiler or upon action burners experience a flame failure, the initial
of the low-water alarm or upon loss of forced burner is to be brought back in to automatic
draft. The closing of the master fuel oil valve is service only in the low-firing position. To avoid
to be alarmed at the main control location. the possibility of false indication due to the
Before any attempt at restarting after a complete failure of the flame scanner in the 'flame-on'
flame out, manual intervention is to be initiated mode, the initial light-off burner is to be fitted
to determine the cause of flame failure and to with dual scanners or a scanner of the self
reset the master fuel-oil valve. checking type.

3.1.2.2 The oil burners are to be so arranged 3.1.3.5 Off-limit conditions of burner primary-air
that they cannot be withdrawn unless oil supply pressure or atomizing- steam pressure are to be
to the burners is cut off. alarmed at the main control location.

3.1.3 Combustion-control safety 3.1.4 Boiler alarms and indications

3.1.3.1 Each burner is to be fitted with a flame 3.1.4.1 Action of the automatic fuel oil or burner
scanner designed to automatically shut off the shut-off arrangement is to be indicated by
fuel oil supply to the burner in the event of flame audible and visual alarms. Means are to be
failure. The flame failure shut off is to be provided to silence the audible alarms without
capable of shutting off the oil supply to the canceling the visual indicator. Alarm systems

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are to be designed so that the alarm cannot event of failure of the automatic control and
remain silenced when the monitored system has sufficient conventional instrumentation is to be
returned to normal running condition. provided so that satisfactory operation of the
boiler under independent manual control can be
3.1.4.2 Each boiler is to be fitted with one high- exercised for lengthy periods of time.
water level alarm and two independent low
water-level sensors and alarms. The low-low 3.2 Propulsion machinery
water-level alarm is to close the master fuel oil
cut- off for the boiler, and is to be set to operate 3.2.1 General
when the water level falls to a minimum safe
level, but at a level not lower than that visible in 3.2.1.1 The fitting of centralized automatic
the gauge glass. Water-level sensors are to be controls for propulsion engines and turbines is
so located as to minimize the effect of roll and not to impair the effectiveness of the safety and
pitch or they are to be provided with a short- speed control devices required by the applicable
time delay (approximately 5 seconds) to prevent parts of Ch.4.
trip-out due to transients or to the vessel's
motion. 3.2.1.2 Plant or engine response to throttle
control demands is to be tested during trials and
3.1.4.3 The alarms for forced-draft failure and after final adjustment to demonstrate that no
for low-water level are to be installed in part of the plant or engine is jeopardized by the
association with limiting controls which are to rate at which the throttle is moved from one
prevent start-up and cause shut-down when extreme position to the other. Overriding of the
unsafe firing conditions exist. Manual resetting remote throttle control is to be possible only
of the control system is to be required before the from the main control location.
boiler can be restarted.
3.2.1.3 The emergency tripping of propulsion
3.1.4.4 The operation status of the boiler is to be machinery is to be possible at the main control
indicated at the boiler by conventional location and at the machine site.
instruments, gauges, lights or other devices to
show the functional condition of fuel, air, feed- 3.2.2 Steam turbines
water and steam circuits of boiler. Monitoring
instruments are also to be provided at the main 3.2.2.1 The astern guardian valve is to open
control location. automatically as a result of a throttle trip or a
maneuvering signal, such as the actuation of a
3.1.5 Logic sequence for boiler controls specific switch or by movement of the throttle
control in the maneuvering range. An alarm is to
3.1.5.1 Where automatically started boilers are indicate any failure of the guardian valve to
installed, they are to be provided with a open.
programmed control to assure a safe cycle of
operation upon initial starting and cycling 3.2.2.2 If scoop circulation is provided for the
between temperature and pressure limits. main condenser, the main circulating pump is to
be automatically started as required for
3.1.5.2 The programmed control is to be satisfactory operation of the propulsion
designed to cycle the boiler in accordance with a machinery.
predetermined sequence and, in addition to the
automatic boiler purge required by 3.1.3.2, is to 3.2.2.3 In the event of low lubricating-oil
include the following:- pressure there is to be an automatic changeover
to the standby lubricating-oil pump(s). The
a) Ignition (spark coming on) is to precede the governor is to be arranged to shut off the steam
opening of the fuel valve; to the ahead turbines upon failure of the
lubricating-oil system.
b) Where it is necessary to cut burners in and
out to handle the load on the boiler and the 3.2.2.4 Alarms at the main control location are to
controls are provided to modulate the air- indicate low vacuum in the condenser,
fuel ratio, the automatic boiler purge period excessive bearing temperature and low
is to start with the modulating control in the lubricating-oil pressure. Remote throttle control-
high firing position and the ignition is not to system power failure indication is to be provided
be turned on until the modulating control at the main control and secondary control
has returned to the low-firing position. locations. An alarm is to be provided at the main
control and secondary control locations to
3.1.5.3 Means are to be provided for indicate that the propeller shaft has been
independent manual control at the boiler in the

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stopped too long on a standby or stop 3.2.4.3 Precautions are to be taken to ensure
maneuver. that it is not possible to continuously run the
main engine in a barred speed range.
3.2.3 Gas turbines
3.3 Emergency diesel engines
3.2.3.1 Automatic control arrangements for gas
turbine modules are to be provided to regulate 3.3.1 These requirements apply to diesel
the quantity of fuel flowing to the burners during engines which are required to be immediately
starting, over the operating power range and available in an emergency and capable of being
when stopping the gas turbine, in a controlled controlled remotely or automatically operated.
manner and with in the safe operating envelope Information is to be submitted alongwith
of the gas turbine. The arrangement is to have instructions to test alarm and safety systems
provision to collect, condition and transmit both demonstrating compliance with the
primary and secondary surveillance signals to requirements.
the local and remote operating locations.
3.3.2 Alarms and safeguards are to be fitted in
3.2.3.2 The control system is to be provided with accordance with Table 3.3.2.
control functions at the component level to allow
direct manual control of the fuel flow and engine 3.3.3 The safety and alarm systems are to be
shut down in the event of failure of the electrical designed to ‘fail safe’. The characteristics of the
power supplies or a critical failure of the engine ‘fail safe’ operation are to be evaluated on the
control system. basis not only of the system and its associated
machinery, but also the complete installation, as
3.2.3.3 Each gas turbine module is to be well as the ship.
provided control unit comprising of minimum
instrumentation necessary for monitoring, 3.3.4 Regardless of the engine output, if
control and surveillance for safe operation both shutdowns additional to those specified in Table
local and remote positions with facility for 3.3.2 are provided except for the overspeed
transfer of control authority through a suitable shutdown, they are to be automatically
selector switch. overridden when the engine is in automatic or
remote control mode during navigation.
The alarms and automatic shut down devices to
be provided are as indicated in Pt.4, Ch.4, Table 3.3.5 The alarm system is to function in
3.13.1. accordance with Pt.5, Ch.22, with additional
requirements that grouped alarms are to be
3.2.4 Diesel engines arranged on the bridge. (See Pt.5, Ch.22,
Cl.2.4.14).
3.2.4.1 In the event of the lubricating oil
pressure dropping to a preset level, there is to 3.3.6 In addition to the fuel oil control from
be an automatic changeover to a standby outside the space, a local means of engine
lubricating oil pump or a reduction in main shutdown is to be provided.
engine speed to a predetermined level. In the
event of a loss of lubricating oil pressure 3.3.7 Local indications of at least those
engines are to stop automatically. parameters listed in Table 3.3.2 are to be
provided within the same space as the diesel
3.2.4.2 Engine alarms are to be in accordance engines and are to remain operational in the
with Table 1.9.1 and Table 1.9.2. event of failure of the alarm and safety systems.

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Table 3.3.2 : Alarms and safeguards

Parameter ≥ 220 kW < 220 kW

Fuel oil leakage from fuel injection pipes Alarm activated Alarm activated
Lubricating oil temperature Alarm for high value
Lubricating oil pressure Alarm for low value Alarm for low value
1
Oil mist concentration in crankcase Alarm for high value
Pressure or flow of cooling water Alarm for low value
Temperature of cooling water (or cooling air) Alarm for high value Alarm for high value
Overspeed activated Alarm activated +
Shutdown

Note 1 : For engines having a power of more than 2250 kW or a cylinder bore of more than 300 [mm].

Section 4

Tests and Trials

4.1 Individual components unintentional grounds and short circuits,

defective electrical or electronic elements.
4.1.1 The manufacturers of control systems are
to certify that the mechanical, electrical, and 4.2 Shop testing
solid-state components utilized have been
satisfactorily tested individually or by acceptable 4.2.1 Upon completion of the control consoles or
lot sampling to establish their suitability for the sections or component assemblies of such
intended service including their exposure to the consoles, the manufacturer is to carry out tests
following conditions :- in the presence of the Surveyor to demonstrate
the satisfactory performance of all controls,
a) shipboard ambient conditions, See Ch.1, instruments and alarms. The tests are to
Sec.1; simulate all control and alarm functions given in
the operational manual as far as practicable.
b) ship motion and vibration as per 2.5; The tests are to demonstrate satisfactory
performance under the following conditions :
c) temperature range as per 2.2;
a) tests to be carried out at rated power supply
d) voltage and frequency tolerances as per at prevailing ambient air conditions;
2.2;
b) loss of power to be simulated;
e) pressure tests as per 4.1.2 and 4.2.
c) the voltage of the electrical supply to be
4.1.2 Hydraulic and pneumatic piping is to be varied plus or minus 10 per cent and where
subjected to pressure tests at 1.5 times the alternating current is used, the frequency is
relief-device settings using the service fluid in to be varied simultaneously to plus or minus
hydraulic systems and dry air or dry inert gas for 5 per cent. The controls are to function
pneumatic systems as the testing media. Means satisfactorily during these variations without
are to be provided for the automatic removal of faults. Where the components selected
moisture from the piping before delivery to the have been tested individually and are
pneumatic control system. certified to function satisfactorily during
these power variations, retesting of final
4.1.3 All electrical control and monitoring circuits assemblies will not be required;
are to be checked and proven free of

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d) all electrical circuits supplying power to 4.3 Trials on board

servo-motors and actuators rated over 100
volts are to be subjected to dielectric- 4.3.1 Upon completion of the installation,
strength tests as required by Ch.8; complete performance tests of all systems are to
be carried out during dock trials and sea trials to
e) vibration tests required by 2.5 may be demonstrate that the system will perform
conducted in shops other than the plant of successfully during standby, maneuvering,
manufacture. When equipment is not steady conditions, and during transfer of
energized during the test it is to perform controls.
satisfactorily after the vibration test;
4.3.2 A copy of the record of the trials is to be
f) variation of hydraulic or pneumatic system submitted for information. It is recommended
pressure ± 20 per cent of normal operating that a copy of the record of the trials be kept on
pressure, except that relief valve pressure board for reference purposes for future
need not be exceeded. The system is to adjustments/testing etc. The record should
operate satisfactorily at the relief valve include details of all adjustments, calibrations,
pressure setting. method of simulating failures and expected
results due to these simulations. The record
should be kept up to date at all times.

Section 5

Machinery Operated from a Centralised Control Station –

‘CCS’ Notation

5.1 General requirements 5.1.4 Additional requirements for controls,

alarms and safeguards are given in 5.2.
5.1.1 Where it is proposed to install control,
alarm and safety systems to the following 5.2 Centralised control station for machinery
equipment, applicable features contained in
Section 2 and Section 3 are to be incorporated 5.2.1 A centralized control station is to be
in the system design. provided at some suitable location, which
satisfies the requirements of 5.2.2 to 5.2.7.
• Propulsion machinery including
essential auxiliaries; 5.2.2 A system of alarm displays and controls is
• Electric power generating plant; to be provided which readily ensures
• Controllable pitch propellers; identification of faults in the machinery and
• Oil fuel transfer and storage systems; satisfactory supervision and related equipment.
• Air compressors; The alarm and control systems are to satisfy the
• Steam generating plant (boilers and requirements of Section 1 and Section 2 as
their auxiliary equipment). applicable.

5.1.2 The arrangements are to be such that 5.2.3 Indication of all essential parameters
corrective actions can be taken at the control necessary for the safe and effective operation of
location in the event of machinery faults, e.g. the machinery is to be provided, e.g.
stopping of machinery, starting of standby temperatures, pressures, tank levels, speeds,
machinery, adjustments of operating powers etc.
parameters, etc. These actions may be effected
by either remote manual or automatic control. 5.2.4 Indication of the operational status of
running and standby machinery is to be
5.1.3 The controls, alarms and safeguards provided.
required by this chapter and Pt.5, Ch.22, as
applicable, are to be provided at the control 5.2.5 At the centralized control station, means of
location. A fire detection system satisfying the communication with the bridge area, the
requirements of Pt.5, Ch.22, Sec.2.13 is, also to accommodation for engineering personnel and if
be provided. necessary, the machinery space are to be
provided.

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5.2.6 In addition to the communication required
by 5.2.5, a second means of communication is 5.2.7 Arrangements are to be provided in the
to be provided between the bridge and the centralised control station so that the normal
centralized control station. One of these means supply of electrical power may be restored in the
is to be independent of the main electrical power event of failure.
supply.

Section 6

Programmable Electronic Systems

6.1 Scope where applicable 5.2. Hardware failures are to

be indicated at least at module level.
6.1.1 These requirements apply to the use of
programmable electronic systems which provide 6.2.8 System configuration, programs and data
control, alarm, monitoring or safety functions are to be protected against loss or corruption in
which are subject to classification. the event of failure of any power supply.

6.1.2 The requirements given in this section do 6.2.9 Access to system configuration, programs
not apply to navigation and loading instruments. and data is to be restricted by physical and/or
logical means providing effective security
6.2 General against unathorised alteration.

6.2.1 Programmable electronic systems are to 6.2.10 Where date and time information is
fulfill the requirements of the system under required by the equipment, this is to be provided
control for all operating conditions, taking into by means of a battery powered clock with
account human safety, environmental impact, restricted access for alteration. Date and time of
damage to vessel as well as equipment, information is to be fully represented and
usability of programmable electronic systems utilized.
and operability of non-computer devices and
systems, etc. 6.2.11 Displays and controls are to be protected
against liquid ingress due to spillage or
6.2.2 Programmable electronic equipment is to spraying.
revert to a defined safe state on initial start up or
re-start in the event of failure. 6.2.12 User interfaces are to be designed in
accordance with appropriate ergonomic
6.2.3 In the event of failure of any principles to meet user needs and enable timely
programmable electronic equipment, the system access to desired information or control of
and any other system to which it is connected, is functions. A system overview is to be readily
to fail to a defined safe state or maintain safe available.
operation, as applicable.
6.2.13 The keyboard is to be divided logically
6.2.4 Where programmable electronic into functional areas. Alphanumeric, paging and
equipment shares resources, e.g. a data specific system keys are to be grouped
communication link, with any control, alarm or separately.
safety system for essential services or safety
critical system, software is to meet the 6.2.14 Where a function may be accessed from
requirements of 6.3.1.5. more than one interface, the arrangement of
displays and controls is to be consistent.
6.2.5 Emergency stops are to be hard-wired and
independent of any programmable electronic 6.2.15 The size, colour and density of
equipment. Alternatively, the system providing information displayed to the operator are to be
emergency stop functions is to comply with the such that information may be easily read from
requirements of 6.3.1.1 and/or 6.3.1.5. the normal operator position under all
operational lighting conditions.
6.2.7 Programmable electronic equipment is to
be provided with self-monitoring capabilities 6.2.16 Display units are to comply with the
such that hardware and functional failures will requirements of International Electro technical
initiate an audible and visual alarm in Commission Standard IEC 950:1991, “Safety of
accordance with the requirements of 1.10 and information technology equipment, including

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electrical business equipment”, in respect of arrangements providing an equivalent level of

emission of ionizing radiation. safety will be subject to special consideration.

6.2.17 Symbols used in mimic diagrams are to 6.3.1.3 For essential services, the system is to
be visually representative and are to be be arranged to operate automatically from an
consistent throughout the systems’ displays. alternative power supply in the event of a failure
of the normal supply.
6.2.18 Multi-function displays and controls are to
be duplicated and interchangeable where used 6.3.1.4 Failure of any power supply is to initiate
for the control or monitoring of more than one an audible and visual alarm in accordance with
system, machinery or equipment. The number of the requirements of 1.10.4 and where
units provided at the control location is to be applicable, for SYJ Notation as given in Pt.5,
sufficient to ensure continuing safe operation in Ch.22.
the event of failure of any one unit. At least one
unit at the main control location is to be supplied 6.3.1.5 Where it is intended that the
from an independent uninterruptible power programmable electronic system implements
supply (UPS). emergency stop or safety critical functions, the
software is to be certified by IRS. Alternative
6.3 Additional requirements for proposals providing an equivalent level of
programmable electronic systems used for system integrity will be subject to special
essential services and safety critical consideration, e.g. fully independent hard wired
systems backup system, redundancy with design
diversity, etc.
6.3.1 The requirements of 6.3.1.1 to 6.3.1.7 are
to be complied with where control, alarm or 6.3.1.6 Control, alarm and safety related
safety systems for essential services, as defined information is to be displayed in a clear,
by Pt.4, Ch.8 or safety critical systems, unambiguous and timely manner and where
incorporate programmable electronic equipment. applicable, is to be given visual prominence over
other information on the display.
a) Safety critical systems are those which
provide functions intended to protect 6.3.1.7 Means of access to safety critical
persons from physical hazards, e.g. fire, functions are to be dedicated to the intended
explosion, etc. or to prevent mechanical function and readily distinguishable.
damage which may result in the loss of
an essential service, e.g. main engine 6.4 System categories
low lubricating oil pressure shutdown.
6.4.1 Programmable electronic systems are to
b) Applications that are not essential be assigned into three system categories as
services may also be considered to be shown in Table 6.4.1 according to the possible
safety critical, e.g. domestic boiler low extent of the damage caused by a single failure
water level shutdown. within the system.

6.3.1.1 Alternative means of operation are to be Consideration is to be given to the extent of the
provided for essential services and wherever damage directly caused by a failure, but not to
practicable, these are to be by provision of a any consequential damage.
fully independent hard wired backup system.
Where these alternative means are dependent Identical redundancy will not be taken into
on any programmable electronic equipment, the account for the assignment of a system
software is to be certified by IRS. category.

6.3.1.2 The system is to be configured such that 6.4.2 The assignment of a programmable
control, alarm and safety function groups are electronic system to the appropriate system
independent. A failure of the system is not to category is to be made according to the greatest
result in the loss of more than one of these likely extent of direct damage. For examples see
function groups. Proposals for alternative Table 6.4.2.

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Table 6.4.1 : System categories

Category Effects System functionality

I Those systems, failure of which will not - Monitoring function for informational
lead to dangerous situations for human / administrative tasks
safety, safety of the vessel and/or threat
to the environment
II Those systems, failure of which could - Alarm and monitoring functions
eventually lead to dangerous situations - Control functions which are
for human safety, safety of the vessel necessary to maintain the ship in its
and/or threat to the environment normal operational and habitable
conditions
III Those systems, failure of which could - Control functions for maintaining
immediately lead to dangerous the vessel’s propulsion and steering
situations for human safety, safety of - Safety functions
the vessel and/or threat to the
environment

Table 6.4.2 : Examples of assignment to system categories

System category Examples

I Maintenance support systems
Information and diagnostic systems
II Alarm and monitoring equipment
Tank capacity measuring equipment
Control systems for auxiliary machinery
Main propulsion remote control systems
Fire detection systems
Fire extinguishing systems
Bilge systems
Governors
III Machinery protection systems / equipment
Burner control systems
Electronic fuel injection for diesel engines
Control systems for propulsion and steering
Synchronizing units for switchboards

6.5 Data communication links including cables, switches, repeater and power
supplies.
6.5.1 Where control, alarm or safety systems
use shared data communication links to transfer 6.5.3 Loss of a data communication link is not to
data, the requirements of 6.5.3 to 6.5.10 are to result in the loss of ability to operate any
be complied with. The requirements apply to essential service by alternative means, See also
local area networks, field buses and other types 6.5.2.
of data communication link which make use of a
shared medium to transfer control, alarm or 6.5.4 The properties of the data communication
safety related data between distributed link, (e.g. bandwidth, access control method,
programmable electronic equipment or systems. etc.) are to ensure that all connected systems
will operate in a safe, stable and repeatable
6.5.2 Data communication is to be automatically manner under all operating conditions. The
restored within 45 seconds in the event of a latency of control, alarm and safety related data
single component failure. Upon restoration, is not to exceed two seconds.
priority is to be given to updating safety critical
data and control, alarm and safety related data 6.5.5 Protocols are to ensure the integrity of
for essential services. Components comprise all control, alarm and safety related data and
items required to facilitate data communication,

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provide timely recovery of corrupted or invalid 6.6.2 For systems of Category III modifications
data. of parameters by the manufacturer are to be
approved by IRS.
6.5.6 Means are to be provided to monitor
performance and identify hardware and 6.6.3 Any modifications made after performance
functional failures. An audible and visual alarm of the tests witnessed by IRS as per item 6 in
is to operate in accordance with the Table 6.8.1 are to be documented and
requirements of 1.10.4 and where applicable, traceable.
requirements as given in Pt.5, Ch.22 for SYJ
notation in the event of a failure of an active or 6.7 Documents to be submitted
standby component.
6.7.1 For the evaluation of programmable
6.5.7 Means are to be provided to prevent electronic systems of category II and III,
unintended connection or disconnection of any documents according to IEC 60092-504
equipment where this may affect the paragraph 10.11 are to be submitted.
performance of any other systems in operation.
6.7.2 For all tests required in accordance with
6.5.8 Data cables are to comply with the the system category, a test plan is to be
applicable requirements of Pt.4, Ch.8. Other submitted and the tests are to be documented.
media will be subject to special consideration.
6.7.3 Additional documentation may be required
6.5.9 The installation is to provide adequate for systems of category III. The documentation
protection against mechanical damage and is to include a description of the methods of test
electromagnetic interference. and test results.

6.5.10 Components are to be located with 6.7.4 Necessary documents for the evaluation of
appropriate segregation such that the risk of programmable electronic systems of Category-I
mechanical damage or electromagnetic are to be submitted upon request.
interference resulting in the loss of both active
and standby components is minimised. 6.7.5 Modifications are to be documented by the
Duplicated data communication links are to be manufacturer. Subsequent significant
routed to give as much physical separation as is modifications to the software and hardware for
practical. system categories II and III are to be submitted
for approval.
6.6 Protection against modification
6.8 Tests and conformance
6.6.1 Programmable electronic systems of
category II and III are to be protected against 6.8.1 Tests and conformance are to be in
program modification by the user. accordance with Table 6.8.1.

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Table 6.8.1 : Tests and conformance according to the system category

No. Tests and evidence Systems Category

I II III
1.
Evidence of quality system
Quality plan for software M M
Inspection of components (only hardware) from M M
sub-suppliers
Quality control in production M M
Final test reports M M S
Traceability of software M M S
2. Hardware and software description
Software description M S
Hardware description M S
Failure analysis for safety related functions only S
3. Evidence of software testing
Evidence of software testing according to quality M S
plan
Analysis regarding existence and fulfillment of S
programming procedures for safety related
functions
4. Hardware tests
Tests according to classification notes W W
5. Software tests
Module tests M S
Subsystem tests M S
System test M S
6. Performance tests
Integration test M W
Fault simulation W W
Factory Acceptance Test (FAT) M W W
7. On-board test
Complete system test M W W
Integration test W W
8. Modifications
Tests after modifications M S/W S/W
M = Evidence kept by manufacturer and submitted on request
S = Evidence checked by IRS
W = To be witnessed by IRS.

Notes:

Definition and notes relating to Table 6.8.1 are as follows:

1. Evidence of quality system

1.1 Quality plan for software

A plan for software lifecycle activities are to be produced which defines relevant procedures,
responsibilities and system documentation, including configuration management generally in
accordance with ISO standard 90003 “Guidelines for the Application of ISO 9001:2000 to the
Computer Software or Equivalent”.

1.2 Inspection of components (only Hardware) from sub-suppliers

Proof that components and/or sub-assemblies conform to specification.

1.3 Quality control in production

Evidence of quality assurance measures on production.

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1.4 Final test reports

Reports from testing of the finished product and documentation of the test results.

1.5 Traceability of software

Modification of program contents and data, as well as change of version has to be carried out in
accordance with a procedure and is to be documented.

2. Hardware and software description

2.1 Software description

Software is to be described, e.g.
- Description of the basic and communication software installed in each hardware unit
- Description of application software (not program listings)
- Description of functions, performance, constraints and dependencies between modules or
other components.

2.2 Hardware description

Hardware is to be described, e.g.
- System block diagram, showing the arrangement, input and output devices and
interconnections
- Connection diagrams
- Details of input and output devices
- Details of power supplies.

2.3 Failure analysis for safety related functions only (e.g. FMEA)
The analysis is to be carried out using appropriate means, e.g.
- Fault tree analysis
- Risk analysis
- FMEA or FMECA.

The purpose is to demonstrate that for single failures, systems will fail to safety and that systems
in operation will not be lost or degraded beyond acceptable performance criteria when specified
by IRS.

3. Evidence of software testing

3.1 Evidence of software testing according to quality plan.

Procedures for verification and validation activities are to be established, e.g.
- Methods of testing
- Test programs producing
- Simulation.

3.2 Analysis regarding existence and fulfillment of programming procedures for safety related
functions
Specific assurance methods are to be planned for verification and validation of satisfaction of
requirements, e.g.
- Diverse programs
- Program analysis and testing to detect formal errors and discrepancies of the description
- Simple structure.

4. Hardware tests

Tests according to Classification Notes “Type Approval of Electrical Equipment used for Control,
Protection, Safety and Internal Communication in Marine Environment” are to be conducted.
Special consideration may be given to tests witnessed and approved by another IACS member
society.

5. Software tests

5.1 Module test

Software module tests are to provide evidence that each module performs its intended function
and does not perform unintended functions.

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5.2 Subsystem tests

Subsystems testing is to verify that modules interact correctly to perform the intended functions
and do not perform unintended functions.

5.3 System test

System testing is to verify that subsystems interact correctly to perform the functions in
accordance with specified requirements and do not perform unintended functions.

6. Performance tests

6.1 Integration tests

Programmable electronic system integration testing is to be carried out using satisfactorily tested
system software and as far as practicable intended system components.

6.2 Fault simulation

Faults are to be simulated as realistically as possible to demonstrate appropriate system fault
detection and system response. The results of any required failure analysis are to be observed.

6.3 Factory Acceptance Test (FAT)

Factory acceptance testing is to be carried out in accordance with a test program accepted by
IRS. Testing is to be based on demonstrating that the system fulfils the requirements specified by
IRS.

7. On-board tests

7.1 Complete system test

Testing is to be performed on the completed system comprising actual hardware components
with the final application software, in accordance with an approved test program.

7.2 Integration tests

On board testing is to verify that correct functionality has been achieved with all systems
integrated.

8. Modifications

Tests after modifications

Modifications to approved systems are to be notified in advance and carried out to Surveyor’s
satisfaction, see Cl. 6.3.5.

End of Chapter

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Chapter 8

Electrical Installations

Contents
Section

1 General Requirements
2 System Design
3 Cables and Busbar Trunking Systems
4 Switchgear and Control Gear Assemblies
5 Rotating Machines - Construction and Testing
6 Converting Equipment
7 Miscellaneous Equipment
8 Electric Propulsion Systems
9 Fire Safety Systems
10 Crew and Passenger Emergency Safety Systems
11 Ship Safety Systems
12 Electrical Equipment for use in Explosive Gas/Combustible Dust Atmospheres
13 High Voltage Systems
14 Trials

Section 1

General Requirements

1.1 Scope any relevant statutory requirements of the

National Authority of the country in which the
1.1.1 The requirements of this Chapter are ship is to be registered.
applicable to both direct current and alternating
current installations unless specifically stated 1.2 Definitions
otherwise.
1.2.1 Normal operational and habitable
1.1.2 The requirements of this Chapter apply to condition is condition under which the ship as a
all ships. Consideration will be given to whole, the machinery, services, means and aids
arrangements or details of equipment which ensuring propulsion, ability to steer, safe
comply with other National or International navigation, fire and flooding safety, internal and
standards in so far as they are not less effective external communications and signals, means of
and reliable. escape and emergency boat winches, as well as
designed comfortable conditions of habitability
The arrangements for vessels intended for are in working order and functioning normally.
restricted services or for special services will be
specially considered. 1.2.2 Emergency condition is a condition
under which any services needed for normal
1.1.3 Whilst these requirements are considered operational and habitable conditions are not in a
to meet those of the "International Convention working order due to the failure of the main
for the Safety of Life at Sea, 1974, including source of electrical power.
amendments", attention should also be given to

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1.2.3 Main source of electrical power is a 1.4 Plans

source intended to supply electrical power to the
main switchboard for distribution to all services 1.4.1 The following plans and details for
necessary for maintaining the ship in normal electrical installations including propulsion
operational and habitable conditions. equipment, if fitted, and auxiliary machinery are
to be submitted in triplicate for approval:
1.2.4 Main generating station is the space in
which the main source of electrical power is a) Schematic diagram of the electrical system
situated. including information such as cable sizes,
type of insulation, normal working currents,
1.2.5 Main switchboard is a switchboard which line drop of voltages and details of
is directly supplied by the main source of protection devices together with rating and
electrical power and is intended to distribute interrupting capacity of circuit breakers and
electrical energy to ship's services. fuses;

1.2.6 Emergency switchboard is a switchboard b) Calculations of prospective short circuit

which in the event of failure of the main current of main busbars and secondary side
electrical power supply system is directly of transformers (Additionally load schedule
supplied by the emergency source of electrical is to be submitted for information);
power or transitional source of emergency
power and is intended to distribute electrical c) Construction details, sectional views, type,
energy to the emergency services. rating, make of rotating machines rated at
100 [kW] and above, where welding is to be
1.2.7 Emergency source of electrical power is applied to shafts of machines and plans
a source of electrical power, intended to supply showing the construction;
the emergency switchboard in the event of
failure of the supply from the main source of d) The arrangement plans and circuit diagrams
electrical power. of switchgear and controlgear giving details
of isolating, protective and control devices,
1.3 Surveys details of bus bars, cable sizes, type of
insulation and normal working currents in
1.3.1 Electrical propelling machinery and the circuits. Additional details such as
associated equipment together with auxiliary mechanical stresses on the bus bars by
services for the safety of the ship are to be short circuit, bus bar supporting
installed in accordance with the relevant arrangements, verification of protective
requirements of this Chapter, surveyed and devices;
have tests witnessed by the Surveyors.
e) General diagrams of emergency circuits,
1.3.2 All generators, motors and transformers of control and alarms for essential services
100 [kW] and over, intended for essential and internal communications together with
services, are to be surveyed during test and if details of sources of supply, cable sizes and
appropriate also during manufacturing. types of insulation and any other information
required for assessment of such circuits;
Where an alternative survey scheme has been
approved by IRS as per Ch.1, Sec.4, the f) Plans for generators, motors and seatings
attendance of the Surveyor during manufac- together with diagrams of control gears,
turing may not be necessary. cables and circuits for electric propulsion
equipment, if fitted. Key diagram and
1.3.3 All electric propelling machinery including explanation of the system are to be
switchgear, control gear, converting equipment, submitted;
cables, main and auxiliary generators, motors
and exciters are to be surveyed by the g) Plans of electric slip couplings, if fitted,
Surveyors during manufacture and testing. showing details of construction and
scantlings together with diagrams of control
1.3.4 For refrigerated cargo installations having gear and other electrical components;
HY class notation, motors are to be tested and
certificates furnished by the manufacturers. h) For tankers and similar vessels, a general
Motors of 100 [kW] or over are to be surveyed arrangement of the ship showing hazardous
by the Surveyors during manufacture and spaces and the location of the electrical
testing. equipment in such spaces. A schedule of
safe type electrical equipment located in
hazardous spaces giving details of the type

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of equipment fitted, the certifying authority - Control, monitoring and safety
and copies of the certificates. devices/systems of equipment for primary
essential services.
1.4.2 Additional information may be required for
vessels engaged in special services or of a 1.5.1.3 Secondary Essential Services
novel design.
Secondary Essential Services are those
1.5 Essential and other services services which need not necessarily be in
continuous operation to maintain propulsion and
1.5.1 Essential services steering but which are necessary for maintaining
the vessel's safety. Example of equipment for
1.5.1.1 Essential services are divided into secondary essential services are as follows:
following types of services:
- Windlass
a) "Primary Essential Services" and - Fuel oil transfer pumps and fuel oil
treatment equipment
b) "Secondary Essential Services". - Lubricating oil transfer pumps and
lubrication oil treatment equipment
Definitions and examples of such services are - Pre-heaters for heavy fuel oil
given in 1.5.1.2 and 1.5.1.3. - Starting air and control air compressors
- Bilge, ballast and heeling pumps
1.5.1.2 Primary Essential Services - Fire pumps and other fire extinguishing
medium pumps
Primary Essential Services are those services - Ventilating fans for engine and boiler rooms
which need to be in continuous operation to - Services considered necessary to maintain
maintain propulsion and steering. Examples of dangerous spaces in a safe condition
equipment for primary essential services are as - Navigation lights, aids and signals
follows: - Internal safety communication equipment
- Fire detection and alarm system
- Steering gears - Lighting system
- Pumps for controllable pitch propellers - Electrical equipment for watertight closing
- Scavenging air blower, fuel oil supply appliances
pumps, fuel valve cooling pumps, lubricating - Electric generators and associated power
oil pumps and cooling water pumps for main sources supplying the above equipment
and auxiliary engines and turbines - Hydraulic pumps supplying the above
necessary for propulsion equipment
- Forced draught fans, feed water pumps, - Control, monitoring and safety systems for
water circulating pumps, vacuum pumps cargo containment systems
and condensate pumps for steam plants on - Control, monitoring and safety devices /
steam turbine ships, and also for auxiliary systems of equipment for secondary
boilers on ships where steam is used for essential services.
equipment supplying primary essential - Equipment used for cooling and maintaining
services lesser ambient temperature (refer Ch.1,
- Oil burning installations for steam plants on 1.7.4)
steam turbine ships and for auxiliary boilers
where steam is used for equipment 1.5.2 Services such as following are considered
supplying primary essential services necessary for minimum comfortable conditions
- Azimuth thrusters which are the sole means of habitability :
for propulsion/steering and associated
lubricating oil pumps, cooling water pumps - cooking;
- Electrical equipment for electric propulsion
plant with lubricating oil pumps and cooling - heating;
water pumps
- Electric generators and associated power - domestic refrigeration;
sources supplying the above mentioned
equipment - mechanical ventilation;
- Hydraulic pumps supplying the above
mentioned equipment - sanitary and fresh water;
- Viscosity control equipment for heavy fuel
oil - electric generators and associated
power sources supplying the above
mentioned equipment.

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1.5.3 Services such as following, which are in 1.7.2 All connections for current-carrying parts
addition to 1.5.1 and 1.5.2, are considered and earthing connections are to be fixed so that
necessary to maintain the ship in a normal they cannot loosen by vibrations. This also
seagoing operational and habitable condition : applies to fixing of mechanical parts when found
necessary.
- cargo handling and cargo gear
equipment; 1.8 Voltage and frequency variations

- hotel services, other than those required 1.8.1 All electrical appliances supplied from the
for habitable conditions; main or emergency systems are to be so
designed and manufactured that they are
- thrusters, other than those for dynamic capable of operating satisfactorily under the
positioning. normally occurring variations in voltage and
frequency. Unless otherwise stated in national
1.6 Ambient reference conditions or international standards, provided the
variations comply with as stated below, all
1.6.1 For details regarding ambient reference equipment are to operate satisfactorily with the
conditions, See Ch.1. variations from its rated value as shown in the
following Tables 1.8.1 to 1.8.3.
1.7 Vibrations, accelerations
a) For alternating current components; voltage
1.7.1 Electrical equipment is to be constructed and frequency variations shown in Table
to withstand when subjected to following : 1.8.1 are to be assumed.

vibrations within the frequency range 5 - 50 Hz b) For direct current components supplied by
and with vibration velocity amplitude 20 d.c. generators or converted by rectifiers,
[mm/sec]. voltage variations shown in Table 1.8.2 are
to be assumed.
peak accelerations caused by the ship's
movements in waves - ± 0.6 g for vessels of c) For direct current components supplied by
length exceeding 90 [m] and ± 1 g for other electrical batteries, voltage variations shown
vessels. in Table 1.8.3 are to be assumed.

Table 1.8.1 : Voltage and frequency variations for a.c. distribution systems

Quantity in operation Permanent variations Transient variations

± 10%
Frequency ± 5%
(recovery time 5 seconds)
+ 6% ± 20% (recovery time 1.5
Voltage
- 10% seconds)

Table 1.8.2 : Voltage variations for d.c. distribution systems

Parameters Variations
Voltage tolerance (continuous) ±10%
Voltage cyclic variation deviation 5%
Voltage ripple (a.c., r.m.s., over steady d.c. voltage) 10%

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Table 1.8.3 : Voltage variations for battery systems

Systems Variations
Components connected to the battery during charging (see Note)
+30%, -25%
Components not connected to the battery during charging
+20%, -25%

Note : Different voltage variations as determined by the charging / discharging characteristics,

including ripple voltage from the charging device, may be considered.

1.8.2 Any special system, e.g. electronic circuits, 1.9.6 The operation of all electrical equipment
whose function cannot operate satisfactorily and the lubrication arrangements are to be
within the limits given in 1.8.1 are not be efficient under such conditions of vibration and
supplied directly from the system but by shock as arise in normal practice.
alternative means, e.g. through stabilized
supply. 1.9.7 All nuts and bolts/screws used to connect
or secure current- carrying parts and working
1.8.3 Contactors and similar electro-magnetic parts are to be effectively locked, to prevent
devices are not to drop out at or above 85 per them from working loose due to vibration.
cent rated voltage.
1.9.8 Generators, motors, conductors and
1.9 Location and construction generally any electrical equipment producing an
external magnetic field are to be placed at such
1.9.1 Electrical equipment is to be placed in distance from the magnetic compass or any
accessible and adequately lighted spaces clear other equipment likely to be affected by such
of flammable material and heat sources such as magnetic field or are to be so screened that the
boilers, heated tanks etc. The spaces should be interfering external magnetic field is negligible
well ventilated, free from accumulations of (deviation less than 0.5°), even when circuits are
flammable dusts, vapours or gases and acid switched on and off.
fumes. The equipment should not be exposed to
risk of mechanical injury or damage from water, 1.9.9 Where electric power is used for
excessive moisture, steam, oil or any other propulsion, the equipment is to be so arranged
dangerous fluid. Where necessarily exposed to that it will operate satisfactorily in the event of
such hazards, the equipment is to be suitably partial flooding by bilge water above the tank top
constructed or enclosed. up to the floor plate level. See also Ch.3, Sec.2.

1.9.2 Live parts are to be efficiently shielded 1.10 Design and construction
from any accidental contact.
1.10.1 Design, construction and installation of
1.9.3 All electrical apparatus and equipment is electrical propelling machinery and associated
to be constructed and installed so as to avoid equipment together with auxiliary services
injury or electrical shock when handled or essential for the safety of ship are to be done in
touched in the course of normal operation. accordance with the relevant requirements of
this Chapter and are to be surveyed and tested
1.9.4 Insulating materials and insulated windings by the Surveyors.
are to be resistant to tracking, moisture, sea air,
oil vapour and any other similar conditions, 1.10.2 Design and installation of other
unless special precautions are taken to protect equipment is to be such as to ensure minimising
them. the risk of fire due to its failure. As a minimum, it
should comply with a National or International
1.9.5 Equipment is not to remain alive through Standard, revised where necessary for ambient
the control circuits and/or pilot lamps when conditions.
switched off by the control switch. This does not
apply to synchronising switches and/or plugs. 1.10.3 Subject to inspection and testing by the
Surveyors, compliance with the recommen-
dations of the International Electrical

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Commission (IEC) publication 92 : "Electro- The wider choice available of such

technical Installation in Ships" or equivalent components suitable for a voltage upto
national standards, may be accepted as meeting 250V is not to be overlooked,
the requirements of this Chapter.
d) Internal circuits of radio, television and
1.10.4 Where the Rules require electrical navigation equipment or the external
equipment to be of a 'safe type', such equipment transmission circuits of radio and radar
is to be certified for the gases/vapours involved. equipment. These may be however subject
The construction and type testing is to be in to statutory regulations.
accordance with IEC publication 79 : "Electrical
Apparatus for Explosive Gas Atmospheres", or 1.11.3 Installations with higher voltages than
an equivalent national standard. specified above may be accepted for special
purposes (e.g. cold cathode discharge lamps,
1.11 Voltages for large auxiliary machinery and for propulsion
machinery) after special consideration, in each
1.11.1 Standard voltages as recommended by case, and subject to the provisions of Sec.13 of
IEC for shipboard installations, will in general be this Chapter.
accepted subject to the following limits :
1.12 Electrical equipment for use in
a) For power and the heating equipment, explosive gas atmospheres
permanently installed and connected to
fixed wiring, except for space heaters 1.12.1 Where the Rules require electrical
(radiators) in accommodation spaces - equipment to be of a "safe type", such
1000V; equipment is to be certified for the
gases/vapours involved. The equipment should
b) For lighting (including signal lamps), space conform to IEC publication 79, "Electrical
heaters in accommodation spaces, socket- Apparatus for Explosive Gas Atmospheres", or
outlets, portable appliances and other an equivalent national standard.
consumers supplied by flexible cables and
for communication and instrumentation 1.12.2 Certified safe type equipment includes
equipment - 250V. the following types of protection :

1.11.2 The requirements of 1.11.1 may be Intrinsically safe Ex "i"

waived for the following applications :
Increased safety Ex "e"
a) For permanently installed power and
heating equipment, where connection by Flameproof Ex "d"
flexible cable is essential because of the
application (e.g. for movable cranes and Pressurized enclosure Ex "p"
other hoisting gear), a maximum of 1000V is
acceptable, 1.12.3 Further, lighting fittings of the air driven
type with pressurized enclosures are considered
b) For portable appliances, which are not to be a "safe type" of lighting fitting.
hand-held during operation (e.g. welding
transformers, refrigerated containers), a 1.12.4 When "safe type" equipment is permitted
maximum of 1000V with connection by in hazardous zones or spaces all switches and
flexible cable and socket outlet, which is protective devices are to interrupt all lines or
interlocked with a switch. At each such phases and, where practicable, are to be
socket outlet a precautionary warning is to located in a non-hazardous zone or space
be permanently and prominently displayed unless specifically permitted otherwise.
indicating the nature and voltage of the Appropriate labels of non-inflammable material
electric supply and the specific purpose for are to be permanently affixed to such
which the socket outlet is intended. Such equipment, switches and protective devices for
arrangements may be installed for identification purposes.
applications in 1.11.2(a) also,
1.13 Enclosures
c) For instrumentation and control equipment
which are part of power and heating 1.13.1 The enclosure types given in Table
installations (e.g. pressure or temperature 1.13.1 are required as a minimum.
switches for start/stop of motors), a
maximum of 1000V, provided that all
components are constructed for this voltage.

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1.14 Creepage and clearance
1.14.2 For bare busbars the minimum clearance
1.14.1 Distance between live parts and between distances in Table 1.14.1 are to be observed.
live parts and earthed metal, whether across Where necessary these distances are to be
surfaces or in air, are to be adequate for the increased to allow for the electromagnetic forces
working voltages considering the nature of the involved.
insulating material and the transient over
voltages developed by switch and fault
conditions.

Table 1.13.1 : Enclosure types in relation to location

(N : Normally not accepted for installation in this location)

Accesso
ries
Control Transfor
Rotating Heating such as
Switchb gear and mers Lighting Socket
Location machi- appli- switches
oards motor and fittings outlets
nes ances connecti
starters rectifiers
on
boxes
Engine and boiler rooms
above the floor IP 22 IP 22 IP 22 IP 22 IP 22 IP 22 IP 44 IP 44
dry control rooms IP 22 IP 22 IP 22 IP 22 IP 22 IP 22 IP 22 IP 22
below the floor N N IP 44 N IP 44 IP 44 N IP 44
closed compartments for
fuel oil and lub.oil IP 44 IP 44 IP 44 IP 44 IP 44 IP 44 N IP 44
separators
Fuel oil tanks N N N N N N N N
Ballast and other water
N N IP 68 N N IP 68 N N
tanks, bilge wells
Ventilation ducts N N IP 44 N N N N N
Deckhouses, forecastle
spaces, steering gear
IP 22 IP 22 IP 22 IP 22 IP 22 IP 22 IP 44 IP 44
compartments and similar
spaces
Ballast pump rooms and
similar rooms below the IP 44 IP 44 IP 44 IP 44 IP 44 IP 44 IP 56 IP 56
loadline
Cargo holds N N IP 44 N IP 55 N IP 56 IP 56
Open deck, keel ducts IP 56 IP 56 IP 56 IP 56 IP 55 IP 56 IP 56 IP 56
Battery rooms, lamp
rooms, paint stores, stores N N EX N EX EX N EX
for welding gas bottles
Dry accommodation
IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 IP 20
spaces
Batch rooms and showers N N N N IP 44 IP 44 N IP 56
Galleys, laundries and
IP 44 IP 44 IP 44 IP 44 IP 44 IP 44 IP 44 IP 44
similar rooms

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Table 1.14.1 : Minimum clearances between bare busbars

Minimum clearance between phases

Voltage between Minimum clearance to earth
or poles
phases or poles
In air [mm] In oil [mm] In air [mm] In oil [mm]
660 or less 16 - 19 -
2200 38 - 38 -
3300 51 13 51 10
6600 63 19 89 25

1.15 Earthing of non-current carrying parts is nevertheless otherwise so guarded that it

cannot be touched and cannot come in
1.15.1 Except where exempted by 1.15.2, all contact with exposed metal.
non-current carrying exposed metal parts of
electrical equipment and cables are to be 1.15.3 Metal coverings of cables are to be
earthed. effectively earthed at both ends of the cable. In
final sub-circuits, other than those installed in
1.15.2 The following parts may be exempted hazardous zones or spaces, earthing at the
from the requirements of 1.15.1: supply end only will be considered adequate.
Single point earthing may be accepted for
a) lamp-caps, where suitably shrouded; instrumentation cables, or cables for intrinsically
safe circuits, if desirable for technical reasons.
b) shades, reflectors and guards supported on
lamp holders or light fittings constructed of, 1.15.4 The electrical continuity of all metal
or shrouded in, non-conducting material; coverings of cables throughout the length of the
cable, particularly at joints and trappings, is to
c) metal parts on, or screws in or through, non- be ensured.
conducting materials, which are separated
by such material from current-carrying parts 1.15.5 Metal parts of portable appliances, other
and from earthed non-current carrying parts than current-carrying parts and parts exempted
in such a way that in normal use they by 1.15.2 are to be earthed by means of an
cannot become live or come into contact earth continuity conductor in the flexible cable or
with earthed parts; cord through the associated plug and socket
outlet.
d) apparatus which is constructed in
accordance with the principle of double 1.15.6 Earthing conductors are to be of copper
insulation; or other corrosion-resistant material and be
securely installed and protected where
e) bearing housings which are insulated in necessary against damage and also, where
order to prevent circulation of current in the necessary, against electrolytic corrosion.
bearings; Connections are to be so secured that they
cannot work loose under vibration.
f) clips for fluorescent lamps;
1.15.7 The nominal cross-section areas of
g) cable clips and short lengths of pipes for copper earthing conductors are, in general to be
cable protection; equal to the cross-section of the current-carrying
conductor upto 16 [mm2]. Above this figure they
h) apparatus supplied at a voltage not are to be equal to at least half the cross-section
exceeding 55 V direct current or 55 V, root of the current-carrying conductor with a
mean square, between conductors, or minimum of 16 [mm2]. Every other earthing
between any conductor and earth in a circuit conductor is to have a conductance not less
isolated from the supply. Auto transformers than that specified for an equivalent copper
are not to be used for the purpose of earthing conductor.
achieving the alternating current voltage;
1.15.8 The connection of the earthing
i) apparatus or parts of apparatus which conductors to the hull of the ship are to be made
although not shrouded in insulating material in accessible locations to permit their ready

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examination and to enable their disconnection
for testing of insulation. They are to be secured - Public address systems.
by a screw or stud of diameter not less than 6
[mm] which is to be used for this purpose only. - Remote emergency stop/shutdown
Bright metallic surfaces at the contact areas are arrangements for systems which may
to be ensured immediately before the nut or support the propagation of fire and/or
screw is tightened and where necessary, the explosion.
joint is to be protected against electrolytic
corrosion. The connection is to remain 1.17.2 Where cables for services as described
unpainted. in 1.17.1 including their power supplies, pass
through high fire risk areas and in addition for
1.16 Bonding for the control of static passenger ships, main vertical fire zones, other
electricity than those which they serve, they are to be so
arranged that a fire in any of these areas or
1.16.1 Bonding straps for the control of static zones does not affect the operation of the
electricity are required for cargo tanks, process service in any other area or zone. This may be
plant and piping systems, for flammable achieved by either of the following measures:
products and solids liable to release flammable
gas and/or combustible dust, which are not a) Cables of a fire resistant type and complying
permanently connected to the hull of the ship with
either directly or via their bolted or welded
supports and where the resistance between i) IEC 60331-31 for overall diameter
them and the hull exceeds 1MΩ. greater than 20 [mm] and
ii) IEC 60331-21 for overall diameter
1.16.2 Where bonding straps are required for less than or equal to 20 [mm]
the control of static electricity, they are to be
robust, that is, having a cross-sectional area of are installed and run continuously within the
about 10 [mm2] and are to comply with 1.15.6 high fire risk area to keep the fire integrity. See
and 1.15.8. Fig.1.17.2.

1.17 Operation under fire conditions b) By running cables in two loops or distributing
cables radially as widely apart as practicable
1.17.1 Electrical services required to be and so arranged that in the event of damage by
operable under fire conditions are as follows: fire atleast one of loops or radial distributions
remains operational.
- Control and power systems to power-
operated fire doors and their status Systems that are self monitoring, fail safe or
indication. duplicated with cable runs as widely separated
as is practicable may be exempted.
- Control and power systems to power-
operated watertight doors and their 1.17.3 “High fire risk areas” are defined as
status indication. follows:

- Emergency fire pump. i) Machinery spaces.

ii) Spaces containing fuel treatment
- Emergency lighting. equipment and other highly
flammable substances.
- Fire and general alarms. iii) Galley and pantries containing
cooking appliances.
- Fire detection systems. iv) Laundry with drying equipment.
v) Spaces as defined by paragraphs
- Fire-extinguishing systems and fire- (8), (12) and (14) of Part 6, Chapter
extinguishing media release alarms. 3, Cl.3.2.2.3.2 for ships carrying
more than 36 passengers.
- Low location lighting, see Pt.6, Ch.4,
Sec.2.

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Fig.1.17.2 : The running of fire resistant type cables

1.18 Additions and alterations

1.18.2 Plans for the proposed modifications are
1.18.1 Additions or alterations (temporary or to be submitted for approval and the additions or
permanent) to the approved load of the existing alterations are to be carried out under the
electrical installations are not to be made unless inspection and to the satisfaction of the
it has been ascertained that the current carrying Surveyors.
capacity and condition of the existing installation
are adequate for the proposed modification.

Section 2

System Design

2.1 General
- the safety of passengers, crew and ship
2.1.1 Electrical installations are to be such that : from electrical hazards is ensured.

- all electrical auxiliary services 2.2 Supply and distribution systems

necessary for maintaining the ship in
normal operational and habitable 2.2.1 The following systems of generation and
conditions are ensured without recourse distribution as detailed in Table 2.2.1 are
to the emergency source of electrical acceptable.
power;
2.2.2 Systems of generation and distribution,
- electrical services essential for safety other than those specified above, will, upon
are ensured under various emergency application, be given special consideration.
conditions; and

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Table 2.2.1 : Systems of generation and distribution

Description Tankers intended for the carriage in bulk of Other vessels

oil, liquefied gases and other hazardous
liquids having a flashpoint not exceeding
60°C (closed cup test)
d.c. two wire insulated system Acceptable Acceptable
(See Note 1)
a.c., single-phase, two wire Acceptable Acceptable
insulated system (See Note 1)
a.c., three-phase, three wire Acceptable Acceptable
insulated system (See Note 2)
a.c. or d.c. earthed systems Normally not acceptable (See Note 3) Acceptable
a.c. three-phase, four wire Not acceptable Acceptable upto 1000V
system with neutral earthed
but without hull return
Hull return system of Normally not acceptable Normally not acceptable
distribution (a.c. or d.c.) (See Notes 4 and 5) (See Notes 4 and 5)

Note 1 : None of the poles/phases is earthed (see also para 2.4).

Note 2 : Neutral is not earthed.

Note 3 : This may be acceptable for -

a) Power supplied control circuits and instrumentation circuits, where technical or safety reasons
require connection to earth, provided the current in the hull is limited to not more than 5 amps in
both normal and fault conditions.

b) Earthed intrinsically safe circuits.

c) Limited and locally earthed systems, provided that any possible resulting current does not flow
directly through any of the dangerous spaces.

d) Alternating current power networks of 1000 Volts root mean square (line to line) and over, provided
that any possible resulting current does not flow directly through any of the dangerous spaces.

e) The electrical systems shall be specially considered for existing vessels built before 1st October,
1994.

Note 4 : This may be acceptable for -

a) Impressed current cathodic protection systems.

b) Limited and locally earthed systems, such as starting and ignition systems of internal combustion
engines, provided that any possible resulting current does not flow directly through any of the
dangerous spaces.

c) Insulation level monitoring devices, provided the circulation current does not exceed 30 mA under
the most unfavourable conditions.

Note 5 : All final subcircuits, i.e. all circuits fitted after the last protective device are to be of two insulated
wires the hull return being achieved by connecting to the hull, one of the busbars of the distribution
board from which wires originate.

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2.3 Voltage and frequency variations maximum load which can be expected to
occur on the lighting installation; and
2.3.1 For installations supplied by generators,
the voltage on the main switchboard's bus-bars - to have sufficient reserve capacity for
is to be kept between 97.5 and 102.5 per cent of starting the largest electric motor on board,
the installation's nominal voltage under all without the transient voltage and frequency
steady load conditions. variations exceeding the values specified in
2.3.
2.3.2 For D.C. installations supplied by batteries,
consideration is to be given to the supply 2.5.2 For a duplicated essential or important
voltage variation between the battery's full- consumer with only one unit driven electrically, it
charged and minimum-charged voltages. For is not expected that electrically driven auxiliary
battery installations with "float charge", the would be used with one generator out of action.
maximum charging voltage is to be considered. Similarly the loads due to side/bow thrusters are
not to be taken in to account while calculating
2.3.3 The transient voltage variations on the the electric load with one generator out of action
main switchboard's bus-bars by the maximum unless necessitated by additional class notation
power and current variations which can occur regarding Dynamic Positioning.
(except under fault conditions), are not to
exceed - 15% and + 20% of the nominal 2.5.3 The arrangement of the generators is to be
voltage. such that the requirements of 2.5.1 would be
met regardless of the speed and direction of the
2.3.4 The voltage drop in each consumer circuit, propulsion machinery or shafting.
by full load on this circuit, is not to exceed 6% of
the nominal voltage, measured from the main 2.5.4 In addition, the generating sets are to be
switchboard's bus-bars to the consumer. For such as to ensure that with any one generator or
battery circuits with supply voltage less than 50 its primary source of power out of operation, the
Volts, 10% voltage drop may be accepted. remaining generating sets are to be capable of
providing the electrical services necessary to
2.3.5 The frequency variations on AC start the main propulsion plant from a dead ship
installations are to be kept within the following condition. The emergency source of power may
limits : be used for the purpose of starting from a dead
ship condition if its capability alone or combined
- 95 - 105 per cent of rated frequency under with that of any other source of electrical power
steady load conditions; and is sufficient to provide at the same time those
services required to be supplied by 2.8.
- 90 - 110 per cent of rated frequency under
transient load conditions. 2.5.5 Where the main source of electrical power
is essential for the propulsion and steering of the
2.4 Earth indication ship, the system is to be arranged such that the
electrical supply to equipment necessary for
2.4.1 Every insulated distribution system is to be propulsion, steering and safety of the ship is
provided with a device or devices to maintained or immediately restored in case of
continuously monitor the values of electrical loss of any one generator in service.
insulation to earth and to give an audible or
visual indication in case of abnormally low 2.5.6 Requirement in 2.5.5 to be fulfilled by the
insulated values. following measures:

2.5 Number, arrangement and capacity of a) Where the electrical power is normally
generators supplied by more than one generator set
simultaneously in parallel operation,
2.5.1 The number and capacity of generators provision of protection, including automatic
are to be such that with any one generator not in disconnection of sufficient non-essential
operation, the capacity of the remaining services and if necessary services those
generators is to be sufficient for : provided for habitability, should be made to
ensure that, in case of loss of any of these
- supplying all essential and other services generating sets, the remaining ones are
mentioned under 1.5.1 and 1.5.2 of this kept in operation to permit propulsion and
chapter which can be expected to be in use steering and to ensure safety.
simultaneously, at full power on the
propulsion plant, and including the

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b) Where the electrical power is normally machinery, it is to have sufficient capacity for the
supplied by one generator provision shall be total load, or the machinery arrangement is to be
made, upon loss of power, for automatic such that the generator and the other auxiliary
starting and connecting to the main machinery can not be used simultaneously.
switchboard of stand-by generator(s) of
sufficient capacity with automatic restarting If the other auxiliary machinery is connected to
of the essential auxiliaries, in sequential the prime mover in such a way that it is possible
operation if required. Starting and to overload the prime mover, an interlocking or
connection to the main switchboard of the other effective means for preventing such
stand-by generator is to be preferably within overloading is to be arranged.
30 seconds, but in any case not more than
45 seconds, after loss of power. Where 2.6.2 When generators driven by reciprocating
prime movers with longer starting time are to steam engines or steam turbines are used, and
be used, the starting and connection time the operation of the boiler(s) depends on electric
are subject to special approval. power supply, then there is to be at least one
generator driven by an auxiliary oil engine or
c) Load shedding or other equivalent gas turbine to enable the boiler plant to be
arrangements should be provided to protect started.
the generators against sustained overload.
2.6.3 Generators and generator systems, having
i) The load shedding is to be automatic. the ship's main propulsion machinery as their
prime mover, may be accepted as part of the
ii) Primary essential services mentioned in ships main source of electrical power, provided:
1.5.1.2 are not to be included in any load
shedding. a) They are capable of operating under all
weather conditions during sailing and during
iii) The secondary essential services manoeuvring, also when the vessel is
mentioned in 1.5.1.3 may be included in stopped, within the limits of voltage and
load shedding provided: frequency variations as specified in 2.3;

a) Following systems, required for b) Their rated capacity is safeguarded during

safety, are not disrupted: all operations given above and is such that
- lighting systems, in the event of any other one of the
- navigation lights, aids and generators failing, the services given in
signals, 1.5.1 and 1.5.2 are maintained;
- internal safety communication
equipment, c) The short circuit current of the generator /
- fire detection and alarm systems generator system is sufficient to trip the
- electrical equipment for watertight generator / generator system circuit-breaker
closing appliances. taking into account the selectivity of the
protective devices for the distribution
b) Immediate availability of following system.
services, required for safety, is not
affected when the power supply is d) Protection is to be arranged in order to
restored to normal operating safeguard the generator / generator system
conditions: in case of a short-circuit in the main bus bar.
- fire pumps and other The generator / generator system is to be
extinguishing medium pumps, suitable for further use after fault clearance.
- bilge pumps,
- ventilating fans for engine and e) It is to be possible to disconnect the
boiler rooms. generator from the propulsion system by a
separate clutch.
iv) The services for habitable conditions
mentioned in 1.5.2 may be included in f) Starting of stand-by generating sets is to be
load shedding. in accordance with 2.5.6b).

2.6 Prime movers for generators 2.6.4 Generators and generator systems, having
the ship's propulsion machinery as their prime
2.6.1 Each generator required according to 2.5 mover but not forming part of the ship's main
is normally to be driven by a separate auxiliary source of electrical power as specified in 2.6.3a)
prime mover. If such prime mover for a may be accepted whilst the ship is at sea to
generator also is used for driving other auxiliary

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supply electrical services required for normal 2.7.4 Each transformer is to be served by
operational and habitable conditions provided : separate circuits on the primary and secondary
sides. Auto transformers used for motor starting
a) There are sufficient and adequately rated are excluded.
additional generators fitted, which constitute
the main source of electrical power, meeting 2.8 Emergency source of power
the requirements as specified in 2.5.3.
2.8.1 A self-contained emergency source of
b) Means are provided to automatically start electrical power is to be provided in all ships.
one or more of the generators, constituting
the main source of electrical power as per 2.8.2 The emergency source of electrical power
2.5.3 or 2.5.6b), upon the frequency and associated transforming equipment, if any,
variations exceeding ± 10 of the limits as transitional source of emergency power,
specified in 2.3 and the voltage variations emergency switchboard and emergency lighting
exceeding the limits as specified in 2.3. switchboard are to be located above the
uppermost continuous deck and are to be
c) The short circuit current of the generator readily accessible from the open deck. They are
and/or generator system is sufficient to trip not to be located forward of the collision
the generator/generator system circuit- bulkhead.
breaker taking into account the selectivity of
the protective devices for the distribution 2.8.3 The location of the emergency source of
system. electrical power and associated transforming
equipment, if any, the transitional source of
d) Where considered appropriate, load emergency power, the emergency switchboard
shedding arrangements are fitted to meet and the emergency electric lighting
the requirements of 2.5.6c). switchboards in relation to the main source of
electrical power, associated transforming
e) On ships having remote control of the ship's equipment, if any, and the main switchboard are
propulsion machinery from the navigating to be such as to ensure to the satisfaction of IRS
bridge means are provided, or procedures that a fire or other casualty in spaces containing
be in place, so as to ensure that supplies to the main source of electrical power, associated
essential services are maintained during transforming equipment, if any, and the main
manoeuvring conditions in order to avoid a switchboard or in any machinery space of
blackout situation. category A will not interfere with the supply,
control and distribution of emergency electrical
2.7 Number and capacity of transformers or power. As far as practicable, the space
power convertors containing the emergency source of electrical
power, associated transforming equipment, if
2.7.1 Where essential and other services any, the transitional source of emergency
mentioned under 1.5.1 and 1.5.2 of this chapter electrical power and the emergency switchboard
are supplied, by transformers or power is not to be continuous to the boundaries of
convertors, the number and rating of machinery spaces of category A or those
transformers or power convertors are to be spaces containing the main source of electrical
sufficient to ensure the operation of essential power, associated transforming equipment, if
services and important consumers even when any, or the main switchboard.
any one transformer or power convertor is out of
action. 2.8.4 Provided that suitable measures are taken
for safeguarding independent emergency
2.7.2 With any one transformer or power operation under all circumstances, the
convertor out of action, the remaining emergency generator may be used
transformer(s) or power convertor(s) should be exceptionally, and for short periods, to supply
adequate for starting the largest essential and non-emergency circuits.
important electric motor, without the transient
voltage and frequency variations exceeding the Exceptionally, whilst the vessel is at sea, is
limits specified in 2.3. understood to mean conditions such as:

2.7.3 Each transformer or power convertor fitted - blackout situation

in accordance with these requirement is to be
installed as a separate unit, with a separate - dead-ship situation
enclosure.
- routine use for testing

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- short-term parallel operation with the
main source of electrical power for the 2.8.4.2 Operation
purpose of load transfer.
Instructions* are to be provided on board to
Unless instructed otherwise by the ensure that when the vessel is under way all
Administration the emergency generator may be control devices (e.g. valves, switches) are in a
used during lay time in port for the supply of the correct position for the independent emergency
ship mains, provided the requirements of 2.8.4.1 operation of the emergency generator set and
and 2.8.4.2 below are complied with. emergency switchboard.

2.8.4.1 Requirements * These instructions are also to contain

information on required fuel oil tank level,
a) To prevent the generator or its prime position of harbour/sea mode switch if fitted,
mover from getting overloaded when ventilation openings etc.
used in port, arrangements are to be
provided to shed sufficient non- 2.8.5 The emergency generator and other
emergency loads to ensure its means needed to restore the propulsion are to
continued safe operation. have a capacity such that the necessary
propulsion starting energy is available within 30
b) The prime mover is to be arranged with minutes of blackout/dead ship condition. For the
fuel oil filters and lubrication oil filters, purpose of this requirement "Blackout" is to be
monitoring equipment and protection understood to mean a "dead ship" condition.
devices as required for the prime mover Emergency generator stored starting energy is
for main power generation and for not to be directly used for starting the propulsion
unattended operation. plant, the main source of electrical power and/or
other essential auxiliaries (emergency generator
c) The fuel oil supply tank to the prime excluded). The requirement of propulsion
mover is to be provided with a low level starting energy being available within 30
alarm, arranged at a level ensuring minutes would remain applicable even when
sufficient fuel oil capacity for the there is no emergency generator installed.
emergency services for the period of
time as required by 2.8.8 and 2.8.9 of For steam ships, the 30 minute time limit is the
this section. time from blackout / dead ship condition to
lighting of the first boiler.
d) The prime mover is to be designed and
built for continuous operation and 2.8.6 Use of emergency generator during lay
should be subjected to a planned time in port for the supply of the ship mains as
maintenance scheme ensuring that it is stated in para 2.8.4 will be specially considered
always available and capable of fulfilling on submission of details of safeguards to ensure
its role in the event of an emergency at its continued availability for its intended
sea. emergency duties.

e) Fire detectors are to be installed in the 2.8.7 Starting arrangements for emergency
location where the emergency generator generating sets
set and emergency switchboard are
installed. 2.8.7.1 Emergency generating sets are to be
capable of being readily started in their cold
f) Means are to be provided to readily condition at a temperature of 0°C. If this is
change over to emergency mode from impracticable, or if lower temperatures are likely
harbour mode. to be encountered, provision acceptable to IRS
is to be made for the maintenance of heating
g) Control, monitoring and supply circuits, arrangements, to ensure ready starting of the
for the purpose of the use of the generating sets.
emergency generator in port are to be
so arranged and protected that any 2.8.7.2 Each emergency generating set
electrical fault will not influence the arranged to be automatically started is to be
operation of the main and emergency equipped with starting devices approved by IRS
services. with a stored energy capability of at least three
consecutive starts. A second source of energy is
h) When necessary for safe operation, the to be provided for an additional three starts
emergency switchboard is to be fitted within 30 minutes unless manual starting can be
with switches to isolate the circuits. demonstrated to be effective.
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2.8.7.3 The stored energy is to be maintained at iii) in all service and accommodation
all time, as follows: alleyways, stairways and exits, personnel
lift cars;
a) electrical and hydraulic starting systems are
to be maintained from the emergency iv) in the machinery spaces and main
switchboard; generating stations including their control
positions;
b) compressed air starting systems may be
maintained by the main or auxiliary v) in all control stations, machinery control
compressed air receivers through a suitable rooms, and at each main and emergency
non-return valve or by an emergency air switchboard;
compressor which, if electrically driven, is
supplied from the emergency switchboard; vi) at all stowage positions for firemen's
outfits;
c) all of these starting, charging and energy
storing devices are to be located in the vii) at the steering gear; and
emergency generator space; these devices
are not to be used for any purpose other viii) at the fire pump, the sprinkler pump and
than the operation of the emergency the emergency bilge pump referred to in
generating set. This does not preclude the 2.8.8.1(d) and at the starting position of
supply to the air receiver of the emergency their motors.
generating set from the main or auxiliary
compressed air system through the non- b) For a period of 36 hours
return valve fitted in the emergency
generator space. i) the navigation lights and other lights
required by the International Regulations
2.8.7.4 Where automatic starting is not required, for Preventing Collisions at Sea in force;
manual starting is permissible, such as manual and
cranking, inertia starters, manually charged
hydraulic accumulators, or powder charge ii) on ships constructed on or after 1
cartridges, where they can be demonstrated as February 1995, the VHF radio installation;
being effective. and if applicable

2.8.7.5 When manual starting is not practicable, - the MF radio installation;

the requirements of 2.8.7.2 and 2.8.7.3 are to be
complied with except that starting may be - the ship earth station; and
manually initiated.
- the MF/HF radio installations.
2.8.8 Passenger ships
c) For a period of 36 hours; unless such
2.8.8.1 The electrical power available is to be services have an independent supply for the
sufficient to supply all those services that are period of 36 hours from an accumulator
essential for safety in an emergency, due regard battery suitably located for use in an
being paid to such services as may have to be emergency:
operated simultaneously. The emergency
source of electrical power is to be capable, i) all internal communication equipment
having regard to starting currents and the required in an emergency which is
transitory nature of certain loads, of supplying generally;
simultaneously at least the following services for
the periods specified herein, if they depend - The means of communication which
upon an electrical source for their operation: is provided between the navigating
bridge and the steering gear
a) For a period of 36 hours, emergency compartment.
lighting:
- The means of communication which
i) at every embarkation station on deck and is provided between the navigating
over sides; bridge and the position in the
machinery space or control room
ii) in alleyways, stairways and exits giving from which the engines are normally
access to the muster and embarkation controlled.
stations;

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- The means of communication which ii) the emergency arrangements to bring the
is provided between the bridge and lift cars to deck level for the escape of
the radio telegraph or radio persons. The passenger lift cars may be
telephone stations. brought to deck level sequentially in an
emergency.
- The means of communication which
is provided between the officer of the g) In a ship engaged regularly on voyages of
watch and the person responsible for short duration, IRS if satisfied that an
closing any watertight door which is adequate standard of safety would be
not capable of being closed from a attained may accept a lesser period than the
central control station. 36 hour period specified in 2.8.8.1(a) to
2.8.8.1(e) but not less than 12 hours.
- The public address system or other
effective means of communication 2.8.8.2 The emergency source of electrical
which is provided throughout the power may be either a generator or an
accommodation, public and service accumulator battery, which is to comply with the
spaces. following:

- The means of communication which a) Where the emergency source of electrical

is provided between the navigating power is a generator, it is to be:
bridge and the main fire control
station. i) driven by a suitable prime-mover with an
independent supply of fuel having a
ii) the shipborne navigational equipment, flashpoint (closed cup test) of not less
where such provision is unreasonable or than 43°C;
impracticable IRS may waive this
requirement for ships of less than 5,000 ii) started automatically upon failure of the
tons gross tonnage; electrical supply from the main source of
electrical power and is to be automatically
iii) the fire detection and fire alarm system, connected to the emergency switchboard;
and the fire door holding and release those services referred to in 2.8.8.3 are
system; and then to be transferred automatically to the
emergency generating set. The automatic
iv) for intermittent operation of the daylight starting system and the characteristic of
signaling lamp, the ship's whistle, the the prime-mover are to be such as to
manual fire alarms and all internal signals permit the emergency generator to carry
that are required in an emergency. its full rated load as quickly as is safe and
practicable, subject to a maximum of 45
d) For a period of 36 hours: seconds; unless a second independent
means of starting the emergency
i) one of the fire pumps required by Ch.9; generating set is provided, the single
source of stored energy is to be protected
ii) the automatic sprinkler pump, if any; and to preclude its complete depletion by the
automatic starting system; and
iii) the emergency bilge pump and all the
equipment essential for the operation of iii) provided with a transitional source of
electrically powered remote controlled emergency electrical power according to
bilge valves. 2.8.8.3.

e) For the period of time required by Ch.6, b) Where the emergency source of electrical
Sec.6, the steering gear if required to be so power is an accumulator battery, it is to be
supplied. capable of:

f) For a period of half an hour: i) carrying the emergency electrical load

without recharging while maintaining the
i) any watertight doors which are required to voltage of the battery throughout the
be power operated together with their discharge period within 12 per cent above
indicators and warning signals. Sequential or below its nominal voltage;
operation of the doors may be permitted
provided all doors can be closed in 60 ii) automatically connecting to the
seconds; emergency switchboard in the event of

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failure of the main source of electrical 2.8.8.6 Where the emergency source of
power; and electrical power is a generator, the emergency
switchboard is to be located in the same space
iii) immediately supplying at least those unless the operation of the emergency
services specified in 2.8.8.3. switchboard would thereby be impaired.

2.8.8.3 The transitional source of emergency 2.8.8.7 No accumulator battery fitted in

electrical power required by 2.8.8.2(a)(iii) is to accordance with this Section is to be installed in
consist of an accumulator battery suitably the same space as the emergency switchboard.
located for use in an emergency which is to An indicator is to be mounted in a suitable place
operate without recharging while maintaining the on the main switchboard or in the machinery
voltage of the battery throughout the discharge control room to indicate when the batteries
period within 12 per cent above or below its constituting either the emergency source of
nominal voltage and be of sufficient capacity electrical power or the transitional source of
and so arranged as to supply automatically in emergency electrical power referred to in
the event of failure of either the main or paragraph 2.8.8.2(b) or 2.8.8.3 are being
emergency source of electrical power at least discharged.
the following services, if they depend upon an
electrical source for their operation: 2.8.8.8 The emergency switchboard is to be
supplied during normal operation from the main
a) For half an hour: switchboard by an interconnector feeder which
is to be adequately protected at the main
i) the lighting required by paragraphs switchboard against overload and short circuit
2.8.8.1(a) and 2.8.8.1(b)(i); and which is to be disconnected automatically at
the emergency switchboard upon failure of the
ii) Services required by paragraphs main source of electrical power. Where the
2.8.8.1(c) (i, iii and iv) unless such system is arranged for feedback operation, the
services have an independent supply for interconnector feeder is also to be protected at
the period specified from an accumulator the emergency switchboard at least against
battery suitably located for use in an short circuit.
emergency.
2.8.8.9 In order to ensure ready availability of
b) Power to close the watertight doors but not the emergency source of electrical power,
necessarily all of them simultaneously, arrangements are to be made where necessary
unless an independent temporary source of to disconnect automatically non-emergency
stored energy is provided. Power to the circuits from the emergency switchboard to
control, indication and alarm circuits as ensure that power will be available to the
required for half an hour. emergency circuits.

2.8.8.4 Where the emergency and/or transitional 2.8.8.10 The emergency generator and its
emergency loads are supplied from a battery via prime-mover and any emergency accumulator
an electronic converter or inverter the maximum battery is to be so designed and arranged as to
permitted voltage variations are to be taken as ensure that they will function at full rated power
those on the load side of the converter or when the ship is upright and when inclined at
inverter. any angle of list up to 22.5° or when inclined up
to 10° either in the fore or aft direction, or is in
The above mentioned voltage variants are not to any combination of angles within those limits.
exceed the following limits, as applicable:
2.8.8.11 Provision is to be made for the periodic
a) Where the system on the load side of the testing of the complete emergency system and
converter or inverter is d.c. : limits as given is to include the testing of automatic starting
in 2.8.8.3. arrangements.

b) Where the system on the load side of the 2.8.9 Cargo ships
converter or inverter is a.c. : limits as given
in 1.8.1. 2.8.9.1 The electrical power available is to be
sufficient to supply all those services that are
2.8.8.5 The emergency switchboard is to be essential for safety in an emergency, due regard
installed as near as is practicable to the being paid to such services as may have to be
emergency source of electrical power. operated simultaneously. The emergency
source of electrical power is to be capable,

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having regard to starting currents and the i) all internal communication equipment as
transitory nature of certain loads, of supplying required in an emergency which is
simultaneously at least the following services for generally as indicated in 2.8.8.1 c) i);
the periods specified herein, if they depend
upon an electrical source for their operation: ii) the shipborne navigational equipment,
where such provision is unreasonable or
a) For a period of 3 hours, emergency lighting impracticable IRS may waive this
at every muster and embarkation station requirement for ships of less than 5,000
and over sides; tons gross tonnage;

b) For a period of 18 hours, emergency iii) the fire detection and fire alarm system;
lighting: and

i) in all service and accommodation iv) intermittent operation of the daylight

alleyways, stairways and exits, personnel signaling lamp, the ship's whistle, the
lift cars and personnel lift trunks; manual fire alarms, and all internal signals
that are required in an emergency.
ii) in the machinery spaces and main
generating stations including their control 2.8.9.2 For period of 18 hours one of the fire
positions; pumps required by Pt.6, Ch.3, if dependent
upon the emergency generator for its source of
iii) in all control stations, machinery control power.
rooms, and at each main and emergency
switchboard; 2.8.9.3 For the period of time required by Ch.6,
Sec.6, the steering gear where it is required to
iv) at all stowage positions for firemen's be so supplied.
outfits;
2.8.9.4 In a ship engaged regularly in voyages
v) at the steering gear; of short duration, IRS if satisfied that an
adequate standard of safety would be attained
vi) at the fire pump referred to in 2.8.9.2, at may accept a lesser period than the 18 hour
the sprinkler pump, if any, and at the period specified in paragraphs 2.8.9.1(b) to
emergency bilge pump, if any, and at the 2.8.9.1(d) and 2.8.9.2 but not less than 12
starting positions of their motors; and hours.

vii) in all cargo pump-rooms of tankers. 2.8.9.5 The emergency source of electrical
power may be either a generator or an
c) For a period of 18 hours accumulator battery, which is to comply with the
following:
i) the navigation lights and other lights
required by the International Regulations a) Where the emergency source of electrical
for Preventing Collisions at Sea in force; power is a generator, it is to be:
and
i) driven by a suitable prime-mover with an
ii) on ships constructed on or after 1 independent supply of fuel, having a
February 1995, the VHF radio installation; flashpoint (closed cup test) of not less
and if applicable than 43°C;

- the MF radio installation; ii) started automatically upon failure of the

main source of electrical power supply
- the ship earth station; and unless a transitional source of emergency
electrical power in accordance with
- the MF/HF radio installations. 2.8.9.5(a)(iii) is provided; where the
emergency generator is automatically
d) For a period of 18 hours; unless such started, it is to be automatically connected
services have an independent supply for the to the emergency switchboard; those
period of 18 hours from an accumulator services referred to in 2.8.9.6 are then to
battery suitably located for use in an be connected automatically to the
emergency: emergency generator; and unless a
second independent means of starting the
emergency generator is provided the
single source of stored energy is to be
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protected to preclude its complete 2.8.9.7 Where the emergency and/or transitional
depletion by the automatic starting emergency loads are supplied from a battery via
system; and an electronic converter or inverter the maximum
permitted voltage variations are to be taken as
iii) provided with a transitional source of those on the load side of the converter or
emergency electrical power as specified inverter.
in 2.8.9.6 unless an emergency generator
is provided capable both of supplying the The above mentioned voltage variants are not to
services mentioned in 2.8.9.6 and of exceed the following limits, as applicable:
being automatically started and supplying
the required load as quickly as is safe and a) Where the system on the load side of the
practicable subject to a maximum of 45 converter or inverter is d.c. : limits as given
seconds. in 2.8.9.6.

b) Where the emergency source of electrical Where the system on the load side of the
power is an accumulator battery it is to be converter or inverter is a.c. : limits as given in
capable of: 1.8.1.

i) carrying the emergency electrical load 2.8.9.8 The emergency switchboard is to be

without recharging while maintaining the installed as near as is practicable to the
voltage of the battery throughout the emergency source of electrical power.
discharge period within 12 per cent above
or below its nominal voltage; 2.8.9.9 Where the emergency source of
electrical power is a generator, the emergency
ii) automatically connecting to the switchboard is to be located in the same space
emergency switchboard in the event of unless the operation of the emergency
failure of the main source of electrical switchboard would thereby be impaired.
power; and
2.8.9.10 No accumulator battery fitted in
iii) immediately supplying at least those accordance with this Section is to be installed in
services specified in 2.8.9.6. the same space as the emergency switchboard.
An indicator is to be mounted in a suitable place
2.8.9.6 The transitional source of emergency on the main switchboard or in the machinery
electrical power where required by 2.8.9.5(a) is control room to indicate when the batteries
to consist of an accumulator battery suitably constituting either the emergency source of
located for use in an emergency which is to electrical power or the transitional source of
operate without recharging while maintaining the electrical power referred to in paragraph
voltage of the battery throughout the discharge 2.8.9.5(b) or 2.8.9.6 are being discharged.
period within 12 per cent above or below its
nominal voltage and be of sufficient capacity 2.8.9.11 The emergency switchboard is to be
and is to be so arranged as to supply supplied during normal operation from the main
automatically in the event of failure of either the switchboard by an interconnector feeder which
main or the emergency source of electrical is to be adequately protected at the main
power for half an hour at least the following switchboard against overload and short circuit
services if they depend upon an electrical and which is to be disconnected automatically at
source for their operation: the emergency switchboard upon failure of the
main source of electrical power. Where the
a) the lighting required by 2.8.9.1(a) to system is arranged for feedback operation, the
2.8.9.1(c). For this transitional phase, the interconnector feeder is also to be protected at
required emergency electric lighting, in the emergency switchboard at least against
respect of the machinery space and short circuit.
accommodation and service spaces may be
provided by permanently fixed, individual, 2.8.9.12 In order to ensure ready availability of
automatically charged, relay operated the emergency source of electrical power,
accumulator lamps; and arrangements are to be made where necessary
to disconnect automatically non-emergency
b) all services required by 2.8.9.1(d) (i, iii and circuits from the emergency switchboard to
iv) unless such services have an ensure that electrical power will be available
independent supply for the period specified automatically to the emergency circuits.
from an accumulator battery suitably located
for use in an emergency. 2.8.9.13 The emergency generator and its
prime-mover and any emergency accumulator

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battery is to be so designed and arranged as to 2.9.3 Design and construction
ensure that they will function at full rated power
when the ship is upright and when inclined at a) UPS units are to be constructed in
any angle of list up to 22.5° or when inclined up accordance with IEC 62040 or an
to 10° either in the fore or aft direction, or is in acceptable and relevant national or
any combination of angles within those limits. international standard.
Also refer to Part 4, Chapter 1, Table 1.7.1.
b) The operation of the UPS is not to depend
2.8.9.14 Provision is to be made for the periodic upon external services.
testing of the complete emergency system and
is to include the testing of automatic starting c) The type of UPS unit employed, whether
arrangements. off-line, line interactive or on-line, is to be
appropriate to the power supply
2.9 Requirements for uninterrupted power requirements of the connected load
system (UPS) units as alternative and/or equipment.
transitional source of power
d) An external bypass is to be provided.
2.9.1 Scope
e) The UPS unit is to be monitored and audible
These requirements to UPS units, as defined in and visual alarm is to be given in a normally
IEC 62040, apply when providing an alternative attended location for –
power supply or transitional power supply to
services as defined in 2.8.8 and 2.8.9. - Power supply failure (voltage and
frequency) to the connected load,
A UPS unit complying with these requirements - Earth fault,
may provide an alternative power supply as an - Operation of battery protective device,
accumulator battery in terms of being an - When the battery is being discharged,
independent power supply for services defined and
in 2.8.8.1c) and 2.8.9.1d). - When the bypass is in operation for on-
line UPS units.
2.9.2 Definitions
2.9.4 Location
Uninterruptible Power System (UPS) –
combination of converters, switches and energy a) The UPS unit is to be suitably located for
storage means, for example batteries, use in an emergency.
constituting a power system for maintaining
continuity of load power in case of input power b) UPS units utilizing valve regulated sealed
failure (IEC 62040:1999). batteries may be located in compartments
with normal electrical equipment, provided
Off-line UPS unit – a UPS unit where under the ventilation arrangements are in
normal operation the output load is powered accordance with the requirements to IEC
from the bypass line (mains) and only 62040 or an acceptable and relevant
transferred to the inverter if the bypass supply national or international standard.
fails or goes outside preset limits. This transition
will invariably result in a brief (typically 2 to 10 2.9.5 Performance
milli-seconds) break in the load supply.
a) The output power is to be maintained for the
Line interactive UPS unit – an off-line UPS unit duration required for the connected
where the bypass line switches to stored energy equipment as stated in 2.8.8 and 2.8.9.
power when the input power goes outside the
preset voltage and frequency limits. b) No additional circuits are to be connected to
the UPS unit without verification that the
On-line UPS unit – a UPS unit where under UPS unit has adequate capacity. The UPS
normal operation the output load is powered battery capacity is, at all times, to be
from the inverter and will therefore continue to capable of supplying the designated loads
operate without break in the event of the supply for the time specified in the regulations.
input failing or going outside preset limits.
c) On restoration of the input power, the rating
of the charge unit shall be sufficient to
recharge the batteries while maintaining the
output supply to the load equipment.

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2.9.6 Testing and survey 2.12.2 A final sub-circuit of rating exceeding 15

A is not to supply more than one point.
a) UPS units of 50 kVA and over are to be
surveyed during manufacturing and 2.12.3 A final sub-circuit of rating 15 A or less is
testing. not to supply more than the following number of
lighting points:-
b) Appropriate testing is to be carried out
to demonstrate that the UPS unit is 10 for .………. 24 - 55 V circuits
suitable for its intended environment.
This is expected to include as a 14 for .………. 110 - 127 V circuits
minimum the following tests:
24 for .………. 220 - 250 V circuits.
- Functionality, including operation of
alarms; This provision is not applicable to final sub-
- Temperature rise; circuits for cornice lighting, panel lighting and
- Ventilation rate electric signs where lampholders are closely
- Battery capacity. grouped; in such cases, the number of points is
unrestricted provided the maximum operating
c) Where the supply is to be maintained current in the sub-circuit does not exceed 10 A.
without a break following a power input
failure, this is to be verified after 2.12.4 Lighting for machinery spaces, control
installation by an appropriate test. stations, work spaces, public spaces, corridors
and stairways leading to boat decks should be
2.10 Essential services supplied from at least two final sub-circuits in
such a way that failure of any one of the circuits
2.10.1 Where essential services are duplicated, does not leave the spaces in darkness.
they are to be served by individual circuits
separated throughout their length as widely as is 2.12.5 For lighting in hazardous areas, switches
practicable and without the use of common are to be of the double-pole type and wherever
feeders, protective devices or control circuits. practicable, located in a non-hazardous area. If
fitted in hazardous areas, these switches are to
2.11 Diversity factor be of flameproof type.

2.11.1 Circuits supplying two or more final sub- 2.12.6 Lighting of unattended spaces, such as
circuits are to be rated in accordance with the cargo spaces and coal bunkers, is to be
total connected load subject, where justified, to controlled by multi-pole linked switches located
the application of a diversity factor. Where spare outside such spaces. Provision is to be made for
ways (feeders) are provided on a section or the complete isolation of these circuits and
distribution board, an allowance for future locking in the "OFF" position of the means of
increase of load is to be added to the total control.
connected load before application of any
diversity factor. 2.13 Motor circuits

2.11.2 The diversity factor may be applied when 2.13.1 A separate final sub-circuit is to be
calculating cable size and when calculating the provided for every motor required for essential
rating of switchgear and fusegear. services and for every motor of 1 [kW] or more.

2.11.3 The Diversity factors are not applicable to 2.13.1 Motors of permanently installed
supply cables to distribution switchboards for submersible bilge pumps are to be connected to
lighting and heating. the emergency switchboard, (if fitted).

2.11.4 The calculation of the diversity factor is to 2.13.2 Cables and their connections to such
be submitted along with all relevant data. pumps are to be capable of operating under a
head of water equal to their distance below the
2.12 Lighting circuits bulkhead deck. The cables are to be suitable for
operation in permanently wet situations, and
2.12.1 Lighting circuits are to be supplied by installed in continuous lengths from above the
final sub-circuits, which are separate from those bulkhead deck to the motor terminals.
for heating and power. This provision need not
be applied to cabin fans and small wardrobe 2.13.3 Under all circumstances it is to be
heaters. possible to start the motor of a permanently

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installed submersible bilge pump from a position requirements regarding steering gear motors,
above the bulkhead deck. See Ch.6).

If an additional starter is provided at the motor, it 2.14.8 Where fuses are installed to protect
is to be so arranged as to permit, in all cases, polyphase motor circuits, means are to be
remote starting. provided to protect the motor against
unacceptable overload in the case of single
2.14 Motor controls phasing.

2.14.1 Every electric motor is to be provided 2.15 Remote stops for ventilation fans and
with an efficient means of starting and stopping pumps
so placed as to be easily accessible to the
person controlling the motor. 2.15.1 Ventilating fans for machinery spaces are
to be provided with means for stopping them
2.14.2 Every motor required for essential from easily accessible control stations located
services and every motor of 0.5 [kW] or more is outside such spaces.
to be provided with the control apparatus as
mentioned in 2.14.4 to 2.14.8. 2.15.2 Motors driving forced and induced
draught fans, independently driven pumps
2.13.3 When motor control gear is being delivering oil to main propulsion machinery for
selected, the maximum current of the motor is to bearing lubrication and piston cooling, oil fuel
be taken as its rated full load current. transfer pumps, oil fuel unit pumps and other
similar fuel pumps, fuel and lubricating oil
2.14.4 Efficient means of isolation are to be purifiers and their attached pumps are to be
provided so that all voltage may be cut off from fitted with remote controls situated outside the
the motor and any associated apparatus space concerned so that the electrical supply
including any automatic circuit breaker. thereto can be disconnected in the event of fire
arising in the space in which they are located.
2.14.5 Where the primary means of isolation
(viz. that provided at the switchboard, section 2.15.3 Where overboard discharges from
board or distribution fuse board) is remote from cooling water or similar pumps are likely to
a motor, one of the following provisions is to be jeopardize the safe launching of lifeboats or life
made : rafts, under any condition of loading of the ship,
then the motors driving these pumps are to be
a) An additional means of isolation fitted provided with suitably located remote shut-off
adjacent to the motor; or arrangements.

b) Provision made for locking the primary 2.16 Fire detection and extinguishing
means of isolation in the OFF position; or systems

c) Provision made so that the fuses in each 2.16.1 Electrical equipment used in operating
line can be readily removed and retained by fire detecting systems is to be served by two
authorized personnel. circuits, one fed from the main power supply
system and the other from the emergency power
2.14.6 Means to prevent the undesired supply system. These feeders are to be
restarting after a stoppage due to low volts or connected to an automatic change-over switch
complete loss of volts are to be provided. This installed in the vicinity of the fire detection panel.
does not apply to motors where a dangerous
condition might result from the failure to restart 2.16.2 Where an electrically driven fire pump is
automatically e.g. steering gear motor. It is, supplied power from the emergency
however, to be ensured that the total starting switchboard, the supply cable to such pump is
current of motors having automatic re-start will not to pass through the main machinery spaces.
not cause excessive voltage drop or overcurrent
on the installation. 2.17 Lift circuits

2.14.7 Means for automatic disconnection of the 2.17.1 Lifts or hoists to be used by passengers
supply in the event of excess current due to and/or crew are to be supplied from the main
mechanical overloading of the motor are to be switchboard, either directly or through a section
provided. (This does not apply to steering gear board, by circuits which do not supply any other
motors and thruster motors. Overload alarms appliance.
are to be provided for these motors. For

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2.17.2 Cable or cables supplying current to (and frequency for alternating current) of the
motors of lifts or hoists are not to be ship's installed system. Full details of the
incorporated within the flexible trailing cable procedure for effecting the connection are to be
used in connection with the control and safety given on this notice.
devices.
2.19.6 Alternate arrangements for providing a
2.18 Heating and cooking equipment temporary external supply will be specially
considered.
2.18.1 Every heating or cooking appliance is to
be controlled as a complete unit by a multi-pole 2.20 Permanent external supply
linked switch mounted in the vicinity of the
appliance. 2.20.1 Details are to be submitted for
consideration in each specific case.
2.18.2 In the case of small heaters, for individual
cabins or similar small dry accommodation 2.21 Protection
spaces where the floor coverings, bulkheads
and ceiling linings are of insulating materials, a 2.21.1 General
single pole switch is acceptable.
2.21.1.1 All installations are to be protected
2.18.3 Heating arrangements of the exposed against accidental over-currents including short
element type are not to be used in any location. circuits and other electrical faults. The choice,
location and characteristics of the protective
2.19 Temporary external supply/shore device are to provide complete and co-ordinated
connection protection to ensure:

2.19.1 Where arrangements are provided for the a) Elimination of the fault to reduce damage to
supply of electric power from a source on shore the system and hazard of fire.
or elsewhere, a connection box is to be installed
in an easily accessible location in a manner b) Continuity of service so as to maintain,
suitable for the convenient reception of flexible through the discriminative action of the
cables from the external source. This box should protective devices, the supply to essential
contain a circuit-breaker or isolating switch and and all other services not directly affected
fuses and terminals of ample size and suitable by the fault.
shape to facilitate a satisfactory connection. The
mechanical stress of the portable cable is to be 2.21.2 Protection against overload
conveyed directly to the metallic framework and
not to electrical connectors. Suitable cables, 2.21.2.1 Protection against overloads may be
permanently fixed, are to be provided, provided by circuit-breakers, automatic switches
connecting the circuit breaker/isolating switch in or fuses. The tripping characteristics of these
the connection box to a linked switch and/or devices are to be appropriate to the system.
circuit breaker at the main switchboard. Fuses rated above 320 A are not to be used for
protection against overload, but may be used for
2.19.2 For alternating current systems an short-circuit protection.
earthed terminal is to be provided for the
reception of three-phase external supplies with 2.21.2.2 The rating or appropriate setting of the
earthed neutrals. overload protective device for each circuit
should be permanently indicated at the location
2.19.3 The external connection is to be provided of the protective device.
with an indicator at the main switchboard in
order to show when the cable is energized. 2.21.2.3 The overload releases of circuit-
breakers for generators and the setting of
2.19.4 Means are to be provided for checking preferential trip relays are to be adjustable or, if
the polarity (for direct current) or the phase of the non-adjustable type, are to be readily
sequence (for three-phase alternating current) of replaceable by others of different values.
the incoming supply. This device should be
connected between the incoming connectors 2.21.3 Protection against short-circuit
and the interrupting device in the connection
box. 2.21.3.1 Protection against short-circuit currents
is to be provided by circuit-breakers or fuses.
2.19.5 A notice is to be provided at the
connection box giving complete information on 2.21.3.2 The breaking capacity of every
the system of supply and the normal voltage protective device is to be not less than the

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maximum value of the short-circuit current which 2.21.4.3 The characteristics of the arrangement
can flow at the point of installation at the instant are to be such that:
of contact separation.
a) When the short-circuit current is broken, the
2.21.3.3 The making capacity of every circuit- circuit-breaker on the load side is not to be
breaker or switch intended to be capable of damaged and is to be capable of further
being closed, if necessary, on short circuit, is to service,
be not less than the maximum value of the
short-circuit current at the point of installation. b) When the circuit-breaker is closed on the
On alternating current this maximum value short-circuit current, the remainder of the
corresponds to the peak value allowing for installation is not to be damaged. However,
maximum asymmetry. it is admissible that the circuit-breaker on
the load side may require servicing after the
2.21.3.4 Every protective device or contactor not fault has been cleared.
intended for short circuit interruption is to be
adequate for the maximum short-circuit current 2.21.5 Protection of circuits
which can occur at the point of installation
having regard to the time required for the short 2.21.5.1 Short circuit protection is to be provided
circuit to be removed. in each live pole of a direct current system and
in each phase of an alternating current system.
2.21.3.5 In the absence of precise data of
rotating machines the following short-circuit 2.21.5.2 Protection against overloads is to be
currents at the machine terminals are to be provided as follows:
assumed. The short circuit current is to be the
sum of short circuit currents of generators and a) Two-wire direct current or single-phase
that of motors; alternating current system - at least one line
or phase,
a) Direct current systems
b) Insulated three-phase alternating current
- Ten times full load current for system - at least two phases,
generators normally connected
(including spare), c) Earthed three-phase alternating current
system - all three phases.
- Six times full load current for motors
simultaneously in service; 2.21.5.3 No fuse, non-linked switch or non-
linked circuit-breaker is to be inserted in an
b) Alternating current systems. earthed conductor. Any switch or circuit-breaker
fitted is to operate simultaneously in the earthed
- Ten times full load current for conductor and the insulated conductors.
generators normally connected
(including spare) - symmetrical RMS, 2.21.5.4 These requirements do not preclude
the provision (for test purposes) of an isolating
- Three times full load current for motors link to be used only when the other conductors
simultaneously in service. are isolated.

2.21.4 Combined circuit-breakers and fuses 2.21.6 Protection of generators

2.21.4.1 The use of a circuit-breaker of breaking 2.21.6.1 In addition to over-current protection,

capacity less than the prospective short-circuit the provisions of 2.21.6.2 to 2.21.6.7 are to be
current at the point of installation is permitted, adhered to as a minimum.
provided that it is preceded on the generator
side by fuses, or by a circuit-breaker having at 2.21.6.2 For generators not arranged to run in
least the necessary breaking capacity. The parallel :
generator breakers are not to be used for this
purpose. - A multi-pole circuit-breaker arranged to
open simultaneously all insulated poles or in
2.21.4.2 Fused circuit-breakers with fuses the case of generators rated at less than 50
connected to the load side may be used where [kW] a multi-pole linked switch with a fuse in
operation of the circuit-breaker and fuses is co- each insulated pole on the generator side.
ordinated. The fuse rating in such cases is to be
maximum 125 per cent of the generator
rated current.

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essential load when the generators are

2.21.6.3 For generators arranged to run in overloaded.
parallel:
2.21.7.2 If required, this load shedding may be
- A circuit-breaker arranged to open carried out in one or more stages according to
simultaneously all insulated poles. This the overload ability of the generating sets, taking
circuit-breaker is to be provided with : into consideration the relative importance of the
loads being thus disconnected.
a) For direct current generators, instantaneous
reverse-current protection operating at not 2.21.7.3 In cargo ships, circuits for cargo
more than 15 percent rated current, refrigeration machinery are to be included in the
last group of services to be disconnected.
b) For alternating current generators :
2.21.8 Protection of feeder circuits
i) A reverse-power protection, with time
delay selected and set within the limits of 2.21.8.1 Isolation and protection of each main
2 per cent to 15 per cent of full load to a distribution circuit is to be ensured by a multi-
value fixed in accordance with pole circuit-breaker, multi-pole fused circuit-
characteristics of prime movers. breakers or multi-pole switch and fuses. The
provisions of 2.21.2, 2.21.3 and 2.21.5 are to be
ii) A device for protection against the effects complied with. The protective devices are to
of parallel connection in opposite phase. allow excess current to pass during the normal
accelerating period of motors. Where multi-pole
2.21.6.4 The reverse-current protection is to be switch and fuses are used, the fuses are
adequate to deal with the reverse-current generally to be installed between the busbars
conditions emanating from the network, e.g. and the switch.
from winches, the reverse-power protection
specified for alternating current generators may 2.21.8.2 Circuits which supply motors fitted with
be replaced by other devices ensuring adequate overload protection may be provided with short-
protection of the prime movers. circuit protection only.

2.21.6.5 A fall of 50 per cent in the applied 2.21.8.3 Motors of rating exceeding 0.5 [kW]
voltage should not render the reverse-current and all motors for essential services are to be
mechanism inoperative, although it may alter the protected individually against overload and
amount of reverse-current required to open the short- circuit. The short-circuit protection can be
breaker. provided by the same protective device for the
motor and its supply cable. For essential motors
2.21.6.6 The following protective gear is also to which are duplicated, the overload protection
be provided for direct current generators may be replaced by an overload alarm, if
arranged to operate in parallel : desired.

a) Where an equaliser connection is in use the 2.21.8.4 For motors intended to provide
reverse-current protection is to be provided uninterrupted service the protective gear is to
in the pole opposite to that in which the have a delay characteristic to enable the motor
series winding is connected, to start, and to operate on overload before the
windings reach an un-acceptably high
b) For compound generators an equaliser temperature. The current which the protective
switch for each generator so interlocked that device will allow to pass indefinitely is not to
it closes before and opens after the main exceed 125 per cent of the rated current.
contacts of the circuit-breaker with which it
is associated, or a three-pole circuit-breaker 2.21.8.5 For motors for intermittent service the
with all poles acting simultaneously. current setting and the delay are to be chosen in
relation to the load factor of the motor.
2.21.6.7 Generator circuit-breakers are normally
to be provided with under voltage release. 2.21.8.6 Where fuses are used to protect
polyphase motor circuits, means are to be
2.21.7 Protection of essential services provided to protect the motor against
unacceptable overloads in the case of single
2.21.7.1 Where generators are operated in phasing.
parallel and essential services are electrically
operated, arrangements are to be made to
disconnect automatically the excess non-

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2.21.9 Protection of power transformers
2.21.10 Protection of lighting circuits
2.21.9.1 The primary circuits of power
transformers are to be protected against short- 2.21.10.1 Lighting circuits are to be provided
circuit by circuit-breakers or fuses. The rating of with overload and short- circuit protection.
fuses or the setting for overcurrent releases of
circuit breakers is not to exceed 125 per cent of 2.21.11 Protection of meters, pilot lamps,
rated primary current. capacitors, control transformers and control
circuits
2.21.9.2 Each of the secondary circuits is to be
provided with a multiple isolating switch as 2.21.11.1 Short circuit protection is to be
shown in Fig.2.21.9.2. provided for voltmeters, voltage coils of
measuring instruments, earth indicating devices
2.21.9.3 When transformers are arranged to and pilot lamps, control transformers and control
operate in parallel, an automatic protective circuits together with their connecting leads by
device is to be provided on the secondary means of protective devices fitted to each
circuits. Switches and circuit-breakers are to be insulated pole or phase.
capable of withstanding surge currents.

Fig.2.21.9.2

2.21.11.2 A pilot lamp installed as an integral 2.21.12 Protection of batteries

part of another item of equipment need not be
individually protected, provided it is fitted in the 2.21.12.1 Accumulator batteries other than
same enclosure. Where a fault in a pilot lamp engine starting batteries are to be protected
would jeopardise the supply to essential against overload and short circuit by devices, in
equipment such lamps are to be individually each insulated pole, placed at a position
protected. adjacent to the battery compartment.

2.21.11.3 Where capacitors for suppression of 2.21.13 Protection of communication circuits

radio interference are fitted to busbars,
generators or steering gear, fuses of appropriate 2.21.13.1 Communication circuits other than
size are to be connected in the capacitor circuit. those supplied from primary batteries are to be
protected against overload and short-circuit.

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Section 3

Cables and Busbar Trunking Systems

3.1 General 3.1.5 Electric cables complying with IEC

Publication 60502 are to have stranded
3.1.1 The requirements of this Section are conductors.
applicable to fixed cables on permanent
installations. For flexible cables, the 3.2 Conductors
requirements apply only as far as applicable.
3.2.1 High conductivity annealed copper only is
3.1.2 Cables are to be of a type approved by to be used.
IRS.
3.2.2 Where the conductor insulation is
3.1.3 Electric cables for fixed wiring are to be composed of vulcanised rubber or of a synthetic
designed, manufactured and tested in rubber liable to contain sulphides, the copper
accordance with the relevant IEC Publication wires are to be tinned or alloy coated and the
stated in Table 3.1.1 or an acceptable relevant surface is to be bright. Similarly the copper wires
standard. are to be tinned or alloy coated when the
insulation is composed of a cambric
3.1.4 The use of flexible cables on permanent impregnated with a product other than bitumen,
installations is to be limited to applications unless an efficient separator is inserted between
where flexibility is necessary, and the lengths of conductor and insulation.
such flexible cables are to be kept as short as
practicable. Additional requirements may be 3.2.3 Conductor composition and stranding is to
specified for flexible cable, depending on the be selected so that adequate flexibility of the
applications. finished cable is assured. Conductors of nominal
cross-section 2.5 [mm2] and less need not be
Table 3.1.1 : Electric cables stranded. This requirement does not apply to
mineral-insulated cables which have solid
Application IEC Publication conductors.
General constructional 3.2.4 Cores of multi-core cables are to be
60092-350
and testing requirements readily identifiable.
Fixed power and control
60092-353
circuits 3.3 Insulating materials
Instrumentation, control
and communication 3.3.1 Permitted insulating materials with
60092-375
circuits up to 60 V maximum rated conductor temperatures are
given in Table 3.3.1.
Control circuits up to 250
60092-376
V 3.3.2 Where a rubber or rubber-like material with
Fixed high voltage power maximum conductor temperature greater than
60502 60°C is used, it is to be readily identifiable.
circuits
Mineral insulated 60702
3.3.3 Consideration will be given to other
insulating materials.

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Table 3.3.1 : Insulating materials & maximum rated conductor temperature

Type of insulating compound Maximum rated conductor

temp. °C
Thermoplastics
Based upon polyvinyl chloride or co-polymer of vinyl chloride and
60
vinyl acetate
Based upon polyethylene 60
Elastomeric or thermosettings
Based upon ethylene propylene rubber or similar (EPM or EPDM) 85
Based upon chemically crosslinked polyethylene 85
Based upon silicon rubber 95
Mineral 95

3.4 Construction refrigerated spaces or exposed to harmful

vaporous including oil vapour they are to have
3.4.1 Electric cables are to be at least of a the conductor insulating materials enclosed in
flame-retardant type. Compliance with IEC an impervious sheath of material appropriate to
Publication 60332-1: Tests on a single vertical the expected ambient conditions.
insulated cable or a test procedure equivalent
thereto, will be acceptable. 3.4.5 Electric cables where it is required that
their construction includes metallic sheaths,
3.4.2 Exemption from the requirements of 3.4.1 armouring or braids are to be provided with an
for applications such as radio frequency or overall impervious sheath or other means to
digital communication systems, which require protect the metallic elements against corrosion.
the use of particular types of cable, will be
subject to special consideration. 3.4.6 Where single core electric cables are used
in circuits rated in excess of 20 A and are
3.4.3 Where electric cables are required to be of armoured the armour is to be of a non-magnetic
a 'fire resistant type', they are to comply with the material.
requirements of IEC 60331-31 for cables of
greater than 20 [mm] overall diameter, otherwise 3.4.7 Electric cables are to be constructed such
60331-21. that they are capable of withstanding the
mechanical and thermal effects of the maximum
Notes: short circuit current which can flow in any part of
the circuit in which they are installed, taking into
a) Installation methods specified in 3.11 are to consideration not only the time/current
be applied. characteristics of the circuit protective device but
also the peak value of the prospective short
b) Cables complying with alternative national circuit current. Where electric cables are to be
standards and suitable for use in a marine used in circuits with a maximum short circuit
environment may be considered. current in excess of 70 kA, evidence is to be
submitted for consideration when required
c) Fire resistant type cables are to be easily demonstrating that the cable construction can
distinguishable, for e.g. by way of colour withstand the effects of the short circuit current.
code.
3.4.8 All high voltage electric cables are to be
d) Following standards may be used for readily identified by suitable marking.
special cables such as electrical data and
optical fibre cables: 3.5 Testing

IEC60331-23 : Electric data cables 3.5.1 Routine tests are to include at least
IEC60331-25 : Optical fiber cables.
- measurement of electrical resistance of
3.4.4 Where electric cables are installed in conductors;
locations exposed to the weather, in damp and
in wet situations, in machinery compartments, - high voltage test;

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retardant cables may be accepted for final

- insulation resistance measurement; circuits only in the following cases :
and
a) Where cables are installed in metallic
- partial discharge tests in case of conduits having internal diameter not
high voltage cables. exceeding 25 [mm] and provided the
conduits are electrically and mechanically
Evidence of successful completion of routine continuous.
tests is to be provided by the manufacturer.
b) Bare lead sheathed cable having conductor
3.5.2 Particular, special and type tests are to be sections not exceeding 4.5 [mm2].
made, when required, in accordance with the
requirements of relevant publication or national 3.9 Current rating
standard.
3.9.1 The highest continuous load carried by a
3.6 Voltage rating cable is not to exceed its current rating. The
diversity factor of the individual loads and the
3.6.1 The rated voltage of any cable is not to be duration of the maximum demand may be
lower than the nominal voltage of the circuit for allowed for in estimating the maximum
which it is used. Cables exposed to voltage continuous load and is to be shown on the plans
surges associated with highly inductive circuits, submitted for approval.
e.g. contactor operating circuits for winches etc.,
are to be given special consideration. 3.9.2 The cross sectional area of the conductors
is to be sufficient to ensure that, under short
3.6.2 Electric cables used in unearthed systems circuit conditions, the maximum rated conductor
are to be suitably rated to withstand the temperature for short circuit operation is not
additional stresses imposed on the insulation exceeded, taking in to account the time current
due to an earth fault. characteristics of the circuit protective device
and the peak value of the prospective short
3.7 Choice of insulating material circuit current.

3.7.1 The rated operating temperature of the 3.9.3 In assessing the current rating of lighting
insulating material is to be at least 10°C higher circuits, every lampholder is to be assessed at
than the maximum ambient temperature liable to the maximum load likely to be connected to it,
be produced in the space where the cable is with a minimum of 60 W, unless the fitting is so
installed. connected as to take only a lamp rated at less
than 60 W.
3.8 Choice of protective covering
3.9.4 Cables supplying winches, cranes,
3.8.1 Cables fitted in the following locations are windlasses and capstans are to be suitably
to have an impervious sheath. In permanently rated for their duty. Unless the duty is such as to
wet situations, metallic sheaths are to be used require a longer time rating, cables for winch or
for cables with hydroscopic insulation. crane motors may be half hour rated on the
basis of the half hour [kW] rating of the motors.
- Decks exposed to weather; Cables for windlass and capstan motors are to
be not less than one hour rated on the basis of
- Bathrooms; the one hour [kW] rating of the motor. In all
cases the rating is to be subject to the voltage
- Refrigerated spaces; drop being within the specified limits.

- Machinery spaces; and 3.9.5 The current ratings given in Table 3.9.1
are based on the maximum operating conductor
- Any other location where water temperatures, given in Table 3.3.1. Where a
condensation or harmful vapour (e.g. oil more precise evaluation of current rating has
vapour) may be present. been carried out based on experimental or
calculated data, details may be submitted for
3.8.2 All cables are to be of flame-retardant type approval.
or fire-resisting type, except that non flame-

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Table 3.9.1 : Electric cable current rating, normal operation, based on ambient temp. of 45°C

Nomina Continuous current rating in amperes (based on ambient temp. 45°C)

l cross-
section Thermoplastic, PVC, PE EP rubber and cross linked PE Silicon rubber or mineral
in Single 3 or 4 Single 3 or 4 Single 3 or 4
[mm ]
2 2 core 2 core 2 core
core core core core core core
1 8 7 6 16 14 11 20 17 14
1.5 12 10 8 20 17 14 24 20 17
2.5 17 14 12 28 24 20 32 27 22
4 22 19 15 38 32 27 42 36 29
6 29 25 20 48 41 34 55 47 39
10 40 34 28 67 57 47 75 64 53
16 54 46 38 90 77 63 100 85 70
25 71 60 50 120 102 84 135 115 95
35 87 74 61 145 123 102 165 140 116
50 105 89 74 180 153 126 200 175 140
70 135 115 95 225 191 158 255 217 179
95 165 140 116 275 234 193 310 264 217
120 190 162 133 320 272 224 360 306 252
150 220 187 154 365 310 256 410 349 287
185 250 213 175 415 353 291 470 400 329
240 290 247 203 490 417 343 570 485 400
300 335 285 235 560 476 392 660 560 460

3.10 Correction factors for current rating ambient temperature the correction factors
shown in Table 3.10.1 are to be applied.
3.10.1 Bunching of cables : Where more than
six cables belonging to the same circuit are 3.10.3 Intermittent Service : Where the load is
bunched together a correction factor of 0.85 is to intermittent, the correction factors in Table
be applied. 3.10.2 may be applied for half hour and one
hour ratings. In no case is a shorter rating than
3.10.2 Ambient temperature : The current one half hour rating to be used, whatever the
ratings in Table 3.9.1 are based on an ambient degree of intermittency.
temperature of 45°C. For other values of

Table 3.10.1 : Correction factors for temperature

Correction factor for ambient air temperature of °C

Insulation material
35 40 45 50 55 60 65 70 75 80 85
PVC, Polyethelene 1.29 1.15 1.00 0.82 - - - - - - -
EPR, XLPE 1.12 1.06 1.00 0.94 0.87 0.79 0.71 0.61 0.5 - -
Mineral, Silicon
1.10 1.05 1.00 0.95 0.89 0.84 0.77 0.63 0.55 0.45 -
rubber

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Table 3.10.2 : Correction factors for intermittent rating

Half-hour rating One-hour rating

Correction factor With metallic sheath Without metallic With metallic sheath Without metallic
2 2 2 2
[mm ] sheath [mm ] [mm ] sheath [mm ]
1.00 Upto 20 Upto 75 upto 67 upto 230
1.10 21 - 40 76 - 125 68 - 170 231 - 400
1.15 41 - 65 126 - 180 171 - 290 401 - 600
1.20 66 - 95 181 - 250 291 - 430 -
1.25 96 - 130 251 - 320 431 - 600 -
1.30 131 - 170 321 - 400 - -
1.35 171 - 220 401 - 500 - -
1.40 221 - 270 - - -

3.11 Installation of cables 3.11.7 Cables having a protective covering

which may damage the covering of other cables
3.11.1 Cable runs are to be, as far as are not to be bunched with those of other
practicable, straight and accessible and as high cables.
as possible above bilges.
3.11.8 The minimum internal radius of cable
3.11.2 The installation of cables across bends, which are not subjected to movements
expansion joints in any structure is to be by expansion when installed, is to be generally
avoided. Where such installation is unavoidable, in accordance with Table 3.11.1.
a loop of cable of length proportional to the
expansion of the joint is to be provided. The 3.11.9 Electric cables are not to be coated or
internal radius of the loop is to be at least twelve painted with materials which may adversely
times the external diameter of the cable. affect their sheath or their fire protection.

3.11.3 Where a duplicate supply is required and 3.11.10 Where electric cables are installed in
provided for any particular service, the two refrigerated spaces they are not to be covered
cables are to follow different routes which are with thermal insulation but may be placed
separated throughout their length as widely as is directly on the face of the refrigeration chamber,
practicable, to minimise the probability of provided that precautions are taken to prevent
simultaneous damage to the two circuits. The the electric cables being used as casual means
provision is also applicable to control circuits. of suspension.

3.11.4 Generator cables are as far as 3.11.11 Cable runs are normally not to include
practicable to be divided between two or more joints. However, if a joint is necessary it is to be
cable runs. These cable runs are to be carried out with prior approval and with due
separated as far apart as practicable. consideration to methods of splicing that retain
the original mechanical and electrical properties
3.11.5 Cables supplying essential or important of the cable and which ensure that all
consumers are generally not to be installed in conductors are adequately secured, insulated
rooms where there is an excessive fire hazard and protected from atmospheric action.
such as paint stores, galleys, etc. purifiers, Terminals and busbars are to be of dimensions
welding-gas bottles etc. adequate for the cable rating.

3.11.6 Cables having insulating materials with 3.11.12 Where electric cables are installed in
different maximum-rated conductor bunches, provision is to be made to limit the
temperatures are not to be bunched together, propagation of fire, which may be achieved by
or, where this is not practicable, the cables are either of the following:
to be operated so that no cable reaches
temperature higher than that permitted for the a) Cables which have been tested in
lowest temperature-rated cable in the group. accordance with IEC 60332-3 Category A
or a test procedure for cables installed in
bunches equivalent thereto.

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b) ( Refer to Fig.3.11.12a, b, c and d ) ii) In enclosed and semi enclosed

spaces, cable runs are to comply
i) Fire stops having at least B0 with the following:
penetrations fitted as follows:
- to have fire protection coating
- Cable entries at the main and applied
emergency switchboard, - to at least 1 metre in every 14 metres
- Where cable enter engine control - to entire length of vertical runs or
rooms, - Fitted with fire stops having at least
- Cable entries at centralized control B0 penetrations every second deck
panels for propulsion machinery and or approximately 6 metres for vertical
essential auxiliaries, runs and at every 14 metres for
- At each end of totally enclosed horizontal runs.
cable trunks, and

Table 3.11.1 : Minimum internal radii of bends in cables for fixed wiring

Cable construction Minimum internal

Overall diameter of radius of bend (times
Insulation Outer covering cable overall diameter of
cable)
Metal sheathed
Thermoplastic and Any 6D
Armoured and braided
elastomeric 600/1000
V and below ≤ 25 [mm] 4D
Other finishes
> 25 [mm] 6D
Mineral Hard metal sheathed Any 6D
Thermoplastic and elastomeric above 600/1000 V
- single core Any Any 20D
- multicore Any Any 15D

3.12 Mechanical protection of cables straps such that in the event of a fire they, and
the cables affixed, are prevented from falling
3.12.1 Cables exposed to risk of mechanical and causing an injury to personnel and/or an
damage are to be protected by metal channels obstruction to any escape route. The spacing of
or casing or enclosed in steel conduit unless the their metallic fixing and straps is generally not to
protective covering (e.g. armour or sheath) is exceed 2.0 m.
adequate to withstand the possible damage.
3.12.5.2 When used on open deck, they are
3.12.2 Cables, in spaces where there is additionally to be protected against ultra-violet
exceptional risk of mechanical damage (e.g. on light.
weather decks, in cargo hold areas and inside
the cargo holds) and also below the floor in 3.12.5.3 The load on the plastics cable
engine and boiler rooms, are to be suitably trays/protective casings is to be within the Safe
protected, even if armoured, unless the steel Working Load (SWL) and the spacing of
structure affords adequate protection. support, in general, is not to exceed 2 metres.

3.12.3 Metal casings for mechanical protection 3.12.5.4 The sum of the total cross-sectional
of cables are to be efficiently protected against area of the cables, based on their external
corrosion. diameter, is not to exceed 40% of the internal
cross-sectional area of the protective casing.
3.12.4 Non metallic protective casings and This does not apply to a single cable in a
fixings are to be flame retardant in accordance protective casing.
with the requirements of IEC Publication 92-101.
Note : Cable trays/protective casings made of
3.12.5 If cable trays/protective casings are made plastic materials are to be approved in
of plastics materials, then they are to comply accordance with the Classification Notes issued
with the requirements in 3.12.5.1 to 3.12.5.4. by IRS.

3.12.5.1 They are to be of approved type and

are to be supplemented by metallic fixing and

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3.13 Earthing of metal coverings supported and secured in a manner that
prevents damage to their coverings.
3.13.1 Metal coverings of cables are to be
effectively earthed at both ends of the cable, 3.14.2 Supports and accessories are to be
except its final sub-circuits, other than those robust and are to be of corrosion-resistant
installed in hazardous zones or spaces, earthing material or suitably corrosion inhibited before
at the supply end only will be considered erection.
adequate. This does not necessarily apply to
instrumentation cables where single point 3.14.3 The distance between supports, for
earthing may be desirable for technical reasons. horizontal as well as vertical runs of cables, is to
be chosen according to the type/size of cable,
3.13.2 The electrical continuity of all metal but generally in accordance with Table 3.14.1.
coverings of cables throughout the length of the
cable, particularly at joints and tappings, is to be 3.14.4 When electric cables are fixed by means
ensured. of clips or straps manufactured from a material
other than metal the material is to be flame
3.13.3 The lead sheath of lead-sheathed cables retardant and the fixings are to be supplemented
is not to be used as the sole means of earthing by suitable metal clips or straps at regular
the non-current carrying parts of items of intervals, each not exceeding 2 [m].
equipment.
3.14.5 Single core cables are to be firmly fixed,
3.14 Securing of cables using supports of strength adequate to
withstand forces corresponding to the values of
3.14.1 Cables, other than those attached to the peak prospective short circuit current.
portable appliances and those installed in pipes,
conduits or special casing are to be effectively

Table 3.14.1 : Distance between supports

External diameter of cable

Non-armoured cables Armoured cables
Exceeding [mm] Not exceeding [mm]
[mm] [mm]
- 8 200 250
8 13 250 300
13 20 300 350
20 30 350 400
30 - 400 450

3.15 Penetration of bulkheads and decks by

cables 3.15.3 Where cables pass through gastight
bulkheads or decks separating hazardous zones
3.15.1 Penetration of watertight bulkheads or or spaces, arrangements are to be such that the
decks is to be carried out with either individual gastight integrity and strength of the bulkhead or
watertight glands or with packed watertight deck are not impaired.
boxes carrying several cables. In either case,
the watertight integrity and strength of the 3.15.4 Where cables pass through non-
bulkheads and decks are to be maintained. watertight bulkheads or structural steel, the
Where cables with polyvinyl chloride insulation holes are to be bushed, in order to protect the
are being installed, particular care is to be taken cables, with lead or other approved material
to avoid damage to the sheathing during the which will prevent damage to the cables by
fitting of watertight bulkhead glands. abrasion. If the steel is 6 [mm] thick, adequately
rounded edges may be accepted as the
3.15.2 Where fire-resisting or fire-retarding equivalent of bushing.
bulkheads or decks are drilled for the passage
of cables, all arrangements are to be such that 3.15.5 Cables passing through decks are to be
this fire resisting or fire retarding property and protected by deck tubes or ducts.
strength are not diminished.

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3.15.6 Materials used for glands and bushings 3.16.11 Non-metallic ducting or conduit is to be
are to be such that there is no risk of corrosion. of flame-retardant material. PVC conduit is not
to be used in refrigerated spaces or on open
3.15.7 Where rectangular holes are cut in decks, unless specially approved.
bulkheads or structural steel the corners are to
be adequately rounded. 3.17 Installation of cables in refrigerated
spaces
3.15.8 The distance from cable penetrations to
flanges of steam pipes or hot oil pipes is to be 3.17.1 The installation of cables in refrigerated
not less than 500 [mm]. spaces is to be avoided as far as possible.

3.16 Installation of cables in pipes and 3.17.2 PVC insulated cables are not to be
conduits installed in refrigerated spaces.

3.16.1 Installation of cables in pipes and 3.17.3 Cables installed in refrigerated spaces
conduits is to be carried out in such a manner are to have a watertight or impervious sheath
that there is no damage to the cable covering. and are to be protected against mechanical
damage. If an armoured cable is used, the
3.16.2 Metal conduit systems are to be earthed armour, unless galvanised or of non-corrosive
and are to be mechanically and electrically material, is to be protected against corrosion by
continuous across joints. Individual short lengths an additional moisture-resisting covering.
of conduit need not be earthed.
3.17.4 Cables are not to be embedded in or
3.16.3 The internal radius of bend of pipes and covered by the thermal insulation. They may be
conduit is to be not less than that laid down for fixed to galvanised perforated plates with a
cables, provided that for pipes exceeding 64 space left between the back of the plate and the
[mm] diameter the internal radius of bend is not wall of the room.
less than twice the diameter of the pipe.
3.17.5 Where cables entering a refrigerated
3.16.4 The drawing-in factor (ratio of the sum of space have to pass through the thermal
the cross-sectional areas of the cables, based insulation, they are to be installed at right angle
on their external diameter, to the internal cross- to such insulation and are to be protected by a
section area of the pipe) is not to exceed 0.4. pipe, sealed at each end. Alternatively, the
cables may be passed through solid door
3.16.5 Expansion joints are to be provided frames, the necessary holes being sealed at
where necessary. each end.

3.16.6 Cable pipes and conduits are to be 3.17.6 Precautions are to be taken to prevent
adequately and effectively protected against the placing of hooks around the cable as a
corrosion. Where necessary, openings are to be casual means of suspension.
provided at the highest and lowest points to
permit air circulation and to prevent 3.17.7 Supporting strips, plating or hangers
accumulation of water. used for securing the cables are to be
galvanised or otherwise protected against
3.16.7 Cable pipes are to be effectively corrosion.
supported, particularly in areas where they are
likely to be subject to heavy vibrations. 3.18 Cables for alternating current

3.16.8 Cables in a conduit should belong to the 3.18.1 Generally, multi-core cables are to be
same temperature class. used in A.C. installations. Where it is necessary
to use single-core cables for alternating current
3.16.9 Where cables are laid in trunks, the circuits rated in excess of 20 A the requirements
trunks are to be so constructed as not to afford of 3.18.2 to 3.18.9 are to be complied with.
passage for fire from one deck or compartment
to another. 3.18.2 Cables are to be either non-armoured or
armoured with non- magnetic material.
3.16.10 Cables used for cold cathode luminous
discharge lamps are not to be installed in metal 3.18.3 If installed in pipe or conduit, cables
conduit unless protected by metal sheath or belonging to the same circuit are to be installed
screen. in the same conduit, unless the conduit or pipe
is of non-magnetic material.

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3.18.4 Cable clips are to include cables of all
phases of a circuit unless the clips are of non- 3.19.3 Cables with a supplementary insulating
magnetic material. belt beneath the protective sheath are to have
additional insulation at those points where the
3.18.5 When installing two, three or four single- insulation of each core makes or may make
core cables forming respectively single-phase contact with earthed metal.
circuits, three-phase circuits or three-phase and
neutral circuits, the cables are to be in contact 3.20 Busbar trunking systems
with one another, as far as possible. In any
case, the distance between the external 3.20.1 Where busbar trunking systems are used
covering of two adjacent cables is not to be in place of electric cables, they are to comply
greater than one diameter. with the requirements of 3.20.2 to 3.20.6, in
addition to the applicable requirements in
3.18.6 In the case of circuits using two or more Section 3.
parallel connected cables per phase, all cables
are to have the same length and cross sectional 3.20.2 The busbar trunking, or enclosure
area. system, is to have a minimum ingress protection
of IP54, according to IEC 60529 Degrees of
3.18.7 Where single core cables of rating protection provided by enclosures (IP Code).
exceeding 50 A and over 30 [m] in length are
used, the phases are to be transposed at 3.20.3 The internal and external arrangements
regular intervals of approximately 15 [m] in order of the busbar trunking or enclosure system are
to obtain the same degree of impedance of to ensure that the fire and/or watertight integrity
circuits. of any structure through which it passes is not
impaired.
3.18.8 Where single core cables of rating
exceeding 50 A are used, magnetic material is 3.20.4 Where the busbar trunking system is
not to be placed between single-core cables of a employed for circuits on and below the bulkhead
group. If these cables pass through steel plates, deck, arrangements are to be made to ensure
all cables of the same circuit are to pass through that circuits on other decks are not affected in
the plate or gland so constructed that there is no the event of partial flooding under the normal
magnetic material between the cables, and angles of inclination given in Chapter 1, Table
suitable clearance is provided between the 1.7.1.
cable core and magnetic material. This
clearance, wherever practicable, is not to be 3.20.5 Supports and accessories are to be
less than 75 [mm] when the current exceeds robust and are to be of corrosion-resistant
300 A. For currents between 50 A and 300 A the material or suitably corrosion inhibited before
clearance may be proportionately reduced. erection. The support system is to effectively
secure the busbar trunking system to the ship's
3.18.9 If single-core cables of current rating structure.
greater than 250 A are run along a steel
bulkhead, wherever practicable the cables 3.20.6 When accessories are fixed to the busbar
should be spaced away from the steel. system by means of clips or straps
manufactured from a material other than metal,
3.19 Cable ends the fixings are to be supplemented by suitable
metal clips or straps, such that, in the event of a
3.19.1 The ends of all conductors of cross- fire or failure, the accessories are prevented
sectional area greater than 4 [mm2] are to be from failing and causing injury to personnel
fitted with soldering sockets, compression type and/or an obstruction to any escape route.
sockets or mechanical clamps. Corrosive fluxes Alternatively, the busbar system may be routed
are not to be used. away from such areas.

3.19.2 Cables having hygroscopic insulation

(e.g. mineral insulated) are to have their ends
sealed against ingress of moisture.

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Section 4

Switchgear and Control Gear Assemblies

4.1 Main and emergency switchboards 4.1.2 Construction of switchboards

4.1.1 Location and installation 4.1.2.1 Switchboards are to have roof with
degree of protection IP 22 and are to be of dead
4.1.1.1 Switchboards are to be installed in front type.
accessible and well ventilated dry spaces free
from flammable gases and acid fumes. On systems with voltages above 50 V up to and
including 1000 V, front and rear dead type
4.1.1.2 Switchboards are to be secured to a switchboards are to be used.
solid foundation and protected against shocks
and damage due to leaks and falling objects. 4.1.2.2 All main switchboards are to be guarded
They are to be self-supported, or be braced to by hand rails either made of hardwood or
the bulkhead or the deck above. In case the insulated. Where access is provided behind a
latter method is used, the means of bracing is to main switchboard, the handrails on the rear are
allow normal deflections of the deck without to be horizontal, and so placed that one cannot
buckling the control cell or assembly structure. accidentally fall into the switchboard. Further,
insulated mats or gratings are to be laid on the
4.1.1.3 Pipes should not be installed directly floor of passage-ways in front of and to the rear
above or in front of or behind switchboards. If of switchboards. Instruments and handles or
such piping is unavoidable, suitable protection is push buttons for switchgear are to be placed on
to be provided in these positions. the front of the switchboard (except for isolating
switches, if used). All other parts which require
4.1.1.4 An adequate, unobstructed working operation, are to be accessible and so placed
space is to be left in front of switchboards. At the that the risk of accidental touching of current
rear, a clearance of at least 0.6 m is to be carrying parts, or accidental making of short-
maintained except that this may be reduced to circuits and earthings, is reduced as far as
0.5 m in way of stiffeners or frames. If practicable.
switchboards are enclosed at the rear and are
fully serviceable from the front, clearance at the 4.1.2.3 Section boards (sub-switchboards) and
rear will not be required unless necessary for distribution boards are to be enclosed unless
cooling. they are installed in a cupboard or compartment
to which only authorised personnel have access,
4.1.1.5 The main switchboard is to be so placed in which case the cupboard may serve as an
relative to one main generating station that, as enclosure.
far as practicable, the integrity of the normal
electrical supply may be affected only by a fire 4.1.2.4 Framework, panels and doors of
or other casualty in one space. The main switchboards are generally to be of steel or
switchboard is to be located as close as aluminium alloy, and are to be of rigid
practicable to the main generating station, within construction.
the same machinery space and the same
vertical and horizontal A60 fire boundaries. An 4.1.2.5 All parts of the main switchboard are to
environmental enclosure for main switchboard, be accessible for maintenance work.
such as may be provided by a machinery control
room situated within the main boundaries of the 4.1.2.6 Equipment for each generator and for
space, is not to be considered as separating the different distribution systems are to be placed in
switchboards from the generators. separate cubicles (panels) or are to be
separated from each other by partitions clearly
4.1.1.6 Where essential services for steering marked with the actual voltages.
and propulsion are supplied from section boards
these and any transformers, converters and 4.1.2.7 Doors, behind which equipment requiring
similar appliances constituting an essential part operation is placed, are to be hinged.
of electrical supply system are also to satisfy Arrangement is also to be provided to keep the
4.1.1.5. hinged doors open.

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4.1.2.8 Cable entrances are generally to be from adequate clearance and creepage distance, in
below or from the side. Cable entries from the accordance with Section 1, to ensure that there
top may be accepted provided watertight glands is no risk of flash-over under normal service
are used. conditions. Where necessary these distances
may have to be increased to allow for the
4.1.2.9 Where the main source of electrical electro-magnetic forces involved.
power is essential for propulsion of the ship, the
main busbars are to be subdivided into at least 4.1.4.5 Connections from bus-bars and from
two parts which are normally to be connected by generator circuit terminals to all circuit breakers
circuit breakers (with or without tripping and fuses are to be installed "short-circuit proof",
mechanism), disconnecting links or switch by i.e. either bare conductors, or insulated
which busbars can be split and reconnected conductors or single-core cable without metallic
easily and safely. Bolted links (e.g. bolted bus sheath/armour /braid are used and these are
bar sections) are not acceptable. So far is mounted on supports of insulating material and
practicable, the connection of generating sets with adequate distance between the different
and any other duplicated equipment is to be poles (phases) and to earthed parts.
equally divided among the busbar divisions.
Equivalent arrangements to the satisfaction of 4.1.4.6 Horizontally installed bus-bars and bare
IRS may be accepted. conductors are to be protected by screens, if
they are placed so low that it could be a risk,
4.1.3 Marking and labels e.g. by tools falling on them.

4.1.3.1 All measuring instruments and all 4.1.5 Equalizer connections

apparatus controlling circuits are to be clearly
and indelibly marked for identification purposes. 4.1.5.1 The current rating of equalizer
An indelible label is to be permanently secured connections and equalizer switches is to be not
to, or adjacent to, every fuse and every circuit less than half the rated full load current of the
breaker, and marked with particulars of the full generator.
load current of the generator or cable which the
fuse or circuit-breaker protects. Where inverse 4.1.5.2 The current rating of equalizer busbars is
time limit and/or reverse current devices are to be not less than half the rated full load current
provided in connection with a circuit breaker, the of the largest generator in the group.
appropriate settings of these devices are to be
stated on the lable. The distribution voltage is to 4.1.6 Instruments for direct current
be indicated. Labels are to be of flame-retardant generators
material and markings are to correspond with
the designations used in the wiring diagrams. 4.1.6.1 For generators not arranged to run in
parallel, at least one voltmeter and one ammeter
4.1.4 Busbars are to be provided for each generator.

4.1.4.1 Busbars and their connections are to be 4.1.6.2 For generators arranged to run in
of copper, all connections being so made as to parallel at least one ammeter for each generator
prevent deterioration of the joint by corrosion or and two voltmeters are to be provided. One of
oxidation. these voltmeters is to be permanently connected
to the busbars and the other is to be provided
4.1.4.2 The sizes of busbars and their with a change-over switch to enable it to be
connections are to be calculated to ensure that connected to any one generator.
their mean temperature rise does not exceed by
more than 45°C from the ambient temperature, 4.1.6.3 For compound wound generators fitted
when running continuously at the normal rating. with equalizer connections, the ammeter is to be
connected to the pole opposite to that connec-
4.1.4.3 Busbars, together with their connections ted to the series winding of the generator.
and supports, are to be capable of withstanding,
without detrimental effect, the mechanical 4.1.7 Instruments for alternating current
stresses which will arise during short-circuits. generators
Further, provision is to be made to allow the
busbars to expand without causing any 4.1.7.1 For alternating current generators not
abnormal stress on their supports. arranged to run in parallel, each generator is to
be provided with at least one voltmeter, one
4.1.4.4 Busbars and other bare conductors are frequency meter, and one ammeter with an
to be mounted on non- deteriorating and non- ammeter switch to enable the current in each
hygroscopic insulating material, maintaining phase to be read or an ammeter in each phase.

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Generators above 50 kVA are to be provided 4.1.9 Instrument transformers

with a wattmeter.
4.1.9.1 The secondary windings of instrument
4.1.7.2 For alternating current generators transformers are to be earthed.
arranged to run in parallel, each generator is to
be provided with a wattmeter, and an ammeter 4.1.10 Circuit-breakers
in each phase conductor or an ammeter with a
selector switch to enable measurement of 4.1.10.1 Circuit-breakers are to comply with IEC
current in each phase. Publication 947-1 and 947-2, "Low Voltage
Distribution Switchgear" or an equivalent
4.1.7.3 For paralleling of the generators, two national standard, amended where necessary
voltmeters, two frequency meters and a for ambient temperature.
synchronising aid comprising either a
synchroscope and lamps, or an equivalent 4.1.10.2 Test reports, based on the
arrangement, are to be provided. One voltmeter requirements of IEC Publication 947-1 and 947-
and one frequency meter are to be connected 2 or an equivalent national standard, are to be
permanently to the busbars, the other voltmeter submitted for consideration when required.
and frequency meter are to be provided with
arrangements to enable the voltage and 4.1.10.3 Circuit-breakers are to be of the trip-
frequency of any generator to be measured. free type i.e. the breaking action initiated by
short-circuit and overcurrent relays, or by
4.1.8 Instrument scales undervoltage coil, when fitted, is to be fulfilled
independently of the position or operation of
4.1.8.1 In general main switchboard instruments manual handle or of other closing devices.
are to be of accuracy class 1.5 and other Further the arrangement is to be such that
switchboard instruments are to be of accuracy automatic repeated breakings/makings by short-
class 2.5. circuits and overcurrents cannot occur.

4.1.8.2 The upper limit of the scale of every 4.1.10.4 Each circuit opening device is to be so
voltmeter is to be approximately 120 per cent of arranged that accidental closing and opening
the normal voltage of the circuit, and the normal does not occur.
voltage is to be clearly indicated.
4.1.10.5 Handles and operating mechanisms
4.1.8.3 The upper limit of the scale of every are to be so arranged that the hand of the
ammeter is to be approximately 130 per cent of operator cannot accidentally touch live metal or
the normal rating of the circuit in which it is be injured through an arc arising from the switch
installed. Normal full load is to be clearly or circuit-breaker, or the rupturing of a fuse. If
indicated. switches are enclosed their handles are not to
operate through unprotected slots.
4.1.8.4 Ammeters for use with direct current
generators, and wattmeters for use with 4.1.11 Fuses
alternating current generators, which may be
operated in parallel, are to be capable of 4.1.11.1 Fuses are to comply with IEC
indicating 15 per cent reverse-current or Publication 269 "Low Voltage Fuse with High
reverse-power respectively. Breaking Capacity" or an equivalent national
standard, amended where necessary for
4.1.8.5 The upper limit of the scale of every ambient temperature.
wattmeter is to be approximately 130 per cent of
the rated full load of the circuit in which it is 4.1.11.2 A report, giving details of test
installed. Rated full load is to be clearly performance, fusing characteristics, temperature
indicated. and insulation tests and details of the
specification to which the fuse has been tested
4.1.8.6 Frequency meters are to be capable of is to be submitted for consideration when
indicating a variation in the frequency from required.
minus 8 per cent to plus 8 per cent of the
nominal frequency of the installation. 4.1.11.3 Fuse-links and fuse-bases are to be
marked with particulars of rated current and
4.1.8.7 Instruments are to have effective rated voltage. Each fuse position is to be
screening, for example, by metal enclosures, in permanently and indelibly labeled with the
order to diminish faulty readings caused by current-carrying capacity of the circuit protected
induction from adjacent current-carrying parts. by it and with the appropriate approved size of
fuse.

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positive means to show the circuit feeding the
4.1.12 Earthing switchboard. Such switchboards are to be
provided with warning notice that all the supply
4.1.12.1 A good, reliable earth connection of all circuits are to be disconnected before
metallic non-current carrying parts is to be maintenance work is undertaken.
insured. Normally, a continuous earth bar will be
required. If other solutions are chosen, earth- 4.2.5 If distribution switchboards are placed in
continuity test may be required. accommodation area then they are also to
comply with the requirements given in Pt.6,
4.1.12.2 If components such as switches, Ch.3, Cl.3.2.2.3.2 IR.6.
instruments, signal lamps, etc. with voltage
exceeding 30V AC and 50V DC are mounted on 4.3 Navigation lights
hinged doors of switchboards or other
enclosures, the doors are to be connected to the 4.3.1 Navigation lights are to be connected
switchboards or enclosures by a separate separately to a distribution board reserved for
flexible earth conductor. this purposes only, and connected directly or
through transformers to the main or emergency
4.1.12.3 Earth conductors are to be so installed switchboard. The distribution board is to be
that they are not likely to suffer mechanical accessible to the officer of the watch on the
damage or corrosion. The earth conductor is to bridge. Provision is to be made on the bridge for
be carried to a separate earth screw inside the such navigation lights to be transferred to an
enclosure of the equipment which is earthed, alternate circuit.
except when separately installed earth
conductors are used. 4.3.2 Each navigation light is to be controlled
and protected in each insulated pole by a switch
4.1.12.4 Earth conductors inside switchboards and fuse or circuit breaker mounted on the
and other enclosures are to be insulated, except distribution board.
when the arrangement is such that the earth
conductor cannot come into contact with 4.3.3 Where the navigation panel is situated in
current-carrying parts. the midships house, the midships sub-
switchboard is regarded as an extension to the
4.1.13 Wiring main switchboard provided that it is supplied
from the main switchboard by two cables each
4.1.13.1 Insulated cables / wires connecting capable of carrying the full load.
components are to be stranded, flame retardant
and manufactured in accordance with a relevant 4.3.4 Each navigation light is to be provided with
and acceptable National Standard or equivalent an automatic indicator giving aural and visual
International Standard. indication of failure of the light. If an aural device
alone is fitted, it is to be connected to a primary
4.2 Distribution switchboards or secondary battery. If a visual signal is used
connected in series with the navigation light,
4.2.1 Large distribution switchboards are to be means are to be provided to prevent extinction
constructed in accordance with 4.1. of the navigation light due to failure of the signal.

4.2.2 All parts which require operation in normal 4.3.5 Transferring of power supply to an
use are to be placed on the front or easily alternate circuit should not render the
accessible from behind front doors. audio/visual alarms inoperative. Means should
be provided to test the audio/visual alarms.
When such parts are placed behind front doors,
the interior front is to comply with enclosure type 4.3.6 Any statutory requirements of the country
IP 20, except that fuses with accessible current- of registration are to be complied with and, on
carrying parts may be permitted, provided that application to IRS, may be accepted as an
the door is lockable. alternative to the above.

4.2.3 Switchboards, supplied from different 4.3.7 The voltage drop between the power
supply circuits, are not to be placed in the same supply terminals and load terminals for
enclosure unless these are separated by navigation lights is to be not more than 2.5 per
partitions of flame retardant material. cent of the rated voltage to ensure required
output and colour.
4.2.4 Switchboards, which are provided with two
or more supply circuits arranged for automatic
standby connection, are to be provided with

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4.4 Control gear arrangements are to be such that arcs occurring

by short-circuit in one cubicle cannot spread to
4.4.1 Control gear is to comply with IEC bus-bars.
Publication 158, "Low Voltage Control Gear", or
an equivalent national standard, amended 4.5 Testing
where necessary for ambient temperature.
4.5.1 Switchgear and control gear assemblies
4.4.2 Control gear, including isolating and with supply voltage of 60 V and above are to be
reversing switches, is to be so arranged that tested as follows:
shunt field circuits are not disconnected without
adequate discharging path being provided. - High voltage test with 1000 V plus twice
the rated voltage with a minimum of
4.4.3 Control gear for essential and important 2000 V. The test voltage is to be
motors are to be separated from each other and supplied for 1 minute at any frequency
from other current carrying parts by screens. between 25 and 100 Hz.
The arrangement is to be such that maintenance
work can be carried out on each unit without - Insulation resistance measuring.
danger when isolated.
4.5.2 Switchgear and control gear assemblies
4.4.4 When installed in main switchboards motor with supply voltage less than 60 V are to be
control gear is to be placed in separate cubicles tested in accordance with 4.5.1 except that the
separated from all other parts of the switchboard test voltage is to be 500 V.
by partitions of flame retardant material. The

Section 5

Rotating Machines - Construction and Testing

5.1 General the machine windings or other conductors and

insulators.
5.1.1 Rotating machines are to comply with the
relevant part of IEC Publication IEC 60092-301, 5.1.6 Steps are to be taken to prevent the ill
or an acceptable and relevant national standard, effects of flow of currents circulating between
and the requirements of this Section. the shaft and bearings.

5.1.2 For all the rotating machines for essential 5.1.7 Where welding is proposed to be applied
services, manufacturer's test records are to be to shafts of machines for securing armature
provided (See also Sec.1). For other machines arms or spiders, stress relieving is to be carried
they are to be available upon request. out after welding. The proposal is to be
submitted for scrutiny and approval.
5.1.3 Shaft materials for electric propulsion
motors and for main engine driven generators 5.1.8 The construction of alternating machines,
where the shaft is part of the propulsion are to be capable of withstanding a sudden
shafting, is to comply with applicable short circuit at their terminals under any
requirements of Pt.2, and to be certified by IRS. operating condition.
Shaft material for other machines is to be in
accordance with either Pt.2 or recognised 5.1.9 Effective means are to be provided to
international or national standard. prevent the accumulation of moisture and
condensation within the machines when they
5.1.4 The rotating parts are to be so balanced are stopped with a provision that such means
that when running at any speed in the normal are switched on at stand-still and switched off at
working range the vibration level does not starting.
exceed the levels specified in IEC 60034.
5.1.10 Coolers : Water-air heat exchangers of
5.1.5 The lubrication arrangement for bearings rotating machines are to be of the double tube
are to be effective under all operating conditions type. In a normally attended position a visual
including the maximum ship inclinations and audible alarm is to be given to monitor
specified in Ch.1 and there are to be effective water cooler leakage.
means to ensure that lubricant does not reach

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5.2 Rating temperature of 45°C and a cooling water
temperature of 30°C.
5.2.1 Ship's service generators including their
exciters, and continuously rated motors are to 5.3.2 If the temperature of the cooling medium is
be suitable for continuous duty at their full rated known to exceed the value given in 5.3.1, the
output at maximum cooling air or water permissible temperature rise is to be reduced by
temperature for an unlimited period, without the an amount equal to the excess temperature of
limits of temperature rise in 5.3 being exceeded. the cooling medium. These temperature rises
Other generators and motors are to be rated in are, if necessary to be reduced to satisfy the
accordance with the duty which they are to requirements of flame-proof equipment.
perform, and when tested under rated load
conditions the temperature rise is not to exceed 5.3.3 If the temperature of the cooling medium is
the values in 5.3. known to be permanently less than the value
given in 5.3.1, the permissible temperature rise
5.3 Temperature rise may be increased by an amount equal to the
difference between the declared temperature
5.3.1 The limits of temperature rise specified in and that given in 5.3.1 upto a maximum of 15°C.
Table 5.3.1 are based on a cooling air

Table 5.3.1 : Limits of temperature rise in °C

Method of Temperature rise °C

measure Air cooled machines Water cooled machines
Item Part of machines
ment of insulation class insulation class
temp. A E B A E B
a.c. windings of turbine type machines
1 (a) ETD or R 50 60 70 70 80 90
having output of 5000 KVA or more
a.c. windings of salient-pole and of
induction machines having output of
(b) ETD or R 50 60 70 70 80 90
5000 KVA or more, or having a core
length of one metre or more
a.c. windings of machines smaller than
2 (a) R 50 65 70 70 85 90
in item 1
T 40 55 60 60 75 80
Field windings of a.c. and d.c. machines
(b) having d.c. excitation other than those in R 50 65 70 70 85 90
items 3 and 4
T 40 55 60 60 75 80
Windings of armatures having
(c) R 50 65 70 70 85 90
commutators
T 40 55 60 60 75 80
Field windings of turbine-type machines
3 R - - 80 - - 100
having d.c. excitation
Low-resistance field windings of more
4 (a) than one layer and compensating T,R 50 65 70 70 85 90
windings
Single-layer windings with exposed bare
(b) T,R 55 70 80 75 90 100
surfaces
Permanently short-circuited insulated
5 T 50 65 70 70 85 90
windings
The temperature rise of these parts shall in no case reach
Permanently short-circuited windings,
6 T such a value that there is a risk of injury to any insulating or
uninsulated
other material on adjacent parts
The temperature rise of these parts shall in no case reach
Iron core and other parts not in contact
7 - such a value that there is a risk of injury to any insulating or
with windings
other material on adjacent parts
Iron core and other parts in contact with
8 T 50 65 70 70 85 90
windings
Commutators and slip-rings, open or
9 T 50 60 70 70 80 90
enclosed

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Table 5.3.1 (Contd.)

Notes:-

1 T = Thermometer method
R = Resistance method
ETD = Embedded Temperature Detector

2 When the commutators, sliprings or bearings of machines provided with water coolers are not in the enclosed air circuits-
cooled by the water cooler, but are cooled by the ambient cooling air, the permissible temperature rise above the ambient
cooling air should be the same as for ventilated machines.

3 When Class F or Class H insulation is employed, the permitted temperature rises are respectively 20°C and 40°C higher than
the values given for Class B insulation.

4 Classes of insulation are to be in accordance with IEC Publication 85 (1957) - "Recommendations for the classification of
material for the insulation of electrical machinery and apparatus in relation to their thermal stability in service".

5.3.4 The limits of temperature rise of electric voltage. The voltage is to recover to rated
slip couplings are to be in accordance with voltage within a time not exceeding 1.5 seconds.
Table 5.3.1, except that when a squirrel cage
element is used the temperature of this element 5.4.4 The transient voltage rise at the terminals
is not to reach an injurious value. The of a generator is not to exceed 20 per cent of
temperature of the field windings is not to rated voltage when rated KVA at a power factor
exceed these limits at all speeds of operation. not greater than 0.8 is thrown off.
Arrangements for reducing the excitation of self
ventilated couplings at low operational speeds 5.4.5 Generators are to be capable of
are permissible. maintaining under steady state short circuit
conditions a current of at least three times the
5.3.5 Alternating current machines of 5000 kVA full load rated current for a duration of at least
output and above and propulsion motors having two seconds or where precise data is available
a total axial core length of 1m or more (including for the duration of any longer time delay which
the ventilating duct), are to have at least three may be provided by a tripping device for
embedded temperature detectors. With discrimination purposes.
multicore machines the total length is to be
taken as the sum of the individual core lengths. 5.4.6 Generators required to run in parallel are
to be stable from no load [kW] up to the total
5.4 Generator control combined full load [kW] of the group, and load
sharing is to be such that the load on any
5.4.1 Each alternating current generator, unless generator does not normally differ from its
of the self-regulating type, is to be provided with proportionate share of the total load by more
automatic means of voltage regulation; voltage than 15 per cent of the rated output [kW] of the
build-up is not to require an external source of largest machine or 25 per cent of the rated
power. output [kW] of the individual machine, whichever
is less.
5.4.2 The voltage regulation of any alternating
current generator with its regulating equipment 5.4.7 When generators are operated in parallel,
is to be such that at all loads, from zero to full the kVA loads of the individual generating sets
load at rated power factor, the rated voltage is are not to differ from the proportionate share of
maintained within ±2.5 per cent under steady the total kVA load by more than 5 per cent of the
conditions. There is to be provision at the rated kVA output of the largest machines.
voltage regulator to adjust the generator no load
voltage. 5.4.8 Generators running in parallel may have a
common neutral connection to earth provided
5.4.3 Generators, and their excitation systems, they are suitably designed to avoid excessive
when operating at rated speed and voltage on circulating currents.
no-load are to be capable of absorbing the This is particularly important if the generators
suddenly switched, balanced, current demand of are of different size and make.
the largest motor or load at a power factor not Generators in which the third harmonic content
greater than 0.4 with a transient voltage dip of the waveform does not exceed 5 per cent
which does not exceed 15 per cent of rated may be considered adequate.

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5.6 Brushgear
Note : This would mostly occur with a neutral
bus with a single grounding resistor with the 5.6.1 The final running position of brushgear is
associated neutral switching. Where individual to be clearly and permanently marked.
resistors are used, circulation of the third
harmonic currents between paralleled 5.6.2 Direct current motors and generators are
generators is minimized. to operate with fixed brush setting from no load
to the momentary overload specified without
5.5 Overloads injurious sparking, or damage to the commutator
or brushes. The commutation is to be checked
5.5.1 Machines are generally to be capable of with an excess current of 20 per cent and for a
withstanding, on test, without injury, the period of time sufficient to judge its quality.
following overload conditions :
5.6.3 Alternating current commutator motors are
a) D.C. generators - an excess current of 50 to operate over the specified range of load and
per cent for 15 seconds after attaining the speed without injurious sparking.
temperature rise corresponding to rated
load, the terminal voltage being maintained 5.7 Inspection and testing
as near the rated value as possible. This
requirement does not apply to the overload 5.7.1 On all machines intended for essential
torque capacity of the prime mover. services, tests specified in Table 5.7.1 are to be
carried out. See also Section 1 'Surveys',
b) A.C. generators - an excess current of 50 subsection 1.3. Any other relevant tests required
per cent for 2 minutes, at 0.6 power factor, by the national standards are also to be carried
after attaining the temperature rise out.
corresponding to rated load, the terminal
voltage and frequency being maintained as Type tests are to be carried out on a prototype
near the rated values as possible. This machine or on the first of a batch of machines
requirement does not apply to the overload and routine tests carried out on subsequent
torque capacity of the prime mover. machines.

c) Motors - At rated speed or in the case of a 5.7.2 The high voltage test is to be carried out at
range of speeds, at the highest and lowest 1000 plus twice the rated voltage with a
speeds, under gradual increase of torque, minimum of 2000 V on new machines,
the voltage and frequency being maintained preferably at the conclusion of the temperature
as near to their rated value as possible, the rise test. The test is to be applied between the
appropriate excess torque given below. windings and the frame with the core connected
Synchronous motors and synchronous to the frame and to any windings or sections of
induction motors are required to withstand windings not under test. Where both ends of
the excess torque without falling out of each phase are brought out to accessible
synchronism and without adjustment of the separate terminals, each phase is to be tested
excitation current preset at the value separately. The test is to be made with
corresponding to rated load. alternating voltage at any convenient frequency
between 25 and 100 Hz of approximately sine
d.c. motors 50 per cent for 15 wave form. The test is to be commenced at a
seconds voltage of not more than one half of the full-test
polyphase a.c. 50 per cent for 15 voltage and is to be increased progressively to
synchronous motors seconds full value, the time allowed for the increase of
polyphase a.c. 35 per cent for 15 the voltage from half to full value being not less
synchronous seconds than 10 seconds. The full test voltage is then to
induction motors be maintained for one minute and then reduced
polyphase a.c. 60 per cent for 15 to one half full value before switching off.
induction motors seconds
5.7.3 When additional high voltage tests are
d) Propulsion machines - Overload tests for required on a machine which has already
propulsion machines will be given special passed its tests or on machines after repair, the
consideration for each installation. voltage of such further tests is to be 75 per cent
of the value given in 5.7.2.

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5.7.4 An insulation resistance test is to be rise test has been carried out is to be at least 1
carried out immediately after the high voltage MΩ.
test. The insulation resistance of a new, clean
dry machine, immediately after the temperature

Table 5.7.1 : Tests to be carried out on electrical rotating machines

a.c. Generators Motors
Sr.
Tests Type Routine Type test Routine
No.
test (1) test (2) (1)
test (2)
1. Examination of the technical documentation, X X X X
as appropriate and visual inspection
2. Insulation resistance measurement X X X X
3. Winding resistance measurement X X X X
4. Verification of the voltage regulation system X X
5. Rated load test and temperature rise X X
measurement
6. Overload test X X(4) X X(4)
7. Verification of steady short-circuit conditions X
(3)
8. Overspeed test X X(5)
9. Dielectric strength test X X X X
10. No load test X X X X
11. Verification of degree of protection X X
12. Verification of bearings X X X X

(1) For machines of less than 100 kW, type tests on prototype machine is acceptable. For 100 kW or
more, tests on at least the first of each batch of machines are to be carried out.
(2) The report of machines routine tested is to contain the manufacturer's serial number of the machine
which has been type tested and the test results.
(3) Verification of steady short-circuit condition applies to synchronous machines only.
(4) Only applicable for machines of essential services rated above 100 kW. For routine tests,
overcurrent test may be carried out in lieu of overload test.
(5) Not applicable for squirrel cage motors.

Section 6

Converting Equipment

6.1 Transformers gaseous or acid fumes. They are to be clear of

non-protected ignitable materials, and so
6.1.1 The following requirements apply to arranged as to be protected against shocks and
transformers of 5 kVA and above. any damage resulting from water, oil, liquid fuel,
steam etc.
6.1.2 Transformers are to comply with the
requirements of IEC Publication 76 or an 6.1.5 The live parts of transformers are to be
acceptable and relevant national standard provided with means of protection against
amended where necessary for ambient accidental contact.
temperature.
6.1.6 Transformers are to be double wound
6.1.3 Transformers may be of the dry type, except those for motor starting.
encapsulated or liquid filled type.
6.1.7 Windings of air cooled transformers are to
6.1.4 Transformers are to be placed in easily be treated to efficiently resist moisture, sea air
accessible well ventilated spaces free from any and oil vapours.
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- 50°C - where air provides cooling of the

Effective means are to be provided to prevent fluid;
the accumulation of moisture and condensation
within the transformers, when de-energized. - 65°C - where water provides cooling of
the fluid.
6.1.8 Each transformer is to be provided with a
nameplate of corrosion- resistant metal giving 6.1.14 The tests given hereunder are to be
information on make, type, serial number, carried out on all transformers at the
insulation class and any other technical data manufacturer's works and a certificate of tests
necessary for the application of the transformer. issued by the manufacturer.

6.1.9 Liquid fillings for transformers are to be a) High voltage test : The test voltage is to be
non-toxic and of a type which does not readily applied, preferably after the temperature
support combustion. Liquid filled transformers rise test, to each winding in turn, between
are to have a pressure relief-device with an the winding under test and the remaining
alarm and there is to be a suitable means windings, core, frame and tank or casing
provided to contain any liquid which may escape connected together and to earth. The test is
from the transformer. to be made with 1 kV a.c. plus twice the
highest voltage between lines with a
6.1.10 When forced cooling is employed, minimum of 2.5 KV at any frequency
whether air or liquid, there is to be monitoring of between 25 and 100 Hz and maintained for
the cooling medium and transformer winding 1 minute without failure.
temperature with an alarm should these exceed
preset limits. There are to be arrangements so b) When additional high voltage tests are
that the load may be reduced to a level carried out and for transformers that have
commensurate with the cooling available. been rewound or subject to extensive repair,
the test voltage may be limited to a value
6.1.11 The inherent regulation of transformers at which is 75 per cent of that stated in (a).
their rated output is to be such that voltage drop
to any point in the installation does not exceed c) Induced high voltage test : To test between
that allowed by 2.3. turns, coils and terminals, an a.c. voltage is
to be applied between the above parts
6.1.12 All transformers are to be constructed to corresponding to twice the voltage
withstand, without damage, the thermal and appearing between these parts when rated
mechanical effects of a short-circuit at the voltage is applied to the terminals. The
terminals of any winding for 2 seconds with duration of the test is to be 1 minute for any
rated primary voltage and frequency without test frequency up to and including twice the
damage. This may be required to be verified by rated frequency.
type test or random test.
d) Insulation resistance : The insulation
6.1.13 The temperature rise of windings of resistance of each winding in turn to all the
transformers above the ambient temperatures other windings, core, frame and tank or
given in Ch.1, when measured by resistance, casing connected together and to earth is to
during continuous operation at the maximum be measured after the high voltage test and
rating, is not to exceed : recorded together with the temperature of
the transformer at the time of the test.
a) For dry type transformers, air cooled
e) Temperature rise : One transformer of each
- 50°C for Class A; size and type is to be given a temperature
rise test. For transformers of rating 100 KVA
- 60°C for Class E; and above, it will be accepted that the
temperature rise test is made on one of
- 70°C for Class B; several identical transformers manufactured
and tested at the same time.
- 90°C for Class F; and
6.2 Semiconductor equipment
- 110°C for Class H.
6.2.1 The requirements of 6.2.2 to 6.2.16 apply
b) For liquid filled transformers to semiconductor equipment rated for 5 [kW]
upwards.

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6.2.2 Semiconductor equipment is to comply introduced in to the ships electrical system are
with the requirements of IEC 146: restricted to a level necessary to ensure that it
Semiconductor convertors, or an acceptable and causes no malfunction of equipment connected
relevant national standard amended where to the electrical installation.
necessary for ambient temperature.
6.2.12 Overvoltage spikes or oscillations caused
6.2.3 Semiconductor static power converter by commutation or other phenomena, are not to
equipment is to be rated for the required duty result in the supply voltage waveform deviating
having regard to peak loads, system transients from the superimposed equivalent sine wave by
and overvoltage. more than 10 percent of the maximum value of
the equivalent sine wave.
6.2.4 Converter equipment may be air or liquid
cooled and is to be so arranged that it cannot 6.2.13 When converter equipment is operated in
remain loaded unless effective cooling is parallel, load sharing is to be such that under
maintained. Alternatively the load may be normal operating conditions overloading of any
automatically reduced to a level commensurate unit does not occur and the combination of
with the cooling available. parallel equipment is stable throughout the
operating range.
6.2.5 Liquid cooled converter equipment is to be
provided with leakage alarms and there is to be 6.2.14 When converter equipment has parallel
a suitable means provided to contain any liquid circuits there is to be provision to ensure that the
which may leak from the system. Where the load is disturbed uniformly between the parallel
semiconductors and other current carrying parts paths.
are in direct contact with the cooling liquid,
provision is to be made for monitoring the liquid 6.2.15 Transformers, reactors, and other circuit
to ensure it has a satisfactory resistivity. devices associated with convertor equipment
are to be suitable for the distorted voltage and
6.2.6 Where forced cooling is used there is to be current waveforms to which they may be
temperature monitoring of the heated cooling subjected.
medium with an alarm and shutdown when the
temperature exceeds a preset value. 6.2.16 Tests at the manufacturer's works are to
include
6.2.7 Cooling fluids are to be non-toxic and of
low flammability. - high voltage test for one minute applied
between terminals and earthed parts at
6.2.8 Converter equipment is to be so arranged a frequency between 25 - 100 Hz. For
that the semiconductor devices, fuses, control system voltage up to 60 V the test
and firing circuit boards may be readily removed voltage is to be 600 V; for system
from the equipment for repair or replacement. voltage between 60 - 90 V the test
voltage is to be 900 V; for system
6.2.9 Test and monitoring facilities are to be voltage over 90 V the test voltage is to
provided to permit identification of control circuit be twice the system voltage plus 1000
faults and faulty components. V;

6.2.10 Protection devices fitted for converter - functional tests;

equipment protection are to ensure that, under
fault conditions, the protective action of circuit - temperature rise test; and
breakers, fuses or control systems is such that
there is no further damage to the convertor or - such other agreed tests as are
the installation. necessary to demonstrate the suitability
of the equipment for its intended duty.
6.2.11 Converter equipment, including any Details of tests are to be submitted for
associated transformers, reactors, capacitors consideration when required.
and filters, if provided, is to be so arranged that
the harmonic distortion, and voltage spikes,

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Section 7

Miscellaneous Equipment

7.1 Accumulator batteries ingress of water, and provided the intended

service is assured in cold conditions.
7.1.1 General
7.1.3.5 Engine starting batteries are to be
7.1.1.1 The requirements of this Section apply to located as close as practicable to the engine(s)
permanently installed secondary batteries of the served. If such batteries cannot be
vented type. accommodated in the battery compartment, they
are to be installed so that adequate ventilation is
7.1.1.2 A vented type battery is one in which the ensured.
electrolyte can be replaced and which may
release gas whilst operating on charge and 7.1.4 Installation
overcharge.
7.1.4.1 Batteries should be so arranged that
7.1.1.3 Proposals for the use of other types of each cell or crate of cells is accessible from the
secondary batteries may be submitted for top and at least one side.
consideration.
7.1.4.2 Cells or crates are to be carried on non-
7.1.2 Construction absorbent insulating supports. Similar insulators
are to be fitted to prevent any movement of cells
7.1.2.1 The cells of all vented type batteries are arising from the motion of the vessel. Adequate
to be so constructed and secured as to prevent space for circulation of air is to be ensured.
spilling of the electrolyte due to inclinations of 40
degrees from normal. The filling plugs are to be 7.1.4.3 Where acid is used as the electrolyte for
so constructed as to prevent spilling of a vented type battery, a tray of acid resisting
electrolyte due to ship's movements, e.g. rolling material is to be provided below the cells unless
and pitching. the deck below is similarly protected.

7.1.2.2 All batteries are to be provided with 7.1.4.4 The interiors of all compartments for
durable labels of flame retardant material, giving vented type batteries, including the shelves, are
information on the application for which the to be painted with corrosion resistant paint with
battery is intended, voltage and capacity. consideration given to the type of electrolyte
Instructions are to be fitted either at the battery actually used.
or at the charging device giving information on
maintenance and charging. 7.1.4.5 A permanent notice is to be fitted to all
compartments for vented type batteries
7.1.3 Location prohibiting naked lights and smoking in the
compartment.
7.1.3.1 Alkaline batteries and lead acid batteries
of the vented type are not to be installed in the 7.1.5 Ventilation
same compartment.
7.1.5.1 Battery compartments, lockers and
7.1.3.2 Batteries are to be located in such a boxes are to be adequately ventilated by an
manner that they are not exposed to excessive independent ventilating system to avoid
heat, extreme cold, spray, steam or other accumulation of inflammable gases. Particular
conditions which would impair performance or attention should be given to the fact that these
accelerate deterioration. gases are lighter than air and tend to
accumulate at the top of the spaces.
7.1.3.3 Batteries are not to be located in an
accommodation space. 7.1.5.2 The battery compartment is to be
provided with an effective air inlet near the floor
7.1.3.4 Large batteries are to be installed in a level.
compartment assigned to them only. A box on
deck would meet this requirement if adequately 7.1.5.3 Natural ventilation may be employed if
ventilated and provided with means to prevent ducts of adequate size can be run directly from
the top of the compartment to the open air with

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no part of the duct more than 45 degrees from 7.1.8.3 Charging devices are to be provided with
the vertical. If natural ventilation is impracticable, suitable switch and fuse gear for protection
mechanical ventilation providing at least 30 against faults such as short circuit, overload and
changes of air per hour is to be installed. Interior connection failures.
surfaces of ducts and fans are to be painted with
corrosion-resistant paint. Fan motors are not to 7.1.9 Maintenance of records for batteries
be located in the air stream.
a) Where batteries are fitted for use for
7.1.5.4 Necessary precautions are to be taken essential and emergency services a
to prevent sparking due to possible contact by schedule of such batteries is to be compiled
the ventilation fan blades with fixed parts. and maintained. The schedule, which is to
be submitted for approval and subsequently
7.1.5.5 All openings through the battery verified during annual surveys, is to include
compartment bulkheads or decks, other than at least the following information regarding
ventilation openings, are to be effectively the battery(ies):
sealed.
- Type and manufacturer’s type
7.1.6 Electrical equipment designation
- Voltage and ampere-hour rating
7.1.6.1 Switches, fuses and other electrical - Location
equipment liable to cause an arc should not - Equipment and/or system(s) served
normally be installed in battery compartments. - Maintenance / replacement cycle dates
Where such equipment is necessary for - Date(s) of last maintenance and/or
operational reasons, the equipment should be replacement
certified for Group II C gases and temperature - For replacement batteries in storage,
Class T1 in accordance with IEC 79, "Electrical the date of manufacture and shelf life.1)
Apparatus for Explosive Gas Atmospheres" or
an equivalent national standard. b) Procedures are to be put in place to ensure
that when batteries are replaced, they are of
7.1.6.2 Cables, with the exception of those an equivalent type.
pertaining to the battery or the local lighting, are
not to be installed in battery compartments c) Where vented2) type batteries replace valve-
except where installation in other locations is regulated sealed3) types, it is to be ensured
impracticable. that there is adequate ventilation4) and that
IRS requirements relevant to the location
7.1.7 Number and rating of batteries and installation of vented types batteries are
complied with.
7.1.7.1 Where batteries are used for starting
main engines, at least two batteries are to be d) Details of the schedule and of the
fitted of such combined size that requirements of procedures are to be included in the ship’s
Ch.4 are complied with. safety management system and be
integrated into the ship’s operational
7.1.8 Charging facilities maintenance routine.

7.1.8.1 All batteries are to be provided with Notes:

charging devices, suitable for the actual service.
Generally, automatically regulated charging 1) Shelf life is the duration of storage under
devices are to be used, operating as floating specified conditions at the end of which a
service with the battery and giving trickle- battery retains the ability to give a specified
charging when the battery is fully charged, or performance.
with change-over arrangement for full(quick)-
charging and automatic trickle-charging. Other 2) A vented battery is one in which the cells
forms for charging arrangements, e.g. charging have a cover provided with an opening
through resistors from a DC net with higher through which products of electrolysis and
voltage, will be specially considered. evaporation are allowed to escape freely
from the cells to atmosphere.
7.1.8.2 In direct current systems means are to
be provided to isolate the batteries from the low 3) A valve-regulated battery is one in which
voltage systems when being charged from a cells are closed but have an arrangement
higher voltage system. (valve) which allows the escape of gas if the
internal pressure exceeds a predetermined
value.

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b) Screw fitting
4) The ventilation arrangements for installation
of vented type batteries which have Goliath E40 250 V
charging power higher than 2kW are to be
such that the quantity of air expelled is at Medium E27 250 V
least equal to:
Small E14 250 V
Q = 110 l n
Miniature E10 24 V
where,
7.2.2.2 Lamps are to be in accordance with the
n = number of cells in series following :

l = maximum current delivered by the B22 upto 200 W

charging equipment during gas
formation, but not less than 25 percent E27 upto 200 W
of the maximum obtainable charging
current in amperes. E40 upto 3000 W

Q = quantity of air expelled in litres/hr. 7.2.2.3 Lampholders are to be constructed of

flame-retarding and non- hygroscopic material.
The ventilation rate for compartments All metal parts are to be of robust construction.
containing valve-regulated batteries Goliath lampholders are to be provided with
may be reduced to 25 per cent of that means for locking the lamp in the holder. The
given above. temperature of cable connections is not to
exceed the maximum conductor temperature
7.2 Luminaries - construction and testing permitted for the cable as given in Table 3.3.1.

7.2.1 General 7.2.3 Fluorescent lighting

7.2.1.1 Lighting which is essential for safety and 7.2.3.1 The ratings of tubular fluorescent lamps
working is to comply with the following are not to exceed 250 V and 80 W.
provisions.
7.2.3.2 Fittings, reactors, capacitors and other
7.2.1.2 Lighting fittings installed in engine rooms auxiliaries are not to be mounted on surfaces
or similar spaces where they are exposed to the which are subject to high temperatures.
risk of mechanical damage are to be provided
with suitable grilled mechanical guards to 7.2.3.3 Capacitors of 0.5mF and above are to be
protect their lamps and glass globes against provided with a means of prompt discharge on
such damage. disconnection of the supply.

7.2.1.3 Precautions are to be taken so that a 7.2.4 Discharge lighting

lamp for one voltage cannot be inserted in a
lampholder for another voltage. 7.2.4.1 Where cold cathode luminous discharge
lamps of normal operating voltage above 250 V
7.2.2 Incandescent lighting are used, a warning notice calling attention to
the voltage is to be displayed at points of access
7.2.2.1 The voltage of tungsten filament to the lamps and where otherwise necessary.
lampholders is not to exceed:
7.2.4.2 Inductance and high reactance
a) Bayonet fitting transformers are to be installed as close as
practicable to the associated discharge lamp.
Normal B22 250 V
7.2.4.3 Every capacitor of 0.5mF or more is to
Small (single contact) B15 s 130 V be provided with means for reducing the voltage
of capacitor to less than 55V within one minute
Small (double contact) B15 d 130 V after disconnections from supply source.

7.2.4.4 All live parts of discharge lamp

luminaries are to be so designed, placed and
installed that they cannot be touched
accidentally or inadvertently. The creepage

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distance along the surface of the glass tube is to with means for maintaining this quality after
be taken into considerations. removal of the plug.

7.2.4.5 All parts of searchlights or arc lamps to 7.4 Heating and cooking equipment
be handled for their operations or adjustment
while in use, are to be so arranged that there is 7.4.1 Heaters are to be so constructed, installed
no risk of shock to the operator. Disconnection and protected that clothing, bedding and other
of every searchlight or arc lamp is to be by a inflammable material cannot come in contact
multi-pole disconnecting switches. with them in such a manner as to cause risk of
fire. There is to be no excessive heating of
If a series resistor is used with an arc lamp, the adjacent bulkheads or decks.
disconnecting switch is to be so placed in the
supply circuit that both the series resistor and 7.4.2 Parts of heaters or cooking appliances
arc lamp are disconnected when the switch is in which must necessarily be handled should not
the "off" position. become heated to a temperature exceeding
55°C for metallic parts and 65°C for nonmetallic
7.3 Accessories - Construction and testing parts; for other parts the temperatures obtained
in service are to be such that the various
7.3.1 Enclosures materials are not subjected in the course of
normal working to any excessive thermal stress.
7.3.1.1 Enclosures are to be of metal or of
flame-retardant insulating materials. 7.4.3 Each separate element rated more than 15
A is considered as a separate consumer, for
7.3.2 Inspection and draw boxes which a separate circuit from a switchboard or
distribution board is required.
7.3.2.1 If metal conduit systems are used,
inspection and draw boxes are to be of metal 7.5 Lightning conductors
and are to be in rigid electrical and mechanical
connection with the conduits. 7.5.1 General

7.3.3 Socket outlets and plugs 7.5.1.1 Lightning conductors are to be fitted to
each mast of all wood, composite, and steel
7.3.3.1 The temperature rise on the live parts of ships having masts or topmasts of wood or other
socket outlet and plugs is not to exceed 30°C. non-conductive material. They need not be fitted
to steel ships having steel masts, unless the
7.3.3.2 Socket outlets and plugs are to be so mast is partly or completely insulated from the
constructed that they cannot be readily short- ship's hull.
circuited whether the plug is in or out, and so
that a pin of the plug cannot be made to earth 7.5.2 Construction
either pole of the socket outlet.
7.5.2.1 In wooden and composite ships fitted
7.3.3.3 All socket outlets of current rating 16 A with wooden masts, the lightning conductors are
or more are to be provided with a switch so to be composed of continuous copper tape
interlocked that the plug cannot be inserted or and/or rope, having a Section not under 100
withdrawn with the switch in the "ON" position. [mm2]. These are to be riveted with copper rivets
or fastened with copper clamps to an
7.3.3.4 Where it is necessary to earth the non- appropriate copper spike not less than 13 [mm]
current-carrying parts of portable or in diameter and projecting at least 150 [mm]
transportable equipment, an effective means of above the top of the mast. If tape is used the
earthing is to be provided at the socket outlet. lower end of the tape is to terminate at the point
at which the shrouds leave the mast, and is to
7.3.3.5 Where distribution systems with different be securely clamped to a copper rope of not
voltages are in use, the socket outlets and plugs less than 13 [mm] diameter. This copper rope is
are to be of such design that a plug for one to be led down the shrouds and is to be securely
voltage cannot be inserted into the socket outlet clamped to a copper plate having an area of at
for a different voltage. least 0.2 [mm2]. This copper plate is to be fixed
to the ship's hull well below the light load
7.3.3.6 On weather decks, galleys, laundries, waterline in such a manner that it is to be
machinery spaces and all wet situations socket immersed under all conditions of heel.
outlets and plugs are to be effectively shielded
against rain and spray and are to be provided 7.5.2.2 In wooden and composite ships fitted
with steel masts, each mast is to be connected
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to a copper plate in accordance with 7.5.2.1. serrated contact type, and efficiently locked.
The copper rope is to be securely attached to Soldered connections are not acceptable.
and in good electrical contact with the mast at or
above the point at which the shrouds leave the 7.5.2.5 The resistance of the lightning
mast. conductors, measured between the mast head
and the position on the earth plate or hull to
7.5.2.3 In steel ships fitted with wooden masts, which the lightning conductor is earthed, is not
the lightning conductors are to be composed of to exceed 0.02 ohms.
copper tape or rope terminating in a spike in
accordance with 7.5.2.1. At the lower end this 7.5.2.6 Suitable means should be provided to
copper tape or rope is to be securely clamped to enable ships when in drydock or on a slipway to
the nearest metal forming part of hull of the ship. have their lightning conductors or steel hulls
connected to an efficient earth on shore. When
7.5.2.4 Lightning conductors are to be run as the ships are in floating docks, suitable means
straight as possible, and sharp bends in the should be provided for earthing these lightning
conductors are to be avoided. All clamps used conductors to the sea.
are to be of brass or copper, preferably of the

Section 8

Electric Propulsion Systems

8.1 General ensure that there is no risk of the motor pulling

out of step in bad weather or when turning in the
8.1.1 All electric propelling machinery including case of vessels having several lines of shafting.
switchgear, control gear, cables, main and
auxiliary generators, motors, exciters and 8.1.8 Motors and generators of 400 [kW] or over
electro-magnetic coupling, is to comply with the are to be provided with means of heating the
relevant Chapter/Sections of the Rules and is to windings to prevent condensation when idle. If
be constructed under Special Survey. steam pipes are used for this purpose the joints
are not to be within the machine.
8.1.2 Prime movers are to comply with the
relevant Section(s) of Ch.4. 8.2 Excitation

8.1.3 Armature shafts and other important steel 8.2.1 Systems dependent on the auxiliary
forgings and castings are to comply with the generators for excitation are to be capable of
requirements of Pt.2. maneuvering and of maintaining power at all
times with a fall of 10 per cent excitation voltage
8.1.4 The torsional vibration characteristics of at the busbars.
the propulsion system are to be submitted as
required by Ch.4, as applicable. 8.2.2 Where motor driven exciters, boosters,
balancers or rectifiers are provided for excitation
8.1.5 Cooling water and lubricating oil systems purposes, provision for an alternative supply of
are to comply with Ch.3, where applicable. excitation is to be made. Where two machines
are used, each of at least 50 per cent of the
8.1.6 Where the arrangements permit a required power, it will be sufficient to provide
propulsion motor to be connected to a one spare machine.
generating plant having a continuous rating
greater than the motor rating, means are to be 8.2.3 Negative boosters are to be provided with
provided to limit the continuous full load torque overspeed protection where necessary.
for which the motor and shafts are approved.
8.2.4 In direct current constant pressure
8.1.7 The torque available for maneuvering is to systems, arrangements for generator and motor
be greater than the trailing torque of the excitation are to be such that if the motor
propeller and of sufficient magnitude to be excitation circuit is opened by a switch or
capable of stopping the propeller and reversing contactor, the generator excitation is
its direction of rotation (within a reasonable time) simultaneously interrupted, or the generator
when the vessel is underway at the maximum voltage is immediately reduced to zero.
service speed. In alternating current installations
the power torque is to be sufficiently high to

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8.3 Maneuvering controls to be arranged and supported in a manner

suitable for withstanding the electro-mechanical
8.3.1 In addition to the requirements of Ch.7, the forces due to a short circuit.
following provisions are to be complied with.
8.5 Overload and short circuit protection
8.3.2 Where bridge or deck control is employed,
alternative control in the engine room is to be 8.5.1 Provision is to be made for protection
provided. against severe overloads, and electrical faults
likely to result in damage to the plant.
8.3.3 Suitable interlocks, operating preferably by
mechanical means, are to be provided to 8.5.2 The overload protection in excitation
prevent damage to the plant as a result of circuits should not lead to opening of the circuit.
incorrect switching, such as the opening of
switches or contactors not intended to be 8.6 Earth leakage detection
operated while carrying current or such as the
simultaneous closing of the ahead and astern 8.6.1 The main propulsion circuit is to be
circuits. provided with means for detecting earth faults.
For direct current equipments exceeding 500 V
8.3.4 Provision is to be made for the manual and for all alternating current equipments, aural
operation, without undue manual effort, of all and visual alarms are to be automatically
maneuvering contactors, switches, field operated on the occurrence of an earth fault, but
regulators and controllers. Where electric, the operation of such devices is not to interrupt
pneumatic or hydraulic aid is used for normal the power supply. A switch may be provided to
operation, failure of such aid is not to result in switch off the aural devices, but in such cases
interruption of power to the propeller shaft and the visual alarm is to remain switched on to
any such device is to be capable of purely indicate that the aural device is switched off.
manual operation without delay. This latter Alternative arrangements will be specially
requirement does not apply to bridge control considered.
equipment.
8.6.2 If an earth connection is used for operating
8.3.5 In propulsion installations with two or more the detector arrangements, then in direct current
generators or two or more motors on one line of systems the earth circuit is to be automatically
shafting the propulsion circuit is to be so opened in order to stop the circulation of fault
arranged that any of these machines can be cut current. In alternating current systems, the fault
out of the circuit without preventing the others current is to be interrupted or limited to a safe
from working. value.

8.3.6 Where steam and oil gauges are mounted 8.6.3 Earth leakage devices are to be arranged
on the main control station, provisions are to be to function for all earth faults exceeding 5 A. In
made so that in case of leakage, steam or oil three-phase star connected alternating current
may not come into contact with the energized generators and motors with neutral points
parts. earthed, the earth leakage device is to operate
on the occurrence of an earth fault in the
8.3.7 Alternative arrangements will be specially windings of the machine, provided that 5 per
considered. cent of the coils at the neutral end of each
phase may be left unprotected by the device. In
8.4 Cables high voltage alternating current systems, where
the capacitive leakage current is high,
8.4.1 Conductors in circuits essential for consideration will be given to increasing this
maneuvering or maintenance of propelling figure of five per cent.
power are to be stranded, having not less than
seven strands, and are to have a nominal cross- 8.6.4 Excitation circuits are to be provided with
sectional area of not less than 2.5 [mm2]. lamps, voltmeters or other means to indicate
continuously the state of the insulation of the
8.4.2 Cables which are connected to the slip excitation circuits under running conditions.
rings of synchronous motors are to be suitably
insulated for the voltage to which they are 8.7 Discharge protection
subjected during maneuvering.
8.7.1 For the protection of field windings and
8.4.3 Cable ends are to be fitted with connectors cables, means are to be provided for limiting the
or connecting sockets of appropriate size and in induced voltage when the field circuits are
such a manner as to inhibit corrosion. They are opened or, alternatively, the induced voltage,

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when the field circuits are opened, is to be taken mover, means are to be provided for suitably
as the nominal design voltage. absorbing or limiting such energy.

8.7.2 Where excitation is obtained from the 8.8.3 Contactors and switches used for
auxiliary busbars, means are to be provided to reversing the rotation of the propulsion motors
limit the voltage induced at the busbars when are to be provided with means for forcibly
the auxiliary circuit-breaker or the distribution opening them if they should in advertently
circuit-breaker opens. remain closed.

8.7.3 Shunt resistors which are connected 8.9 Electro-magnetic couplings

across the field circuit of synchronous
propulsion motors, when they are functioning as 8.9.1 Propulsion arrangements incorporating
asynchronous motors, are to be suitably electro-magnetic couplings will receive special
insulated for the voltage induced when consideration.
reversing, and are to be amply rated to allow for
inadvertent delay during the reversing operation. 8.10 Alarms

8.8 Safety devices 8.10.1 Where machines have enclosed

ventilation systems, an aural alarm device is to
8.8.1 Where separately driven direct current be provided and arranged to operate if the
generators are connected electrically in series, temperature of the heated air exceeds the
means are to be provided to prevent reversal of predetermined safe value.
the direction of rotation of any of them on the
failure of the prime movers. 8.11 Identification

8.8.2 Where, on stopping or reversing the 8.11.1 All important circuits, instruments and
propeller, the regenerated energy transmitted by apparatus are to be clearly labeled for
the propulsion motor is such as to cause a identification.
dangerous increase of speed in the prime

Section 9

Fire Safety Systems

9.1 Fire detection and alarm systems members of the crew. One indicating unit is to
be located in the main fire-control station.
9.1.1 Fire detection and alarm systems are to be
fed by exclusive circuits from two sources of 9.1.4 Clear information is to be displayed on or
electrical power, one of which is to be an adjacent to each indicating unit about the
emergency source, with automatic changeover spaces covered and the location of the section.
facilities located in, or adjacent to, the main fire
detection indicator panel. 9.1.5 No section covering more than one deck
within accommodation, service spaces and
9.1.2 Detectors and manually operated call control stations is normally to be permitted
points are to be grouped into sections. The except a section which covers an enclosed
activation of any detector or manually operated stairway. The number of enclosed spaces in
call point is to initiate a visual and audible fire each section are to be limited to the minimum
signal at the control panel and indicating units. If considered necessary in order to avoid delay in
the signals have not received attention within identifying the source of fire. In no case are
two minutes an audible alarm is to be more than fifty spaces permitted in any section.
automatically sounded throughout the crew
accommodation and service spaces, control 9.1.6 In passenger ships, if there is no fire
stations and machinery spaces of Category A. detection system capable of remotely and
This alarm sounder system need not be an individually identifying each detector, a section
integral part of the detection system. of detectors shall not serve spaces on both
sides of the ship nor on more than one deck and
9.1.3 Indicating units are to denote the section in neither shall it be situated in more than one
which a detector or manually operated call point main vertical zone except that IRS, if it is
has operated. At least one unit is to be so satisfied that the protection of the ship against
located that it is easily accessible to responsible fire will not thereby be reduced, may permit such

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a section of detectors to serve both sides of the 9.2.3 In cargo ships such units are to indicate in
ship and more than one deck. In passenger which section served by the system fire has
ships fitted with individually identifiable fire occurred and are to be centralized on the
detectors, a section may serve spaces on both navigating bridge and in addition, alarms from
sides of the ship and on several decks but may the unit are to be placed in positions other than
not be situated in more than one main vertical on the navigating bridge, so as to ensure that
zone. the indication of fire is immediately received by
the crew.
9.1.7 A section of fire detectors which covers a
control station, a service space or an 9.2.4 Any electrically driven power pump,
accommodation space is not to include a provided solely for the purpose of continuing
machinery space of Category A. automatically the discharge of water from the
sprinklers, is to be brought into action
9.1.8 The fire detection system is not to be used automatically by the pressure drop in the system
for any other purpose, except that closing of fire before the standing fresh water charge in the
doors and similar functions may be permitted at pressure tank is completely exhausted.
the control panel.
9.2.5 For passenger ships, electrically driven
9.1.9 A loop circuit of an addressable fire sea-water pumps for automatic sprinkler
detection system, capable of interrogating from systems are to be served by not less than two
either end of the loop any detector served by the circuits reserved solely for this purpose, one fed
circuit, may comprise more than one section of from the main source of electrical power and
detectors. Such sections are to be separated by one from the emergency source of electrical
devices which will ensure that if a short circuit power. Such feeders are to be connected to an
occurs anywhere in the loop only the attached automatic change-over switch situated near the
section of detectors will be isolated from the sprinkler pump and the switch is to be normally
control panel. No section of detectors between closed to the feeder from the main source of
these devices is in general to include more than electrical power. The switches on the main and
50 detectors. emergency switchboards are to be clearly
labeled and normally kept closed.
9.1.10 A loop circuit of an addressable fire
detection system is not to be situated in more 9.2.6 The automatic alarm and detection system
than one main vertical zone, nor is a loop circuit is to be fed by exclusive feeders from two
which covers a control station, a service space sources of electrical power, one of which is to be
or an accommodation space to include a an emergency source, with automatic changer-
machinery space of Category A. over facilities located in, or adjacent to, the main
alarm and detection panel.
9.1.11 The wiring for each section of detectors
in an addressable fire detector system is to be 9.3 Fire pumps
separated as widely as practicable from that of
all other sections on the same loop. 9.3.1 When the emergency fire pump required
by Ch.9 is electrically driven, the power is to be
9.2 Automatic sprinkler system supplied by a source other than that supplying
the main fire pumps. This source is to be located
9.2.1 Each section of sprinklers is to be provided outside the machinery spaces containing the
with means for giving an alarm signal main fire pumps and their source of power and
automatically at one or more indicating units drive units.
whenever any sprinkler comes into operation.
Such alarm systems are to be constructed so as 9.3.2 So far as is reasonably practicable the
to indicate if any fault occurs in the system and electrical cables to the emergency fire pumps
with provision for testing the alarm and the are not to pass through the machinery spaces
indicators for each section of sprinklers. containing the main fire pumps and their source
of power and/or prime mover(s). Where the ship
9.2.2 In passenger ships such units are to give arrangements are such that the cables have to
an indication of any fire and its location in any pass through these spaces the cables are to be
space served by the system and are to be of a fire resistant type and specially protected
centralized on the navigating bridge or in the against mechanical damage, e.g. run in heavy
main fire control station, so as to ensure that gauge pipe.
any alarm from the system is immediately
received by a responsible member of the crew. The cables are to be of a fire resistant type
where they pass through other high fire risk
areas.

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9.4.4 Means of cutting off power to the galley, in
9.4 Fire safety stops the event of a fire, are to be provided outside the
galley exits, at positions which will not readily be
9.4.1 Means of stopping all ventilating fans are rendered inaccessible by such a fire.
to be provided, outside the spaces being served,
at positions which will not readily be cut off in 9.5 Installation of electrical and electronic
the event of a fire. The provisions for machinery equipment in engine rooms protected by
spaces are to be independent of those for other fixed water-based local application fire-
spaces. fighting systems (FWBLAFFS)

9.4.2 Machines driving forced and induced Definitions:

draught fans, independently driven pumps
delivering oil to main propulsion machinery for Protected space:
bearing lubrication and piston cooling, oil fuel
transfer pumps, oil fuel unit pumps, cargo oil - A machinery space where a
pumps and other similar fuel pumps are to be FWBLAFFS is installed.
fitted with remote controls situated outside the
space concerned so that they may be stopped in Protected areas:
the event of fire arising in the space in which
they are located. - Areas within a protected space which is
required to be protected by FWBLAFFS.
9.4.3 In passenger ships carrying more than 36
passengers, all power ventilation systems, Adjacent areas:
except cargo and machinery space ventilation,
which is to be in accordance with 9.4.2 are to be - Areas, other than protected areas,
fitted with master controls so that all fans may exposed to direct spray.
be stopped, in the event of fire, from either of
two separate positions which are to be situated - Areas, other than those defined above,
as far apart as is practicable. where water may extend. See also
Fig.9.5.1.

Fig. 9.5.1

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Electrical and electronic equipment enclosures Note :

located within areas protected by FWBLAFFS
and those within adjacent areas exposed to 1. Additional precautions may be required to
direct spray are to have a degree of protection be taken in respect of:
not less than IP44, except where evidence of
suitability is submitted to and approved by IRS. a) tracking as the result of water
entering the equipment.
The electrical and electronic equipment within
adjacent areas not exposed to direct spray may b) Potential damage as the result of
have a lower degree of protection provided residual salts from sea water
evidence of suitability for use in these areas is systems.
submitted taking into account :
c) High voltage installations.
a) the design and equipment layout,
b) position of inlet ventilation openings, and d) Personnel protection against electric
c) cooling airflow for the equipment. shock

2. Also refer to requirements indicated in Pt.6,

Ch.3, Sec.4, Cl. 4.5.6.

Section 10

Crew and Passenger Emergency Safety Systems

10.1 Emergency lighting 10.1.6 Where emergency lighting fittings are

connected to dimmers, provision is to be made,
10.1.1 For the purpose of this section upon the loss of the main lighting, to
emergency lighting, transitional emergency automatically restore them to their normal level
lighting and supplementary emergency lighting of illumination.
are hereafter referred to under the generic name
'emergency lighting'. 10.1.7 Fittings are to be specially marked to
indicate that they form part of the emergency
10.1.2 Emergency lighting is to be arranged so lighting system.
that a fire or other casualty in the spaces
containing the emergency source of electrical 10.2 General emergency alarm system
power, associated transforming equipment and
the emergency lighting switchboard does not 10.2.1 An electrically operated bell or klaxon or
render the main lighting system inoperative. other equivalent warning system installed in
addition to the ship's whistle or siren, for
10.1.3 The level of illumination provided by the sounding the general emergency alarm signal is
emergency lighting is to be adequate to permit to comply with the requirement of this Section.
safe evacuation in an emergency, having regard
to the possible presence of smoke. 10.2.2 The system is to be capable of operation
from at least the navigating bridge and at a
10.1.4 The exit(s) from every main compartment position adjacent to the alarm signal distribution
occupied by passengers or crew is to be panel.
continuously illuminated by an emergency
lighting fitting. 10.2.3 The alarm system is to be fed by
exclusive circuits, one from the main source of
10.1.5 Switches are not to be installed in the electrical power and one from an emergency
final sub-circuits to emergency light fittings source of electrical power with automatic
unless the light fittings are serving normally change-over facilities located in, or adjacent to
unmanned spaces, i.e. storage-rooms, cold the main alarm signal distribution panel.
rooms, etc. Where switches are fitted they are to
be accessible only to ships crew with provision 10.2.4 The alarm system is to be audible
made to ensure that the emergency lighting is throughout all the accommodation and normal
energised when such spaces are manned. crew working spaces with all doors and
accesses closed and is to have a sound
pressure level, in the 1/3-octave band above the

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fundamental, of not less than 75dB(A) and at equipment required in an emergency, provision
least 10 dB(A) above normal ambient noise is to be made, at a position adjacent to the
levels, with the ship underway in moderate emergency system control panel, to silence the
weather, when measured at the sleeping public address system.
positions in the cabins and one metre from the
source. An audible alarm level of 120 dB(A) is 10.3.7 The public address system may be used
not to be exceeded in any space. for sounding the general emergency alarm and
the fire alarm provided that in addition to the
10.2.5 With the exception of bells, the alarm is requirements of 10.2.
to have a signal frequency between 200 Hz and
2.5 kHz. a) the emergency system is given automatic
priority over any other system input;
10.2.6 Where the special alarm fitted to summon
the crew from the navigation bridge, of fire b) there are means to automatically override
control station, forms part of the ship's general any volume controls so as to ensure the
alarm system, it is to be capable of being specified sound pressure levels are met;
sounded independently of the alarm to the
passenger spaces. c) there are multiple amplifiers having their
power supplies so arranged that a single
10.3 Public address system fault will not cause the loss of more than
one amplifier;
10.3.1 Public address systems installed in
accordance with Pt.6, Ch.4 are to comply with d) there are segregated cable routes to public
requirements of this Section. rooms, alleyways, stairways, and control
stations so arranged that any single
10.3.2 Where the public address system forms electrical fault or a fire in any one main
part of the internal communication equipment vertical fire zone as defined by Pt.6, Ch.3,
required in an emergency it is to be fed by other than the zone in which the public
exclusive circuits, one from the main source of address control station is located, will not
electrical power and one from an emergency interfere with the sounding of the
source of electrical power with automatic emergency alarm through the remaining
change-over facilities located adjacent to the system;
public address system.
e) more than one device is provided for
10.3.3 Amplifiers are to be continuously rated for generating the sound signals for the
the maximum power that they are required to emergency alarms;
deliver into the system for audio and, where
alarms are to be sounded through the public f) short circuit protection is fitted for individual
address system, for tone signals. loudspeakers.

10.3.4 Loudspeakers are to be continuously 10.3.8 Where more than one alarm is to be
rated for their proportionate share of amplifier sounded through the public address system they
output. are to have recognizably different characteristics
and additionally be arranged so that any single
10.3.5 Amplifiers and loudspeakers are to be electrical failure which prevents the sounding of
selected and arranged to prevent feedback and any one alarm will not affect the sounding of the
other interference. remaining alarms.

10.3.6 Where the public address system does

not form part of the internal communication

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Section 11

Ship Safety Systems

11.1 Watertight doors ingress of water with ratings as defined in IEC

Publication 529 or an acceptable and relevant
11.1.1 The electrical power required for power- national standard, as follows :
operated sliding watertight doors is to be
separate from any other power circuit and a) Electrical motors, associated circuits and
supplied from the emergency switchboard either control components, protected to IPX7
directly or by a dedicated distribution board standard.
situated above the bulkhead deck. The
associated control, indication and alarm circuits b) Door position indicators and associated
are to be supplied from the emergency circuit components protected to IPX8
switchboard either directly or by a dedicated standard, where the water pressure testing
distribution board situated above the bulkhead of the enclosures is to be based on the
deck and for passenger ships be capable of pressure that may occur at the location of
being automatically supplied by the transitional the component during flooding for a period
source of emergency electrical power in the of 36 hours.
event of failure of either the main or emergency
source of electrical power. c) Door movement warning signals, protected
to IPX6 standard.
11.1.2 For passenger ships, where the source
for opening and closing the watertight doors 11.1.7 Watertight door electrical controls
have electric motors, unless an independent including their electric cables are to be kept as
temporary source of stored energy is provided, close as is practicable to the bulkhead in which
the electric motors are to be capable of being the doors are fitted and so arranged that the
automatically supplied from the transitional likelihood of them being involved in any damage
source of emergency electrical power. which the ship may sustain is minimized.

11.1.3 A single electrical failure in the power 11.1.8 An audible alarm, distinct from any other
operating or control system of power-operated alarm in the area, is to sound whenever the door
sliding watertight doors is not to result in a is closed remotely by power and sound for at
closed door opening or prevent the hand least five seconds but no more than ten seconds
operation of any door. before the door begins to move and is to
continue sounding until the door is completely
11.1.4 Availability of the power supply is to be closed. The audible alarm is to be supplemented
continuously monitored at a point in the by an intermittent visual signal at the door in
electrical circuit adjacent to the door operating passenger areas and areas where the noise
equipment. Loss of any such power supply is to level exceeds 85 dB(A).
activate an audible and visual alarm at the
central operating console at the navigating 11.1.9 A central operating console is to be fitted
bridge. on the navigating bridge and is to be provided
with a 'master-mode' switch having :
11.1.5 Electrical power, control, indication and
alarm circuits are to be protected against fault in a) a 'local control' mode for normal use which
such a way that a failure in one door circuit will is to allow any door to be locally opened and
not cause a failure in any other door circuit. locally closed after use without automatic
Short circuits or other faults in the alarm or closure, and;
indicator circuits of a door are not to result in a
loss of power operation of the door. b) a 'doors closed' mode for emergency use
Arrangements are to be such that leakage of which is to allow any door that is opened to
water into the electrical equipment located be automatically closed whilst still permitting
below the bulkhead deck will not cause the door any doors to be locally opened but with
to open. automatic reclosure upon release of the
local control mechanism.
11.1.6 The enclosures of electrical components
necessarily situated below the bulkhead deck 11.1.10 The 'master mode' switch is to be
are to provide suitable protection against the arranged to be normally in the 'local control'

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mode position; be clearly marked as to its closing appliances, which are intended to
emergency function. ensure the watertight integrity of the ships
structure in which they are located, the indicator
11.1.11 The central operating console at the system is to be designed on the fail-safe
navigating bridge is to be provided with a principle. The system is to indicate if any of the
diagram showing the location of each door, with doors or closing appliances are open or are not
visual indicators to show whether each door is fully closed or secured.
open or closed. A red light is to indicate a door
is fully open and a green light, a door fully 11.2.2 Where such doors and appliances are to
closed. When the door is closed remotely a red be operated at sea, the requirements of 11.1 are
light is to indicate the intermediate position by to be complied with as far as is practicable.
flashing. The indicating circuit is to be
independent of the control circuit for each door. 11.2.3 The electrical power supply for the
indicator system is to be independent of any
11.1.12 The arrangements are to be such that it electrical power supply for operating and
is not possible to remotely open any door from securing the doors.
the central operating console.
11.2.4 For the requirements of side shell doors,
11.2 Shell doors, loading doors and other stern doors and bow doors, also refer to Pt.3,
closing appliances Ch.12, Sections 5 and 6.

11.2.1 Where it is required that indicators be

provided for shell doors, loading doors and other

Section 12

Electrical Equipment for use in Explosive

Gas/Combustible Dust Atmospheres

12.1 General
Power filled Ex 'q'
12.1.1 The installation of electrical equipment in
areas containing flammable gas or vapour Encapsulated Ex 'm'.
and/or combustible dust, is to be minimized as
far as is consistent with operational necessity 12.2.2 Consideration may be given to the use of
and the provision of lighting, monitoring, alarm equipment of the following types:
or control facilities enhancing the overall safety
of the ship. a) equipment such as control panels, protected
by purging and pressurisation and capable
12.2 Selection of equipment of being verified by inspection as meeting
the requirements of IEC 79-2;
12.2.1 When apparatus is to be installed in
areas where an explosive gas atmosphere may b) simple non-energy-storing apparatus having
be present, unless permitted otherwise by negligible surface temperature rise in
12.2.2, it is to be of a 'safe type', as listed below, normal operation, such as limit switches,
certified or approved by a competent authority strain gauges, etc., incorporated in
for the gases encountered. The construction and intrinsically-safe circuits;
type testing is to be in accordance with IEC
Publication 79: Electrical Equipment for c) radio aerials having robust construction,
Explosive Gas Atmospheres or an acceptable meeting the relevant requirements of IEC
and relevant national standard. 79-15;

Intrinsically safe Ex 'i' d) electrical apparatus with type of protection

'n' or 'N' provided it is in a well ventilated
Increased safety Ex 'e' area on open deck and not within 3 [m] of
any flammable gas or vapour outlet.
Flameproof Ex 'd'
12.2.3 Where apparatus is to be installed in
Pressurized enclosure Ex 'p' areas where combustible dusts may be present

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in quantities sufficient to create an explosive of the equipment for the auto-ignition

atmosphere, it is, when practicable, to be of a temperature of the gases and dusts
type certified or approved by a competent encountered.
authority for the dusts and additionally any
explosive gases encountered. 12.3.2 All switches and protective devices from
which equipment located in dangerous zones or
12.2.4 Electrical equipment for use in spaces is supplied are to interrupt all poles or
combustible dust atmospheres is to be so phases and, where practicable are to be located
designed and installed as to minimize the in non-hazardous zone or space. Such
accumulation of dust which may interfere with equipment, switches and protective devices are
the safe dissipation of heat from the enclosure. to be suitably labeled for identification purposes.

12.2.5 Where equipment certified for 12.3.3 Metal coverings of cables installed in
combustible dust, is not available, consideration dangerous zones or spaces are to be effectively
will be given to the use of apparatus complying earthed at both ends.
as a minimum, with the following requirements
provided no explosive gases will be present: 12.3.4 Cables associated with intrinsically-safe
circuits are to be used only for such circuits.
a) the enclosure is to be at least dust protected They are to be physically separated from cables
(IP5X) having, when type tested, an ingress associated with non-intrinsically-safe circuits,
of fine dust within the enclosure not e.g. neither installed in the same protective
exceeding 10 g per [m3] of free air space, casing nor secured by the same fixing clip.
and
12.3.5 Where there is risk of intermittent contact
b) the surface temperature of the apparatus, between armour and exposed metalwork, non-
under the most onerous combination of metallic impervious sheath is to be applied over
normal operating conditions, but in the metallic armour of cable.
absence of a dust layer, is to be at least
10°C below the auto-ignition temperature of 12.4 Dangerous zones and spaces
the dusts encountered, or
12.4.1 Dangerous zones or spaces and sources
c) the equipment is to be certified intrinsically- of hazard for ships intended for the carriage in
safe having a temperature classification bulk of oil, liquefied gases and other hazardous
ensuring compliance with (b), or liquids, and the requirements for ships carrying
vehicles with fuel in their tanks, are defined in
d) pressurized and operated in accordance 12.9 to 12.12. The following principles are to
with procedures ensuring, prior to its apply in general, and where any specific
reenergisation, the absence of dust within arrangement does not fall into any of the
the enclosure following loss of categories covered by 12.9 to 12.12.
pressurisation and consequent shutdown,
and having surface temperature complying 12.4.2 A dangerous zone or space may arise
with (b), or from the presence of any of the following:

e) simple apparatus included in intrinsically- a) spaces or tanks containing either

safe circuits or radio aerials, complying with
12.2.2 (b) or (c) respectively. i) flammable liquid having a flashpoint
(closed-cup test), not exceeding
12.3 Installation of electrical equipment and 60°C;
cabling
ii) flammable liquid having a flashpoint
12.3.1 The method of installation and application exceeding 60°C, heated or raised by
of safe type equipment is to be in accordance ambient conditions to a temperature
with IEC 79-14, or the national code of practice within 15°C of its flashpoint;
relevant to the standard to which the equipment
has been certified. Any special requirements laid iii) flammable gas.
down by the equipment certification
documentation are also to be observed. The b) piping systems or equipment containing fluid
ambient temperature range for which the defined by (a) and having flanged joints or
apparatus is certified, is to be taken to be -20°C glands or other openings through which
to 40°C, unless otherwise stated, and account is leakage of fluid may occur under normal
to be taken of this when assessing the suitability operating conditions;

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h) zones within a 1.5 [m] radius of flanged
c) spaces containing solids, such as coal or joints, or glands or other openings defined
grain, liable to release flammable gas and/or by 12.4.2(d) and (e);
combustible dust;
i) zones within a 3 [m] radius of bunds or
d) piping systems or equipment associated barriers intended to contain spillage of
with processes (such as battery charging or liquids defined by 12.4.2(a).
electrochlorination) generating flammable
gas as a by-product and having openings 12.5 Semi-enclosed spaces
from which the gas may escape under
normal operating conditions; 12.5.1 Semi-enclosed spaces are considered to
be spaces limited by decks and/or bulkheads in
e) piping system or equivalent containing such a manner that the natural conditions of
flammable liquids not defined by (a), having ventilation are sensibly different from those
flanged joints, glands or other openings obtained on open deck.
through which leakage of fluid in the form of
a mist or fine spray may occur under normal 12.6 Ventilation
operating conditions.
12.6.1 Where an enclosed or semi-enclosed
12.4.3 The following zones or spaces are space is provided with mechanical ventilation
regarded as dangerous: ensuring at least 12 air changes/hour, and
leaving no areas of stagnant air, it may be
a) the interiors of those spaces or tanks regarded in consideration of dangerous zones,
defined by 12.4.2(a) and (c); as an open area.

b) spaces separated by a single bulkhead or 12.6.2 Where the rate of ventilation air flow, in
deck from a cargo defined by 12.4.2(a); relation to the maximum rate of release of
flammable substances reasonably to be
c) enclosed or semi-enclosed spaces expected under normal conditions, is sufficient
containing pipework or equipment defined to prevent the concentration of flammable
by 12.4.2(b) and (d); substances approaching their lower explosive
limit, consideration may be given to regarding as
d) enclosed or semi-enclosed spaces with non-dangerous, the space, ventilation and other
direct opening into a dangerous space; openings into it, and the zone around the
equipment contained within.
e) zones within a 3 [m] radius of ventilation
inlets or outlets, hatches or doorways or 12.7 Pressurisation
other openings into dangerous spaces, and
within 3 [m] of the ventilation outlets of 12.7.1 A space having access to a dangerous
spaces regarded by 12.5 as open areas and space or zone as defined under 12.4.3(c) to (i)
which contain the pipework or equipment may be regarded as non-dangerous if fulfilling
defined by 12.4.2(b); space where the all the following conditions:
hazard results from flammable gas or
vapour having a density relative to that of air a) access is by means of an air-lock, having
of more than 0.5, the dangerous zone is gas-tight steel doors, the inner of which as a
considered to extend vertically downward to minimum, is self-closing without any hold-
solid deck, or for a distance of 9 [m], back arrangement;
whichever is the lesser;
b) it is maintained at an overpressure relative
f) zones within a 3 [m] radius of flanged joints, to the external hazardous area by ventilation
or glands or other openings defined by from a non-dangerous area;
12.4.2(b); in the case of gas or vapour
having a relative density of more than 0.5, c) the relative air pressure within the space is
the dangerous zone is considered to extend continuously monitored and, so arranged,
vertically downwards as described under that in the event of loss of overpressure an
(e); alarm is given and the electrical supply to all
equipment not of a safe type is
g) zones within a 1.5 [m] radius of the automatically disconnected. Where the shut-
ventilation outlets of spaces regarded as down of equipment could introduce a
open areas containing items defined under hazard, an alarm may be given, in lieu of
12.4.2(d); shutdown, upon loss of overpressure, and a
means of disconnection of non-safe type

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electrical equipment, capable of being

controlled from a manned station, provided 12.9.6 Cofferdams adjoining cargo tanks
in conjunction with an agreed operational
procedure; where the means of a) intrinsically-safe equipment of category 'ia';
disconnection is located within the space
then it is to be effected by equipment of a b) electric depth-sounding devices hermetically
safe type; enclosed, located clear of the cargo tank
bulkhead, with cables installed in heavy
d) any electrical equipment required to operate gauge steel pipes with gastight joints up to
upon loss of overpressure, lighting fittings the main deck;
and equipment within the air-lock, is to be of
a safe type; c) cables for impressed current cathodic
protection systems (for external hull
e) means are to be provided to prevent protection only) installed in heavy gauge
electrical equipment other than of a safe steel pipes with gas tight joints up to the
type, being energized until the atmosphere upper deck;
within the space is made safe, by air
renewal of at least 10 times the capacity of d) through runs of cables, installed in heavy
the space. gauge steel pipes with gas tight joints.

12.8 Cable and cable installation 12.9.7 Cargo pump rooms:

12.8.1 Electric cables are not to be installed in a) intrinsically-safe equipment;

dangerous zones or spaces, except where
specifically permitted by 12.9. to 12.11 or when b) electrical equipment as defined in 12.9.6(b)
associated with intrinsically-safe circuits. and (c);

12.8.2 In addition to other requirements in this c) flameproof lighting fittings (symbol d);
chapter, cables in dangerous zones or spaces,
or which may be exposed to cargo oil, oil vapour d) pressurised lighting fittings (symbol p) of
or gas, are to be either: either the air driven type, of pressurised
from an external source of protective gas
a) mineral insulated with copper sheath, or and arranged to be de-energised
automatically on loss of pressurization;
b) armoured or braided (for mechanical
protection and earth detection) with non- e) gas detector heads having sinter-type
metallic impervious sheath. flametrap protection, included within an
intrinsically-safe circuit, the gas detector
12.9 Requirements for tankers intended for system is to be certified;
the carriage in bulk of oil cargoes having a
flash point not exceeding 60°C (closed cup f) general alarm sounders of flameproof type,
test) without internal sparking contacts;

12.9.1 The following requirements define the g) through runs of cables, confined to pump
electrical equipment permitted within dangerous room entrances only, installed in heavy
spaces and zones and are in addition to the gauge steel pipes with gas tight joints.
requirements of 12.1 to 12.8.
12.9.8 Spaces under cargo tanks (e.g. duct
12.9.2 The requirements for cargo tanks also keels): Electrical equipment as defined in
apply to cargo slops tanks. 12.9.6(a) and (b) and 12.9.7(c) to (f).

12.9.3 The relevant gas group and temperature 12.9.9 Enclosed or semi-enclosed spaces
class for safe type equipment in the defined immediately above cargo tanks or having
locations are IIA T3. bulkheads immediately above and in line with
cargo tank bulkheads, compartments for cargo
12.9.4 Where intrinsically-safe equipment is hoses, spaces other than cofferdams adjoining
required, consideration will be given to the use and below the top of a cargo tanks, e.g. trunk,
of simple apparatus incorporated in intrinsically- passageways and holds:
safe circuits, as defined in 12.2.2(b).
a) intrinsically-safe equipment, this is to be of
12.9.5 Cargo tanks: intrinsically-safe equipment category 'ia' where the spaces or
of category 'ia':
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compartments are not mechanically pressurized in accordance with 12.7, non-
ventilated; safe type equipment is permitted within the
space.
b) safe type lighting fittings;
12.9.14 Electrical installations in enclosed or
c) through runs of cable; semi-enclosed spaces having a direct opening
into any dangerous space or zone are to comply
d) general alarm sounders as defined by with the requirements for the space or zone to
12.9.7(f). which the opening leads.

12.9.10 Zones on open deck within 3 [m] of any 12.10 Requirements for ships for the carriage
cargo oil tank outlet or vapour outlet (e.g. cargo of liquefied gases in bulk
tank or cofferdam hatch; sight port; tank
cleaning opening; ullage opening; sounding pipe 12.10.1 See Pt.5 for relevant Rules for Ships for
cargo pump room entrance and ventilation Liquefied Gases.
intakes and exhausts), zones on open deck over
all cargo tanks (including all ballast tanks within 12.11 Requirements for ships intended for
the cargo tank area) to the full width of the the carriage in bulk of other flammable liquid
vessel, plus 3 [m] forward and 3 [m] aft of the cargoes
cargo tank area or any spillage barrier installed
aft of the cargo tanks area, up to a height of 2.4 12.11.1 See Pt.5 for relevant Rules for Ships for
[m] above the deck. Liquid Chemicals.

a) safe type equipment; 12.12 Special requirements for ships with

spaces for carrying vehicles with fuel in their
b) through runs of cable, cable expansion tanks, for their own propulsion
bends are not to be within 3 [m] of any
cargo tank or vapour outlet. 12.12.1 Passenger ships with special category
spaces above the bulkhead deck for carrying
12.9.11 Zones within 5 [m] of any vehicles:
pressure/vacuum valve, or at any height above
and within a 10 [m] radius (measured a) electrical equipment fitted within a height of
horizontally) and within a 3 [m] radius below of 45 [cm] above the vehicle deck, or any
any such vent not of the high velocity type: platform on which vehicles are carried, or
within the exhaust ventilation trunking of the
a) safe type equipment; special category space, is to be of a safe
type;
b) through runs of cable.
b) electrical equipment situated elsewhere
12.9.12 Spaces below the level of, and having within the space is to have an enclosure of
direct openings onto, the main deck, but outside ingress protection rating of at least IP55.
the dangerous zone previously described: (See IEC Publication 529: Classification of
Degrees of Protection Provided by
a) safe type equipment; Enclosures), if not of a safe type.

b) through runs of cable. 12.12.2 Passenger ships with special category

spaces below the bulkhead deck for carrying
12.9.13 Mechanically ventilated or pressurized vehicles: electrical equipment fitted within the
spaces: space and within the space's exhaust ventilation
trunking, is to be of certified safe type.
a) where a space of the type defined by
12.9.12 is provided with a self closing door 12.12.3 Passenger ship with cargo spaces,
for the opening onto the main deck and has other than special category spaces, for carrying
mechanical ventilation, the air intake for vehicles:
which is remote from any dangerous space
or zone, non-safe equipment is permitted a) electrical equipment within such a cargo
within the space; space, or within the space's exhaust
ventilation trunking, is to be of a safe type;
b) where a space opening into a dangerous
into a dangerous zone or space is provided b) all electrical circuits terminating in the cargo
with an airlock, is separated from the cargo space are to be provided with multi-pole
by at least two gastight bulkhead, and is linked isolating switches located outside the

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cargo hold. Provision is to be made for 12.13.3 Switches, protective devices, motor
locking in the off position. This does not control gear of electrical equipment installed in a
apply to safety circuits such as those for fire, paint store are to interrupt all poles or phases
smoke or gas detection. and preferably are to be located in non-
hazardous space.
12.12.4 Cargo ships with spaces for carrying
vehicles: 12.13.4 In the areas on open deck within 1 m of
inlet and exhaust ventilation openings or within 3
a) electrical equipment fitted within a height of m of exhaust mechanical ventilation outlets, the
45 [cm] above the vehicle deck, or within a following electrical equipment may be installed:
height of 45 [cm] above the vehicle deck, or
within the cargo space's exhaust ventilation - electrical equipment with the type of
trunking, and any equipment associated protection as permitted in paint stores or
with safety circuits such as those for fire,
smoke or gas detection, located within the - equipment of protection class Ex 'n' or
cargo space, is to be of a safe type;
- appliances which do not generate arcs
b) the requirements of 12.12.1(b) apply to in service and whose surface does not
other equipment within the space; reach unacceptably high temperature or

c) the requirements of 12.12.3(b) apply to - appliances with simplified pressurised

circuits terminating in the space. enclosures or vapour-proof enclosures
(minimum class of protection IP55)
12.13 Requirements of electrical equipment whose surface does not reach
allowed in paint stores and in the enclosed unacceptably high temperature
spaces leading to paint stores
- cables as specified in 12.13.1.
12.13.1 Electrical equipment is to be installed in
paint stores and in ventilation ducts serving such 12.13.5 The enclosed spaces giving access to
spaces only when it is essential for operational the paint store may be considered as non-
services. hazardous, provided that:

Certified safe type equipment of the following - the door to the paint store is a gastight
type is acceptable: door with self-closing devices without
holding back arrangements,
a) intrinsically safe Ex 'i'
- the paint store is provided with an
b) flameproof Ex 'd' acceptable, independent, natural
ventilation system ventilated from a safe
c) pressurised Ex 'p' area,

d) increased safety Ex 'e' - warning notices are fitted adjacent to

the paint store entrance stating that the
e) special protection Ex 's'. store contains flammable liquids.

Cables (through-runs or terminating cables) of Note: The paint stores and inlet and exhaust
armoured type or installed in metallic conduits ventilation ducts under 12.13.1 are classified as
are to be used. Zone-1 and areas on open deck under 12.13.4
as Zone 2, as defined in IEC Standard 60092-
12.13.2 The minimum requirements for the 502, Electrical Installation in Ships - Part 502 :
certified safe type equipment are as follows: Tankers-special features.

- explosion group II B A watertight door may be considered as being

gastight.
- temperature class T3.

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Section 13

High Voltage Systems

13.1 Scope disconnected for maintenance and for insulation

resistance measurement.
13.1.1 The requirements of this Section apply to
a.c. three-phase systems with nominal voltage 13.3.6 All earthing impedances are to be
above 1 kV and upto 15 kV. connected to the hull. The connection to the hull
is to be so arranged that any circulating currents
13.1.2 The nominal voltage is the voltage in the earth connections do not interfere with
between phases. radio, radar, communication and control
equipment circuits.
13.1.3 Where necessary for special application,
higher voltages may be accepted by IRS. 13.3.7 In the divided systems with neutral
earthed, connection of the neutral to the hull is
13.2 High voltage and low-voltage to be provided for each section.
segregation
13.4 Degrees of protection
13.2.1 Equipment with voltage above 1 kV is not
to be installed in the same enclosure as low 13.4.1 Each part of the electrical installation is to
voltage equipment, unless segregation or other be provided with a degree of protection
suitable measures are taken to ensure that appropriate to the location, and as a minimum
access to low voltage equipment is obtained the requirements of IEC Publication 60092-201
without danger. are to be followed.

13.3 System design 13.4.2 The degree of protection of enclosures of

rotating electrical machines is to be at least
13.3.1 It is to be possible to split the main IP23. The degree of protection of terminals is to
switchboard into atleast two independent be at least IP44.
sections, by means of at least one circuit
breaker or other suitable disconnecting devices, 13.4.3 For motors installed in spaces accessible
each supplied by at least one generator. If two to unqualified personnel, a degree of protection
separate switchboards are provided and against approaching or contact with live or
interconnected with cables, a circuit breaker is moving parts of at least IP4X is required.
to be provided at each end of the cable.
13.4.4 The degree of protection of enclosures of
13.3.2 Services which are duplicated are to be transformers is to be at least IP23.
divided between the sections.
13.4.5 For Transformers installed in spaces
13.3.3 In a neutral earthed system, in case of accessible to unqualified personnel a degree of
earth fault the current is not to be greater than protection of at least IP4X is required. For
full load current of the largest generator on the transformers not contained in enclosures, see
switchboard or relevant switchboard section and clause 13.14.1.
not less than three times the minimum current
required to operate any device against earth 13.4.6 The degree of protection of metal
fault. It is to be assured that at least one source enclosed switchgear, controlgear assemblies
neutral to ground connection is available and static converters is to be atleast IP32. For
whenever the system is in the energized mode. switchgear, control gear assemblies and static
converters installed in spaces accessible to
13.3.4 Electrical equipment in directly earthed unqualified personnel, a degree of protection of
neutral or other neutral earthed systems is to at least IP4X is required.
withstand the current due to a single phase fault
against earth for time necessary to trip the 13.5 Air clearances
protection device.
13.5.1 In general, for Non Type Tested
13.3.5 Means of disconnection are to be fitted in equipment phase-to-phase air clearances and
the neutral earthing connection of each phase-to-earth air clearances between non-
generator so that the generator may be insulated parts are to be as specified in Table
13.5.1.

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Table 13.5.1

Nominal Voltage [kV] Minimum air clearance [mm]

3 - 3.3 55
6 - 6.6 90
10 - 11 120
15 160
Notes
1 Intermediate values may be accepted for nominal voltages
provided that the next higher air clearance is observed.

2 In the case of smaller distances, appropriate voltage impulse test

must be applied.

13.6 Creepage distances A system is defined effectively earthed (low

impedance) when this factor is lower than 0.8.
13.6.1 Creepage distance between live parts
and between live parts and earthed metal parts A system is defined non-effectively earthed
for standard components are to be in (high impedance) when this factor is higher than
accordance with relevant IEC Publication for the 0.8.
nominal voltage of the system the nature of the
insulation material and the transient overvoltage 13.7.3 Power transformers : Power
developed by switch and fault conditions. transformers are to be provided with overload
and short circuit protections. When transformers
13.6.2 For non-standardised parts within the are connected in parallel, tripping of the
busbar section of a switchgear assembly, the protective devices at the primary side has to
minimum creepage distance is to be at least 25 automatically trip the switch connected at the
[mm/kV] and behind current limiting devices 16 secondary side.
[mm/kV].
13.7.4 Voltage transformers for control and
13.7 Protection instrumentation : Voltage transformers are to
be provided with overload and short circuit
13.7.1 Faults on the generator side of circuit protections on the secondary side.
breaker : Protective devices are to be provided
against phase-to-phase faults in the cables 13.7.5 Fuses : Fuses are not to be used for
connecting the generators to the main overload protection.
switchboard and against interwinding faults
within the generators. The protective devices 13.7.6 Low voltage systems : Low voltage
are to trip the generator circuit breaker and to systems supplied through transformers from
automatically de-excite the generator. In high voltage systems are to be protected against
distribution systems with a neutral earthed, overvoltage. This may be achieved by:
phase to earth faults are also to be treated as
above. i) direct earthing of the low voltage
system;
13.7.2 Faults to earth : Any earth fault in the ii) appropriate neutral voltage limiters;
system is to be indicated by means of a visual iii) earthed screen between the primary
and audible alarm. In low impedance or direct and secondary windings of trans-
earthed systems, provision is to be made to formers.
automatically disconnect the faulty circuits. In
high impedance earthed system, where 13.8 Rotating machinery
outgoing feeders will not be isolated in case of
an earth fault, insulation of the equipment is to 13.8.1 Stator windings of generators :
be designed for the phase to phase voltage. Generators stator windings are to have all phase
ends brought out for the installation of the
Note: Earthing factor is defined as the ratio differential protection.
between the phase to earth voltage of the
healthy phase and the phase to phase voltage. 13.8.2 Temperature detectors : Rotating
This factor may very between 1/√3 and 1. machinery is to be provided with temperature
detectors in their stator windings to actuate

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audiovisual alarm in a normally attended there is no relative motion between fixed and
position whenever the temperature exceeds the moving portions.
permissible limit. If embedded temperature
detectors are used, means are to be provided to 13.11.4 Shutters : The fixed contacts of
protect the circuit against overvoltage. withdrawable circuit breakers and switches are
to be so arranged that in the withdrawable
13.8.3 Tests : In addition to the tests normally position the live contacts are automatically
required for rotating machinery, a high covered.
frequency high voltage test in accordance with
IEC Publication 60034-15 is to be carried out on 13.11.5 Earthing and short-circuiting : For
the individual coils in order to demonstrate a maintenance purposes an adequate number of
satisfactory withstand level of the inter-turn earthing and short-circuiting devices are to be
insulation to steep fronted switching surges. provided to enable circuits to be worked upon
with safety.
13.9 Power Transformers
13.12 Auxiliary systems
13.9.1 Dry type transformers have to comply
with IEC Publication 60726. Liquid cooled 13.12.1 Source and capacity of supply : If
transformers have to comply with IEC electrical energy and/or physical energy is
Publication 60076. Oil immersed transformers required for the operation of circuit breakers and
are to be provided with the following alarms and switches, a store supply of such energy is to be
protections: provided for at least two operations of all the
components.
- liquid level (Low) - alarm However, the tripping due to overload or short-
circuit, and under-voltage is to be independent
- liquid temperature (High) - alarm of any stored electrical energy sources. This
does not preclude shunt tripping provided that
- liquid level (Low) - trip or load reduction alarms are activated upon lack of continuity in
the release circuits and power supply failures.
- liquid level (High) - trip or load reduction
13.12.2 Number of external supply sources :
- gas pressure relay (High) - trip. When external source of supply is necessary for
auxiliary circuits, at least two external sources of
13.10 Cables supply are to be provided and so arranged that
a failure or loss of one source will not cause the
13.10.1 Cables are to be constructed in loss of more than one generator set and/or set
accordance with the IEC Publication 60092-353 of essential services.
and 60092-354 or other equivalent Standard.
Where necessary one source of supply is to be
13.11 Switchgear and controlgear from the emergency source of electrical power
assemblies for the start up from dead ship condition.

13.11.1 Switchgear and controlgear assemblies 13.12.3 High voltage test : A power-frequency
are to be constructed according to the IEC voltage test is to be carried out on any
Publication 60298 and the following additional switchgear and controlgear assemblies.
requirements.
The test procedure and voltages are to be
13.11.2 Mechanical construction : Switchgear is according to the IEC Publication 60298.
to be of metal - enclosed type in accordance
with IEC Publication 60298 or of the insulation - 13.13 Installation
enclosed type in accordance with the IEC
Publication 60466. 13.13.1 Electrical equipment : Where equip-
ment is not contained in an enclosure but a
13.11.3 Locking facilities : Withdrawable circuit room forms the enclosure of the equipment, the
breakers and switches are to be provided with access doors are to be so interlocked that they
mechanical locking facilities in both service and cannot be opened until the supply is isolated
disconnected positions. For maintenance and the equipment earthed down. At the
purpose, key locking of withdrawable circuit entrance of the spaces where high-voltage
breakers and switches and fixed disconnectors electrical equipment is installed, a suitable
is to be possible. Withdrawable circuit breakers marking is to be placed which indicates danger
are to be located in the service position so that of high voltage. As regard the high-voltage
electrical equipment installed out-side above

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mentioned spaces, the similar marking is to be and are to be provided with means to ground all
provided. metallic shielding components (i.e. tapes, wires
etc.)
13.13.2 Cables
13.13.2.5 High voltage cables are to be readily
13.13.2.1 In accommodation spaces, high identifiable by suitable marking.
voltage cables are to be run in enclosed cable
transit systems. 13.13.2.6 Before a new high voltage cable
installation or an addition to an existing
13.13.2.2 High voltage cables are to be installation is put into service, a voltage
segregated from cables operating at different withstand test is to be satisfactorily carried out
voltage ratings and from each other, in on each completed cable and its accessories.
particular, they are not to be run in the same
cable bunch, nor in the same ducts or pipes, or, The test is to be carried out after an insulation
in the same box. Where high voltage cables of resistance test.
different voltage ratings are installed on the
same cable tray, the air clearance between When a d.c. voltage withstand test is carried out
cables is not be less than the minimum air the voltage is to be not less than:
clearance for the higher voltage side in 13.6.
However, high voltage cables are not to be - 1.6 (2.5 Uo + 2kV) for cables of rated
installed on the same cable tray for the cables voltage (Uo) upto and including 3.6 kV,
operating at the nominal system voltage of 1 kV or
and less. - 4.2 Uo for higher rated voltages.

13.13.2.3 High voltage cables, in general, are to where Uo is the rated power frequency voltage
be installed on carrier plating when they are between conductor and earth or metallic screen,
provided with a continuous metallic sheath or for which the cable is designed.
armour which is effectively bonded to earth;
otherwise they are to be installed for their entire The test voltage is to be maintained for a
length in metallic casings effectively bonded to minimum of 15 minutes.
earth.
After completion of the test the conductors are
13.13.2.4 Terminations in all conductors of high to be connected to earth for a sufficient period in
voltage cables are to be, as far as practicable, order to remove any trapped electric charge.
effectively covered with suitable insulating
material. In terminal boxes, if conductors are not An insulation resistance test is then repeated.
insulated, phases are to be separated from
earth and from each other by substantial Alternatively, an a.c. voltage withstand test may
barriers of suitable insulating materials. be carried out upon advice from high voltage
cable manufacturer at a voltage not less than
High voltage cables of the radial field type, i.e. normal operating voltage of the cable and it is to
having a conductive layer to control the electric be maintained for a minimum of 24 hours.
field within the insulation, are to have
terminations which provide electric stress Note : Tests specified in IEC Publication 60502
control. will be considered adequate.
Terminations are to be of a type compatible with
the insulation and jacket material of the cable

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Section 14

Trials

14.1 General be carried out with the machine hot, if possible.

The insulation resistance of generator and motor
14.1.1 Before a new installation, or any cables, field windings and control gear is to be
alteration or addition to an existing installation, is at least 1 MΩ.
put into service the tests and trials specified in
this Section are to be carried out. These tests 14.3 Earth continuity
and trials are intended to demonstrate the
general condition of the installation at the time of 14.3.1 Tests are to be made to verify that all
completion. They are in addition to any earth continuity conductors are effective and
acceptance tests which may have been carried that the bonding and earthing of metallic conduit
out at the manufacturer's works. and/or sheathing of cables is effective.

14.2 Insulation resistance measurement 14.4 Performance

14.2.1 Insulation resistance is to be measured 14.4.1 It is to be established that the provisions

using a self-contained instrument such as a of the Rules have been complied with respect to
direct reading ohm-meter of the generator type the criteria mentioned in this sub-section.
applying a voltage of at least 500 V. Where a
circuit incorporates capacitors of more than 2mF 14.4.2 Temperatures of joints, connections,
total capacitance, a constant-voltage type circuit-breakers and fuses.
instrument is to be used to ensure accurate test
readings. 14.4.3 The operation of engine governors,
synchronising aids and devices, overspeed trips,
14.2.2 Power and light circuits : The insulation reverse-current, reverse-power, over-current
resistance between all insulated poles and earth and under-voltage trips and other safety
and, where practicable, between poles, is to be devices.
at least 1MΩ. The installation may be
subdivided and appliances may be disconnected 14.4.4 Efficient lubrication, absence of vibration
if initial tests produce results less than this or abnormal noises and satisfactory alignment/
figure. holding down arrangements.

14.2.3 Internal communication circuits : Circuits 14.4.5 Satisfactory commutation, excitation and
operating at 55 V and above are to have an performance of each generator throughout a run
insulation resistance between conductors and at full rated load.
between each conductor and earth of at least 1
MΩ. Circuits operating at less than 55 V are to 14.4.6 Voltage regulation of every generator
have an insulation resistance of at least 0.33 when full rated load is suddenly thrown off.
MΩ.
14.4.7 For alternating current and direct current
14.2.4 Switchboards, Section boards and generators, satisfactory parallel operation and
distribution boards : The insulation resistance is [kW] load sharing of all generators capable of
to be at least 1 MΩ when measured between being operated in parallel at all loads up to
each busbar and earth and between busbars. normal working load. For alternating current
This test may be made with all circuit-breakers generators satisfactory parallel operation and
and switches open, all fuse links for pilot lamps, kVA load sharing of all generators capable of
earth fault-indicating lamps, voltmeters, etc., being operated in parallel at all loads up to
removed and voltage coils temporarily normal working load.
disconnected, where otherwise damage may
result. 14.4.8 All essential motors and other important
equipment are to be operated under service
14.2.5 Generators and motors : The insulation conditions, though not necessarily at full load or
resistance of generators and motors, in normal simultaneously, for a sufficient length of time to
working condition and with all parts in place, is demonstrate that they are satisfactory.
to be measured and recorded. The test should

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14.4.9 Normal and emergency lighting, heating

and various appliances (galley, pantry etc.) and 14.4.12 Propulsion equipment is to be tested
corresponding electrical circuits are to be tested, under working conditions and operated in the
as far as practicable, under normal working presence of the Surveyors and to their
conditions. satisfaction. The equipment is to have sufficient
power for going astern to secure proper control
14.4.10 Internal communication systems are to of the unit in all normal circumstances. In
be checked to demonstrate their suitable and passenger ships the ability of the machinery to
specified functioning. Particular attention is to be reverse the direction of thrust of the propeller in
given to engine order telegraphs, docking sufficient time, under normal maneuvering
telegraphs, helm indicators, fire detection and conditions, and so bring the ship to rest from
alarm systems, emergency alarms, morse signal maximum ahead service speed, is to be
lamp, navigation light indicator panel and demonstrated at the sea trial.
telephones.
14.5 Voltage drop
14.4.11 Operation of the emergency source of
power is to be checked. The working of any 14.5.1 Voltage drop is to be measured, where
apparatus intended to be fed by this source is to necessary, to verify that this is not excessive.
be checked as well as automatic change-over
switches, if any.

End of Chapter

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Chapter 10

Requirements for Fusion Welding

Contents
Section

1 General
2 Fusion Welded Pressure Vessels
3 Welded Pressure Pipes

Section 1

General

1.1 Scope 1.2.2 In the first instance, and before work is

commenced, the Surveyors are to be satisfied
1.1.1 The requirements of this Chapter apply to that the required quality of welding is attainable
the welding of pressure vessels, pressure pipes with the proposed welding plant, equipment and
and the welded structures of machinery. procedures.

1.1.2 The term 'fusion weld', for the purpose of 1.2.3 The welding plant and equipment are to be
these requirements, is applicable to welded maintained in an efficient working condition.
joints made by manual, semi-automatic or
automatic electric arc welding processes. 1.2.4 The procedures are to include the regular
Special consideration will be given to the systematic supervision of all welding, and the
proposed use of other fusion welding processes. welders are to be subjected by the works'
supervisors to periodic tests for quality of
1.2.General requirements for welding plant workmanship. Records of these tests are to be
and welding quality kept and are to be available for inspection by the
Surveyors.
1.2.1 The welding plant and equipment are to be
installed under cover and so arranged that all 1.2.5 All welding is to be to the satisfaction of
welding is carried out in positions free from the Surveyors.
draughts and adverse weather conditions.

Section 2

Fusion Welded Pressure Vessels

2.1 Manufacture of Class 1 and Class 2 equipment and procedures and to arrange for
fusion welded pressure vessels carrying out preliminary tests as stated in 2.3.

2.1.1 Fusion welded pressure vessels 2.1.2 In the case of Class 1 approval,
constructed to Class 1 and Class 2 arrangements are to be made for the survey
requirements will be accepted only if during construction and testing of a full size
manufactured by firms equipped and competent welded pressure vessel.
to undertake high quality welding. In order that
firms may be approved for this purpose, it will be 2.1.3 The welding plant and equipment are to be
necessary for the Surveyors to visit the works suitable for undertaking work of the standard
for the purpose of inspecting the welding plant, required for Class 1 and Class 2.

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2.3.2 The maximum plate thickness which will

2.1.4 The works are to have an efficient testing be approved in pressure vessel construction will
laboratory, suitably equipped to carry out tensile, depend on the thickness of the test plates used
bend and impact tests, the x-ray examination of in the preliminary tests; the test plates are,
pressure vessels, and the metallographic however, to be at least 20 [mm] thick.
examination of welds. The works are also to be
equipped with a suitable heat treating furnace 2.3.3 The test plates and the pressure vessel,
with satisfactory means of temperature control. mentioned in 2.1.2, are to be representative as
regards materials and approximate shell
2.1.5 Alternative arrangements which, in the thickness of the production vessels for which
opinion of the Surveyors, ensure an equally high approval is desired.
standard of quality control may be submitted for
consideration. 2.3.4 The welded seams of the test plates are to
be radiographed, and the Surveyors are to
2.1.6 On completion of inspection and tests, the select portions of the test plates containing the
Surveyor's report, including the results of the welded joint from which specimens are to be
preliminary tests and also, for Class 1 approval, provided for the following tests:
the results of the tests on the pressure vessel,
as required by 2.1.2, is to be submitted for the a) Tensile;
consideration of IRS. The report should also
include the radiographs and particulars of any b) Bend;
fusion welded pressure vessels previously
constructed at these works. c) Hardness;

2.2 Manufacture of Class 3 fusion welded d) Impact - For Class 1 application and for
pressure vessels steels in Groups 2 and 3;

2.2.1 Class 3 pressure vessels will be accepted e) Fatigue - For Class 1 application and for
if constructed by firms whose works are steels in Groups 2 and 3;
equipped to undertake the welding of pressure
vessels of this Class. Preliminary tests would f) Micrographs, at 100 and 300 magnifications,
require to be carried out as stated in 2.4. of weld center, fusion zone and parent plate,
for Class 1 application and for steels in
2.3 Preliminary tests for Class 1 and Class 2 Group 2 and 3;
fusion welded pressure vessels
g) Macrograph of full section weld;
2.3.1 Preliminary tests to demonstrate the
quality of welding are to be carried out by the h) Chemical analysis of deposited weld metal;
firm under supervision of the Surveyors. The
test requirements will be based on the types of i) Chemical analysis of test plates.
steels and on the welding process to be used.
For approval purposes, the types of rolled steel 2.3.5 Where the welding is carried out by an
plates specified in Pt.2, Ch.3 are grouped as established and approved process, the fatigue
follows : tests and micrographs in 2.3.4(e) and (f) will not,
in general, be required. Furthermore, as an
Group 1 : Carbon and carbon-manganese alternative to 2.3.4(i), a guaranteed analysis
steels - specified minimum obtained from the steelmaker will be accepted.
tensile strength not exceeding
2
500 [N/mm ]; 2.3.6 If a firm intends to manufacture pressure
vessels either of a different group of steel or by
Group 2 : Carbon and carbon-manganese means of a different welding process from that
steels - Specified minimum used in the preliminary tests on which the
tensile strength 500-520 original approval was based, further tests will be
[N/mm2]; required to cover the proposed welding
procedure. In such cases full details of the
Group 3 : Alloy steels. material, plate thickness and welding process
proposed are to be submitted for consideration,
when the requirements for further preliminary
tests will be indicated.

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2.4 Preliminary tests for Class 3 fusion b) Specimen No. 2 :- Transverse bend test.
welded pressure vessels The shape and preparation of the specimen
and procedure for testing are to comply with
2.4.1 Preliminary tests to demonstrate the the requirements of 2.5.11;
quality of welding are to be carried out by the
firm under the supervision of the Surveyors. The c) Specimen No. 3 :- Nicked bend test. The
test requirements will be based on the welding specimen is to have a slot cut into each side
process used, but are to be similar to those on the centreline of the weld and
described in 2.4.2 to 2.4.6. perpendicular to the plate surface. The
specimen is then to be broken in the weld,
2.4.2 Two test assemblies, of sufficient and the fracture is to reveal a sound
dimensions to prepare test specimens, as homogeneous weld, substantially free from
required by 2.4.3, are to be prepared using slag inclusions, porosity and coarse
plates of thickness representative of the crystalline form.
thickness of the pressure vessels to be
manufactured. Alternatively, one test assembly 2.4.4 If any of the tests fail, further two re-test
may be prepared to provide all the test specimens are to be prepared and tested.
specimens required by 2.4.3 and for retest Should any of these two further re-tests also fail,
purposes. Test assemblies need not be the reasons for the failure are to be investigated
prepared for circumferential seams, except in and the results are to be submitted to IRS for
cases where the vessel has only circumferential review.
seams or where the process for welding the
circumferential joints is significantly different 2.4.5 Where two test assemblies have been
from that used for longitudinal joints. prepared, one re-test is to be taken from each
test assembly.

2.4.3 Test specimens, as shown in Fig.2.4.1, are

to be tested as follows : 2.4.6 If both the re-test values are satisfactory,
the re-test values may be accepted.
a) Specimen No. 1 :- Tensile test for joint. The
shape and preparation of the specimen are 2.5 Routine tests for Class 1 and Class 2
to conform to the requirements of 2.5.12. fusion welded pressure vessels
The tensile strength obtained is to be not
less than the minimum specified tensile 2.5.1 Two test plates, each of sufficient
strength for the plate material; dimensions to provide one complete set of
specimens required by 2.5.9 are to be prepared
for each pressure vessel. They are to be

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attached to the shell plate in such a manner that

the edges to be welded are a continuation and
simulation of the corresponding edges of the
Fig.2.5.1 : Test specimen
longitudinal joint. The welding process,
procedure and technique are to be the same as
employed in the welding of the longitudinal joint.

2.5.2 As an alternative to 2.5.1, one test plate

may be prepared to provide all the test
specimens required by 2.5.9 and for re-test
purposes.

2.5.3 Test plates need not be prepared for the

circumferential seams, except in cases where a
pressure vessel has circumferential seams only,
or where the process for welding the
circumferential joints is significantly different
from that used for the longitudinal joints; in
which case one test plate is to be prepared
having a welded joint which so far as possible is
a simulation of the circumferential seams. The
test plate is to provide all the test specimens
required by 2.5.9 and for re-test purposes. 2.5.4 The test plates are to be cut from the shell
Where a number of similar vessels are made at plate or plates forming the appropriate seam,
the same time, it will suffice if, test plates are and before being detached are to be stamped
provided for each 30 [m] of circumferential by the Surveyor.
welded seam.
2.5.5 Where there is insufficient material
available on the shell plates for the provision of
test plates, acceptance may be given to test
plates cut from another plate, provided that this
plate is from the same cast and in the same
heat treatment condition.

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b) The diameter of the all weld metal test

specimen at the reduced parallel position is
to be not less than 14 [mm], except in the
case of thin plates, where the largest
practicable diameter should be used. The
gauge length of the specimen is to be 5
times the diameter;

c) The dimensions of the all weld metal test

specimen are shown in Fig.2.5.2 (a), and
their location when two specimens are used,
in Fig.2.5.2 (b);

d) The tensile strength of the weld metal is not

to be less than the minimum specified for
the plate material and not more than 145
[N/mm2] above this value;

e) The percentage elongation, A, is to be not

2.5.6 The thickness of test plates is to be the less than that given by :
same as that of the pressure vessel.
980 − R
2.5.7 Test plates are to be so supported, during A=
welding, that warping is reduced to a minimum. 21.6

2.5.8 The test plates are to be straightened where R is the tensile strength [N/mm2]. In
before being subjected to heat treatment, and addition, this elongation is to be not less than 80
for this purpose the test plates may be heated to per cent of the equivalent minimum elongation
a temperature below that required for the final specified for the plate.
heat treatment.
2.5.11 Specimen no. 2 :- Transverse bend test.
2.5.9 One set of test specimens is to be cut from The following conditions are to be satisfied :
the test plates as shown in Fig.2.5.1. The results
of the tests are to comply with the requirements a) Two bend test specimens of rectangular
detailed in 2.5.10 to 2.5.14. section are to be cut from the test plate
transversely to the weld, one to be bent with
the outer surface of the weld in tension, and
the other with the inner surface in tension;

b) The specimens are to have a width equal to

1.5 times the thickness of the specimen,
and the mid-portion is to coincide with the
centreline of the weld. The edges are to be
rounded to a radius, r, not exceeding 10 per
cent of the thickness;

c) Where the plate thickness does not exceed

25 [mm], the thickness of the specimens is
to be the full thickness of the plate. Where
2.5.10 Specimen no. 1 : Tensile test for the weld the plate thickness exceeds 25 [mm], the
metal - The following conditions are to be specimens, in all cases, are to have a
satisfied : thickness of 25 [mm] and are to be prepared
by discarding metal from the surfaces which
a) One weld metal tensile specimen is to be will be in compression when the test is
taken from Class 1 pressure vessels having applied. See Fig.2.5.3 (a) and (b);
a shell thickness not exceeding 70 [mm],
and for all Class 2 pressure vessels. Where d) Where the thickness of the plate permits,
the shell thickness of Class 1 pressure the bend specimens may be prepared as
vessels exceeds 70 [mm], two such shown in Fig.2.5.3 (c);
specimens are to be taken, one above the
other;

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e) For each specimen the weld reinforcement c) The tensile strength obtained is to be not
is to be removed by grinding or machining less than the minimum specified tensile
so that the outer and inner surfaces of the strength for the plate material.
weld are flush with the surface of the plate;
2.5.13 Specimen no. 4 : Macro-specimen. The
f) The specimen is to be mounted on roller following conditions are to be satisfied :
supports with the centre of the weld midway
between the supports. A former, with its axis a) Macrograph of a complete cross-section of
perpendicular to the specimen, is to bend the weld, including the heat affected zone, is
the specimen by pushing it through the clear to show a satisfactory penetration and
space between the supports. The diameter fusion, and an absence of significant
of the former and the clear space between inclusions or other defects;
the supports will depend upon thickness of
the specimens, and these dimensions are b) Should there be any doubt as to the
shown in the following table in terms of the condition of the weld as shown by macro-
thickness, t, of the specimen; etching, the area concerned is to be
examined by a micrograph.
Minimum
specified 2.5.14 Specimen no. 5 : Charpy V-notch impact
Clear space
tensile Diameter of test - Class 1 pressure vessels only
between
strength of former
supports
plate The following conditions are to be satisfied :
[N/mm2]
< 460 2t 4.2t a) Three Charpy V-notch impact test
specimens are to be cut transversely to the
≥ 460 < 510 3t 5.2t weld, parallel to the plate surface and at
≥ 510 < 620 4t 6.2t mid-plate thickness. The notch is to be cut
at approximately the centre of the weld, and
the axis of the notch is to be perpendicular
g) After bending, there is to be no crack or to the surface of the plate. See Fig.2.5.5;
defect exceeding 1.5 [mm] measured across the
specimen or 3 [mm] measured along the b) The dimensions and tolerances of the
specimen. Premature failure at the edges of the specimens are to be in accordance with Pt.2
specimen will not lead to rejection. Ch.2;

2.5.12 Specimen no. 3 : Tensile test for joint. c) The average energy value obtained from the
The following conditions are to be satisfied : Charpy V-notch test specimen is to be not
less than 27 J when the temperature of the
a) One reduced section tensile test specimen specimen at the time of the test does not
is to be cut transversely to the weld or, in exceed 50°C;
the thick plate, as many tensile test
specimens as may be necessary to d) Where it is proposed to use impact tests
investigate the tensile strength throughout other than the Charpy V-notch type, details
the whole thickness of the joint; are to be submitted for consideration;
The weld reinforcement is to be removed by
grinding or machining so that the outer and e) The foregoing impact test are not applicable
inner surfaces of the weld are flush with the to pressure vessels operating at low metal
surface of the plate. The dimensions of the temperatures, and for such cases the
reduced section tensile test specimens are results of the weld metal impact tests will be
shown in Fig.2.5.4. The width, B, at the specially considered.
reduced section is to be at least 25 [mm];
2.5.15 The test assemblies are to be heat
b) Where the plate thickness exceeds 30 [mm], treated in accordance with 2.10.
the tensile test may be effected on several
reduced section specimens, each with a 2.5.16 If any of the tests fail, further two re-test
thickness of at least 30 [mm] and a width at specimens are to be prepared and tested.
the effective cross-section of at least 25 Should any of these two further re-test also fail,
[mm]; the reasons for the failure are to be investigated
and the results are to be submitted to IRS for
review.

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2.5.17 Where two test assemblies have been
prepared, one re-test is to be taken from each
test assembly.

2.5.18 If both the re-test values are satisfactory,

the re-test values may be accepted.

2.6 Routine tests for Class 3 fusion welded

pressure vessels

2.6.1 Routine weld tests are not required for

Class 3 pressure vessels, but occasional check
tests on the quality of the welding may be
carried out at the discretion of the Surveyors.

2.7 Construction and workmanship

2.7.1 Cutting of plates

2.7.1.1 Plates are to be cut to size and shaped

by machine flame cutting and/or machining.

2.7.1.2 Where the plate thickness does not

exceed 25 [mm], cold shearing may be used
provided that the sheared edge is cut back by
machining or chipping for a distance of one-
quarter of the plate thickness but in no case by
less than 3 [mm].

2.7.1.3 All plate edges, after being cut and

before further work is carried out upon them, are
to be examined for laminations, and also to
ensure that any sheared edges are free from
cracks. Visual methods may be supplemented
by other techniques at the discretion of the
Surveyors.

2.7.2 Welded joints

2.7.2.1 Only full penetration butt welds are

acceptable for longitudinal and circumferential
main joints.

2.7.2.2 The joints are to be welded from both

sides of the plates unless otherwise approved.

2.7.2.3 Details of the welded joints between

dished ends and shells, flat ends and shells or
rectangular headers and methods of attaching
standpipes, branches, compensating plates and
pads are generally to be in accordance with
Fig.2.7.2.1, Fig.2.7.2.2 and Fig.2.7.2.3
respectively.

Fig.2.7.2.1 : Typical attachments of

dished ends to cylindrical shells

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2.7.2.4 Before welding is commenced, it is to be removed and the surface dressed smooth by
ascertained that the plate edges are in grinding prior to radiography.
alignment within the following limits :

a) 10 per cent of the plate thickness with a

maximum of 3 [mm] for longitudinal joints;

b) 10 per cent of the plate thickness plus 1

[mm] with a maximum of 4 [mm] for
circumferential joints.

2.7.2.5 If the plates are of unequal thickness,

and the difference between the surfaces
exceeds that given in 2.7.2.4 for the thicker
plate, the thicker plate is to have a smooth taper
with a slope not exceeding 15 degrees. See
Fig.2.7.2.4.

2.7.2.6 Wherever practicable, the welding is to

be carried out in the downhand position. In the
case of circumferential joints in cylindrical shells,
means are to be adopted to ensure compliance
with this requirement. 2.7.2.8 Fillet welds are to be so made as to
ensure proper fusion and penetration of the weld
2.7.2.7 Steel backing strips, if used, are to be of metal at the root of the fillet.
same nominal composition as the plates to be
welded and, where practicable, are to be 2.7.2.9 The arc is to be struck only on those
parts of the parent metal where the weld metal

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is to be applied, or on the weld metal already
deposited. Accidental arc strikes are to be 2.7.4.6 Seams in plates may be welded prior to
removed by grinding followed by magnetic forming provided that, on completion of forming
particle or dye penetrant testing to the and subsequent heat treatment, they meet the
satisfaction of the Surveyors. specified mechanical test requirements and that
they are examined radiographically throughout
2.7.2.10 Preheating and maintenance of their length after forming. After forming, the
minimum inter-pass temperature are to be surfaces of such seams in alloy steel parts, also
employed where necessitated by the joint carbon steel parts over 25 [mm] in thickness are
restraint, thickness of the plate or composition of to be ground smooth and inspected for cracks
the material to be welded. by magnetic particle crack detection, dye
penetration or other means at the discretion of
2.7.3 Welding consumables the Surveyors.

2.7.3.1 All consumables intended for use in the 2.7.5 Fitting of tubes to drums and headers
welding of pressure vessels are to be stored in a
dry place and are to be treated in accordance 2.7.5.1 The tube holes in drums or headers are
with the manufacturer's instructions. to be formed in such a way that tubes can be
effectively tightened in them. Where the tube
2.7.3.2 In order to ensure that the quality of ends are not normal to the tube plates, there is
welding consumables is being consistently to be a neck or belt of parallel seating of at least
maintained, they are to be subjected to a regular 13 [mm] in depth, measured in a plane through
system of periodic testing and inspection. the axis of the tube at the holes. Where the
tubes are practically normal to their plates, this
2.7.3.3 Where routine tests are frequently parallel seating is to be not less than 10 [mm] in
carried out in respect of pressure vessels made depth.
in the normal course of production, such tests
may be regarded as meeting the requirements 2.7.5.2 Tubes are to be carefully fitted in the
of 2.7.3.2. tube holes and secured by means of welding,
expanding and bevelling or by other approved
2.7.4 Forming shell sections and end plates methods. The tubes are to project through the
neck or belt of parallel seating by at least 6 [mm]
2.7.4.1 Plates for shell sections and end plates and, where they are secured from drawing out
are to be formed to the required shape by any by means of bellmouthing only, the included
process that will not impair the quality of the angle of belling is to be not less than 30
material. Tests to demonstrate the suitability of a degrees.
process may be required at the discretion of the
Surveyors. 2.7.6 Attachments and fittings

2.7.4.2 Shell plates are to be formed to the 2.7.6.1 All lugs, brackets, branches, manhole
correct contour up to the extreme edges of the frames and reinforcements around openings
plates. and other members are to conform to the shape
of the surface to which they are attached.
2.7.4.3 So far as possible, hot and cold forming
is to be carried out by machine. Forming by 2.7.6.2 Doubling plates with well rounded
hammering, with or without local heating, is not corners are to be fitted in way of attachments
to be employed. such as lifting lugs, supporting brackets and
feet, to minimise load concentrations on
2.7.4.4 All plates which have been hot formed or pressure shells and ends. Compensating plates,
locally heated for forming are to be normalized pads, brackets, and supporting feet are to
on completion of this operation. If, however, hot bedded closely to the surface before being
forming is carried out entirely at a temperature welded, and are to be provided with a 'tell-tale'
within the normalizing range, subsequent heat hole not greater than 9.5 [mm] in diameter, open
treatment will not be required for carbon and to the atmosphere to provide for the release of
carbon- manganese steels. In both instances entrapped air during heat treatment of the
alloy steels may, in addition, be required to be vessel, or as a means of indicating any leakage
tempered. during hydraulic testing and in service

2.7.4.5 All plates which have been cold formed 2.7.6.3 The attachment by welding of such
to an internal radius less than 10 times the plate fittings to the main pressure shell after post-weld
thickness are to be given an appropriate heat heat treatment is not permitted, except where
treatment. the material involved is mild steel, when welding

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will be permitted only if it is necessitated by the Surveyor's satisfaction on completion of the

method of construction employed. Prior approval hydraulic test.
of the Surveyor must be obtained before any
welding is carried out. In no circumstances is 2.7.7 Tolerances for cylindrical shells
any welding to be carried out after heat
treatment on vessels made of carbon or carbon- 2.7.7.1 Measurements are to be made to the
manganese steels with tensile strength surface of the parent plate, not to a weld, fitting
exceeding 500[N/mm2], or of alloy steel. or other raised part.

2.7.6.4 Where the fittings referred to in 2.7.6.3, 2.7.7.2 In assessing the out-of-roundness of
together with flats and other attachments for pressure vessels, the difference between the
supporting internal and external components, maximum and minimum internal diameter
are welded to the main pressure shell, the measured at one cross-section is not to exceed
welding is to be of comparable standard to that the amount given in Table 2.7.7.1.
required for the vessel, and the material used is
to be of compatible composition. 2.7.7.3 The profile, measured on the inside or
outside of the shell by means of a gauge of
2.7.6.5 The finish of all welds attaching pressure designed form of the shell, and having a length
parts and non-pressure parts to the main equal to one-quarter of the internal diameter of
pressure shell is to be such as to allow the vessel, is not to depart from the designed
satisfactory examination of the welds. In the form by more than the amount given in Table
case of Class 1 pressure vessels, these welds 2.7.7.1 This amount corresponds to, x, in
are to be ground smooth, if necessary, to Fig.2.7.7.1.
provide a suitable finish for crack detection
tests, which are to be carried out to the

Table 2.7.7.1 : Permitted out of roundness

Nominal internal diameter of Difference between maximum Maximum departure from

vessel [mm] and minimum diameters designed form
≤ 300 1.2 [mm]
> 300 ≤ 460 1.6 [mm]
> 460 ≤ 600 2.4 [mm]
> 600 ≤ 900 1.0 per cent of internal diameter 3.2 [mm]
> 900 ≤ 1220 4.0 [mm]
> 1220 ≤ 1520 4.8 [mm]
> 1520 ≤ 1900 5.6 [mm]
> 1900 ≤ 2300 6.4 [mm]
> 2300 ≤ 2670 19 [mm] 7.2 [mm]
> 2670 ≤ 3950 8.0 [mm]
> 3950 ≤ 4650 19 [mm] 0.2 per cent of internal diameter
> 4650 0.4 per cent of internal diameter 0.2 per cent of internal diameter

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Table 2.7.7.2 : Circumferential tolerance

Outside diameter (nominal inside diameter plus twice

Circumferential tolerance
actual plate thickness) [mm]
300 to 600 inclusive ± 5 [mm]
Greater than 600 ± 0.25 per cent

2.7.7.4 Shell sections are to be measured for

out-of-roundness, either when laid on their sides a) Class 1 pressure vessels - All butt welded
or when set up on end. When the shell sections seams in drums, shells, headers and pipes
are checked while lying on their sides, each together with the test plate or plates are to
measurement for diameter is to be repeated be subjected to 100 per cent radiographic
after turning the shell through 90 degrees about examination. For circumferential butt welds
its longitudinal axis. The two measurements for in extruded connections, pipes, tubes,
each diameter are to be averaged, and the headers and other tubular parts of 170 [mm]
amount of out-of-roundness calculated from the outside diameter or less, 10 per cent of the
average values so determined. total number of welds are to be
radiographed;
2.7.7.5 There are to be no flats or peaks at
welded seams, and any local departure from b) Class 2 pressure vessels - Spot radiographs
circularity is to be gradual. are to be taken at selected regions of each
main seam. The test plate or plates are to
2.7.7.6 The external circumference of the be fully radiographed and at least 10 per
completed shell is not to depart from the cent of the length of each main seam is to
calculated circumference (based upon nominal be so examined.
inside diameter and actual plate thickness) by
more than the amount given in Table 2.7.7.2. 2.8.1.2 Butt welds in furnaces, combustion
chambers and other pressure parts for fired
2.8 Non-destructive examination of fusion pressure vessels under external pressure, are to
welded pressure vessels be subjected to spot radiographic examination.

2.8.1 Radiographic examination 2.8.1.3 Where the surface finish of any weld
which has to be radiographed is such that it will
2.8.1.1 The extent of the radiographic prevent accurate radiographic examination, the
examination of welded seams of Class 1 and surface is to be machined or ground to provide a
Class 2 pressure vessels is to be as follows : smooth contour to the Surveyor's satisfaction.

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2.8.2 Ultrasonic examination

2.8.1.4 Lead type is to be fixed to the plate
adjacent to the weld so that each radiograph is 2.8.2.1 In Class 1 pressure vessels where plate
marked in such a way that the corresponding thickness exceeds 50 [mm], ultrasonic
portion of the welded seam can be readily and examination may be accepted as an alternative
accurately identified. to radiographic examination. Such examination
is to be effected by an approved operator using
2.8.1.5 The length of weld covered by each an approved technique and an approved
radiograph is to be such that the metal thickness recording system. Supplementary examination
along the incidental beam at the extremity of the by radiography may be required at selected
exposure is not to exceed the actual thickness locations.
by more than 10 per cent.
2.8.3 Magnetic particle testing
2.8.1.6 Image quality indicators (penetrameters)
of an approved type are to be placed at either 2.8.3.1 In Class 1 and Class 2 pressure vessels,
end of each radiograph and on the surface of the welds on standpipes, compensating plates,
the plate facing the source of radiation. stubs and branches, etc. of ferritic steel which
have not been radiographed are to be magnetic
2.8.1.7 Image quality indicators of the step-hole particle tested at the rate of 10 per cent of such
type are to be placed alongside the welded welds. This may be increased or decreased, if
seam, parallel to its length, and are to have a not practicable, at the discretion of the
hole in each step of a diameter corresponding to Surveyors. For non-magnetic materials, dye
thickness at that step, or are to have some penetrant examination will be accepted.
similar device whereby the step thickness can
be identified when the radiographic film is 2.9 Repairs to welded seams on fusion
examined. welded pressure vessels

2.8.1.8 The radiographic technique employed is 2.9.1 Class 1

to be such that the smallest diameter hole
visible in the radiograph is not to exceed 3 per 2.9.1.1 In the case of Class 1 pressure vessels
cent of the weld thickness for welds not where non-destructive tests show unacceptable
exceeding 50 [mm] thick, or 2.5 per cent for defects in the welded seams, the defects are to
welds exceeding 50 [mm] thick. The steps are to be repaired and are to be shown by further non-
bear these proportions to the weld thickness destructive tests to have been eliminated to the
radiographed, and the radiographic technique is Surveyor's satisfaction.
to be capable of revealing changes of metal
thickness of these percentages. 2.9.2 Class 2

2.8.1.9 Image quality indicators of the wire type 2.9.2.1 In the case of Class 2 pressure vessels,
are to be placed across the weld, and the when a spot radiograph reveals unacceptable
smallest diameter wire which can be seen in the defects in the welded seam, at least two further
radiograph is to have a diameter not greater radiographs are to be made in the length of weld
than 1.5 per cent of the weld thickness if the represented by the first radiograph, in locations
weld thickness is between 10 [mm] and 50 selected by the Surveyor. If these reveal no
[mm], and not greater than 1.25 per cent of the further unacceptable defects, the defects
weld metal thickness if the thickness is between revealed by the first radiograph are to be
50 and 200 [mm]. repaired and re-radiographed. If the check
radiographs reveal unacceptable defects, then
2.8.1.10 The use of gamma-rays may be either :
permitted in certain circumstances, and details
should be submitted for consideration and a) the whole length of weld represented is to
approval. be cut out and rewelded, then subjected to
spot radiography as if it were a new weld,
2.8.1.11 Radiographs are to be examined by the and the original test plates associated with
Surveyors on the original films using a viewing the weld are to be similarly treated; or
device of suitable illuminating power.
b) the whole length of the weld represented is
to be radiographed. Unacceptable defects
are to be repaired and are to be shown by
radiography to have been eliminated.

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2.10 Post-weld heat treatment of pressure vessels, where indicated in Table 2.10.1, are to
vessels be efficiently heat treated on completion of the
welding of the seams and of all attachments to
2.10.1 General the shell and ends, and before the hydraulic test
is carried out.
2.10.1.1 Dependent upon the grade of steel and
plate thickness, Class 1 and Class 2 pressure

Table 2.10.1 : Post-weld heat treatment

Plate thicknesses [mm], above which post-weld

heat treatment is required
Type of steel
Other pressure
Steam raising plant
vessels
Carbon and carbon manganese steels with minimum
specified tensile strengths between 360 to 510 [N/mm2] 20 30
without low temperature impact values
Carbon and carbon manganese steels with minimum
specified tensile strengths between 360 to 510 [N/mm2]
Not applicable 40
with low temperature impact values of 27 J at -20°C or
10°C below design temperature whichever is lower
All thicknesses to be
Alloy steels
heat treated

2.10.2 Basic requirements uniformly in the furnace to a temperature not

exceeding 400°C and subsequently cooling in a
2.10.2.1 Heat treatment is to be carried out in a still atmosphere.
properly constructed furnace which is efficiently
maintained and has adequate means of 2.10.2.3 The temperature and soaking periods
temperature control, and is fitted with are to be so selected as to relieve residual
pyrometers which will measure and record the stresses without undue deterioration of the
temperature of the furnace charge. properties of the material.

2.10.2.2 The heat treatment is to consist of 2.10.2.4 Recommended soaking temperatures

heating the vessel slowly and uniformly to a and periods are given in Table 2.10.2.
suitable stress relieving temperature, soaking for
a suitable period, followed by cooling slowly and

Table 2.10.2 : Recommended soaking temperatures and periods

Time at recommended temperatures, per 25 [mm] of

Type of steel Soaking temp. in °C
thickness
Carbon and carbon
580 - 620 1 hour, minimum period 1 hour
manganese
1 Cr 1/2 Mo 620 - 660 1 hour, minimum period 2 hour
2 1/4 Cr 1 Mo 660 - 690 2 hours, minimum period 2 hours

2.10.2.5 Where materials other than those ensure the heat treatment of the entire length of
detailed in Table 2.10.2 are used for pressure the longitudinal seam.
vessel construction, full details of the proposed
heat treatment are to be submitted for 2.10.2.7 Where it is proposed to adopt special
consideration. methods of heat treatment, full particulars are to
be submitted for consideration. In such cases it
2.10.2.6 Where pressure vessels are of such may be necessary to carry out tests to show the
dimensions that the whole length cannot be effect of the proposed heat treatment.
accommodated in the furnace at one time, the
pressure vessels may be heated in sections,
provided that sufficient overlap is allowed to

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Chapter 10 Part 4
Page 14 of 17 Requirements for Fusion Welding

2.10.3 Test assemblies pressure vessels as for their respective test

assemblies:
2.10.3.1 Test assemblies are to be heat treated
in the same furnace and at the same time as the a) Rate of heating;
pressure vessels which they represent.
b) Maximum temperature;
2.10.3.2 Alternatively, it may be permissible to
heat treat the test plates separately from the c) Time held at maximum temperature; and
pressure vessels, provided that the Surveyor is
satisfied with the means adopted to ensure that d) Condition of cooling.
the following factors will be the same for the

Section 3

Welded Pressure Pipes

3.1 General 3.1.4 Slip-on sleeve and socket welded joints

3.1.1 Manual or semi-automatic electric arc Slip-on sleeve and socket welded joints are to
welding is to be used for butt and socket welded have sleeves, sockets and weldments of
joints in pipes, for branch pieces and for the adequate dimensions conforming to IRS Rules
attachment of flanges. Oxy-acetylene welding or recognized standard.
may also be used, but, in general, is suitable
only for butt joints in pipes not exceeding 100 Slip-on sleeve and socket welded joints may be
[mm] diameter or 9.5 [mm] thickness. used in Class III piping systems, of any outside
diameter.
3.1.2 Where pressure pipelines are assembled
and butt welded in place, the piping is to be In particular cases, slip-on sleeve and socket
arranged well clear of adjacent structures to welded joints may be allowed by IRS for piping
allow sufficient access for preheating welding, systems of Class I and Class II having outside
heat-treatment and examination of the joints. diameter less than or equal to 88.9 [mm] except
for piping systems conveying toxic media or
Joint preparation, tolerances and edge services where fatigue, severe erosion or
preparation, are to be appropriate to the welding crevice corrosion is expected to occur.
process and in accordance with recognized
standards and/or approved drawings. The 3.1.5 Acceptable methods of flange attachment
preparation of edges is to be carried out by are illustrated in Fig.2.3.1 in Ch.2.
mechanical means and where flame cutting is
used, oxide scales, notches are to be removed 3.1.6 Welding consumables meeting the rule
by grinding or chipping back to sound metal. requirements and, where used, fusible root
inserts, are to be suitable for the materials being
3.1.3 Butt welded joints shall be full penetration joined.
type with details according to the following:
3.1.7 All welds in high pressure and high
a) For class I piping: temperature pipelines are to have a smooth
surface finish and even contour, if necessary
- Double vee groove joint or they are to be made smooth by grinding.

- with a backing strip or equivalent 3.1.8 Preheating under temperature control is to

be employed in accordance with Table 3.1.2,
b) For class II and III piping: when necessitated by the dimensions and
composition of the materials to be welded and is
- a single vee groove joint or equivalent to be effected by a method which ensures
uniformity of temperature at the joint. The
The tolerances on the alignment of pipes to be method of heating and the means adopted for
welded are to be in accordance with Table 3.1.1. temperature control are to be to the satisfaction
Higher tolerances for class III pipes may be of the Surveyors.
specially considered.

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Table 3.1.1 : Tolerances on alignment of pipes

Diameter and thickness of pipes Tolerances [mm]

All diameter and thickness with permanently fitted backing ring 0.5
Pipes welded without backing ring
- Inside diameter < 150 mm and thickness upto 6.0 mm 1.0
included
- Inside diameter < 300 mm and thickness upto 9.5 mm 1.5
included
- Inside diameter 300 mm and above and thickness > 9.5 mm 2.0

Table 3.1.2 : Preheating temperatures

Type of steel Thickness of thicker Minimum preheating

part [mm] temperature (°C)
Mn
C and C-Mn steels C+ ≤ 0.40 ≥ 20 (2) 50
6

Mn ≥ 20 (2)
C+ ≤ 0.40 100
6
0.3 Mo > 13 (2) 100
1 Cr – 0.5 Mo < 13 100
≥ 13 150
2.25 Cr – 1 Mo and 0.5 Cr – 0.5 Mo – 0.25 V (1) < 13 150
≥ 13 200
Notes :

1. For these materials, preheating may be omitted for thicknesses upto 6 [mm] if the results of
hardness tests carried out on welding procedure qualification are considered acceptable by IRS.

2. For welding in ambient temperature below 0°C, the minimum preheating temperature is required
regardless of the thickness unless specifically approved by IRS.

The values given in the Table 3.1.2 are based examined for defects by the appropriate method
on the use of low hydrogen processes. Higher specified in 3.2.2 to 3.2.4. The test welds are
preheating temperatures may be employed then to be sectioned at positions selected by the
when low hydrogen processes are not used. Surveyor, one surface of each section being
prepared, etched and examined for defects in
3.1.9 The welding procedure proposed for the the weld and heat effected zones.
attachment of flanges, valve chests and other
fittings to pipes, pipes-to-pipes and the 3.1.11 In the case of pipes of branch pieces of
fabrication of branch pieces, whether in carbon alloy steel, mechanical tests and tests to
or alloy steel, is to be approved by the destruction may also be required to demonstrate
Surveyors in the first instance before work is that the joints are of adequate strength.
commenced. For this purpose representative
specimens of such parts will be required for 3.1.12 Check tests of the quality of the welding
examination and testing. are to be carried out periodically at the
discretion of the Surveyors.
Tack welds forming part of the finished weld are
to be made using approved, welding procedure. 3.2 Non-destructive examination of welded
pipes
3.1.10 The assembly for the weld procedure test
and the welding technique should simulate the 3.2.1 In addition to visual examination of pipes
conditions under which the work is to be done welds by the Surveyors, non-destructive
on the installation. Test welds are to be examination of butt and fillet welds is to be
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Chapter 10 Part 4
Page 16 of 17 Requirements for Fusion Welding

carried out in accordance with 3.2.2 to 3.2.5 to 3.2.2 Butt welds are to be subjected to
the satisfaction of the Surveyors. radiographic examination in accordance with
Table 3.2.1. For radiographic examinations and
Radiographic and ultrasonic examination is to required standards of sensitivity, See 2.8.
be carried out with an appropriate technique by
trained operators using an approved procedure 3.2.3 The use of ultrasonic examination in lieu of
depending on the criticality of the joint. radiographic examination as required by 3.2.2
will be specially considered.

Table 3.2.1 : Radiographic examination of butt welds

Class of pipe Outside diameter of pipe Extent of examination

I ≤ 76.1 [mm] Selected welds at Surveyor's discretion
> 76.1 [mm] 100 percent of welds
Selected welds at Surveyor's discretion
II > 101.6 [mm]
Atleast 10% 1)
Note 1) Surveyor may apply more stringent requirement depending upon kind of materials, welding
procedure and controls exercised during fabrication.

Table 3.2.2 : Magnetic particle or liquid penetrant flaw detection testing of fillet welds

Class of pipe Outside diameter of pipe Extent of examination

I ≤ 76.1 [mm] Selected welds at Surveyor's discretion
> 76.1 [mm] 100 percent of welds
II > 101.6 [mm] Selected welds at Surveyor's discretion

3.2.4 Fillet welds are to be subjected to pieces are to be heat treated on completion of
magnetic particle or liquid penetrant flaw fusion welding.
detection testing in accordance with Table 3.2.2.
3.3.2 Recommended soaking temperatures and
The equipment is to be suitable for flaw periods for post-weld heat treatment are given in
detection and may require calibration against Table 3.3.1.
standard samples. The acceptance criteria for
welds is to be generally in accordance with the 3.3.3 Any proposal to use oxy-acetylene welding
national or international standard. for the fabrication of pipes and branch pieces
will be the subject of special consideration. Due
3.2.5 Defects in welds are to be rectified and re- consideration should be given to the need for
examined by the appropriate test method, all to normalizing and tempering after such welding.
the satisfaction of the Surveyors.
3.4 Heat treatment after forming of pipes
3.2.6 Ultrasonic examination may be required in
special cases in addition to above non- 3.4.1 Heat treatment should preferably be
destructive testing. carried out in a suitable furnace provided with
temperature recording equipment without
3.3 Post-weld heat treatment impairing the specified properties of the
materials. Tests may be carried out if necessary.
3.3.1 Carbon and carbon-manganese steel Localized heat treatment of welded joints
pipes and fabricated branch pieces having a extended sufficiently along the pipe length on
thickness exceeding 30 [mm] are to be heat either side of the joint, carried out with approved
treated on completion of fusion welding. All procedure, can be also accepted.
thicknesses of alloy steel pipes and branch

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Table 3.3.1 : Post-weld heat treatment

Type of steel Heat treatment of temperature °C

Carbon and carbon-manganese Normalizing 880 to 940
0.3 Mo Normalizing 900 to 940
1 Cr 1/2 Mo Normalizing 900 to 960 tempering 640 to 720
2 1/4 Cr 1 Mo Normalizing 900 to 960 Tempering 650 to 780
0.5 Cr – 0.5 Mo Normalizing 930 to 980
– 0.25V Tempering 670 to 720
Other alloys steels Subject to special consideration

Table 3.3.2 : Stress relieving temperatures

Type of steel Thickness of Stress relief heat treatment

thicker part [mm] temperature (°C)
C and C-Mn ≥ 15 (1) (3) 550 to 620
0.3 Mo ≥ 15 (1) 580 to 640
1 Cr – 0.5 Mo >8 620 to 680
2.25 Cr – 1 Mo and 0.5 Cr – 0.5 Mo – 0.25 V Any (2) 650 to 720
Notes:

1. When steels with specified Charpy V notch impact properties at low temperature are used, the
thickness above which postweld heat treatment shall be applied may be increased by special
agreement with IRS.

2. Heat treatment may be omitted for pipes having thickness ≤ 8 [mm], diameter ≤ 100 [mm] and
minimum service temperature 450°C.

3. For C and C-Mn steels, stress relieving heat treatment may be omitted upto 30 [mm] thickness by
special agreement with IRS.

3.4.2 Hot forming should generally be carried for all grades other than carbon and carbon-
out within the normalizing temperature range of manganese steels having UTS 320, 360 and
850 – 1000°C for all grades. When carried out 410 [N/mm2].
within this temperature range no subsequent
heat treatment is required for carbon, carbon- 3.4.4 Stress relieving is to be carried out after
manganese and carbon-molybdenum steels. For welding for other than oxy-acetylene welding
Chrome-molybdenum and Carbon-molybdenum- process in accordance with Table 3.3.2.
vanadium steels, a subsequent stress relieving
heat treatment is to be carried out in accordance The stress relieving heat treatment is to consist
with Table 3.3.2. When the hot forming is carried in heating the piping slowly and uniformly to a
out outside the normalizing temperature range, temperature within the range indicated in the
a subsequent heat treatment in accordance with table, soaking at this temperature for a suitable
Table 3.3.1 is required. period, in general one hour per 25 [mm] of
thickness with minimum half an hour, cooling
3.4.3 After cold forming, when bent to a radius slowly and uniformly in the furnace to a
measured at the centerline of the pipe of less temperature not exceeding 400°C and
than four times the outside diameter, heat subsequently cooling in a still atmosphere.
treatment in accordance with Table 3.3.1 is
required. 3.4.5 For oxy-acetylene welding, heat treatment
is to be carried out depending upon the type of
In any case, a stress relieving heat treatment is steel in accordance with Table 3.3.1.
to be carried out in accordance with Table 3.3.2

End of Chapter

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Chapter 11

Spare Gear

Contents
Section

1 General Requirements
2 Spare Parts Recommended for Main and Auxiliary Machinery Installations

Section 1

General Requirements

1.1 General must take into account the design and

arrangements of the machinery and the
1.1.1 Adequate spare parts for propelling and intended service and operation of the ship.
essential auxiliary machinery together with the Account should also be taken of the
necessary tools for maintenance and repair are recommendations of the manufacturers and any
to be readily available for use. applicable statutory requirements of the country
of registration of the ship.
1.1.2 The spare parts to be supplied and their
location is the responsibility of the Owners but

Section 2

Spare Parts Recommended for Main and Auxiliary Machinery

Installations

2.1 List of minimum required spare parts electric generators for essential
services;
2.1.1 The spare parts recommended for main
and auxiliary machinery installations are shown Table 2.1.5 : Spare parts for main and
in the following Tables:- auxiliary boilers;

Table 2.1.6 : Spare parts for auxiliary

Table 2.1.1 : Spare parts for main internal machinery.
combustion engines;
2.1.2 In ships with multi-engine installations,
Table 2.1.2 : Spare parts for main steam spare parts need only be carried for one main
turbines; engine.

Table 2.1.3 : Spare parts for auxiliary steam 2.1.3 Where additional units of adequate
turbines; capacity are fitted, for auxiliary machinery of
each type required for essential services, no
Table 2.1.4 : Spare parts for auxiliary internal spare parts are required.
combustion engines driving

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Table 2.1.1 : Spare parts for main internal combustion engines

Number required
Sr. Ships for Ships for
Item Spare parts
No. unrestricted restricted
service service
Main bearings or shells for one bearing of each size
1 Main bearings 1 -
and type fitted, complete with shims, bolts and nuts
Pads for one face of Michell type thrust block, or 1 set 1 set
Complete white metal thrust shoe of solid ring type,
1 1
2 Main thrust block or
Inner and outer race with rollers, where roller thrust
1 1
bearings are fitted
Bottom end bearings or shells of each size and type
fitted, complete with shims, bolts and nuts, for one 1 set -
Connecting rod cylinder
3
bearings Top end bearings or shells of each size and type
fitted, complete with shims, bolts and nuts, for one 1 set -
cylinder
4 Cylinder liner Cylinder liner, complete with joint rings and gaskets 1 -
Cylinder cover, complete with valves, joint rings and
gaskets. For engines without covers the respective 1 -
5 Cylinder cover valves for one cylinder unit
Cylinder cover bolts and nuts for one cylinder Half set -
Exhaust valves, complete with casings, seats,
2 sets 1 set
springs and other fittings for one cylinder
Air inlet valves, complete with casings, seats,
1 set 1 set
springs and other fittings for one cylinder
Starting air valve, complete with casing, seat,
6 Cylinder valves 1 1
springs and other fittings
Cylinder overpressure sentinel valve, complete 1 1
1 set
Fuel valves of each size and type fitted complete
see 1/4 set
with all fittings, for one engine
foot note 1
Crosshead type: Piston of each type fitted, complete
with piston rod, stuffing box, skirt, rings, studs and 1 -
nuts
7 Pistons
Trunk piston type: Piston of each type fitted,
complete with skirt, rings, studs, nuts, gudgeon pin 1 -
and connecting rod
8 Piston rings Piston rings, for one cylinder 1 set -
Telescopic cooling pipes and fittings or their
9 Piston cooling 1 set -
equivalent, for one cylinder unit
Lubricator complete, of the largest size, with its
10 Cylinder lubricators 1 -
chain drive or gear wheels
Fuel pump complete, or when replacement at sea is
11 Fuel injection pumps practicable, a complete set of working parts for one 1 -
pump (plunger, sleeve, valves springs etc).
High pressure fuel pipe of each size and shape
12 Fuel injection piping 1 -
fitted, complete with couplings
Scavenge blowers 1 set
Rotors, rotor shafts, bearings, nozzle rings and gear
13 (including see -
wheels or equivalent working parts of other types
turbochargers) foot note 2
Suction and delivery valves for one pump of each
14 Scavenging system 1 set -
type fitted

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Table 2.1.1 : Spare parts for main internal combustion engines (Contd.)

Number required
Sr. Ships for Ships for
Item Spare parts
No. unrestrict restricted
ed service service
Complete bearing bush, of each size fitted in the
1 set -
Reduction and/or reverse gear case assembly
15
gear Roller or ball race, of each size fitted in the gear
1 set -
case assembly
Piston rings of each size fitted 1 set -
Main engine driven air
16 Suction and delivery valves complete of each size
compressors Half set -
fitted
Special gaskets and packing of each size and type fitted for cylinder cover and
17 1 set -
cylinder liner for one cylinder
Footnotes :
1 (a) Engines with one or two fuel valves per cylinder: one set of valves, complete.
(b) Engines with 3 or more fuel valves per cylinder : two fuel valves complete per cylinder and a sufficient
number of valve parts, including the body, to form with those fitted in the complete valves, a full engine set.

2 The spare parts may be omitted where it has been demonstrated, at the builder's test bench for one engine of
the type concerned that the engine can be maneuvered satisfactorily with one blower out of action.
The requisite blanking and blocking arrangements for running with the blower out of action are to be available
on board.
Notes

1 The availability of other spare parts, such as gears and chains for camshaft drive, should be specially
considered and decided upon by the Owners.
2 When the spare parts are utilized, new spare parts are to be supplied as soon as possible.

Table 2.1.2 : Spare parts for steam turbines for main propulsion
Number required
Sr. Ships for Ships for
Item Spare parts
No. unrestricted restricted
service service
Bearing bushes, of each size and type fitted for
1 Main bearing the rotor, pinion and gear wheel shafts, for one 1 -
engine
Pads of each size for one face of Michell type
thrust or rings for turbine adjusting block, or each
2 Turbine thrust 1 set 1 set
size fitted for one engine. Assorted liners for 1
block where fitted
Pads for one face of Michell type thrust block, or 1 set 1 set
Complete white metal thrust shoe of solid ring
1 1
3 Main thrust block type, or
Inner and outer race with rollers where roller thrust
1 1
bearings are fitted
Carbon sealing rings, where fitted, with springs for
4 Turbine shaft 1 set 1 set
each size of sealing rings and type of gland
Strainer baskets or inserts for filters of special
5 Oil filters 1 set 1 set
design of each type and size
Notes
1 The availability of other spare parts should be specially considered and decided upon by the Owners.
2 When the spare parts are utilized, new spare parts are to be supplied as soon as possible.

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Table 2.1.3 : Spare parts for auxiliary steam turbines

Number required
Sr. Ships for Ships for
Item Spare parts
No. unrestricted restricted
service service
Bearing bushes or roller bearings of each size and
1 Main bearings type fitted for the shafts of the turbine rotor and of 1 1
the reduction gearing, if any, for one engine
Pads of each size for one face of Michell type
thrust or rings for turbine adjusting block, or each
2 Turbine thrust 1 set 1 set
size fitted for one engine. Assorted liners for 1
block where fitted
Carbon sealing rings, where fitted, with springs,
3 Turbine shaft for each size of sealing rings and type of gland, for 1 set 1 set
one engine
Strainer baskets or inserts, for filters of special
4 Oil filters 1 set 1 set
design, of each type and size
Notes
1 The availability of other spare parts should be specially considered and decided upon by the Owners.
2 When the spare parts are utilized, new spare parts are to be supplied as soon as possible.

Table 2.1.4 : Spare parts for auxiliary internal combustion engines driving electric
generators for essential services
Number required
Sr. Ships for Ships for
Item Spare parts
No. unrestricted restricted
service service
Main bearings or shells for one bearing of each
1 Main bearings size and type fitted, complete with shims, bolts 1 -
and nuts
Exhaust valves, complete with casings, seats,
2 sets -
springs and other fittings for one cylinder
Air inlet valves, complete with casings, seats,
1 set -
springs and other fittings for one cylinder
2 Cylinder valves Starting air valve, complete with casing, seat,
1 -
springs and other fittings
Cylinder overpressure sentinel valve, complete 1 -
Fuel valves of each size and type fitted complete
Half set -
with all fittings, for one engine
Bottom end bearings or shells of each size and
type fitted, complete with shims, bolts and nuts, for 1 set -
one cylinder
Top end bearings or shells of each size and type
3 Connecting rod bearings
fitted, complete with shims, bolts and nuts, for one 1 set -
cylinder
Trunk piston type : gudgeon pin with bush for one
1 set -
cylinder
4 Piston rings Piston rings, for one cylinder 1 set -
Telescopic cooling pipes and fittings or their
5 Piston cooling 1 set -
equivalent, for one cylinder unit
Fuel pump complete, or when replacement at sea
6 Fuel injection pumps is practicable, a complete set of working parts for 1 -
one pump (plunger, sleeve, valves springs etc).
High pressure fuel pipe of each size and shape
7 Fuel injection piping 1 -
fitted, complete with couplings
Special gaskets and packings of each size and
8 Gaskets and packings 1 set -
type fitted, for cylinder covers and cylinder

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Table 2.1.5 : Spare parts for boilers (main and auxiliary)

Number required
Sr. Ships for Ships for
Item Spare parts
No. unrestricted restricted
service service
Tube stoppers or plugs, of each size used, for
1 Tube stoppers or plugs 20 10
boiler superheater and economiser tubes
2 Fire bars Fire bars for one boiler, where coal fired 1 set Half set
3 Oil fuel burners Oil fuel burners complete, for one boiler 1 set 1 set
2 sets 2 sets
Gauge glasses of round type
per boiler per boiler
4 Gauge glasses 1 set for 1 set for
Gauge glasses of flat type every two every two
boilers boilers

Table 2.1.6 : Spare parts for auxiliary machinery

Number required
Sr. Ships for Ships for
Item Spare parts
No. unrestricted restricted
service service
Pumps

1 Reciprocating pumps

1.1 Valves Valve with seats and springs, each size fitted 1 set 1 set

1.2 Piston rings Piston rings, each type and size for one piston 1 set 1 set

2 Centrifugal pumps

2.1 Bearings Bearing of each type and size 1 1

2.2 Rotor Rotor sealing of each type and size 1 1

3 Gear type pumps

3.1 Bearing Bearing of each type and size 1 1

3.2 Rotor Rotor sealing of each type and size 1 1

Air compressor

1 Piston rings Rings of each size fitted for one piston 1 set 1 set

Suction and delivery valves, complete, of each

2 Valves Half set Half set
size fitted

Notes

1 The availability of other spare parts should be specially considered and decided upon by the Owners.

2 When the spare parts are utilized, new spare parts are to be supplied as soon as possible.

3 When a sufficiently rated standby pump is available, spare part for the pump may be dispensed with.

End of Chapter

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