इंटरनेट मानक Disclosure to Promote the Right To Information Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. “जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न’ 5 तरफ” Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru “The Right to Information, The Right to Live” “Step Out From the Old to the New” IS 15324 (2003): Shipbuilding - Selection and Testing of Air Starting Systems - Code of Practice [TED 19: Marine Engineering and Safety Aids] “!ान $ एक न’ भारत का +नम-ण” Satyanarayan Gangaram Pitroda ““IInnvveenntt aa NNeeww IInnddiiaa UUssiinngg KKnnoowwlleeddggee”” “!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता हहहहै””ै” Bhartṛhari—Nītiśatakam “Knowledge is such a treasure which cannot be stolen” IS 15324:2003 Wtikr J-ill* @M%+J-r-mT?rti#hTa miTTmFi* @kw-HfaFi-Rm Indian Standard SHIPBUILDING— SELECTION AND TESTING OF AIR STARTING SYSTEMS — CODE OF PRACTICE ICS 47.020.20 0 BIS2003 BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002 June 2003 Price Group 3 Marine Engineering and Safety Aids Sectional Committee, TED 19 FOREWORD This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Marine Engineering and Safety Aids Sectional Committee had been approved by the Transport Engineering Division Council. A ship is required to be provided with the equipment for starting the main and auxiliary engines so that the necessary initialchargeofstarting airorinitialelectricpower canbedeveloped onboard shipwithout external aid. This standard covers the requirements for equipment using airstarting systems. Whilepreparing this standard, following have been taken intoconsideration: a) The capacity ofthe air compressors isnormally related tothe capacity of the air receivers. b) Safety requirements laid down by the classification societies for the entire air starting system have been taken into account. c) Efforts have been made by giving all the requirements pertaining to selection and testing of air starting systems inorder to facilitate small shipyards to speci~ the scope of supply to various suppliers. The composition ofthe Committee responsible for formulation ofthis standard isgiven inAnnex A. Forthe purpose of deciding whether a particular requirement of this standard iscomplied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS2:1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained inthe rounded off value should bethe same asthat ofthe specified vahre inthis standard. IS 15324:2003 Indian Standard SHIPBUILDING— SELECTION AND TESTING OF AIR STARTING SYSTEMS — CODE OF PRACTICE 1 SCOPE 3.2 Purchaser— The party purchasing the machines and equipments. Theterm ‘purchaser’ shall also cover This standard coversselectionandtesting offollowing a person or persons authorized in writing by the itemsonboardofashipusingcompressedairforengine purchaser to act on his behalf for inspection of the starting: machines. a) Air receivers, 3.3 Manufacturer— The party manufacturing the b) Air compressors, and machines and equipments. The manufacturer may or c) Pipes and fittings. may notbethe supplier. 2 REFERENCES 4 AIR RECEIVERS The following standards contain provisions which 4.1 General through reference inthis text, constitute provisions of . 4.1.1 On ships, at least two air receivers shall be this standard. At the time of publication, the editions provided approximately each of equal capacity, for indicated were valid. All standards are subject to starting ofengines. revision and parties to agreements based on this standard are encouraged to investigate the possibility 4.1.2 Air receivers, intended for starting of engines of applying the most recent editions of the standard may also be used for auxiliary services provided indicated below: sufficient additional capacity for this purpose is available. 1SNo. Title 4.1.3 Thedesign, manufacture, marking andtesting of 1239 Mild steeltubes, tubulars andother the airreceivers shall be inaccordance with IS 2825. wrought steel fittings: (Part 1): 1990 Mild steeltubes (j2j?hrevision) 4.1.4 In installations, where the main engine clutches are pneumatically operated, separate air receiver for (Part 2): 1992 Mild steel tubulars and other this purpose shall beprovided. wrought steel pipe fittings ~ourth revision) 4.2 Total Capacity 2825:1969 Code for unfired pressure vessels 4.2.1 The combined capacity of the air receivers 4310: 967 Weldable steel pipe fittings for intended for starting of reversible engines shall be so marine purposes determined that itissufficient to carry out 12starting manoeuvres andmay beapproximated bythe formula 4693: 968 Specification for steel accessories givenbelowandbasedupontheassumption that initial for marine piping systems and final pressures in the air receiver would be 5727: 981 Glossary of terms relating to 30kg/cm2and 9kg/cm2respectively. compressors and exhausters (first ~ revision) J J.a X3~ X[(Z+b XPm~XnA)+0.9]. V~Xcxd 11323:1984 Specification for steel gate valves D foruseinmarine pipework system where 3 TERMINOLOGY J. total capacity of airreceivers; D. For the purpose of this standard the following bore diameter ofthe main engine, incm; definitions inaddition tothose given inIS5727 shall /./. stroke ofthe main engine, incm; apply. Vh= swept volume of one cylinder ofthe main 3.1 Supplier—The party supplying themachines and engine, in litres; equipments. Thesupplier mayormaynotbetheactual z . number of cylinders ofmain engine; manufacturer ofthemachines. Theterm ‘supplier’shall also cover anyparty with whom the supplier placesan P=me mean effective pressure ofmain engine, in kg/cm2; order for partial compliance. IS 15324:2003 u= 0.771 fortwo stroke engines; 5.2 Capacity —— 0.685 for four stroke engines; 5.2.1 The airquantity, Qin l/h, airdelivered byallthe b= 0.058 for two stroke engines; compressors and related to intake conditions shall not —. 0.055 for four stroke engines; be lessthan: c= 1.0forsinglescrewinstallationswithengine coupled directly tothe shafting; Q=l.7J(p-9) —— 1.5for single screw installations with two where equallysizedenginescoupledtotheshafting through detachable couplings; J = total capacity of air receivers, inlitreand —— 2.0 for twin-screw installations with each calculated inaccordance with 4.2; and line of shafting having a directly coupled engine; P = maximum working pressure inthe starting airreceivers, inkg/cm2. —— 2.0 for twin-screw installations with two equally sized engines connected to a 5.2.2 Where main engine driven air compressor is reduction gear box through detachable provided, its capacity shall not exceed 50 percent of couplings; the capacity stipulated in5.2.1. d = 1.0whenp =30kg/cm2 5.3 Design Ifp islessthan 30kg/cm2,then 5.3.1 The compressor manufacturer shall certi~ that 0.05s4 the design and materials of the air compressor are d= suitable formarine use,that is,designed to operate in l+@ II-0.0hsd.p,”: various conditions of trim, heel, vibrations, marine P= maximum working pressure ofairreceiver, atmosphere, etc, in accordance with the rules of the inkg/cm2; classification societies. e= Euler’s number (2.718); 5.3.2 Grey cast iron shall not be employed in the nA = 0.06n0 + 14,when nOS 1000; construction of crankshaft and connecting rods of air compressors of reciprocating type. nA = 0.25n0 – 176, when nO>1 000; and 5.3.3 Cooler dimension shall be based on aseawater n,,[Min-’] = rated speed. temperature of at least 32°C in case of water cooling 4.2.2 For installations with reversing gears or and an air temperature of at least 45°C in case of air controllable pitch propellers, the starting air capacity cooled compressors. Where fresh water cooling isto maybereduced to0.5ofthecapacity required by4.2.1 beproposed, thefreshwater inlettemperature shallnot but not lessthan necessary for 6 manoeuvres. exceed 40”C. 4.2.3 Separate air capacity fo r auxiliary engines 5.3.4 Cooler water spaces of the compressors and exceeding that required for main en gines need to be coolersshallbeprovided withsafetyvalvesorbursting provided. However, starting air capacity may be discs so that ample relief is provided in the event of approximated bytheformula given in4.2.1 exceptthat rupture of atube. value ofcmay bechanged t~asunder: 5.3.5 Compressors shall be so designed that the c = 0.30 for one auxiliary engine. discharge air temperature from the compressor does = 0.45 fortwo auxiliary engines. not exceed 93”C. A small fusible plug or an alarm = 0.60 for three auxiliary engines. operatingat121“Cshallbeprovided onthecompressor = 0.75 for four auxiliary engines. dischargetogivewarning ofexcessiveairtemperature. 5 COMPRESSORS 5.3.6 High-pressure stage air coolers shall not be locatedinthecompressorjacket cooling water spaces. 5.1 General 5.3.7 Each compressor stage shallbe provided with a 5.1.1 At leasttwo aircompressors, oneofwhich shall suitablesafetyvalvewhichcannotbeisolatedandshall beindependent ofthemain engines, shallbeprovided becapable ofpreventing the pressure being exceeded on each ship for changing the air receivers within lh by more than 10percent even if the discharge valve fromatmospheric pressuretothepressuresufficientfor from thecompressor isclosed. required number of starts. 5.3.8 Each compressor stage shall be fitted with a 5.1.2 Independentaircompressors,onshipswithengine pressuregauge.Themaximum permissible pressure for power less than 150kW, may be manually operated thestageshallbe indicated onthe pressure gauge with and connected to acorrespondingly small capacity air redmarking . receiver. 2 IS 15324:2003 5.3.9 Where one compressor stageconsists ofseveral manufacturer’s instructions. The direction of rotation cylinders, eachofwhich canbeshutoff, eachcylinder shall becorrect. shal1beprovidedwithonesafetyvalveandonepressure The compressor shall run at full load for 2h and the gauge. following shallberecorded: 5.3.10 Thermometers shallbefittedtoeachstageoutlet a) Motor input, oncompressors having apowerconsumption of20kW b) Inlet airpressure andtemperature, andabove. Thethermometers shallbemarked withthe maximum permissible temperature. c) Discharge airpressure and temperature, d) Lubricantoil,quantity,pressureandtemperature, 5.3.11 Allcompressorsshallbefittedwithoilandwater traps andafter cooler behind the final stage. e) Cooling water or air pressure and temperature, and 5.3.12 Water traps, after coolers and air receiver betweenthestagesshallbeprovided withdrainsattheir f) Motor temperature rise. lowestpoints. 5.6 Shop Trials 5.4 Name Plate 5.6.1 Cylinder, cylinder heads andcylinder liner shall 5.4.1 Eachcompressor shaIIbefittedwithanamepIate be hydrostatically tested to 1.5 times the final containing the following information: compression ofthe stage inquestion. a) Indication of source ofmanufacture, 5.6.2 The compressed air containing chambers of the b) Month and year of manufacture, intermediateandaftercoolemoftheaircompressor shall be hydrostatically tested to 1.5 times the final c) FAD of compressor, compression ofthe stage inquestion. d) Maximum discharge pressure, 5.6.3 Arunning test ofat least 8hshall be carried out e) Number of revolution per minute, toprove the following: f) Power consumption, and a) Capacity, g) Number of stages. b) Power consumption, 5.5 Production Test c) Satisfactory operation, and The production test isto consist of pre-test procedure d) Operation of instruments and alarms. and preliminary tests. During the running test, all the parameters are to be 5.5.1 Pre- Test Procedures checkedJrecorded. 5.5.1.1 Determination ofphysical data 5.6.4 After the test, moving parts of the compressor a) Weight of compressor unit c omplete, wet and shallbeexamined. dry; and 6 PIPES AND FITTINGS b) Dimensional survey (overall dimensions). 6.1 General 5.5.1.2 Hydrostatic test 6.1.1 Thepipes,fittings andaccessories shallconform 5.5.1.3 Flushing toIS 1239(Part 1),IS 1239(Part 2), IS4310, IS4693 and IS 11323. The compressor unit to be flushed with hot oil after partial final assembly. 6.1.2 Castironshallnotbeused inthe manufacture of compressed airpiping and fittings. 5.5.1.4 Instrument calibration 6.1.3 Screwed connections (ermeto or keelaring Test instruments are to be checked against standards. Thecompressor gaugepanelinstrumentstobechecked coupling) can beused inthe piping. against test instruments. 6.2 Finish 5.5.1.5 Electrical equipment Allpipes,fittingsand accessoriesfabricated from mild Afunctional testis tobecarried outonswitchgear and steel shall be cleaned by pickling, blowing by protectionpanelincluding lubricantoil,airtemperature compressed airand painted from outside. and motor overheat trips. 6.3 Testing 5.5.2 Preliminary Tests After fabrication, the piping shall be hydrostatically The compressor shall run in accordance with the tested to 1.5timesthe design pressure. 3 IS 15324:2003 ANNEX A (Foreword) COMMITTEE COMPOSITION Marine Engineering and SafetyAids Sectional Committee, TED 19 Organization Representative(s) D.G. Shipping, Mumbai SIRIB. K. BISWAS(Chairman) SW A. CHATARIEE(Alternate) Alcock Ashdown &Co Ltd, Bhavnagar S}OOP. MrrRA SHIUK.J. ROY(Mernate) Bureau Veritas, Mumbai Smr P.B. WARRIER Central Institute of Fisheries Technology, Cochin DRT. K. SWASAD Sw K. L.RAMAKRISHANA(N,4/fernate) Cochin Shipyard Ltd, Cochin StIRIMATHEWGEORGE SHFUK.K. S.NAMBIAR(Alternafe) Essar Shipping Ltd, Mumbai SmuV. SRIMVASAN Greaves Cotton &Co Ltd, Mumbai CAPTS. SOOTA StmuH.L.SHAH(Alternate) Garden Reach Shipbuilders & Engineers Ltd, Kolkata Swu S.MAJI . Goa Shipyard Ltd, Goa StmrrRAGWEERSJNGH SHSUV. DASGOPTA(Alternate) Great Eastern Shipping, Mumbai SNiuARUNSHARMA Hindustan Shipyard Ltd, Visakhapatnam SHIUA.SESHAGUURAO SHRIS.LAKSHMINASAYAN(AAlternate) Institute ofMarine Engineers, Mumbai Stuu A. R.@TNSN CDRJASBIRSINGH(Alternate 1) SHFOK. R. SACHAR(Alternate II) Institute of Marine Technologists, Mumbai SIIRIDONDYER SHRID. B. lRANL(A1/ernate) Indian Register of Shipping, Mombai SHRI1.N. BOSE SHIUU.S.KALGHATG(LAlternate) Kirloskar Oil Engines, Pune SHRIS.C. SARDESAi SHIUP. S. BHAVE(Alternate) Kolkata Port Trust, Kolkata SIIRIS.ROY SHRIG. SEN(A/ternate) Lloyd’s Register of Shipping, Mumbai SHRIT. K. MITRA SHRtS.C. SABHARWA(LAlfernate 1) SNRIJ. D.GROVER(Alternate H) Ministry ofCommunication, New Delhi DR.ASHOKCHANDRA SHRiV.V. SINGH(Alfernate) Mazagon Dock Ltd, Mumbai SHRLS. K. MURTHV SifruA. H. SoI.Aiw(Alternate) Ministry of Defence, Directorate of Marine Engineers, New Delhi CDRA. P.V.THAMPAN A:WSTAIJTDIRECTOR(SYSTEMW) (Akerrrufe) Ministry ofDefence, Directorate of Standardization, New Delhi CAPTP.R. SANGLIKAR SHRIA. R. C. VA!JMA(Alternate) Mather &Platt (India) Ltd, Mumbai Stuu D.R. BAPAT SHRIK.BASHWARAN(Alternate) Mumbai Port Trust, Mumbai SHRIR. K. KHATTAR Smu S.P. DEOKOUAR(Alternate) Ministry of Surface Transport (Development Wing), New Delhi SHRIG. P.ROY SHP.IT, K. DOTTA(A[fertrate) Ministry of Surface Transport (SBR), New Delhi DEVELOPMENATDVISOR(SBR) SHRSR. K. SEN(Alternate) Nitin Fire Production System Ltd, Mumbai SHRIB. R.MALLYA National Ship Design and Research Centre, Visakhapatnam DIRECTOR B.E. Pumps, Kolkata SHRICHANOANDASSGUPTA Shaparia Dock &Steel Co Pvt Ltd, Mumbai SHRIC. N. MISTRY Swastic Rubber Prodocts, Pune GENERALMANAGER The Company of Master Mariners oflndi~ Mumbai CAPTV.N. AINOLEY The Indian National Shipowners Association, Mumbai SHRIM. M. PiPLANI (Continued onpage 5) 4 IS 15324:2003 (Co.tinuedfrompage 4 ) Organization Representative(s) The Shipping Corporation of India, Mumbai SturrS, K. BHALLA Smu B.N. AOVANl(Alternate) Varun Shipping, Mumbai SHIUB. L. MEHTA Vijay Fire Protection Systems Pvt Ltd, Mumbai SHIUJATINOERAR. SALOT SHFOHARISHR. SALOT(Alternate) BIS Directorate General SHiUA. R. GULATI,Director &Head (TED) [Representing Director General (Ex-oficio)] Member Secretary StuuV. ARUMUCAM Joint Director (TED), BIS 5