Section 1 General requirements
Clasification Society 2024 - Version 9.40
Clasifications Register Rules and Regulations - Rules and Regulations for the Classification of Naval Ships, January 2023 - Volume 2 Machinery and Engineering Systems - Part 2 Prime Movers - Chapter 1 Reciprocating Internal Combustion Engines - Section 1 General requirements

Section 1 General requirements

Parent topic: Chapter 1 Reciprocating Internal Combustion Engines

1.1 Application

1.1.1 Engines providing power for Mobility or Ship Type systems are to be constructed under survey and in accordance with the requirements of this Chapter (see also Vol 1, Pt 1, Ch 2, 3.9 Machinery and Engineering Systems notations).

1.1.2 This Chapter is to be read in conjunction with the requirements for Machinery and Engineering Systems in Vol 2, Pt 1, Ch 1 General Requirements for Classification of Engineering Systems and Vol 2, Pt 1, Ch 3 Requirements for Design, Construction, Installation and Sea Trials of Engineering Systems. Specific attention is drawn to the transverse requirements in Vol 2, Pt 1, Ch 3, 4 Operating conditions.

1.1.3 The requirements of this Chapter are applicable to reciprocating internal combustion engines operating on liquid, gas or dual fuel for use in Mobility or Ship Type systems (hereinafter referred to as engines). The requirements of Vol 2, Pt 2, Ch 1, 3 Crankshaft design do not apply to engines intended for Mobility or Ship Type systems where power does not exceed 110 kW.

1.2 Scope

1.2.1 For the purposes of this Chapter engine type, expressed by the manufacturer/licensor’s designation, is defined by:
  1. the bore and stroke;
  2. the method of injection (i.e. direct injection, indirect injection, pilot injection);
  3. the fuel pump and injection system (independent line to fuel oil valve, common rail);
  4. the valve and injection operation (by cams or electronically controlled);
  5. the fuel(s) used (liquid, dual-fuel, gaseous, etc.);
  6. the working cycle (4-stroke, 2-stroke);
  7. the gas exchange (naturally aspirated, turbocharged, etc.);
  8. the method of turbocharging (pulsating system, constant pressure system);
  9. the charging air cooling system (with or without intercooler, number of stages);
  10. cylinder arrangement (in-line, vee, etc.);
  11. the maximum continuous power per cylinder (or maximum continuous brake mean effective pressure) at maximum continuous speed;
  12. the manufacturer and type of governor (and control system if applicable) fitted.

1.2.2 A complete engine includes the control system, turbocharger(s) and all ancillary systems and equipment referred to in this Chapter that are used for operation of the engine for which there are rule requirements; this includes systems allowing the use of different fuel types.

1.2.3 Arrangements for gas only or dual fuel engines will be specially considered. For the requirements for trunk piston internal combustion engines supplied with low pressure (less than 1 MPa) natural gas (methane) as fuel, see Rules and Regulations for the Classification of Ships, July 2022 Pt 5, Ch 2, 15 Engines supplied with low pressure gas.

1.2.4 Primary exhaust gas emissions abatement plant (where fitted) is to meet the requirements of this Chapter; additionally, it is to meet the requirements of Vol 2, Pt 12 Emissions Abatement Plant. Where secondary exhaust gas emissions abatement systems are fitted to engines, they are to meet the requirements of Vol 2, Pt 12 Emissions Abatement Plant.

1.3 Approval process

1.3.1 All engines intended for installation on an LR Class ship are to be type approved by LR (see LR Type Approval System Procedure TA14 for details of the LR Type Approval process).

1.3.2 Each complete engine, as defined in Vol 2, Pt 2, Ch 1, 1.2 Scope, intended for installation on an LR Classed vessel, is to have an LR Engine Certificate.

1.3.3 For the first engine of a type the approval process and the engine certification process may be performed simultaneously.

1.3.4 To apply for an LR Engine Certificate, the following are to be submitted:
  1. a list of all documents identified in the ‘for information’ and ‘for appraisal’ columns of Table 1.1.1 Plans and particulars to be submitted with the relevant drawing numbers and revision status. This list is to cross-reference the approved plans previously submitted as part of the engine Type Approval and identify any plans that have been modified.
  2. where there is a licensor/licensee arrangement the list required by Vol 2, Pt 2, Ch 1, 1.3 Approval process 1.3.4.(a) is to cross-reference the drawings submitted by the designer as part of the engine Type Approval. This list is to identify all changes where the approved design has been modified by the licensee. Where the licensee proposes design modifications to components, a statement is to be made confirming the licensor’s acceptance of the proposed changes. If designer/licensor’s acceptance is not confirmed, the engine is to be regarded as a different type and is subject to the complete appraisal and type testing process.
  3. all documents with changes from the approved design are to be submitted for review/appraisal.
  4. In all cases the complete set of endorsed documents and the list referenced in Vol 2, Pt 2, Ch 1, 1.3 Approval process 1.3.4.(a), which are to be provided by the manufacturer, will be required by the Surveyor(s) attending the manufacturer’s works. Where a licensee/licensor arrangement is in place, this set of documents may be a combination of licensor and licensee documents.

1.3.5 An LR Engine Certificate is issued upon satisfactory completion of engine assembly, with associated component testing (see Vol 2, Pt 2, Ch 1, 2 Materials and components) and factory acceptance testing (see Vol 2, Pt 2, Ch 1, 11 Factory Acceptance Test and Shipboard Trials of Internal Combustion Engines) or issued in accordance with the alternative approach for product assurance approved by LR, see Vol 2, Pt 1, Ch 1, 6.4 Alternative system of inspection.

1.3.6 For appraisal of emergency generator engines and turbochargers additional submissions are required. See Vol 2, Pt 2, Ch 1, 1.4 Submission requirements 1.4.4 and Vol 2, Pt 2, Ch 1, 1.4 Submission requirements 1.4.5, as applicable.

1.4 Submission requirements

1.4.1 The plans and information are to be submitted as required in Table 1.1.1 Plans and particulars to be submitted and Vol 2, Pt 2, Ch 1, 1.4 Submission requirements 1.4.2 to Vol 2, Pt 2, Ch 1, 1.4 Submission requirements 1.4.8 as applicable

Table 1.1.1 Plans and particulars to be submitted

Document For information For appraisal
(X indicates reason for submission)
Engine particulars (LR Form 2073 with general engine and ancillaries information, Project Guide, Marine Installation Manual), see Note 1 X
Material specifications of principal components with information on non-destructive material tests and pressure tests X
Engine cross-section X
Engine longitudinal section X
Engine frames, welding drawings, see Notes 2 and 3   X
Main engine foundation and holding down and securing arrangements X
(metal chocks) 		X
(non-metallic chocks)
Bedplate and crankcase of cast design X  
Bedplate and crankcase of welded design, with welding details and welding instructions, see Notes 2 and 3   X
Bedplate/oil sump welding drawings, see Note 2   X
Thrust bearing assembly, see Note 4 X  
Thrust shaft or intermediate shaft (if integral with engine)   X
Thrust bearing bedplate of welded design, with welding details and welding instructions, see Note 2   X
Frame, see Note 3, framebox, see Note 3, and gearcase of cast construction X
Tie rod X
Connecting rod, assembly, see Note 5 X
Crosshead, assembly, see Note 5 X
Piston rod, assembly, see Note 5 X
Piston, assembly, see Note 5 X  
Piston head X  
Cylinder jacket/ block of cast construction, see Note 3 X
Cylinder cover, assembly, see Note 5 X
Cylinder liner X
Counterweights (if not integral with crankshaft), including fastening X
Crankshaft, details (for each crankthrow)   X
Crankshaft, assembly (for each crankthrow)   X
Crankshaft calculations, (see Vol 2, Pt 2, Ch 1, 3 Crankshaft design) X  
Camshaft drive, assembly, see Note 5 X
Flywheel or turning-wheel X
Shaft coupling interface arrangement including dimensions and material details X
Details of shielding and insulation of exhaust pipes and other parts operating at an elevated temperature, which might be impinged by flammable fluid(s) as a result of a system failure X
Schematic layout or other equivalent documents for the engine, see Note 6  
  • Starting and control air systems
   X
  • Fuel system
   X
  • Lubricating oil system
   X
  • Cooling water system
   X
  • Hydraulic systems
   X
  • Engine control and safety system
   X
High pressure fuel injection pump assembly X  
High pressure parts for fuel oil injection system, see Note 7   X
Shielding arrangements for high pressure piping - fuel, hydraulic and flammable oils, (see Vol 2, Pt 2, Ch 1, 8.1 Fuel oil, hydraulic and high-pressure oil systems 8.1.1)   X
Fastening arrangements for main bearings X
Fastening arrangements for cylinder heads and exhaust valve (two stroke design) X  
Fastening arrangements for connecting rods X  
Vibration dampers/detuners and moment compensators X
Construction and arrangement of vibration dampers X  
Details of mechanical joints of piping systems X
Oil mist detection and/or alternative arrangements X
Construction of accumulators for electronically controlled engine X
Construction of common accumulators for electronically controlled engine   X
Construction of accumulators for hydraulic oil and fuel oil   X
Arrangement and details of the crankcase explosion relief valve where applicable (see Vol 2, Pt 2, Ch 1, 10 Safety arrangements) X
Calculation results for crankcase explosion relief valves (see Vol 2, Pt 2, Ch 1, 10 Safety arrangements)   X
Construction and arrangements of hydraulic systems for actuation of sub-systems:  
  • Control valves, high-pressure pumps, pipes and accumulators
X  
  • Drive for high pressure pumps
 X  
  • Valve bodies, if applicable
 X  
For engine control, alarm monitoring and safety systems, the plans and information Vol 2, Pt 2, Ch 1, 1.4 Submission requirements 1.4.3, see Note 8   X
Generator set test results that state the engine maximum load steps which satisfy the quality of power supply requirements specified in Vol 2, Pt 9, Ch 1, 2.1 Quality of power supplies (QPS))   X
Planned operating profiles for the vessel at sea and during manoeuvring as agreed with the Operators   X
List of sub-contractors for main parts X  
Operation and service manuals, see Note 9 X
Risk-based analysis (for engine control system), see Note 10 X
Test program resulting from risk-based analysis (for engine control system), see Note 10 X  
Production specifications for castings and welding procedures X
Evidence of quality control system for engine design, production and in-service maintenance, see Notes 5 and 11 X
Type approval certification for environmental tests of control components, see Note 12 X  
Details of the engine type test program and the type test report, see Note 13   X
Engine test schedule (FAT and shipboard trials, see Vol 2, Pt 2, Ch 1, 1.4 Submission requirements 1.4.2)   X
Documentation verifying compliance with inclination limits (see Vol 2, Pt 1, Ch 3, 4.6 Inclination of ship )   X
Combustion pressure—displacement relationship   X
Plans and details for dead ship condition starting arrangements, see Vol 2, Pt 7, Ch 3, 12.11 Dead ship condition starting arrangements.   X
Note 1. LR Form 2073 will be supplied on application. Note that the turbochargers, if required to be Type Approved, are to have plans and particulars submitted as detailed in Vol 2, Pt 2, Ch 1, 1.4 Submission requirements 1.4.5.
Note 2. For approval of materials and weld procedure specifications. The weld procedure specification is to include details of pre- and post-weld heat treatment, weld consumables and fit-up conditions.
Note 3. For each cylinder for which dimensions and details differ.
Note 4. If integral with engine and not integrated in the bedplate.
Note 5. Including identification of components to ensure traceability in accordance with the Rules for the Manufacture, Testing and Certification of Materials, July 2022.
Note 6. Details of the system so far as supplied by the engine manufacturer such as: main dimensions, operating media and maximum working pressures.
Note 7. The documentation to contain specifications for pressures, pipe dimensions and materials.
Note 8. The submission is to include a general overview of the operating principles, supported by schematics explaining the functionality of individual systems and sub-systems. The information is to relate to the engine capability and functionality under defined operating and emergency conditions such as recovery from a failure or malfunction, with particular reference to the functioning of programmable electronic systems and any sub-systems. The information is also to indicate if the engine has different modes of operation, such as to limit exhaust gas emissions and/or to run under an economic fuel consumption mode or any other mode that is electronically controlled.
Note 9. Operational manuals are to contain maintenance requirements (servicing and repair) including details of any special tools and gauges that are to be used with their fitting/settings together with any test requirements on completion of maintenance. They are to include a description of each system’s particulars and include reference to the functioning of sub-systems.
Note 10. Where engines rely on hydraulic, pneumatic or electronic control of fuel injection and/or valves, the risk-based analysis is to address the mechanical, pressure containing, electrical, electronic and programmable electronic systems and arrangements that support the operation of the engine. It is to demonstrate that failure of the control system will not result in the operation of the engine being degraded beyond acceptable performance criteria for the engine and that suitable risk mitigation has been achieved in accordance with Vol 2, Pt 2, Ch 1, 3.3 Information to be submitted. The risk-based analysis will not be explicitly approved by LR.
Note 11. Including quality plan for sourcing, traceability, design, installation and testing of all components used in the fuel and hydraulic oil systems installed with the engine. See Vol 2, Pt 2, Ch 1, 8.1 Fuel oil, hydraulic and high-pressure oil systems 8.1.10.
Note 12. Tests are to demonstrate the ability of the control, protection and safety equipment to function as intended under the specified testing conditions as per Lloyd’s Register Type Approval Test Specification Number 1.
Note 13. The type test report may be submitted shortly after the conclusion of the type test. For electronically controlled engines evidence of type testing of the engine with the programmable electronic system, or a proposed factory acceptance test plan at the engine builders with the programmable electronic system functioning, is to be submitted to verify the functionality and behaviour under normal operating and fault conditions of the programmable electronic control system. Where required this is to include proposals for short-term, high power operation.
1.4.2 A schedule of testing at the engine packager’s or system integrator’s facility, pre-sea trial commissioning and sea trials is to be submitted. The test schedules are to identify all modes of engine operation and the sea trials are to include typical port manoeuvres under all intended engine operating modes. The schedule is to include:

  1. testing and trials to demonstrate that the engine is capable of operating as described in Table 1.1.1 Plans and particulars to be submitted, Note 10;

  2. tests to verify that the response of the complete mechanical, hydraulic, electrical and electronic system is as predicted for the intended operational modes; and

  3. testing required to verify the conclusions of the risk-based analysis.

    The scope of these tests is to be agreed with LR based on the risk-based analysis.

1.4.3 In addition to the applicable plans and particulars required by Vol 2, Pt 9, Ch 1, 1.4 Documentation required for design review the following information for control, alarm, monitoring and safety systems relating to the operation of an electronically controlled engine is to be submitted:

  1. Engine configuration details, see Vol 2, Pt 2, Ch 1, 4.3 Control engineering systems 4.3.2.

    1. Local and remote means to carry out system configuration.
    2. Engine builder procedures for undertaking configuring.
    3. Roles and responsibilities for configuration (e.g. Engine builder, engine packager, system integrator or other nominated party) with accompanying schedule.
    4. Configurable settings and parameters (including those not to be modified from a default value).
    5. Configuration for propulsion, auxiliary or emergency engine application.

  2. Software quality plans, including configuration management documents.

  3. Software safety evidence.

  4. Software assessment inspection report such as SCA or IEC 61508, as applicable.

Configuration records are to be maintained and are to be made available to the Surveyor at testing and trials and on request in accordance with Vol 2, Pt 9, Ch 1, 1.7 Alterations and additions and Vol 2, Pt 9, Ch 12, 1.2 Trials 1.2.3.

1.4.4 Emergency generator engine plans, information and test schedules, required for design appraisal, are to be in accordance with Vol 2, Pt 9, Ch 2 Electrical Power Generator and Energy Storage.

1.4.5 For turbochargers, the following plans and particulars are to be submitted. The submission requirements vary depending on the category of the turbocharger; category A, B and C turbochargers are defined in Vol 2, Pt 2, Ch 1, 12.1 General 12.1.2:

  1. Category A (on request):
    1. Turbocharger specification including type, compression ratio and operating condition.
    2. Cross-sectional drawing with principal dimensions and names of components.
    3. Containment test report.
    4. Test program.
  2. Category B:
    1. Turbocharger specification including type of turbine and compressor, compression ratio, bearing and cooling method.
    2. Cross-sectional drawing with principal dimensions and materials of housing components for containment evaluation.
    3. Documentation of containment in the event of disc fracture.
    4. Operational data and limitations, i.e.:
      • Maximum permissible operating speed (rpm);
      • Alarm level for overspeed;
      • Maximum permissible exhaust gas temperature before turbine;
      • Alarm level for exhaust gas temperature before turbine;
      • Minimum lubrication oil inlet pressure;
      • Lubrication oil inlet pressure low alarm set point;
      • Maximum lubrication oil outlet temperature;
      • Lubrication oil outlet temperature high alarm set point;
      • Maximum permissible vibration levels, i.e. self- and externally generated vibration;

        (Alarm levels may be equal to permissible limits but are not to be reached when operating the engine at 110 per cent power or at any approved intermittent overload beyond 110 per cent.).

    5. Arrangement of lubrication system, all variants within a range.
    6. A list of main current suppliers and subcontractors for rotating parts and an operation and maintenance manual.
    7. Type test reports.

  3. Category C:

    1. Plans and particulars as for Category B.
    2. Drawings of the housing and rotating parts (shaft, wheels, blades and nozzle) including details of blade fixing for turbine and compressor.
    3. Material specifications (including density, Poisson’s ratio, range of chemical composition and mechanical properties (at room temperature), and high-temperature strength characteristics as well as creep rate and rupture strength for the design service life (parts subject to 450 degrees Celsius or more)) of all parts mentioned above including details of the material and quality control system to be used for these parts.
    4. Welding details and welding procedure of above-mentioned parts, if applicable.
    5. Documentation* of safe torque transmission when the disc is connected to the shaft by an interference fit.
    6. Information on expected lifespan, considering creep, low cycle fatigue and high cycle fatigue.
    7. Operation and maintenance manuals*.
    8. Arrangements of cooling system.
      Note * Documentation is to be provided applicable to two representative sizes in a generic range of turbochargers.

1.4.6 Where considered necessary LR may require additional documentation to be submitted.

1.4.7  The following information is to be submitted to LR for acceptance of oil mist detection equipment and alarm arrangements:
  1. Description of oil mist detection equipment and system including alarms.
  2. Copy of the test house report in accordance with the requirements of Test Specification No. 4. See also Vol 2, Pt 2, Ch 1, 13.4 Crankcase oil mist detection system.
  3. Schematic layout of engine oil mist detection arrangements showing location of detectors/sensors and piping arrangements and dimensions.
  4. Maintenance and test manual which is to include the following information:
    1. Intended use of equipment and its operation;
    2. Functionality tests to demonstrate that the equipment is operational and that any faults can be identified and corrective actions notified;
    3. Maintenance routines and spare parts recommendations;
    4. Limit setting and instructions for safe limit levels; and
    5. Where necessary, details of configurations in which the equipment is and is not to be used.
1.4.8 Where engine components are subject to autofrettage, the following information is to be submitted (see also Vol 2, Pt 2, Ch 1, 2.4 Autofrettage):
  1. Drawings and other related documents/information for products to be subjected to autofrettage, including material grade and dimensions.
  2. Details of product quality assurance processes.
  3. Place of manufacture and details of external providers of products subjected to autofrettage.
  4. A report detailing how repeatability and reliability of the autofrettage process is achieved. This is to include the following:
    1. method of autofrettage;
    2. method to control extent of autofrettage;
    3. calibration of the autofrettage system; and
    4. details of how the critical parameters affecting product characteristics are controlled.
  5. Method for recording results and list of data that is recorded.
  6. Finished component and/or system testing.

1.5 Additional submission requirements for naval vessels

1.5.1 In addition to the requirements of Vol 2, Pt 2, Ch 1, 1.4 Submission requirements and Table 1.1.1 Plans and particulars to be submitted, the plans and information in Vol 2, Pt 2, Ch 1, 1.5 Additional submission requirements for naval vessels 1.5.2 and Table 1.1.2 Plans and particulars to be submitted for naval vessels are to be submitted.

1.5.2 Risk Assessment (RA) as required by Vol 2, Pt 1, Ch 3 Requirements for Design, Construction, Installation and Sea Trials of Engineering Systems is to be submitted. The RA is to be carried out in accordance with the requirements of Vol 2, Pt 1, Ch 3, 18 Risk Assessment (RA) and is to include the following associated sub-systems:

  • Starting and stopping.
  • Fuel oil.
  • Lubricating oil.
  • Cooling water (fresh and sea).
  • Air induction.
  • Exhaust.
  • Engine mounting.
  • Control and monitoring.
  • Electrical power supplies.
  • Hydraulic oil (for valve lift).

It is not necessary to consider failure modes relating to the engine components.

Table 1.1.2 Plans and particulars to be submitted for naval vessels

Document For information For appraisal
(X indicates reason for submission)
Control engineering aspects in accordance with Vol 2, Pt 9 Electrotechnical Systems. X
Details of the securing and collision arrangements (see also Vol 2, Pt 1, Ch 3, 3.3 Calculations and specifications 3.3.5 and Vol 2, Pt 1, Ch 3, 5.3 Machinery fastenings to Vol 2, Pt 1, Ch 3, 5.7 Resin chocks). X
Arrangement of interior lighting, where provided. X
Calculations and information for short-term high power operation where applicable. X
Power/speed operational envelope. X
Where it is proposed to use alloy castings, micro alloyed or alloy steel forgings or iron castings:
Details of the chemical composition, heat treatment and mechanical properties. 		X
System Operational Concept covering the Propulsion system, see Vol 2, Pt 1, Ch 3, 3.4 System operational concept. X
System Design Description for engine systems, see Vol 2, Pt 1, Ch 3, 3 Documentation required for design review. X
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