UK Flag towards CBM

by Debasis Mazumdar Head of ISM Head of ISO 9001/14001 Certification Maritime & Coastguard Agency HQ UNITED KINGDOM

MCA
Under White Flag in the list of Paris MOU for Port State Control Inspections 1527 Vessels registered under British Flag With 17.11 Million Gross Tonnage
Tanker 9% Bulker 2% Car Carrier 4% Cargo 10%

Offshore/Tug 23% Container 17%

RoRo 9% Passenger 6% Other 20%

New Edition of ISM Code

As you are all aware the new edition of the ISM Code is effective 1 July 2010, and the no. of pages in the new book is nearly double by IMO so its worth a read specially the Guidelines section.39/73 I shall highlight the changes which are linked to Condition Based Maintenance

IMO Resolution MSC.273(85)

Comes into effect on 1 July 2010 No major changes The following minor amendments have been introduced: Definitions 1.1.10 Major non-conformity means an identifiable deviation that poses a serious threat to the safety of personnel or the ship or a serious risk to the environment that requires immediate corrective action and includes or the lack of effective and systematic implementation of a requirement of this Code Objectives 1.2.2.2 establish safeguards against all identified risks assess all identified risks to its ships, personnel and the environment and establish appropriate safeguards

IMO Resolution MSC.273(85)

Masters responsibility & Authority 5.1.5 periodically reviewing the safety management system and reporting its deficiencies to the shore based management Development of plans for shipboard operations 7 The company should establish procedures, for the preparation of plans and instructions including checklists as appropriate, for key shipboard operations concerning the safety of the personnel, ship and protection of the environment the prevention of pollution. The various tasks involved should be defined and assigned to qualified personnel.

IMO Resolution MSC.273(85)

Emergency Preparedness 8.1 The company should establish procedures to identify, describe and respond to potential emergency shipboard situations, and establish procedures to respond to them. Reports and analysis of non-conformities, accidents and hazardous occurrences 9.2 The company should establish procedures for the implementation of corrective action, including measures intended to prevent recurrence. Maintenance of ship and equipment 10.3 The Company should establish procedures in its safety management system to identify equipment and technical systems the sudden ..

IMO Resolution MSC.273(85)

Company verification, review and evaluation 12.1 The company should carry out internal safety audits on board and ashore at intervals not exceeding twelve months to verify whether safety and pollution-prevention activities comply with the safety management system. In exceptional circumstances, this interval may be exceeded by not more than three months. 12.2 The company should periodically evaluate the efficiency of and when needed, review effectiveness of the safety management system in accordance with the procedures established by the company.

Risk Analysis & Safeguard

ISM 1.2.2.2:assess all identified risks to its ships, personnel and the environment and establish appropriate safeguards. Companies to establish Risk Analysis and safeguard risks What is the major risk that could be covered by CBM ????? Answer to the RISK of Machinery Failure is CBM and UK Flag will support this

Some Statistics
No. of lives lost due to safety related accidents/incidents as per IMO records 2002=1308, 2006=1825 Nearly 25% of casualties at sea are caused by machinery failure (IMO) Nearly 50% of accidents on Fishing Vessels are due to Machinery Failure 60% of Machinery Failure takes place immediately after a maintenance activity

Machinery Failure after Maintenance

This is when Predictive Maintenance which is Condition Based Maintenance stepped in. As stone age adage goes: If aint broken why fix it The techniques used for condition based maintenance are: Vibration monitoring Lube oil analysis Thermal imaging Engine performance measurement Ultrasonics

Vibration Monitoring

VIBREX vibration monitoring module Figure 1: Vibration sensor location for online turbocharger vibration monitoring

Thermography in Condition Monitoring

Thermography is a quick surveillance technique for determining the general health of an engineering plant. By detecting the infrared radiation emitted by a body to produce a thermal map of its surface a thermographic camera is an invaluable tool in condition monitoring. The image thus produced is called a thermogram. The temperature variation is indicated in different colours or in shades of grey. It is a very useful condition monitoring aid for both electrical and mechanical equipment when used to identify hot spots (or cold spots in electric circuits). Identifying areas of equal temperatures (isotherms) in the baseline images and detecting variations by subsequent trending can provide very early warning signs of equipment failure. This explores the potential of thermography in monitoring and assessing the condition of machinery on board ships.

Thermal Imaging Survey Aux. Engine Main Switch Board

60.9C

Fault Overheating Investigate cause

23.0C

Condition Based Maintenance

If RISK can be analysed without opening up the machinery and fault rectified avoiding an accident or incident and finally a step to save lifeMaritime & Coastguard Agency would support such an activity through its recognised Classification Societies Many Class Societies are carrying out this risk based approach and issue class notation for condition based maintenance

Accidents & Lessons learnt

Recently on a British Flag vessel there has been a loss of life of a seaman falling overboard due failure of the gangway winch gear box while preparing Gangway to pick up Pilot MAIB Report published July2010 reveal that the gear box has been opened up for survey and boxed up incorrectly by ships crew as there was no proper maintenance manual The accommodation ladder was set free when the hoist winch gearbox failed

Accident on UK Ship
the gearbox had been incorrectly reassembled by the ships crew following maintenance. Factors leading to this error included: the lack of technical information held; an ineffective management system of onboard maintenance

Cause of Death
Damaged ladder

Hoist winch

Damage to Equipment

Oil sump

Intermediate bearing housing

Fragments from the intermediate bearings inner roller race

Lesson Learnt
If CBM was implemented by the Company, then by vibration monitoring & thermal imaging the defects in the gear box could be identified and rectified before hand saving a life. There are so many incidents of Main Engine Crank case explosion after an inspection for faulty box up and hot spot creation, which could have been avoided, if CBM was in place. Many CPP Failures have occurred due to incorrect boxing up after a survey causing severe accidents

To Conclude
Condition Based Maintenance is the way forward UK Flag will support CBM by accepting Class decisions which will help to reach MCA Mission: Safer Lives Safer Ships Cleaner Seas

Thank you for Listening

Any Questions? My Contact details: debasis.mazumdar@mcga.gov.uk Phone: +44 23 8032 9100 www.mcga.gov.uk

Thanks to
MAIB for some report extracts & pictures IMO for statistics used Gopinath Chandroth, CEng, MSc, PhD, MIMarEST for vibration and thermograph in put Seatec Condition Monitoring