Canship Ugland Limited

Condition Monitoring Categorization/Tracking of Unplanned Maintenance

To Be Discussed
Introduction Tracking of number of occurrences per vessel Tracking of occurrences in accordance with equipment group Tracking of occurrences in according to root cause Actions taken to date How does CUL compare Equipment Inspection Practices

Introduction
In an effort to improve reliability and to make a more structured approach to the up keep of the managed fleet tracking of equipment breakdowns commenced in the latter part of 2007. In order to utilize processes already in place the following categorization was used: To determine equipment category Ships Research Institute Norway (SFI) Group System was chosen as this is part of our planned maintenance system structure. To determine cause of failure DNVs MSCAT methodology was chosen as this is our root cause investigation tool. Our approach also aligned company procedures with one of the TMSA Element 4 best practice guidelines.

Number of Occurrences Per Vessel

The number of occurrences per vessel is monitored in order to evaluate work load onboard comparing with percentage outstanding maintenance.

Tracking of Occurrences in Accordance With Equipment Group

Unplanned maintenance is tracked in accordance with SFI equipment group in order to determine if a particular type of equipment is proving un reliable. When analyzing this sister ships are also compared.

Tracking of Occurrences According To Root Cause

Unplanned maintenance is categorized by root cause in order to determine if training and/or procedure changes are required. During analyzing, vessels with similar equipment are compared to identify common problems.

Actions To Date
Replaced one type of portable gas meters, additional training onboard in correct care of portable gas meters. Included bow loading system training course in matrix for Senior Engineering Officers. Sourced training in correct separator maintenance procedures. Further investigation of mechanical seal failures on pumps in HFO service. Training of ship staff in structural hull inspections. Company training booklet in correct greasing procedures. Sourcing training material in correct methods when replacing ball bearings. Revising maintenance procedures in regards to electrical equipment by making greater use of thermal imaging.

Reliability - How Does CUL Compare?

When comparing Off Hire data CUL compares favorably in all areas apart from reliability of the bow loading system.

Methods and Equipment

Methods
Equipment Unplanned Maintenance Data Performance Monitoring Data Oil Analysis Thermal Imaging Data Megger Readings Critical Equipment Reliability in Service Cost to Maintain

Tools
Calibrated Test Equipment for Pressure, Temperature and Signal Generators for Monitoring Equipment Equipment Performance Data pumps, coolers, etc. Thermal Image Camera Megger Meter Engine Performance Monitoring Equipment Bore scope Vibration Monitoring

Typical Bore Scope

USES
The bore scopes allows the internal inspection of many components without the requirement of disassembly to have a look inside. Access can be through pressure gauge connections or other easily accessible openings. Photographic evidence can be collected to show internal condition.

Applications
Pumps Coolers Tubular Heat Exchangers Pipelines Steam Turbines Internal Combustion Engines Boiler Tubes Engine Turbo Chargers Difficult to see areas within equipment that would normally require disassembly of components to get to the required area.

Ballast Pump

Steam Turbine Gearing

Turbine Blades

Inert Gas Fan

Exhaust Valve Main Engine

Benefits
Inspections can be arranged with normal maintenance as an example the interior of an engine cylinder coincides with the changing of injectors. Equipment does not have to be fully opened for inspection. This saves time, materials, assembly difficulties and provides a record of the internal condition. Predictive maintenance and life cycles can be determined based on more than recommendations but on actual inspection.

Benefits
Downtime is reduced. Reduction in parts consumed as part of normal inspection. Alignment of drive components has not been altered. Integrity of most seals, gaskets and fasteners are not disturbed. Reduces follow up when re-commissioning equipment.

Conclusion
There is much equipment available to the Marine Industry to evaluate the condition of machinery and pipelines to ensure reliability and cost effective maintenance. The approach taken by Canship is to gather data and determine the equipment that does require additional monitoring to ensure reliable, cost effective maintenance without any reduction in the maintenance standards. This has proven to be effective with costs and reliability.

Conclusion
In times of monetary restraints, the decision to spend money to maintain equipment must be balance with the best procedures to evaluate the requirements and benefits of doing so. Evaluation of specific equipment will indicate those which need additional monitoring tools to ensure reliability and also the most suitable tool for the task.

Closing Thoughts
When man was first to go into space, two countries, faced with the same challenge of record keeping in space took different approaches to meet the need. One country spent an unknown amount of money to develop a pen that would write in zero gravity, at any temperature, with an ink that would not be affected by temperature. The other country took a box of pencils. There are ways to address the requirements of maintenance without un-necessary high costs. Select the right test equipment to meet your requirements.

Thank You