What is Maintenance?

The technical meaning of “maintenance” involves functional checks, servicing, repairing or replacing of necessary devices, equipment, machinery and supporting utilities in industrial and residential installations.

Objectives of Maintenance

• Minimize loss of productive time
• Minimize repair time & cost
• Keep productive assets in working condition
• Minimize accidents
• Minimize total maintenance cost
• Improve the quality of products

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Author: Md Taifur Rahman

Dangers of entering an enclosed space:

1. Toxic atmosphere

A toxic atmosphere may cause various acute effects including impairment of judgment, unconsciousness and death.

2. Oxygen deficiency

     Can be lacking for:

• Displace of air by another gas
• Various biological processes or chemical reaction
• Absorption of air

3. Flammable or explosive atmosphere

A flammable atmosphere present a risk of fire or explosion. Such atmosphere can arise from the presence of flammable liquid or gas or suspended combustible dust in air inside the enclosed space.

4. The flowing dangers may present too like:

• Oxygen enrichment
• Flowing liquid or free flowing solids
• Excessive heat.

Implementation of “Permit-to-enter” system for entry into enclosed spaces:

• Before entering an enclosed space must have a valid permit
• Entry into enclosed space check list must be followed according the SMM manual
• The space must be segregated by blanking off or isolation
• The space must be properly ventilated.
• Proper and practicable atmosphere testing must be carried out.
• Frequent atmosphere check during work must be carried out.
• Must have a continuous Ventilation during work
• Rescue team and related equipment’s including SCBA to be kept ready
• Must have a designated person at the entrance of enclosed space to alert for help.
• Designated person should ensure the entry persons wearing proper PPE with SCBA
• The duty officer in Bridge/ CCR/ECR should be known about the entry
• A reliable means of communication should be agreed and tested.
• In case of failure of ventilation system the person should leave the place immediately.
• There has to be a system to record entry and leaving enclosed space
• A reporting time interval from enclosed space should be agreed.

After completion of work designated person should ensure entry persons and related equipment’s are safely withdrawn.

Author: Md Taifur Rahman

Preparation:

• Toolbox meeting carried out.
• Carry out a proper risk assessment and work permit taken
• Enclosed is space entry permit to be taken and enclosed space entry procedure to be followed
• Inform bridge and put warning notice at ECR
• Block the starting mechanism and stop the L.O pump
• Open indicator cocks and engage turning gear
• Propeller clearance taken
• Turning gear must be operated only in remote mode
• All personnel involved should not have any object in their pocket
• Instrument/tools to be used should be checked and counted

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Author: Capt. Kamal Ahmed.

I was once hired by my client to get the approval for loading by the Port Warden in the 2^nd loading port as the actual healing moment was more than the permissible healing moment. The situation was as follows:

1. The original stow plan which was sent to the shipper by the charterer for loading Port A+ Port B was total for 65,700.00 M/T.
2. Cargo for loading as per shippers request in the beginning was:

• Lot 1 –  minimum /maximum 27 000 M/T for  discharge port A
• Lot 2: Minimum 30000 M/T for discharge Port B , Minimum 6600 M/T   for discharge port C,
• Total of 63600 M/T

3. In the stowage plan which the Master had sent for loading was “64,453.202” M/T. The Master mixed Lot 1 & Lot 2 in hold no 7, which cannot be done as lots have to be separated naturally, and not separated artificially. The Master’s explanation was that the change of the stow is done in order to satisfy the stability requirements as per the port warden at the 1^st load port. The vessel was not satisfying the shipper’s requirements for natural separations of Lot 1 and Lot 2.

The task consisted of the vessel taking the cargo. As per preliminary stow plan 65 700, Lot 1 and Lot 2 which had to be separated naturally. In the same plan, the vessel had to be stable in the 2^nd load port as well as in the 1^st, 2^nd & 3^rd discharge port.

The main challenge was that the vessel had a draft restriction of 12.80 M in the first discharge port.

We faced the following problems in preparing the grain stability form for the Port Warden:

The grain calculation has to be carried out with an untrimmed end as the loading with a trimming machine (Trimmed End/Grain Stability Booklet) is very expensive.

With arrival draft of 12.80 M at the 1^st discharge port, the bending moment was about 120% with natural separation with cargo 65,700.00 M/T. We tried to minimize the bending moment at less than 99%, but the draft was more than 13.4 M at 1^st port of discharge. The actual healing moment was more than the permissible healing moment.

We tried our grain stability calculation with 6500 M/T of Ballast Water in After Peak Tank (100% full), No. 5 DB Tank (Port + Starboard, 100%), No. 4 DB Tank (Port + Starboard, 100%), No. 3 DB Tank (Port + Starboard, 50%), the actual Healing Moment was less then Permissible Healing Moment, Bending Moment was less than 99% but the draft was 14.5 M aft.  We proposed to the Port Warden that 6500 M/T of Ballast water has to be pumped out at the anchorage at the 1^st discharge port.  The Port Warden agreed as the calculation met all the conditions, with a draft of 12.80 M.

In order to load the grain, the Chief Officer has to consider the following points:

• If the vessel loading up to winter or summer marks
• If the vessel having a draft restriction at loading or discharge port
• If the vessel loading minimum or maximum quantity
• If the actual healing moment were more than the permissible healing, the Chief Officer should consider keeping the smaller holds slack where healing moment for the slack compartments will be less. Also taking Ballast water at loading port may reduce the actual healing moment. 

In addition, the Chief Officer needs to ensure to:

• To comply with regulations mentioned in SOLAS CHAPTER VI 1974.
• Always calculate the healing moment with untrimmed ends as the trimmed ends is cost effective.
• That the Loading Manual in some vessels provides the healing moments in trimmed ends and that there is no indication of Untrimmed Ends. If the forward and after part of the cargo spaces are Hopper type, then the grain stability can be done considering “Untrimmed Ends”.
• Secure and seal those bulkheads to check if they are made grain tight and remain grain tight during the voyage, for smaller vessel where the forward/aft bulkheads are movable, Reference Bulletin No. SSB 02/2015 issued by “Transport Canada”, dated February 24, 2015.
• Pay particular attention to the stowage factor of the grain. If the situation permits, the slack holds are the last holds to complete.
• Refer to Bulletin No. 03/2002 issued by “Transport Canada” regarding “Deviation from the Load Conditions and Limitations given in the Approved Loading Manual. The vessel’s structural integrity has to be always maintained. Block loading refers to stowage of cargo in a block of two or more adjoining holds – with holds adjacent to such blocks remaining empty. To avoid overstressing the hull structure in the part loaded condition, careful consideration must be given to the amount of cargo in each laden hold and the anticipated sailing draft. The Bending Moment and the Shearing force (Harbor & Sea Condition) in all stages of loading and during the voyage to be within the permissible limits.
• That the loading computer of the vessel has to be “Certified by the Classification Society”.
• That the hold bilge pump & water ingress system has to be in operational condition. This is one of the main requirements of the Port Warden.
• While preparing the Grain Stability Calculation, it is advisable for filled compartment to take maximum trimmed volume and healing moment for untrimmed ends for particular compartment.
• To take “Maximum KG and Free Surface Moment” for compartments filled with liquid.
• While preparing loading sequence the number of Loader with loading rate should be taken into account.

The points mentioned above are pivotal when loading grain and preparing a grain stability form so that it gets an approval for loading by either the Port Warden or a NCB/AMSA surveyor.

Image Credit:  www.rbrodarstvo.com

Preparations:

Dry docking survey is to be done every 2 ½ years interval , 2 times in 5 each year cycle , called annual docking and special docking survey. Special survey is carried out every 5 years interval.

As a Chief Engineer of a vessel , he must study the time of  dry docking due , verify annual or special , and  prepare documents & defect list to be repaired , at least 3 months priority for easy and efficient supports from ship company.

Preparation of Documents:

• The necessary plans , drawings , instruction manuals , service records of previous docking to be collected and kept ready . Copy of plans and drawing to be sent to dockyard on request.
• List and intend the followings to be supplied in time
• Needful machinery spares repair materials for ship staff’s job
• Paints
• Collect and keep ready for special tools and devices
• Issued needful instructions for safety , fire precaution and pollution prevention.
• Issue assignments for the work to be done before entering dry dock and to be undertaken by E/R staffs under 2nd Engineer supervision.

Repair List

A.  Repair list to be provided as:

1. Works to be done by yard
2. Works to be done by ship staffs

B.  The following dock yard repair items to be mentioned details with their specifications as follow:

• Sea chest and grids      – Location , No. of Zinc anodes fitted.
• Sea suction valves         – Location ,No. of valves , Types , Material , Dimensions
• O/B Discharge valves    – Location ,No. of valves , Types , Material , Dimensions
• Piping repairs                – Location , Material , Size , Length , No. of bends
• Structural Repairs          – Frame No. , Dimensions and scantlings , Class of steels
• Machinery Repairs         – Maker’s name , Type and Model , Nature of repair
• Machinery Survey          – Class , Due date
• Under water potion:

1. Rudder         – To measure pintle clearance , check locking arrangement
2. Propeller      – To fair up if any distortion and defects , to polish and lacquer
3. Rope guard  – To open and check , renew if necessary
4. Stern tube    – Wear down to be measured , check simplex sea
5. Tail shaft      – To withdraw  if special survey .

C.  During docking Chief Engineer must attend all Class Surveyor inspections .

D.   Discuss and arrange with Ship Repair Manager to harmonize work program between yard and ship staff, always regarding safety of the ship and lives.

E.  Alternations and additional works may occur during the course of repairs. If any, Chief Engineer should make additional repair list. Attending Superintendent or owner representative will issue order to shipyard.

Jobs for Engine room staff:

Engine room staff to be organized and assigned for the jobs to be done by dockyard as follows:

• To mark and labeled dock yard repair items.
• To show location of repair items to dock yard crew and check their work assessment . To co-operate in some places. ( Drain of water to correct tank etc )
• To check and record measurement taking for Rudder pintle clearance and stern tube wear down .
• If repair works for rudder , propeller , tail shaft withdrawing , stern tube repair and renewal shaft seal , provide an Engineer and crew to check and note down the work done by dockers. C/E himself require to be stand by there.
• Assigned an Engineer for leakage test for stern tube seal .
• To check correct numbers and position of zinc anodes fittings . Inspect to uncover them before undocking.
• To check correct use of material fitting , sizes and dimension.
• To note daily work done by dock yard and enter to Chief Engineer log.
• To keep fire watch where the hot work take places.

Engine room staffs to be organized and assigned for the jobs to be done by themselves as follows:

1. Works to be done before docking procedures must be carried out as follows

• Collection of  special tools, hand tools , marks and keep ready
• Label tag the repair items
• Cleaning of E/R tank top & bilge wells , Clear drain tanks.
• Take M/E crank shaft deflection and recorded.
• Test and keep ready emergency light , generator , emergency air compressor, emergency fire pump.
• Prepare cooling water connections for fridge and air conditioning plant
• Prepare shore power supply connection
• Topping up F.O tanks and Record all tanks’ sounding.
• Pressed up air bottles and tight shut.
• Shut down the boiler properly.

2.  Before entering dry dock , explain procedures and assigned duties. ( Times recording , Diesel Generator stopping , Shore power and cooling water connection etc)

3.  The following works to be assigned and distributed among engine room staff in group for supervision:

• Valves from bilge and ballast system , cooling water system , steam line and air lines…. to be overhauled.
• Waste & corroded piping to be rectified as necessary.
• Necessary coolers to be cleaned.
• Scheduled maintenance to be done, if any .
• C.S.M survey items to be done , if any.
• E/R cleaning and painting.

4.  Discuss with 2nd Engineer in every mourning regarding work progress.

5.  To enter all daily work done by themselves in Chief Engineer log.

6.  Instructions and check lists to be issued for undocking procedures , to inform abnormal condition.

7.  Provide fire stand-by duty day and night.