Marine Repair Fundamentals

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Courtesy of Liquefied Gas Carrier- Safety and operational matters Courtesy of Liquefied Gas Carrier- Safety and operational matters. MEMBRANE DESIGN – GAS TRANSPORT TECHNIGAZ (GTT) –GT96 http://www.liquefiedgascarrier.com/LNG-vessel-construction.html

Courtesy of DYNAMICS – General Ships and Heavy Industry Repairs http://dynamicco.com/surface-preparation

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Cargo Handling Equipment A research unveils that every year more than 10,000 containers fall overboard and spill their cargo into the ocean; 50 % of this happens due to negligence in the cargo handling.

Definition Maintenance is a set of organized activities that are carried out in order to keep an item in its best operational condition with minimum cost. The combination of all technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function.

activities of maintenance function could be either repair or replacement activities, which are necessary for an item to reach its acceptable productivity and operational condition. these activities should be carried at minimum possible cost

Added/additional cost to operation Old Thought Added/additional cost to operation Limited to fixing the unit once it breaks because it was the cheapest alternative

New Thinking One of the most important functions that contribute to the success of the business Required by Law

Maintenance Objectives Maximizing production and operation or increasing facilities availability at the lowest cost and at the highest quality and safety standards Reduce breakdowns and emergency shutdowns Optimizing resource utilization

Maintenance Objectives (cont’d) Reduce downtime Improve spares stock control Improve equipment efficiency and reduce scrap rate

Maintenance Objectives (cont’d) Minimize energy usage Optimize equipment useful life Provide reliable cost and budgetary control Identify and implement cost reductions

Types Preventive (routine) Improvement Corrective Breakdown Emergency Planned Maintenance (Proactive) Preventive (routine) Improvement Corrective Unplanned Maintenance (Reactive) Breakdown Emergency

Paragraph 10.1 of ISM Code states “ The company should establish procedures to ensure that the ship is maintained in conformity with the provisions of the relevant rules and regulations and with any additional requirements which may be established by the company”

One of the primary responsibilities of a ship owner and ship management company is that the ship hull structures, machinery and equipment are maintained and operated in conformity with the applicable rules and regulations and any relevant additional requirements, procedures, and standards established by the Company and Regulatory Bodies

Responsibility starts from the top Management of the Company who should be committed to direct efforts, resources and investments in order to ensure that their ships are properly maintained and operated by qualified and competent crew both ashore and on-board

Planned Maintenance System Merchant shipping has undergone a great transformation over the past three decades Shipping market is highly competitive which coupled with high crewing cost and fuel costs leads to high operational costs Paramount factor involve in vessel operation is the Maintenance Cost

Planned Maintenance System Manage/keep this cost to a minimum Preventive – Planned Maintenance Planned Maintenance – equipment is opened up for routine maintenance after a specified time interval Section 10.3 of ISM Code states that the …… “Company should identify equipment and technical system the sudden operational failure of which may result in hazardous situation.”

Maintenance Onboard Efficient maintenance can help with prolonged life and favorable outcome Machine up to date and is smooth running condition Avoid stoppages and to maintain charter party speed and consumption requirement

In a ship’s engine room, where the maximum machines are located, engineers and crew carry out the maintenance for safe and efficient operation. Each machine onboard requires maintenance which has to be carried out at regular interval of time

Maintenance requires manpower and time It is important to plan the maintenance of the machinery in advance so that the machinery can be overhauled and maintained properly Efficient planning and adequate usage of equipments is the key to productive maintenance

Types of Maintenance Procedures Corrective or Breakdown Maintenance Maintenance is carried out once the machinery breaks down. This is not a good method as situation may occurs wherein the machinery is required in emergency. Advantage - machinery parts is used to its full life or until it breaks. This might get costly as during breakdown several other parts may also get damaged

Types of Maintenance Procedures Preventive or Schedule Maintenance System Known as Planned Maintenance System (PMS). Carried out as per the running hours like 4000 hrs, 8000 hrs etc or by the calendar interval like 6 monthly, yearly etc. of the machinery. The maintenance is carried out irrespective of the condition of the machinery. The parts have to be replaced if it is written in the schedule, even if it still can be used

Types of Maintenance Procedures Condition Maintenance System In this system the machinery parts are checked regularly with the help of sensor etc. The condition of the machinery is accessed regularly and the maintenance is done accordingly. This system requires experience and knowledge as wrong interpretation may damage the machinery and leads to costly repairs which may not be acceptable by the company

A Maintenance Plan is therefore followed by every shipping company to ensure that the ship machinery maintain a particular standard of operation and safety. A Maintenance Plan is an imperative element of ship’s routine operation and also forms an integral component of ship’s maintenance mechanism

The main objective of a maintenance plan is to make sure that the work is done in the least possible time with utmost efficiency and at optimum cost

Maintenance Plan To carry out a successful maintenance plan, among others, the following steps are considered in order to form a strategic approach

Identifying the problem Establishing the cause Proposing a solution Evaluating solution Implementing the solution Evaluating effectiveness Solving

Maintenance Plan The shipping company must consider the following to develop maintenance procedure for a particular ship: Manufacturer’s maintenance guidelines and specifications. Equipment history (failures, defects, damages, and remedial actions) Guidelines in the ISM Code

Maintenance Plan Age of the ship Third party inspection Consequences of failure of equipment on safe operation of the ship Critical equipment and system Intervals of maintenance

Maintenance Plan Following steps are included in the approach for maintenance procedure: Establishment of maintenance intervals Methods and frequency of inspections Specification of the type of inspection Type of measuring equipment to be used

Maintenance Plan Establishment of appropriate acceptance criteria Assignment of responsibility for inspection activities to appropriately qualified personnel Clear definition of reporting requirements and mechanism

Maintenance Plan Maintenance interval forms the most important aspect of the maintenance plan. The maintenance interval decided in the plan is based on the following factors: Manufacturers recommendation and specifications Practical experience of the engineers in operation and maintenance of ship and its machinery

Maintenance Plan Historical trends obtained from the results of routine inspections, and in nature and rate of failures The use of the equipment – continuous, intermittent, standby or emergency Practical and operational restrictions Guidelines for intervals specified as part of class, convention, administration and company requirement