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Hatch Cover Seminar Alandia Marine Helsinki dd 27/03/2014 By Walter Vervloesem (FNI) Chairman IMCS Group of Companies Ltd (UK) Man. Dir IMCS Training Academy

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Hatch Cover SeminarAlandia Marine

Helsinki dd 27/03/2014

By

Walter Vervloesem (FNI)

Chairman IMCS Group of Companies Ltd (UK)

Man. Dir IMCS Training Academy

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IMCS Training Academy

27/03/2014 Alandia Marine – Hatch Cover Seminar

W. Vervloesem (FNI)� Chairman of IMCS Group of Companies Ltd (UK) – 19 offices.� MD of IMCS Training Academy� Chairman NI Belgian Branch� Ex Chief Officer (reefer, gen. cargo, container & LPG)� Working as marine surveyor since 1989

Specialist fields:P&I related surveys, Ship inspections (P&I, H&M, S&P, Flagstate), ISM (lead – auditor),Hatch Cover inspections, Containers, Lashing & Securing of heavy lifts.

Publications: major reference works all published by the Nautical Institute� Ship Survey and Audit Companion� Hatch Cover Inspections� Mooring & Anchoring Ships – Vol 2� Co-author of "The Nautical Institute on Command"

Training:Instructor for the SDT-IMCS hatch cover training course since 2001 and working under aconsultancy contract with SDT on development of ultrasound applications in the marineindustry for SDT since 2003

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Agenda

� Back to basics - Loadline issues

� Inspections

� Design issues

� Understanding hatch covers

� Key parts

� Sea & cargoworthiness

� Due diligence

� Applicable rules and conventions

� Inspecting hatch covers

� Hatch cover testing

� Ultrasonic testing (v/s hose testing)

� Workshop27/03/2014 Alandia Marine – Hatch Cover Seminar

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Back to basics

Loadline

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Back to basics

The ship’s loadline….

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Back to basics

….and how to manage it!

27/03/2014 Alandia Marine – Hatch Cover Seminar

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Back to basics

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Back to basics

� Loadline:

� Limit to which ships may be loaded

� Safeguarding life and property at sea

� Loadline = Freeboard = Safety

� Ships have to be “weathertight” in any sea condition

� Openings giving access to ship must be weathertight

� Weathertightness = No water from “weatherside” to enter ship

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Back to basics

Hatch cover leakage:

27/03/2014 Alandia Marine – Hatch Cover Seminar

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Back to basics

� ICLL = Convention = Law

� Hatch covers:

� Strength

� Tightness

� Securing (bearing pads – cleats: explain)

� Other openings

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Back to basics

� Are hatch covers that pass an ultrasonic test weathertight???

NO!!!

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Inspections

� Hatch cover porblems

� Many ships have hatch cover issues

� Leaking & deficient hatch covers affect:

� Ship (stability, sinking, pollution)

� Crew (safety, injuries)

� Cargo (wet damage, fire, …)

� Vehicles for disaster

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Inspections

�Despite inspection by

� Class

� Flagstate

� Portstate control

�H&M

�Audits

� P&I

�Why so many hatch cover problems?

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Inspections

� Lack of understanding of hatch cover basics

� Failure to understand that hatch covers are fine pieces of engineering

(need for detailed inspection, testing and proper repairs)

� Proper maintenance

� Correct operation

� False economies

� Improper/temporary repairs (passing inspection)

� Cheap repairs, non-original spare parts

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Inspections

� Frequently heard comments & questions when making remarks

and in case of claims:

� Ship just in DD

� No problems during PSC

� No damage to cargo last voyages

� Class & Statutory documents valid

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Inspections

� Role of class throughout history?

� Proof of seaworthiness

� Reliability

� Confidence

� Condition for cargo underwriters.

� Facts & figures→more problems with hatch covers than we know

� Owners still ultimately responsible

� Seminar: improving maintenance and understanding

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Design issues

�Many different design factors to be considered

� Hatch way dimensions

� Available deck space/stowage height for stowing the panels

� Required coaming height, extent of opening

� Type of operation (opening and actuating mechanisms, available power,

required opening/closing time, available crew, ...)

� Repair possibilities (shore specialists/ship’s crew, spare part availability)

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Design issues

� Carriage of cargo on hatch covers

� Required degree of tightness

� Cost (min – max scantling, steel price,...)

� Required/Max. panel weight (ship’s gear, shore gear,...)

� Construction type (open web, double skin,.. ) & required

fittings (cleats, packing,...)

� Trading pattern (warm/cold, tropical rainshowers/speed of

closing)

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Design issues

Hatch types categorized according to:

� Shape of panels

� Method of construction

� Operation & specific features

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Understanding hatch covers

27/03/2014 Alandia Marine – Hatch Cover Seminar

Weathertightness:

ICLL 1966:� "The means of securing weathertightness shall be to the satisfaction of the

Administration. The arrangements shall ensure that the tightness can bemaintained in any sea condition and for this purpose tests for tightness shall berequired at the initial survey and may be required at periodical surveys and at annual inspections or at more frequent intervals") (Reg. 16-4).

� "Weather tight means that in any sea conditions water will not penetrate into

the ship“ (Reg. 3-12).

� Watertight = water will not be passing through the sealing arrangements from

both directions across the seal

� Weathertightness ≠ Watertightness

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Understanding hatch covers

Watertightness

� “Water will not be passing through the sealing arrangements from both

directions across the seal” (under a certain head of pressure)

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Understanding hatch covers

Cookie box principle:

� Box with coverlid = rigid

� Box without coverlid = flexible

� Ship is like box with holes in coverlid = flexible

� Hatch covers are strengthened panels ≠ flexible

� Movements at sea cause the ship to bend and flex

� Panels do not move in unison with ship

� Hatch covers have to be flexibly mounted

� Making system too rigid → failure

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Understanding hatch covers

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Understanding hatch covers

Panel movements in 3 directions:

�Fx: Longitudinal

�Fy: Transversal

�Fz: Vertical

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Understanding hatch covers

� Loadline & Weathertightness:

� Keep water out in any sea condition and proper securing of hatch covers

(Loadline)

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Understanding hatch covers

Weathertightness:

� How to achieve weathertightness:

� 3 safety barriers

� Panel plating

� Sealing system

� Drain

� 3 types of tightness:

� Weathertight

� Partly weathertight

� Non-weathertight (see IACS Rec 14)

� PWT/NWT subject to class approval

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Understanding hatch covers

27/03/2014 Alandia Marine – Hatch Cover Seminar

Packing rubber:

� Design compression

� Contact ≠ compression

� Ultrasonic testing = info on compression

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Understanding hatch covers

� Packing rubber discard criteria: let’s talk mm

� Rubber size: 70 x 40

� Design compression: 25% of thickness = 10mm

� Discard criteria: 50% of design compression = 5mm

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Key parts

� Damaged packing rubber = symptom, not cause!

� Hatch cover key parts:

� Bearing pads (steel to steel contact)

� Locators/stoppers

� Packing rubbers

� Operation mechanism

� Drain system

� Hatch panels

� Compression bar

� Securing mechanism

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Key parts

� Hatch covers are fine pieces of engineering and delicate pieces

of equipment

� Tolerances/clearances and limits are in range of mm.

� Lack of, or improper, maintenance will quickly affect hatch cover

condition and operation

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Sea- & Cargoworthiness

� Seaworthiness:

� Technical:

� Construction

� Class & statutory certificates

� Cargo

� Is vessel suitable for cargo and cargo suitable for ship

� Cooling – ventilation – cleanliness – hatch cover tightness

� Cargoworthiness = part of seaworthiness

� Voyage

� Bunkers – provisions – crew

� Spare parts

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Due Dilligence

� Due diligence = taking good/reasonable care

� In case of a claim, how to assess if due diligence was

exercised?

� Could a reasonable inspection have revealed the defect?

� If so, would a diligent ship owner have carried out repairs?

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Due Dilligence

� In case of cargo claims, hatch covers will be inspected in detail to

ensure that they were in good condition at the outset of the

voyage & that due diligence was exercised

� Hatch covers made to withstand rigours of ocean voyage without

foam and ramnek!

� Extraordinary movements/distorOon > design compression →

water in drain → onto cargo = covered by insurance

� P&I mutuality → Due diligence

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Due Dilligence

Conclusion:

� In order to avoid that the due diligence aspect can be argued, ensure that

hatch covers are able to withstand detailed scrutiny

� Easy for qualified surveyor to find evidence of poor maintenance/lack of due

diligence

� This evidence may also indicate/prove non-compliance with rules/regulations

(statutory issues)

� How to prove that due diligence was exercised? (Workshop item)

� Consider inspection by third part at regular intervals

� Leaking hatch covers – think about legal issues

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Applicable rules & conventions

� Some applicable conventions, regulation and rules related to

hatch covers:

� SOLAS

� Loadline

� MARPOL

� CSWP

� ILO/MLC

� Class

� ISM & SMS?

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Applicable rules & conventions

� Class: Seaworthiness

� Technical and strength aspects

� Statutory issues (when appointed by Flag state)

� Class + Statutory requirements = SAILING

� Industry: Contract for transporting cargo

� Contract of affreightment (charter party)

� Owner to provide seaworthy ship (incl. hatch covers)

� Most claims not for failure to provide a technically fit ship, but for failure

to comply with cargoworthiness requirements (diligence) which are part

of seaworthiness

� Class+Statutory+Industry requirements = TRADING (= $$$$)

� Class and Industry have different priorities and different

approach re-hatch cover inspections/testing27/03/2014 Alandia Marine – Hatch Cover Seminar

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Inspecting hatch covers

� Inspection comprises:

� Visual inspection:

� Structural condition

� Clearances/wasteage

� Maintenance (lubrication, painting,....)

� Due diligence aspect

� Testing:

� Hose test

� Ultrasonic test

� Visual inspection or testing alone is not sufficient to conclude that

hatch covers are weathertight, in good condition and that due

diligence has been exercised.

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Visual inspection: Main problems found:

38

Inspecting hatch covers

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Hatch cover testing

� Testing - Class point of view:

� Hose test (class method): sufficient to identify big leaks which may affect

seaworthiness/safety of ship and crew (check for water in hold)

� Ultrasonic testing considered as alternative testing method, subject to

IACS UR Z17 being observed

� Under IACS UR Z17, class will appoint a service supplier (but have not

attended training themselves)

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Hatch cover testing

� Testing - Industry point of view:

� Apart form ship and crew, also cargo needs to be protected to satisfy

contractual obligations

� Wetting damage to cargo should be avoided (30% of dry cargo claims

every year)

� Ultrasonic testing is preferred/required for testing hatch covers as it

provides enhanced security

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Ultrasonic testing

� Ultrasound testing is generally not well received by ship

owners/managers.

� Why?

� Lack of understanding of how ultrasound testing works

� Because there is a tendency to believe that ultrasound testing is too strict

and that no vessel can pass an ultrasonic test.

� Ultrasonic tests: how does it work?

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Ultrasonic testing

� How does it work?

� Receiver & transmitter

� OHV = reference value

� Leaks are compared against OHV

� Packing rubber

� Irregular (air/ultrasounds can pass)

� Contact & compression

27/03/2014 Alandia Marine – Hatch Cover Seminar

Ultrasonic W aves Generation

••

Sherlog Multi - transm itterBi-sonic mode 39,2 kHz - 39,6 kHz

Tanktop

Hatch Cover Hatch Cover

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Ultrasonic testing

� Difference between hose test and ultrasonic test:

� Hose test → contact

� Ultrasonic test → compression (Demo)

� Advanced loss of compression will result in a “no- contact” situation

when at sea, allowing water to pass through the packing

rubber/compression bar interface.

� If you know that you still have compression on the packing rubber when

in port, you know that the packing will be able to compensate for relative

movement between panels and coaming and maintain contact with the

compression bar even if the vessel flexes in a seaway.

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Ultrasonic testing

� Why is ultrasonic testing providing more safety than a hose test?

� Water entry with hose test indicates lack of contact

� Hose test: only water entry - compression can not be measured

� Hose test goes primarely for cracks/defects that affect safety, but small

leakage in rubber no problem (still drain to prevent water from entering

the ship’s hold)

� US test: compression - US fail/pass criteria = 10% OHV

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Ultrasonic testing

� Ultrasonic testing: advantages:

� Indication of compression (= enhanced safety)

� Pin point accuracy (efficient & economic repairs)

� Testing with cargo in hold

� No risk for pollution

� One man operated, no interference with operations

� No weather/temperature restrictions

� No need to remove welding equipment (DD repairs)

� Reliable/repeatable results

� Tamper proof print out of test results (ship’s history & due diligence

(evidence)

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Ultrasonic testing

� Ultrasonic testing: any drawbacks?

� Non-type approved equipment being used

� Used by non-qualified operators

� Non-calibrated

� Class not suficiently aware of ultrasound testing (use, interpretation of

results and training)

� Ultrasound testing: requirements IACS UR Z17:

� Class type approved equipment

� Qualified operator (2,5 day training course available in line with IACS Z17

requirements)

� Calibrated equipment

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WORKSHOP

“We carried out a hose test yesterday (with very high pressure),

and there were no leaks in the holds. Now an ultrasonic test

reveals tightness problems. How is this possible?”

• Hose test = contact

• The higher the pressure, the less chance for leakage iwo the cross joints

• Ultrasonic test = compression

• With hose tests, the first thing to do is to check if there is no water leaking from the drains.

• If water leaks from drains, then there is a problem with the packing rubber (or other defects)

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WORKSHOP

“Hatch covers can be tested with the hatch covers closed, but

without the cleats”

• Hatch covers have to be closed and battened down.

• Panel weight alone is sufficient for design compression

• Battening of the hatch covers is not only necessary to ensure that hatch covers are properly

closed, it also gives an indication of:

• Proper closing & closing sequence observed (cleats/wedges,…)

• Hatch panels properly aligned in seagoing position

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WORKSHOP

“The hatch covers are leaking (or failing an ultrasonic test), so we

will tighten up the cleats with a key and a piece of pipe”

• Hatch covers are resting on bearing pads, so extra tightening will not improve tightness

• Excessive tightening makes the securing system too rigid and will cause failure

• Saying so is clear sign of lack of understanding of hatch cover basics

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WORKSHOP

“The hatch covers are leaking, so we will apply Ramnek tape”:

• Hatch covers are type approved (no need for extra sealant if well designed)

• Sealing tape is a plaster on a wooden leg and indicates that the ship’s staff knows that hatch

covers are leaking.

• Ramnek may enhance corrosion, block side drains, become damaged/torn

• In case of a claim, it will be up to the ship to prove that hatch covers are tight and well

maintained, which is difficult.

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WORKSHOP

“We have cargo damage because of leaking hatch covers. What

documentation should we present to the P&I surveyor:· Maintenance logs & test reports

· Work schedule

Reports/evidence of corrective action

. Work specifications

. Orders for spare parts

· Accounts

· Standing instructions

· Reports and correspondence

· Logbook entries

· Hatch patentee manual

· Valid (relevant) certificates

· Evidence of planning voyage.

· Proof of operating the ship in a good/seamanlike manner during the voyage

(C/C, RPM) (part of documentation to be on board as part of Owner’s SMS)

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WORKSHOP

“The hatch covers were found damaged/leaking so we instructed

the master/agent to look for the cheapest repair shop in the area”

• Ensure that hatch covers can pass an ultrasonic test after repairs

• Check that repairs are carried out in line with good industry practice

• Check that repairs are documented in the ship’s system

• Advise class/flagstate

• Check that original spares are used and replenish spares after repairs.

27/03/2014 Alandia Marine – Hatch Cover Seminar

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27/03/2014 Alandia Marine – Hatch Cover Seminar