TOPIC 4A-Shipboard

Maintenance and Repair

I-Core Principles & Safety Protocols of Shipboard
Maintenance
Lockout/Tagout (LOTO) - The Foundation of Safe LOTO Philosophy
Maintenance -is not merely a procedure; it's a philosophy of safety. It's about creating
LOTO -is a critical safety protocol aimed at protecting personnel from an absolute barrier between personnel and hazardous energy sources. It
hazardous energy during equipment maintenance. It serves as a encompasses electrical, hydraulic, pneumatic, thermal, and mechanical
comprehensive process that ensures an absolute barrier is created between energy.
workers and energy sources, minimizing the risk of accidents.
Core Principles & Procedures

Preparation Notification Shutdown Isolation

Identify energy sources using equipment manuals Inform affected personnel before initiating the Safely follow the manufacturer's guidelines for De-energize circuits, close valves, and block
and schematics. process.
Loading… shutting down the equipment. moving parts.

Lockout/Tagout Application Energy Verification Release from LOTO

Apply individual locks and tags to each isolation Test for the absence of energy using appropriate Conduct post-work inspections, remove tools,
point. tools. inform personnel, and ensure the equipment is ready
before removing locks/tags.
Legal & Regulatory Context
OSHA (Occupational IMO (International
Safety and Health Maritime Organization)
Administration)
In the United States - Detailed Provides guidelines for maritime
under standard 1910.147, safety, including energy isolation
emphasizing the control of protocols.
hazardous energy during
servicing.

Local Regulations
Many countries have their own versions of LOTO regulations tailored to
industry-specific needs.

LOTO is mandated by various regulations (e.g., OSHA, IMO guidelines). Failure to

comply can result in severe penalties.
 Key Elements of LOTO
Types of Hazardous Energy Critical Tools for LOTO

• Electrical: Live circuits or stored electrical charges. • Lockout devices (e.g., padlocks, valve covers).

• Loading…
Hydraulic and Pneumatic: Pressurized fluids and gases powering • Tagout devices (e.g., warning tags with clear identification).
machinery.

• Mechanical: Moving parts, stored tension in springs, or gravity- • Test equipment for energy verification (e.g., multimeters for
driven components. electrical circuits).

• Thermal: Hot surfaces or liquids, including steam.

• Chemical: Reactive or flammable substances.

Training & Awareness
Workers involved in maintenance must be trained on LOTO procedures to ensure safety and compliance.

Recognizing Energy Hazards Understanding LOTO Devices Regular Refresher Courses

The foundation of safety begins with proper Training includes proper application steps for Scheduled training sessions ensure continuous
identification of potential energy sources in various lockout/tagout devices used in marine adherence to protocols and knowledge retention
shipboard equipment. environments. among crew members.

Training should be comprehensive and ongoing, with practical demonstrations reinforcing theoretical knowledge to maximize safety during maintenance
operations.
Toolbox Meeting
Toolbox meeting (also known as a safety briefing or pre-task meeting) -is a short,
focused discussion held among the crew or team before the commencement of a
specific task or operation. Its primary purpose is to enhance safety, ensure clear
communication, and address potential risks associated with the task at hand.
Key Objectives of a Toolbox Meeting

Identify Hazards Review Procedures Ensure Readiness Promote Communication

Discuss potential risks and dangers Go over the steps of the task, ensuring Verify that all necessary tools, Encourage team members to ask
specific to the operation (e.g., working all crew members are familiar with the equipment, and protective gear (like questions, clarify doubts, and voice
at heights, handling cargo, or navigating plan and their individual helmets, gloves, or harnesses) are in concerns.
confined spaces). responsibilities. good condition and available.

Address Emergency Protocols

Discuss what to do in case of an

emergency, including evacuation routes
or first-aid measures.
When Toolbox Meetings are
Held
1 Before starting high-risk tasks
For example, mooring operations, lifting heavy loads, or engine
maintenance.

During significant changes in tasks or working

conditions
For example, weather changes, equipment issues.

At the start of each shift

To align the team and reinforce safety culture.
II- SAFETY PROTOCOLS
Respiratory Protection
Consider the type of hazard (dust, fumes, gases). Use appropriate cartridge filters or
self-contained breathing apparatus (SCBA).

Hand Protection
Select gloves based on the chemical or mechanical hazards. Nitrile gloves for oils,
leather gloves for welding, etc.

Eye and Face Protection

Face shields for grinding, welding helmets for arc welding, and safety goggles for
chemical splashes.

Fall Protection
Harnesses, lanyards, and lifelines for working at heights. Inspect equipment regularly.
Confined Space Entry - Managing Invisible Dangers

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Hazard Assessment Atmospheric Testing Entry Permits - Formal Rescue Procedures -
Precision is Key Authorization Preparedness is
Before entry, conduct a thorough
Paramount
hazard assessment. Identify Use calibrated gas detectors to Entry permits should include:
potential hazards (oxygen measure oxygen levels, Authorized entrants, Entry Have a trained rescue team and
deficiency, toxic gases, flammable flammable gas concentrations, supervisor, Hazards identified, appropriate rescue equipment on
vapors). and toxic gas levels. Record Control measures, Emergency standby. Practice rescue drills.
readings. procedures.
 Hot Work Permits - Controlling Ignition Sources
Fire Prevention Measures Permit Content

Proactive Steps: Hot work permits should include:

• Cover or remove flammable materials. • Location of hot work.

• Use fire blankets to contain sparks. • Type of hot work.

• Have fire extinguishers readily available. • Fire prevention measures.

• Assign a fire watch for a specified period after hot work is • Authorized personnel.
completed. • Permit validity period.
Electrical Safety
Arc Flash Hazards Grounding and Bonding
Understand the dangers of arc flash. Ensure proper grounding and
Use appropriate arc flash PPE. bonding to prevent static electricity
buildup and electrical shock.

Electrical Testing Equipment

Use calibrated multimeters, insulation testers, and other testing equipment.
Chemical Safety - Handling Hazardous Substances
Responsibly

Safety Data Sheets (SDS) Chemical Storage Spill Response

Provide detailed information on chemical Store chemicals according to their Have spill response kits and trained personnel
hazards, handling, storage, and emergency compatibility. Segregate incompatible available. Follow proper spill cleanup
procedures. chemicals. procedures.
 III. Routine Maintenance and Repair Procedures FOR
COMMON SHIPBOARD EQUIPMENTS
Pumps (Centrifugal) - Maintaining Fluid Flow Advanced Troubleshooting:

Detailed Maintenance: • Hydraulic Institute Standards -Refer to Hydraulic Institute standards

for pump performance and troubleshooting.
• Vibration Analysis -Use vibration analysis equipment to monitor
pump health.
• Computational Fluid Dynamics (CFD) -Use CFD simulations to
• Laser Alignment -Use laser alignment tools to ensure proper pump
analyze pump performance and identify potential problems.
and motor alignment.

• Bearing Temperature Monitoring -Use infrared thermometers to

monitor bearing temperatures.

• Impeller Inspection -Inspect impellers for wear, corrosion, and

cavitation damage.
B. Electric Motors
Motor Current Signature Analysis (MCSA)
Use MCSA to detect motor faults, such as broken rotor bars and winding faults.

Thermography
Use infrared thermography to identify hot spots and potential motor failures.

Partial Discharge Testing

For high voltage motors, use partial discharge testing to detect insulation defects.

Motor Rewinding
Motor rewinding requires specialized equipment and expertise. Follow
manufacturer's specifications.
C. Valves (Gate) - Controlling Fluid Flow

Ultrasonic Testing Valve Seat Lapping Actuator Calibration Valve Selection

Use ultrasonic testing to detect Use specialized lapping tools to Calibrate valve actuators to ensure Select valves based on the fluid,
valve wall thickness and restore valve seat integrity. proper valve operation. pressure, temperature, and
corrosion. application.
D. Air Compressors - Providing
Compressed Air
Air Dryer Maintenance
Maintain air dryers to ensure dry compressed air.

Intercooler and Aftercooler Maintenance

Clean and inspect intercoolers and aftercoolers.

Safety Valve Testing

Test safety valves regularly.

Compressor Types
Reciprocating, rotary screw, and centrifugal compressors.
E. Generators - Generating Electrical
Power
Governor Calibration
Calibrate governors to maintain stable engine speed.

AVR Testing and Calibration

Test and calibrate AVRs to ensure stable voltage output.

Synchronizing and Load Sharing

Understand generator synchronizing and load sharing principles.

Generator Protection
Understand generator protection systems, such as overcurrent, overvoltage, and
undervoltage protection.
F. Steering Gear - Ensuring Vessel Maneuverability

Rudder Stock Inspection Hydraulic Oil Analysis Emergency Steering Drills Steering Gear Types
Conduct hydraulic oil analysis to Understand the operation
Inspect rudder stock bearings and monitor oil condition and detect Conduct regular emergency principles of hydraulic, electro-
seals to ensure proper alignment potential contamination or steering drills to ensure crew hydraulic, and electric steering
and prevent water ingress to the degradation before it causes proficiency in manual operation gear systems commonly found on
steering compartment. system failure. during primary system failure. modern vessels.
IV- Common and basic tools typically used for routine maintenance

Hand Tools

Hammers -Used for tasks like removing rust or striking chipping tools.

Wrenches (Spanners) -For tightening or loosening bolts and nuts, especially in deck fittings and machinery.

Screwdrivers -Essential for working with screws on deck equipment, panels, and fixtures.

Pliers -Useful for gripping, bending, or cutting wires, especially during cable maintenance.

Chisel -is a tool with a characteristically shaped cutting edge of blade on its end; for carving or cutting a hard material such as wood, stone, or metal by hand, struck with a mallet, or mechanical power
mechanical power
Rust and Paint Removal Tools

Chipping Hammers Wire Brushes Scrapers

To remove rust, scale, or old paint from deck For cleaning surfaces and preparing them for To strip off old paint or stubborn grime.
deck surfaces. repainting.
Painting Equipment

Paint Rollers and Brushes Spray Guns Scraper Sandpaper

Often used for larger areas Is a hand tool or implement used Is an abrasive material used for
For applying fresh coatings of requiring efficient paint used for removing unwanted for smoothing and finishing
of paint to protect the deck from application. materials, such as paint, rust, surfaces by removing small
from corrosion. adhesive, or dirt, from surfaces. amounts of material through
surfaces. abrasion.
Cleaning Tools

Scrub Brushes and Mops Deck Buckets High-Pressure Washers

For cleaning the deck of dirt, salt residue, or For holding water or cleaning solutions while For removing stubborn dirt and grime from
residue, or spills. while scrubbing. from deck surfaces.
Measurement Tools
Measuring Tapes and Calipers Sounding Tapes Micrometers

Used for checking the level of liquids in Are specially designed for the
For precise measurements during in tanks, such as ballast or fuel. measurement of very small objects.
maintenance and inspections.
Rigging Tools

Hoist Shackles and hooks Wire rope and slings Cargo nets and straps
A mechanical device used for lifting or lowering heavy Essential components used in various lifting, rigging, Essential components in lifting and rigging Essential tools for securing and transporting various
lowering heavy objects or loads vertically. rigging, and securing applications across different applications, widely used across various industries, various types of cargo, including goods, equipment,
different industries, including construction, industries, including construction, maritime, equipment, and materials.
manufacturing, maritime, and material handling. manufacturing, and material handling.
handling.

Grease Guns
For lubricating pulleys and other rigging equipment.
Welding and Cutting Tools

Utility Knife Hacksaw Portable Welding Machines Oxy-Acetylene Cutting Torches

Is any type of knife used for general Is a versatile hand tool designed for
Machines Torches
general manual work purposes. Such for cutting various materials, primarily For repairs and reinforcement of For cutting or shaping metal on deck.
Such knives were originally fixed-blade primarily metal and plastic. metal components. Welding machine deck.
blade knives with durable cutting machine is a device used for fusing
edges suitable for rough work such as fusing metals. The machine emits an
such as cutting cordage, an electrical arc from an electrode
cutting/scraping hides, butchering electrode which melts metal or
butchering animals, cleaning fish supplies filler into a joint between two
scales, reshaping timber, and other between two pieces of metal.
other tasks.
Personal Protective Equipment (PPE)
Basic Protection Height Safety

Gloves, Goggles, and Hard Hats -To ensure crew safety during Harnesses and Safety Belts -For working at heights.
during maintenance tasks.
Portable Power Tools

Drills and Grinders Angle Grinders Sander

For making holes or smoothing surfaces. Commonly used for cutting or grinding metal Is portable power tool used for smoothing,
metal surfaces. smoothing, polishing, or cleaning a surface,
surface, as of wood, plastic, or metal
Deck-Specific Tools

Hydraulic Jacks Deck Scalers Marlinspike

For adjusting or lifting heavy equipment. For heavy-duty rust removal. A tool for working with ropes, such as
equipment. splicing or untying knots.
V- Documenting Shipboard
Maintenance
Define Maintenance Tasks in PMS
• Establish a list of all maintenance activities required for critical
critical systems (e.g., engines, navigation equipment, safety
safety systems).

• Include routine inspections, servicing, and replacements for

each piece of machinery.

Schedule Maintenance Activities

• Plan tasks based on the equipment manufacturer's
recommendations or regulatory requirements.

• Use PMS software or records to set due dates (e.g., weekly,

weekly, monthly, annual maintenance schedules).
Record Details in PMS/ Logs
Date and Time Task Performed Personnel Involved
When the activity was conducted. Clear description of the maintenance Names of crew or technicians who
done. handled the task.

Observations Actions Taken Materials Used

Any findings like wear, damage, or Repairs, replacements, or adjustments Include part numbers and quantities of
anomalies. carried out. spare parts or consumables.

Signature or Approval
By the supervising officer or responsible engineer.
Track Equipment Condition & Update Documentation

Track Equipment Condition Update Documentation Continuously

• PMS records help monitor trends in equipment performance or • Ensure the PMS database is updated after every maintenance
performance or recurring issues. activity to reflect the latest status of equipment.
• Highlight machinery nearing its end-of-life or requiring enhanced
attention.
Comprehensive Approach
Effective documentation requires a multi-faceted strategy combining technology and systematic procedures.

Electronic PMS Systems Data Logging and Trend Digital Photography and Classification Society
Trend Analysis Videography Surveys
Utilize electronic PMS systems Use data logging systems to Use digital photography and Prepare accurate and detailed
systems for efficient data monitor equipment performance videography to document documentation for classification
management and analysis. and identify trends. maintenance and repair society surveys.
activities.
VI- Troubleshooting and Escalation

Visual Inspection Verify System Settings Monitor Operational Parameters

• Examine the equipment for obvious damage, • Cross-check the current operating settings • Check readings such as temperature,
damage, wear, leaks, or loose connections. settings against the manufacturer's pressure, voltage, and current.
connections. recommendations. • Compare these values with normal operating
• Check for warning lights or alarm indicators • Ensure control switches, valves, and ranges provided in manuals.
on control panels. breakers are in the correct positions.
• Look for external signs like unusual
vibrations, noises, or smells.
Troubleshooting Steps

Reset and Restart Isolate the Problem Refer to Manuals and Logs Check for Common Causes
For equipment failures, attempt a controlled reset or restart Test components individually to pinpoint the issue. Use Consult equipment manuals for troubleshooting flowcharts Ensure adequate power supply or fuel delivery. Verify
restart (following proper shutdown and start-up diagnostic tools like multimeters, pressure gauges, or or guidance. Review maintenance logs for past issues or Verify proper lubrication and cooling systems are
procedures). Observe any changes in performance. thermal scanners as applicable. recurring problems. functioning.

Temporary Repairs Communicate and Escalate Always Prioritize Safety

If a quick fix is possible (e.g., sealing a minor leak), Inform the responsible officer or engineer about unresolved Follow lockout/tagout (LOTO) procedures if applicable. Use
implement it to maintain operations until a permanent issues. Document the problem and troubleshooting steps personal protective equipment (PPE) during
solution is feasible. for reporting and decision-making. troubleshooting.
Advanced Techniques
Root Cause Analysis (RCA) Failure Modes and Effects Analysis (FMEA)
Use RCA techniques to identify the underlying causes of equipment Use FMEA to identify potential failure modes and their effects.
equipment failures. effects.

Remote Diagnostics Shore-Based Technical Support

Utilize remote diagnostics to troubleshoot equipment problems. Establish strong communication channels with shore-based
problems. based technical support.