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Friday, January 13, 2017

Valve Control Fuel Pump (SULZER)


Engine room fire free



1.      No smoking proper notices. Smoking in designated area only
2.      Drip trays to be oil free
3.      No leaks, If leaks rectify ASAP
4.      E/R floors to be oil free
5.      Bilge and tank tops to be oil free
6.      Tank sounding pipes to be shut and self closing arrangement & working properly
7.      Air vents to be properly maintained(esp. wire gauge or flame trap)
8.      Proper heating temp of fuels to be maintained (no fuel with flash point <60*C to be stored E/R)
9.      Chemicals, paints to be stored in designated places. Gas bottle outside E/R
    Garbage management to be followed :
1.      No oily rags to be kept near hot areas (esp. boiler, incinerator & purifier)
2.      All oil rags collection bin to have tight lids & all bins emptied into one big bin in w/s before UMS
11.  High press pipes double skin
12.  Pipe lines flanges carrying f.o, l.o press is more than 4 bar should be covered by FN tape
13.  Hot pipes to be lagged & lagging to be oil free
14.  Exhaust trunking to be oil free
15.  Seal pot to be filled with water (i.e. the drain of exh manifold)
16.  Spark arrestor on funnel to be clean & oil free
17.  High press pipe to be properly cleaned and lid piece to be used as a lining for the clamps
18.  Boiler & EGB well maintained. All safety trips tried out regularly (pre post purges)
19.  Incinerator to be well maintained (esp. furnace walls. if not metal plate gets hot)
20.  All M/E safety trips to be tried out as per PMS
21.  Maintain engines in good condition (esp. to avoid scav fire, c/case explosion)
22.  Fire detection system to be tested regularly and to be in good working condition
23.  All fire fighting equipments in good working condition & tested/ inspected regularly (fixed fire fighting,damper,flap)
24.  Electrical fires :
1.      All motor insulation checked regularly
2.      Fuses to be of correct rating
3.      Loose connection to be avoided & periodic switch board checks for loose connections
4.      All equipment safety trips/overload to be tested as per PMS
5.      Checks for overheating signs in equipment & switch board. Nothing behind switch board
6.      Short circuit protection & earth lamps to be checked
7.      Arc chutes to be cleaned regularly
8.      Avoid overloading of plug points
25.  Hot works :
1.      When carrying out hot work check list to be filled
2.      Normal hot work area is identified (esp. workshop)
3.      While hot work, proper fire rounds to be carried out
4.      Provide portable fire extinguisher near hot work place
5.      Special care for hot work in tanks.

CO2 total flooding system




  System requirements:

¥      CO2 and SOLAS (Reg 5)
o   Isolated from engine room & cargo space.
o   1.5 times heavier than air. Smothers the fire.
o   Stored in cylinder about 55 bars. Expands to about 450 times its volume. (0.56m3/Kg)
o   30% of gross volume of biggest cargo space
o   40% of gross volume of machinery space
o   50% of the gas discharged within 1 min
o   85% of the gas discharged within 2 mins
o   Machinery sector valve with alarm
o   Activated from locally or remote station outside the engine room
o   Safeguard against unauthorized access
¥      Requirements of CO2 bottle
o   Stamped pressure (52 bar)
o   Bursting disc (177-193 bar) @ 63OC
o   Recharging if 5% of content is lost
o   Hydraulically tested 228 bar
o   If bottle>10 years, internal & external inspection
o   Stored at < 55 degC
o   Level tested – radioactive level indication
o    
¨   Inspection:
¥      Entry requirement:
o   Consider as enclosed space
o   Follow the procedure of enclosed space entry.               
o   Risk assessment to be carried out.
o   Testing of atmosphere should be considered
o   Arrangement of ventilation, adequate lighting & satisfactory exhaust fan operation

¥      Weekly:
o   Cabinet door & key position
o   General cleanliness & lighting
o   Satisfactory of exhaust fan operation
o   CO2 alarm & stopping function of ventilation & pumps.
o   E/R flaps working condition.






¥      Monthly:
o   Pull wire
o   Sketches
o   Pullys to be checked for corrosion & greased
o   Co2 manifold  relief valve to be checked
o   Master v/v operating condition to be checked locally with precaution
o   Installation check monthly to ensure no leakage

¥      For cable operating system, wires and accessories checked every 3 months

¥      Annually:
o   CO2 line and nozzle to be blow through with compressed air
o   All control valves to be inspected

¥      Quantity of CO2 in the cylinder should be checked once every 4 years (25% yearly, or 50% biennially)-every bottle must be check once every 4 years
¥      Internally inspected every 5 years
¥      CO2 bottles to be hydraulically tested 20 years after date of installation and every 5 years thereafter

¨   Limitations:
o   If > 10 – 12 mins : ineffective
o   Total evacuation – time wasted if crew injured
o   Heavy bottles – recharge, maintenance facilities
o   “One – off” no reserve
o   Leakage
o   Accidental release
o   No protection to personnel
o   Little cooling effect
o   Highly asphyxiating
o   Static electricity.

¨   Operation of CO2 flooding system:
¥      Steps to be taken before operation:
o   Should be employed if the master is fully convinced that the situation is out of control
o   All personnel to be evacuated from the machinery space, head count to carried out.
o   All remote (quick closing) closing valves to be closed such as  HO service to M/E, DO & HO from sett tank to purifier, DO service to generators.
o   All openings such as entrances skylight, funnel flaps to be closed.
o   Stop all ventilation fans from remote position.
o   All fuel, Lo pumps to be stopped from remote position.
o   Upon opening the control box, activates the CO2 alarm warning all personnel that CO2 is going to be released.







¨   Reoccupation in E/R after releasing CO2 total flooding system
¥      Observation before re – entry:
o   24 hours by ABS
o   Ensure that the fire in the compartment is fully extinguished and could be ascertained by:
ü  No steaming water vaporized in boundary cooling.
ü  No blistering of paints along the bulkhead & temperature is < 100OC (feeling the bulkhead)
ü  By feeling the bulkhead or hearing any hissing sound of fire
ü  By checking the bulkhead temperature by laser thermometer.

¥      Re – Entry:
o   Upon satisfactory from the observation company checklist “Re – Entry after CO2 flooding” should be filled up.
o   Two person (min) ready with firemen’s outfit with SCBA set & life line with pressurized hose.
o   One responsible person should be stand by at the entrance and establish communication and co-ordination.
o   Radio communication should be provided if possible.
o   Confirm the permission from master to entry.
o   Entry to be made from possible lowest position (if possible use exit door).
o   Enter the E/R side by side and extinguish small fire if present.
o   Upon confirmation of no fire “re – occupation procedure to be commenced.
o   Record all the timings.
o   Engine compartment should be well ventilated before any damage inspection.