Coursework 1 Stais Gkoumas 97.5%

7/25/2019 Coursework 1 Stais Gkoumas 97.5%

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NAVAL ARCHITECTURE OCEAN AND MARINE ENGINEERING

NM916

Systems Availability & Maintenance

Dr I. Lazakis

Coursework 1

Maintenance Applications in Maritime &

Chemical Industry

Gkoumas Dimitrios

Reg. No. 201580394

Stais Giorgos

Reg. No. 201582379


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2Stais Giorgos|Gkoumas Dimitrios

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Registration Number :201580394 Name : Gkoumas Dimitrios,Registration Number:201582379 Name:Stais Giorgos

Class Code :NM916 Coursework Title: Maintenance Applications in

Maritime and Chemical Industry

Lecturer: Dr . I. Lazakis

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Table of Contents

1. Introduction 4

2. Chemical Industry 52.1 Serious Accidents in Chemical Industry 5

2.2 Substances present in facilities to be maintained 8

2.2.1 The Corrosion hazard 9

2.3 Maintenance Methods 10

2.3.1 Planned Maintenance System 10

2.3.2 Corrosion Monitoring 11

2.3.3 Risk Based Inspection 13

2.3.4 Reliability Centered Maintenance 13

a. Hazop Analysis 14

b. Failure Mode and Effects Analysis (FMEA) 15

c. Fault Tree Analysis (FTA) 15

3. Maritime Industry 16a. Corrective Maintenance 17

b. Preventive Maintenance 18

c. Predictive Maintenance 18

d. Opportunistic Maintenance 19

3.1 Reliability Centered Maintenance 19

4. Summary Table 20

5. Conclusion 22

6. References 23

7. Appendix 25


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1. Introduction

One of the largest industries in the world is the chemical industry. The alone

shipments in 1990 was 309 billion dollars while in 2000 the amount reached to 460billion dollars. This industry is one of the biggest industrial sectors in Europe as well,

with sales of 530 billion euros and a workforce of 1.2 million people. A wide variety of

substances were produced by chemical factories which are very essential for use in a

very broad range of applications in all sectors of the economy. The main chemical

substances are:

Base chemicals (petrochemicals, basic inorganics and polymers) produced in

large volumes.

Specialty chemicals (auxiliaries for industrial processes, active ingredients for

the pharmaceuticals industry and plant protection, paints & inks, biocides, and

dyes) produced in lower volumes.

Consumer chemicals (perfumes ,cosmetics, soaps and detergents).

The safety regulations in chemical industry are some of the strictest compare to

other industries. Due to the very aggressive substances, the high pressures and

temperatures and the stress which placed on equipment, regular revision, servicing

and maintenance is required. The size and the type of the plants are major factors

which designate the maintenance procedures as they often require complete shut-

downs.

Large-scale production is mostly run as continuous operation while small-scale

production, often run as a batch operation. In both productions there are technical

systems like chemical reactors (which have to withstand high or low temperatures and

pressures), separation devices (filtration, distillation, etc.), and fluid systems for liquids

and gases (valves, tanks, pumps).

The maintenance workers must meet the safety regulations and be aware of the

risks and dangers because of the complexity nature of chemical plants. In addition, in

many cases they come into close contact with a broad variety of hazardous chemicals.


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2. Chemical Industry

2.1 Serious Accidents in Chemical Industry

The BHOPAL Accident 1984

December 2nd, 1984. The main tank of the herbicide production unit in Bhopal was

damaged as a result 20 tons of highly toxic methylisocyanate to leak out. The toxic gas

spread into the residential areas in a very short time. The number of fatalities few hours

later were more than 7,000 and more than 20,000 totally. 100,000 people suffered

permanent injuries and approximately 570,000 people suffered acknowledged healthdamage.

The PIPER ALPHA Accident 1988

Morning of July 6th 1988, Piper Alpha was a large offshore platform in the North

Sea, the compressor A was turned-off for maintenance. A relief valve was removed for

maintenance too. A worker closed the open pipe provisionally in the end of his shift as

he did not finished the work. On the operation document has noted that the compressor

was not ready. The fatal mistake was that the document was delivered to the safety

department, without the status of the compressor become known to the head of

production. In the same day the compressor B failed suddenly and as the production

staff assumed that compressor A was ready to operate so the gas was transferred to

the compressor. A huge explosion occurred and three tons of gas per second leaked

out. The construction started to melt very fast and the platform finally collapsed. 167

people died in the inferno.

The Williams Olefins Plant explosion 2013

Apetrochemical plant was located inGeismar,Louisiana.The catastrophic failure

of the central heat exchanger triggered a huge explosion. Two workers were killed and

more than 100 injured. The effects of the explosion were felt several miles away.

Investigations was launched by TheU.S. Occupational Safety and Health

Administration (OSHA) and the U.S. Chemical Safety and Hazard Investigation

Board (CSB) in order to determine the cause of this failure.
https://en.wikipedia.org/wiki/Petrochemicalhttps://en.wikipedia.org/wiki/Geismar,_Louisianahttps://en.wikipedia.org/wiki/Louisianahttps://en.wikipedia.org/wiki/U.S._Occupational_Safety_and_Health_Administrationhttps://en.wikipedia.org/wiki/U.S._Occupational_Safety_and_Health_Administrationhttps://en.wikipedia.org/wiki/U.S._Chemical_Safety_and_Hazard_Investigation_Boardhttps://en.wikipedia.org/wiki/U.S._Chemical_Safety_and_Hazard_Investigation_Boardhttps://en.wikipedia.org/wiki/U.S._Chemical_Safety_and_Hazard_Investigation_Boardhttps://en.wikipedia.org/wiki/U.S._Chemical_Safety_and_Hazard_Investigation_Boardhttps://en.wikipedia.org/wiki/U.S._Occupational_Safety_and_Health_Administrationhttps://en.wikipedia.org/wiki/U.S._Occupational_Safety_and_Health_Administrationhttps://en.wikipedia.org/wiki/Louisianahttps://en.wikipedia.org/wiki/Geismar,_Louisianahttps://en.wikipedia.org/wiki/Petrochemical


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Fig1. Summary Table of serious accidents in chemical industry (1974-2003)

(Source: Application of Risk and Reliability Methods for Developing Equipment Maintenance StrategyJens P. Tronskar Ph.D., 30 November 2004, DNV)

It is obvious that in industries such as chemical with dangerous substances, accidents

could be fatal and quite serious for the surrounding environment. Well organized

maintenance is quite important not only for the facility but also for the workers safety.

Many times pitfalls can be overlooked but with systematic analysis many of the past

accidents could have been prevented. Often, errors and mistakes in maintenance

procedures lead to averse changes in the plant.

Fig2. Frequency of accidents regarding the phases of maintenance.


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Fig3. Significant causes and contributing factors of 93 accidents.

(Source: Maintenance and Changes, INTERNATIONAL SOCIAL SECURITY ASSOCIATION (ISSA),2007)


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2.2 Substances present in facilities to be maintained

The possibility of come into contact with hazardous substances in chemical plants is

huge for the maintenance workers. The useof hazardous and dangerous products,

the emissions from substances as a result of operating activities, and substances that

may be presentin production facilities that are maintained, are the three most common

sources. Some major categories of substances that are regularly encountered are:

In petrochemicalinstallations, residues of crude m ineral oi l, which may contain

carcinogenic polycyclic aromatic hydrocarbons

A usual problem in oil refineries is the potential emission of the toxic gashydrogen su lph ide(H2S).

Heavy metalssuch as mercury may be also present. The most common

locations for mercury accumulation are separators and heat exchangers. In this

situation, regular monitoring of mercury and chlorine gas is essential.

During maintenance procedures, for instance during plant shutdowns, workers

certainly come into much closer contact with and hazardous substances andproduction equipment than during normal operations. Constant contact with those

substances or emissions could be due to opened machinery, pipes and valves.

Fig4. Maintenance operation in progress


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2.2.1 The Corrosion hazard

Corrosion is a major problem for the chemical industry. In 2000, the total capital

expenditures for the chemical industry was approximately $15 billion, with $604 million

to $1.8 billion annual corrosion costs. For the petrochemical industry, the total capital

expenditures was $1.8 billion with $73 million to $220 million per year in corrosion

costs.

In the past few years, with many efforts and new methodologies, the industry has

concentrated on minimizing the costs and corrosion failures. One solution is the use of

corrosion-resistant alloys. There are also some other techniques such as the

implementation of corrosion monitoring, and the use of planned maintenance.

Fig5. Corrosion effects in various components


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2.3 Maintenance Methods

2.3.1 Planned Maintenance System (PMS)

In order to avoid failure and damages by corrosion, chemical industries use the

method of planned maintenance by regularly replacing plant equipment etc. This

maintenance procedure is essential and constitutes the final phase of control.

Scheduled shutdown periods must take place for the planned maintenance to begin

so as to inspect the equipment and the mechanism. Decisions about which tools and

equipment must be replaced or refurbished should be taken during the maintenance.

Industries try to organize shutdown periods with short duration in order to minimize the

losses since the inspection and maintenance costs are high. The competed

department is responsible to schedule the maintenance well in advance.

Fig6. Factors contributing to a policy of planned maintenance.

(Source: CHEMICAL, PETROCHEMICAL, AND PHARMACEUTICAL, Michael P.H. Brongers & Ivelisse Tubens)


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2.3.2 Corrosion Monitoring

In the Corrosion Monitoring method by using probes, which more commonly

are either mechanical or electrochemical appliances, we can continuously take a

large number of measurements in combination with some other ways like sentry

holes, UTM, crack detection and of course visual examination which can assist us

to check the rate of corrosion on each system. The main disadvantage of the

probes is that in few cases return error readings due to various deposits. All these

corrosion sensors should be installed in areas where the risk is high and could

cost a lot of money in case of malfunction.

There are two types of corrosion monitoring: the continuously one and at regular

scheduled intervals. The benefits of the first one, is that we can take immediateactions once we see something abnormal. On the other hand in the second one,

in case something goes wrong between two scheduled intervals nobody are going

to notice it so the results are not so efficient. Finally the periodical monitoring is

usually carried out during turnaround.

Fig7. Techniques for monitoring corrosion in a process plant.



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Below some techniques of corrosion monitoring method in chemical industry are

described, including their Advantages and Disadvantages.

Fig8. Corrosion monitoring techniques



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2.3.3 Risk Based Inspection (RBI)

Risk Based Inspection and is a methodology applied in the Chemical Industry as

part of their Process Safety Management. Plans for inspections, refurbishment, repairs

and displacements are based on the risk assessment of this maintenance strategy.

This inspection is done so as to manage assets and equipment which is exposed to

dangerous chemicals and pressure in a safe way. Those chemicals must be kept inside

of pressure boundaries as per their original design criteria.

Key Benefits of Risk-Based Inspections :

A more economic method compared to traditional inspection, usually by usingmeans of nondestructive testing (NDT)

More credible equipment and plant operation.

Determination of the operational risks related to equipment, via material

degradation Reduction of the downtime

Through the application of RBI analysis, materials of construction are considered to

identify the frequency of inspections that should take place as well as the type of

damage that can lead to failure, where it may occur and the cost-effective inspectiontechniques. Higher priority for inspection are given to the items with a high probability

of failure and subsequent impact than items that are of low impact. This method allows

a more rational application of inspection resources. The main resources are focusing

on specific and several assets that it is more likely to present a risk to the facility.

2.3.4 Reliability Centered Maintenance (RCM)

Hundreds of chemicals are produced every day and are used globally for making

consumer goods and not only, thats why the chemical industries are extremely

diverse.

For years, companies have concentrated on making their equipment more reliable,

and on correcting perceived problems with technology. Unfortunately while the use of

better and advanced technology has usually resulted in huge increases in productivity,

ways and methods for the prevention of major accidents have not indicate the same


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development. Recent reviews show that the most significant contributors to accidents

are either the human errors or the lack of adequate management systems. Reliability

Centered Maintenance (RCM) is being extensively used into this industrial area,

fulfilling strict regulations and development criteria.

Techniques

The methods approved byOccupational Safety and Health Administration (OSHA)

include:

Hazard and Operability Analysis (Hazop)

Failure Modes and Effects Analysis (FMEA)

FTA, or Fault Tree Analysis.

All of them are included into the RCM process used in chemical companies.

a. Hazop Analysis

In the Hazard and Operability Analysis method all variables and parameters of a

system are checked thoroughly in order to identify possible deviations from the initial

ones which can cause operation failures. Each time there is a deviation, the team:

Takes the decision whether any resultant of interest would conclude from

reliable causes of the deviation,

Specifies all the features that secure the system from possible deviation,

Suggests ways to minimize the possibility of the deviations.

The findings of a Hazop Analysis are usually recorded in a work-sheet which includes

the most important entries such as: Deviation, Likelihood causes, Actions required,

Actions Distribution, Safeguards, Team suggestions etc.
https://en.wikipedia.org/wiki/Occupational_Safety_and_Health_Administrationhttps://en.wikipedia.org/wiki/Occupational_Safety_and_Health_Administration


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b. Failure Mode and Effects Analysis (FMEA)

The FMEA method is a qualitative approach which implicates all the possible failure

modes of a system and the effects of them. All these effects are extensively evaluated

and documented in order to find possible ways to minimize the chance of this failure.

Due to the fact that the FMEA method is centered on component breakdowns, few

problems which have to do with the process chemistry could be bypassed. On the

other hand, this method is more accurate in non-reactive chemistry such as blending,

coating, crushing etc. The main advantage of this method is that it provides an

analytically awareness of possible failures of a system.

c. Fault Tree Analysis (FTA)

FTA is a method for designating the connection between the human mistake and

appurtenance failure once something is not working properly in a system. This method

depict the joint of some failure events which have as a result the complete system

breakdown, known as Top Event.

By using this method, we can easily identify how often a system failure take place

but on the other hand this frequency doesnt assist us to recognize the main reason

which caused the system damage. In order to portray this method we usually use a

fault-tree diagram where the top event or root is placed in the top and show us the

main malfunction and below are all the possible causes based on AND and OR gates.


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3. Maritime Industry

Nowadays most of the world products are transported by ships with more than

million seafarers employed on them. As a result properly maintained vessels is a

must in order to prevent the asset itself, cargo carried and the environment from any

kind of pollution. So various maritime regulatory and administration authorities joint

together in order to impose a list of regulations that all vessels must comply to secure

their seaworthiness.

Maintenance approaches for each ship manager/operator are different and

extensively described in ISM Code and Planned Maintenance System (PMS) but

generally can be split in three major categories as per BS 4778:

Corrective ( or failure-based maintenance including breakdown)

Preventive ( or schedule-based maintenance)

Predictive ( or condition-based maintenance)

Fig9. Maintenance types diagram

(Source: Systems Availability & Maintenance Hand-outs, Dr .I . Lazakis)

Whenever crew are planning to perform any kind of above maintenance plans in

any machinery item they have to follow some steps:

Plan the work Prosecute a Risk Assessment Arrange workshop/tools

Shutdown the item Perform the repairs works Test the item Delivery for

operation


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Below more details for each type of maintenance plans are described:

a. Corrective Maintenance

This type of maintenance is often used when there is a suddenly breakdown of amachinery item for example a ballast pump shaft. The advantages of this type of

maintenance are the below:

Only required spares parts are used

Minimize the expenses especially for vessels which are going for scrap

On the contrary the disadvantages are quite more:

Depends on the machinery item sometime ship and crew safety is exposed

In case of spare parts unavailability the costs are multiplied

Item working efficiency is decreased and lifecycle is shortened

The quality of repairs are poor due to fast decisions

b. Preventive Maintenance

This type of maintenance is known as Planned Maintenance System (PMS). In this

type all maintenance works are carried out as per OEM Instructions on a time-basedintervals for example every 1500 running hours or on calendar-based intervals for

example every 6 months. Even if the spare part is in good working condition, it should

be replaced when it reaches the interval limitation. The disadvantage of this method is

that sometimes the spare parts can be used again and minimize the overall cost but in

order to avoid future breakdowns are replaced.

c. Predictive Maintenance

This type of maintenance is based on the Condition Monitoring of each item by

collecting data from various sensors/gauges, analyze them and react accordingly. By

this way we have a lot of advantages. Firstly, only minimum spare parts are used,

suddenly breakdowns are eliminated and crew have more time for the rest works which

might be more important. The most common ways to collect data for the CM are the

below:


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o Lubricant Analysis: Crew onboard take various lube oil samples from various

critical equipment (Main Engine, Aux Engines, Stern Tube, Thermal Oil etc.)

and send them to external laboratories for extensive analysis. Depends on the

results Technical Superintendent and Chief Engineer can take the required

actions.

o Vibration Monitoring: By using various sensors, engine crew can monitor the

vibration of various equipment (TurboCharger, Pumps etc.) and if the results

are above the limits then they will take some further actions for example:

Turbine Bearing Housing Replacement.

o Physical Measurements: Engine Crew take various periodic measurements

mostly as per ISM Code in order to examine the condition of the item. Such

measurements are crankshaft deflection, bearings clearances, rotor axial

position, shaft bearing temperatures, sterntube bearing temperatures and wear

down, Megger Test etc. Except from the main machinery items some of the

auxiliary ones require extra care. As a result crew also takes various

measurement from Coolers, Heaters, Pumps, Fans and Filters.

o Visual Inspection: Engine Crew perform periodic inspection to various critical

places. Such as crankcase, bedplate structure, thrust bearings, vibration

dampers, ducts etc.

There are some other types of maintenance which either not commonly used

onboard ships or they combine all above types together. Some of them are:

d. Opportunistic Maintenance

In this type, maintenance is take place when there is free time for crew and the system

is not in operation mode. For example an unplanned overhauling of a purifier by

replacing all tear and wear parts despite the scheduled major overhauling as per PMS.


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3.1 Reliability Centered Maintenance (RCM)

In this type, maintenance procedures are scheduled based on a qualitative risk based

method in order to find the optimum balance between the three majors types of

maintenance.

In any case, as it is compulsory each vessel to maintain the minimum safety

standards, Classification Societies in order to ensure that they have established

onboard periodical machinery renewal surveys on a regular basis which are:

Annual Inspection

Intermediate Inspection

Special Survey/ Dry-docking Inspection

Below we can see an example of daily maintenance hours of engine crew:

Fig10. The Ship Crews maintenance Hours

(Source: Shields et al. 1996)

Finally if the vessel has an approved type of Machinery Maintenance Plan, some

of the machinery items can be credited for survey based on examination by the Chief

Engineer which has as an advantage the reduction of Class Surveyor onboard visits

and less Classification Fees.

In Appendix I are shown which items can be credited by Class surveyor and

which by ships Chief Engineer.


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4. Summary Table

ChemicalIndustry

MaritimeIndustry

Corrective Maintenance performedonly in case of a

component failure. Usefulin case a specific

component is at the

completion of its lifetime

Applicable in the maritimesector as well, for instancelaid-up ships or ships close

to be scrapped

Preventive Applicable in both sectors, performed on calendarbased intervals

o PMS Chemical plants use themethod of planned

maintenance by regularlyreplacing plant equipment

The main maintenancemethod in maritime

industry.

o KPI Not applicable in thechemical industry

Implemented mostly innew-building ships

o TMSA, ISM Not applicable in thechemical industry Highly applicable by tankercompaniesPredictive Maintenance takes place when the maximum intervals

reached. The various applicable techniques in eachsector are presented below:

o RCM

o RBI

o ConMon

o CMMS

Opportunistic This method is used in both industries when anunplanned opportunity becomes available


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Reliability tools &Techniques

Both sectors use those tools but due to high complexityeach industry selects the most adequate ones

Qualitative tools

o FMEA

o HAZOP

oSWIFT Quantitative tools

o FTA

o Monte Carlo

Rules / Regulations Very strict rules due tothe hazardous working

environment (contact withdeadly substances and

fatal accidents)

Strict rules depending onthe type of the vessel andthe navigation area. Vary

among countries

Personnel training High level trainedpersonnel

Well trained personnel

Spare Parts Easy accessible aschemical plants are

located on-shore

Impossible when thevessel is underway

Responsible personnelfor maintenance

Ship crew, externalworkshop, shipyard

Maintenance department


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5. Conclusion

To conclude, it must be mentioned that the role of maintenance is utmost

importance in both Chemical and Maritime Industry as it keeps all the equipment in

good operation condition avoiding any stoppages, increasing items lifecycle and the

most significant, to reach the desired productivity. Both maritime and chemical are

quite complex industries so an advanced and well organized maintenance is valuable

for the smooth operation of a vessel or a chemical plant respectively.

However that there are differences between the methods and the tools which are

used for maintenance. One of the main differences between these two sectors is thatin Maritime one, the onboard crew have to monitor the condition, proceed with regular

intervals, analyze and evaluate the data at their own criticism as the technical

department is located far away without being easy contactable any time. Another

importance difference is the availability of the spare parts which in maritime industry it

could take many days to reach to the vessel something that may cause great loss of

earnings due to this delay. In order each company to maintain the imposed standards,

customers satisfaction, highest quality in the most cost efficient way sometimes

combines more than one of the above mentioned maintenance methods but on

different way.


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6. References

1. Optimization of Preventive Maintenance in Chemical Process Plants, DuyQuang andMiguel Bagajewicz, Industrial & Engineering Chemistry Research, May 2010

2. Chemical, Petrochemical and Pharmaceutical, Appendix V, Michiel P.H Brongers and

Ivelisse Tubens

3. Best practice for Risk Based Inspection as a part of plant integrity management, TWI and

Royal & SunAlliance Engineering, 2001

4. An expert system for reliability centered maintenance in the chemical industry, D.J.Fonseca and G.M. Knapp , Department of Industrial Engineering, University of Alabama,

2000

5. Application of Risk Based maintenance with life and financial assessment on fossil-fired

power plants, Akio Fuji, Hruki Eguchi, Chie Fukuoka, Tatsuro Tanoue, Research

Laboratory of Ishikawajima-Harima Heavy Industries Co, 2015

6. Maintenance and Changes, INTERNATIONAL SOCIAL SECURITY ASSOCIATION

(ISSA), 2007

7. Application of Risk and Reliability Methods for Developing equipment Maintenance

strategy, Jens P. Tronskar ,DNV , November 2004

8. Maintenance and hazardous substances- maintenance in the chemical industry.

European Agency for Safety and Health at work

9. Maintenance and Changes in Plants with High Safety Requirements ,ISSA, 2007

10. Study of existing Reliability Centered Maintenance (RCM) approaches used in different

industries, N. Cotaina, F. Matos, J. Chabrol, P. Pete, University of Madrid

11. Development of Ship Maintenance Performance Measurement Framework to

Assess the Decision Making Process to Optimize in Ship Maintenance Planning,

Yousef Alhouli, 2011

12. Inspection-based Preventive Maintenance, Paul Dean, Shire Systems Limited


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13. Machinery Planned Maintenance and Condition Monitoring, LRS, Shipwright,

March 2013

14. Good Maintenance On Board Ships, ClassNK, January 2015

15. Considerations for Classification Societies with Respect to Vibration ConditionMonitoring (VCM), Maryon Williams-John McNeil, 2011

16. Probabilistic risk assessment of condition monitoring of marine diesel engines,

Dikis Konstantinos-Lazakis Iraklis- Turan Osman, 2014

17. Risk-Informed Regulation of Marine Systems Using FMEA, US Coast Guard

Marine Safety Center

18. International Maritime Organization, Solas, 2014

19. Internation Maritime Organization, International Safety Management (ISM)Code and Guidelines on Implementation of the ISM Code 2010, 2014

20. International Association of Classification Societies, IACS

21. System Availability & Maintenance Hand-outs, Dr. I. Lazakis


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7. Appendix

Fig11. List of Machinery items examined by Surveyor and C/E

(Source: Lloyds Register Ship Right March 2013)


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Fig12. Continuous of the List of Machinery items examined by Surveyor and C/E

(Source: Lloyds Register Ship Right March 2013)

Documents

Coursework 1 Stais Gkoumas 97.5%