Halkidon shipping corporation safety manual for RO-RO passenger vessels [1999, DOC]

CONTENTS

12.1 Basic Precautions
12.2 Engine Room Lifting Equipment
12.3 Electrical Equipment Dangers and Safety Precautions
12.4 Emergency Electrical Supply
12.5 Turning Machine by Hand
12.6 Machinery Precautions
12.7 Fire Flaps and Remote Shut Offs
12.8 Over speed Trips, Alarms and Safety Devices
12.9 Bilge High Level Alarms
12.10 Steam Pipes
12.11 Boiler and Pressurised Systems Maintenance of
12.12 Engineering Boilers
12.13 Boilers Operation of
12.14 Unmanned Machinery Spaces
12.15 Refrigeration Plant
12.16 Ladders and Floor Plates
12.17 Fuel System
12.18 Oil Tank Gauge Glasses
12.19 Electrical Circuits
12.20 Fuse Pullers
12.21 Escape Routes from Machinery Spaces
12.22 Soot Blowing
12.23 Engine Room Pollution Precautions & Procedures

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12.1 BASIC PRECAUTIONS
12.2 ENGINE ROOM LIFTING EQUIPMENT
The deck department is to assist in any difficult or unusual rigging in the engine room and always to assist in rigging for heavy lifts. All lifting gear should be marked with its safe working load (SWL) and never intentionally used beyond that stated limit. Lifting appliances, which are not marked with their safe working load, should not be used.
Before any item of machinery is lifted its weight should be ascertained to ensure that working loads are not exceeded.
When equipment (in particular pistons) are to be lifted by means of screw in eye bolts the eye bolts should be checked to ensure that they have collars, that the threads are in good condition and that the bolts are screwed hard down onto their collars. Screw holes for lifting bolts in piston heads should be cleaned and the threads checked to see that they are not wasted before the bolts are inserted.
12.3 ELECTRICAL EQUIPMENT DANGERS AND SAFETY PRECAUTIONS
The risks of electric shock are much greater onboard ship than they are normally ashore because of the conditions of wetness; high humidity and high temperature (causing sweating) reduce the contact resistance of the body. In those conditions, severe and even fatal shocks may be caused at voltages as low as 60V. In such conditions extra precautions should be taken such as using low voltage equipment, placing insulating mats, wearing rubber boots and ensuring the work area is as dry as possible.
Instructions on the treatment for electric shock should be posted in every space containing electrical equipment and switchgear. Immediate, on the spot treatment of an unconscious patient is essential.
Before commencing maintenance work on any electrically powered machinery ensure the power has been disconnected. This can be achieved by removing the applicable fuse or tripping and locking the appropriate breaker. Additionally DO NOT OPERATE warning signs/tags shall be positioned at the respective isolating and control points. Only competent persons with sufficient technical knowledge should carry out electrical maintenance work.
Work on or near live equipment should be avoided but when it is essential, necessary precautions shall be taken to avoid accidental contact.
Wristwatches, metal identity bracelets and rings should be removed. They provide low resistance contacts with the skin. Metal fittings on clothing and footwear are also dangerous.
Meter probes should have only minimum amounts of metal exposed and insulation of both probes shall be in good order. Care should be taken that the probes do not short circuit adjacent connections. In measuring voltage greater than 35OV the probe should be attached and removed with the circuit dead. Contact with the deck or metal, particularly if it is wet, should be avoided. Foot wear if damp or with metal studs or rivets may give inadequate insulation. The use of a dry insulating mat in the work area is recommended at all times.
Another man, who should be competent in the treatment of electric shock, should be continually in attendance.
The working position adopted should be safe and secure to avoid possible fatal contact with live parts arising from a slip or stumble on the movement of the vessel. Insulated gloves and shoes should be worn where practical.
12.4 EMERGENCY ELECTRICAL SUPPLY
Where installed the emergency generator shall be well maintained and tested weekly.
12.5 TURNING MACHINERY BY HAND
Care is to be exercised when turning machinery by hand instead of power. This applies mainly to winches where the handle can fly back and cause serious injury, or starting lifeboat engines or the emergency fire pump.
12.6 MACHINERY PRECAUTIONS
Whenever personnel operate turning/rotating equipment such as lathes, drills, etc. they must wear appropriate close fitting clothing. Gloves, rings and long necklaces should not be worn. Long hair is also dangerous and appropriate measures should be taken to avoid its entanglement in machinery.
Any machine that can be started remotely, either manually or automatically, shall be clearly marked KEEP CLEAR THIS MACHINE MAY START WITHOUT WARNING.
Personnel required to work in machinery spaces, which have high noise levels, must wear hearing protection either earmuffs or earplugs.
12.7 FIRE FLAPS AND REMOTE SHUT OFFS
The operation of fire flaps and remotely operated shut offs of all types are to be included in the weekly maintenance schedules. All must be kept lubricated and free to operate as per design. Operating positions and compartments they serve must be clearly indicated.
12.8 OVER SPEED TRIPS, ALARMS AND SAFETY DEVICES
Shall be maintained in good working order. Testing shall take place MONTHLY with the pertaining condition report sent to the office as soon as possible thereafter.
Remote controls fitted for stopping machinery or pumps or for operating oil tank quick closing valves should be tested monthly to ensure that they are functioning satisfactorily.
N.B. Extreme care must be taken not to trip a tank being used. Valves must be reset after testing.
12.9 BILGE HIGH LEVEL ALARMS
Bilge high-level alarms shall be tested weekly.
12.10 STEAM PIPES
All steam and condensed pipes and fittings, which by their location and temperature present a hazard, should be adequately lagged or shielded to avoid injury from burning. The insulation should be properly maintained particularly in the vicinity of oil systems.
When valves or filter covers have to be removed or similar work carried out on pressurised systems the respective part of the system should be isolated by closing the appropriate valves. Drain cocks should be opened to ensure that pressure is off the system.
When joints of pipes, fittings, etc. are being broken the fastening should not be completely removed until the joint has been eased open and it has been established that no pressure remains in the system.
Before machinery or steam pipe systems are opened to the steam supply all drains should be opened and the steam introduced very slowly. The drains should be kept open until all the water has been expelled.
12.11 BOILER AND PRESSURISED SYSTEMS MAINTENANCE
Wherever possible two-valve separation must be maintained between any pressurised part of system and that part being opened or worked upon. The Chief Engineer must authorise all work and ensure adequate safety procedures are followed prior to the start of the work. Before commencing work ensure:
1. All applicable pressure gauges read zero.
2. All drains have been opened and checked to verify pressure has been relieved.
3. All necessary valves have been lashed closed and DO NOT OPERATE warning signs posted as and where required.
4. Valves lashed to be logged.
12.12 ENTERING BOILERS
Personnel shall not be permitted to enter a boiler until,
1. All burners have been removed.
2. All stop valves to the boiler lashed closed.
3. PERSONNEL IN BOILER AND DO NOT OPERATE signs posted.
4. Boiler drums are well ventilated. Lack of oxygen may occur in boilers or other pressure vessels particularly where oxygen-absorbing chemicals have been used to prevent rusting.
5. A responsible man assigned as watchman and stationed outside the boiler to all for assistance if required. THE WATCHMAN SHOULD NOT ATTEMPT TO RESCUE. HE IS THERE TO RAISE THE ALARM AND SUMMON THE RESCUE PARTY. RESCUE MUST BE MADE USING BREATHING APPARATUS.
6. Rescue procedures have been laid out and understood with resuscitation equipment on hand.
7. Boiler soot and ash is irritating and highly toxic. Personnel entering boiler drums shall wear protective dust masks.
12.13 BOILERS OPERATION
A notice should be displayed at each boiler setting out operating instructions. Information provided by the manufacturers of the oil burning equipment should be displayed in the boiler room.
To avoid the danger of a blow back when lighting boilers the correct flashing up procedure should always be followed:
1. There shall be no free oil on the furnace floor.
2. The oil should be at the correct temperature for its grade if not the temperature for its grade the temperature of the oil must be regulated before lighting is attempted.
3. The furnace should be blown through with air to clear any oil vapour.
4. A specially provided torch should always be used for lighting a burner unless an adjacent burner in the same furnace is already lit. Other means of ignition such as introducing loose burning materials into the furnace should not be used. An explosion may result from attempts to re light a burner from the hot brickwork of the furnace and therefore this method must never be used.
5. If all is satisfactory, the operator should stand to one side, inserting the lighted torch and then turn the fuel on. Care should be taken that there is not too much oil on the torch, which could drip outside the boiler and possibly cause a fire.
6. If the oil does not light immediately the fuel supply should be turned off and the furnace ventilated by allowing air to blow through for two or three minutes to clear any oil vapour before a second attempt to light is made. During this interval the burner should be removed and the atomiser inspected to ensure that they are in good order.
7. If there is a total flame failure while the burner is alight the fuel supply should be turned off.
The escape route from the boiler fronts and firing spaces shall be kept clear.
Gauge glass protection covers should always be in place when the glass is under pressure. If a gauge glass or cover needs to be replaced or repaired the gauge should be shut off and drained before the cover is removed.
12.14 UNMANNED MACHINERY SPACES
No one should enter or remain in an unmanned machinery space alone unless he has received permission from a responsible or superior officer. Before entering the space, regularly thereafter and upon leaving the space he must report by telephone to the duty deck officer.
Necessary written safety precautions should be clearly displayed at all entrances that unmanned machinery is likely to start automatically.
All machinery spaces should always be adequately illuminated.
When machinery is on bridge control the bridge must be advised when a change in machinery setting is contemplated by the engine room staff and before changing machinery to engine room control.
12.15 REFRIGERATION PLANT
No one should enter a refrigerated room without first informing a responsible person who should be instructed to raise the alarm if an absence is prolonged.
The space or flat in which refrigerated machinery is installed should be adequately ventilated and illuminated. Regular daily inspections shall be made.
Freon gas when heated directly gives off toxic fumes. In consequence it is important to evacuate all lines and machinery of gas before commencing any hot work repairs. Thereafter keep appropriate valves open to prevent pressure build up.
All refrigerated rooms should have a means of opening the door from the inside and an alarm capable of being activated inside which sounds in the galley or other commonly attended space. The alarm and door release systems shall be tested at least weekly.
Those likely to enter the refrigerated spaces should make themselves familiar, in the dark, with the alarm and release systems.
Refrigerator doors, when open, should always be secured and not allowed to swing freely.
If padlocks are fitted to refrigerated doors, ensure that when entering the space the padlock is also taken inside.
Do not enter a refrigerated space if leakage of refrigerant (freon) is known or suspected. A responsible officer must be informed and an appropriate assessment made. If it is necessary to enter the space it should be thoroughly ventilated and those entering be protected by breathing apparatus.
A watchman should be in constant attendance (see ENCLOSED SPACE Chapter 4). Freon gas is heavier than air and has a distinctive oily smell; it is not toxic unless heated. However in sufficient quantities it will displace oxygen and cause suffocation.
Personnel charging or repairing refrigeration plant should be fully aware of the precautions to be taken when handling refrigerant.
When refrigerant plants are being charged through a charging connection in the compressor suction line, it is sometimes the practice to heat the cylinder to evaporate the last of the liquid refrigerant. This must only be done by placing the cylinder in hot water or some similar indirect method and NEVER by heating the cylinder directly with a blowlamp or other flame.
12.16 LADDERS AND FLOOR PLATES
All ladders, grating and floor plates are to be maintained free of debris and obstructions and kept clean. Spills of oil and grease shall be promptly removed.
When gratings, floor plates, hand rails, ladders, etc. are removed to facilitate access for maintenance the resultant opening(s) shall be clearly indicated and roped off to warn personnel.
Where provided, lifting handles should be used when a floor plate is removed or replaced. When lifting handles are not available the plate should be levered up with a suitable tool and a chock inserted before lifting. On no account should fingers be used to prize up the edges.
A stage or ladder should always be used when working beyond normal reach.
When work is done at a level above the bottom platform precautions should be taken against heavy objects failing below. A firmly secured bucket or box should be used to hold tools and loose parts of machinery.
Metal ladders are not to be used near switchboards.
12.17 FUELSYSTEM
Weighted cocks fitted to fuel sounding pipes shall never be wedged/tied open. When not is use cock caps must be screwed shut. Compliance with this instruction will avoid the real possibility of oil overflowing from a sounding pipe and igniting on any adjacent hot surfaces.
Caution is required when filling any settling or other tank to prevent it overflowing especially in an engine room where exhaust pipes or other hot surfaces are directly below. Manholes or other openings in the tanks should always be secured so that, should a tank accidentally overflow the resultant oil is directed to a safe place through the overflow arrangements.
Fuel or hydraulic oil leaking onto a hot surface can easily ignite and cause a serious fire. Leakage shall be promptly dealt with. Where required, adequate screening arrangements shall be in place and kept maintained.
12.18 OIL TANK GAUGE GLASSES
Certain oil tanks have column type gauge glasses fitted with self-closing vales or weighted cocks. These valves or weighted cocks must never be wedged or tied in the open position.
12.19 ELECTRICAL CIRCUITS
Defective electrical circuits or equipment including portable lights shall be immediately disabled/isolated and tagged DO NOT OPERATE. Repairs should be effected as soon as possible.
Switchboard should be adequately guarded against accidental contact. All switchboard doors and protective panels must be in place to all times except when being serviced. An additional safety precaution shall be the positioning of insulated floor mats around the danger areas.
12.20 FUSE PULLERS
A fuse puller is always to be used to remove or replace fuses.
12.21 ESCAPE ROUTES FROM MACHINERY SPACES
These routes shall be well known and well marked with distinctive fluorescent arrows and yellow lines. Whenever practicable there should be at least two and preferably more exists available. If local pilfering conditions require certain doors to be locked it is essential that the pertaining keys be in the possession of a responsible duty officer and fire watchman. Additionally the respective key should be hung on the inside of the door in glass fronted box or similar. The door locking system shall be mortise door locks and padlocks.
12.22 SOOT BLOWING
Soot blowing sparks from the funnel are a potential hazard on all ships but particularly tankers. Additionally, black smoke is a pollutant and extended emission in port can result in fines. The Engineering Officer shall only blow soot after having first gained permission from the Chief officer. Soot blowing in port is usually not allowed and should be avoided.
Unintentional emission of sparks often occurs during long voyages but also during port operations. If necessary, the duty officer on deck shall suspend cargo operations, tank cleaning, etc. until the hazard clears. With this in mind it is advisable to minimise open hatches, tank lids, butterworth plates, etc.
On applicable vessels, tankers, etc. the funnel spark arrester shall be maintained in good order to operate as designed.
12.23 ENGINE ROOM POLLUTION PRECAUTIONS & PROCEDURES
For pollution precautions please refer to the STANDING INSTRUCTIONS, POLLUTION PREVENTION. All relevant personnel shall make themselves familiar with the contents and procedures as laid out in the SOPEP MANUAL.