You are on page 1of 17

USING ULTRASOUND FOR CLASS TYPE APPROVED TIGHTNESS TESTING OF HATCH COVERS AND PREDICTIVE MAINTENANCE OF SHIPBORNE MACHINERY.

Presentation at ACI 4th Optimising Ship Management Conference Rotterdam (The Netherlands) 2626-27/01/2011 By Walter Vervloesem & Tom Murphy SDT Inetrnational (Belgium)

What is ultrasound?
Sound at any frequency above 20kHz Typical operating range is 36-40kHz Use heterodyning to produce an audible signal from the ultrasound which I can not only listen to but analyse

How do I apply PdM?


Few people do more than pay lip service to their PdM programmes What percentage of your maintenance is driven by predictive data? When PdM conflicts with CMMS, who wins? Planned maintenance in this application is expensive, but PdM is cheap. Who wins? Predictive data, health data should be initiating and closing your maintenance activities the measurement cycle.

The measurement cycle

What can I find with ultrasound?


Friction Turbulence Impacts IF you have performed an FMEA and that shows up friction, turbulence or impacting as a potential defect characteristics, ultrasound should be the most important tool in your toolbox. Works in contact mode and airborne mode

Applications
Steam systems leaks and traps Compressed air leaks Electrical systems defects that dont generate heat Hydraulic systems valve inspection, cylinder inspection On-condition lubrication Rotating and linear motion especially good for slowspeed bearings Many applications but always using the same tool

Policy of SDT International


Provide an ultrasonic solution for problems which can not be identified with existing techniques Enhance
failure finding defining rectifying action of existing problems with ultrasound.

Ultrasonic tightness testing tools


Using the best stethoscope does not make you the best doctor Correct diagnose of a problem requires: Right tool Training (advantages, testing techniques limitations and drawbacks should be fully understood, evaluation of results) Knowledge about the item to be tested (see IACS UR Z17 for service suppliers)

History of ultrasonic tightness testing on board ships


Tightness testing of vehicles (1980-1990) Trials on board ships & learning by trial and error (1990 2001) Class Type Approved equipment (2001) Requirements for service suppliers (IACS UR Z17) Preferred tightness testing technique by cargo interests and P&I clubs

Basic principles of ultrasonic testing


OHV = reference value Importance of leaks evaluated against OHV Readouts > 10% OHV indicate that too much compression is lost and will not allow the packing rubber to compensate for movements of the ship when in a seaway.

Difference between ultrasonic testing and hose testing


Hose tests give an indication of physical contact between rubber and compression bar/mating surface Ultrasonic tests give indication about the compression status of the sealing system Loss of contact loss of compression DEMO video/live demo

US tightness testing of hatch covers and predictive maintenance


US testing = indication of compression Reduced compression = indication of problem Lack of compression root cause Root cause = more structurally related (resting pads, compression/coaming defects) If not picked up in an early stage, situation will aggravate quickly and become unacceptable, leading to serious problems with hinged systems, panel positioning, excessive loads on wheels, overcompression of rubbers, jacks,..)

US tightness testing of hatch covers and predictive maintenance


Thanks to the repeatability feature of class type approved equipment, you are able to monitor and evaluate deterioration of the compression which allows you to: Focus on root cause Plan repairs well in time Carry out repairs in an early stage (and check efficiency of repairs made) Use resources where (and when) they are most needed Increases flexibility Reduce costs Perform to a higher standard Avoid unpleasant surprises when a vessel fails a test just prior to loading. Improve safety of the ship (DRI, loadline,)

Remember
US testing gives you an indication of the tightness and compression status of the sealing system and does not reflect the overall fitness of the hatch cover system. Tightness testing does not replace a visual inspection Regular monitoring of the hatch cover tightness will reveal defects in an early stage and reflects good practice and due diligence which is important from a commercial point of view (charterers/shippers, P&I,).

For questions and assistance with training, planning and setting up systems, pls contact SDT international.

Biography Walter Vervloesem


W. Vervloesem (FNI)
Chairman of IMCS Group of Companies Ltd (UK) 17 offices. Manager of the IMCS Training Academy. Ex Chief Officer (reefer, gen. cargo, container & LPG) and shore based since 1989. Working as marine consultant and surveyor for several Antwerp based and international companies. Fellow of the Nautical Institute and founder of the Nautical Institute Belgian Branch. Author of "Ship Survey and Audit Companion" (published by Nautical Institute 04/2000)) Author of Hatch Cover Inspections (published by the Nautical Institute - 08/2003) - Author of Mooring and Anchoring Ships (published by the Nautical Institute - 10/2009) - Co-author of "The Nautical Institute on Command" (published by the Nautical Institute") Instructor for the SDT-IMCS hatch cover training course since 2001 and working under a consultancy contract with SDT on development of ultrasound applications in the marine industry for SDT since 2003

Biography Tom Murphy


Thomas J. Murphy C.Eng.
Managing Director of Reliability Team Limited. 30 years post-graduate experience in the measurement and application of vibration, infrared and ultrasound. Consultant in predictive maintenance, FMEA and Root Cause Analysis.

Co-Author of Hear More - a guide to using ultrasound for leak detection and condition monitoring

Trainer of ultrasound courses to ASNT Level 1, Level 2 and implementation courses to maximise the benefit of ultrasound.