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Consequences of Maritime Critical Infrastructure
Accidents
Environmental Impacts
Modeling—Identification—Prediction—Optimization—Mitigation
Consequences of Maritime
Critical Infrastructure
Accidents
Environmental Impacts
Modeling—Identification—Prediction—
Optimization—Mitigation
Magdalena Bogalecka
Gdynia Maritime University, Gdynia, Poland
Elsevier
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v
vi Contents
The probabilistic general model of critical infrastructure accident consequences including the superposition of three
models, the process of initiating events generated by a critical infrastructure accident, the process of environment
threats, and the process of environment degradation is presented in the book. The designed model is adopted to the mar-
itime transport critical infrastructure understood as a ship network operating at the sea waters. The proposed model,
methods, and tools are applied to this critical infrastructure accident with chemical release consequences modeling and
identification, on the basis of the statistical data coming from reports of chemical accidents at the Baltic Sea and world
sea waters, and prediction. The model also includes the cost analysis of losses associated with those consequences of
chemical releases. Further, under the assumption of the stress of weather influence on the ship operation condition in
the form of maritime storm and/or other hard sea conditions existence, critical infrastructure accident consequences are
examined, and the results are compared with the previous ones. Finally, the critical infrastructure accident losses opti-
mization is performed, and practical suggestions and procedures of these losses mitigation are given.
Chapter 1, Introduction to the analysis of critical infrastructure accident consequences, is an introduction to the sub-
ject associated with the critical infrastructure accident consequences. The concept of the general model of critical infra-
structure consequences is introduced, and basic notions used in the general model as well as in three particular models
of which the general one is built are presented.
In Chapter 2, Shipping as a critical infrastructure, shipping belonging to the transport sector is considered a critical
infrastructure. The Baltic Sea and the worldwide sea-born shipping and its environmental footprint, especially con-
nected with the sea accidents, are presented. Moreover, the detailed notions concerned with the initiating events gener-
ated by the accident of a shipping critical infrastructure, dangerous for the environment and implicating the
environment threats, which then lead to the environment degradation, are introduced.
In Chapter 3, Modeling critical infrastructure accident consequences, the general semi-Markov model of critical
infrastructure accident consequences is designed. The process of initiating events, the process of environment threats,
and the process of environment degradation are defined. To build models of these particular processes, the vectors of
initial probabilities of these processes staying at their particular states, the matrices of probabilities of these processes
transitions between their particular states, the matrices of conditional distribution functions, and the matrices of condi-
tional density functions of these processes conditional sojourn times at their particular states are defined. The distribu-
tions, such as uniform, exponential, chimney, double trapezium, and quasitrapezium, are suggested and introduced to
describe those processes conditional sojourn times at the particular states. Next, the mean values of particular processes
conditional sojourn times at their states having these distributions are determined. In addition, the unconditional distri-
bution functions of the sojourn times at the particular states of these processes, the mean values of their unconditional
sojourn times, and limit values of transient probabilities at the particular states are determined. Further, the superposi-
tion of the process of initiating events, the process of environment threats, and the process of environment degradation
is done to create the joint probabilistic general model of critical infrastructure accident consequences. Finally, the
unconditional transient probabilities and mean values of sojourn total times of the joint general process at its particular
states, for the sufficiently large time, are determined.
The order of Chapters 3 8 corresponds to the subtitle of the book, that is, “Modeling—Identification—Prediction—
Optimization—Mitigation.” Moreover, the order of these chapters can be seen as a scheme about how to apply, step by
step, proposed methods and procedures of modeling, identification, prediction, and optimization. Chapters 4 7 are con-
structed similarly, according to the scheme: theoretical background and its application to the Baltic Sea and world sea
waters.
In Chapter 4, Identification of critical infrastructure accident consequences, the theoretical background of identifica-
tion of the process of initiating events, the process of environment threats, and the process of environment degradation
is presented. There are methods and procedures for estimating unknown basic and distribution parameters as well as
identifying distribution functions of those processes sojourn times at particular states. Next, these methods and
ix
x Preface
procedures are applied to the identification of particular processes that are parts of the general model of critical infra-
structure accident consequences at the Baltic Sea and world sea waters.
In Chapter 5, Prediction of critical infrastructure accident consequences, the general model of critical infrastructure
accident consequences is practically applied to its prediction at the Baltic Sea and world sea waters. Namely, uncondi-
tional mean sojourn times, limit values of transient probabilities, and approximate mean values of sojourn total times at
particular states of three particular processes of the general model for the fixed sufficiently large time are determined.
Finally, applying the expression for total probability, the unconditional transient probabilities and mean values of
sojourn total times of the joint process linking the process of initiating events, the process of environment threats, and
the process of environment degradation for the fixed time are found.
In Chapter 6, Modeling critical infrastructure accident losses, the functions of the environment losses associated
with the process of environment degradation without and with considering the climate weather impact are defined.
There are presented procedures and formulae estimating the unknown parameters of these functions of losses. Next, the
expected values of the total environment loss without and with considering the climate weather impact, generated by
the accident of one of ships of the shipping critical infrastructure network operating at the Baltic Sea waters, for the
fixed time interval, are determined and compared each other. In addition, the indicator of resilience to the loss associ-
ated with the critical infrastructure accident related to the climate weather change is proposed.
In Chapter 7, Optimization of critical infrastructure accident losses, the methods based on the results of the general
model of critical infrastructure accident consequences and the linear programming are proposed to the critical infra-
structure accident losses optimization without and with considering the climate weather impact. The method of the
optimization of critical infrastructure accident losses determining optimal values of limit transient probabilities at partic-
ular states of the process of environment degradation that minimize the expected value of total environment losses con-
cerned with the critical infrastructure accident for the fixed interval of time is proposed. These tools are practically
tested to the minimizing losses associated with a chemical release generated by an accident of a ship critical infrastruc-
ture network operating at the Baltic Sea waters.
Chapter 8, Mitigation of critical infrastructure accident losses, contains an overview of the obtained values of losses
associated with the shipping critical infrastructure accident without and with considering the climate weather change
impact, and results of their optimization are presented as well. Moreover, the general procedures and the new strategy
assuring lower environment losses concerned with chemical releases caused by an accident of ship critical infrastructure
network operating within the Baltic Sea or world sea waters are proposed.
The book is completed with a summary containing the evaluation of obtained results, the perspective of future
research on the considered problems, and the suggestion of other practical application of the proposed general model of
critical infrastructure accident consequences.
Moreover, the list of appropriate references is enclosed in bibliography. Appendices include the tables with realiza-
tions of conditional lifetimes at particular states of the process of initiating events, the process of environment threats,
and the process of environment degradation used in the identification of the unknown parameters of these processes.
The table of chi-square distribution necessary for the identification of these processes and summarized procedure of
application of the general model of critical infrastructure accident consequences is also given.
Presented in the book the theoretical background of the methods and procedures of critical infrastructure accident
consequences modeling, identification, prediction and optimization, and their practical applications to the forecasting
and optimization of the environment losses caused by the chemical releases generated by an accident of a ship critical
infrastructure network allows one to improve the quality in the field of maritime environment protection. The need of
common considering the initiating events, environment threats, and environment degradation in the accident conse-
quences analysis is obvious and very important in the maritime transport. Linking three processes, the process of initiat-
ing events, the process of environment threats, and the process of environment degradation is an original and novel
approach to the maritime critical infrastructure accident consequences analysis not used in other scientific descriptions
by now.
The book is offered to academics, researchers, consultants, practitioners, and other professionals to apply the pro-
posed theoretical background in various areas of risk assessment, environment control and protection, and accident
impacts analysis and management, having clear pattern in maritime sector to follow.
Acknowledgment
It is a genuine gratefulness and warmest regard to acknowledge and thank Prof. Krzysztof Kołowrocki for his inspira-
tion, ideas, and suggestions as well as for his great support and encouragement.
xi
Chapter 1
Chapter Outline
1.1 Basic notions of process of initiating events 2 1.3 Basic notions of process of environment degradation 4
1.2 Basic notions of process of environment threats 3
The critical infrastructure is a complex system in its operating environment, and significant features are its inside and
outside dependencies, which, in the case of its degradation, have significant destructive influence on the health, safety
and security, economics, and social conditions of large human communities and territories (Council Directive 2008/
114/EC; Moteff et al., 2003; Sergiejczyk and Dziula, 2013). The critical infrastructure accident is understood as an
event that changes the critical infrastructure safety state into another safety state that is worse than the critical safety
state, which is dangerous for the critical infrastructure itself, its operating environment and has disastrous influence on
human health and activity (Dziula et al., 2014; Kołowrocki, 2013a,b; Kołowrocki and Soszyńska-Budny, 2012a,b;
Rinaldi et al., 2001) as well. Each critical infrastructure accident can generate the initiating events, causing dangerous
situations in the critical infrastructure operating surroundings. The process of these initiating events can result in this
type of environment threats and lead to the dangerous environment degradations (Fig. 1.1).
Thus the probabilistic joint general model of critical infrastructure accident consequences includes the models of the
process of initiating events generated either by the critical infrastructure accident or by its loss of safety critical level,
the process of environment threats, and the process of environment degradation (Bogalecka, 2010; Bogalecka and
Kołowrocki, 2006, 2015a,b, 2016, 2017a).
By using the statistical data from free-accessible reports of chemical accidents at sea (CEDRE, 2018; GISIS, 2018),
the proposed model is applied to modeling, identifying, and predicting the critical infrastructure accident consequences
generated by the critical infrastructure defined as a ship operating within the Baltic Sea area (Fig. 1.2) and to the cost
analysis of losses associated with these consequences as well. Furthermore, under the assumption of the stress of clima-
teweather influence on the operation conditions in the form of maritime storm and other hard sea conditions existence,
the mentioned critical infrastructure accident consequences and losses associated with them are examined, and the
results are compared with the previous results, not considering the weather impact. Finally, the critical infrastructure
accident losses optimization and mitigation are performed, and practical suggestions and procedures for reducing the
critical infrastructure accident losses are proposed.
In the experiment sea area, statistical data from Fig. 1.2 are placed in the neighborhood of the maritime ferry route
(Bogalecka and Kołowrocki, 2018a). The considered maritime ferry is a passenger/ro-ro cargo ship operating in the
south of the Baltic Sea, between Gdynia and Karlskrona ports on a regular everyday line. The approximate maritime
ferry sea water route is 135 nautical miles long. Moreover, the extension of general model of critical infrastructure acci-
dent consequences application using the wider data collected at the world sea waters and ports is given. The obtained
results of the considered cases were compared with each other.
FIGURE 1.1 Interrelations of the critical infrastructure accident consequences general model.
The modeling, identification, prediction, and optimization methods, algorithms, and procedures are adapted from
Kołowrocki and Soszyńska-Budny (2011), where they were used related to operation processes of industrial systems,
such as the maritime ferry technical system and the port oil piping transportation system, and significantly developed to
an accident consequences analysis.
To construct the general model of critical infrastructure accident consequences and to apply it practically, the basic
notions concerned with these three particular processes by which the model is composed of are listed and named in
Sections 1.11.3.
H lj ðtÞ—the conditional distribution function of sojourn time of transition between states of the process of initiating
events,
hlj ðtÞ—the conditional density function of sojourn time of transition between states of the process of initiating
events,
M lj —the mean value of conditional sojourn time of transition between states of the process of initiating events,
H l ðtÞ—the unconditional distribution function of sojourn time of transition at states of the process of initiating
events,
θl —the unconditional sojourn time at states of the process of initiating events,
M l —the mean value of unconditional sojourn time at states of the process of initiating events,
pl —the limit value of transient probabilities at particular states of the process of initiating events,
l
M^ —the mean value of sojourn total time at particular states of the process of initiating events for the fixed time.
niðk=lÞ —the total number of the process of environment threats departures from the state siðk=lÞ during the experimental
time,
piðk=lÞ ð0Þ—the probability of initial state of the conditional process of environment threats at the initial moment t 5 0;
pijðk=lÞ —the probability of transition between states of the conditional process of environment threats,
ηijðk=lÞ —the random conditional sojourn time of transition between states of the conditional process of environment
threats,
ij
Hðk=lÞ ðtÞ—the conditional distribution function of sojourn time of transition between states of the conditional process
of environment threats,
hijðk=lÞ ðtÞ—the conditional density function of sojourn time of transition between states of the conditional process of
environment threats,
ij
Mðk=lÞ —the mean value of conditional sojourn time of transition between states of the conditional process of environ-
ment threats,
i
Hðk=lÞ ðtÞ—the unconditional distribution function of sojourn time of transition at states of the conditional process of
environment threats,
4 Consequences of Maritime Critical Infrastructure Accidents
ηiðk=lÞ —the unconditional sojourn time at states of the conditional process of environment threats,
i
Mðk=lÞ —the mean value of unconditional sojourn time at states of the conditional process of environment threats,
i
pðk=lÞ —the conditional approximate value of transient probabilities at particular states of the process of environment
threats in the subarea Dk , while the process of initiating events is in the state el ;
i
M^ ðk=lÞ —the mean value of sojourn total time at particular states of the process of environment threats for the fixed
time.
i
M^ ðkÞ —the mean value of sojourn total time of the joint process linking the process of initiating events, the process
of environment threats, and the process of environment degradation at particular states in the subarea Dk ; for the
fixed time,
LiðkÞ ðtÞ—losses associated with the process of environment degradation in the subarea Dk ; at the environment degra-
i
dation state rðkÞ ;
LðkÞ ðtÞ—losses associated with the process of environment degradation in the subarea Dk ;
LðtÞ—the total value of losses associated with the process of environment degradation in all subareas Dk of the con-
sidered critical infrastructure operating in the area D;
i
KðkÞ ðtÞ—the cost function expressing the losses associated with the process of environment degradation in the sub-
i
area Dk ; at the environment degradation state rðkÞ ;
CðtÞ—the semi-Markov climateweather change process (affecting losses associated with the process of environ-
ment degradation),
cb —the state of the climateweather change process,
w—the number of climateweather change process states,
qb —the conditional approximate value of limit transient probabilities at the particular states of the climateweather
change process,
ρðkÞ —the coefficient of the climateweather change process impact on the losses associated with the process of the
environment degradation in the subarea Dk ;
½LiðkÞ ðtÞðbÞ —conditional losses associated with the process of environment degradation in the subarea Dk ; at the envi-
i
ronment degradation state rðkÞ , while the climateweather change process at the critical infrastructure accident area
is at the climateweather state cb ;
½LðkÞ ðtÞðbÞ —conditional losses associated with the process of environment degradation in the subarea Dk , while the
climateweather change process is at the climateweather state cb ;
LðkÞ ðtÞ—unconditional losses associated with the process of environment degradation in the subarea Dk ; impacted by
the climateweather change process,
LðtÞ—the total value of unconditional losses associated with the process of environment degradation in all subareas
Dk of the considered critical infrastructure operating in the area D; impacted by the climateweather change
process,
RIðkÞ —the indicator of the environment of the subareas Dk resilience to losses associated with the critical infrastruc-
ture accident related to the climateweather change,
RI—the indicator of the environment of the entire area D resilience to losses associated with the critical infrastruc-
ture accident related to the climateweather change,
q_iðkÞ —the optimal value of limit transient probabilities qiðkÞ at the particular states of the process of environment deg-
radation in the subarea Dk ;
L_ðkÞ ðtÞ—the minimum value of losses associated with the process of environment degradation in the subarea Dk ;
_
LðtÞ—the minimum total value of losses associated with the process of environment degradation in all subareas Dk
of the considered critical infrastructure operating in the area D;
L_ ðkÞ ðtÞ—the minimum value of losses associated with the process of environment degradation of the subarea Dk ;
impacted by the climateweather change process,
_
LðtÞ—the minimum total value of losses associated with the process of environment degradation in all subareas Dk
of the considered critical infrastructure operating in the area D; impacted by the climateweather change process,
RI_ðkÞ —the indicator of the environment of the subareas Dk resilience to losses associated with the critical infrastruc-
ture accident related to the climateweather change, after the optimization,
_
RI—the indicator of the environment of the entire area D resilience to losses associated with the critical infrastruc-
ture accident related to the climateweather change, after the optimization.
Chapter 2
Chapter Outline
2.1 Overview of ship accidents at Baltic Sea and world sea 2.2.2 Threats from chemical releases into marine
waters 8 environment 15
2.2 Consequences of maritime transport of chemicals for 2.2.3 Marine environment degradation effects coming
people, environment, and infrastructure 14 from chemical releases 20
2.2.1 Initiating events caused by world sea ship traffic
accidents 14
The European Commission described critical infrastructure as an asset or system which is essential for the maintenance
of vital societal functions. The damage to a critical infrastructure, its destruction, or disruption by natural disasters, ter-
rorism, criminal activity, or malicious behavior may have a significant negative impact for the security of the European
Union and the well-being of its citizens.
There are two main sectors of European Critical Infrastructure that are divided into some subsectors (Council
Directive 2008/114/EC):
G Sector I—energy:
G electricity (infrastructures and facilities for generation and transmission of electricity in respect of the supplied
electricity),
G oil (oil production, refining, treatment, storage, and transmission by pipelines), and
G gas (gas production, refining, treatment, storage, and transmission by pipelines, LNG terminal).
G Sector II—transport:
G road transport,
G rail transport,
G air transport,
G inland waterways transport, and
G ocean and short-sea shipping and ports.
Transportation infrastructure is defined as the physical distribution systems critical in supporting the national secu-
rity and economic well-being of a nation, including the national airspace systems, airlines, aircraft, airports, roads and
highways, trucking and personal vehicles, ports and waterways, and the vessels operating thereon, mass transit, both
rail and bus, pipelines, including natural gas, petroleum, and other hazardous materials, freight and long haul passenger
rail, and delivery services (Moteff et al., 2003; Pursiainen, 2007; US President’s Commission on Critical Infrastructure
Protection, 1997).
According to the previous discussions, shipping is a maritime segment of the general transportation system, the
safety of which strongly depends on the individual ships that are components of the maritime transportation system.
Consequently, ships are components of the critical infrastructure (Blokus-Roszkowska et al., 2016a). The technical con-
dition of a ship, crew training, and traffic safety are influential factors for the whole safety of the transportation system.
In addition, the shipping subsector is a critical infrastructure network that interacts with other sectors. For example, the
shipping and the wind energy sector interact with each other. Wind farms occupy some marine areas. There is usually a
safety zone of 500 m around wind farms with restrictions for shipping, and a buffer zone of 500 m around the cables,
where anchoring of vessels is prohibited (Bogalecka et al., 2016). On the other hand, shipping may cause accidental
pollution and in this way have influence on the proper operation of other critical infrastructures. In other words, the
inside and outside dependencies of the critical infrastructures are observed and defined as a linkage or connection
between two infrastructures, through which the state of one infrastructure influences or is correlated to the state of the
other (Rinaldi et al., 2001). The system inside dependencies are the ones within a system itself, that is, the relationship
between components and subsystems in a system causing state changes of other components and subsystems and in a
consequence, resulting in changes of the system state. The system outside dependencies are those coming from the
system-operating environment (external factors), including changes of the system state caused from outside the system
conditions, for example, climate changes, changes of its functionality, location, other objects, government, and human
decisions (regulations, economic, and public policy). The occurrence of these dependencies is defined as the critical
infrastructure network cascading effect. It means the degrading effects occurring within an infrastructure and between
infrastructures in their operating environment, including situations in which one infrastructure causes degradation of
another one, which again causes additional degradation in other infrastructures and in their operating environment.
Taking this into consideration, we can define the critical infrastructure as a complex system in its operating environ-
ment, the significant features of which are inside-system dependencies and outside-system dependencies that in the case
of its degradation have a significant and destructive influence on the health, safety and security, economic, and social
conditions of large human communities and territory areas.
In reference to the Baltic Sea the set of ships operating within this area’s waters at a fixed moment of time (or at the
fixed time interval) is called the dynamic Baltic Shipping Critical Infrastructure Network—BSCIN (Bogalecka et al.,
2016). The BSCIN is an element of the Global Baltic Network of Critical Infrastructure Networks—GBNCIN that
closely cooperates and interacts with the Baltic port critical infrastructure, the Baltic ship traffic, and port operation
information critical infrastructure that are described in Blokus-Roszkowska et al. (2016b) and Guze and Ledóchowski
(2016), respectively, and also are elements of the GBNCIN. The objects of these critical infrastructures are vulnerable
to damage, caused by external factors, occurring threats of other critical infrastructures and their networks, finally caus-
ing environment degradation.
2.1 Overview of ship accidents at Baltic Sea and world sea waters
The maritime transport is used for the transportation of goods and passengers by sea. The shipping also allows move-
ment of large quantities of goods over long distances if the cargo delivery time does not matter. The main traffic lanes
connect Asiatic, African, European, and American economic centers, crossing the Atlantic, Pacific, and Indian oceans
(Fig. 2.1).
These days, there are usually more than 80,000 ships in ocean and sea areas around the world at any given moment
(Fig. 2.2).
FIGURE 2.2 Number of moving ships on the world sea waters (September 10, 2015, 17:38). Generated from: www.marinetraffic.com.
The unusual traffic density at some regions is observed. For example, 15% of the global transportation is focused
within the Baltic Sea (Andersson et al., 2016; HELCOM, 2009; Luhtala, 2010; Ojala, 2015; Posti and Häkkinen, 2012).
It means that there are more than 70,000 ships entering and leaving the Baltic Sea every year, and about 2000 vessels
on the Baltic Sea at any time (Fig. 2.3). The main destinations for cruise ships include St. Petersburg, Copenhagen,
Tallinn, Helsinki, and Stockholm (Caban et al., 2017; Hänninen and Rytkönen, 2006; HELCOM, 2018a; Nikula and
Tynkkynen, 2007; Serry, 2014).
The traffic intensity in any world region and a number of ships recorded by automatic identification system may be
observed in real time through the Internet (www.marinetraffic.com).
More than half of the goods are regularly transported by the sea, either in a bulk or a packaged form. The United
Nations Conference on Trade and Development estimates that the operation of merchant ships contributes about 380
billion dollars in freight rates within the global economy, equivalent to about 5% of the total world trade (International
Chamber of Shipping, 2018). The most popular chemical cargos are petroleum hydrocarbons, palm and vegetable oils,
and methanol.
A lot of chemicals transported by the sea if introduced into the marine ecosystem, may create a hazard to human
health and marine life, harm living resources, damage amenities, or interfere with other marine users. These chemical
cargoes, because of their properties and behavior in the marine environment, are divided into two main groups: oils and
other chemicals, also called hazardous and noxious substances (HNS) (IMO, 2002).
The spilled oil threatens the marine ecosystem causing damages to wildlife and their habitats and poisoning exposed
organisms. These effects may appear immediately after the oil release or in the later stage of spillage through long-term
exposure. Moreover, the spilled oil undergoes natural processes, dependent on its properties as well as the weather con-
dition, such as evaporation, spreading, dispersion, emulsification, dissolution, sedimentation, oxidation, and biodegrada-
tion (Fig. 2.4).
Emulsification is one of the most negative effects that means formatting the water in oil emulsions, often called
“chocolate mouse.” The formatted emulsion keeps the oil on the sea water surface and significantly affects the environ-
ment, also being the barrier disturbing a gas exchange between the sea water and the air (AMSA, 2003; IMO, 2005;
ITOPF, 2011; Ornitz and Champ, 2002). HNS when released into the marine environment, may rapidly evaporate, float
on the water surface, dissolve in the water, sink to the bottom, or reveal more than one of these behaviors at the same
time (Fig. 2.5). Moreover, HNS may also react between themselves or with the sea water and air components
(HELCOM, 2002; IMO, 1999, 2002; Purnell, 2009).
The huge traffic is one of the reasons behind sea accidents and consequently accidental pollution (Butt et al., 2013;
EMSA, 2018a, 2018b; HELCOM, 2014; ITOPF, 2019). In the field of accidental marine pollution, oil spills are one of the
biggest sea accidents, and a chemical cargo release is often accompanied by a spillage of the ship’s fuel. Approximately
5.74 million tons of oil was spilled in the marine ecosystem as a result of tanker incidents and accidents from 1970 to 2018.
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drilled the counterpoise and the column for the governor spindle. I
suppose the twist-drill had its origin in these Hartford works.
I never saw any twist-drills in England except at Mr. Whitworth’s,
and these I thought were the funniest things I ever did see. They
were twisted by the blacksmith out of square bars and with a uniform
quick twist, were left rough, and did not fill the hole, and the ends
were flattened out in the form of the common drill to scrape, and not
to cut.
When I returned from England in 1868 twist-drills were coming into
general use in this country. After 1876 the firm of Smith & Coventry
introduced them in England.
At that time almost everything in machine-shops was done in the
old-fashioned way, and accuracy depended entirely on the skill of the
workman. The tool work left much to be done by the fitter.
Interchangeability was unknown, even in screw-threads. For
example, when nuts were removed from a cylinder head, pains had
always to be taken that each nut was replaced on its own bolt, as no
two were exactly of a size. This condition developed a class of very
skillful all-round workmen; but my earliest observation showed me
that in manufacturing it was important that so far as possible the
personal factor should be eliminated. I adopted the rule that in
mechanical work there was only one way to insure that anything
should always be done right, and that was to make it impossible that
it should be done wrong. For example, in my governor gears their
true running required that the bore should be absolutely correct, both
in position and in direction. I had seen many gears bored. They were
held in the jaws of a chuck and trued by marking their projecting side
when running with a piece of chalk. It was evident that absolute truth
could hardly ever be reached in this way, and the approximation to it
depended wholly on the skill and pains of the workman. Besides,
much time was lost in setting each wheel. These objections were
much aggravated in the case of bevel-gears.
I met these difficulties in this way. In standardizing my governors I
found it necessary to make eight sizes, but managed to use only
three different pairs of gears. I made a separate chuck for each of
these six wheels, the faces of which were turned to fit the top and
inner ends of the teeth, the same surfaces to which I had seen the
chalk applied. When the castings were received from the foundry the
first operation on them was to bed them to their chucks, which were
covered with a thin coating of red lead for this purpose. The
workman was careful to remove only projecting imperfections without
touching the true surfaces of the teeth. After this the gears, being
held firmly to their chucks by means of a yoke, were bored rapidly
and always with absolute truth. Result: their running was practically
noiseless.
Mr. Freeland taught me the secret of producing true cylindrical
surfaces by grinding with a wheel. It was to let the swiftly revolving
wheel traverse the surface as it rotated, touching only the highest
points, and these very lightly. This avoided the danger of errors from
the springing of either the piece or the wheel, which under strong
pressure is sure to take place to some extent, even in the best
grinding-machines. I have found this delicacy of touch to be a most
difficult thing to teach the ordinary workmen. They often manage to
produce by grinding a surface more imperfect than it was before.
I took extreme pains to insure that the axes of the joint pins should
intersect the axis of the governor spindle and those of the governor
balls, and should be equidistant from the center of the counterpoise,
these parts of the joints having been turned to true spherical forms
by means of a circular tool-rest. For this purpose I employed a
feeling-gauge, consisting of a cylindrical stem fitting the hole as
drilled, with a curved arm projecting from this stem and terminating in
a point that would rub on the external surface of the balls. By this
means we almost always detected some slight inaccuracy, which
was remedied by the use of a round file. The joint holes were
afterwards finished with long reamers, the cutting portion of which
was in the middle of their length. The front end of the reamer fitted
the drilled hole and extended quite through the joint, so guiding the
cutting edges as they entered, and the back end of the reamer filled
the hole that had been reamed.
I finally tested their alignment by bringing the last of the five joints
together after the others had been united, when the forked link
should swing freely to the ball without the least tendency in either
direction from its exact place. This it always did.
Some time afterwards I adopted the plan of dispensing with heads
and washers on the joint pins, reaming the holes in the central
portions of the joint slightly smaller than those in the arms and
making the pin a hard fit in the former. There was never any
tendency for a pin to get loose in the running of the governor. I also
at a later date cut the counterpoise in two a short distance above the
joints, so that the mass of its weight did not need to be started and
stopped when the speed of the governor changed. I could not see,
however, that this was of any advantage, although when the
governor balls were pulled around by hand no motion was imparted
to the mass of the counterpoise. The action was apparently quite
perfect before.
CHAPTER III
Engineering conditions in 1860. I meet Mr. Allen. Mr. Allen’s inventions. Analysis of
the Allen link.