Course Guide Lines-Tanker Safety

GUIDE LINES

Training of Masters Officers on Tankers

and

Compiled by LESLIE HEMACHANDRA

Effective date: 1st August 2005

1

Introduction The mandatory requirements for the training of masters, officers and ratings on tankers are set out in Regulation V/1 of the Annex to the STCW Convention, as amended in 1995, and Section A-V/1 of the STCW Code. These guide lines will be effective from 1st August 2005 . Health and Safety: Conduct of training All Training Institutes must adhere to applicable regulations made under the Health and Safety at Work. Training Institutes are required to make assessments of any potential risks to the health and safety of staff and trainees that may be associated with their activities. They are also required to identify, implement, monitor and review effective measures for minimizing and controlling them. In addition, Training Institutes will be required to make effective arrangements for dealing with any emergency, incident or accident that may occur during the course of training . Training for masters and officers on tankers Scope

This training is intended for masters, officers and ratings serving on tankers who are required to undertake additional training and familiarization in accordance with the IMO Convention on Standards of Training, Certification and Watchkeeping (STCW), as amended in 1995, and the STCW Code.

Structure

The training is in two stages: i Familiarization Intended for officers and ratings assigned specific duties and responsibilities related to cargo or cargo equipment on tankers. This stage of training is common to all types of tanker and consists of three options: -

at least three months sea-going service on tankers, in order to gain operational experience and knowledge of safe operational practices in loading, carrying and discharging bulk oil, chemical or liquefied gas cargoes; or

2

-

at least one month sea-going service on tankers of less than 3,000 GT engaged on voyages not exceeding 72 hours in order to gain sufficient operational experience and knowledge of loading and discharging procedures; or

. ii Specialized Intended for masters, chief engineer officers, chief mates, second engineer officers and any person with immediate responsibility for loading, discharging and care in transit or handling of cargo, such as cargo officer or cargo engineer. The training at this stage is specialized according to the type of cargo – oil, chemical or liquefied gas. Entry standards

There are no specific entry standards to the first stage familiarization training. Entry to the second stage of specialized training is dependent upon completion of the first stage familiarization training.

Course intake limitations The number of trainees on each course will depend upon the availability of instructors, equipment and facilities available for conducting the training. Staff requirements

All training and instruction must be given, and assessments carried out, by properly qualified personnel. Instructors must understand the specific objectives of the training and be familiar with the operation of tankers and the equipment commonly found in them. In addition, those involved should have: i ii

a knowledge of instructional techniques and of training methods and practice; an understanding of assessment methods and practice;

3

iii

Outcomes

Assessment

have gained practical instructional and assessment experience under the supervision and to the satisfaction of experienced instructors/assessors.

The outcomes to be achieved in the familiarization training are set out in Annex A. The outcomes for the specialized training in oil, chemical and liquefied gas tanker operations are at Annexes B, C and D respectively. Training Institutes must devise appropriate instruments of assessment, for consideration as part of the approval process. 100% attendance is required. Accurate records should be made of the assessment instruments used, showing how evidence is generated. Records of candidates’ achievements must be kept and retained for subsequent verification. A written test would be carried out at the end of training.

Facilities and equipment

Appropriate instructional facilities including internationally recognized facility to simulate shipboard conditions, visual aids and other equipment as necessary. .Facilities and equipment must be available which enable practical demonstrations and exercises to be undertaken in the context of the specific objectives of the training.

The facilities must include: -

copies of the most important text books and regulatory texts as shown in Annex E on display and available for reference pictures and technical drawings of oil, chemical and liquefied gas tankers, as appropriate equipment for demonstrating (where practicable) the physical properties of oil, chemical and gases carried in bulk in merchant ships specialized equipment, on display and available for demonstration as required, including: -

personal safety and personal protective equipment

-

oxygen resuscitator

-

gas indicator tubes

-

portable measuring equipment

and

detecting

4

Training plan

For those following planned training schemes approved by DMS leading to first certificates of competency, it is intended that the familiarization training should form an integral part of the overall training programme and be complementary to other studies. The specialized training programme may also be integrated into such a training programme where shipboard training is being undertaken on oil, chemical or liquefied gas tankers. In these circumstances, the training may be undertaken in progressive stages during collegebased phases and the intervening periods of sea service. It is not appropriate to specify the duration of the learning provided achievement of the specified standard (outcomes) is properly assessed and recorded. Alternatively, for candidates who are not following a planned and structured training programme, the training may be provided as full time block courses as described. A single course covering combinations such as petroleum and chemical need not include repetition of the familiarization elements for each type of cargo. Conduct of training Training and assessment must be undertaken by persons qualified in accordance with the provisions of Section A I/6 of the STCW Code. . The specialized training should incorporate two parts, which may be delivered concurrently: a general part concerning principles involved and a part on the application of those principles to ship operation. As much use as possible should be made of shipboard operation and equipment manuals, videos and other suitable visual aids and demonstration equipment. Every opportunity should be taken to introduce a discussion of the part to be played by the shipboard safety organization.

5

Quality standards

The arrangements for delivering the training and assessing competence must be continuously monitored through a quality standards system to ensure achievement of defined objectives. Training Institutes are required to maintain a quality standard through documented procedures that shall be inspected and monitored by DMS The quality standards system and evaluation arrangements may be part of Training Institute’s overall quality assurance system.

Documentation

Satisfactory completion of each stage of training and attainment of the desired standard will be attested to by a certificate issued by the centre, in the format approved by DMS. Approval Training Institutes offering training and assessment must be approved by DMS.

Guidelines on structure and content of tanker familiarization course The following guidelines apply where the training is provided as a full time block course. The duration of the course will depend on the background and prior knowledge and experience of course participants. However, where potential candidates have limited prior experience, it is unlikely that the stated objectives can be achieved in less than 30 hours instruction overall. The course should be based on the syllabus given at paragraphs 2 to 7 of Section A-V/1 of the STCW Code. It should be designed so as to achieve the outcomes listed below and must include practical demonstrations where appropriate. Outcomes At the end of the course the student should have the specialized technical knowledge to serve on a tanker and be assigned specific duties and responsibilities related to cargo or cargo equipment. The student will have gained sufficient knowledge of the practical application of the basic principles and concepts of safe tanker operations in order to carry out those duties. The familiarization training will enable the student to demonstrate an understanding of these principles and will include:-

6

Characteristics of cargoes An outline treatment of the physical properties of oil, chemicals and gases carried in bulk. A simple explanation of the kinetic theory of evaporation; condensation; volatility; vapour pressure/temperature relationship; influence of pressure on boiling temperature; saturated, true and Reid vapour pressures; partial pressures; diffusion; the effect of high vapour pressure cargoes; vapour density. Elements of the chemistry of acids and bases, incompatibility, and chemical reactions of well known groupings sufficient to enable the proper utilization of shipboard safety codes. Flammability The fire triangle; difference between fire and explosion; defining the flammable range; practical significance of lower and upper flammable limits; the meaning and effect of flashpoint and its relationship with the lower flammable limit; classification of cargoes by flashpoint and auto-ignition temperature. Toxicity Simple explanation of principles and basic concepts: routes of entry of toxic materials into the blood stream; local and systemic poisoning; irritants; threshold limit values; occupational exposure standards / limits as time weighted averages; defining parts per million; particular toxic effects of hydrocarbon gases; benzene and hydrogen sulphide and other commonly carried chemicals; where to look for information. Accidents to personnel and associated first-aid do's and don’ts. Hazards Flammability and explosion hazards; effects of cargo contamination on flashpoint; sources of ignition; static and current electricity; smoking hazards; chemical and impact sparks; hot work; fixed and portable electrical equipment; spontaneous combustion; pyrophoric iron sulphides. Reactivity hazards: an appreciation of the practical consequences of self reaction, polymerisation, effects of temperature, impurities as catalysts; reactions with air, water and other chemicals. Corrosion hazards: dangers to personnel; attacks on constructional materials; effects of concentration and evolution of hydrogen.

7

Hazard Control Tanker design for safety; the safety barrier; the hazardous and gas-free zones; maintaining the gas-free zones; gas atmospheres in cargo tanks during loading, discharging, ballasting and tank washing; water padding, drying agents and monitoring techniques; anti-static measures. Segregation; cargo inhibition and the importance of compatibility of materials. Closed gauging and closed loading systems; vapour recovery; control of tank atmospheres; monitoring techniques; ventilation systems; gas dispersion; weather considerations; principles of flame screens and flame arrestors. Electrical protection methods. General safety precautions and "good housekeeping" . Safety equipment and protection of personnel Entry into dangerous spaces; case histories; oxygen deficiency, with particular reference to inert gas systems; flammable, toxic and inert gas atmospheres; testing of enclosed space atmospheres; types of instruments and their operating principles; calibration; how and what to test for; rescue and escape procedures. Specialized fire-extinguishing appliances. Breathing apparatus and tanker evacuating equipment; safe use of protective clothing and equipment; use of resuscitators and other rescue and escape equipment. Pollution hazards and prevention Environmental concerns on the release of oil, chemicals and gases; marine pollution and air pollution including effect of specific gravity and solubility, vapour pressure and atmospheric conditions; pollution prevention methods; the shipboard oil pollution emergency plan (SOPEP); clean ballast and segregated ballast; garbage controls; action in event of spillage or risk of spillage: reporting, notification and containment procedures. Tanker operations Note: This section should be directed as much as possible to the type of vessel that the candidate is expected to join, where this is known. General design characteristics of oil, gas or chemical tankers as appropriate; typical pumping and pipeline arrangements, ring main, direct line, deep well; gauging devices and instruments for ullages and temperatures; open and closed gauging; vapour control arrangements, venting systems; ship/shore safety check lists; log book keeping and night orders; general description of cargo and tank operations during a voyage cycle; duties of watchkeepers at each stage of the

8

voyage cycle; cargo monitoring; definitions and terminology, back pressure, pressure surge; action of watchkeepers during an emergency; case studies.

9

(A) SPECIFICATION FOR TRAINING IN TANKERS (OIL) Guidelines on structure and content of oil tanker training programme The following guidelines apply where the training is provided as a full time block course. The duration of the course will depend on the background and prior knowledge and experience of course participants. However, where potential candidates have limited prior experience, it is unlikely that the stated objectives can be achieved in less than 30 hours instruction overall. The course should be based on the syllabus given at paragraphs 8 to 14 of Section A-V/1 of the STCW Code and designed so as to the achieve the outcomes listed below. Outcomes At the end of the course the student should have the relevant technical knowledge to assume the responsibilities of Master, Chief Officer, Chief Engineer, Second Engineer or of any other person having direct responsibility for cargo operations. The course will include those outcomes as stated in the familiarization training but will be addressed in greater detail in accordance with the requirements of the students. In addition to those outcomes as outlined in the familiarization training, the course will include the following principles: International and National Regulations and Codes of Practice Explanation of the relevant regulations, conventions and codes of practice as they apply to oil tankers. The legal implications, responsibilities and consequences. The IMO Manual on Oil Pollution. The International Safety Guide for Oil Tankers and Terminals (ISGOTT). Characteristics of cargoes (to include a revision of those topics covered in the familiarization course) Definitions; chemical and physical properties of oil cargoes; chemical symbols; molecular structure of hydrocarbon products; relationship between molecular structure and physical properties; chemical composition of crude oils; refining into products; vapour pressures and their measurement. Associated hazards (to include a revision of those topics covered in the familiarization course) Flammability, explosiveness and toxicity; medical aspects of the health hazards; inert gas composition; electrostatic hazards.

10

Oil Tanker Design and Equipment General arrangements of oil tankers; design evolution; accommodation ventilation. Pump room arrangements; cargo, ballast, tank and pipeline systems; types of cargo pumps and characteristics; stripping pumps and pipelines. Cargo heating systems. Gauging systems and alarms; alarm systems and mandatory requirements; control systems; the inert gas system, construction and operation; venting requirements; gas detectors and oxygen analysers; design of crude oil washing systems; types of tank washing machines, fixed and portable; cargo hoses; insulating flanges; electrical continuity; anti-static measures; safety aspects of electrical systems. Oil Tanker Operations Cargo calculations; the use of calibration tables; loading and discharging plans and procedures; ballasting; tank cleaning operations, crude oil and water washing; precautions when using slop tanks; safety precautions; inerting, purging and gas freeing procedures, the critical dilution line; ship-to-ship transfers; monitoring and the use of checklists; ship/shore liaison; repair and maintenance procedures; permits to work; safety factors; hot and cold work; precautions; control of entry into enclosed spaces, gas detection, instrument maintenance and calibration; Importance of the proper supervision of personnel. Pollution Control MARPOL; published prevention guidelines; constructional requirements; ballast, cargo and slop tank arrangements; piping arrangements; monitoring equipment; permitted discharges; the IOPP Certificate; the Oil Record Book; the action to be taken in the case of a spill at sea or in port; mitigating the effect; oil spill clean up equipment; reporting requirements; air pollution and proposed measures to reduce; gases/vapours involved; containment procedures; vapour recovery systems; precautions whilst operating vapour recovery . Emergency Procedures Hazard and risk; definitions; reduction of risk to an acceptable level; elements of risk reduction; design considerations; alarm and shut down systems; information and communication structures; role of safety officers; Actions in the event of failure of services essential to cargo or following collision, stranding, spillage or other incident; contingency planning; legal requirements;

11

organization; training and practice; rescue drills; teamwork; use of safety equipment, including breathing apparatus and escape equipment; check lists; ship/shore liaison; reporting; case studies. Fire fighting on oil tankers. Safe entry into and rescue from enclosed spaces. Medical first-aid procedures and the use of resuscitation equipment.

(B)GUIDELINES ON STRUCTURE AND CONTENT OF CHEMICAL TANKER TRAINING PROGRAMME The following guidelines apply where the training is provided as a full time block course. The duration of the course will depend on the background and prior knowledge and experience of course participants. However, where potential candidates have limited prior experience, it is unlikely that the stated objectives can be achieved in less than 34 hours instruction overall. The course should be based on the syllabus given at paragraphs 15 to 21 of Section A-V/1 of the STCW Code. The course should be designed so as to the achieve the outcomes listed below. Outcomes At the end of the course the student should have the relevant technical knowledge to assume the responsibilities of Master, Chief Officer, Chief Engineer, Second Engineer or of any other person having direct responsibility for cargo operations. The course will include those outcomes as stated in the familiarization training but will be addressed in greater detail in accordance with the requirements of the students. In addition to those outcomes, as outlined in the familiarization training, the course will include the following principles: International and National Regulations and Codes of Practice Explanation of relevant regulations, conventions, codes of practice as they apply to chemical tankers, the legal implications, responsibilities and consequences; The International Safety Guide for Oil Tankers and Terminals (ISGOTT), the International Chamber of Shipping (ICS) Tanker Safety Guide (Chemicals), ICS Safety in Chemical Tankers, US Coast Guard Chemical Data Guide, IBC Code (IMO).

12

Characteristics of cargoes (to include a revision of those topics covered in the familiarization course) Chemical and physical properties of cargoes, chemical symbols, molecular structure of organic and non-organic products, relationship between molecular structure and flammable/toxic properties; reactivity of cargoes, corrosion and segregation; chemical groups and industrial usage, vapour pressures and their measurement. Associated hazards (to include a revision of those topics covered in the familiarization course) Flammability, explosivity and toxicity; medical aspects of the health hazards; inert gas composition; electrostatic hazards; sources of hazard data. Chemical Tanker Design and Equipment General arrangements of chemical tankers; design evolution; Accommodation ventilation, airlocks. Pump room arrangements, cargo, ballast tank and pipeline systems; types of cargo pumps, stripping systems, alarm systems and mandatory requirements. Control systems; gauging systems and alarms; overflow control; tank temperature systems and alarms; inert gas systems and generators, construction and operation; venting requirements; gas detectors and oxygen analysers; design of tank cleaning systems; cargo hoses; insulating flanges; electrical continuity; anti-static measures; materials of construction; safety factors of electrical systems. Chemical Tanker Operations Cargo calculations; the use of calibration tables; loading and discharging plans and procedures; ballasting; tank cleaning materials and operations; precautions using slop tanks; disposal of waste and washings; inerting, purging and gas freeing procedures, the critical dilution line; operational monitoring, the use of checklists; ship/shore liaison. This section should include a cargo planning exercise to enhance understanding of the practical implications of cargo characteristics, ship design and equipment and operational procedures on safe and correct handling of cargoes. Permits to work; control of entry into enclosed spaces; gas detection; instrument maintenance and calibration. Use of safety equipment. Control of entry into pump rooms and enclosed spaces. Precautions to be taken before the repair and maintenance of pumping, piping, electrical and control systems.

13

Pollution Control MARPOL; pollution prevention guidelines; constructional requirements. Monitoring equipment; permitted discharges; the IOPP certificate, Certificates of Fitness, Noxious Liquid Substance Certificate, the Oil Record Book; action to be taken in the event of a spill at sea or in port; mitigating the effect; oil spill clean up equipment; reporting requirements; atmospheric emissions and the proposed measures to reduce atmospheric pollution; containment procedures; vapour recovery systems; precautions. Emergency Procedures Hazard and risk assessment; definitions, elements of risk reduction; design considerations; alarm and shut down systems; information and communication structures; role of safety officers. Actions in the event of failure of services essential to cargo or following collision, stranding, spillage or other incident; contingency planning; legal requirements; organization, teamwork and planning; drills and practice; use of safety equipment, including breathing apparatus and escape equipment; ship/shore liaison in the event of emergency. Case studies. Fire fighting on chemical tankers. Safe entry into and rescue from enclosed spaces. Medical first-aid procedures and the use of resuscitation and decontamination equipment.

(C) GUIDELINES ON STRUCTURE AND CONTENT OF LIQUEFIED GAS TANKER TRAINING PROGRAMME The following guidelines apply where the training is provided as a full time block course. The duration of the course will depend on the background and prior knowledge and experience of course participants. However, where potential candidates have limited prior experience, it is unlikely that the stated objectives can be achieved in less than 34 hours instruction overall. The course should be based on the syllabus given at paragraphs 22 to 34 of Section A-V/1 of the STCW Code and designed so as to the achieve the outcomes listed below. Outcomes At the end of the course the student should have the relevant technical knowledge to assume the responsibilities of Master, Chief Officer, Chief Engineer, Second Engineer or of any other person having direct responsibility for

14

cargo operations. The course will include those outcomes as stated in the familiarization training but will be addressed in greater detail in accordance with the requirements of the students. In addition to those outcomes as outlined in the familiarization training, the course will include the following principles: International and National Regulations and Codes of Practice Explanation of the relevant regulations, conventions and codes of practice as they apply to liquefied gas tankers. The legal implications, responsibilities and consequences. The IMO IGC Code, the International Chamber of Shipping (ICS) Tanker Safety Guide (Liquefied Gas), the Society of International Gas Tanker and Terminal Operators (SIGTTO) Liquefied Gas Handling Principles on Ships and in Terminals. Characteristics of cargoes (to include a revision of those topics covered in the familiarization course) An outline of the important physical and chemical properties of liquefied gases carried in bulk, including aspects of production and principal applications. The definition of a gas, simple gas laws, the gas equation, density of gases, diffusion and mixing of gases, compression of gases, liquefaction of gases, refrigeration of gases, critical temperature, the practical significance of flashpoint, upper and lower explosive limits, auto ignition temperature, compatibility of gases, reactivity, polymerization and inhibitors. The properties of single liquids, including densities of liquids and vapours, variation with temperature, vapour pressure and temperature, enthalpy, vaporization and boiling liquids. The nature and properties of solutions, including the solubility of gases, miscibility between liquids, and the effects of temperature change, densities of solutions and dependence on temperature and concentration, effects of dissolved substances on melting points and boiling points, hydrates, their formation and dispersion; hygroscopicity; drying of air and other gases; dew point and other low temperature effects. Associated hazards (to include a revision of those topics covered in the familiarisation course) Flammability, upper and lower flammable limits, flammable range, flash point, auto ignition temperature. Potential flammable atmospheres in cargo tanks, other enclosed spaces, deck and jetty areas. Health, toxicity, modes by which liquefied gases and their vapours may be toxic; the toxic properties of inhibitors and of products of combustion of both materials

15

of construction and of liquefied gases carried; acute and chronic effects; systemic poisons and irritants. TLVs, occupational exposure limits; Cryogenic and toxic effects on skin, inhalation and ingestion. Oxygen deficiency. IMO Medical First Aid Guide. Administering of antidotes. Environmental hazards. Effect of specific gravity, solubility and vapour density with respect to dispersion. Jettison of cryogenic liquids. Sources of ignition. Hot work. Certified safe fixed and portable electrical equipment. Static and current electricity. Liquefied Gas Tanker Design and Equipment (a) Cargo Containment Pressurized, semi-pressurized, and fully refrigerated types of ship. Principles of containment systems for each type of ship. IMO tank types, their construction, materials, coatings and insulation. Compatibility of materials of construction. Construction rules and surveys. Damage assumptions, location of cargo tanks, standard of damage, survival requirements. (b) Cargo Handling Systems and Equipment General arrangement. Main types of pumps, and pumping arrangements, practical aspects of operation suction head, discharge head, flow rates, booster pumps and de-icing. Piping, expansion devices, actuators, filters and strainers, vaporisers, heaters, vapour return systems, inert gas generators, storage and distribution of inert gas. Temperature and pressure monitoring systems, cargo venting systems, gauging system, instrumentation systems and alarms, gas detection systems, cargo boil off systems. CO2 monitoring systems . (c) Reliquefaction systems Cycles, direct, single stage, two stage, cascade and indirect systems. Plant operation, compressors, condensers, relief devices. LNG boil off as fuel and associated safety devices. Liquefied Gas Tanker Operations Procedures to control the potential hazards of fire and explosion and the risk to health and the environment. Inerting, gassing up, cooling down from ambient, preparations for loading, ship/shore checklist, loading, condition maintenance on passage, segregation of cargoes, sampling discharging, changing grades, removal of liquid residue, tank cleaning procedures, warming up tanks, purging, with inert gas, gas freeing. Ballasting and de-ballasting. Ship/Ship transfer. Emergency means of discharging cargoes.

16

Safe Practice and Equipment Calibration and use of portable gas measuring equipment. Precautions and procedures before entry into enclosed spaces. Supervision of personnel during potentially hazardous operations. Personal protective equipment, breathing apparatus, escape sets, canister type respirators, resuscitators, protective clothing and equipment, rescue equipment. Precautions before and during, repair and maintenance of equipment. Emergency Procedures Importance of developing ships emergency plans, shipboard emergency organization. Emergency shutdown systems, emergency release systems, closure of valves and stopping of equipment. Action to be taken in the event of failure of systems or services essential to cargo. Action to be taken in the event of collision, stranding, spillage, envelopment of the ship in a toxic or flammable vapour, leaks, fire, and personnel casualty. Fire fighting equipment on gas tankers, water sprays, dry powder systems.

17

Documents and reference books In addition to appropriate instructional facilities, visual aids and other teaching aids and equipment, the following documents should be on display and available for reference as required: Code of Safe Working practices for Merchant Seamen SOLAS, MARPOL, STCW conventions International Medical First aid Guide EH40/9X Occupational Exposure Limits 199X Emergency Procedure for Ships Carrying Dangerous Goods (EMS) ACOP: Dangerous Substances in Harbour Areas Guidance Note GS $) Relevant periodicals and magazines (i.e. hazardous cargo Bulletins) and manufactures’ literature. Oil Record Book Part 1 and Part 2 International Safety for Tankers and Terminals ICS Tanker Safety Guide ICS Safety Guide for Liquefied Gas. ICS Safety Guide for Chemicals IBC Code IGS Code Cargo Record Book (Noxious Gas Substances) USCG Chemical Data Guide Inert Gas Guide Lines for oil, Chemical and Liquefied Gas Tankers Ship to Ship Transfer Guide 9petroleum) BCH Code Gas Carrier Code Liquefied Gas Tanker Principles Crude Oil Washing (IMO) Examples of : - a Procedures and Arrangements manual - a Chemical tanker Cleaning Guide - a Tank Coating Compatibility Guide

Conditions for approval of short courses 1

The training centre is responsible for ensuring that trainees meet the entry requirements for the relevant training programme and other conditions for the issue of a certificate (where applicable).

2

The same person must not undertake the training and assessment of an individual candidate

18

3

The training centre must advise the headquarters of DMS if there is any change (e.g. in facilities, equipment, staff) that is likely to affect the conduct of the training and/or assessment.

4

Certificates shall be issued only to those trainees who successfully complete the training programme and meet other requirements for the issue of the certificate.

5

All certificates shall be issued in the form approved by DMS

6

Full records of all certificates issued to trainees must be retained by the centre and kept in such a way that authenticity or confirmation of issue of a certificate can be verified at a later stage if necessary

.

19