360 quality inspections for reefer ships ships in service department – training material marine...

360 Quality Inspections for Reefer Ships Ships in Service Department – Training Material

Marine Division

April 2010

360 Quality Inspections

The objectives of the 360 Quality Code

360 Quality Code Documentation

Subjects for the inspection

Inspection and Certification

3Bureau Veritas Training Material _ April 2010

In order to prevent damage to cargo during physical handling and contamination of the cargo, and to ensure that reefer installation and power generation plant are of adequate capacity and maintained in good condition, the members of the 360 Quality Association have developed the Code for handling of Reefer cargoes in Specialized Reefer Ships and Ports.

The Code creates an industry standard that is fully endorsed by all the participating companies, therefore specialized reefer vessels may be audited according to the 360 Quality code and the 360 Quality Association have approved Bureau Veritas to undertake inspections under the auspices of the code.

360 Quality Inspections


The objectives of the 360 Quality Code

The Code ensures that damage caused to any unit of cargo shipped on a specialized reefer ship can be accounted for at any point in the supply chain with the common goal to improve the supply chain. The Code formalizes the cooperation between the shipping lines and their service providers.

The Code creates an industry standard that is fully endorsed by all the participating companies.

The scope of the Code is the part of the supply chain that is either under the direct control of the Shipping Lines or is a joint responsibility of the Shipping Lines and its service providers, such as Terminals and Stevedores.


The handling procedures of the Code bring transparency and accountability into all elements covered by the scope.

The Code recognizes that the Shipping Lines and their service suppliers have to jointly work for better service to their customers. The feedback resulting from the proper implementation of the Code not only provides a measure of the performance of the participants involved directly in the handling of cargo in ships and terminals but even to others who form the remaining links in the supply chain.

Specialized reefer vessels may be audited according to the 360 Quality code.


The Code applies to the core fleet of the members. A ship is considered to be part of the core fleet if it is either owned or chartered for a period of minimum 12 months.


Vessel

IT SHOULD BE NOTED THAT THE 360 QUALITY INSPECTION/CERTIFICATION EXCLUDES CARGOINSPECTIONS.


360 Quality Code Documentation1. 360 Quality Code, edition January 2010

360 Quality Code January 2010.pdf

2. Guidance notes for inspections of reefer ships, edition September 2009360 Quality Guidance Note for Ships September 2009.pdf

3. Inspection Checklist for Ships, edition January 2010360 Quality Association, Inspection Checklist for ships, edition January 2010.xls

The surveyor shall document his findings on the Inspection checklist for Ships using the Guidance Notes.


The subjects for the inspection are divided into 13 groups according to the Guidance notes jointly prepared by members of the 360 Quality Association, Classification Societies and approved Organisations for Inspection, which provide more detailed information on selected items of section 6 to the Code in order to harmonize possible variations in interpretations by Surveyors.

Furthermore the Guidance notes inform the ship Owners/managers about the Code requirements.

The Surveyor is guided with background information on each group of subjects. Per group of subjects the required ‘verifications’ are described in detail for each question.

Subjects for the inspection


Quality policy & awareness

Weather tightness

Hydraulic system

Cargo gear

Gratings

Side shorings

Lighting in holds

Drains

Cleaning

Cargo holds and cooler spaces

Reefer equipment

Power generation

Temperature management

Selected items of section 6 of the 360 Quality Code


Qa01. Is the Zero Damage Computer Based Training CD available on board and used for training?The surveyor checks if the Zero Damage CBT and Administrator program are available on board. The surveyor also checks the

training records.

Qa02. Is the Vessel Checklist used for each stage of the voyage?The surveyor checks if the Vessel Checklist is used FOR EACH

STAGE of the voyage; pre-loading stage, loading stage, sea voyage and unloading stage. The Checklist must be filled in truthfully.

Qa03. Is the Vessel Checklist properly archived on the vessel?The surveyor checks if the Vessel Checklists are properly filed in a signed hardcopy for a minimum period of 1 year. The Checklist

must be signed by a responsible officer.

Quality policy and awareness


Qa01/Qa02 - Damage Report – Master and Chief Officer must show clear understanding on use of such damage reports


Qa04. Are walking boards used during loading/discharging of fruit cargoes?The surveyor checks visually if walking boards are used during the

handling of the cargo. This will be more apparent during the final stages of the loading or unloading operations of a cargo compartment.

Qa06. Are all pallet obstructions in the cargo holds removed, fenced off or marked?

Ships, without pallet obstructions must score maximum points on this question.

Qa09. Is on board routing software with shore based support available on board? As an example systems like Seaware, SPOS, Bridge, Bon Voyage

and Ocean Systems are accepted on board routing systems.


Wt01. Is the permanent compression of the sealing rubbers of weather deck hatches less than 25% when the hatch cover is opened?

Gasket material in the periphery of the covers and cross joints need to be checked for deformation due to excessive compression, ageing and damage. Signs, which show that the gasket material has suffered a permanent compression set by more than 25% of the depth, may require renewal.

Wt03. Are joints of sealing rubbers of weather deck hatches without gaps?Self explanatory

Wt04. Are sealing rubbers of weather deck hatches flexible?Signs, which show that the gasket material has lost its elasticity,

may require renewal. Any specially moulded rubber sections should be checked to ensure that they are in position and have not worn out or been permanently set.

Weather tightness

Ships without hatches e.g. side-loaders must get full points on all questions related to ingress of water.


Wt07. Are compression bars without deformation?Steel to steel contact between hatch cover side plate and the

coaming is essential for exact compression set of the gasket. Over compression of the gasket can lead to a permanent set.

Deformation of compression bars (including the cross joints) needs to be checked as this may be cause for leakage.

Are compression bars without excessive wear (including rust)? Corrosion of compression bars (including the cross joints) needs to

be checked as this may be cause for leakage.

Wt08. Are the side cleats free of excessive wear or corrosion and without deformation?

Locaters are fittings or members used to retain the hatch covers in the correct sealing position. Therefore locators need to be checked for deformation or distortion. All peripheral and cross joint cleats

need to be checked for wear and deformation.


Wt09. Are the rubbers of the side cleats flexible?The Surveyor verifies if the rubbers of the side cleats are still flexible.

Wt10. Are the rubbers of the side cleats not painted?The Surveyor verifies if the rubbers of the side cleats are painted.

Wt11. Are the top wedges free of excessive wear or corrosion and without deformation?All top wedges need to be checked for wear and deformation.

Wt13. Are the hatch coaming drains free flowing and return valves unblocked?

Draining arrangement in the periphery of the hatch covers and at the cross joints need to be checked to ensure that water which enters is drained away to the deck. This is not applicable on CA equipped and operated ships, where a CA plug is inserted in these drains.


Wt14. Are quarterly hose test and log entry in log done? Log entry can be made in deck log or other appropriate document.

Wt15. Are sufficient replacement parts for the hatch covers available?The Surveyor shall determine if the vessel maintains enough spare parts in the way of sealing rubbers and special moulds to enable it to renew such fittings. In general, spares to replace all weather deck

hatch cover sealing rubbers and moulds of one hatch are considered sufficient. The ship shall also maintain a small amount of cleats and wedges. For example, a vessel, which has had all hatch seals renewed recently may carry a smaller number of corner pieces and lengths of rubber (as new built). On the other hand, a vessel, which has e.g. more than 50% of all rubbers damaged, will need to carry more in spare!


Hatch Covers – Accesses to cargo holds

Wt01/Wt03/Wt07- Compression gasketsWt08/Wt09/Wt10- Side Cleats

Wt07- Compression bars


Hatch Covers – Accesses to Cargo Holds

The vessel GAP is to reviewed and familiarized withAll accesses to cargo holds are to be examined


Applicable to ships fitted with hydraulically operated hatch covers.Ships without hydraulic operated hatches and/or cargo gear must get full points for these questions.

Hy01. Are the hydraulic piping and hydraulic connections without excessive rust?The surveyor checks the actual condition of the hydraulic piping,

connections, pipe mounting and brackets with respect to corrosion.

Hy02. Are the hydraulic hoses and joints without signs of excessive wear and/or ageing?The surveyor checks the actual condition of the flexible hoses and joints with respect to excessive wear and ageing.

Hy03. Are the hydraulic hoses correctly installed and free of any twists or damage hazards?The hydraulic hoses must be correctly installed (proper length, type, fittings), correctly positioned, free of any twists and safe from physical damage hazards.

Hydraulic system


Hy05. Is the hydraulic system of the hatches without any signs of leakage?

Any buckets, tins or rags placed in the immediate vicinity of hydraulic piping system may point to leakages. Leakages are never acceptable and need to be rectified.

Hy06. Is the hydraulic system of the cargo gear without any signs of leakage?The surveyor should limit to those parts of the hydraulic system that may actually contaminate the cargo.

Hy08. Has an annual pressure test of the hydraulic system (at relief valve pressure) been performed?Annually test all piping with empty cargo holds to relief valve pressure by opening and closing each main- and tween-deck hatch cover

completely, ensuring pressure rises to lift the system relief valves at each extremity (open and close). This test can be done by the ship’s crew. Proof shall be furnished by an entry in the Engine logbook and signed by the chief engineer.


Hydraulic Hatch Covers - Weather deck

Hy01/Hy02/Hy03/Hy05/Hy06 – Hydraulic installations – applicable also to tween decks

Note: This should test every piece of piping to the maximum pressure it can be subjected to without undue additional work. In normal operation, the relief valves should not lift if the operator stops when the hatch is opened/closed. In that respect this test can be considered as a test above normal working pressure.


Tween deck hydraulic hatch covers - open Tween deck hydraulic hatch covers - closed


Hy03 - Tween deck hydraulic hoses Hy08 - Logbook recording of yearly hydraulic pressure test


Cg01. Is the cargo gear regularly maintained according to a planned maintenance system and without overdue items?The surveyor verifies if a planned maintenance system is in place for the cargo gear and interchangeable components. Maintenance items which are more than 3 months overdue are not allowed.

Cg02. Is all cargo gear operational (smooth operation)?The surveyor should do a visual inspection during operation (preferred) or obtain a statement from the responsible officer.

Cg03. Is the cargo gear register up to date with valid endorsement by Class?The surveyor need to make sure that the cargo gear book is updated and the cargo gear has been regularly inspected and load tested.

Cargo gear


CARGO GEAR

Deck cranes

Deck Crane Load Test Certificates

Deck Cranes Maintenance Program Endorsed Cargo Gear Register Book


The surveyor carries out a condition survey of gratings including documentation of findings. Ships that because of their design don’t require ratings must get full points on all questions concerning gratings.

Gr01. Are the wooden or aluminium gratings without visual damage (1%tolerance)?If the extent of fresh damages is such that consideration needs to be given by the surveyor, he should take into account the extent of the damage and the availability of spares. The surveyor should establish if the fresh damages are due to condition of gratings or general wear and tear.

Gr02. Are the wooden gratings without excessive wear or aluminium gratings without deformation?Small dents to aluminium gratings, less than 10 mm deep can be accepted.

Gratings


Gr05. Are the grating supports without visual damage?Some gratings need to be lifted at random to verify the condition. This applies only for wooden gratings.

Are the grating supports without excessive wear?Some gratings need to be lifted at random to verify the condition. This applies only for wooden gratings.

Gr06. Are the spar deck wooden planks without visual damage?Not more than 1% damaged wooden plank is tolerated. The Surveyor checks by random the condition of the wooden plank.

Gr07. Are the spar deck wooden planks without excessive wear?Not more than 1% excessively worn wooden plank is tolerated. The Surveyor checks by random the if planks are splintering and corners are rounded off.


Gr08. Are the gratings free of movement, tilting or sliding?The Surveyor verifies if the gratings are not tilting or sliding, preferably when it can be observed that a forklift or a pallet jack is used to handle cargo.

Gr09. Are the grating decks flush?The Surveyor verifies if the difference in height on the grating board is less than about 1 cm.

Gr10. Are the spar decks flush?The Surveyor verifies if the difference in height on wooden planks is less than about 1 cm.

Gr11. Have grating repairs been done properly i.e. no patchwork?Damaged gratings need to be replaced in full. Patch-work within any one grating board is not considered acceptable.


Gr12. Is information available about the strength of the gratings?Proof of sufficient strength of gratings shall be available on board e.g. by respective information from grating manufacturer, from managers or from shipyard.

Gr13. Is the strength of the gratings in line with the Code, minimum 5 tons forklift including cargo?This question is not applicable if the information under D13 is not

available.


Gr14. Are sufficient spare grating boards and supports available?The surveyor shall determine if the vessel maintains enough spares in relation to the actual condition of the gratings. In general, in case of wooden gratings, at least 2 % of the total grating area shall be kept available as spare. Where several types of gratings are fitted on board, spare gratings of each type shall be kept available on board. If the state of the gratings implies that the vessel has difficulties in maintaining the gratings in a good condition, more spare gratings may be required than the 2% mentioned above.

Are sufficient spare spar deck wooden planks available?The surveyor shall determine if the vessel maintains enough spares in relation to the actual condition of the planks. If the vessel has shown to normally be able to keep up with damaged plank replacement, then that spare stock level is sufficient. In general, in case of spar decks with wooden planks, at least 2 % of the total spar deck area shall be kept available as spare. However, a vessel, which has a lot of planks

damaged, will need to carry more spare.Note: Planks of soft wood are unsuitable for use in reefer ships.


Gr01 – Gr14: Tween deck wood gratings


Gr14: Damaged wood gratings with replacement nearby


The surveyor will carry out a condition survey of side shorings including documentation of findings. Ships with vertical bulkheads that do not require side shorings must be given the maximum score on all items concerning side shorings.

Ss01. Are the side shorings free of visual damage?The surveyor verifies damages on the plywood or aluminium boards.As a general rule, not more than 1% damaged side shorings are

tolerated.

Ss02. Are the support stays between the side boards and the ship’s side free of visual damage?

The surveyor checks that support stays are not cracked or delaminated. Not more than 1% damaged support stays are tolerated.

Side shorings


Ss07. Are all flared areas provided with side shoring?Exceptions can be made for small distances of about 30 cm transversal and about 5 mtrs longitudinal in lower decks.

Ss08. Is documentation available to show that side shorings have sufficient strength according to design criteria?Please refer to attachment 1 for the design criteria. Generally, side shorings should withstand all forces exerted by palletized cargoes in any weather condition. For the purpose of calculation acceleration

values of 1,0 g vertical and 0,8 g horizontal are recommended but as a minimum the requirements from the Code of Safe Practice for Cargo Stowage and Securing, Appendix 13 shall be taken into account.

The calculations shall be initiated by the respective ship owner and be carried out by the classification society or engineering consultants and be an integral part of the cargo securing manual.

Ss09. Is the construction of the side shorings adequate (e.g. no pipe shorings)?Side shorings made of unprotected steel pipes, bars or similar are not considered adequate.


Gr12/Gr13: Wood gratings strength characteristics

Ss01-E5: Side shoring


Li01. Are cargo hold light covers present and undamaged?Plastics/glass covers are present and undamaged on cargo hold

lights. The Surveyor should give an indication of the amount of damaged plastic covers.

Li02. Are cargo hold lights properly protected against handling damage?Lights fitted in refrigerated compartments shall preferably be flush with the panel surface of hold insulation or fitted in between (and protected by) deck girders as to prevent damage during cargo handling. Lights which are exposed to the panel surface and which are well protected by a cover are also acceptable.

Li03. Are cargo hold lights installed flush with the surface?All lights fitted in refrigerated compartments shall preferably be flush with the panel surface of hold insulation or fitted in between (and

protected by) deck girders as to prevent damage during cargo handling.

Lighting in holds


HOLD LIGHTING

Ceiling lights flush with transverse beams Longitudinal bhd with flush lighting


Dr01. Are the bilges clean and clear?

Dr02. Are the drain collecting points clean and clear?Reference is made to drain collecting points under gratings and on tweendeck hatch coamings.

Dr05. Are cooler drip trays clean and clear?Cooler drip trays should be clean (no debris, no rust flakes) an d clear.

Dr06. Is the defrosting system of the drip tray drains working properly?The surveyor should test if the defrosting system is working properly (preferred) or obtain a statement from the responsible officer.

Drains


Air bags used as dunnage

Ventilation fans and cooling areas


Cl01.Are proper cleaning records maintained on board and available for inspection?

Proper records shall be made available to surveyors which will enable them to verify:

1. There is a cleaning plan for refrigerated cargo spaces

2. It is easy to follow the cleaning of cargo spaces by records kept on board

3. There is sufficient chemicals for cleaning available on board

Cl02. Is a High Pressure cleaning machine available on board?

The Surveyor verifies the presence of a High Pressure cleaning machine.

Cleaning


Ch01. Are the bulkhead insulation panels in a sound condition?The Surveyor should verify the bulkhead insulation panels for holes or other damages. Fresh damages should be taken into consideration and old damages should have been repaired. In case of visible holes, the rating will be “NO”.

Ch02. Are the deck head panels under insulated decks in sound condition?The Surveyor verifies the deck head panels for holes or other damages. Fresh damages should be taken into consideration and old damages should have been repaired. In case of visible holes, the rating will be “NO”.

Ch03. Are return air screen openings intact and clear?The Surveyor verifies that the return air screens are present, intact and unobstructed. In case of deviations, the rating will be “NO”.

Cargo holds and cooler spaces


Rf01. Is a valid class certificate for the reefer installation available?The Surveyor verifies that the class certificate for the reefer installation is on board and valid.

Rf14. Is the planned maintenance system available on board for the reefer system?The Surveyor asks for the documentation for the planned maintenance system and briefly verifies if this system appears organized and in use.

Reefer equipment


Pg04. Are the auxiliary engines in an apparent good order and condition?The Surveyor checks visually the external condition of auxiliary

engines. There should be no excessive leakage of lubrification oil, fuel oil, cooling water or exhaust gases.

Pg05. Is the planned maintenance system available on board for the auxiliary engines?The Surveyor asks for the documentation for the planned maintenance system and briefly verifies if this system appears organized and in use.

Power generation


Te09. Are carriage instructions available for the current and previous reefer cargoes?

The Surveyor asks for the most recent carrying instructions for refrigerated cargoes. Especially instructions for the latest, on-going voyage with refrigerated cargo must be available on board.

Temperature management


Inspections

Each ship to which the Code applies shall be subject to the inspections specified below:

An initial inspection before the ship is put in service or before the certificate required under section 9.2. of the Code is issued for the first time.

A renewal inspection at intervals not exceeding two years with a grace period of 3 months.

Any additional inspections as determined by the 360 Quality Association.

The inspections shall be carried out in accordance with the Guidance Notes issued by the 360 Quality Association.

Inspections and Certification


It is recommended that the inspection is completed in one visit. However it is accepted that the inspection is done in two visits within a period of not more than 3 months. The last visit shall be done within 3 months after the expiry date of the existing Certificate.

The inspections of ships shall be carried out by duly qualified BV Surveyors.

The equipment of the ship after inspection shall be maintained to conform with the provisions of section 6 of the Code by the ship owner.

Qualified Surveyors for carrying out inspections

A qualified surveyor is an NS surveyor who has at least 3 years experience as a marine surveyor with an experience onboard reefer ships.

On appointment to undertake a 360Q Vessel Inspection, the Surveyor is to advise DNS_CAP and is to confirm previous survey experience on such vessels.


The Surveyor is to follow and complete, where applicable, the Inspection checklist for Ships released by the 360 Quality Association to conduct the inspection.

Specialized reefer ships may be engaged in cargo handling operations during 360 Quality inspections.

As a rule, at least 50% of the cargo spaces need to be accessible to ensure minimum scope of inspection carried out by the Surveyor. If the condition of the cargo holds in 50% of the holds is found to be in such a state that the Surveyor cannot, without doubts, judge the condition of the cargo spaces, he may at his discretion complete the inspection after having inspected all the cargo spaces.

Conduct of Inspections


How to fill in the vessel inspection checklist

The Surveyor is to use the guidance notes for inspection of ships to complete, where applicable, the Inspection checklist for Ships released by the 360 Quality Association during inspection.

The Surveyor must specify the findings on the questions of the checklist in the comments column, e.g. the location of damage, excessive wear and tear, improper repairs, leakages etc.

If the ship’s design is such that a certain question is not applicable, this will be indicated in the column “Not applicable (N.A.)” unless otherwise stated in the guidance notes.

An example of how to fill in the 360Q Vessel Inspection Checklist and the associated inspection result, edition January 2010.xls


A 360 Quality Certificate as well as a copy of the Report of Inspection shall be issued after the initial or renewal inspection in accordance with the provisions of the 360 Quality Code.

Such Certificate shall be issued by BV Surveyor to the client if the ship scores :

a) a minimum of 60% in each of the following “group of subjects” in the checklist : weather tightness, hydraulic system, gratings, side shorings, cleaning, cargo holds & cooler spaces, reefer equipment, power generation

and temperature management, and

b) a minimum of 70% of in total.

A copy of the certificate as well as a copy of the Report of Inspection shall be transmitted to the DNS_CAP by the surveyor.

Issue of Certificate and Report of Inspection


If the ship fails to meet any of the criteria mentioned above, these failed group of subjects shall be corrected and re-inspected within a period of not more than 3 months before such Certificate can be issued.

If the ship is reinspected and fails the second time on these group of subjects, a complete inspection of all items will be required.

A copy of the Certificate shall be transmitted as soon as possible to the 360 Quality Association by DNS_CAP.

The 360 Quality Certificate shall be drawn up in a form corresponding to the model given in Appendix No. 3 of the 360 Quality Code.


Duration and validity of Certificate

The 360 Quality Certificate shall be issued for a period not exceeding two years from the date of expiry of the existing Certificate, or from the date of the initial inspection.

The renewal inspection has to be carried out within a time window of three months before, until three months after the expiry date of the existing Certificate.

When the renewal inspection is completed within three months before the expiry date of the existing Certificate, the new Certificate shall be valid from the date of completion of the renewal inspection to a date not

exceeding two years from the date of expiry of the existing Certificate.


When the renewal inspection is completed after the expiry date of the existing Certificate, the new Certificate shall be valid from the date of completion of the renewal inspection to a date not exceeding two years from the date of expiry of the existing Certificate.

When the renewal inspection is completed more than three months before the expiry date of the existing Certificate, the new Certificate shall be valid from the date of completion of the renewal inspection to a date not exceeding two years from the date of completion of the renew inspection.

A Certificate issued under section 9.2 of the 360 Quality Code shall cease to be valid if the relevant inspection is not completed within the required period.


http://www.360quality.org/


END

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