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Lloyd’s Register ESP for Bulk Carriers Preparation for Special Survey
For the purpose of this post, we’ll focus on double skin bulk carriers:
The ESP Code has been developed to provide a consistent survey standard for the regular and safe survey of the cargo and ballast areas of oil tankers and bulk carriers. The intention of the Code is to ensure that an appropriate level of review of plans and documents is conducted and consistency in application is attained. Such review of survey reports, survey programmes and planning documents should be carried out at the managerial level of the Administration or organization recognized by the Administration (hereinafter both are referred to as “the Administration”).
Parts A and B of annex A of the Code provide the requirements for bulk carriers with single-side skin and double-side skin construction respectively. Parts A and B of annex B of the Code provide the requirements for oil tankers with double-hull and non-double-hull construction respectively.CHAPTER 1: GENERAL
1.1 Application
– The Code shall apply to all self-propelled double-side skin bulk carrier of 500 GT and above.
– The Code shall apply to surveys of hull structure and piping systems in way of cargo holds, cofferdams, pipe tunnels, void spaces, fuel oil tanks within the cargo length area and all ballast tanks.
– For bulk carriers with hybrid cargo hold arrangements, the requirements of part A of Annex A shall apply to cargo holds of single-side skin.
– The surveys shall be carried out during surveys prescribed by regulation I/10 of the Convention.1.2 Definitions:
1.2.1 Double-side skin bulk carrier: Constructed generally with single deck, topside tanks, and hopper side tanks in cargo spaces. Intended primarily to carry dry cargo in bulk including ore carriers and combination carriers, in which all cargo holds are bounded by a double-side skin.1.2.2 Ballast tank: Used primarily for salt water ballast.
1.2.3 Spaces are separate compartments such as holds, tanks, cofferdams and void spaces bounding cargo holds, decks and outer hull.
1.2.4 Overall survey: Intended to report on overall condition and determine extent of additional close-up survey.
1.2.5 Close-up survey: Structural components (normally within reach of hand) subjected to close visual inspection range of surveyor.
1.2.6 Transverse section: Cross section of hull perpendicular to ship’s centreline. Includes all longitudinal members such as plating, longitudinals and girders at the deck sides, bottom, inner bottom, hopper sides, inner sides, top wing inner sides and longitudinal bulkheads.
1.2.7 Representative spaces: Expected to reflect condition of other spaces of similar type and service and with similar corrosion prevention systems. When selecting representative spaces, account should be taken of the service and repair history onboard and identifiable critical structural areas and/or suspect areas.
1.2.8 Suspect areas: Locations showing substantial corrosion and/or are considered by the surveyor to be prone to rapid wastage.
1.2.9 Substantial corrosion: Assessment of corrosion patterns indicates wastage > 75% but within acceptable limits. For ships built under the IACS Common Structural Rules, substantial corrosion indicates a gauged (or measured) thickness between Tnet + 0.5mm and Tnet.
1.2.10 Corrosion prevention system: Normally considered full hard protective coating (should be epoxy or equivalent). Other coating systems which are neither soft nor semi-hard coatings, may be considered acceptable as alternatives provided that they are applied and maintained in compliance with the manufacturer’s specifications.
1.2.11 Coating condition:
A) GOOD: Only spot rusting.
B) FAIR: Local breakdown of coating at edges of stiffeners and weld connections and/or light rusting over 20% or more of areas under consideration, but less than that as defined for POOR condition.
C) POOR: General breakdown of coating over 20% or more of areas or hard scale at 10% or more of areas under consideration.1.2.12 Critical structural areas: Locations identified from calculations to require monitoring or from service history of subject ship or from similar/sister ships to be sensitive to cracking, buckling or corrosion which would impair the structural integrity of the ship.
1.2.13 Cargo length area: Part of ship which includes all cargo holds and adjacent areas including fuel tanks, cofferdams, ballast tanks and void spaces.
1.2.14 Intermediate survey: Carried out either at the second or third annual survey or between these surveys.
1.2.15 Prompt and thorough repair: Permanent repair completed at the time of survey to satisfaction of surveyor, therein removing need for imposition of any associated condition of classification or recommendation.
1.2.16 Convention: Means the International Convention for the Safety of Life at Sea 1974 as amended.
1.2.17 Specially consideration/considered: (in connection with close-up surveys and thickness measurements) means sufficient close-up inspection and thickness measurements are taken to confirm the actual average condition of the structure under the coating.
1.2.18 Pitting corrosion: Defined as scattered corrosion spots/areas with local material reductions which are greater than the general corrosion of the structure under the coating.
1.2.19 Edge corrosion: Defined as local corrosion at free edges of plates, stiffeners, primary support members and around openings.
1.2.20 Grooving corrosion: Typically local material loss adjacent to weld joints along abutting stiffeners and at stiffener or plate butts or seams.
1.2.21 Administration: Administration or organisation recognised by the Administration.
1.3 Repairs:
1. Areas that affects the ship’s structural, watertight or weathertight integrity should be promptly and thoroughly repaired. Such as:
A) Side structure and side plating
B) Deck structure and deck plating
C) Bottom structure and bottom plating
D) Inner bottom structure and inner bottom plating
E) Inner side structure and inner side plating
F) Watertight or oiltight bulkhead
G) Hatch covers or hatch coamings1.4 Surveyors
For bulk carriers of 20,000 tons DWT and above, two surveyors should jointly carry out the first scheduled renewal survey after bulk carrier passes 10 years of age (i.e. third renewal survey), and all subsequent renewal surveys and intermediate surveys.1.5 Thickness measurements and close-up surveys
In any kind of survey, thickness measurements should be carried out simultaneously with close-up surveys.2 RENEWAL SURVEY
2.1 General
A) Date: Commenced at the fourth Annual Survey, complete by fifth anniversary date.
B) Scope: In addition to Annual Survey requirements, ensure hull and related piping is in satisfactory condition for new period of validity of Cargo Ship Safety Construction Certificate.
– All cargo holds, ballast tanks, including double-bottom and double-side tanks, pipe tunnels, cofferdams and void spaces bounding cargo holds, decks and outer hull should be examined and supplemented by thickness measurement and testing.
* Ensure structural integrity: Discover substantial corrosion, significant deformation, fractures, damages or other structural deformation.
– All piping systems within above spaces should be examined and operationally tested under working pressure.
* Ensure tightness and satisfactory condition.
2.2 Dry-dock survey
Dry dock survey should be part of renewal survey:
– Minimum of two inspections of ship’s external bottom during five-year period.
* In all cases, maximum interval between bottom inspections should not exceed 36 months.
– For ships of 15 years of age and over, inspection of ship’s external bottom should be carried out in dry dock.
– For ships of less than 15 years of age, alternate inspections not conducted in conjunction with renewal survey may be carried out with ship afloat.
2.3 Space protection:
– Ballast tank corrosion prevention system should be examined. If the hard protective coating is: found in POOR condition/not renewed/not applied at construction/or soft or semi-hard coating has been applied, those tanks should be examined annually.
* Thickness measurement should be carried out where extensive corrosion exists.
– When cargo holds with hard protective coating is found in good condition, the extent of close-up surveys and thickness measurements may be specially considered.
2.4 Hatch covers and coamings:
Thorough inspection of H/C sets within forward 25% of ship (normally greatest sea loads) and 1 additional set, so that all sets are assessed at least once every five years.
– Stowage and securing in open condition
– Proper fit and efficiency of sealing in closed condition
– Operational testing of hydraulic and power components, wires, chains and link drives.
– Cover panels, including side plates, stiffeners attachments that may be accessible in open position by close-up survey (for corrosion, cracks, deformation)
– Sealing arrangements of perimeter and cross joints (check gaskets for condition and permanent deformation, flexible seals, gasket lips, compression bars, drainage channels and non-return valves)
– Clamping devices, retaining bars, cleats (for wastage, adjustment, and condition of rubber components)
– Closed cover location devices (for distortion and attachment)
– Chain or rope pulleys
– Guides
– Guiderails and track wheels
– Stoppers
– Wires, chains, tensioners and gypsies
– Hydraulic system, electrical safety devices and interlocks
– End and interpanel hinges, pins and stools where fitted
– At each hatchway, check coamings with plating, stiffeners and brackets for corrosion, cracks and deformation, especially coaming tops including close-up survey.
– Where considered necessary, test sealing arrangement effectiveness by hose/chalk test supplemented by dimensional measurements of seal compressing components.
– Pontoons where fitted
– Bunker tank vents’ flame screens
– Bunker and vent piping systems
– Thickness measurement of hatch cover and coaming plating and stiffeners should be carried out
2.5 Extent of overall and close-up surveys:
An overall survey of all tanks and spaces should be carried out at Renewal Survey.
– Fuel Oil tanks in cargo length area:
At No. 1 Renewal Survey (age 5 or less): None
At No. 2 Renewal Survey (age 10 or less): One
At No. 3 Renewal survey (age 15 or less): Two
At No. 4 Renewal survey (age > 15): Half of all, minimum two
– Peak tanks should be examined internally at each renewal survey.
– Different tanks should be examined at each renewal survey, on a rotational basis.
2.6 Extent of thickness measurements
– To determine general and local levels of corrosion in the transverse web frames in all water ballast tanks, and transverse bulkhead plating.
2.7 Extent of tank pressure testing:
All boundaries of water ballast tanks, deep tanks and cargo holds used for water ballast within cargo length area should be pressure tested. For fuel tanks, only representative tanks should be pressure tested.
– Boundaries of ballast tanks should be tested with a head of liquid to the top of air pipes.
– Boundaries of ballast holds should be tested with a head of liquid to the near to top of hatch.
– Boundaries of fuel oil tanks should be tested with a head of liquid to highest point that liquid will rise under service conditions.
2.8 Additional Renewal Survey requirements:
– After determining compliance with Reg. XII/12 and XII/13: examine and test water ingress detection system and alarms, and means of draining and pumping tanks forward of collision bulkhead and bilges forward of foremost cargo hold.3 ANNUAL SURVEY
3.1 General
3.2 Hull
3.3 Weather decks, hatch covers and coamings
3.4 Cargo holds: If bulk carrier is between 10 to 15 years, 2 selected cargo holds overall survey and examination of all pipings and penetrations. If 15 years and more, cargo holds overall survey and examination of all pipings and penetrations.
3.5 Ballast tanks
3.6 Additional annual survey requirements4 INTERMEDIATE SURVEY
4.1 General
4.2 Double-side skin bulk carriers 5 to 10 years
A) Ballast tanks: Overall survey.
B) Cargo holds: Overall survey.
C) Extent of thickness measurement: To determine general and local corrosion levels at areas subjected to close-up survey.
4.3 Double-side skin bulk carriers 10 to 15 years
A) Same as 10 years Renewal Survey scope except Fuel Tanks internal examination and all tanks pressure testing not required.
B) Underwater Survey may be considered in lieu of Dry Dock Survey.
4.4 Double-side skin bulk carriers exceeding 15 years old
A) Same as 10 years Renewal Survey scope except Fuel Tanks internal examination and all tanks pressure testing not required.
B) Dry Dock Survey should be part of the Intermediate Survey.5 PREPARATIONS FOR SURVEY
5.1 Survey programme
5.1.1 Owner in cooperation with the Administration shall work out a specific survey programme prior to commencement if any part of renewal survey and, for double-side skin bulk carriers over 10 years of age, the intermediate survey.
5.1.1.1 Prior to survey programme development, survey planning questionnaire shall be completed by the owner based on information set out in annex 4B.
5.1.1.2 Survey programme at intermediate survey may consist of survey programme at the previous renewal*************
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*************1. Documentation for selecting tanks, holds, areas and structural elements to examine:
A) Survey status and basic ship information
B) Survey report file
– Reports of structural surveys
– Condition evaluation reports
– Thickness measurement reports
C) Supporting documents
– Survey programme
– Structural plans of cargo holds and ballast tanks
– Previous repair history
– Cargo and ballast history
– Inspection by ship’s personnel in reference to: General structural deterioration, bulkheads and pipings leakages, coating condition or corrosion prevention system
– Any other information which will help identify suspect areas and critical structural areas
D) Main structural plans (scantlings drawings), including information regarding use of High-Tensile Steel (HTS)
E) Relevant previous survey and inspection reports from both Classification Society and Owner
F) Information regarding use of ship’s holds and tanks, typical cargoes and other relevant data
G) Information regarding level of corrosion prevention level on the new building
H) Information regarding maintenance level during operation2. Submitted survey programme should account for close-up survey, thickness measurements and tank testing, and should include relevant information:
A) Basic ship information and particulars
B) Main structural plans (scantlings drawings), including information regarding use of High-Tensile Steel (HTS)
C) Plans of holds and tanks
D) List of holds and tanks with information on use, protection and use of coating
E) Conditions of survey (e.g. information regarding hold and tank cleaning, gas-freeing, ventilation, lighting, etc.)
F) Provisions and methods of access to structures
G) Equipment for surveys
H) Nominations of holds, tanks, areas for close-up survey
I) Nominations of sections for thickness measurement
J) Nominations of tanks for testing
K) Damage experience related to ship in question5.4 Equipment for surveys
A) Thickness measurement: Normally Ultrasonic test equipment
B) Fracture detection equipment: Radiographic, Ultrasonic, Magnetic Particle, Dye Penetrant
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