the imo pspc requirement for coatings technical file; how to use it to reduce life cycle costs...

The IMO PSPC Requirement forCoatings Technical File;

How to use it to Reduce Life Cycle Costs

Delmar Doyle, Sr. DirectorNACE International

The Aim of PSPC?

- To move from this - To this

PSPC Standards

For the regulation to prove it achieves what is has set out to achieve…

This Standard is based on specifications and requirements which intend to provide a target useful coating life of at least 15 years, which is considered to be the time period, from initial application, over which the coating system is intended to remain in “GOOD” condition.

PSPC Poses Challenges/Opportunities

• Should result in Improved design• A greater need for qualified inspectors • A greater demand for education in coating management• A more systematic approach to inspection (objectivity)• New technology solutions for equivalent systems• Increased automation and control of processes• Better data recording & retrieval• Management tools

Coatings Technical File

• For the life of the ship the Coatings Technical File (CTF) requirement “should” be the most beneficial part of PSPC.

• It should provide the information, but more importantly, the metrics for managing preservation in ship construction, ship inspection and ship ownership. That is, it should reduce life cycle costs.

QA The Problem

• The IMO PSPC clearly indicates what is to be included in the CTF - but: does not state the amount of information needed

Do all the individual readings need to be recorded or the summary? Are photographs of the surface condition required or not necessary?

• “Paper” process• Lots of information - Not in a manageable form/format • Preservation QA data time lag• Reliance on ‘trust’ vs. verifiable data• Delayed adjudication of deficiencies• Data not used to manage process• QA data cannot be trended or analyzed• Rework

Data needs

• IMO PSPC Ballast Tank regulations require the:

– measurement and recording of the inspection process at each build stage

– production of a Coating Technical File upon completion– How big 6,300,1000 pages....? – It seems we do not know?

• NACE is preparing a set of Best Practices that will be submitted to IMO for review .

The Parties Involved

• In new-build contracts today the parties involved include:– Ship-owner– Shipyard

• Painting Contractor• Coating Manufacturer

– Class Societies• What does each party expect

from the CTF?

Ship Builder Goals Coating Technical File

• Insure that ship meets PSPC and Owners requirements• Detailed records on how the ship was constructed• Evaluate quality of their various preservation teams• Eliminate rework• Evaluate quality of the inspection process• Real time correction of preservation errors

Ship Owners Goals Coating Technical File

• Achieve a 15 year useful coating life • Insure they know how the ship was constructed• Evaluate quality of Shipyard Preservation efforts• Basis for evaluating quality of coating application • Data in an electronic format

• Paperless data file• Have meaningful preservation management tool• Minimize life time preservation costs

• Can be as high as 25% of docking maintenance costs

QA Data TodayExamples: (Recent findings)

– Calculation errors– Out-of-spec reading acceptance– Overwrites of data– Unreadable data– Signatures by unqualified inspectors – Transcription errors– QA Data received 53 days after project completion

• With > 72 errors

Coating Technical FilePaperless Components

– Real-time preservation QA data collection, recording, storage and analysis tool

– Need standardized as vehicle for automating preservation QA data collection

– Micro-computer/hand held data collection• Direct input from DFT and environmental meters• Form Templates• Exports to web-administered database

– Electronic data transmission– Does not change QA requirements described in PSPC

Paperless CTF

Tablet computer

WorkstationHand held computer

TGIDatabase

Laptop computer

Database Server

Instrument

Workstation

IntranetIntranet

Reporting

Data Aggregation

Hardware Architectural Diagram

Paperless CTF

• Automated data capture• QA inspection reports filled out online• Immediate system feedback for Inspector at jobsite• Secure electronic storage & transmission of data• Reports automatically generated• Engineering adjudication electronically triggered and

documented

• From the ship specification:– Ship Structure (by unit/block and then by tank)– Coatings Library– Coating System Library

• From the inspection processes:– Inspector’s Register– Inspection Records– Data Collection

• All supported by a structured data collection regime, and a “change log”

• Automatic production of daily log

Paperless CTF

.

Sample CTF Screen Shot

Sample CTF Screen Shot

Inspection Process Overview

QA readings upload directly to database • Immediate system feedback for Inspector at

jobsite• Data stored for analysis/history• Reports automatically generated• Engineering adjudication electronically triggered

and documented

QA Data Tomorrow• Automated data capture

– Measuring Instruments– Direct read instruments and handheld transmitting to

Computer• Automated calculations• Annotated out-of-spec conditions• Electronic Storage/Transmittal of Data

– Electronic shop records• Automated/timely report generation

– Management/Engineering reports– Metrics

Summary

• Without a solid Coatings Technical File it is unlikely that a 15 year coatings life can be achieved

• Consistent detailed “best practices” or requirements for what should be included in the CTF are the cornerstone– NACE is preparing and will discuss with various organizations before submittal for IMO

consideration

• Direct electronic data recording is needed• Data needs to provide metrics to evaluate performance

– Quality Control by shipyards– Inspection by Class Societies– Minimizing lifetime preservation costs for Shipowner

.