U.S. Coast Guard Issues Safety Alert and Technical Advisory
United States Coast Guard Assistant Commandant for Marine Safety, Security and Stewardship Washington, DC issues Technical Advisory on Oil Content Monitors and a Safety Alert on fires caused by high temperature components associated with turbochargers and engine exhaust systems.
•Oil Content Monitor (OCM) has a unique vulnerability which facilitates convenient tricking.
September 16, 2008: The United States Coast Guard has been informed by various sources that a particular model Oil Content Monitor (OCM) has a unique vulnerability which facilitates convenient tricking. DECKMA model OMD-2005 utilizes a handle operated ball valve which when rotated allows a metal extension attached to the valve handle plate to come into contact with a magnetic micro-switch. This action in turn causes the unit's internal processor to interpret the position of the handle as indicating that the Oily Water Separator (OWS) discharge sample is being sensed by the monitor. By placing a magnet near the micro-switch or by using items such as a binder clip, this interlocking function is disabled and the valve may be repositioned to allow clean water to flow continuously to the OCM. OMD-2005 units delivered after January 2005 have been fitted with a cover plate which makes this intervention slightly more difficult. Owners of units that do not have this cover plate are encouraged to obtain one by contacting their equipment's technical representatives.
It is important to note that this particular manufactured meter is not the only unit that can be tricked. Units manufactured by other companies may also have similar vulnerabilities. Port and Flag State inspection personnel, auditors, class representatives, and owner /operator technical personnel should always be alert when examining this equipment. USCG inspection and investigation processes have revealed many methods used to disable OCM functionalities. Within the OCM cabinetry simple jumpers, swapped wires, disconnected wires, the addition of internal switches, etc., have been discovered. Externally, the use of flushing water during operations, additional clean water connections to the discharge sample line, additional powering capabilities to the three-way valves or discharge control valves, mechanical overrides limiting the action of electro-pneumatic operated control valves, the use of screwdrivers to over-ride interlocks and switches, etc.., have been noted at one time or another.
The USCG strongly recommends that personnel associated with the maintenance, operation, inspection, and testing of OWS and OCM equipment be alert for the types of improper modifications and deliberate manipulations stated above.
This technical advisory is provided for informational purpose only and does not relieve any domestic or international safety, operational or material requirement. Developed and distributed by the Office of Investigations and Analysis, United States Coast Guard Headquarters, Washington, DC. United States Coast Guard Assistant Commandant for Marine Safety, Security and Stewardship Washington, DC.
•Preventing Engine Exhaust System Fires (Marine Safety Alert 5-08)
September 17, 2008: This Safety Alert addresses the issue of preventing unwanted fires caused by high temperature components associated with turbochargers and engine exhaust systems in close proximity to combustible ship structures.
Two recent marine casualties involving inspected passenger vessels resulted in personnel injury, fire damage to machinery and ship structures, operational down time and lost revenues. In both cases, the vessels were recently re-powered with new turbocharged engines having exhaust systems designed to operate at higher temperatures than the previous engines. Investigations into each case identified common discrepancies as follows:
1. Failure to properly insulate or shield combustible ship structures from engine exhaust systems in accordance with 46 CFR §182.430.
2. Failure to properly submit documentation for plan review, which may have identified failures to comply with 46 CFR regulations.
As a result of these recent incidents and due to other related casualties involving small passenger vessels, the U. S. Coast Guard strongly recommends vessel owners and operators to:
Inspect vessel engine exhaust systems, machinery spaces, and exhaust compartments to verify that lagging and insulation are properly installed to shield hot surfaces and combustible materials. Proper insulation and shielding methods will help to prevent fires due to flammable and combustible liquids spraying onto hot surfaces (i.e. turbochargers, exhaust piping) and will prevent combustible surfaces (i.e. wood, fiberglass, FRP) from heating up to ignition temperatures due to close proximity to hot surfaces. Pay particular attention to areas where exhaust systems penetrate bulkheads and decks, making sure that combustible surfaces are properly shielded and/or insulated using non-combustible materials.
Ensure that proper submittals for plan review are made and documented with the local U.S. Coast Guard Sector Office of Prevention. Plan reviews are required whenever engines and/or propulsion systems are changed or modified. This includes re-engine projects where engines are not replaced in-kind, but with different types of engines or engine manufacturers.
This safety alert is provided for informational purposes only and does not relieve any domestic or international safety, operational or material requirement. Developed by the District 11 Prevention Division and distributed by the Office of Investigations and Analysis, United States Coast Guard Headquarters, Washington, DC.
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