Top 10 Towing Vessel Material Failures—Part I

The U.S. Coast Guard Office of Investigations and Analysis recently conducted an analysis of all material failures on towing vessels after a reportable marine casualty in 2004-2008.

This study analyzes material failures that are the “first events” of marine casualties for towboats on rivers and other inland waters; tugs engaged in harbor operations, ship dockings, and lightering barges; and tugs towing offshore barges on coastal routes.
Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil/. Navigate to missions/investigations/safety reports.

Towline
In many instances “towline” refers to a facing wire or to an inter-barge connection wire. Failure of these wires is at times attributed to operator error in the handling of the boat or error of the deck crew who might have fastened it incorrectly. In some instances the wire was either too small or too worn to be safe.

Fuel Filter
As a material failure, a fuel filter becoming clogged with dirt, water, or both is more common on towing vessels than it is on other commercial vessels.

Steering Gear
Linkage. Although the term “linkage” does not precisely identify a component in a steering system, we cannot overemphasize the number of different mechanical connecting components that exist in a vessel’s steering system.
Hose. Most hose failures are a burst along its length. Crimped-on end fittings also fail, occasionally without warning.Rudder. Less than half of all rudder casualties are the direct result of groundings or flotsam strikes, and the exact causes of most of these casualties are never attributed to one particular event. In more than 20 percent of these casualties the rudder has been lost.
Ram. Casualties related to this major component are both hydraulic and mechanical. Hydraulic failures are commonly stuck pistons and blown seals. Half of all mechanical ram-related failures involve the attachment of the ram to the rudder.
Pump. The same mounting and connecting failures noted with rams occur with steering pumps, accounting for approximately 40 percent of failures. Sixty percent of pump failures are with the pump internals—seals and bearings.

The list continues in part 2.

Top 10 Towing Vessel Deficiencies—Part II

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil. Navigate to missions/investigations/safety reports.

See Part I here.

Fire Pumps 46 CFR 27.301
Owner/operator checklist:

• Ensure fixed pumps have been fitted with a remote-start control and that the control is in working order. If fire-main valves have to be operated from this remote location, ensure that the valves open properly.Portable pumps, along with the hose and nozzle, must be stowed outside the machinery space. A 50-foot hose is required. The portable pump must be a dedicated fire pump; it may not be used to pump oily mixtures.

Vessel Response Plan 33 CFR 155.1040, 155.1060
With regard to towboats that push tank barges, the most common items that are either lacking from or not sufficiently addressed in the response plan are:

• certification that response resources are able to respond to a “worst-case discharge,”
• volume and type of oil that would be discharged in a worst-case discharge,
• responsibilities of the qualified individual for immediate communication with the NRC,
• vessel-specific information and the captain of the port zone information for the areas in which the barge will operate.

Owners/operators must use the “Homeport” web portal, http://homeport.uscg.mil to submit a response plan for approval. Click “help” and navigate to the “vessel response plan submitter.”

Vessel Security Plan 33 CFR 104, Subpart D
Owner/operator checklist:

• The company security officer or vessel security officer must ensure that the vessel security plan (VSP) is audited annually. The plan must also be audited if the owner or operator of the vessel changes or if there has been any change in the operations of the vessel not addressed in the existing VSP.
• If the results of an audit indicate that the VSP must be amended, an amended plan must be submitted to the Coast Guard’s Marine Safety Center.
• Vessel security officers must conduct at least one drill that tests individual elements of the VSP every three months while the vessel is in service.
• Annual exercises are required to test communication and notification procedures and elements of resource availability, coordination, and response.
• Records of drills, exercises, and all other security activities must be kept for two years.

Wiring Materials and Methods
Missing junction box or switch plate covers and exposed dead-end wires account for 27 percent of inspection deficiencies.

Guards for Exposed Hazards Missing guards for moving machinery is the most common deficiency in this category.

Stay tuned for:
Top 10 towing vessel material failures.

Top 10 Towing Vessel Deficiencies—Part I

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil/. Navigate to missions/investigations/safety reports.

The U.S. Coast Guard Office of Investigations and Analysis recently examined vessel deficiencies in various vessel classes to identify the 10 most common deficiencies in each class.
We share these so that owners can take corrective action, rectify problems prior to scheduling the next Coast Guard examination, and ensure continual compliance with safety and environmental requirements.

General Alarm 46 CFR 27.201
Missing alarm placards and visual indicators as well as inoperable audible indicators are frequent deficiencies on towing vessels.

Running Lights Inoperable or Defective 46 CFR 25.10-3
Many towing vessels are found to have inoperable stern, masthead, and sidelights. In some instances the installation of these lights conflicts with the International and Inland Navigation Rules.

Owner/operator checklist:

• Inspect running lights periodically, paying particular attention to the condition of the lenses, wattage, and focal height of the light bulbs.
• The bulb’s filament must be at the same height as the middle portion of the lens.
• Household bulbs are not acceptable.

Remote Fuel Shut-off Valves 46 CFR 27.207
Any fuel line that supplies fuel directly to a diesel engine must have a shut-off valve that can be remotely operated from outside the space.

Owner/operator checklist:

• All mechanical linkages for the valve must be kept clean and lubricated.
• The valve control must be labeled in one-inch letters. Instructions should be posted in the vicinity of the emergency fuel shut-off valve control.

Fire Detecting Control Panel 46 CFR 27.203
Owner/operator checklist:

• Ensure all of the control panel’s required features function properly, including power-available indicator light, audible alarm, visible indication of the zone (or zones) of the fire’s origin, means to silence the audible alarm, and a circuit fault detector test switch.
• Labels for all switches and indicators must be in place.
• Documentation that the system was certified (by a registered professional engineer or a recognized classification society) should be on board.
• Be prepared to demonstrate proper operation during each examination or boarding.

Life Buoys SOLAS, Ch. III, Reg. 31, 46 CFR 160.050-6
Owner/operator checklist:

• Life buoys on UTVs are not required to be marked with the name of the vessel and the vessel’s hailing port, but the information on the manufacturer’s label must be readable.
• For UTVs operating under SOLAS, life buoy stowage positions should be marked with “life buoy” or with IMO’s life buoy symbol.
• Owners/operators should check that the required number of life buoys are equipped with self-igniting lights, self-activated smoke signals, and that the buoyant line is not oxidized.

The list continues in part 2.

Top 10 Small Offshore Supply Vessel Deficiencies—Part II

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil/. Navigate to missions/investigations/safety reports.

See Part I here.

Light Fixtures 46 CFR 129.410, Guards for Exposed Hazards 46 CFR 127.330
Approximately 30 percent of light fixture deficiencies are due to missing or damaged fixtures.

Missing guards for moving machinery and missing insulation on exhaust piping are the most common findings in this category. Additionally, hot surface guards are sometimes missing from cooking appliances.

Battery-Operated Lanterns 46 CFR 129.440 & 129.450
Inspectors occasionally discover that the portable lantern for the pilothouse or the one at the access to the engine room is missing.

Fire Control Plan 46 CFR 131.945
Common deficiencies:

• The plan is not properly posted or is missing.


• The plan is not modified when the vessel is altered.

Junction Boxes 46 CFR 111.81
The most common deficiency is a missing cover. Inspectors also observe that junction boxes are insecurely mounted.

General Alarm 46 CFR 131.805 & 131.810, 46 CFR 111.15 & 112.55
The switch must be clearly labeled “General Alarm” and each bell must be labeled in half-inch upper-case letters: “GENERAL ALARM—WHEN BELL RINGS GO TO YOUR STATION.” A common deficiency is a missing label.

Stay tuned for:
Top 10 towing vessel deficiencies.

Top 10 Small Offshore Supply Vessel Deficiencies—Part I

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil. Navigate to missions/investigations/safety reports.

The U.S. Coast Guard Office of Investigations and Analysis recently examined vessel deficiencies in various vessel classes to identify the 10 most common deficiencies in each class.

We share these so that owners can take corrective action, rectify problems prior to scheduling the next Coast Guard examination, and ensure continual compliance with safety and environmental requirements.

Oily Water Separator 33 CFR 151.10
Common deficiencies:

• Documentation of routine preventive maintenance is not available to the inspector.
• Documentation that attests to OWS calibration is not on board.

Owners/operators: Ensure that an appropriate crewmember is available to demonstrate proper operation for the inspector.

Hull Plating 46 CFR 126.140, USCG NVIC 7-68
Inspectors typically find breaches in the hull plating, a temporary repair that had not been previously documented, and wastage of structural members.

Watertight Doors 46 CFR 174.210, 46 CFR 131.893
Common findings include hinges and dogs that need lubrication or adjustment, warped doors, and deteriorated gaskets.

Occasionally inspectors find required “watertight door” markings have been painted over.

EPIRB 46 CFR 133.60(a)
All offshore supply vessels must have a (Category 1) 406-MHz Emergency Position Indicating Radio Beacon (EPIRB) installed in a float-free system.

Most noteworthy is the number of unregistered EPIRBs.

Owner/operator checklist:

• Check the status of EPIRB registration at (888) 212-SAVE or BeaconRegistration.NOAA.gov.
• Inspect the EPIRB and the hydrostatic release mechanism before leaving port.
• Occasionally remove the EPIRB from its bracket to exercise the hydrostatic release.
• Ensure that the EPIRB is switched off before manually releasing the bracket to inspect the mechanism.
• Ensure the hydrostatic release unit for the EPIRB is replaced prior to its expiration date.

Running Lights Inoperable or Defective 46 CFR 129.430
Many vessels have inoperable stern, mast, and sidelights, and, in some instances, the installation of these lights was also found to conflict with the International and Inland Navigation Rules.

Vessels of 65 feet or more in length or 100 gross tons or more in size must also have navigation lights that are compliant with UL 1104 standards.

For more information:
For more information about small passenger vessel inspections, contact your local Coast Guard Sector/Inspections Division. For a listing of sector offices, click on “Sector Map” on http://homeport.uscg.mil.

The list continues in part 2.

Top 10 Cargo Vessel Deficiencies—Part II

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil/. Navigate to missions/investigations/safety reports.

See Part I here.


Lighting Fixture 46 CFR 111.75-20
All light fixtures subject to damage must have a guard or be made of high-strength material. The majority of deficiencies are related to the guard or missing or damaged fixtures.

Generators 46 CFR 111.12 & 112.50
More than 40 percent of all generator deficiencies indicate that the crew and/or shipyard personnel were either unavailable or unable to demonstrate proper operation.

Twenty percent are due to water, oil, or exhaust leakage, where any visible leakage will result in an “835” deficiency.

Fixed Carbon Dioxide 46 CFR 91.25-20 and 147.65, NVIC 6-72
Owner/operator checklist:

• All piping controls, valves, and alarms need to be checked for proper operation and 90 percent charge must be verified.


• The pressure drop through cylinder connections may not exceed 150 psi per minute over a two-minute period while subjected to the test pressure.


• All carbon dioxide cylinders must be retested every 12 years.

Wiring Materials and Methods 46 CFR 111.60, 46 CFR 111.81
Using temporary wiring where equipment must be hard-wired is the most common finding (40 percent), and dead-end wires account for 18 percent of inspection deficiencies.

General Watertight Integrity
Owner/operator checklist:

• After a drydocking, ensure that any labels removed by the shipyard are replaced.


• If modifications involve removing cables or pipes that ran through watertight bulkheads, ensure that the shipyard sealed the holes.


• Inspect all weatherdeck tank vents for rust-thru perforations.

For more information:
For more information, contact your local Coast Guard Sector/Inspections Division. For a listing of sector offices, click on “Sector Map” on http://homeport.uscg.mil/.

Stay tuned for:
Top 10 Offshore Supply Vessel Deficiencies

Top 10 Cargo Vessel Deficiencies—Part I

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil/. Navigate to missions/investigations/safety reports.

The U.S. Coast Guard Office of Investigations and Analysis recently examined vessel deficiencies in various vessel classes to identify the 10 most common deficiencies in each class.

We share these so that owners can take corrective action, rectify problems prior to scheduling the next Coast Guard examination, and ensure continual compliance with safety and environmental requirements.

Oily Water Separator 33 CFR 151.10
Common deficiencies:

• Documentation of routine preventive maintenance is not available to the inspector.
• Documentation that attests to OWS calibration is not on board.

Owners/operators: Ensure that an appropriate crewmember is available to demonstrate proper operation for the inspector.

Hull and Deck Plating 46 CFR 126.140, USCG NVIC 7-68

Hull Plating. Inspectors typically find breaches in the hull plating or a temporary repair that had not been previously documented, as well as wastage of structural members.

Deck Plating. Common deficiencies include cracked (hatch) corner brackets, cracks in the vessel’s winch foundations, and deck plating wastage.

Watertight Doors 46 CFR 170.270
Common findings include hinges and dogs that need lubrication or adjustment, warped doors, and deteriorated gaskets.

Operators should be prepared to demonstrate manual closing, in addition to closing doors under power. All hardware for the hydraulics must be approved by an appropriate classification society.

Fire Main 46 CFR 95.10
The most common deficiencies are leaks and wasted piping.

Owners should have enough personnel on hand to demonstrate proper operation of all fire pumps so the appropriate pressures (at remote outlets) can be verified.

Survival Craft 46 CFR 199.150 & 199.190
Miscellaneous davit-related items include worn rollers/wasted track, badly rusted gripes, bent/twisted hooks on the falls and the gripes, and wastage of the davit arms where the gripes make contact.

For more information:
For more information, contact your local Coast Guard Sector/Inspections Division. For a listing of sector offices, click on “Sector Map” on http://homeport.uscg.mil/.

The cargo vessel list continues in part 2.

Top 10 Tank Barge Deficiencies—Part II

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil/. Navigate to missions/investigations/safety reports.

See Part I here.




Cargo Pump 46 CFR 32.50
Before inspection, owners/operators should look for (and repair) common deficiencies. Checklist:

• Besides checking for obvious leakage, check the pump’s discharge pressure gauge.


• The diesel’s water temp and oil press gauges must be in good working order.


• Be sure the lagging on the diesel’s exhaust pipe is in good condition and its fan belt protective guard is in place.


• Ensure that there’s a guard covering the reduction gear shaft assembly between the diesel and the pump.


• Operating personnel must be prepared to demonstrate emergency shut-down procedures.

Vapor Control Components 46 CFR 39.20-1
Common deficiencies:

• cracks and pinhole leaks in the vapor piping,


• the half-inch diameter permanent stud on the vapor connection flange is often broken or missing.

Vessel Response Plan 33 CFR 155.1030, 1040 & 1060
The most common items that are either lacking from or not sufficiently addressed in the response plan are:

• certification that response resources are able to respond to a “worst-case discharge,”


• volume and type of oil that would be discharged in a worst-case discharge,


• responsibilities of the qualified individual for immediate communication with the NRC,


• vessel-specific information and the captain of the port zone information for the areas in which the barge will operate.

Owners/operators must use the “Homeport” web portal, http://homeport.uscg.mil/, to submit a response plan for approval. Click “help” and navigate to the “vessel response plan submitter.”

Cargo Control and Gauging Devices 46 CFR 38.10-20, 39.20-3 & 39.20-9
Owner/operator checklist:

• If the barge is equipped with magnetically coupled rising-stick gauges, ensure that the sticks aren’t bent and that the markings on the sticks are legible.


• If equipped with automatic-float continuous-reading tape gauges that are fitted with sight-glasses, ensure that no glass piece is cracked and that the assemblies are vapor-tight.


• Be prepared to test the high-level alarms in the inspector’s presence.

Hull and Deck Plating USCG NVIC 7-68

• Hull Plating. Inspectors typically find breaches in the hull plating as well as wastage of structural members. Occasionally an inspector notices a temporary repair that had not been previously documented.


• Deck Plating. A common defect is a crack where a cargo tank’s main access trunk meets the deck.

Cargo Tanks

• Leaking welds are sometimes found along the perimeters of bulkheads.

For more information:
For more information, contact your local Coast Guard Sector/Inspections Division. For a listing of sector offices, click on “Sector Map” on http://homeport.uscg.mil/.

Stay tuned for:
Top 10 Cargo Vessel Deficiencies

Top 10 Tank Barge Deficiencies—Part I

Excerpted from “Top Ten Deficiencies Found on Vessels.” Full text available on http://homeport.uscg.mil/. Navigate to missions/investigations/safety reports.

The U.S. Coast Guard Office of Investigations and Analysis recently examined vessel deficiencies in various vessel classes to identify the 10 most common deficiencies in each class.

We share these so that owners can take corrective action, rectify problems prior to scheduling the next Coast Guard examination, and ensure continual compliance with safety and environmental requirements.

Cargo Transfer Hoses 33 CFR 154.500, 156.170
The most common deficiency: Required marking that identifies hose use and maximum allowable working pressure is missing or illegible.

The hose’s date of manufacture and the date of its last pressure test must also be recorded, but not necessarily marked on the hose. If a hose is kinked, gouged, or otherwise deformed, it should be removed from service regardless of its ability to pass the pressure test. Unmarked hoses that are not in service should not be on board.

Running Lights 33 CFR 84.09, 17, & 19 and 46 CFR 153.953
The most common deficiencies:

• lack of a recent coat of “matte black” paint on the background screens,
• bent mounting stanchions,
• cracks where the stanchion meets the deck.

If a stanchion was straightened or replaced, check that the light sectors are in compliance and the wires weren’t damaged. All portable lights must be presented for inspection.

Cargo Transfer Piping, Valves and Gauges 33 CFR 156.170
The most common deficiency: Packing glands on valve stems need maintenance.

The maximum allowable working pressure must be stenciled on the piping. Operators must document all pressure testing.

Thermal Fluid Cargo Heater 46 CFR 61.30
Gauges are often found to be out of calibration, and sight glasses are sometimes cracked.

The operational test includes verification of the flame safety guard and the automated controls and valves. The required pressure for a hydrostatic test is 1½ times the MAWP. The owner/operator must ensure that personnel are available to conduct testing.

Cargo Tank Access–Manholes and Gauging Ports 46 CFR 42.15-30, USCG NVIC 7-68
Common deficiencies include:

• wastage at the top of the trunk where the gasket on a manhole cover or a gauging port cover seats against the trunk,
• wastage of the cover around the gasket groove,
• deterioration of the gasket,
• wastage of the bolts and bolt holes that form the manhole cover,
• loose or missing bolts on tank access ladder brackets,
• wasted or holed cargo tank stand-pipes,
• stress cracks and pinhole perforations where the trunk meets the deck.

For more information:

For more information about commercial vessel inspections, contact your local Coast Guard Sector/Inspections Division. For a listing of sector offices, click on “Sector Map” on http://homeport.uscg.mil/.

The tank barge list continues in part 2.