LPG SHIPPING SUGGESTED COMPETENCY STANDARDS Guidance and Suggested Best Practice for The LPG Industry in the 21st Century SIGTTO INTRODUCTION In 2006, SIGTTO published a set of standards for the LNG shipping industry, a move that was welcomed by members, but that created a demand for a similar set of standards for the LPG Industry. LPG shipping, while a more ‘mature’ market when compared to LNG, continues to expand and remains a critically important part of the Shipping Industry. The issues and challenges of LPG shipping need to remain at the front of the industry’s mind if it is to maintain its excellent safety record. This set of standards will form the default minimum for best practice. We believe that they can and should be built upon by operators, who are encouraged to develop additional appropriate standards for their own operations and ships. We also believe that these standards should be improved upon or adapted where necessary, to provide standards that are truly relevant and usable. In early 2007, SIGTTO set up a new working group to tap into the experience that was held within its membership. The standards that emerged from that exercise have been collated into this book and were formally adopted by the SIGTTO board in Athens on the 14th May 2008. They have been written using the ‘competence based methodology’ that is widely used in STCW and the industry in general. As a guidance document, this set of standards is not, and cannot be, considered mandatory. However, we do believe that they represent current best practice for operational training standards for Officers and so they should at least be considered for adoption by the individual or the company. III HOW TO USE THESE STANDARDS Each of the main sections provides a summary of the tasks and knowledge that are considered necessary to satisfactorily perform within a particular group, such as deck management or cargo equipment operations. To provide guidance on usage, the following example works through the system to get to details of the knowledge required in a particular subject for a particular operating group - in this case for Deck Management. Example Section 1 – Deck Management Unit 1 – Develop Familiarisation and Understanding of LPG Transportation Requirements The section (and each of the sections) begins with a summary of what the unit is about. This is followed by a list tiles ‘Outcomes of effective performance – You must be able to do the following:’ which provides a list of general ‘competencies’ that are necessary to function efficiently at all levels within the Deck Management team. There is now a second list with each of the numbered items in the list relating to specific knowledge you must have if you are part of the Deck Management team. Reading each of these will provide you with a summary of the knowledge and understanding you should have and the things you should be able to do if you are performing effectively at that rank. To continue with the example from the first page: Management – What you must know: 1a. The properties and characteristics of liquefied petroleum and other relevant gases. (Underpinning knowledge required 1.1 (ALL)) The italicised comment underneath the list item now refers to the specific information, known as underpinning knowledge, that you will find in the tables contained within the appendices. In this particular instance you will find that 1.1 relates to Physics and Chemistry and that the comment (ALL) means that everything within section 1.1 should be fully understood by that rank. You can cross check this by looking at the ‘ticks’ within the tables, following the column that says ‘Deck Management’. IV CONTENTS Deck - Management .........................................................................................................................................7 Deck Management (1) Develop Familiarisation and Understanding of LPG Transportation Requirements ....................9 Deck Management (2) Manage and Operate Safety Systems and Equipment .........................................................10 Deck Management (3) Prepare and Implement A Detailed Plan for the Entire Cargo Cycle ......................................11 Deck Management (4) Monitor and Review Cargo Operations .............................................................................12 Deck Management (5) Plan for and Manage Cargo Operations Under Non-Standard Conditions ...........................13 Deck Management (6) Plan For and Manage Cargo Operations Under Emergency Conditions ...............................14 Deck Management (7) Ensure the Integrity of Cargo Containment, Cargo Equipment and Cargo Related Spaces ................................................................................................................15 Deck Management (8) Develop an Awareness of the Commercial Aspects of LPG Transportation .............................16 Deck - Operational .......................................................................................................................................17 Operational Deck (1) Develop Familiarisation and Understanding of LPG Transportation Requirements ...................19 Operational Deck (2) Manage and Operate Safety Systems and Equipment .........................................................20 Operational Deck (3) Execute Planned Cargo Cycle Operations ...........................................................................21 Cargo Equipment - Management .......................................................................................................................23 Cargo Equipment Management (1) Develop Familiarisation and Understanding of LPG Transportation Requirements .............................................................................25 Cargo Equipment Management (2) Manage and Operate Safety Systems and Equipment .........................................26 Cargo Equipment Management (3) Ensure Effectiveness of the Entire Cargo Cycle ....................................................27 Cargo Equipment Management (4) Plan for and Manage Cargo Operations Under Non-Standard Conditions .................................................................................28 Cargo Equipment Management (5) Plan for and Manage Cargo Operations Under Emergency Conditions ................29 Cargo Equipment Management (6) Ensure Effectiveness of Maintenance, Testing and Inspection of Cargo Equipment and Spaces ...........................................................................30 Cargo Equipment Management (7) Control the Operation of Cargo Reliquefaction Equipment and Associated Systems ..........................................................................................31 Cargo Equipment Management (8) Ensure Integrity of Electrical Plant and Control Systems ........................................32 Cargo Equipment - Operational .......................................................................................................................33 Cargo Equipment Operations (1) Develop Familiarisation and Understanding of LPG Transportation Requirements .............................................................................35 Cargo Equipment Operations (2) Manage and Operate Safety Systems and Equipment .........................................36 Cargo Equipment Operations (3) Execute Planned Cargo Cycle Operations ..........................................................37 Cargo Equipment Operations (4) Plan for and Manage Cargo Operations Under Non-Standard Conditions .................................................................................38 Cargo Equipment Operations (5) Plan for and Manage Cargo Operations Under Emergency Conditions ................39 Cargo Equipment Operations (6) Maintain the Integrity of Cargo Containment, Cargo Equipment and Cargo Related Spaces ................................................................................40 Underpinning Knowledge .......................................................................................................................41 Recommended References .......................................................................................................................64 V 35 Develop Familiarisation and Understanding of LPG Transportation Requirements Unit summary / What this unit is about: This unit identifies the competence necessary to develop familiarisation with and understanding of LPG transportation requirements. Outcomes of effective performance - You must be able to do the following: Identify the properties and characteristics of liquefied petroleum and other relevant gases and determine their i. impact on safety and vessel operations Identify the regulations and guidelines, vessel designs, characteristics, materials and cargo related equipment and ii. determine the impact on cargo storage, transportation and containment Determine specific loading and discharging features and cargo cycles and confirm individual responsibilities for iii. those involved Identify the ship-to-shore interface and equipment and determine any issues they might raise during vessel and iv. cargo operations Confirm the specific vessel and cargo operations risk assessment requirements and processes for those involved v. Identify the complete cargo cycle, and the cargo equipment required for each cargo cycle stage, including any vi. specific features and issues which may arise. Operational – what you must know: 1a. The properties and characteristics of liquefied petroleum and other relevant gases (Underpinning knowledge required 1.1 (All)) 1b. Personnel safety, vessel safety and environmental considerations related to the carriage of LPG; the differences between ‘flammable’ and ‘toxic’ cargoes (Underpinning knowledge required 1.4, 1.5.1, 1.6 (All), 1.7.1 (All)) 1c. The regulations and guidelines related to the carriage of LPG at sea (Underpinning knowledge required 1.3 (All)) 1d. The features of LPG ship design: Fully pressurised, semi-refrigerated, fully refrigerated and Ethylene designs. Safety systems, how and why they differ from other typical ship designs, safety features and the differences they make to ship operations and cargo storage (Underpinning knowledge required 1.2.1, 1.2.2, 2.1.1, 2.1.3, 2.1.5, 2.1.7) 1e. LPG cargo reliquefaction system types – including direct, cascade and indirect systems - typical operating parameters and specific features and how they relate to the method of cargo management (Underpinning knowledge required 2.13 (All)) 1f. The materials used on LPG ships, where they are used and why they are suitable for their purpose (Underpinning knowledge required 1.2.1, 1.5 (All)) 1g. Cargo tank filling capacities, limitations and associated features – including ‘over-fill protection’ (Underpinning knowledge required 3.6.1, 3.6.2) 1h. How different types of ship-to-shore interface processes and equipment might impact on vessel, mooring and cargo operations (Underpinning knowledge required 3.3 (All), Series 4.n.4 as appropriate) 1i. Safe and efficient LPG & ballast-handling practices (Underpinning knowledge required 2.2.1, 4.1.1) 1j. LPG-specific risk assessment requirements and processes (Underpinning knowledge required 1.8.1) 1k. Individual areas of responsibility. (Underpinning knowledge required 1.9.1). Cargo Equipment Operations 1 36 Manage and Operate Safety Systems and Equipment Unit summary / What this unit is about: This unit identifies the competence necssary to manage the operation, testing and inspection of safety systems and equipment onboard LPG Carriers. The systems and equipment covered by this unit include, but are not limited to, the following systems and specific features: Emergency shut down system ? ship/shore link ? fusible plugs/sensors ? cargo machinery space flooding system activation ? deck/water spray ? gas detection systems – fixed and portable ? proof of functionality ? fixed fire fighting systems ? airlocks. ? Outcomes of effective performance – what you must do: Identify the safety systems and equipment required for carriage of LPG, its parameters, operating specifications and i. limits and maintenance requirements Confirm that the status of the safety systems and equipment meets operating parameters and requirementsii. Confirm appropriate monitoring systems and required tests for safety systems and equipmentiii. Confirm individual responsibilities for maintaining, testing and inspecting safety systems and equipmentiv. Verify the results of maintenance, testing and inspection of safety systems and equipment and where they are not in v. line with required parameters, determine the relevant action and/or inform the appropriate person Operate safety systems and equipment as required in line with regulations, procedures, guidelines and safety vi. practice Provide accurate and complete records.vii. Operational – what you must know: 2a. Operational parameters, specifications, limits and maintenance requirements for LPG safety systems and equipment (Underpinning knowledge required 3.4 (All), 3.5 (All)) 2b. Monitoring systems, requirements and tests for safety systems and equipment (Underpinning knowledge required 3.1 (All), 3.2 (All)) 2c. Individual areas of responsibility (Underpinning knowledge required 1.9.1) 2d. The actions to take in the event of non-compliance of safety systems and equipment and who needs to be informed (Underpinning knowledge required 1.9.1) 2e. How to operate safety systems and equipment, and the related regulations, procedures, guidelines and safety practice (Underpinning knowledge 1.3 (All), 3.3.1, 3.4.1, 3.5.1, 3.7.1) 2f. Record keeping requirements. (Underpinning knowledge required 1.11.1). Cargo Equipment Operations 2 37 Execute Planned Cargo Cycle Operations Unit summary / What this unit is about: This unit identifies the competence necessary to ensure the effectiveness of the entire cargo cycle and the systems and equipment required for cargo cycle operations onboard an LPG Carrier from refit to refit: Cargo tank preparation ? drying and inerting the cargo system ? gassing up ? cooling down ? loading ? loaded passage ? discharge ? ballast passage ? warming up ? inerting and gas freeing ? cargo grade change. ? Outcomes of effective performance – you must be able to do the following: Determine activities and own responsibilities involved in specific cargo cycle operations from plans provided and i. instructions received Confirm with those involved in the planned operation that they understand the responsibilities of others where ii. relevant Prepare for and carry out operational activities in line with planned procedures, guidelines, health, safety and iii. environmental practice Operate all cargo machinery in accordance with organisational and manufacturers guidelines and system iv. parameters Carry out and monitor checks at relevant times and critical points, and advise others as required, to confirm correct v. and appropriate implementation of the operational plan Identify non-standard and emergency operating conditions from alarms and other relevant sources and take relevant vi. action and/or inform the appropriate person in a timely and safe manner. Provide feedback to relevant personnel and record appropriate informationvii. Identify the stages of the cargo cycle and the requirements for each stage. Confirm the issues, operational aspects viii. and health and safety considerations which may impact on the plan. Operational – what you must know: 3a. Cargo cycle stages, what the cargo plan covers, safety and organisational monitoring requirements for cargo cycle operations (Underpinning knowledge required 4.1.1, 4.2 (All), 4.3 (All), 4.4 (All), 4.5 (All)) 3b. The typical and usual issues and operational aspects that could have an impact on the plan (Underpinning knowledge required 4.1.1, 4.2 (All), 4.3 (All), 4.4 (All), 4.5 (All)) 3c. Specific checks required for each operation and their frequency (Underpinning knowledge required 4.1.1, 4.2 (All), 4.3 (All), 4.4 (All), 4.5 (All)) 3d. Individual responsibilities for all aspects of the cargo cycle (Underpinning knowledge required 1.9.1) 3e. The operating procedures, operational parameters and limitations of cargo machinery and systems (Underpinning knowledge required Chapter 2 (All), 3.1(All), 3.2 (All), 3.3 (All), 3.6 (All), 3.8 (All)) 3f. Implementation procedures, guidelines and health, safety and environmental practice. (Underpinning knowledge required 1.3 (All)). Cargo Equipment Operations 3 38 Plan for and Manage Cargo Operations Under Non-Standard Conditions Unit Summary / What this unit is about: This unit identifies the competence required to ensure the effectiveness of cargo operations on LPG Carriers under non-standard conditions including, but not limited to, the following situations: Cargo pump failure ? gas freeing a single tank ? ship-to-ship transfer ? stenching agents ? inhibitors. ? Outcomes of effective performance – what you must do: Determine the type, nature and scale of the non-standard condition from either alarms or other means of detectioni. Identify the available options in order to deal with the non-standard condition in a safe and controlled mannerii. Carry out risk assessments and planning for each option and determine the most appropriate plan and course of iii. action to deal with the situation Provide accurate and clear instructions and information to relevant people to carry out the planiv. Put the agreed plan into operation in a timely and safe mannerv. Monitor the effects of the plan as required, identify and make appropriate adjustments vi. Review the plan and operational procedures at the appropriate time and identify lessons learnt and provide feedback vii. to the relevant people, systems and organisation. Management – what you must know: 4a. Types of non-standard conditions and applicable regulations, procedures, guidelines and safety practice for dealing with them (Underpinning knowledge required 1.3 (All), 5.1.1, 5.2 (All), 5.3, 5.4, 5.5, 5.6, 5.7, 5.8.1) 4b. How to carry out risk assessments (Underpinning knowledge required 1.8.1) 4c. How to formulate, adjust and implement contingency plans (Underpinning knowledge required 1.10 (All)) 4d. Individual levels of responsibility and the importance of checking and confirming understanding of instructions given (Underpinning knowledge required 1.9.1) 4e. The importance of reviewing the plan and course of action taken. (Underpinning knowledge required 4.1.2). Cargo Equipment Operations 4