C C S 技术通告 Technical Information (2013) Technical Information No.11 Total No.45 Apr. 25, 2013 (Total pages: 2+10) TO: All relevant shipping companies, CCS Branches and Offices, CCS ship/product surveyors Turbocharger safety warning (NA and NR type turbochargers) --- The Republic of the Marshall Islands Maritime Administrator Marine Safety Advisory No.16-13 The Office of The Maritime Administrator of the Republic of the Marshall Islands issued the Marine Safety Advisory No.16-13 to all masters, ship s owners, operators of merchant ships. The Information of Marine Safety Advisory (MSA No.16-13): the Republic of the Marshall Islands Maritime Administrator has received a safety alert regarding NA and NR type turbochargers. This safety alert applies to owners and operators of turbochargers with grey cast iron casings of type NR12, NR14, NR15, NR17, NR20, NR24, NR26, NR29, NR34, NA34, NA40, NA48, NA57 and NA70. MAN Diesel & Turbo SE (Hereinafter referred to as MAN ) have issued Alert Service Bulletin No.ASB2013/02/18, which includes a Safety Instructions addendum, relating to the safety and safe operation of the turbochargers specified above. Please note the request of the Alert Service Bulletin to contact the MAN Company with details of the work numbers and years of production of all MAN turbochargers on board your ships. In the case of licensed production, you will also need to provide the details of the manufacturer. Please also pay particular attention to the recommendation and advice on page 2-3 of the Bulletin and the Safety Instructions contained in the Addendum. Introduction of Alert Service Bulletin (No.ASB2013/02/18)and Safety Instructions addendum: Following comprehensive testing and field observations of the safety performance of turbochargers specified above, MAN have established that the casing design used for these turbochargers which was once considered state of the art does not provide the same level of containment safety as our current designs do and current regulations require. In particular we have observed that grey cast iron casings are not sufficiently strong to withstand extreme load situations which may for example occur in the very rare case of a rotor failure. In addition to the details information of turbocharger work number(s), year of production and the contact details, MAN gave some detail recommendation and advice in Alert Service Bulletin and Safety Instructions addendum, and requires that immediate action should be taken. For example: 1 / 2
1) The personnel should not unnecessarily dwell in the vicinity of a turbocharger while it is in operation. For this, defined newly hazardous area, recommended optimization of your path through the engine room, and do not use the operating panel which is attached to the engine close to the turbocharger; 2) The execution of maintenance work as defined in the Instruction Manual should be partly changed until further notice as per addendum Safety Instructions ; 3) Additional maintenance work recommended --- Compressor inspection procedure as per addendum Safety Instructions ; 4) Regular maintenance work according to the Instruction Manual, carried out by authorized personnel and original spare parts produced by MAN Diesel & Turbo or any of its licensees, and by actively avoiding over-speed, poor fuel quality and foreign object impact e.g. by ensuring a clean air supply and keeping the engine (e.g. exhaust valves and injection nozzles) in good condition. 5) Wear appropriate protective clothing, protective goggles, safety boots, hard helmet etc. as recommended in the Instruction Manual of your turbocharger. 6) Please forward this Bulletin to your affected technical operating personnel and/or your charterers, if applicable! Etc., for more details, Please refer to the attachment No.2: Alert Service Bulletin (No.ASB2013/02/18)and Safety Instructions addendum This Technical Information should been paid attention by ship s company and ship/product surveyor of the Society. Hereby notify the above. Attachment No.1: Marine Safety Advisory (MSA No.16-13) Attachment No.2: Alert Service Bulletin and Safety Instructions addendum (ASB2013/02/18) This Technical Information is published on CCS website (www.ccs.org.cn) and is to be forwarded by CCS branches to Ship s Owner and Ship Management Companies in relevance to their business area. For any questions,please contact the Ship Business Operation Dept. of CCS Headquarters without hesitation. Tel: (010) 58112288; Fax: (010) 58112842; E-mail : so@ccs.org.cn 2 / 2
Attachment No.1 Republic of the Marshall Islands Office of the MARITIME ADMINISTRATOR 11495 COMMERCE PARK DRIVE, RESTON, VIRGINIA 20191-1506 TELEPHONE: +1-703-620-4880 FAX: +1-703-476-8522 EMAIL: maritime@register-iri.com WEBSITE: www.register-iri.com MARINE SAFETY ADVISORY NO. 16-13 To: Subject: Regional Marine Safety Offices, Nautical Inspectors, Masters, Owners/Agents TURBOCHARGER SAFETY WARNING Date: 21 March 2013 Please be advised that the Republic of the Marshall Islands Maritime Administrator has received a safety alert regarding NA and NR type turbochargers. This safety alert applies to owners and operators of turbochargers with grey cast iron casings of type NR12, NR14, NR15, NR17, NR20, NR24, NR26, NR29, NR34, NA34, NA40, NA48, NA57 and NA70. MAN Diesel & Turbo SE has issued an Alert Service Bulletin No.ASB2013/02/18, (attached) which includes a Safety Instructions addendum, relating to the safety and safe operation of the turbochargers specified above. Please note the request on the first page of the Bulletin to contact the company with details of the work number and year of production of every MAN turbocharger on board and, in the case of licensed production, also the name of the manufacturer. The second page contains recommendations and advice and Safety Instructions are contained in the Addendum. MSD 001 (11/01) 1 of 10 MSA No. 16-13
Attachment No.2 MAN Diesel & Turbo SE Prime Serv Turbocharger Important Safety Warning ALERT Service Bulletin ASB2013/02/18 Alert SB-No.: ASB2013/02/18 Subject Product safety warning for previous generation turbochargers with grey cast iron casings of type NR12, NR14, NR15, NR17, NR20, NR24, NR26, NR29, NR34, NA34, NA40, NA48, NA57, NA70 Important operational instruction relating to safety and the safe operation of the above turbochargers Serial Numbers Concerned With a high degree of probability your NR or NA turbocharger is affected by this product warning (the older the turbocharger the more likely). This Alert Service Bulletin (ASB) relates to the casing material of your turbocharger, where the traditional grey cast iron is safety critical. Since there is no clear indication for you to distinguish traditional grey cast iron material from modern nodular cast iron material, we kindly ask you to contact us and to submit the respective work number(s) and year of production of your entire MAN turbocharger population and in case of licensed production also the name of the maker for our detailed check and review whether your turbocharger is truly affected (contact details see below). You can find this information in the Instruction Manual or on the type plate of the turbocharger. We will then revert back to you as soon as possible with a clear written statement on whether or not your turbocharger(s) is/are affected. Current Analysis As a world leader for high-quality turbomachinery applications, we take our responsibility to actively monitor the performance of our products in operation very seriously. This product monitoring enables us to assist you as our valued customer in maintaining the safe and reliable long-term operation of our products, and to constantly improve our products and services to you. With this ASB we would like to inform you about the results of our product monitoring efforts regarding the containment characteristics of the above listed turbochargers equipped with grey cast iron casings. Following comprehensive testing and field observations of the safety performance of these turbochargers, we have established that the casing design used for these turbochargers which was once considered state of the art does not provide the same level of containment safety as our current designs do and current regulations require. In particular we have observed that grey cast iron casings are not sufficiently strong to withstand extreme load situations which may for example occur in the very rare case of a rotor failure. In case of such a catastrophic breakage of turbomachinery e-mail: TC-ASB-Feedback@mandieselturbo.com 1-3
ALERT Service Bulletin ASB2013/02/18 components, there is a risk that fragments may be released, or that the casing can be dislodged from the turbocharger. This in turn creates a substantial risk for the health and safety of operating personnel including the risk of bodily or even fatal injury and a risk of damage to adjacent machines or property, including the risk of fires. Compliance Mandatory / immediate action required Recommendation/Advice The risks associated with the containment failure of grey cast iron casings may be reduced by strictly adhering to the safety instructions of the Instruction Manual, in particular by observing our recommendation that personnel should not unnecessarily dwell in the vicinity of a turbocharger while it is in operation. We have furthermore defined a hazardous area (see addendum Safety Instructions ) which should be avoided while the turbocharger is in operation. This newly defined hazardous area is larger than the area previously described in the Instruction Manual. The execution of maintenance work as defined in the Instruction Manual should be partly changed until further notice as per addendum Safety Instructions. Please instruct your operating personnel accordingly. In our experience, most cases of containment failure are caused by a compressor wheel breakage. According to our investigations and test results, a breakage of the compressor wheel will predominantly occur if there is a pre-damaged compressor wheel or turbine wheel which results in a spontaneous major unbalance of the rotor at high turbocharger speed, causing a rotor damage with consequential destruction of the compressor wheel. To assess and reduce the potential risk of a critical compressor wheel damage we recommend to inspect the compressor wheel for pre-damage. Our Service Department (contact details: see below) can provide the necessary support and information on how to conduct such an inspection. Please refer also to addendum Safety Instructions. The risk of a compressor wheel damage in particular and a rotor damage in general can be minimized by regular maintenance work according to the Instruction Manual, carried out by authorized personnel, and by actively avoiding overspeed, poor fuel quality and foreign object impact e.g. by ensuring a clean air supply and keeping the engine (e.g. exhaust valves and injection nozzles) in good condition. Finally, we explicitly request your support to assure the implementation of precautionary and preventive measures by asking you to please forward this ASB to all your operators (or charterers, if applicable) using the affected NR and NA turbochargers. e-mail: TC-ASB-Feedback@mandieselturbo.com 2-3
ALERT Service Bulletin ASB2013/02/18 This ASB is intended as an initial advisory relating to possible risks associated to turbochargers with grey cast iron casings. It is being issued so that you can take immediate and proper precautions and implement the appropriate preventive measures quickly. Further information on technical remedies will follow. Please be assured that we regret the inconvenience caused. We are working with the highest priority to offer additional safety information and/or commercially available upgrade solutions wherever feasible as quickly as possible or complete turbocharger retrofits with additional operational benefits. Contact Our Service Department is always at your disposal: MAN Diesel & Turbo SE 86224 Augsburg Germany TC-ASB-Feedback@mandieselturbo.com Hotline: +49 821 322 4402 Fax: +49 821 322 49 2830 Please forward this information to your affected technical operating personnel and/or your charterers, if applicable! e-mail: TC-ASB-Feedback@mandieselturbo.com 3-3
MAN Diesel & Turbo SE PrimeServ Turbocharger Addendum to ASB2013/02/18 Safety Instructions Organizational safety instructions Make sure that only instructed personnel enters the engine room. You can significantly reduce the risk for your personnel by these measures: 1. Do not enter the turbocharger hazardous area while the engine is in operation, unless this is unavoidable. 2. Minimize your stay in the engine room and operate your engine exclusively from the engine control room. Do not use the operating panel which is attached to the engine close to the turbocharger 3. Wear appropriate protective clothing, protective goggles, safety boots, hard helmet etc. as recommended in the Instruction Manual of your turbocharger. 4. Only employ original spare parts produced by MAN Diesel & Turbo or any of its licensees and authorized technical service. Fig. 1: Red zone = hazardous area (extended compared to the area in the Instruction Manual) In any case please optimise your path through the engine room in order to minimize your stay in the hazardous area. e-mail: TC-ASB-Feedback@mandieselturbo.com 1-5
Safety Instructions Addendum to ASB2013/02/18 Fig. 2: Example path around the engine Change of maintenance work We recommend also to change the maintenance work as follows - please refer to the work item number in your turbocharger manual. Please make sure that the Instruction Manual you are working with corresponds with your turbocharger. Work item 901 / 501 Description in the manual Inspection for abnormal noise and vibrations Recommendation Stay out of the hazardous area (ref. Fig. 1) for this inspection. In case of an abnormal noise stay away from the turbocharger, stop the engine immediately, identify and eliminate the source of the noise before re-starting the engine. 903 Check turbocharger and system pipes for leaks Carry out this work only when engine is stopped. Oil leaks as well as gas leaks can also be identified by residues when the engine is stopped. e-mail: TC-ASB-Feedback@mandieselturbo.com 2-5
Safety Instructions Addendum to ASB2013/02/18 905 / 508 911 / 504 913 / 503 915 / 502 917 / 505 Check all the fixing screws, casing screws and pipe connections for tight fit Turbine dry cleaning Turbine wet cleaning Compressor wet cleaning Cleaning of air filter Carry out this inspection only when the engine is stopped. Use it regularly at reduced engine load according to the description of turbine wet cleaning. Use it regularly at reduced engine load according to the manual. Stop using the cleaning device. Carry out this work only when engine is stopped. Make sure that the filter mat is always installed properly and undamaged. In case a U-pipe manometer is installed on your turbocharger stop using it. 506 Inspection of sealing air valve Carry out this work only when engine is stopped. Jet Assist Ensure that jet-assist pressure does not exceed 4 bar (as per operating manual). In case you require further assistance please contact MAN Diesel & Turbo for recommendations. Please stay out of the hazardous area also in case of maintenance work on the engine. Additional maintenance work recommended By carrying out the below mentioned maintenance, you substantially decrease the risk that the compressor wheel and turbine wheel of the turbocharger can fail. Compressor inspection procedure 1. Inspection of compressor wheel for pre-damage: o Remove the silencer according to the work cards in your manual. o Check the leading edges of the compressor for foreign object damage (FOD) impact o X e-mail: TC-ASB-Feedback@mandieselturbo.com 3-5
Safety Instructions Addendum to ASB2013/02/18 o Check the compressor wheel and the insert piece for rubbing marks. o If you find traces of FOD impact or rubbing marks, contact the MAN Diesel & Turbo Service Department for further assistance. Do not re-start the engine without prior consultation. e-mail: TC-ASB-Feedback@mandieselturbo.com 4-5
Safety Instructions Addendum to ASB2013/02/18 2. The suction area of the compressor in front of the silencer and the air intake casing must be free from foreign objects at all times during the operation of the engine. 3. The intake of foreign objects into the suction area of the compressor has to be prevented. 4. The operation of the turbocharger is allowed only with a correctly assembled and undamaged filter mat. 5. In case of a surging of the turbocharger foreign particles, which may stay in the charge air cooler, can enter the suction area of the compressor. After a surging incident the engine must be stopped and the inspection procedure described in 1. should be carried out before a re-start of the engine. 6. For all works in the area of the turbocharger, the silencer has to be covered so that foreign objects cannot get into the silencer. 7. The opening at the silencer and the opening in the compressor volute has to be covered when the silencer is disassembled. 8. The surrounding of the turbocharger has to be cleared from foreign objects before recommissioning after engine stop. 9. The silencer must be protected against mechanical damages and it is not allowed to step on the silencer. Please forward this information to your affected technical operating personnel and/or your charterers, if applicable! e-mail: TC-ASB-Feedback@mandieselturbo.com 5-5
Acknowledgment of Receipt To: MAN Diesel & Turbo SE Fax: +49 821 322 49 2830 From: Date: Ref.: ASB2013/02/18 Pages 1 Re: MAN Diesel & Turbo Alert Service Bulletin ASB2013/02/18 We herewith confirm and acknowledge receipt of MAN Diesel & Turbo s Cover letter (shipowner/manager) Alert Service Bulletin ASB2013/02/18 Addendum to Alert Service Bulletin ASB2013/02/18 Safety Instructions, dated February 19, 2013. By: (Mr./Ms.) Firm: Date: Signature: