1. How to use it to Reduce Life Cycle Costs
The IMO PSPC Requirement for
Coatings Technical File;
How to use it to Reduce
Life Cycle Costs
Delmar Doyle, Sr. Director
NACE International

2. The Aim of PSPC?
- To move from this To this

3. 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.

4. 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

5. 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.

6. 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

7. 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
Coating Thickness – to ensure not too much was added
Adhesion – to make sure it stuck
Porosity – to make sure that rust spots did not occur .

8. 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?

9. 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

10. 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

11. QA Data Today Examples: (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

12. Coating Technical File Paperless 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

13. Paperless CTF

14. 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

15. Paperless CTF 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 .

16. Sample CTF Screen Shot

17. Sample CTF Screen Shot

18. 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

19. 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

20. 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 .