Environmental Management in Shipbuilding Industry

Faculty of Health

School of Health Sciences

Bachelor Environmental & Occupational

Health and Safety

ENVS2710 ENVIRONMENTAL CONTROL

PRACTICES

Identification Number : C3177837

Student Name : Hajamuhaideen Sheik Mohamed

Date : 27 March 2013

ENVIRONMENTAL MANAGEMENT IN

SHIPBUILDING INDUSTRY

Environmental Management in Shipbuilding Industry

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TABLE OF CONTENTS

1. SUMMARY-------------------------------------------------------------------------------------------------- 3

2. INTRODUCTION ------------------------------------------------------------------------------------------ 3

3. INDUSTRIAL OPERATIONS GENERATE ENVIRONMENTAL

POLLUTION IN SHIPYARD---------------------------------------------------------------------------- 3

3.1 WELDING OPERATION ---------------------------------------------------------------------- 3

3.2 SURFACE TREATMENT --------------------------------------------------------------------- 4

3.3 ABRASIVE BLASTING ---------------------------------------------------------------------- 4

3.4 PAINTING AND COATING ----------------------------------------------------------------- 5

3.5 SHIP MAINTENANCE AND REPAIR ----------------------------------------------------- 5

4. NOISE ------------------------------------------------------------------------------------------------------- 5

5. ENVIRONMENTAL ASPECT AND ENVIRONMENTAL IMPACT ---------------------------- 5

6. RECOMMENDED CONTROL MEASURES--------------------------------------------------------- 8

6.1 AIR POLLUTION ------------------------------------------------------------------------------ 8

6.1.1 RECOMMENDATION AND BENEFITS--------------------------------------------- 8

6.1.2 LEGISLATION --------------------------------------------------------------------------- 9

6.1.3 FINANCIAL COST---------------------------------------------------------------------- 9

6.2 WATER POLLUTION

6.2.1 RECOMMENDATION AND BENEFITS -------------------------------------------- 10

6.2.2 LEGISLATION --------------------------------------------------------------------------- 11

6.3 DEPLETION OF NATURAL RESOURCES----------------------------------------------- 12

7. OTHER RECOMMENDED CONTROL MEASURES

7.1 HOUSEKEEPING AND PREVENTIVE MEASURES ---------------------------------- 13

7.2 EDUCATION AND TRAINING ------------------------------------------------------------ 13

7.3 INVENTORY MANAGEMENT ------------------------------------------------------------ 13

8. CONCLUSION------------------------------------------------------------------------------------------- 14

9. REFERENCE--------------------------------------------------------------------------------------------- 14


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1. SUMMARY

This report examines significant environmental pollutions likely to cause significant impacts,

environmental changes that are affected by the SHIPBUILDING industry. This report shows

that, one of the heavy metal fabrication sector shipyard involve a large number of materials are

used in a shipyard for various process and activities that can impact major changes to the

environment also contribute to significant climate changes.

Taking a holistic approach to address the environmental pollutions during construction and other

phases of shipyard industry; therefore, recommend some control measures on those

identifications liable with legal legislations.

2. INTRODUCTION

The shipyard processes such as construction, maintenance and repairing activity creates a

tremendous amount of pollution to the environment; that is presenting unique problem in terms

of applying pollution control techniques. The construction phase in shipyard is a significant

number of processes; which are constituted with significant changes to the environment.

One of the primary areas focuses on shipbuilding environmental impact is climate change.

Which are constituted with discharge of waste water, emission of air pollution, pollutants in soil,

water and the energy consumption of raw materials.

3. Industrial Operations Generate Environmental Pollution in Shipyard

The direct environmental impacts in shipbuilding should naturally incur by construction,

maintenance and repair of ships. Always construction will generate major pollution to the

environment; beside construction, typically ship maintenance and repair operation also associate

environmental pollution. Here the following activities that are gradually generating

environmental pollution in shipbuilding;

I. Welding Operation

II. Surface treatment operation include Painting and coating, abrasive blasting operation

III. Ship Repair and Maintenance Operation and

IV. Noise

3.1 WELDING OPERATION

The welding process involves bonding two metals by heating the surfaces to exceedingly

high temperatures and melting the two metals together with molten filler. Among the other


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welding process in shipbuilding, electric arc welding is most popular and emitting the most

significant quantity of harmful gases to the atmosphere.

Emissions from welding process including Greenhouse Gas (GHG), toxic chemicals and

substances which include ozone (O3), Particulate matter (such as Carbon, nitrates, sulphates

& Ammonia), Carbon monoxide (CO), Sulphur dioxide (SO2), Nitrogen Oxides (NO3) and

lead.

Those all above particle is a key source of dangerous air pollution. Other hazard and

dangerous in welding fumes include nickel, lead, carbon dioxide, carbon monoxide; nitrogen

oxides and ozone (O3) added with dissolved solids and generate water pollution. Electricity

is the major source of welding operation; therefore may affect global warming by the source

of fossil fuel.

3.2 SURFACE TREATMENT

Surface treatment operation is as during the “Ship construction, as well as during various

ship maintenance and repair activities. These include operations such as the cleaning and

coating of steel, cleaning tanks and cargo areas and painting and paint removal.

Surface treatment is among the most environmentally hazardous processes in the

shipbuilding industry (OSHA 2006)” reference from www.oecd.org/sti/ind/46370308.pdf

Emissions of Particulate Matters (sodium chloride, carbon, sulfates), Volatile organic

compounds which are involved in depletion of ozone layer and greenhouse effect, zinc which

is generated air pollution and the operation also create noise.

3.3 ABRASIVE BLASTING

Abrasive blasting is that the process technique prepares surfaces for coating and painting in

construction of ships, maintenance and repair activities. This process generates particulate

matters, and abrasive. Particulate matters and disposing dust, causes respiratory and other

human health problems if its cause to inhaled.

Where fugitive emissions from blasting operations can be travelled over that area, by air or

by water will generate significant impact on public and environment. In shipyard other most

practical blasting operation is dry-abrasive blasting, which is transmit on compressed air to

push the abrasive contents onto the surface element including rust and paint chips at very

high velocity. This generates Particulate matter emissions, which is representing a major

source of hazardous and dangerous air pollutants.

http://www.oecd.org/sti/ind/46370308.pdf


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3.4 PAINTING AND COATING

Painting and Coating operation is typically large single source of volatile organic compound

emission from shipyards. Painting waste can account for more than 50% of the total

dangerous waste generated at shipyard. Both activity use significant number of chemicals

that hazardous or flammable, such as thinner or solvent, and the activity release significant

air pollutants including lead, Particulate Matter (organic & inorganic particulate), Volatile

Organic Compound (benzene & hydrocarbons), lead and zinc. Those are the particulates

significantly generate impacts to the environment through air pollution and depletion of

ozone layer.

When using high pressure equipment to wash the surface generates alkalies, organics, and

solvents in metal contaminated with metal creates water pollution to the environment.

3.5 SHIP MAINTENANCE AND REPAIR

“The maintenance and repair services include ship conversations, overhaul, servicing

programs and damage repairs of ships and their equipment” Reference from www.

www.oecd.org/sti/ind/46370308.pdf . This will be generating of dangerous waste of oil,

hydraulic fluids & lubricants, thinners, acids and anti freeze. When the particles mixed with

water may cause water pollution to the environment.

4. NOISE

In shipyard many activities are creating foremost source of noise. That noise is naturally

affect people who are affianced in the noise generating activity, as well as who located in the

area. “Workers in shipyard may exposed to continuous sound levels of between 85 dbA to

105 dbA” www.oecd.org/sti/ind/46370308.pdf .

5. CAUSE AND EFFECT- ENVIRONMENTAL ASPECTS AND ENVIRONMENTAL

IMPACTS

Here the following industrial activities which are classified as generating more

environment pollution in the order of importance in shipbuilding industry.




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Industrial

Activity /

Process

Environmental

Aspect

Environmental

Impact

Priority

Level Rational or explanation for Priority level

Painting and

Coating

Emission of particulate Matter such as Organic and

Inorganic particles, Nitrates, hydrocarbons, lead,

ammonia, sulphates, during paint mixing and spray

painting operation at shipyard construction stage.

Toxic and hazardous vapour when mixing enamel

paint with thinner.

Air Pollution

1

Inhalation of toxic and flammable vapour

generates from painting process will cause

serious health issue to human.

Flown of painting particles during ship

painting process will contaminate with water

change the nutritional effects.

The open area painting process is the main & a

significant source of air pollution. It can be

easily visualized during the process.

Emission of VOCs during the spray painting

process will significantly affect ozone layer.

Use of solid is a major risk factor of chronic

obstructive pulmonary disease and lung cancer.

Exposed Volatile Organic Compound (Benzene,

hydrocarbons) during enamel spray paints. Depletion of

Ozone layer

Zinc, Alkalies, Organic and solvent (paint),

Discharge of Hazardous and toxic vapours are

contaminated with water and spills & leakage of

paints when process carried out on wet surface.

Water pollution

Welding

Operation

Emissions of Ozone (O3) such as nitrogen oxides

(NOx), volatile organic compounds (VOCs),

Particulate Matter such as carbon, Nitrate, sulphate

and ammonia; Carbon Monoxide (CO), Sulphur

Dioxide (Non combustion source) at during electric

arc and gas welding operation.

Air pollution

2

Emission of carbon monoxide is the major

source of global warming and as well as air

pollution source too.

Emission of sulphuric dioxide is severely

damage to human health (May cause

permanent lung failure inhalate 20ppm)

Sulphur dioxide emitted to atmosphere oxidise

by oxidants to sulphur trioxide finally absorbed

by water vapour as sulphuric acid mist.

VOCs produce methane and photochemical

oxidants contributing to green house effect.

Increase temperature to the atmosphere

For welding operation electricity is the main

resource, so that the use of high electricity all

resources are consumed.

Depletion of

natural resources

(Global warming)


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Industrial

Activity /

Process

Environmental

Aspect

Environmental

Impact

Priority

Level Rational or explanation for Priority level

Surface

Treatment

Emissions of Particulate Matter (10) such as

Sodium chloride, carbon, sulphates from ship

cleaning and coating process. Solvent cleaners and

paint stripper.

Air Pollution

3

Emission of particulate matter (PM10) chronic

exposure to particles contributes to the risk of

developing cardiovascular and respiratory

diseases, as well as lung cancer.

Cleaning of hulls and tanks using waste water

contaminated with oil and solvent may cause

low nutrition in water.

Preparation of metal fabrication will increase

the noise exposure level >85dbA may result in

Noise induced deafness.

Waste water contaminated with paint chips,

cleaning and paints stripping solvents, surface

contaminants and oil residues from bilges.

Water pollution

Heavy metal operation during installation and

fabrication process Noise

Abrasive

Blasting

Removed existing pigmented coating and substrate

Fugitive Emissions, Particulate Matters

Operation been carried out by compressor air to

remove existing paint.

Air pollution

4

Removed silicon may cause chronic respiratory

effect to human

Anti-foulant removed during blasting process,

when ship’s prepared for dry blasting VOCs an ingredient in the formation of low

level ozone regulating hazardous air pollution.

Ship

Maintenance

and Repair

Discharge of oils, leaks and spills contaminated

with water and soil

Water &

Soil pollution 5

Hydraulic fluid, lubricant, fuel and thinner

leaks or discharge during maintenance process.

When the process being carried out on sea

level may cause water pollution.


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6. RECOMMENDED CONTROL MEASURES

As on the above table shows that shipyard industrial activity such as Painting and coating

operation is the highest priority level consequent with welding and surface treatment process.

Here recommend to analyse the top three priority level and research existing control

measures to minimise the environmental pollution in safe level.

Priority

Level

Environmental

Aspect

Environmental

Impact

Existing

Control Measure

1

1. Emissions from mixing and spray painting

(Particulates & hydrocarbons)

Air

Pollution

Wet or dry scrubber and

Fixed filters system at

exhaust ventilation

2. Emissions in arc and gas welding operations

(carbon monoxide & sulphur dioxide)

Capture and collection

system (torch fumes

extractor)

3. Emissions from ship cleaning and coating

process (PM10), carbon and sulphates

Electrostatic Precipitator

(ESP) system.

2

4. Wastewater discharge from Surface treatment

operation grinding , blasting substances

surface contaminant, containing oil & grease

residues from bilges and storm water

Water

pollution

Grease trap, drainage

system

3

5. Resource consumption (high electricity

consumption for welding operation) Depletion of

natural

resources

Motion detection sensor

installed at ROBOT

welding

The best way to minimise pollution is to eliminate the work. Some organisation tremendously

implemented pollution control methods and techniques that increase efficiency and increase

profits; and simultaneously reduce (or) control environmental impacts. This method

differently can be done, such as control material, re-engineering process to communicate

reuse by products, improving management practices and control substitution of toxic

chemicals.

6.1 AIR POLLUTION

Here the three different types of emissions and their independent control measures may

charge significant financial impact. The system replacement such as frequency of

changing filters and maintenance cost all need to be considered. It may sort of higher

cost impact to the organisation.

6.1.1 RECOMMENDATION AND BENEFITS

The recommended type of air pollution control system for the three major emissions

Local Exhaust Ventilation system (LEV). This method is use to control air


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contaminants by trapping them together at or near source, large amount of dust or

fumes where generated, and control the source. Local exhaust ventilation system is

more effective way to controlling high toxic contaminants before they reach into the

workers breathing zones. The diameter of particles may differ from 100 micron to 0.01

micron or less. Air cleaning is a device that designs the purpose of removing

atmospheric airborne impurities such as dust, vapour, fume and smoke.

6.1.2 LEGISLATION

Workplace safety and health (General provision) regulation stipulated that under

section 5 and 39 gases, vapour and other impurities generate from any process may

provide sustainable ventilation system to maintain and circulating fresh air workplace.

Environmental Protection and Management Act (Chapter 94A) under part IV Air

pollution control section 10 – 14 stipulated that to take adequate preventive measure

to control the air pollution in environment.

Environmental Protection and Management (Air Impurities) Regulations

6.1.3 FINANCIAL COST

The cost local exhaust ventilation system is depend on the specification such as

required parameter area in M², size of the equipment & filters and the number of

outlets. So that the minimum cost to provide LEV at any premises S$ 25,000/-.

Local Exhaust Ventilation system at confined hot work area

Local Exhaust

ventilation duct


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Air filtering method using LEV

6.2 WATER POLLUTION

6.2.1 RECOMMENDATION AND BENEFITS

The best method to control water pollution is Segregation. Reduce wastewater pollution

in various methods of treatment for disposal. Diluted wastewater after treatment may be

used for irrigation.

Primary Treatment:

In the primary treatment, screens, grit and sedimentation chamber are used in a serial

order. After the water passes through, chlorine gas is used to kill microbes. However,

various types of organic waste cannot be separated.

Secondary Treatment:

This method, organic matter is biological degraded by microbes. The biological

degradation of organic matter takes place under aerobic conditions. The sludge material

settle in the sedimentations tanks and is removed through sludge digester

Territory Treatment:

This method, the chemical remaining in the water are segregated and removed.

Segregation method is a significant cost reducing method to control water pollution at

shipyard. And also which can excess min 10years to 15years rather than else. It can be


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controlled the Trade Effluent of Biochemical oxygen demand (BOD) & Total

suspended solid (TSS) within the specified concentration before discharge into a public

Sewer/ Watercourse/ Controlled watercourse.

SEGREGATION WASTEWATER DIAGRAM

CONTINUOUS PROCESS DIAGRAM

6.2.2 LEGISLATION

Sewerage and Drainage (Trade Effluent) Regulation


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Environmental Protection and Management Act

Environment Protection and Management (Trade Effluent) Regulation

Code of Practice on Pollution Control under the section of (4.1)

6.3 DEPLATION OF NATURAL RESOURCES

In shipyard industry have various methods to control and protect the natural resource by

minimising the usage of electricity for welding operation. The best method to doing a

welding operation with minimizing the source of electricity is ROBOT WELDING

MACHINE. Significant of energy source can be saved during the process and accuracy

is even better than the actual welding. Concern about environment air pollution can be

controlled by LEV system.

Robot Welding in shipyard

Process of Robot welding in ship during construction


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7. OTHER RECOMMENDED CONTROL MEASURES

7.1 HOUSEKEEPING AND PREVENTIVE MEASURES

Conduct regular housekeeping practices when the task is completed.

Hose and electric conductor must be elevated over or placed under the walkway

or working surface.

To conduct regular maintenance and services of changing filter on local exhaust

ventilation system.

Emergency passage ways must be maintained and free from corrosive and

flammable materials to store and the steps free of oil and grease spill &leaks.

Toxic substance and hazardous chemical to store at designated storage area

under surveillance.

Toxic, flammable materials, hazardous chemical are prohibited to use and

stored at confined spaces.

Do not discharge any toxic and hazardous waste or substances directly into

water before proceeding segregation process.

7.2 TRAINING AND EDUCATION

Establish sustainable training programs and practices that prevent stormwater

pollution include with prevention of stormwater training in new employee

during orientation.

Incorporate stormwater pollution prevention system to accomplishment all into

annual job performance evaluation

Provide relevant material to educate employees for prevent air and water

pollutions.

7.3 INVENTORY MANAGEMENT

To keep and maintain record keeping for hazardous and toxic chemicals &

substance in and out record by permits.

Control Hazardous and flammable material to the environment by using

automated software system at storage area.


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8. CONCLUSION

The direct environmental impact of shipbuilding, which may the process constitute with

the construction, maintenance and repairs of ships. However, those activities have

created significant source of potential environment pollution, include handling of large

amount of toxic chemicals, fumes, fluids. Potential risks are revealing from various

type of hazardous and toxic contaminants to the environment. Those are aggravated in

the industry. In shipbuilding industry more activities have been doing in open air

environment, and secondly most activity near by the waterfront location. This is clearly

defining the potential pollutants to go directly into the aquatic environment. Hence,

those been raised more pollution and give significant impact to the environment.

Follow the adequate control measure during the process that can be minimised impact

and virtually safe the environment.

9. REFERENCES

1. Environmental Hazards: Marine pollution / Martha, Gorman 1952

2. Marine Debris: sources, Impacts and solution / James M.Ceo, Donald B. Rogers,

Editors 1997

3. Environmental pollution and control (Fourth Edition) J. Jeffery Peirce, Ruth F.

Weiner, P. Aarne Vesilind 11/1997

4. U.S Environment protection agency “Shipbuilding and ship repair Sector” web url...

5. “Environmental and climate changes issues in Shipbuilding Industry” November

2010 from OECD council Working Party on Shipbuilding (WP6) web url.....

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