Annexure IV
Syllabus for Refresher & Updating training course (Upgradation course) for
Operational & Management level
1. Standards of Training, Certification & Watch-keeping (STCW) 78: as amended in Year 2010. Major
revisions in 1995 and 2010 – Manila amendments.
Overview of comprehensive revision, Need & Benefits of comprehensive review, Terms of reference,
Calendar of Events, Action Dates, Salient changes in STCW Convention.
2. Engine-room resource management:
The main focus of resource management relate to the non-technical skills associated with the social
interaction between team members, situation awareness and the decision-making.
The systems approach, Safety of Operations, Environmental issues, Co-operation and Teamwork
Situational Awareness Management ,Decision-making, Human Factors and Human Error, Crisis
Managements and Human Behaviour, Leadership and Workload Management, Time management, Risk
Assessment and Risk Management, Identification of and breaking error chains, Efficient use of
resources and delegation, Communications, Planning and Prioritizing, Identification of cause of problem
and timely correct response, Methodical and logical approach to fault diagnosis and problem solving
Identification and justification of "assumptions", Emergency Preparedness, Contingency Planning
3. Propulsion plant and auxiliary machinery:
Basic Construction and operation principles of machinery systems, Safety & emergency procedures for
operation of propulsion plant including control systems, preparation, operation, fault detection and
necessary measures to prevent damage of machinery items.
Latest developments - OWS requirements & operation.
Developments in marine incinerator and sewage plant.
Safety measures to be taken for repair and maintenance including the safe isolation of shipboard
machinery and equipment required before personnel are permitted to work on such machinery or
equipment.
Use/ maintenance/ repair of appropriate specialized tools, machine tools and measuring instruments.
Interaction of participants discussing machinery breakdown and emergencies & methods for carrying
out safe emergency / temporary repairs.
Interpretations of hand books, machinery drawings, piping, hydraulic & pneumatic diagrams.
4. Use internal communication systems
Required performance:
State the importance of: – communicating effectively in all circumstances
Orders, instructions, reports and exchange of information being clear, accurate and concise
Using accepted marine terminology, and proper methods are employed
Chief or second Engineer being kept informed as required
The bridge being informed and consulted as required
5. Electrical, Electronic and Control systems:
Programmable Logic Controllers
Evolution of Control Systems – Requirements & Limitations of a controller. PLC Conventional
controllers vs. PLCs – Advantages & Applications of PLC systems in Process controls.
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Layout of a PLC system, Input and Output Devices, Central Processing Unit, Power supply unit, Input
and Output Modules.
Types of Inputs - Digital and Analogue – Practical sensors Type of outputs - Relay, Transistor and Triac
outputs, Processing of inputs/ outputs – signal conditioning, Signal conversions, DACs and ADCs,
Optocouplers (Optoisolators).
Programming – Languages for Programming. - Types of Programming devices -Steps in programming,
Ladder Diagram –, Execution of a ladder programme, Scan cycle. Instruction List – Preparation of
Instruction List, Entering programmes into PLC
Built-in-devices in PLCs – Internal relays, Timers, Counters
Testing and trouble-shooting – General Checks, Testing inputs, Testing outputs, Trouble shooting
techniques, watch dog timers, replication etc. Frequently occurring faults, Case studies, PLCs in marine
application – Vessel Management system.
6. Leadership & Teamworking skills – Operational Level:
Shipboard personnel management training, task & work load management, planning & co-ordination.
Ability to apply task and workload management, including: planning and coordination, personnel
assignment, time and resource constraints, prioritization.
Explain the importance of personnel management onboard vessels. Effect of reduced manning levels.
Need for onboard training. Effect of new training procedures and requirements both ashore and onboard.
Workload management and job assignment. Importance of prioritization. The order of prioritization such
as personnel safety, vessel and machinery safety, cargo operations and commercial matters, plant
efficiency etc. Ensuring that workload does not result in fatigue and excess stress. Awareness of
resource limitations and the need for effective utilization.
Effective communication - Importance of effective communication in normal activities onboard vessel
and especially during emergencies
Team work - The importance of team work on board vessels. Leadership - Explain that good teams
require good team leaders, role of leadership in effective shipboard organization. Explain the
characteristics of a good leader. Explain what makes a good team member.
Situational Awareness - Explain the significance of awareness of emerging situations during vessel
operation. Especially during vessel maneouvers, and during operations such as major maintenance jobs.
Knowledge and ability to apply decision-making techniques: situation and risk assessment identify and
consider generated options, selecting course of action, evaluation of outcome effectiveness.
Related Conventions & National Legislations – Aims & Objectives of Maritime Labour Convention.
Decision making - Strategies for evaluating options. Considerations given to views of other members.
Effect of time constraints in decision making. Evaluating different course of action based on
effectiveness, ability, safety, cost, etc.
7. Overview of recent amendments to SOLAS:
Discuss the amendments to SOLAS in the last five years including the following:
May 2006 amendments LRIT - The new regulation on LRIT is included in SOLAS chapter V on Safety
of Navigation.
May 2006 amendments - Amendments to SOLAS Chapter II-2 - Fire protection these include
amendments relating to Regulation 9 - Containment of fire.
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Amendments to SOLAS Chapter III - Life-saving appliances and arrangements.
In Regulation 7 - Personal life-saving appliances, the amendments add a new requirement for infant
lifejackets and for larger passengers.
Amendments to SOLAS Chapter V - Safety of navigation
The amendment adds a new paragraph to Regulation 22 - Navigation bridge visibility to allow ballast
water exchange at sea.
December 2006 amendments - Revised passenger ship safety standards, Prevention of accidents
involving lifeboats, Protective coatings.
May 2008 amendments - Amendments to SOLAS Chapter XI 1 to add a new Regulation 6 (Additional
requirements for the investigation of marine casualties and incidents) to make mandatory parts I and II
of the new Casualty Investigation Code.
December 2008 amendments - Amendments to the SOLAS Convention and to the 1988 Load Lines.
Protocol to make mandatory the International Code on Intact Stability, 2008 (2008 IS Code).
December 2008 amendments - Amendments to SOLAS chapter VI to make mandatory the International
Maritime Solid Bulk Cargoes Code (IMSBC Code) The IMSBC Code will replace the Code of Safe
Practice for Solid Bulk Cargoes (BC Code),
June 2009 amendment - ECDIS and BNWAS to be made mandatory under SOLAS.
May 2010 amendment-"Goal-based standards" (GBS) for oil tankers and bulk carriers
Amendments to Merchant Shipping (MS) Act 1958 (last 5years) and outline of rules framed there
under.
Importance of certificate, Defaced-mutilated-certificates.
CDC - Eligibility criteria, Issuance and renewal, New CDC, Cancellation/suspension of CDC
Age limits for seafarers. Unseaworthy and unsafe ships Official Log Books – Type of entries, offences
to be recorded, illness, death, birth, marriage Recognition of certificates granted by other countries.
Obligation of certificate holder to serve on Indian Ships and exemptions.
Employment of foreign seafarers on Indian ships.
Protection to Indian seafarers under MS Act. Marine casualties Rules, case studies.
8. IMO measures to prevent Pollution & MARPOL Amendments in the last five years:
Revised Annex I from 2007
Surveys and Certification
Requirements for machinery spaces of all ships
Tanker requirements-construction, equipments, control of operational discharges of oil
SOPEP
Revised Annex II from 2007
Categorization of Noxious Liquid Substances, Surveys, Certification, Design construction arrangement
and equipment, operational discharges of residues of NLS, SMPEP
Amendments to Annex III and V in the last five years
Annex IV-Revised Sewage Treatment Plant requirements
Revised annex VI from 1st July 2010
Annex VI amendments adopted in October 2008 introduced
Additional emission control areas
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(1) New fuel quality requirements beginning from July 2010
(2) Tier II and III NOx emission standards for new engines
(3) Tier I NOx requirements for existing pre-2000 engines
9. Fire prevention / Fire Safety measures for Oil Tankers, Chemical Tankers, Liquefied Gas
Carriers - Hi-Fog system. Safety of personnel and ship:
Explain: BLEVE, Boil Over, Pyrolysis, Dry distillation, pyrophoric fires, fires due to static electricity,
and back draught, bacterial fires.
Case studies on oxy acetylene explosion and discuss about its replacement with oxy hydrogen gas.
Discuss flash point, ignition point and their importance in regard to fire.
Discuss about flammability chart and prevention formation of vapours and limiting the concentration of
vapours within flammable limits to avoid a flame formation.
Different methods of extinguishing (basic 4 methods) and their relevance to the latest systems.
Structural Fire integrity improvement – insulated bulk heads.
Advanced Fire detection systems like laser and infra red systems-Hi-fog system as total flooding system.
Use of low expansion foam on the deck for fire-fighting oil and chemical tankers – the requirement of
improving the surface tension – use of alcohol resistant foam etc.
Use of high expansion foam in the closed area like engine room, pump room etc.
Fire Safety measures for chemical Tankers
Pressure and pool fire in Gas Carriers
Explain the importance of starvation in putting out the fire in a gas carrier.
Fire fighting in passenger ships – modifications and change in the rules and regulations- case studies.
10. Refresher Training in Medical First Aid (As per Maritime Labour Convention, 2006 requirement):
Minimum requirements for seafarers to work on a ship - Medical certificate in the ILO format
Health protection, medical care, welfare and social security protection
Medical care on board ship and ashore, Ship-owners’ liability, Health and safety protection and accident
prevention, Access to shore-based welfare facilities, Social security, Marine casualties
11. PSSR Upgradation:
Explain the developments and changes in shipboard organization over the years.
The role of ISM in improving personnel safety.
Discuss statistics on shipboard accidents and casualties.
Bringing about a safety culture onboard.
Seafarer’s rights and responsibilities.
Drug and alcohol control policies and the importance of effective implementation.
Fatigue and its role in accidents. Fatigue management principles.
12. Tribology in Marine Applications: Lubrication
Explain Tribology- dealing with friction, wear, and lubrication of interacting surfaces in relative motion
(as in bearings or gears) Engine Oil Degradation and Contamination
Types of Oils-mineral and synthetic
Timed cylinder lubrication – cylinder oil properties
Consequences of over and under lubricating
Electronic Alpha Cylinder Lubrication System – principle of operation
Injector unit fitted to modern camshaftless slow speed engines
Sterntube lubrication- developments, Hydrox 21 lubricants
Bearings – Design changes of main, bottom end and crosshead bearings – bearing metal - Tin
Aluminium Thin shell bearings, Journals/Pins -Surface Roughness,
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Bearing defects-Cavitation erosion, Electrical Erosion Damage, Electrostatic erosion damage, Fretting
damage, White metal bearing corrosion.
Alternate design of stay bolt for main bearing of MAN B & W.
13. Current Status of Fuel Technology:
Low NOx tuning, increased compression ratio, delayed injection timing, changed exhaust valve timing,
and Exhaust gas recirculation.
NOx reducing technology-Direct water injection, Humidification, Emulsified fuel.
Selective catalytic reduction- abatement strategies for tackling NOx and Sox. Technology for 2 stroke
and 4 stroke engines.
Smoke reduction measures.
Common rail technology-advantages, Injection pressure factor in smoke emission, Smoke Reduction
Using Common Rail System, Steam Injection to Reduce NOx,
LNG reliquifaction plant principle, Diesel engine with a reliquifaction plant for LNG ships.
Electronically controlled camshaft-less low speed diesel engines, RT flex and ME engines overview.
Current version of ISO 8217 2010 fuel standards. Catfines, Sodium/Vanadium presence-limitations in
FO.
1 4. Propulsion plant and auxiliary machinery:
Design features, operative mechanism & operation of machinery & associated auxiliary.
Surveillance, performance assessment and maintaining safety of propulsion plant and auxiliary
machinery.
Functions and mechanism of automatic control for Main Engine & auxiliary machinery.
Dual fuel concept, operating principle - low pressure and high pressure injection of natural gas.
Gas diesel engines of Wartsila & other engine manufacturers.
15. Advanced Technology in Shipbuilding Materials, developments in ship building, ship repair, yard
practices and ship board requirements:
Detection of machinery malfunction, location of faults and action to prevent damage, Inspection and
adjustment of equipment, Non-destructive examination, Developments in welding techniques.
Ship yard practices – friction stir welding, plasma and laser cutting tools.
Cladding of hull with non ferrous material like copper nickel alloy and aluminium alloys.
Repair by sandwich over lay system.
Non destructive testing using Alternating Current Potential Drop method and digital radiography.
Prediction maintenance using thermography (infra red and laser techniques), vibration analysers etc.
Replacement of oxy acetylene with oxy hydrogen gas, for gas cutting and gas welding process.
Under water repairs – stern tube seal replacement and under water welding. Water jet cutting tools.
Metal lock and metal lace techniques.
Repair by composite patches – using graphite flakes.
16. Instrumentation & Control Systems: Manage operation, maintenance, trouble shooting restoration
of electrical, electronic and control & monitoring equipment to operating conditions - including PLC
controls:
High Voltage on Ships
Evolution of HV Ships - Levels of High Voltage used in ships. Advantages and limitations of using HV
Types of short circuits in Power systems – Methods adopted to minimize effects of Short Circuit
Arc Flash – Arc Blast – Potential injuries resulting from Arc Flash and Arc Blast, Flash Protection
Boundaries, Personnel Protective Equipment.
Circuit Breakers – Important Design factors - Breakers used in HV systems, Advantages of using
VCBs.
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HV work procedures – Permit to work – Sanction to test – HV line Testers, Portable Earthing apparatus,
Description and usage of Insulation Resistance measurement of HV equipments - Polarization index.
Electrical Propulsion
Evolution – Advantages – Flexibility of layout, Load Diversity, Ease of control, low noise,
Propulsion options – Use of Synchronous, Induction and DC motors for propulsion, Speed & Torque
control of propulsion motors, Convertors – Synchro convertor, PWM convertor, Cyclo convertor, layout
of propulsion control.
Troubleshooting
Planning logical sequence vs impulsive conclusions – Background knowledge of equipment, memory,
logical thinking, diagnostic aids, social skills, basic steps, prevention of recurrence of faults, Test
equipments.
17. Maritime Labour Convention (MLC) 2006:
General obligations, Definitions and scope of application, Fundamental rights and principles, Seafarers’
employment and social rights, Implementation and enforcement responsibilities.
Minimum requirements for seafarers to work on a ship
Minimum age, Medical certificate, Training and qualifications, Recruitment and placement.
Conditions of employment
Seafarers’ employment agreements, Wages, Hours of work and hours of rest, Entitlement to leave,
Repatriation, Seafarer compensation for the ship’s loss or foundering, Manning levels, Career and skill
development and opportunities for seafarers’ employment.
Accommodation, recreational facilities, food and catering
Health protection, medical care, welfare and social security protection
Medical care on board ship and ashore, Ship-owners’ liability, Health and safety protection and accident
prevention, Access to shore-based welfare facilities, Social security.
Compliance and enforcement
Flag State responsibilities, General principles, Authorization of recognized organizations, Maritime
labor certificate and declaration of maritime labor compliance, Inspection and enforcement, On-board
complaint procedures, Marine casualties, Port State responsibilities, Inspections in port, Onshore
seafarer complaint-handling procedures, Labour-supplying responsibilities.
18. Leadership & Managerial skills – Management Level:
Leadership & Managerial skills - Knowledge of shipboard personnel management and training.
Stress & Fatigue management: Ability to apply task and workload management, including: planning and
Coordination, personnel assignment, time and resource constraints prioritization.
Knowledge and ability to apply effective resource management: allocation, assignment, and
prioritization of resources, effective communication on board and ashore, decisions reflect consideration
of team experience, assertiveness and leadership, including motivation, obtaining and maintaining
situation awareness.
Risk Assessment and Management: Knowledge and ability to apply decision-making techniques:
situation and risk assessment, identify and generate options, select course of action, evaluation of
outcome effectiveness, development, implementation, and oversight of standard operating procedures.
Risk assessment & Management during machinery o'haul can be discussed.
19. Class Surveys:
Introduction -, Need for Classification, The International Association of Classification Societies – IACS.
Classification - Scope of classification, Assignment, maintenance, suspension and withdrawal of class
Classification surveys.
Surveyors - Qualities and qualifications of Surveyors.
Statutory Certification of Ships - Framework Recognized Organizations.
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Classification Notations - Class symbol, Construction mark, Service notations, Navigation and operating
area notations, Additional class notations.
Assignment, Maintenance, Suspension and Withdrawal of Class - Assignment of class
Maintenance of class, Suspension of class, Withdrawal of class, Notification of suspension or
withdrawal.
Surveys - An Overview of Requirements and Certification - Definitions and procedures related to
classification surveys, Class surveys periodicity and scope, Class certificate, Definitions and procedures
related to statutory surveys and inspections, Statutory certificates.
Certification and Surveys / Close up Surveys for all types of ships - Planning maintenance including
statutory and class verifications.
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