Coal Cargoes - Know The Dangers: Safety Alert

Safety Alert
Coal Cargoes – Know the Dangers

Introduction
Coal is a potentially hazardous
cargo and serious incidents
continue to arise. In some
instances it would appear that
those on board were not entirely
familiar with the risks, and on
other occasions the coal was not
carried in accordance with
regulatory requirements or best
practice.
One example involved a crew

member who was using a rotary
wire brush on deck to remove
patches of rust from the hatch
coaming of a closed hold
containing coal, possibly creating
Photo Courtesy of Crius Marine Surveyor

a source of ignition. While
operating the equipment an
explosion took place inside an
adjacent hold, blowing the hatch
covers upwards and propelling
the crew member over the ship’s
rail into the sea. He suffered
serious injuries as a result.
In another case a vessel with a cargo of Indonesian coal on IMSBC Code

board saw smoke rising from one of the holds while anchored
The International Maritime Solid Bulk Cargoes (IMSBC) Code
outside the discharge port. The vessel had been asked to
contains a detailed schedule regarding the carriage of coal,
ventilate the holds just prior to berthing. However, in the
describing the particular hazards associated with this cargo
absence of firm orders the vessel’s crew decided to ventilate
and specifying the precautionary measures to be taken. The
the holds anyway in case they were instructed to berth at short
IMSBC Code classifies coal as Group B (ie cargoes which
notice. The vessel did not berth until several days later during
possess a chemical hazard which could give rise to a
which time the cargo in several holds began to self-heat.
dangerous situation on a ship). Additionally, the IMSBC Code
On another occasion a deck rating on board a vessel carrying classifies coal as Group A (ie cargoes which may liquefy if
coal was asked to take samples from inside a cargo hold and shipped at a moisture content in excess of their transportable
collapsed at the base of a vertical ladder leading from the main moisture limit) if 75% or more of the material consists of fine
deck. Another deck rating entered the hold to assist him but particles under 5mm in size.
collapsed in the same location, as did two more crew
The requirements of the IMSBC Code schedule for coal should
members in succession. Although all four crew members were
be read, understood and closely followed.
eventually rescued, one lost his life and the others required
hospital treatment for respiratory injuries.
Cargo Declaration
The shipper’s cargo declaration should be scrutinised carefully
to determine which hazards are associated with the coal to be
loaded. However, in some parts of the world it should be borne
in mind that the cargo declaration may not necessarily be
accurate. For example, declarations regarding coal cargoes
from Kalimantan province, Indonesia, often state incorrectly
that there is no self-heating risk. All coal cargoes from
Kalimantan should be treated as being liable to self-heat. In
the event of doubt, Members may forward a copy of the cargo
declaration to the Managers for comment.
Potential Hazards
Methane (CH4)
occasionally encounters situations where crew members are
Some coal cargoes produce methane, a non-toxic gas which over-reliant on temperature probes and assume that all is well
is flammable at concentrations of between 5% and 16% in air. if the readings are less than 55°C which may not necessarily
Ventilation should be carried out to ensure that the methane be the case. Monitoring the level of carbon monoxide as
content of the atmosphere inside the cargo holds is always required by the IMSBC Code is a far more accurate means of
less than 20% of the Lower Explosive Limit (LEL) for methane. detecting self-heating at an early stage.
If coal with a methane hazard is to be loaded, all sources of
Coal should only be accepted for shipment if the temperature
ignition (eg smoking, hot work, naked flames, activities that
of the cargo is less than 55°C. Additional information can be
may produce sparks) should be prohibited on deck, within the
found in the Club’s Loss Prevention Bulletin on the Monitoring
cargo spaces and inside enclosed spaces adjacent to the
of Self-Heating Coal Cargoes Prior to Loading. Once a cargo
cargo holds. Since methane is lighter than air, it should also
hold has been loaded and the hatch covers have been closed,
be remembered that methane gas may build up inside deck
the amount of carbon monoxide inside the compartment
houses and other compartments if they contain access
should be monitored closely to determine whether or not self-
hatches or other cargo hold openings which are not gas tight.
heating is taking place. If the level of carbon monoxide in any
cargo space reaches 50 ppm or exhibits a steady rise over
Self-Heating, Oxygen Depletion and Carbon Monoxide three consecutive days, a self-heating condition may be
(CO) developing. Should such a situation arise the IMSBC Code
lists the action to be taken thereafter.
Some coal cargoes may self-heat due to oxidation. This
process produces carbon monoxide, an extremely toxic, Breathing air with an oxygen content of less than 12% can
odourless and colourless gas which also depletes the amount lead to unconsciousness. Less than 6% may result in death.
of oxygen in the atmosphere. Since introducing fresh air into The speed with which personnel may be overcome by oxygen
the cargo spaces will increase the risk of combustion, self- depletion can be rapid, to the extent that they may collapse
heating coal should be ventilated only if it becomes necessary before they realise what is happening. Although exposure to
to dissipate the accumulation of methane gas. Any ventilation carbon monoxide gas can be fatal even at low concentrations,
carried out in such circumstances should therefore be kept to it is often the lack of oxygen that is the main cause of such
a minimum. incidents.
If self-heating coal reaches a temperature of 55°C or over it As with methane, carbon monoxide is lighter than air and may
may spontaneously combust. Temperature probes accumulate inside enclosed spaces such as deck houses with
(thermocouples) may be placed within the body of the cargo cargo hold access arrangements inside which are not gas
to aid the early detection of self-heating but their limitations tight. No one should be permitted to enter the cargo holds or
need to be understood. Self-heating is often localised and a adjacent compartments until the atmosphere has been tested
temperature probe may not detect cargo nearby which has and found to be safe. Enclosed space entry procedures
begun to self-heat as coal is thermally insulating. The Club should always be followed.
Safety Alert
Given the importance of monitoring gas levels in cargo holds

and adjacent enclosed spaces, it is essential that the vessel’s
gas detectors are in full working order, calibrated correctly and
not overdue for servicing. Any crew member responsible for
operating such equipment should be fully trained and familiar
with its use.
Photo Courtesy of Crius Marine Surveyor

In the event of potential hazards such as the presence of toxic
or flammable gas or reduced oxygen levels, the entrances to
cargo holds and adjacent enclosed spaces should be locked
shut and warning notices prohibiting access should be posted.
Liquefaction
If the shipper’s cargo declaration states that the coal is Group

A in addition to Group B, the accompanying certification and
test reports providing the moisture content and transportable the sulphur content of the cargo, therefore they should be
moisture limit (TML) of the cargo should be checked carefully asked to provide such information if they fail to do so. In order
to verify that the moisture content is less than the TML. The to monitor the possible corrosive effects of carrying high
IMSBC Code requires the shippers to arrange for the moisture sulphur coal, the vessel should be provided with a means of
content to be determined not more than seven days prior to measuring the pH value of cargo hold bilge water from outside
loading, repeating the test if significant precipitation is the cargo spaces.
experienced between the time of testing and loading. The
shippers are also required to ascertain the TML not more than
six months prior to loading, or earlier if the composition or Conclusions
characteristics of the cargo change in the interim. If coal is to be loaded, the shipper’s cargo declaration should
The vessel should also carry out regular “can” tests throughout be examined in detail to identify the properties of the cargo
loading in accordance with the guidance set out in Section 8.4 and the associated hazards. It should also be remembered
of the IMSBC Code. As an additional precaution it may also that some cargo declarations may not be entirely accurate.
be prudent to carry out “can” tests even if the coal has not All crew members should be informed about the possible risks
been declared as Group A, particularly if it appears to be wet before loading, perhaps during a shipboard safety meeting
or damp or if the proportion of fine particles seems to be high. prior to arrival. The hazards and precautions may also be
If a “can” test results in the appearance of free moisture or fluid discussed when carrying out risk assessments or holding
conditions, the Managers should be contacted immediately as toolbox talks.
further laboratory tests and expert advice may be required.
Members requiring further guidance are advised to contact the
Loss Prevention department.
Sulphur
Coal from certain locations may have a high sulphur content.

If the coal or the cargo holds are wet, the sulphur and water
may react to produce sulphurous acid which is corrosive and
may damage hold steelwork, particularly if the coatings are not
in good condition. The reaction also produces toxic gas and
hydrogen. The IMSBC Code requires the shippers to declare
West of England Insurance Services (Luxembourg) S.A., Tower Bridge Court, 226 Tower Bridge Road, London, SE1 2UP
Loss Prevention Dept: T: +(44) (0)20 7716 6106 F: +(44) (0)20 7716 6061 E: loss.prevention@westpandi.com W: www.westpandi.com

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Safety Alert

Coal Cargoes – Know the Dangers

One example involved a crew

Photo Courtesy of Crius Marine Surveyor

In another case a vessel with a cargo of Indonesian coal on IMSBC Code

Given the importance of monitoring gas levels in cargo holds

Photo Courtesy of Crius Marine Surveyor

If the shipper’s cargo declaration states that the coal is Group

Coal from certain locations may have a high sulphur content.

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