SHIP

HANDLING
FACILITIES
 INTRODUCTION

 CLO 3: Develop the related management acumens and other generic skills
required in a shipyard industry
 A shipyard would normally be equipped with
appropriate facilities to handle ships that come for
planned or corrective maintenance.

The business of maintaining ships is a lucrative one.

Value
Shipyards often compete with each other in order to
Chain get customers.

Analysis A good track record helps to sustain its business.

To become competitive in the industry a shipyard must

not only have skilled manpower and strong financial
standing but it must also be seen to embrace good
principles of value chain analysis
 Value Chain Analysis
 Looking at the shipyard as a business entity a shipyard manager should
understand what constitutes his shipyard’s support activities, primary activities
 he should then be able to relate these two activities towards developing further
his shipyard’s competitiveness,
 realizing that the lack of ‘value’ in his value chain may actually affect his
shipyard’s competitiveness and profit margin.
 Building and repair sites
 In order to facilitate the repair of a vessel in a shipyard, the vessel is brought to
a shipyard either through its own power or towed using a tug boat.
 Normally, for safety reasons a vessel’s movement into a shipyard for repairs is
coordinated and programmed through an early mutual arrangement between
shipyard and ship owner’s representatives.
 A vessel’s expected arrival time is planned such that upon its arrival at the
shipyard, its intended purpose and expected works are already prepared much
earlier, its materials and spares requirements are also planned much earlier to
ensure no delays are encountered.
 Building and repair sites
 This is done through a systematic project planning by shipyard’s project
management team tasked to look after the vessel’s work requirements.
Sometimes, only berthing is required where only certain afloat works need to be
done whilst tied alongside the wharf.
 However, if more works are required such as underwater works, repairs to
propellers, shafts or underwater gratings and anodic protections, the vessel
would require to be upslipped or even lifted using a crane onto a cradle support
on a hard court.
 When upslipping is required, there
would be a further requirement later
on, such as down-slipping.

Building
For a large vessel, it cannot be up-
and repair slipped using a slipway, but a dry dock.

sites
While berthed in the shipyard, works
that require lifting operations are
usually provided for by shipside cranes
and ship may be pulled conveniently to
other nearby outfitting berths if
required.
Repair activities
 Ships are launched according to the type of
launching facilities available in the shipyard.

Some launching facilities available are the

slipway, graving dock, floating dock, syncrolift,
marine straddle carrier etc.

Launching Large ships are usually launched down a slipway

or flooded up in a dock where they are built.

methods
A dock where a ship is built can also be called a
building dock.

In the case of a shipyard with a building dock, the

large modular hull blocks that comprise the ship
are assembled on a level line of building blocks.
Building docks tend to be
shallower than graving docks as
the ship is flooded up
considerably lighter than the
lightship condition.

The building dock very often

has concrete ramps built into
the head end of the dock to
Launching
allow vehicular access without
the need for using cranes. methods
The building dock is also very
wide to allow for the concurrent
construction of more than one
vessel.
 Launching methods
 Besides building ships, a shipyard also caters to repairing of ships.
 Prior receiving of ship at shipyard a lot of arrangement and planning are carried
out between ship owner representatives and shipyard representatives.
 Prior to docking, a docking plan, (as shown below) must be made available by
ship owner to a dock master to enable him to plan the necessary docking
arrangements with regards to correct placement of keel blocks and bilge blocks
to avoid placing them at the wrong places, hence damaging the hull.
Docking
Plan
 Slipway.
 A slipway consists of a ground way and a sliding way that support the cradle on
which the ship is to be launched.
 The slipway may be constructed with concrete, wood, steel or a combination of
these.
 Ground ways continue from the building space into the water.
 They may be permanently left in place or removed and stored between
launchings.
 Outshore ways are permanently under water.
 Inshore ways are occasionally submerged in a tidal area.
 Ground ways
 The width of the ground ways is restricted by the width of the sliding ways.
 Ground ways are slightly wider than sliding ways.
 Frequently, only two ground ways are used for endways launches but it is
possible to use one, two, three or four ground ways.
 For sideways launches usually three are used, sometimes four.
 Sideways launch ground waysare much steeper than end ways launch ground
ways.
 Sliding Ways
 This is the structure on which the ship travels into the water.
 Sliding ways were traditionally made of timber.
 Nowadays, the ways are made from steel.
 The bottom edge of the sliding way and the top edge of the ground ways are
usually clad in a slippery
 surface.
 A slipway provides for an inclined building berth (a building berth that is inclined
at an angle) and a launch way that may facilitate either end launching or side
launching operations.
 End launching
 A brief explanation of both end and side launching using the slipway is given below;
 End launching takes space and needs a big breadth of water way adjoining the shipyard for a smooth
launching operation.
 The depth of water should be sufficient to cover the aft draft upon sliding into the water.
 The inclination of the building berth should be approximately 0.045 - 0.065 to 1, to ensure enough
gravitational effect for vessel to slide into the water.
 The vessel is initially constructed on curved body blocks and centre line blocks to hold the structure in
place, these with the keel block, bilge and cribbing blocks were built around the vessel as the structure
grew.
 When completed, the vessel weight istransferred from the centre line blocks to a launching cradle.
 The cradle sides are designed to slide down the launching ways into the water, stern first.
 On launching, the vessel slides backwards down the slipway on the frame until it floats by itself.
End
launching
of a ship
 Summary of end launching

OCCUPIES SPACE VESSEL SLIDE DOWN TRADITIONAL METHOD

THE LAUNCH WAYS
STERN FIRST
 Side Launching
 Side launching is favored by shipyards that have little space and access to a deep
area of water, such as along a riverside.
 Some slipways are built so that the vessel is alongside to the water and has to be
launched sideways.
 This is due to the limitations of the water channel that would not allow lengthwise
launching, however side launching occupies a much greater length of shore line.
 With this method the designer must ensure that the vessel is very “stiff” and will
return to the upright position after the extreme tipping motion.
 Not all ships could withstand the side launch procedure without capsizing.
 This method requires many more plate runs to support the weight of the ship
 Side Launching
 The choice for side launching is determined by the limited breadth of water way,
lack of
 water depth and stability considerations for a ‘stiff’ vessel.
 Hence, for side launching the Project Manager must ensure that the ship is ‘stiff’
prior launching. Stiffness is achieved by having G1M > GM.
 G1 is the new position of COG after weight is shifted down on board prior
launching.
 In other words the measure of stability is determined by how big G1M is.
 The bigger the G1M as compared to GM, the stiffer the ship and easier for it to
return back to the upright position after launching.
 Graving Dock
 A graving dock refers to a canal shape that is cut into the land and looks like a giant
 grave (hence the word ‘graving’).
 Originally built using massive masonry blocks, the blocks form steps or sills that
workers can walk on during docking.
 The dock usually has a cambered floor and large gutters at the side to clear water in
an efficient manner.
 The dock is usually emptied by large drains at the caisson end connected to pumps.
 Ingress of water is through culverts delivering several hundreds of tones per minute.
 Floating Docks
 Floating docks are still frequently used around the world and have the capability of being moved to
many locations and are considered by some to be greater value for money than graving docks.
 Floating docks are really ships themselves.
 Usually built of steel, the structure is mainly a set of floating tanks serviced by ballast lines to
pump rooms.
 The floating dock is moored and submerged in the water to permit ships to enter.
 It also has the capability to be brought to a vessel that is badly damaged and unseaworthy.
 The dock can be maneuvered underneath ships and has the ability to change its own trim to
coincide with that of the ship to be picked up (docked).
 Most floating docks have workshops and facilities and accommodation to allow full support for
repair activities.
 Ship Lift (Syncro Lift)
 A ship lift is a counter weighted platform that lowers into the water to allow the
ship to be maneuvered over the centre line blocks.
 The platform raises and in a similar manner to a floating dock, picks up the
vessel.
 For very short terms out of the water the ship is left on the lift.
 For extended periods the ship is moved on a rail system.
 The rail systems are dependent on the size of the yard and on the facilities, but
it is quite common to move a vessel 1 kilometer inland.
 Marine straddle carrier
 These are mobile lifting devices that run out over the water on designed piers to
straddle the area where the boat will be lifted from.
 The vessel is pulled in over slings that had been previously lowered into the water.
 The slings are then strategically placed to lift the vessel at its strongest location.
 Load cells on the straddle indicate unequal loads so some adjusting is necessary for
new vessels to the straddle driver.
 Marine straddles are increasing in size with some available at 500 ton capacity.
 They place slings under the boat, then lift the boat out of water and move it to where it
is to be worked on. This method is used for smaller boats of up to 250 ton.
 The capacity may increase with time as a shipyard expands.
Preparation and clearing for removal and refitting of large
components whilst
afloat/on hard court or dock
 Both the ship and the dock site must be adequately prepared before docking.
 Prior arrangement must be made between ship owner and shipyard with regards
to requirements of tug boat services, time of ship’s arrival at shipyard vicinity
and any other specific requirements by ship.
 Usually, the shipyard would have appointed a project manager to handle the
ship throughout its duration at shipyard.
 The ship would also need to appoint an officer (usually an engineer) as the
contact person who will deal with the shipyard project manager on all matters
pertaining to the ship’s project at the shipyard
 Pre-docking preparation by ship owner
 This preparation must be done by the ship owner before the ship is towed to the shipyard.
 The ship must be brought to lightship condition at an even keel. This means the ship must be at the following
conditions:
 o Have no cargo
 o De-ammo (for military ship)
 o De-fueled
 o De-provisioned
 o Have minimum ballast
 o Trimming by stern
 o No power, no service (all movements by tug boat maneuvers)
 o Have all safety switches turned on (especially bilge water level sensors)
 o Navigation lights turned on (if moving at night)
 o Only critical and minimum ship personnel on board
 Pre-docking preparation by shipyard
 Exact time and date of docking must be in line with the correct tide conditions.
 This must be ascertained through communication between ship owner and shipyard (Project Manager).
 Once date and time of docking is finalized, ship’s docking plan must be made available to the dock
master by the ship owner (through the shipyard Project Manager).
 If docking in a graving dock is involved, the dock master must ensure that docking blocks are arranged
according to the ship’s docking plans.
 The dock master will arrange the docking blocks to align with the ship’s frame stations as per docking
plans.
 If docking is required on an inclined slipway the docking blocks must be positioned on the cradle
according to the docking plan, ensuring that the lateral supports are in position.
 If docking is required on a synchronous lift the preparation is similar to docking in a graving dock, with
blocks arranged on platform in accordance with the docking plans.
 Preparation after docking (after up-
slipping) or pre-works preparation
 After docking operation is completed by dock master, the ship is transferred to a covered location for repairs, if
possible.
 Certain preparations are carried out by project manager prior actual repair works.
 Before starting any repair works the following preparations must be ensured by the project manager for smooth and
safe work flow;
 o Adequate shore services are provided, such as electrical supply, fixed telephone line for easy communication
 o Provision of adequate fire main connections and portable fire-fighting appliances
 o Checking of vessel for safety and ensuring no fire hazards on board
 o Take remedial measures to minimize fire risks
 o Issuance of gas free certificate, for entry into tanks by shipyard workers/sub-con
 o Issuance of hot work permits
 o Adequate welding sentries
 o Issuance of confine space permit
 Pre-launch preparation (pre down-slip
preparation on completion of works)
 On completion of repair works in the shipyard and before launching or down slipping,
 appropriate checks are to be made jointly by ship staff and project manager (shipyard
 staff) to ensure water-tight integrity of underwater hull, valves and piping. If work was
 earlier done by the shipyard, the checks would be the sole responsibility of the shipyard
 while ship staff monitors to avoid warranty issues. However, if no work was done earlier
 on a particular equipment (eg underwater valves) and appropriate checks (on valve
watertightness) are required before launching then the sole responsibility of checking
rests with
 the ship staff while the project manager or shipyard staff only monitors and take
remedial action (under ship owner’s financial liability) if anything goes wrong.
 The following checks are normally carried out prior launching of ship after completion
of works in the shipyard.
 o Pressure testing of piping lines or compartment as required
 o Checking of all underwater valves
 o Checking of all electrical fittings
 o Checking of the steering gear system
 o Checking of the propulsion system
 o Checking of the communication system
 o Ensuring that all shipyard services such as electrical supply, telephone lines and
shore fire main connections are disconnected
 Calculations and observations
 For new construction projects, many vital stability calculations must be done
before every launch, and observations must be carried out after launch.
 These are usually the job of the naval architect, and the project manager must
collaborate with the design department accordingly.
 All of these calculations are performed multiple of times.
 There are preliminary and final calculations, each of which are checked and
rechecked a number of times.
 The following list of calculations is a summary required:
 o displacement
 o centre of gravity
 o vessel position on building slip
 o condition afloat
 o buoyancy during launching
 o way end pressure
 o moment against tipping
 o pivoting
 strength of hull
 o pre-pivoting and pivoting condition
 o pre-pivoting drafts
 o fore - poppet calculations
 o drop off calculations
 Construction, Refitting and Repairs
 Understanding the work scope and work packages
 A work scope shows the important information regarding system, equipment,
nature of defect, work required to be done, how to do it, what spares and
material are required to rectify the defect.
 Final test and nature of acceptance required to ensure work done meets the
required standards or test protocol.
 The work scope is usually prepared by the ship’s owner, if he is unable to
prepare the work scope, the work is usually entrusted upon the repairer who
would normally carry out a survey of the defect prior coming up with a detailed
work scope.
 Only after a work scope is developed can it be costed through a work order.
 Thus, one must know the difference between a work scope and a work order.
 This work order would indicate exactly what needs to be done, how many people to do it and
how long would it takes to do it.
 The cost is derived through the number of man-hours required as well as the cost of spares and
materials.
 For spares and materials there would be a margin for extra services such as documentation etc.
 If work done is covered under approved tariff rates, the rates shall then be applicable for
costing.
 For non-tariff items, costs would cover man-hour costs and spares/materials. A profit margin
would then be set based on shipyard regulations.
 Terms and conditions of contracts
 Once a contract is signed between the ship owner and shipyard to carry out
repairs on board a ship, the work shall be done within the time frame stated in
the contract document.
 Any delays caused by ship owner, the liability shall be borne by ship owner.
 Any delays caused by shipyard in not being able to comply with the
requirements set out in the contract, such as warranty defects, poor
workmanship or defective spares/materials shall be the liability of shipyard.
 Compliance/coordination of various
requirements
 Whilst repairs are being carried out by shipyard, both ship owner and shipyard
representative shall comply with all the terms and conditions as mutually agreed
between both parties.
 The project manager shall be responsible to complete the project as required by
the contract.
 The ship owner shall appoint his representative to liaise with the project
manager on all matters pertaining to the project.
 Progress of project shall be monitored through periodic progress meetings to be
attended by both parties.
 Elements of management
 In line with the best management practices as practiced worldwide the basic
guidelines in managing an organization or a small project shall adhere to the
governing principles of POLC, namely Planning, Organizing, Leading and
Controlling.
 By following strictly these four principles one can strongly say that good
management is being practiced.
 In a shipyard, when we talk about management it covers the whole aspects of
operating a shipyard and that will also include any project being carried out
within the shipyard, whether it involves ship repairs or construction.