For Marine Engineers For Deck Officers
Surveys, Certification and Requirements
CHAPTER 5
Importance of Surveys Certifications
Documentation, Reports and Plans
Certificates and Documents for Manning
T
he shipowner is responsible to make sure that the entire construction process is kept under the eye of recognized independent survey body, which will assess the construction process, materials used and tests performed as per the industry standards.The owner will get a classification society for the ship which will ensure that the ship is monitored continuously in all the stages of its life, from blueprint to recycling.
1. Initial Stage:
Ship design and its component parts are assessed against the requirements of the nominated standard in a process referred to as design appraisal. Design appraisal does not include verification of any special requirements customised to owners (for such requirements special supervisor should be appointed as per owner’s request).
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Survey in Yard
Ship Design
Importance of Survey:
2. Under Construction Stage:
Survey to ensure that the original design assumptions are met and that the relevant manufacturing standards are complied.
3. In-Service Stage:
Survey should be carried out to ensure changes to the
component do not compromise the classification requirements (Changes result from modification, repair, and degradation.
Modification and repair should be in-line with requirements of rules and survey standards as prescribed by the classification society).
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Construction in Yard
In Service Dry Dock Survey
The main idea behind getting a survey complied vessel is:
• To obtain class notation with respect to standards of the vessel in order to determine premium for hull and machinery insurance
• Promote safety of life, property, and environment
• Develop technical standards (rules) for design and construction of ships
• Approve designs against their standards
• Conduct surveys during construction to ensure the ship is built in accordance with the approved design and
requirements of the rules
• To act as a recognized organization to carry out statutory surveys and certification as delegated by maritime
administrations
• Assist in research and development program
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• Comply with regulations for in-service inspection and periodic survey during its operation
• Support international organizations – IMO, ISO, IACS The shipowner must ensure and make arrangements that the surveyor of the classification society is informed of sea trails as class surveyor presence during that time is very important.
Surveyor in Yard
A ship without required certificates can be detained and will not be allowed to sail until inspected and issued with proper certificates.
The owner, ship managers, and captain are responsible to ensure the ship has all the certificates, which are renewed well ahead of time.
Following is the list of certificates and documents, which a newly built ship has to carry:
Certificates:
• The certificate of registry provided by the flag state
• Letter from class stating the name, flag and class of the vessel. The classification certificates to be transcribed in the register of ships published periodically by the society Certification:
Each classed vessel is subjected to a specified program of periodic surveys after delivery. These surveys are carried on a five-year cycle and comprises of:
Once the surveyor assesses and successfully tests various components, systems, machinery, and equipment on board the constructed vessel, the class will endorse various renewal certificates which will act as a proof that the ship is seaworthy for international water and its hull, machinery and relevant systems are compliant as per international standards.
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• Annual surveys
• Intermediate Survey
• Class renewal/special survey (held every 5 years)
• Safety management certificate –Interim certificate should be received
• SMS Shipboard manuals should be available on board along with a Copy of DOC
• International load line and exemption certificate
• International tonnage certificate
• International anti fouling system certificate
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• Certificate of insurance in respect to civil liability for oil pollution damage
Hull Fouling
• Ship sanitation control certificate
• Passenger ship safety certificate (for passenger or ROPAX vessels etc.)
• International certificate of fitness for carriage of dangerous cargo (chemical, noxious substance etc.)
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• Cargo ship safety construction and equipment certificates and Form E
Hazardous Cargo Ship
• Cargo ship radio equipment certificate and Form R
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• Cargo gear and lifting equipment inspection booklet, chain register
• Certificate of insurance for War Risk entry
• Continous Synopsis Record and Form II & III
• Certificate of insurance or other financial security in respect of civil liability for oil pollution damage
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• Protection & Indemnity Insurance Trading for wreck removal and contact with fixed platforms
• Radio station license and radio service document
• Ship security plan
• Ship to Ship transfer plan and booklet Documents, Reports and Plan:
• Certificate of insurance or other financial security in respect to civil liability for bunker pollution damage
• Certificate of entry for Protection & Indemnity Insurance
• International sewage pollution prevention certificate
• International oil pollution prevention certificate
• International air pollution prevention certificate
• International ship security certificate
• VDR certificate of compliance
• International energy efficiency certificate
• Check all certificates are in date and endorsed as per Certificate of Registry
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• Noise survey report
• Fire safety operational booklet
• Ship specific man-overboard recovery plan
• Plan for SAR co-operation for passenger ships
• AIS test Report
• Deviation curve for compass
• Cargo securing manual and cargo handling booklet
• MSDS plan
• Enhanced survey report and continuous synopsis record booklet
• Approved Ship Oil Pollution Emergency Plan -
SOPEP/SMPEP (If not yet approved vessel should have an unapproved copy)
• Intact stability booklet
• Damage control plan and booklet
• Fire safety and control plan
• Emergency towing procedure manual for the ship
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Towing of Ship
• Volatile organic compound management plan
• Garbage management plan and booklet
• Ship energy efficiency management plan
• Energy efficiency design index technical file
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• Ship construction file and structure access manual
• Oil spill equipment checked for quantity, condition, and instructions to all crew regarding its use
• EPIRB registration to be arranged
Garbage Record: Photo Credit- Ciacho5/Wikimedia
Photo Credit- Paromita Mukherjee
• Articles of Agreement (AOA) signed by officers and crew
• Official Log Book (OLB) – As required by flag state regulations
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• Passport, visas, CDCs and other important
documents(e.g. yellow fever certificate) of officers and crew to be collected, and kept with master
• Check if sufficient cash is available on board for emergency purchases
Ship Cash Locker
Important Documents
Certificates and Documents for Manning:
• Check flag state licenses and endorsements of all officers and crew
• Open and enter all relevant details in ship’s logbooks and documents. Also enter details of members comprising the safety committee
• Safe Manning Certificate – Check Minimum Manning against on-signers
• Check validity of certificates and endorsements of officers and crew as per STCW’95
• Check required officers have GMDSS certificates
• Pre-joining medical report and drug & alcohol (D&A) declaration received
• Crew list (needed for sailing) is prepared and copy of it is kept in office
• Provision to maintain rest hour record
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Once the ship receives all the certificates and other important documents, the last stage of a ship construction process prior to final delivery is Sea Trials. The company/owner will decide if the minimum manning crew or the ship’s crew (apart from the takeover crew which is already present) will join the ship before sea trails or after sea trails.
*It is advisable to get all the ship staff onboard before the sea trials to ensure maximum hands on deck are available and the ship staff, which will be taking care of the ship for next 5-9 months, has a fair idea about the ship.
Complete Ship Crew
Sea Trials
CHAPTER 6
Importance of Sea Trials Different Tests in Sea Trials Sea Trials Preparation Checks During Sea Trials
S
ea trials is a general term, which refers to a series of rigorous, underway tests to determine that the ship's hull, mechanical, electrical, and other systems function as required.Trials typically have three phases:
• Dock trials (including machinery trials, conducted while the ship is still tied to the pier)
• Builder’s trials (done at sea by the contractors, who built the ship)
• Acceptance trials (conducted at sea and ashore by class surveyor) - Discrepancies noted during trials must be corrected prior to delivery
The sea trails of a ship are important components of the
Importance of Sea Trials: contract to accomplish the following objectives:
• To exhibit the operational characteristics of the ship at sea to ensure the design, construction, machinery and
equipment used by the builder are working together properly
• To exhibit the continuity of the ship’s power and
performance to make it seaworthy in all normal conditions
• To exhibit the maximum power and speed produced by the ship’s machinery is as per the plan
• To exhibit the maneuverability of the ship and its control system to ensure safety of the ship for turning, slow moving, stopping and course keeping
• To check the fuel consumption of the ship is as per the builder’s agreement
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• To get a performance baseline for the ship so that ship operators will have a standard to compare current operating data for monitoring of plant performance and operational capabilities
• Performance baseline data is also important for populating onboard performance monitoring systems used in optimizing vessel operations in later dates
• To have a certified ship specific operational data for insurance claim purpose
• To get the relative rating of energy efficiency of the ship to acquire its EEDI characteristics
• Last but not the least, to exhibit compliance with classification and regulatory requirements in terms of safety and pollution prevention
The main propulsion machinery is specifically targeted in sea trail as the propulsion system can only be tested in the water, out at sea.
List of trials, which are normally performed during sea trails (for ship types already built by shipyard earlier):
• Endurance trials of propulsion plant
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The intent behind sea trial is to test the machinery that can only be operated once the ship is waterborne or those systems whose trails were not performed in shipyard.
Main Engine
Different Tests in Sea Trials:
• Astern trial of propulsion plant
• Ahead steering
• Astern steering
• Bow thruster test
• Centralized Propulsion Control System
• Auxiliary Means of Steering
• Quick Reversal from Ahead to Astern of propulsion plant
• Slow Steaming Ability of propulsion plant
• Navigation equipment
• Auxiliary engine plant trials (if not done in yard)
• Other engine room machinery operation (if not done in yard)
• Deck machinery operation (if not done in yard)
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Bow Thruster
List of trials that can be additionally requested to the builder by the owner:
The following trials are additional and compulsory for the shipyard constructing a type of ship for the first time:
• Economy Trials
• Turning Circles
• Z Maneuver
• Initial Turning
• Pullout
• Direct Spiral
• Standardization Trials
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• Reverse Spiral
• Low Speed Controllability
• Emergency Propulsion Systems
• Diesel Electric Propulsion System Trials (if installed)
• Gas Turbine Propulsion System Trials (if installed)
• Electric Drive Propulsion System Trials (if installed)
Maneuvering Trials: Photo By- Sarthak Satta Mohapatra
It is important that the shipyard team and the owner’s representative (seafarers and superintendent) must have an understanding so that the tests and trials to be conducted and all the planning is clear, including the depth of
instrumentation and the data to be recorded.
The takeover crew should do the following preparations:
Preparation of tools:
The sea trial of a ship mainly includes measuring of various parameters to define the operational capability of machinery and systems. For this, special measuring tools are required which the shipyard will provide for the trail period, if it is mentioned in the contract.
Competent authority must calibrate all the tools, which will be used by the yard for sea trials, and the owner from the yard can ask a copy of the calibration report.
Sea Trails Preparations: If there are no such terms about the tools and calibration procedure, the owner should make a sea trail instrumentation proposal so that the builder can arrange for important
measuring tools.
Following are some basic parameters, measurements, and tools, which are commonly used:
Temperature measurement: For temperature measurements, apart from the temperature measuring tools installed in the machinery/ system, the yard may use these instruments:
• Thermocouples
• Liquid-in-glass thermometers
• Distant-reading vapor pressure thermometers
• Resistance thermometers
• Infrared temperature sensor
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Pressure measurement: For pressure measurements, apart from the pressure measuring tools installed in the machinery/
system, the yard may use these instruments:
• Bourdon type gauges
• Transducers –To convert pressure into pneumatic or electrical signals
• Bellows gauges - Utilized for measuring low-pressure differentials up to 50 PSI
• Diaphragm gauges
• Deadweight gauges – Provide greater accuracy for systems without major pressure fluctuations
• Liquid column gauges (Manometers)
Torque and power measurement: The main engine and propulsion plant performance can be analyzed by measuring the power in the shaft using the following instruments:
• Shaft torsion meter: For measuring the torsional deflection of a shaft
• Shaft power meters: The shipboard meter can be used in the sea trials if there is an agreement between the owner and yard
• Shaft thrust meters: For measuring the thrust developed by the propeller in the axial direction of the shafting
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Pressure Gauges
• Shaft speed measurement: Apart from portable
tachometers, the shipboard speed indicator can be used in the sea trials if there is an agreement between the owner and yard
Exhaust/ flue gas analysis tools: To ensure that the exhaust gas produced by the main and auxiliary engine and the boiler are as per MARPOL air pollution norms.
• Orsat Analyzer: Popularly used in shipyards to check the flue gas composition, it comprises of number of pipettes containing chemical reagents, which absorb the respective gas constituent from the sample
• Automatic flue gas analyzer
Flow measurement: Fluid flow is an important parameter, which is measured in the sea trials.
• Positive displacement flow meter
• Coriolis type flow meters
• By differential pressure measurement - using orifice plate, flow nozzle and venturi plate with indicating and recording instruments
Viscosity measurement: The viscosity of fuel supplied to the engine and boiler has to be measured for machinery
performance data.
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Exhaust Emission: Photo by –Kaka Kaler
• Automatic viscometers
Wind speed and direction measurement: wind speed and direction are important to get the overall performance of ship’s main engine and speed of the ship.
• Cup anemometer
• Biram anemometer
• Deflecting-Vane Anemometer
• Wind direction indicator
• Ultrasonic Wind Sensors - for both wind speed and direction
Time measurement: Whenever machinery is tested under sea trails, it will be done for duration of time which will be recorded.
• Ship's Clocks - Ensure all clocks are synchronized
• Stop Watches
• Chronographs
Other Important Preparations:
• Ensure that the entire measuring instrument installed on the ship and those, which will be used by the shipyard, are calibrated
• Sensors, including remote and local, which will be used in the sea trials are calibrated
• The operating condition of the plant must be pre-decided by the yard and the owner with other factors such as draft, speed, power etc.
• Ship's ballasting and de-ballasting instructions should be prepared and distributed to the trial crew supervisors
• Signal system should be designed and installed
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• Since the result of the test may not be 100% accurate, correction factors should be obtained and the
concurrence of owner’s technical representatives has to be established
• Data forms - paper or digital (to record sea trial data), should be prepared and the graphical interface checked against the ship as built, preferably same data forms which are used for dock trials to allow for proper data quality assurance
• Trial operating and yard crew should be trained (unless previously trained or experienced)
• Calculation sheets or Data Acquisition System (DAS) and computerized Quality Analysis (QA) sheets should be prepared, with dummy calculations and correction tables
• A sample of the fuel expected to be used in the engine and boiler must be sent to a laboratory for gravity and
heat content determination when fuel rates are to be calculated
• Trial agenda, procedures, and schedules should be prepared and furnished to the owners for comments
• Before undocking, all underwater jobs must be completed and checked by CE
• All the bridge equipment are tested at least one more time for their operation
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Ship’s Bridge
• Check fire detection system testing before sea trials
• A test procedure should address operational checks of all contactors, bells, and lights before dock trials/sea trials
• Inspect the work of shipyard staff for final acceptance before going to sea trials. Unsatisfactory work should be informed to company representatives and dockyard manager
• Trial control and data acquisition system should be planned and facilities installed, including appropriate communications and reference material
• Sea trails duration must be enough to perform tests for all the machinery, which are included in the sea trail list.
Generally, 30 hours is a good duration to perform the sea trails
• A predetermined machinery start up plan should be worked out to establish:
• All personnel must be vigilant to ensure that the ship’s systems have been restored to their optimum seagoing
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The respective responsibilities of yard and ship’s personnel
The appropriate protective equipment to be worn
Machinery Inspection
Checks During Sea Trials:
condition and properly re-commissioned prior to final testing
• Prior to refloating from a dry dock, ship’s personnel should carry out an external examination to ensure that all openings in the hull are properly secured
• The propulsion plant to be tested in sea trial for at least 4 hours. Various tests as described under “List of trails normally conducted during sea trails” are performed
• The maneuvering and control system must be checked along with performing turning circle test, Z maneuver test, ahead, astern and crash maneuvering test etc.
• For various exhaust systems, (main engine, auxiliary engine, boiler etc.) a visual leak inspection to be carried out when machinery is operated during the sea trials
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Main Propulsion Plant Inspection during Sea Trials Check Exhaust Trunks for Leakage
• Bow thrusters to be tested for operational performance at sea
• 100% redundancy test to be carried out in the sea trials for steering gear system
• Reduction gear of the engine to be inspected during sea trials
• Shaft alignment calculation to be recorded and verified
• Test the number of main engine starts from the air reservoir, without replenishment, to see if the required number of starts is adequately provided
• Segregated ballast system to be tried and tested in sea trials
• Operational inspection of transformers to be carried out
• Check the general and other alarm systems while the ship propulsion plant is operational
• Fresh water generator capacity test can be carried out
• Perform the operational tests on the steering gear
• Perform the local maneuvering test and emergency steering gear test
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Steering Gear Alarm Panel