Section 22.4 Managing Surveys and Repairs During Dry-Dock

Once the bulk carrier is in dry-dock, a period of intense activity begins, involving shipyard personnel, Class surveyors, company superintendents, specialist contractors, and the ship’s crew. The Master, while not directly managing the shipyard workers, retains overall responsibility for the vessel’s safety, security, and for ensuring that the work carried out aligns with the owner’s interests and regulatory requirements. Effective coordination, communication, and oversight are key.

1. Master’s Role and Responsibilities During Dry-Dock:

Overall Safety and Security of the Vessel: Even in dry-dock, the Master is responsible for the ship’s safety (e.g., fire prevention, stability on blocks, safe access) and security.

Liaison and Coordination:

Company Superintendent: Work closely with the attending company superintendent, who typically manages the commercial and technical aspects of the dry-docking.

Shipyard Project Manager: Maintain regular communication with the shipyard’s project manager regarding work progress, schedules, and any issues.

Classification Society Surveyors: Facilitate surveys, provide access, and discuss findings and repair requirements with Class surveyors.

Flag State/Other Inspectors: Accommodate any inspections by Flag State or other authorities.

Ship’s Crew: Supervise and coordinate the work of the ship’s crew who may be involved in maintenance, cleaning, or overseeing specific jobs.

Monitoring Work Progress and Quality:

While the superintendent takes the lead, the Master and senior officers should actively monitor the progress and quality of repairs and maintenance work being carried out by the shipyard and contractors, particularly for items critical to the vessel’s operation and safety.

Compare work done against the dry-dock specification.

Raise any concerns about quality or deviations from the specification with the superintendent immediately.

Witnessing Tests and Trials:

Witness important tests and trials of repaired or overhauled equipment (e.g., machinery trials, system tests, tank tests) along with the Chief Engineer/Chief Officer and Class surveyor.

Ensure all tests are satisfactory before accepting the work.

Managing Ship’s Crew:

Assign duties to ship’s staff for overseeing specific jobs, carrying out ship’s force work, maintaining security, and ensuring safety.

Manage crew working hours and rest periods, especially if they are heavily involved in the dry-dock work.

Address crew welfare needs during the extended port stay.

Cost Control Awareness: While the superintendent manages the budget, the Master should be mindful of potential cost implications of additional work or delays and discuss these with the superintendent.

Documentation and Record Keeping:

Maintain a detailed log of all significant events, work progress, inspections, tests, and any problems encountered during the dry-dock.

Ensure all shipyard job completion certificates, test reports, and Class survey reports are collected and reviewed.

Safety Oversight:

Ensure ship’s crew adhere to both shipboard and shipyard safety procedures (e.g., hot work permits, enclosed space entry permits, use of PPE).

Participate in or ensure ship’s representation at shipyard safety meetings.

Monitor fire safety precautions, especially during hot work.

Ensure gangway safety and proper access to the vessel.

2. Key Activities and Surveys During Dry-Dock:

Hull Inspection and Treatment:

Detailed inspection of the underwater hull for damage, corrosion, or fouling once cleaned.

Thickness gauging (UTM) as required by Class.

Repair of any hull damage.

Application of anti-corrosive and anti-fouling paint systems.

Propeller and Rudder:

Inspection of propeller for damage, polishing, or repair.

Rudder inspection, measurement of pintle and bearing clearances, and seal checks.

Tailshaft Survey:

Wear-down measurements.

Inspection of stern tube seals (often renewed).

Depending on the survey cycle, may involve partial or full withdrawal of the tailshaft for inspection.

Sea Chests and Sea Valves:

Opening, inspection, cleaning, and overhaul of all sea chests, sea inlet/outlet valves, and overboard discharge valves.

Anchors and Chains:

Anchors and chains ranged out on the dock bottom for inspection, gauging, cleaning, and remarking. Swivel and shackle overhaul.

Tank Inspections:

Internal inspection of ballast tanks, fuel tanks, and other tanks as per Class requirements and the dry-dock specification. This includes checking coatings, anodes, and structural condition.

Machinery Overhauls:

Main and auxiliary engine overhauls as scheduled.

Servicing of pumps, compressors, purifiers, heat exchangers, boilers, etc.

Steering gear overhaul and testing.

Piping Renewal/Repairs: As identified in the specification or found during inspection.

Statutory Surveys: Completion of all outstanding items for Annual, Intermediate, or Special Surveys by the Classification Society and Flag State (if applicable). This includes testing of safety equipment, fire-fighting systems, and pollution prevention equipment.

3. Dealing with “Discoveries” (Unforeseen Work):

Inevitability: It is common for additional defects or necessary repairs (“discoveries”) to be found once equipment is opened up or structures are closely inspected.

Assessment and Prioritization: The superintendent, in consultation with the Master, Chief Engineer, and Class surveyor, will assess the necessity and urgency of any newly discovered work.

Approval and Cost Implications: Additional work usually requires owner’s approval and will have cost and time implications. Clear communication with the company is essential.

Impact on Schedule: Major discoveries can impact the dry-docking schedule.

4. Safety Management in the Shipyard:

High-Risk Environment: A shipyard is a high-risk environment with many simultaneous operations, hot work, heavy lifting, and movement of personnel and equipment.

Shipyard Safety Regulations: Ship’s crew must be made aware of and strictly adhere to the shipyard’s safety rules and permit-to-work systems.

Coordination: Close coordination between ship’s staff and shipyard safety personnel is vital.

Ship’s Own Safety Procedures: Continue to apply relevant aspects of the ship’s SMS, particularly for work being done by ship’s crew or in areas under their control.

Emergency Preparedness: Understand the shipyard’s emergency response procedures and how they integrate with the ship’s own plans.

5. Preparing for Undocking and Departure:

Completion of Work: Ensure all specified work is completed to a satisfactory standard and signed off by Class, the superintendent, and relevant ship’s officers.

Final Inspections: Conduct final inspections of all repaired areas and systems.

Closing of Hull Openings: Verify that all sea valves, sea chests, and any other hull openings are properly closed and secured before flooding the dock.

Pre-Undocking Checks: Carry out pre-undocking checklists.

Stability Condition: Ensure the vessel is in a safe and stable condition for undocking.

Testing of Critical Systems: Test main engine, steering gear, and essential navigational equipment before sea trials or departure.

Documentation: Ensure all survey reports, repair certificates, and updated vessel drawings are onboard.

Sea Trials (if required): Conduct sea trials as per Class or owner’s requirements to verify the performance of machinery and systems after major overhauls.

Managing a dry-docking period effectively requires strong teamwork between the ship’s senior officers, the company superintendent, and the shipyard. The Master’s leadership in maintaining safety, ensuring quality oversight, and facilitating smooth coordination is crucial for a successful outcome, leading to a vessel that is safe, compliant, and ready for its next period of operation.