Monitoring New Ship Construction

While the management of Ship Repairs and Conversion is the responsibility of Port Engineers, those assigned to monitor new ship construction are known as Marine Surveyors. As such, their respective responsibilities as the "On-site Ship-Owner's Representatives, usually involve three specific tasks, as follows:

INSPECTION
Preliminary review of drawings of the new vessel, discussing with the responsible naval architects the extent to which statutory Rules and Regulations apply to the type of vessel to be built and the degree of compliance therewith in the development of said drawings and ultimately, the evidence of regulatory body approval and any "comments and or restrictions" pertaining thereto. As construction progresses, additional drawings should be reviewed and discussed with the naval architects. This will enable the Marine Surveyor to acquire a gradually increasing degree of familiarity with the drawings as they relate to the actual construction, and improved understanding of ship construction progress as the structural interpretation of related drawings. In due course, the Surveyor will inevitably develop a sense of expectation in actual construction progress relative to the drawings. This evolution of the professional learning curve is particularly important in that it enables the Surveyor to detect more readily, any indications of deviation from the drawings and specifications, either apparent or deliberate.

EVALUATION
Close observation of construction methodology, the type and frequency of quality control procedures, including specific provisions within the Shipbuilding Contractor's corporate "Industrial Quality Control" program, and any such additional quality control requirements specified by the Ship-Owner's Ship Construction Drawings and Technical Specifications. Among others, quality of welding ranks highly, plus the use of non-hazardous materials such as insulation, hull paint, accommodation deck covering, etc.

OBSERVATION
Attendance of operational testing of equipment, machinery and systems, including load testing of winches, generators, accommodation ladders, water¬tightness of exterior doors, hydrostatic testing of pressure vessels, and accurate recording of all test results. In some cases it may be necessary to witness operational testing of certain machinery items and systems equipment at the manufacturer's shops and assembly plants, prior to delivery of said items to the Shipyard. In all cases, it is advisable for the Marine Surveyor to maintain written notes of events and tests witnessed, observations made, etc., on a daily basis. The written daily notes should be refined and entered into a more formal Weekly Log and continued for the duration of the construction period. The Weekly Log, if properly kept, will become a useful source of reference in drafting the weekly Project Progress Report to management. In addition to keeping a written record of industrial progress the Marine Surveyor should be especially vigilant in observing apparent or deliberate deviations from specifications, drawings and mandatory safe practices. Besides making a written note of such observations, they should be discussed with the Shipyard Contractor's designated Construction Superintendent for proper investigation and immediate correction.

TERMINOLOGY
In new construction, the basic hull structure consists of several parts and features that include: a) - The hull body, including all attached structures both internal and external. b) - Deckhouses, superstructure and casings. c)- Various welded foundations for main propulsion plants, auxiliary engines, pumps and related equipment, deck cranes, lifeboat davits, anchor windlass and mooring winches. d) - Structural configurations such as bulwarks, bollards, and hatch coaming, pad-eyes, mooring cleats and structural stiffeners. e) - Bulkhead, deck and side shell penetrations fully welded in-place, on both sides of the plating. f) - The precision fitting of stand pipes through decks and bulkheads, sea suction valves and overboard discharge valves penetrating the hull plating with adequate continuous welding thereof. g) - Any unusual welded attachments that may exert stress or strain upon the deck, shell plating or bulkheads.

DOCUMENTATION
This consist of records, instructions, Regulatory Body Approval and/or Certification for machinery, equipment and systems, including the following literature ranging from actual construction to normal operation, such as:

1. General Arrangement Drawings, detailed construction and assembly drawings, equipment installation drawings (as applicable), including structural, fluid, electrical, hydraulic, pneumatic and instrumentation connections thereto.

2. Operating Manuals, schematics, trouble-shooting charts, Spare Parts manuals, specific sources for procurement of parts and/or Tech-Rep services, domestic and foreign.

3. The following items do not normally fall within the purview of the Marine Surveyor but are listed as operational essentials for good ship management. Operating Logs for navigation, engineering, medical, stewardship, cargo management and official communication.

SCOPE OF SURVEY COVERAGE
These instructions apply to the survey of new construction of steel vessels meeting the requirements for classification by an approved member of the International Association of Classification Societies, (IACS), as applied to hull structure, load line, and the Safety of Life at Sea (SOLAS Safety Construction). They do not apply to Mobile Offshore Drilling units or High Speed Craft. Nor do they apply to the manufacture of certain equipment, appendages and fittings, such as castings and forgings integral to the hull structure; Bow or stern loading doors and ramps integral with the shell; hatch covers; rudders and rudder stock. Where warranted, formal acceptance by the Marine Surveyor of such specific items as those listed above, may occur at the point of manufacture, based upon his/her inspection and documentation of same for further verification at the Shipyard.

International Association of Classification Societies (IACS).
The membership of this organization consists of ten classification societies, founded in Hamburg, Germany, September 11, 1986 and currently headquartered in London, England. Current members include the following:

ABS - American Bureau of Shipping. BV - Bureau Veritas CCS - China Classification Society DNV - Det Norske Veritas GL - Germanischer Lloyd KR - Korean Register of Shipping LR - Lloyd's Register NK - Nippon Kaiji Kyokai (ClassNK) RINA - Registro Italiano Navale RS - Russian Maritime Register of Shipping

Objectives and authority of IACS
The primary objectives of IACS are to ensure safe ships and clean seas. By virtue of technical support, verification of regulatory compliance, active research and technical development, the pro-active functions of IACS make a significant contribution to uniformity of regulation and maritime safety. The scale of this effort is evident in the fact that over 90 percent of the world's maritime trade is carried by ships covered by classification design, construction, and ship-life compliance with the Rules and Standards established and enforced by the ten Member Societies.

Authority of IACS
This organization is not a governmental body. However, by virtue of having been granted "Consultative Status" by the (U.N.- approved) International Maritime Organization (IMO), it is the only non-governmental organization with observer status and capable of developing and applying applicable rules. The scope of these rules can be read in the 'INTERNATIONAL CONVENTION FOR THE SAFETY OF LIFE AT SEA (SOLAS). Additional information is available from hftp://en.wikipedia.org/wiki/International Association of Classification Societies.

LOCATION
The intent of coverage extends to construction of hull structures and appendages within the Prime Shipbuilding Contractor's own Shipyard, at the shops and/or facilities of Sub-Contractors to the Prime Contractor, either on their own premises or at alternate locations.

CERTIFICATION AND QUALIFICATION
Marine Surveyors assigned to the task of monitoring new construction for quality control and compliance with applicable regulatory rules, are required to be certified by an authorized body upon successful completion of an approved course of study and qualified to perform in this capacity as determined by successfully passing an appropriate examination, to the satisfaction of the assigned examining officer.

SCOPE OF SURVEY FOR NEW HULL CONSTRUCTION
The following items are minimum requirements pertaining to a formal survey of new construction:

9-1 - Survey methods required by the Rules for Classification.

9-2 - Documentation to be available for the Surveyor during construction.

9-3 - Classification and statutory survey requirements.

9-4 - Relevant IACS and statutory requirement references.

The following documents, approved by the Classification Society are to be made available to the Marine Surveyor:

9-5 - Plans and supporting documents.

9-6 - Non-Destructive Examination plans.

9-7 - Welding consumable details.

9-8 - Welding procedure specifications.

9-9 - Welding plan or details.

9-10 - Welder's qualification records.

9-11 - NDE operator's qualification records.

9-12 - Documents to be inserted into the ship construction file.

9-13 - List of specific activities that are relevant to the shipbuilding functions. This list may vary according to type of vessel and/or the construction facilities.

PROOF OF COMPLIANCE
During construction, the shipbuilder is required to make available to the Surveyor, documentary evidence that all materials, parts and equipment furnished for the vessel and installed on board, have been manufactured under survey in accordance with the Statutory Rules of the Classification Society. This documentation should then be delivered to the Ship-owner, and a copy of same to the vessel for inclusion in the ship's Machinery History. Additionally, a copy of said documentary evidence shall be made available to the U.S. Coast Guard Inspector, if the vessel is to be registered under the American flag.

CONSTRUCTION SHIPYARD FACILITY
Prior to the start of construction the Classification Society representative shall review the Shipyard Facilities; Production Equipment; Executive Management Organization and Operating Procedures; Documentary Control System; Naval Architectural Design Department; Engineering Division; Material and Parts Procurement Division; Industrial Safety Program and Facilities; Construction Division and related Production Program; Employee Training Program, Trade Apprenticeship Program, etc., to determine if the Shipyard qualifies as an adequate facility for the construction of ships. The foregoing detailed inspections are required by the Classification Society in the absence of recent evidence or experience of new ship construction work (within the past twelve months), or in the event of major modification and/or addition to the shipyard premises and/or equipment. Likewise, the rigid verification is applicable in the event of a significant organizational change of management and/or personnel having occurred that may adversely impact the ship construction process and level of technical competence. Furthermore, where there is tangible evidence that the Shipbuilder has contracted to construct an entirely different type and/or design of vessel, with which the Shipbuilder and/or his workforce have no prior experience. In such cases, the Shipyard may be granted provisional authority to proceed with construction of a totally new design, under the surveillance of an authorized Classification Society Surveyor, providing that the new design and construction features conform to pre-existing Classification Rules and Statutory Requirements, and do not include design and construction features that are not approved by said Rules for Classification.

SURVEY PLANNING FOR NEW SHIP CONSTRUCTION
It is customary for a shipyard to convene a Pre-Construction Meeting attended by top level Shipyard Management; the prospective Ship-Owner (and his Ship Superintendent), the designated Classification Society Surveyor; and where applicable, Legal Advisors to the Shipyard and to the prospective Ship-Owner. Among the several topics on the agenda of such meetings is a detailed discussion of those items listed in Paragraph 9 - SCOPE OF SURVEY FOR NEW HULL CONSTRUCTION, including the relative priority and applicable sequence of such items, and assignment of responsibility for same among Shipyard Staff members. In the event of Sub-Contractors being scheduled to participate in the construction project their representatives should also attend, along with any manufacturers or vendors of major components such as Main Propulsion Engines; Deck Machinery and Equipment; Electrical Generators, Equipment and accessories; Accommodation Furnishings; Navigation and Communication Equipment and Systems; Fire Fighting and Alarm Systems; Refrigeration and Air Conditioning Equipment and Systems; Sanitary Fixtures and Sewage Treatment Systems and Holding Tanks; Life Saving Equipment and Systems, etc., etc.. Such a meeting affords an opportunity for the various participants to meet each other and to exchange pertinent information regarding their respective functions, responsibilities and products. Detailed records of the Pre-Construction Meeting should be made by Shipyard Staff and copies made available to all participants.

PROJECT PROGRESS MEETINGS
Subsequent Progress Meetings should be scheduled at least on a weekly basis, between the Surveyor and his Primary Shipyard Point of Contact, to review pertinent construction status and statutory compliance, and/or apparent lack thereof. All topics shall be recorded and "Problem Items" flagged for "Correction or Resolution" thereof. Should there be a serious instance of "Non -Compliance", the Surveyor may find it necessary to request stoppage of construction work in the problem area, pending a thorough investigation and prompt correction and resolution to the satisfaction of the Surveyor.

QUALITY STANDARDS FOR NEW CONSTRUCTION
During new construction, Shipbuilding Quality Standards for the hull structure should be discussed and established during the Pre-Construction Meeting. For vessels constructed for classification by ABS Rules the structural fabrication will be in accordance with Guide for Shipbuilding and Repair Quality Standard for Hull Structures During Construction.

EXAMINATION AND TEST PLAN FOR NEW CONSTRUCTION
Plans of the items intended to be examined and tested shall be provided to the attending Surveyor by the Shipbuilder. As a minimum, they should include the following:

12 - 3.a - Proposals for the examination of completed steelwork (aka the BLOCK PLAN), are to include details of joining structural blocks together at the pre-erection and erection stages or at other relevant stages.

12 - 3.b - Proposals for "fit-up" examinations where necessary.

12 - 3.c - Proposals for testing of the structure to include leak and hydrostatic, plus all watertight and weathertight closing appliances.

12 - 3.d - Proposals for non-destructive examination (NDE).

12 - 3.e - Any other proposals specific to the vessel type or to the applicable Statutory Requirements.

NOTE: The plans and any modifications to them shall be submitted to the designated Surveyor in sufficient time to allow for review and approval of same prior to the commencement of the relevant construction phase. Likewise, the Shipbuilder is required to provide sample rates of NDE, proposals for steelwork survey, tank testing requirements, etc., if the actual construction process warrants it.

COMPLIANCE WITH NEWBUILDING SURVEY PLANNING
The Society is required to provide evidence, such as records, check lists, inspection and test records, etc., that its designated Surveyors have in fact complied with the requirements of the new building survey planning and actually participated in the relevant activities shown in the Shipbuilder's examination and test plans. All the information contained within this paragraph is to be made available by the Shipbuilder, for audit purposes.

RESPONSIBILITY
The Shipbuilder is required to deliver documents for the Ship Construction File. Where pertinent items have been developed or provided by another party, such the Ship-Owner, the originating party is responsible for delivery of such documents.

DOCUMENTS TO BE INCLUDED
The following list of documents for new ship construction is specifically required by the AMERICAN BUREAU OF SHIPPING. For new ships built in accordance with the Rules and Requirements of other I.A.C.S. members similar documents would normally apply. It is generally recognized that the purpose of documents held in the Ship Construction File onboard the vessel, is to facilitate inspection (survey) and repair and maintenance, and therefore, is to include in addition to documents listed in Table 1, but not limited to the following:

14 - 1.a - As-built structural drawings including scantling details material details, and as applicable, wastage allowances, location of butts and seams, cross section details and locations of all partial and full penetration welds, areas identified for close attention and rudders [Section 7-3-2 of the ABS Rules for Survey After Construction (Part 7) for Hull Surveys].

14 - 1.b - Manuals required for classification and statutory requirements (e.g., loading and stability, bow doors and inner doors and side shell doors and stem doors - operations and maintenance manuals) [3-2-16 27 of the ABS Rules for Building and Classing Steel Vessels]

14 - 1.c - Ship structure access manual, as applicable

14 - 1.d - Copies of certificates of forgings and castings welded into the hull [Sections 2-1¬6 and section 2-1-5 of the ABS Rules for Materials and Welding (Part 2)]

14 - 1.e - Details of equipment forming part of the watertight and weathertight integrity of the vessel

14 - 1.f - Tank testing plan including details of the test requirements [Section 3-7-1 of the ABS Rules for Building and Classing Steel Vessels]

14 - 1.g - Corrosion protection specifications [3-2-18 5 of the ABS Rules for Building and Classing Steel Vessels].

14 - 1.h - Details for the in-water survey, if applicable, information for divers, clearances measurements instructions, etc., tank and compartment boundaries [Appendix 7-A-1 of the ABS Rules for Survey After Construction (Part 7)]

14 - 1.i - Docking plan and details of all penetrations normally examined at drydocking [3-1-2/11 and 3-2-217 of the ABS Rules for Building and Classing Steel Vessels and Section 7-4-1 of the ABS Rules for Survey After Construction (Part 7)]

14 - 1.j - Coating Technical File, for vessels subject to compliance with the IMO Coating Performance Standard (PSPC) as a class requirement under the I.A.C.S. Common Structural Rules. [Section 6 of the ABS Guide for The Class Notation Coating Performance Standard (CPS)].