Innovative Drydock Expansions - NSRP
Innovative Drydock Expansions - NSRP
Innovative Drydock Expansions - NSRP
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<strong>Innovative</strong> Expansion of Dry Dock Facilities<br />
plus Other Innovations in Dry Dock Design<br />
<strong>NSRP</strong> All-Panel Meeting<br />
April 24, 2013<br />
Stuart White<br />
Director of Shipyard Infrastructure, Maritime & Waterways<br />
Steve Maguire<br />
Principal Consultant, First Marine International
Presentation Content<br />
<br />
<br />
<br />
<br />
<br />
Royal HaskoningDHV<br />
First Marine International (FMI)<br />
Trends in Ship Sizes<br />
Dry Dock Expansion Options<br />
Case Study - Resent Dock<br />
Widening and Lengthening<br />
Project<br />
Other Dry Dock Innovations<br />
<br />
<br />
<br />
Equilibrium Filling Valves<br />
Dewatering Pumps<br />
Dock Gates<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 2<br />
24 April 2013
Royal HaskoningDHV<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Global consultancy: design, engineering, and project<br />
management services provider<br />
Leader in sustainability and innovation<br />
Top 10 of independently owned, non-listed companies<br />
Top 40 worldwide design consultancy<br />
Sales in excess of $900 million (USD)<br />
7,000 experienced and diverse team members<br />
Leading professionals in our fields<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 3<br />
24 April 2013
Shipyard Life Cycle Services<br />
<br />
<br />
Global leader in shipyard design<br />
Experience of complete shipyard life cycle<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Market research<br />
Feasibility studies<br />
Concept design<br />
Detailed design<br />
Construction supervision<br />
Shipyard operations<br />
Benchmarking<br />
Performance improvement<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 4<br />
24 April 2013
First Marine International (FMI)<br />
Formed in 1991<br />
Acquired by Royal Haskoning in 2008<br />
Clients: Shipyards, Governments, Others<br />
Worked in Over 50 Countries<br />
US Industry Benchmarking (1995, 2000, 2005, 2007)<br />
Support Directly to US Shipbuilders/<strong>NSRP</strong><br />
Market research<br />
Strategic planning<br />
Facilities development<br />
Benchmarking and performance improvement<br />
Pre-production operations development<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 5<br />
24 April 2013
Shipping Trends Affecting Dry Dock Size<br />
<br />
FMI market analysis shows increased numbers of larger<br />
ships worldwide<br />
Capesize bulk carriers > 80%<br />
Post-panamax container ships > 60%<br />
Panamax bulk carriers > 45%<br />
Suezmax bulk carriers > 25%<br />
Larger ships have<br />
highest growth rate<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 6<br />
24 April 2013
Larger Ships Calling in US Waters<br />
Over 110,000 vessel moves in the US Gulf each year<br />
Panama Canal beam limit from 32m (106’) to 49m (161’)<br />
Facilities world-wide reacting to trend for larger ships<br />
Panamax<br />
New<br />
Panamax<br />
LENGTH<br />
BEAM<br />
10 15 20 25<br />
DRAFT<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 7<br />
24 April 2013
Options for <strong>Drydock</strong> Expansion<br />
<br />
<br />
<br />
<br />
<br />
Existing facilities often very constrained<br />
Dock lengthening Options<br />
<br />
<br />
<br />
<br />
Carried out behind intermediate gate or bund<br />
Timed to suit dock operations<br />
Dock Widening Options<br />
Use existing dock profile (if possible)<br />
Widening of entrance difficult<br />
Dock Deepening Options<br />
<br />
<br />
Deeper sill formed within dock<br />
Dock walls and drainage system tricky<br />
Ideally expansion works completed whilst existing facility<br />
remains operational<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 8<br />
24 April 2013
Case Study: Dock Widening and Lengthening<br />
<br />
<br />
<br />
<br />
<br />
<br />
Leading International Ship Repair facility expansion<br />
Previous dock area: 355m x 60m extended to 400m x 64m<br />
New maximum vessel width of 60m<br />
Captures larger market share of VLCC’s<br />
Maersk Triple-E Class now accommodated<br />
Dock expansion carried out with dock in use<br />
Enlargement cost comparatively good value<br />
Dock entrance can be widened without complete closure<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 9<br />
24 April 2013
Shipyard Expectations<br />
<br />
<br />
<br />
<br />
Keep the dock in use for as long as possible<br />
<br />
<br />
Minimise construction time<br />
Kept existing head wall in place<br />
Dock used as a wet berth while the gate is out and entrance<br />
modifications carried out<br />
Replace all Mechanical and Electrical (M&E) services<br />
Maintain use of ‘temporary’ M&E services throughout<br />
construction period<br />
<br />
<br />
Modified one half of the dock’s M&E at a time<br />
Installed temporary substations<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 10<br />
24 April 2013
Case Study<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 11<br />
24 April 2013
Dock Extension<br />
Dock Lengthening<br />
Extended Section<br />
Broken Longitudinal Section<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 12<br />
24 April 2013
Dock Extension Construction<br />
<br />
<br />
Buried Concrete Diaphragm Walls<br />
Ground Anchors used to reduce construction footprint<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 13<br />
24 April 2013
Dock Extension Construction<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 14<br />
24 April 2013
Dock Widening<br />
Cope Dock Arm Rail Detail<br />
Transverse Cross Section<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 15<br />
24 April 2013
Dock Widening<br />
Concrete Legend<br />
Existing to remain<br />
To be removed<br />
To be added<br />
Cope Dock Arm Rail Detail<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 16<br />
24 April 2013
Dock Widening Construction<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 17<br />
24 April 2013
Dock Entrances<br />
<br />
<br />
<br />
<br />
<strong>Innovative</strong> solution needed to avoid dock closure and large<br />
entrance cofferdams<br />
Limpet dams therefore used<br />
<br />
Dock could be used as a wet berth<br />
Gate widening<br />
<br />
<br />
<br />
Winch capacity kept the same<br />
Sheaves re-used<br />
Gate bearings re-used<br />
Concrete Sealing Face<br />
<br />
<br />
Vertical stainless steel plate<br />
Adjustment Rolled Steel Angles (RSAs)<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 18<br />
24 April 2013
Limpet Dams<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 19<br />
24 April 2013
Dock Entrances<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Sectional Plan of Limpet Dam and<br />
Meeting Face<br />
Page 20<br />
24 April 2013
Dock Gate<br />
<br />
<br />
Spanning flap gate on open hinges<br />
New gate constructed using existing hinges<br />
Gate Elevation<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 21<br />
24 April 2013
Dock Gate<br />
Typical Gate Section<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 22<br />
24 April 2013
Construction Phasing<br />
<br />
<br />
<br />
<br />
<br />
Phasing of construction critical to project success<br />
Shipyard needs to plan operations around contractor and<br />
visa versa to limit construction downtime and shipyard<br />
disturbance<br />
Replacement of M&E and need for temporary supplies has<br />
to be carefully phased and managed<br />
Crane and lifting restrictions to be planned<br />
Flexibility and cooperation from all parties needed<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 23<br />
24 April 2013
Case Study: Conclusions<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Expansion of existing facilities are often very challenging<br />
Investment value likely to be high<br />
<strong>Innovative</strong> design work often required<br />
Planning and construction sequencing critical to success<br />
Construction space, waste and movement of materials<br />
needs to be well managed<br />
Cooperation and flexibility from Shipyard and Contractor<br />
The continued use of the facility during construction can be<br />
achieved<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 24<br />
24 April 2013
Other Dry Dock Design Innovations:<br />
Pump Syphonic Discharge<br />
Typical section through Pumphouse<br />
Purpose of Syphon:<br />
<br />
Syphonic effect means pumping head<br />
is only to tide level, not to crest of<br />
pipe or higher level<br />
<br />
Pipe crest above sea level prevents<br />
water back flowing into dock and<br />
avoids large diameter valve<br />
<br />
Initial higher energy to create syphon<br />
then reduces to ‘working’ energy<br />
<br />
Syphon breaker installed to prevent<br />
reverse flow (electrically operated)<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 25<br />
24 April 2013
USE OF SUBMERSIBLE PUMPS FOR DOCK<br />
DEWATERING (1) :<br />
Typical section through Pumphouse<br />
<br />
Mixed flow submersible pumps<br />
recently introduced as an economical<br />
alternative to large impeller pumps<br />
<br />
Suitable for smaller repair docks or<br />
building docks (speed of dewatering<br />
is less critical)<br />
<br />
Pumps easily removed/replaced for<br />
maintenance<br />
<br />
Capacities up to 11,000m 3 /hr<br />
(4 such pumps could typically empty a dock of size<br />
300mx40m in under 3 hours)<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 26<br />
24 April 2013
USE OF SUBMERSIBLE PUMPS FOR DOCK<br />
DEWATERING (2) :<br />
Further economies available where two building docks are located together –<br />
pumps can be transferred between shafts of each dock by crane, or sharing<br />
the discharge culvert as a flooding culvert:<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 27<br />
24 April 2013
Recent Developments in Dry Dock Design<br />
CONTAMINATED WATER REMOVAL<br />
Shipyards now obliged<br />
to avoid discharging<br />
contaminants to sea<br />
Recent development of<br />
contaminant removal<br />
system - dirty water<br />
routed via drainage<br />
channel to dedicated<br />
pump which discharges<br />
to storage tank or onsite<br />
treatment works<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 28<br />
24 April 2013
DOCK FLOODING VALVES<br />
Equilibrium Filling Valve - simple<br />
and reliable device to control dock<br />
flooding<br />
Located in dock abutment(s)<br />
Steel cylinder lifts vertically above<br />
an orifice by hydraulic ram<br />
Minimal mechanical effort due to<br />
equal pressure around cylinder<br />
Closes under self weight under<br />
full flow<br />
Typically one or two installed<br />
- low maintenance<br />
Sections through EFV<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 29<br />
24 April 2013
DOCK ENTRANCE SILT JETTING<br />
Flap gate recess outside dock entrance often prone to siltation<br />
RH often incorporates jetting pipes in sill, connected to dewatering pump<br />
discharge pipe<br />
Each time dock is dewatered, jetting pipes discharge water under<br />
pressure to clear silt from gate recess<br />
For large silt depositions, install dedicated silt pump for frequent jetting<br />
Jetting pipes in use in Cammell Laird dock, UK<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 30<br />
24 April 2013
Inverted ‘T’ Gates<br />
<br />
<br />
Docks wider than approx 90m<br />
(300ft) gates cannot easily<br />
span<br />
RH pioneered inverted ‘T’ gate<br />
- gravity structure<br />
Reversible after ship docking -<br />
fully maintainable whilst in<br />
service<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 31<br />
24 April 2013
Inverted T Gates<br />
<br />
3 designed in Korea<br />
including the worlds longest<br />
at 131m<br />
Recently 2 in China and 4<br />
in Brazil<br />
<strong>NSRP</strong> Conference<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
Page 32<br />
24 April 2013
ANY <strong>NSRP</strong> Conference QUESTIONS?24<br />
Page 33<br />
<strong>Innovative</strong> Dry Dock Facility <strong>Expansions</strong><br />
April 2013
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