Bbme2015 Heavy Lift Workshop Ocean [PDF]

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Heavy Lift Technical Workshop: Ocean Transport

Heavy Lift Technical Workshop: Ocean Transport

HEAVY LIFT TECHNICAL WORKSHOP

OCEAN TRANSPORT

Introduction of your teacher Ing. Cornelis (Cees) Coppens -

graduated at the Maritime and Training Academy in Amsterdam 7 years sailing the high seas in officer ranks achieving the Master’s license graduated at the Dutch Maritime Shipbroker Association - Rotterdam 25 years working worldwide as Port Captain with Mammoet/BigLift Shipping presently Consultant and Lecturer at Breakbulk Events & Media

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Heavy Lift Technical Workshop: Ocean Transport

The transportation of heavy lift items over the ocean ranks among the most challenging and complex services in logistics and is handled by specialized companies on specialized ships

Type of heavy lift ships - submersible ship (flo/flo) - open deck ship (ro/ro) - heavy lift ship (lo/lo) 2

Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Shipping

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

History of heavy lift lo/lo ships 1929: S.S. “Lichtenfels” of DDG Hansa with 120 mt lifting boom for locomotives 1978: M.V. “Trifels” of DDG Hansa with two 320 mt Stuelcken derricks 1980: DDG Hansa went bankrupt, leaving Mammoet Shipping and Jumbo Shipping as the only remaining heavy lift lo/lo specialists of importance in that time 2015:

BigLift Shipping Jumbo Shipping Rolldock SAL BBC HHL Intermarine Cosco

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Definitions for heavy and oversized cargo -

too large/heavy for standard containers and flatracks too heavy for conventional harbour/ship cranes exceeding the deck strength of conventional ships requires designed support and load spreading requires specific engineered securing methods requires reduced accelerations during transport

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Heavy Lift Technical Workshop: Ocean Transport

Typical heavy cargo items -

fully erected (harbour) cranes mobile cranes transtainers reactors towers locomotives submarines modules mining equipment (ship) engines (mega) yachts

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Selecting a heavy cargo ship - size, volume, deck space - deck strength - speed (transit time) - canal passage limitation - passage of bridges on the voyage (air draft) - port restriction for length, width, draft / quay height - crane capacity and required outreach - age (eventual cargo insurance requirements) - reputation of the ship and her owners

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Heavy Lift Technical Workshop: Ocean Transport

Contacting a heavy lift company - direct - via shipbroker - open tender

Shipping contracts (lo/lo) - fixing/booking note - contract of carriage - Bimco heavyliftvoy ( standard contract type) note: BIMCO is the world’s largest international shipping association

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Heavy Lift Technical Workshop: Ocean Transport

Shipping terms

-

(full) liner terms liner terms hook/hook fios lifo filo

The handling and ocean transport of heavy cargo requires thorough planning, accurate design and calculations

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Planning, design and calculations -

stowage plan loading sequence rigging plans crane simulations sling forces rigging weight ship’s stability during lifting operation ship’s stability during sea voyage deck strength accelerations at the ocean lashing/securing plan voyage planning

Stowage plan -

total volume to be accommodated broken stowage factor weight and dimension of each individual unit deck option stackability weight distribution acceleration forces hazardous items cargo protection hot work areas friction 27

Heavy Lift Technical Workshop: Ocean Transport

Situation: 100 ton module on wooden skids standing on a steel ship's deck with 15 degrees list

Question: does it shift or not ?

Fs

FF

FP

FS = sliding force FG = gravity force FP = perpendicular force FF = friction force

15

FG

Cosinus (90 - 15) = FS / FG

FS = 100 ton x cosinus 75 = 26 ton

Cosinus 15 = FP / FG

FP = 100 ton x cosinus 15 = 97 ton

FF = Phi x FP

FF = 0.35 x 97 = 34 ton

CONCLUSION: FF > FS

The module does not shift

Phi = friction coefficient

Phi wood/steel = 0.35 Phi teflon/teflon = 0.04

Fs

FF

FP

FG

15

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Heavy Lift Technical Workshop: Ocean Transport

Loading sequence -

chronological cargo delivery reducing frequent rigging changes eventual discharge sequence defined stowage positions day/night work preference stackability

Rigging/lifting plan -

lifting positions available lifting height of the crane(s) expected tidal effects during the lifting operation quay height required outreach position CoG (Center of Gravity) of the cargo lifting and/or spreader bar requirement expected sling/grommet forces stability of the lift

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Heavy Lift Technical Workshop: Ocean Transport

Stability of the lift

.

COG

Stability of the lift

.

stable

COG

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Heavy Lift Technical Workshop: Ocean Transport

Stability of the lift

.

COG

Stability of the lift

.

unstable

COG

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Heavy Lift Technical Workshop: Ocean Transport

Stability of the lift

.

COG

Stability of the lift

.

(just) stable

COG

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Heavy Lift Technical Workshop: Ocean Transport

Stability of the lift

LIFTING BEAM

.

COG

Stability of the lift

LIFTING BEAM

.

COG

stable

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Heavy Lift Technical Workshop: Ocean Transport

Stability of the lift

LIFTING BEAM

.

COG

Stability of the lift

LIFTING BEAM

.

COG

unstable

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Rigging/lifting materials -

lifting beam spreader sling grommet shackle

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Heavy Lift Technical Workshop: Ocean Transport

Lifting beam

Spreader beam

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Sling Grommet

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Heavy Lift Technical Workshop: Ocean Transport

Wide body shackles - larger bow diameter - smaller pin compared to standard heavy duty shackles pro: con:

better D/d ratio for slings/grommets on the bow not suitable for connecting grommets

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Heavy Lift Technical Workshop: Ocean Transport

Diameter/diameter ratio Bending a wire reduces the strength Eb = 1 – 0.5/ √D/d Eb = bending efficiency D = Diameter pin (or object) d = diameter wire

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Heavy Lift Technical Workshop: Ocean Transport

Important ! This reduction is for the MBL and not for the WLL MBL = Minimum Break Load WLL = Working Load Limit note: WLL includes the design factor (formerly safety factor)

WLL = MBL / DESIGN FACTOR (typical design factor = 5)

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Heavy Lift Technical Workshop: Ocean Transport

Design Factor -

wear abrasion damage variations in the loads

Various international classifications DNV = Det Norske Veritas IMCA = International Marine Contractors Association EN = European Norm

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Heavy Lift Technical Workshop: Ocean Transport

Advantage DNV rules D/d ratio is included in the design(safety) factor for grommets with the corresponding shackle

Sling force calculation using a lifting beam Sling force 60

LIFTING BEAM Sling force

LOAD 100 TON

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Heavy Lift Technical Workshop: Ocean Transport

Sling force calculation using a lifting beam

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Sling force = 50 ton / cosinus 30 = 58 ton

LIFTING BEAM Sling force = 50 ton

LOAD 100 TON

note: own weight of slings, shackles and beam is ignored in this calculation

Sling force calculation using a spreader beam

sling force sling force

60 SPREADER BEAM

sling force

LOAD 100 TON

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Heavy Lift Technical Workshop: Ocean Transport

Sling force calculation using a spreader beam

sling force = 8 ton sling force = 50 ton

60 SPREADER BEAM

sling force = 50 ton

LOAD 100 TON

note: own weight of slings, shackles and beam is ignored in this calculation

Rigging weight calculation The weight of the rigging (beams, spreaders, grommets, shackles) can easily reach up to 100 mt or even more and has to be added to the weight of the load during lifting - maximum crane capacity / reach - influence on stability (MG-value) - influence on required ballast water during lifting

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Lifting a heavy load with ship’s cranes 52

Heavy Lift Technical Workshop: Ocean Transport

Lifting the load by

TRANSFERING WATER

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Different lifting situations - lifting from the quay - lifting from a trailer or spmt - lifting from a floating barge spmt = self propelled modular transporter

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Heavy Lift Technical Workshop: Ocean Transport

Crane simulations - free passage of ships construction parts - free passage of other cargo objects - available lifting height at several positions - critical crane positions for MG calculations - matching clients’ required installation work - positioning onto trailer, barge or quay

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Heavy Lift Technical Workshop: Ocean Transport

Sling force calculation tandem lift - angle of each individual rigging arrangement - stress in each individual rigging arrangement - required material, length and capacity

CRANE 1

CRANE 2 70

MODULE WEIGHT: 500 TON

.

15 meter

.

COG

COG

10 meter

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Heavy Lift Technical Workshop: Ocean Transport

Weight in crane 1:

Weight in crane 2:

Sling forces crane 2:

10/25 x 500 = 200 ton

15/25 x 500 = 300 ton

cosinus 35 = 150 ton / sling force sling force = 150 / cos 35 = 183 ton

CRANE 1

CRANE 2 35

MODULE WEIGHT: 500 TON

.

15 meter

0

.

COG

COG

10 meter

Ship stability during lifting The Center of Gravity can change dramatically during a lifting operation with the ship’s cranes Therefore increased stability may be required

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Heavy Lift Technical Workshop: Ocean Transport

Stability calculations have to be made for a

worst-case scenario - crane jibs in highest position - (unfavorable) ballast conditions during transfer

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Ship stability

Why does a vessel float in water ?

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Heavy Lift Technical Workshop: Ocean Transport

Archimedes 287 BC - 212 BC

The (practical) rule of Archimedes The upward (B)uoyancy force on a vessel in a fluid is equal to the weight of the displaced fluid

Generally regarded as the greatest mathematician and scientist of antiquity and one of the three greatest mathematicians of all time Archimedes' principle indicates that the upward buoyant force that is exerted on a body immersed in a fluid, whether fully or partially submerged, is equal to the weight of the fluid that the body displaces

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Heavy Lift Technical Workshop: Ocean Transport

In floating condition forces G and B are equal and in one vertical line

.G

.B

G = Center of Gravity B = Center of Buoyancy

Definition of ship stability The ability of the ship to resist the overturning forces she encounters

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Heavy Lift Technical Workshop: Ocean Transport

Ship stability can be subdivided into longitudinal stability transverse stability initial static stability ( < 7 degrees) dynamic stability ( > 7 degrees)

Longitudinal stability - trim - hogging - sagging 64

Heavy Lift Technical Workshop: Ocean Transport

Transverse initial static stability for lists of < 7 degrees

Initial static stability (practical rule) During lifting operations of heavy cargo the minimum required static stability (M above G) has to be > 1 meter

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Heavy Lift Technical Workshop: Ocean Transport

(M)etacenter Metacenter is the point where lines intersect of upward force of buoyancy and the center line of the ship (virtual transverse rotation point of the ship)

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Heavy Lift Technical Workshop: Ocean Transport

If the vessel is forced to list, the position of B changes G and B are now not any more in one vertical line This results in a righting moment

.M .G

.B

M = Metacenter G = Center of Gravity B = Center of Buoyancy

MG is the (initial static) stability .M .G

.B

MG = MK - GK MK = MB + BK

. K(keel)

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Heavy Lift Technical Workshop: Ocean Transport

Calculation MK (barge shape) MK = MB + BK 3

MB =

1 LXW 12 L X W X D

BK =

1 D 2

L = LENGTH W = WIDTH D = DRAFT

Calculation MG (barge shape) 3

MB =

60 x 10

12 x 60 x 10 x 2

= 4.17 meter

BK = 1/2 x 2 = 1 meter

MK = MB + BK = 4.17 + 1 = 5.17 meter

GK = 3 meter

MG = MK - GK = 5.17 - 3 = 2.17 meter

.

M

.

G BARGE

BARGE weight: 1200 ton dimension: 60 x 10 x 6 meter draft: 2 meter

. .

B

K

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Heavy Lift Technical Workshop: Ocean Transport

Moment equation Moment = Force x distance

Moments = 0 seesaw in ballance person left is 150 kg person right is 60 kg d1 = 2 mtr d2 = ? mtr

60 x d2 - 150 x 2 = 0 60 x d2 = 150 x 2 60 x d2 = 300 d2 = 300 : 60 = 5 mtr

Influence of 250 ton load on deck The Center Of Gravity shifts upwards and reduces the MG value !

.

G LOAD

. . .

M G' BARGE + LOAD

BARGE weight: 1200 ton dimension: 60 x 10 x 6 meter draft: 2 meter

G BARGE

. .

B

LOAD (homogeneous) weight: 250 ton dimension: 5 x 5 x 2 meter

K

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Heavy Lift Technical Workshop: Ocean Transport

(1200 x 3) + (250 x 7) = (1200 + 250) x G’K G’K =

(1200 x 3) + (250 x 7) (1200 + 250)

= 3.69 meter

.

G LOAD

. . .

BARGE

. .

LOAD (homogeneous)

M G' BARGE + LOAD

weight: 1200 ton dimension: 60 x 10 x 6 meter draft: 2 meter

G BARGE

B K

weight: 250 ton dimension: 5 x 5 x 2 meter

How to manipulate (increase) the MG value of a lo/lo heavy cargo ship -

fill-up the (lower) ballast tanks bunker extra fuel in the lower fuel tanks remove hatch pontoons de-ballast (high) wing tanks load extra cargo on the tank top lower the crane jib(s) 70

Heavy Lift Technical Workshop: Ocean Transport

TRANSVERSE DYNAMIC STABILITY LISTS > 7 DEGREES

Righting lever GZ = MG x sinus (heel)angle

.M (heel)angle

Z.

.B

.G M = Metacenter G = Center of Gravity B = Center of Buoyancy

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Heavy Lift Technical Workshop: Ocean Transport

Overturning forces -

wind waves flooding (due to damage) cargo shifting abrupt change of course

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Heavy Lift Technical Workshop: Ocean Transport

ADOPTION OF THE INTERNATIONAL CODE ON INTACT STABILITY, 2008 (2008 IS CODE)

I.M.O. STABILITY REQUIREMENTS: UP TO 30 DEGREES > 5.5 CM RADIANS BETWEEN 30 AND 40 DEGREES > 3 CM RADIANS UPTO 40 DEGREES > 9 CM RADIANS MAXIMUM RIGHTING LEVER AT AN ANGLE OF HEEL > 25 DEGREES RIGHTING LEVER > 20 CM AT AN ANGLE OF HEEL > 30 DEGREES INITIAL METACENTRIC HEIGHT > 15 CM I.M.O. = INTERNATIONAL MARITIME ORGANIZATION RADIAN = ANGULAR MEASUREMENT IN MATHEMATICS ( AT 57.3 DEGREES THE LENGTH OF THE ARC OF 1 RADIAN IS EQUAL TO THE RADIUS)

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Heavy Lift Technical Workshop: Ocean Transport

The stability tank is not acting as counter ballast, but it increases the waterplane area

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Heavy Lift Technical Workshop: Ocean Transport

Manipulate (reduce) the MG-value during voyage -

acceptable accelerations on cargo and ship constructions matching the calculated lashings on the cargo safety and comfort of the crew

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Acceleration calculations - longitudinal lashing force - transverse lashing force - uplift lashing force

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Heavy Lift Technical Workshop: Ocean Transport

Lashing calculations

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Heavy Lift Technical Workshop: Ocean Transport

Lashing type -

push-pull bar stoppers shear plate wire lashing system lashing chain lashing belt

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

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Heavy Lift Technical Workshop: Ocean Transport

Different lashing systems should never be mixed for securing in the same direction!

During the sea voyage actual accelerations can be measured with the Octopus Ship Motion Monitoring and Advisory System -

connected to (3) acceleration sensors in the ship linked with GPS linked with SPOS

GPS = Global Positioning System SPOS (Ship Performance Optimisation System) is the world’s leading onboard weather routing system taking into account weather, ocean current and ship characteristics (in combination with ECDIS = Electronic Chart Display and Information System)

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Heavy Lift Technical Workshop: Ocean Transport

Safetrans program calculates the maximum expected accelerations for a certain duration of the voyage in a designated sea area in order to simplify securing requirements reducing severe North Atlantic (DNV) rules

(always in consultation with clients and eventual warranty surveyors)

Deck strength calculations The footprint of heavy cargo can result in point pressure and stressing the ship’s deck strength -

load spreaders/deck pillars may have to be installed supports may be required

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Heavy Lift Technical Workshop: Ocean Transport

Process safety -

visually inspect the entire gear, spooling devices, sheaves, swivels prevent slipping of wires over bollards / hook during rigging run the bight of grommets over the ram and never around the shaft secure all other cargo items, stacked pontoons, equipment, etc. ‘clean’ the deck and organize / remove all loose items in the area always start with fully charged radios slightly slack the breast lines check ballast system, tank soundings and capacities never exceed the WLL (Working Load Limit) decide on a cut-off time, considering darkness and weather condition only necessarily required persons on board (ballast water on one side) determine dangerous locations reduce disturbing noise (forklifts, trucks, trailers, ventilation fans) safety/toolbox meeting 89

Heavy Lift Technical Workshop: Ocean Transport

Personal safety -

wear protective clothing, helmet, safety shoes, harness, gloves, goggles be aware of the dangerous areas, especially during heavy lift movements strictly follow the instructions from the ship’s management never step backwards on a ship’s deck without carefully watching never walk underneath a load never run on a ship’s deck never enter a hold or enclosed space without a ship’s representative stay away from any welding/grinding work during a heavy lift operation stay on the quay at a safe distance ! be always alert in this dynamic environment !

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