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FeaturesFeature 1: Shipping Business — Initiatives for Dry Docking to Realize Safe Navigation

Senior Managing Executive Officer in charge of Seamen Department and Marine Safety Administration Department

Hisahiro Ohshima

In the Shipping Business, it is important to reliably ensure safety in four areas: safety of human life; then safety of the environment (a social asset); safety of cargo (customers’ assets); and safety of ships (the ship owners’ assets). In this feature, we discuss the concept of preventive maintenance, which is a prerequisite for safety assurance, the foundation of our business operations, by examining activities during dry docking as concrete examples of preventive maintenance.

Safety is Our Highest Management PriorityJust as people get a complete medical checkup, the practice of periodic maintenance servicing is essential for the health of ships. As the President noted earlier in this report, the first

principle in the Iino Group’s Management Philosophy states

“Safety is the foundation of our business operations.”

We consider safety as our most important management

priority because accidents involving ships not only threaten

human life but also pose a risk of damage to customer

assets, environmental pollution and other serious problems.

In many ways, ships under international voyage are like

independent communities, they must take care of their own if

a malfunction or accident occurs by themselves. Accordingly,

a mindset of doing everything possible to prevent failures

and malfunctions is extremely important for reliably ensuring

the safety of human life, the environment, cargoes, and own

ships. And performing routine preventive maintenance is at

the heart of this mission.

There are three categories of ship maintenance and repairs:

1) maintenance at sea, 2) maintenance in port, and 3) dry-

dock work. Dry-dock work involves major maintenance that

cannot be repaired at sea and can be compared to a person

undergoing a regular health checkup or complete medical

checkup at a hospital to help prevent illness. In addition, the

periodic execution of thorough examinations and repairs at

repair shipyards is mandated by law.

The Iino Group’s ship management company, Iino Marine

Service Co., Ltd., engages in various types of ship

maintenance servicing and dry-dock work in accordance with

Since the propeller and rudder stay underwater constantly, maintenance inspections of these parts can only be performed while the ship is in dry dock. The maintenance inspection method is explained on page 17.

Rust is the mortal enemy of ships. The hull’s shell plating, the part that tugboats push against, is one of the most easily damaged parts of a ship. The shell plating maintenance process is described using photographs on page 16.

Dry-dock work involves a wide range of maintenance services. For instance…

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Feature 1: Shipping Business — Initiatives for Dry Docking to Realize Safe Navigation

a safety management manual according to the International

Safety Management Code (ISM Code). The company’s

services have gained a high reputation by customers outside

the Group.

Types of Ship Surveys and Their PurposeIn addition to Special Surveys conducted every five years, we carry out Intermediate Surveys, Docking Surveys, and so on.Ship surveys can be broadly divided into three types:

1) Registration Surveys / Classification Survey These are executed mainly during construction to confirm whether

the hull structure, fire protection structure, escape and fire-fighting

facilities, electrical facilities and other items comply with regulations.

When a ship passes the survey tests, a ship survey certificate valid for

a period of five years is issued.

2) Class Maintenance SurveysThere are four main types of class maintenance surveys: Special,

Intermediate, Annual, and Docking surveys. A Special Survey

is executed every five years from the date of completion of the

Registration Survey or of the previous Special Survey, and an

Intermediate Survey is executed during the second or third year

following a Special Survey. These are all mandated under the Ship

Safety Act.

3) Status SurveysThese are surveys required under international treaties, such as the

International Convention for the Safety of Life at Sea (SOLAS) and

the International Convention for the Prevention of Pollution from

Ships (MARPOL). The surveys are executed each year, focusing

mainly on safety radio surveys, equipment surveys, and construction

surveys.

Special Surveys categorized into Class Maintenance Surveys are mandatory and inspections, maintenance and repairs are conducted at a dry dock.

CLOSE UP　：Docking Survey Process (including Bottom Survey)

With assistance from tugboats, a ship enters a repair shipyard dry dock. After all the water is pumped out from a dry dock and the hull bottom is fully exposed, which means it can then be inspected and serviced.

1

Rust is then carefully removed, and the hull is repainted to prevent corrosion.

Workcompleted.

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The Role of the Superintendent (Marine and Technical)The advance preparation for dry-dock is the key to the success of dry-dock work.Detailed plan and preparation work are essential to accomplish

proper dry-dock work. The key is the dry-dock specification,

a planning document that dictates detailed work procedures,

processes and budget. Preparation of an appropriate specification

will largely dictate the success of dry-dock work.

Superintendents (who assists in ship maintenance and servicing on

shore) are in charge of preparing the dry-dock specification and dry-

dock work selection, and ascertain the condition of the hull, facilities

and equipments of the ship to be dry-docked on the basis of routine

ship visits. This superintendent compiles approximately 3,000 work

procedures and guidelines into a dry-dock specification, using as

a guide the condition of sister ship and other ship equipped with

similar facilities.

Selection of a shipyard to perform dry-dock work is another important

task of the superintendent. Once the dry-dock specification has been

prepared, the superintendent engineer negotiates with shipyards,

obtains price quotes and places a work order. In human terms, the

importance of this task can be compared to selecting a hospital. The

decision is based on factors such as cost, dry-dock work quality, the

distance from the shipyard to the ship’s main shipping routes and

shipyard congestion. It is also necessary to consider matters such as

the risk of international conflict near the shipyard location, the natural

environment and seasonal factors. The Iino Group currently performs

dry-dock work mainly at shipyards located in Singapore, Spain, the

Netherlands and the Yangtze River Basin in China,.

Maintenance inspection of the propeller and propeller shaft is executed in accordance with specific survey criteria. Re-installation of the propeller demands accuracy at the micron level (0.001 mm).

CLOSE UP　：Propeller and Propeller Shaft Maintenance Inspection Work Flow2

The propeller boss cap* is removed. The propeller is removed from the propeller shaft.

The propeller shaft is extracted and the stern tube is inspected.

Press fitting (propeller re-installation) is performed with the ship class inspector in attendance.

The propeller is carefully polished. The completion of the maintenance inspection.

*A cap for attaching the propeller boss (the part that attaches the propeller fins to the propeller shaft)

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A Meticulous Checking System for Different Type of shipWide-ranging procedures are executed, encompassing everything from equipments and engine safety confirmation to hull recoating.Potential accidents that cause the greatest risk are seawater getting

into the ship or oil pollution from a fuel tank or cargo from a cargo

tank leaking out into the sea. Any of these accidents will be caused

by problems such as physical wear and tear on the hull and welding

parts corrosion. Since cargo differs by type of ships (crude oil, LNG,

LPG, etc.), it is necessary to carry out surveys according to each

ship’s cargo characteristics.

For instance, crude oil produces highly corrosive hydrogen sulfide,

which can damage the inside of cargo tanks on crude oil carriers.

Therefore, during dry-dock work it is necessary to erect scaffolding

inside the cargo tanks and carefully examine every nook and cranny

of the interior.

For example the leakage of liquefied gas from cargo tanks could

lead to a serious accident, the inside of these cargo tanks is also

examined, and inspectors must confirm whether the safety devices

would work properly if a gas leak were to occur. In addition to

Special Surveys and Intermediate Surveys of liquefied gas carriers,

the Iino Group carries out intensive examinations once every ten

years.

As we have seen, ship facilities differ by ship type, so the details

of surveys and repairs differ as well. For dry-dock work, in addition

to work that varies by type of ships, a wide variety of maintenance

and performance test are executed simultaneously,

including checking the safety of hull, equipment

and engine maintenance servicing, repainting and

propulsion machinery adjustment. During dry-dock

work, not only the superintendent, but also the key

crew members take part in surveys and repairs of

the ship’s equipment and hull and offer suggestions

as necessary. The opinions of crew members are

particularly important for making decisions during

work on equipment and facilities, because in some

cases trouble and failure can only be identified

at sea. Cooperating and exchanging information

with service engineers dispatched from equipment

manufacturers is important in parts inspection and

replacement. The time spent in dry dock varies

depending on the ship’s condition and years of

service. It can range from as little as a week to about

20 days for ships that have been in service for 10 to

15 years.

Doublecheck conducted at sea by both human and maintenance system are standard practice.Routine checking of facilities and equipment by navigation officer

and engineer, and a rapid response when malfunctions occur are

essential for ensuring safe, efficient sailing. The Iino Group seeks

to reduce accident risk at sea by using doublecheck procedures

performed both manually and by electric planned maintenance,

never relying solely on electronic maintenance systems. We make

use of our knowledge and experience gained aboard ship to

perform maintenance work at sea as necessary.

The results of these safety activities have been highly regarded

by external organizations. To transport cargo such as crude oil

and petrochemical products, it is necessary to pass inspections

conducted by major oil companies, and Iino Group vessels routinely

achieve a high pass rate in these inspections. For example, the

Shell Group recognizes shipping companies with outstanding

performance in areas such as safety and risk management. The Iino

Group was proud to win the Shell Chemicals Carrier of the Year

Award in 2011, 2012, and 2014.

Our reputation is the result of constant safety awareness by all

employees. We will continue our safety assurance efforts with the

aim of complete elimination of accidents, and will enthusiastically

work to increase customer satisfaction.