COMPETENCY DEMONSTARTION REPORT
COMPETENCY DEMONSTARTION REPORT
CARRER EPISODE -1 : Replacement of propeller blades for container carrier ( Mitsui OSK Lines ) at Keppel Shipyard Tuas, Singapore .
INTRODUCTION
CE 1.1
Period: 12 July 2012 to 31 August 2022
Designation: Senior Engineer ( Machinery)
CE 1.2
Keppel Shipyard possesses an unrivaled track record for the repair, conversion and upgrading of a diverse range of vessels. Our marine expertise includes
Conversionof Floating Production, Storage and Offloading (FPSO) /Floating Storage and Offloading (FSO) vessels, Floating Storage and Re-Gasification Units (FSRU) and drillshipsRepair of all types of marine vessels including tankers, containerships, bulkers and LNG / LPG carriers
Upgrading and life extension of vessels
Jumboisation of vessels
Fabrication of turrets and topside modules
CE 1.3
BACKGROUND
Since the replacement of the propeller involves 3 steps namely 1) removal of the propeller cap / cone 2) Disconnecting the propeller securing nut 3) removal of propeller from its original position. Now I have to design the procedure for the disconnection of the above items in a sequential manner . The steps involved are
Inspection of the aft stern construction drawing, determine the strong point for the lifting of propeller blade, after which design the pad eyes .Arrangement of the lifting gears, lashing equipments, air pumps, hydraulic fittings, hoses
Prepare a lifting plan for the entire process
Prepare and conduct a JHA (Job hazard analysis ) as the tonnage of the equipments are more than 20T and its complexity.
Preparation of the lifting gear certificates, organise the QA team for inspections.
Re instatement of the above items in the sequential manner and carry out the inspection at various stages.
CE 1.4
The organisational flow chart is attached and my position is highlighted in blue
PERSONAL ENGINEERING ACTIVITY
CE 1.5
From the beginning of the process , first thing I had to do is to fetch all the tonnage and dimesions of the items involved . For that , during the kick off meeting , I will highlight the relevant drawings that has to be provided, which will be circulated by the owner through the ship repair manager.
Once I receive the datas, I will circulate the above drawings to the engineering department for the calculation and verification of the pad eyes. Once the pad eyes are verified , I will sit with the rigging team to generate a detailed lifting plan for the propeller , based on the tonnages. Further the above plan will be sent to engineering department for further stress calculations. The above department will advise further for the change in the lifting gears as required.
CE 1.6
This work method statement is to define the lifting and shifting of propeller .Propeller 84 ton / diameter 8800mm/ 6 blades
Preparation prior to operationDocument/Site Preparation:
Preparation of relevant documents for lifting arrangement. (Responsible Party: Machinery Lead)
Lifting gear certificates - (Responsible Party: Lifting Lead)
Prepare lifting plan:
Choosing the appropriate lifting gears (chain blocks, shackles and wire slings).
Conduct JHA prior to the lifting/shifting operation with all personnel reflected in Organization Chart Submit relevant documents (lifting arrangement, calculation, MPI reports and risk assessment) for review. (Responsible Person: KSL machinery Lead)
Site preparation
Any obstruction items to be clear before the lifting/shifting operation.
Communication check between KSL Lifting Lead and KSL Production Team by using walkie-talkie.
Ensure all material iwo tail shaft and intermediate shaft are removed.
All removed hand rails and walkway platform are properly secure and alternative walkway should be provided
The lifting area should be barricaded and only authorized personnel should be allowed to enter.
All the additional lifting gears has to be checked and verified by safety Lead prior to the lifting/shifting operation.
Coordinate and highlight in the VSCC meeting about the withdrawal of propeller to be carried out. PTW to apply for Dismantling and Boxing up activities.
A Lock out, Tag out should be installed to the Turning gear to avoid any accidental turning of engine while working on the propeller at dock bottom.
CE 1.7
Lifting and shifting of propeller
Once lifting arrangement is done, setup the hydraulic tools and loosen the propeller nut. Unscrew the nut and lower down the nut to the floor with the help of the cradle.
Put necessary marking on the propeller and prepare hydraulic tools for propeller jumping.
Hook up the fwd chain blocks to the propeller and slowly jump the propeller from the tailshaft taper.
Once the propeller is free from the tailshaft, setup chain blocks on the rudder side and pull the propeller from the taper and make clear for about 1 feet.
CE 1.8
CE 1.9
To weld the engineering designed eye lugs and set up a side block rigging arrangement for shifting out the propeller blade. Based on the below lifting arrangements , side blocks ( with 120 ton ) capacity winches are operated and shift the propeller from one side to the other. Further after reaching towards the yard crane, hook up the yard crane onto the 4 blades and lift it to the ground.
CE 1.10
After the withdrawal of the propeller, I will request the vessel superintendent and the class surveyor to witness the MPI test ( Magnaflux test ) . Test will be performed by an approved QA personnel. The competency of the person and the equipment test certificate has to be produced in front of the surveyor. Outbooard seals will be overhauled during the process. Once seals are installed complete, the propeller will be reinstated in the same manner.
-71755085090000The communication flow / emergency preparedness during the entire lifting process is as follows.
1.11
Access Control
Access control will be managed by KSL HSE and KSL Machinery Lead led by KSL Project Manager in charge in their respective areas on ground. Only authorized personnel identified by green vests are allowed to enter lifting operation vicinity and carry out related works concerning with lifting operation. Watchmen will be deployed to prevent unauthorized personnel from trespassing.
SUMMARY
1.12
I was able to adopt my engineering skills with project at the time of problems and failures ina successful manner which was highly appreciated. The project helped me a lot as professionally as well as in enhancing my skills in management, through manpower deployment and scheduling of the tasks as per priority.
COMPETENCY DEMONSTARTION REPORT
CARRER EPISODE -2 : Magnaflux inspection of the propulsion shaft for a bulk carrier named CASTILLO DE CATOIRA at Keppel Shipyard Tuas, Singapore .
INTRODUCTION
CE 2.1
Period: 12 July 2012 to 31 August 2022
Designation: Senior Engineer ( Machinery)
CE 2.2
Keppel Shipyard possesses an unrivaled track record for the repair, conversion and upgrading of a diverse range of vessels. Our marine expertise includes
Conversionof Floating Production, Storage and Offloading (FPSO) /Floating Storage and Offloading (FSO) vessels, Floating Storage and Re-Gasification Units (FSRU) and drillshipsRepair of all types of marine vessels including tankers, containerships, bulkers and LNG / LPG carriers
Upgrading and life extension of vessels
Jumboisation of vessels
Fabrication of turrets and topside modules
CE 2.3
BACKGROUND
Since the magnaflux inspection of the propulsion shaft involves 3 steps namely 1) removal of the propeller 2) Disconnecting the coupling bolts and intermediate shaft 3) removal of propulsion shaft. Now I have to design the procedure for the disconnection of the above items in a sequential manner . The steps involved are
Inspection of the aft stern construction drawing, determine the strong point for the lifting of propeller blade, after which design the pad eyes .Arrangement of the lifting gears, lashing equipments, air pumps, hydraulic fittings, hoses
Prepare a lifting plan for the entire process
Prepare and conduct a JHA (Job hazard analysis ) as the tonnage of the equipments are more than 20T and its complexity.
Preparation of the lifting gear certificates, organise the QA team for inspections.
Coordinate the inspection between the owners and classification societies
Re instatement of the above items in the sequential manner and carry out the inspection at various stages.
CE 2.4
The organisational flow chart is attached and my position is highlighted in blue
PERSONAL ENGINEERING ACTIVITY
CE 2.5
From the beginning of the process , first thing I had to do is to fetch all the tonnage and dimesions of the items involved . For that , during the kick off meeting , I will highlight the relevant drawings that has to be provided, which will be circulated by the owner through the ship repair manager.
Once I receive the datas, I will circulate the above drawings to the engineering department for the calculation and verification of the pad eyes. Once the pad eyes are verified , I will sit with the rigging team to generate a detailed lifting plan for the propeller , intermediate shaft and tailshaft separately based on the tonnages. Further the above plan will be sent to engineering department for further stress calculations. The above department will advise further for the change in the lifting gears as required.
CE 2.6
This work method statement is to define the lifting and shafting of Tail Shaft and Intermediate Shaft.
Propeller 42ton / Tail Shaft 10.2M X 1.45 M, weight 26T / Intermediate Shaft 10.4M X 1.45M, Weight 21T
Preparation prior to operation
Document/Site Preparation:
Preparation of relevant documents for lifting arrangement. (Responsible Party: Machinery Lead)
Lifting gear certificates - (Responsible Party: Lifting Lead)
Prepare lifting plan:
Choosing the appropriate lifting gears (chain blocks, shackles and wire slings).
Conduct JHA prior to the lifting/shifting operation with all personnel reflected in Organization Chart Submit relevant documents (lifting arrangement, calculation, MPI reports and risk assessment) for review. (Responsible Person: KSL machinery Lead)
Site preparation
Any obstruction items to be clear before the lifting/shifting operation.
Communication check between KSL Lifting Lead and KSL Production Team by using walkie-talkie.
Ensure all material iwo tail shaft and intermediate shaft are removed.
All removed hand rails and walkway platform are properly secure and alternative walkway should be provided
The lifting area should be barricaded and only authorized personnel should be allowed to enter.
All the additional lifting gears has to be checked and verified by safety Lead prior to the lifting/shifting operation.
Coordinate and highlight in the Castillo de Catoira VSCC meeting about the withdrawal of propeller, Tail shaft and Intermediate Shaft to be carry out. PTW to apply for Dismantling and Boxing up activities.
A Lock out, Tag out should be installed to the Turning gear to avoid any accidental turning of engine while working on the propeller at dock bottom.
CE 2.7
Lifting and shifting of propeller
Once lifting arrangement is done, setup the hydraulic tools and loosen the propeller nut. Unscrew the nut and lower down the nut to the floor with the help of the cradle.
Put necessary marking on the propeller and prepare hydraulic tools for propeller jumping.
Hook up the fwd chain blocks to the propeller and slowly jump the propeller from the tailshaft taper.
Once the propeller is free from the tailshaft, setup chain blocks on the rudder side and pull the propeller from the taper and make clear for about 1 feet.
CE 2.8
Intermediate shaft rigging arrangement
Extract the (fwd and aft) coupling bolts with sleeve using hydraulic jacks and install 4 nos of service bolts at each flange to temporarily hold the shaft.
Lash up and Hook up the trolley chain blocks on to the intermediate shaft and secure it as per the attached lifting arrangement.
Slowly take out the service bolts and keep adjusting the chain blocks to assist in the removal of bolts.
Once the service bolts are removed, lift up the shaft using the chain blocks according to the arrangement .CE 2.9
Install a 8ton eyebolt on the tail shaft and hook up a chain block on the flywheel using lashing wires.
Slowly use the fwd chain block and pull 1/4 of the tail shaft out.
Lash up the tail shaft and hook up to the aft trolley chain block to support the weight of the shaft vertically
Continue pull out the tail shaft from the stern tube
CE 2.10
After the withdrawal of the propeller shaft , I will request the vessel superintendent and the class surveyor to witness the MPI test ( Magnaflux test ) . Test will be performed by an approved QA personnel. The competency of the person and the equipment test certificate has to be produced in front of the surveyor.
-71755085090000The communication flow / emergency preparedness during the entire lifting process is as follows.
2.11
Access Control
Access control will be managed by KSL HSE and KSL Machinery Lead led by KSL Project Manager in charge in their respective areas on ground. Only authorized personnel identified by green vests are allowed to enter lifting operation vicinity and carry out related works concerning with lifting operation. Watchmen will be deployed to prevent unauthorized personnel from trespassing.
SUMMARY
2.12I was able to adopt my engineering skills with project at the time of problems and failures ina successful manner which was highly appreciated. The project helped me a lot as professionally as well as in enhancing my skills in management, through manpower deployment and scheduling of the tasks as per priority.
COMPETENCY DEMONSTARTION REPORT
CARRER EPISODE -3: Lifting of the new scrubber unit and up-righting the unit using 2 cranes.
INTRODUCTION
CE 3.1
Period: 12 July 2012 to Till date
Designation: Senior Engineer (Machinery)
CE 3.2
Keppel Shipyard possesses an unrivaled track record for the repair, conversion and upgrading of a diverse range of vessels. Our marine expertise includes
Conversionof Floating Production, Storage and Offloading (FPSO) /Floating Storage and Offloading (FSO) vessels, Floating Storage and Re-Gasification Units (FSRU) and drillships
Repair of all types of marine vessels including tankers, containerships, bulkers and LNG / LPG carriers
Upgrading and life extension of vessels
Jumboisation of vessels
Fabrication of turrets and topside modules
CE 3.3
BACKGROUND
Growing awareness of the marine environment protection leads to more stringent emission requirements .New regulation for the sulphur gas emissions under 0.5% by marine pollution ( MARPOL) took immediate effect in 2020.However due to unstable supply and price of the low sulphur fuel, the only way to use current high sulphur fuel oil is installing SOx scrubber. Therefore the installation of the scrubber has been of ship owners' growing interests. Unique features of the SOx scrubber includes
1)Minimised commercial loss
2)Customised system for vessel
3)High quality material and reliable sensors
4)Cost saving
5)Saving DWT
The below mentioned is the uprighting and installation of a scrubber unit onto the scrubber housing ( use of tandem lifting )
CE 3.4
The organisational flow chart is attached and my position is highlighted in blue
Project Manager
KSL Mechanical technicians
KSL Machinery
Rigging team
Safety Officer
PERSONAL ENGINEERING ACTIVITY
CE 3.5
From the beginning of the process , first thing I had to do is to fetch all the tonnage and dimensions of the items involved . For that , during the kick off meeting , I will highlight the relevant drawings that has to be provided, which will be circulated by the owner through the ship repair manager.
Once I receive the datas, I will liase the above drawings provided by the maker for the calculation and verification of the pad eyes. Once the pad eyes are verified , I will sit with the rigging team to generate a detailed lifting plan for the lifting of the scrubber unit. Further the above plan will be sent to the engineering department for further stress calculations. The above department will advise further for the change in the lifting gears as required.
CE 3.6
This work method statement is to define the lifting and installation of the scrubber unit.
Scrubber unit- 10 tonnes
Preparation prior to operation
Document/Site Preparation:
Preparation of relevant documents for lifting arrangement. (Responsible Party: Machinery Lead)
Lifting gear certificates - (Responsible Party: Lifting Lead)
Prepare lifting plan:
Choosing the appropriate lifting gears (chain blocks, shackles and wire slings).
Conduct JHA prior to the lifting/shifting operation with all personnel reflected in Organization Chart Submit relevant documents (lifting arrangement, calculation, MPI reports and risk assessment) for review. (Responsible Person: KSL machinery Lead)
Site preparation
Any obstruction items to be clear before the lifting/shifting operation.
Communication check between KSL Lifting Lead and KSL Production Team by using walkie-talkie.
CE 3.7
Lifting and shifting of scrubber unit and uprighting using 2 cranes
Check and verify all barricades are in place and only authorised persons are within the lifting radius. Proper signage and watchmen to be present.
Machinery team to hook up the scrubber unit as per the lifting plan.
Scrubber will be lifted to one feet from the crate provided and checked for levelness from the ground..
The scrubber will be lifted up to half a meter before turning to 90 degrees
Crane 1 will be slowly hook up until the unit is in vertical position and crane 2 will slowly hook down until the unit is in 90 degrees.
Upon uprighting crane 2 will be fully released and remove the wires
Crane 1 will be continuously hooked up to install onto the foundation
CE 3.8
Scrubber lifting / rigging arrangement
CE 3.9
De rigging of the lifting gears
Ensure proper seating of the unit onto the foundation
Remove lifting gears from the scrubber unit
Remove the barricades and signages
Keep all the lifting gears in proper storage area
Return the lifting gear to the HSE personnel to notify the completion of the process
-717549850900HSE Manager
Asst HSE Manager
HSE Officer
`S`ing Point / BACO
VHF Channel 3
Rescue Team
6 team member
Fire Fighting Team
6 team member
Search Team
6 team member
Individual Trade
Machinery:
Piping: NA
Shipwright: NA
Electrical: NA
-717549850900The communication flow / emergency preparedness during the entire lifting process is as follows.
3.10
Access Control
Access control will be managed by KSL HSE and KSL Machinery Lead led by KSL Project Manager in charge in their respective areas on ground. Only authorized personnel identified by green vests are allowed to enter lifting operation vicinity and carry out related works concerning with lifting operation. Watchmen will be deployed to prevent unauthorized personnel from trespassing.
SUMMARY
3.11
I was able to adopt my engineering skills with project at the time of problems and failures in a successful manner which was highly appreciated. The project helped me a lot as professionally as well as in enhancing my skills in management, through manpower deployment and scheduling of the tasks as per priority.
PROFESSIONAL ENGINEER
Summary Statement
These are the competency Units and Elements. These elements must be addressed in the Summary Statement.
Competency Element A summary of how you have applied the element Paragraph number in the career episode(s) where
the element is addressed
PE1 KNOWLEDGE AND SKILL BASE PE1.1 Comprehensive, theory based understandingof the I applied my engineering professional knowledge throughout the project for getting assigned objectives CE 1.3 ,2.3 ,3.3
underpinningnaturaland physicalsciencesandthe engineeringfundamentals applicable to the engineering discipline. Documented the current system of repair data in the form of JHA ( job hazard analysis). CE 1.5 , 2.5, 3.5
Created a standard template for the similar jobs documenting all the relevant datas. Created a detailed work procedure for the Entire operation consulting with relevant team members . PE1. 2 Conceptual Evaluated solutions suggested using engineering tools
Formulated a system by studying datas and procedures given by the owners , specialist and manuals.
Standardized reports and data sheet CE 1.7, 2.7, 3.7
understanding of the mathematics, numerical analysis, statistics, and
computer and information CE 1.8, 2.8, 3.8
sciences which underpin the engineering discipline. CE 1.6, 2.6, 3.6
PE1.3 In-depth understanding of specialist bodies of knowledge within the engineering discipline. Used engineering tools (Detailed Activity Diagrams, Stress analysis) to visualize how the s Systems should work.
Utilized manuals, rigging team, conduct team meetings to break down details that must be known for the job that must be carried out. CE
CE 1.6, 2.6, 3.6
1.7. 1.8, 1.9, 2.7, 3.7
PE1.4 Discernment of knowledge development and research directions within the engineering discipline. Suggested and formulated a standard template for the similar operational activities.
Created a separate data base involving the procedures that has to be deployed for various activities with different sizes. CE 1.8, 1.9, 2.9, 3.9
PE1.5 Knowledge of contextual factors impacting the engineering discipline. Realized that coordination of the engineering disciplines was not done previously as such many delays were caused during the entire process. CE 1.6, 1.7, 1.8, 1.9, 2.6, 3.6, 2,8, 2.9
PE1.6 Understanding of the scope, principles,
norms, accountabilities and bounds of contemporary engineering practice in the specific discipline. Templated the usage of the lifting gears , inter departmental activities wherever involved during the entire operation.
Planned activities to be done with regards to certain deadlines thru creation of a Gantt chart that will monitor progress throughout the creation of the project study.
Recommended creation of a detailed database and automation of forms for the creation of lifting plans based on the operational requirements. CE 1.8, 1.9, 2.8, 2.9,3.5
CE 1.6, 1.7, 2.6,2.7,3.6
CE 1.8, 1.9, 2.8, 2.9, 3.5
PE2ENGINEERING APPLICATION ABILITY
PE2.1 Application of established engineering methods to complex engineering problem solving. Design the pad eyes that needs to be welded during the process of lifting, detailed lifting plan generated inclusive the weight of the gears involved to get an accurate weight stress analysis for the operation and renewal CE 1.6, 1.8, 2.6, 2.7, 2.8,3.5
PE2.2 Fluent application of engineering techniques, tools and resources. Flow charts to designate the flow levels of information and authority to deputise during various levels of activities.
Proper forecasting of the manpower, generate the amount of consumables for the operation.
Make sure and load tested each and every set of lifting gears involves, pad eyes that are welded for the activity CE 1.9, 1.10, 2.10,3.9
CE 1.6, 1.7,2.6, 2.7, 3.5
CE 1.8, 1.9, 2.8, 2.9,3.5
PE2.3 Application of systematic engineering synthesis and design processes. Formulated a functional diagram to designate the work processes.
Designed a proper communication channel to cascade down the information and instruction at each level. CE 1.10 , 2.10, 3.9
PE2.4 Application of systematic approaches to the conduct and management of engineering projects. Lead the team in conducting improvements study for Prototype Production Department and Product Development Unit on DesMichels Corporation and Information Systems Improvement for University Hotel Accommodation and Services. Responsibilities include:
distributing tasks evenly to all team members
coordinating with the organization for schedule of visits and interviews
documenting current system
leading the team in analyzing the problem
helping in formulating and evaluating proposed solutions
managing implementation plans
presenting the outcome of the study to the organization CE 1.5,2.5, 3.4
PE3PROFESSIONAL AND PERSONAL ATTRIBUTES
PE3.1 Ethical conduct and professional Accountability. Exercised leadership to guarantee the projects will yield positive solutions and within the time and resources allocated.
Encouraged team members to enthusiastically contribute to the accomplishment of project goals and acknowledged their contributions. CE 1.3, 2.3, 3.3
CE 1.4, 2.4, 3.4
PE3.2 Effective oral and written communication in professional and lay domains. Prepared and presented early project developments with organization management teams for discussion and guidance.
Displayed phenomenal knowledge of flowcharting techniques used in all conducted improvement projects and created work procedure. CE 1.5, 2.5, 3.4
CE 1.6, 1.7, 1.8, 2.6, 2.7, 2.8, 3.7
PE3.3 Creative, innovative and pro-active demeanor. Redesigned the template for the JHA as everyone can allocate the details and generate the lifting plan.
CE 1.5, 1.8, 1.9, 2.5, 2.6, 3.5
PE3.4 Professional use and management of information. Performed observations and documented process flows used in the analysis phase of projects completed.
Verified data used in making standardized reports sent by maker are reliable and accurate by checking specific measures presented on the report before using them instantly. CE 1.5,2.5, 3.5
CE 1.6, 2.6, 3.6
PE3.5 Orderly management of self and professional conduct. Chose projects that can benefit the most from the improvement project and would have high impact.
Demonstrated interest to life-long learning development by providing areas of further study alongside the improvement project.
CE 1.12, 2.12, 3.11
CE 1.11, 2.11, 3.11
PE3.6 Effective team membership and team leadership. Accepted the role of being the team leader for the improvement project for both machinery Department and yard Development Unit
Pursued expert assistance and professional advice when come across complex problems in the analysis phase of the repairs
Proposed and agreed upon by the team a methodology on how to effectively document the current logical system
Gained confidence and trust that I can finish creating the whole repair procedure thru proper time management. CE 1.12, 2.12, 3.11
CE 1.12, 2.12, 3.11
CE 1.12, 3.11, 2.12
