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HEGER DRY DOCK, INC Structural/Marine Engineers
531 Concord Street Holliston, MA 01746
Tel 508-429-1800 Fax 508-429-1811
Letter 16-87L Page 1
16‐87L December7,2016Attention: EddieGoldman,SeniorDockmaster([email protected]) JustinGleaton,Dockmaster([email protected])Re: RequestforHEGERCertificationofDryDockNo.2locatedinBAESanFrancisco,CAReferences:
(1) HEGERStructuralandMechanical/ElectricalControlInspectionReportforFDDNo.2,Aug2016(2) INTERNATIONALINSPECTIONUltrasonicGaugingSurveyReportforFDDNo.2,Jan2016(3) DRYDOCK#2FacilityCertificationReport,December1987(4) BRUCES.ROSENBLATT&ASSOCIATESDDNo.2FiniteElementAnalysis,August2016
Enclosures:
(1) HEGERDrawingPackage(2) TRITONMooringLimitations
Gentlemen: HEGERDRYDOCK,INC.hasbeenaskedtocommerciallycertifyDryDockNo.2atBAESYSTEMS’sSanFranciscoShipyardinaccordancewithUSGCSFLCSTDSPEC8634.ThecertificationofthefloatingdrydockwillbebasedonthematerialandoperationalinspectionperformedbyWaleedSayedandMichaelNaylor,bothengineersatHegerDryDock,onAugust8ththroughthe12th,2016.SeeReference1formoreinformationonsurveyresults.InordertoissueacommercialcapacitycertificationforDryDockNo.2,HegerDryDockconductedadesignreviewtoestablishoperationallimitationsbasedonthedock’scurrentcondition.TheobjectiveofthisletteristopresenttheresultsofHEGER’sdesignreview.Thereviewoutlinesthedrydock’slimitationsandnotablestructuraldeficienciesofthedock’scurrentcondition.Thedesignreviewincludes:
Transversebendinganalysis/FEAreview Longitudinalbendinganalysis Localstrengthcalculationsbasedonhydrostaticheadpressure Intactstabilitycalculations ReviewofBAE’smooringcalculationsandlimitations
HEGERhascompiledahistoryofthedock’sdrawingsforthepurposeofevaluatingandperformingthedesignreview.RefertothefollowingdrawingsofEnclosure1formoreinformation: A‐001 GENERALARRANGEMENT
S‐301 SECTION‐TYPICALTRANSVERSE S‐302 SECTION‐TRANSVERSENWTBULKHEADS‐303 SECTION‐TRANSVERSEWT/NWTBULKHEAD
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 2
DescriptionofDockDryDockNo.2isaonepiecetypesteelfloatingdrydock.ThedrydockwasconstructedbytheBethlehemSteelCorporationattheirSanFranciscoYardin1970.ThedesignofthedrydockwasdonebyEarlandWright,ConsultingEngineersofSanFrancisco.Thedock’spontoonisdividedintoforty(40)ballasttanks;twenty(20)porttanksandtwenty(20)starboardtanks.Eachballasttankis40’‐0”longx84’‐0”wide.Eachballasttankisfloodedviaa20”diameterbutterflyvalveoperatedbyanelectricactuatorlocatedonthesafetydeck.Eachballasttankisdewateredbyasingle‐stagemixedflowverticalshaftpumpwithanapproximatecapacityof6,000GPM.Thepumpsandvalvesareoperatedremotelybypushbuttonsinthecontrolhouse.Thereisan18’‐0”widebuoyancychamberlocatedalongthedock’scenterline.Thebuoyancychamberisdividedintofive(5)compartmentsofvaryinglengthslongitudinally.
PRINCIPALCHARACTERISTICSOFTHEDOCK
AgeofDock.....................................................................46yearsLengthOverall...............................................................900’‐0”LengthofPontoon.......................................................800’‐0”BreadthOverall.............................................................186’‐0”BreadthbetweenWingwalls...................................150’‐0”HeightofWingwallAboveKeel..............................66’‐0”PontoonDepth..............................................................20’‐0”DesignCapacity(18”Freeboard)..........................59,600LTDesignKeelLoadLineRating.................................84LT/ft
RefertoEnclosure1foraGeneralArrangementdrawingofthedrydock.BuoyantCapacityHEGERhasreviewedthedrydock’sbuoyantliftcalculationsshownintheFCR(seeReference3).Thedockhadanoriginaldesignbuoyantliftcapacityof59,600LT.Thedock’sFacilityCertificationReportassumedthefollowingdocklightweightproperties:
DockLightweight(NoBallast)................................15,500LTVerticalCenterofGravity.........................................25.00ftabovebaseline
FreeboardmeasurementstakenonJanuary3,1986showedthedockwascapableofachievingalightdraftof4.48feet.Thisrepresentsadocklightweightof17,400LT(dockweight&residualballastof1,900LT).Thedockhasanoperatingfreeboardof18inches(equivalenttoadockdraftof18.50feet).Atthisoperatingfreeboardthedockhasadisplacementof77,170LT.Basedonthe1986freeboardmeasurements,thedockwouldhaveabout59,670LTofbuoyantcapacityavailabletoliftavesselandtrimmingwater.DuringHEGER’sinspectionofthedock(August2016),asignificantamountofmuddepositwasobservedintheballasttanks.Someareashadmuddepositsofapproximatelytwofeet.Therehasalsobeenextensivestructuralmodificationtothedocksuchastheadditionof1/2“doublerplatestothepontoondeck,newwingwallcranes,andsix(6)stabilitysponsons.Theconcernisthatthemuddepositsandstructuralmodificationsovertheyearshaveincreasedthedock’slightweightandthe1986buoyantcapacityisnolongerachievableatthe18”operatingfreeboard.
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 3
MorerecentFEAreport(seeReference4)indicatesthedock’scurrentlightweighthasincreasedby3,750LTto:
DockLightweight(NoBallast)...............................................19,250LTVerticalCenterofGravity.........................................................26.22ftabovebaseline
Inordertogainadditionalliftcapacitythathasbeencompensatedbytheabove‐mentionedaddedweight,HEGERsuggestscertificationofthedock’sliftcapacityatalower12”ofpontoondeckfreeboard.Thereducedoperatingfreeboardwouldgain2,159LTofliftcapacity.Basedonthemostcurrentdocklightweightinformation,thedockwouldhaveabuoyantcapacityof58,000LTat12”ofoperatingfreeboardand55,800LTat18”ofoperatingfreeboard.Ifadditionalliftcapacityisdesired,ballasttankswouldhavetobemucked.Itisimportanttonotethatalthough12”ofoperatingfreeboardispermittedbyABSrules,MIL‐STDrulesmandatean18”operatingfreeboardforthiscapacitydock.HEGERwillneedtofieldverifyDryDockNo.2’scurrentdockweightandliftcapacitywithfieldmeasurementsatthenextsurveypriortoissuingacommercialcertification.IntactStabilityoftheDryDockDryDockNo.2wasrenovatedin2008byaddingsix(6)40’x12’sponsonsinordertoincreaseitstransverseintactstabilityfordockingphases3and4.HEGERhasdevelopedanallowableKGversusvesselweightcurveforthefloatingdrydockforaminimumGMof3.28feetasrequiredbyABS.ThestabilitycurveisshownFigure1below.Plottedpointsthatfallonorbelowthislineareacceptable,pointsaboveareunacceptable.
FIGURE1–IntactStabilityCurve
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 4
MaximumSubmergenceDraftsDryDockNo.2’scurrentsubmergenceberthlimitsthedock’smaximumpossiblesubmergenceto59’‐6”,witha6‐fttide(accordingtoBAE).AllowableHeadPressuresBasedonthemaximumachievabledraftandthecorrespondinginternalballasttankwaterlevels,HEGERhascalculatedthemaximumallowableheadpressuretobeabout28‐ft,duringadockingevolutionofacapacityvessel,providedanengineeredpumpingplanisfollowed.Anemptydockorunloadedtankexperiencesahydrostaticheadpressureofabout10‐ft,duringasubmergenceevolutionprovidedanengineeredpumpingplanisfollowed.ExternalShellThedesignofthedock’sexternalshellthicknessrequirementistypicallygovernedbythestrengthrequiredtoresisthydrostaticheadpressuresexperiencedduringadockingevolution.HEGERhascalculatedtheallowablehydrostaticheadpressuretheexternalshellcansafelyresistforagivencorrodedplatethicknessusingthedock’sdesignedstiffenerspacing(typically25”).Theoriginaldesignthicknessofthewingwallsideshellplatingwas7/16”or0.44inches.TheallowableheadpressureisbasedonbasedonABSRulesforBuilding&ClassingSteelFloatingDryDocks2009.TheresultsareasfollowsandareshowninFigure2:
PlateThickness Corrosion AllowableHeadPressure
0.35inches 20% 28.2feet 0.30inches 31% 18.4feet 0.25inches 43% 10.7feet
FIGURE2–AllowableHeadPressurevs.PlateThicknessCurve
10.0
15.0
20.0
25.0
30.0
35.0
40.0
0.24 0.26 0.28 0.30 0.32 0.34 0.36 0.38 0.40
Allo
wab
le Head
Pressure (ft)
Plate Thickness (in)
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 5
TocreatethechartinFigure2,theassumptionisthattheanglestiffenersweldedtotheshellplatehave15%corrosionorless.HEGERhasreviewedthedock’smostrecentUTsurveyconductedbyInternationalInspectioninJanuary2016inordertoevaluatethedock’scurrentcondition,after45yearsofservice,withtheintentofdetermininganallowableheadpressureonatankbytankbasis.Allowableheadpressureisbasedonremainingmaterialthicknessoftheshellplate.TheUTsurveyresultsofthedock’sexternalshellplatingindicateareasofsignificantmetalthicknessloss.AreasofextensivecorrosionwereconfirmedbyHEGER’sAugust2016visualinspectionwithnumerousobservedholesintheplating.Themostnotableareasofcorrosionare:
OutboardShellPlating,specificallyinwayofthesplashzone(2‐ftbelowthepontoondeckto10‐
ftabovethepontoondeck)
Connectionoftheinboardwingwallsandthepontoondeck
Therehavebeenongoingrepaireffortstothedock’soriginalexternalplatingtofixareasofextensivecorrosionandholed‐throughplating.Somelocationshavebeenrepairedbyinstallingdoublerplatesoverlocalizedholes.Otherareasoftheexternalshellhavebeenrepairedbycroppingandreplacing40‐ftx10‐ftstiffenedplatepanels.Thethicknessofthenewplatepanelshasbeenincreasedto1/2”fromtheoriginal7/16”.ThemajorityoftheexternalshellrepairshavebeenmadetotheEastandWestoutboardshellswithabout20%ofthedock’soriginalplatepanelsbeingreplaced.NOTE:Theamountofvesselloadplacedoveratankgroupwilldirectlycorrelatetotheamountofheadpressurethattankgroupexperiencesinadockingevolution.Therefore,theamountofvesselloadthatcanbepositionedoveraspecifictankgroupwillbelimitedbytheminimummeasuredUltrasonicThickness(UT)measurementsurveyedinthattankgroup.
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 6
PontoonDeck&TransverseBendingStrengthThedock’soriginalpontoondeckisseverelycorrodedasreflectedinthemostrecentultrasonicthickness(UT)measurementssurveyedbyInternationalInspectioninJanuary2016(seeReference2).UTmeasurementsweretakeninternallyandmeasuredthethicknessoftheoriginaldeckplateonly.Doublerplateshavebeeninstalledonthetopsideofthedrydock’soriginalpontoondeckplateoverabout65%ofthesurfacewithaconcentrationtowardsthedock’scenterline.Thedoublerplatesare1/2”inthicknessandareconnectedtothedock’soriginalpontoondeckplatevia2”x6”slotweldslocatedalongtransverseandlongitudinalstructure.Theseslotsweldsareconsideredessentialastheyprovidethedoublerplateswithrequiredbucklingcapacity.Thehalf‐inchdoublerplateswereinstalledtofortifytheoriginaldeckplateasanalternativetoremovingandreplacingthecorrodedplatingandstiffeners.HEGERhasanalyzedthedrydock’spontoondeckforbothlocalhydrostaticpressureandtransversestrengthrequirementswhenliftingakeellineloadingatthedock’scenterline.Hydrostaticpressurethicknessrequirementsaresimilartothoseoutlinedintheexternalshellsectionofthisletterasthestiffenerspacingissimilar.Anallowableheadpressureratingof28feetisrecommendedataminimum.Thetransversebendingcalculationswereanalyzedusingaloadingof68LT/fttoverifythelocalstructuralcapacitysuggestedbythedock’smostrecentFEAreport(seeReference4).IntheFEAreport,thedock’stransversecapacityisgovernedbyaconservativeremainingthicknessassumptionofthepontoonbottomplating.Thelatest2016UTmeasurementsshow20%corrosioninthemostsuspectplaces;theFEAanalysismodeledportionsofthebottomat50%toallowforfuturecorrosion.Belowisthepontoondeckthicknessrequirementstosupport68LT/FTbasedonlocationoffofdockcenterlinefromtheanalysis.
*Controlledbyhydrostaticheadpressureof28feet. Areviewofallowablepontoondeckvehiculartrafficlimitationswasnotconductedaspartofthisdesignreviewasitdoesnotinfluencethesafetyofthevesselindrydock.
LocationoffDockCenterline(ft)
PlateThicknessRequired(in)
0‐1.5 0.431.5‐3.5 0.383.5‐9 0.369‐27 0.4027‐32 0.35*32‐44 0.35*44‐50 0.35*50‐54 0.35*54‐67 0.35*
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 7
MooringInordertomeetHEGERcertificationrequirements,adrydockneedstobeadequatelymooredtothepier.InMayof2016,TroyGillum,PEofTritonEngineering,Inc.conductedanengineeringanalysisofDryDockNo.2’smooringtodeterminetheoperationalwindspeedrestrictions,basedonafewdifferentvesseltypesondrydockandthedirectionofthewind.SeeEnclosure2formoreinformation.ToobtainandmaintainHEGERcertification,BAEwillberequiredtoadheretothesewindspeedrestrictionstomaintainasafeoperationofthedrydock.Thismayprecludedockinglargervesselsuntilthemooringisstrengthened.Inaddition,ifavessel’ssailarealimitstheallowablewindspeedfromanydirectiontobelow65knots,basedonmooringstrength,itshouldnotbedocked.Ifwindeventsareforecastedthatmayexceedtheallowedwindspeedforaparticularvessel’ssailarea,proceduresneedtobeinplacetoundockthatvesselbeforethepredictedeventoccurs.The65knotlimitationisbasedona10yearmeanrateofoccurrencefortheSanFranciscolocationaccordingtotheAppliedTechnologyCouncil.HEGERrecommendsthatBAEbeginexploringmethodsofstrengtheningtheirmooringdolphinsinordertoincreasethemaximumallowablewindspeedstomeetcurrentASCEcriterion.LongitudinalStrengthHEGERhasreviewedthedrydock’slongitudinalbendingcalculationsshownintheFCR(seeReference3).Thedock’soriginaldeflectionlimitwas+/‐3inches.HEGERhasperformedcorrespondinglongitudinalstrengthcalculationtoverifythedockhasadequatelongitudinalstrength.BasedonUTreports,wehaveassumedalldockstructureiscorroded15%oforiginalthicknesswiththeexceptionofthepontoondeckwhichwehaveassumedtobe50%corroded.HEGERhasconcludedthedockhasadequatelongitudinalstrengthforthecurrent+/‐3inchesdeflectionlimit.Thedock’slongitudinaldeflectionshouldbemonitoredduringalldockoperationstoensurethelimitationsarenotexceeded.Anengineeredpumpingplanshouldbedevelopedfordockingandundockingevolutionstominimizelongitudinalstressanddeflection.ConclusionandRequiredRepairsforHEGERCertificationHEGER’sprimaryconcernwiththedock’scurrentstructuralconditionistheseverelycorrodedshellplating,withnumberofholed‐throughareas.Theholes,locatedthroughoutthedock,impedethewatertightintegrityofnumerousballasttanksandraisethefollowingconcerns:
1. Thedockcannotholddraftwithoutoperatingpumpstooffsettheleakingofballasttanks.ThiswasconfirmedandobservedinHEGER’ssubmergencetestconductedinthe2016controlinspection.
2. Theholed‐throughplatingcreateslocalhydrostaticstrengthdeficiencieswhichputcorrodedareasofthedockatriskoffailure.Duetolackofmaterialstrength,thereisthepotentialfortheseholestoenlargesignificantlyduringadockingevolution,toapointwheretheamountofexternalleakagecannotbeoffsetbythedock’spumps.Itshouldalsobenotedthatthedockdoesnothaveemergencycross‐connectvaluesintheevent
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 8
anindividualtank’spumpislost,thuslosingtheabilitytooffsetexternalleakage.InorderforHEGERtocertifythisdock,BAEwillberequiredtorepairthestructurallydeficientareasoftheexternalshellandmakerepairstoholesintheexternalshelltore‐establishthedock’swatertightintegrityandensuresafedockoperations.BasedonHEGER’sknowledgeofthedock’sdesignreview,visualconditionsurvey,andmostrecentUTsurvey,areasofthedock’sstructuraldeficiencieshavebeenmappedoutontheinboardandoutboardwingshellsandthepontoondeckinthedrawingslistedbelow.HEGERhasassignedaPriority1or2totheareasofmoststructuralconcern.Priority1areaswillneedtoberepairedpriortoHEGERcertification.Theseareasareeitherheavilycorrodedasindicatedbythedock’sUTsurveyorcontainholesorotherdeficienciesnotedinthe2016controlinspection.ThesquarefootageofPriority1areasisapproximately21,600sqft.Priority2areaswillneedtoberepairedbeforethesubsequentHEGERre‐certification.Theseareasalsoshowsignsofsignificantcorrosion.Untilthepriority2areasarerepaired,therewillneedtobeoperationalrestrictionsregardingallowedheadpressureintheseareas.ThesquarefootageofPriority2areasisapproximately41,400sqft.Inthedrawingslistedbelow,allareasaregenerallymappedoutonatankbytankbasis.Itisrecommendedtheexternalshellintheseareasbecroppedoutandreplacedwithafabricatedinsertplatetoproperlyrepairthearea.Intheeventofsmallisolatedholes,adoublerplatemaybeinstalledasatemporaryfix.SeethefollowingdrawingsinEnclosure1formoreinformationonUTmeasurementsandPriority1or2repairareas:
A‐002 PONTOONDECK‐1OF2A‐003 PONTOONDECK‐2OF2A‐004 WESTOUTBOARDWINGWALLA‐005 EASTOUTBOARDWINGWALLA‐006 WESTINBOARDWINGWALLA‐007 EASTINBOARDWINGWALLA‐008 PONTOONBOTTOM‐1OF2A‐009 PONTOONBOTTOM‐2OF2
Themajorityofthepontoondeckhasbeencoveredwitha1/2"doublerplate.Thisisnotaviablelongtermsolutionforthedock.HEGERrecommendsamaintenanceplanbedevelopedtoproperlyreplacethecorrodeddeckpanelswithinsertplates.Notethatthedockwasoriginallydesignedwith1/2”highstrengthsteel(yieldpointof50ksi).HEGERrecommendsanypontoondeckreplacementsbe3/4"highstrengthsteel.Notethatthismaycorrespondtoasmallreductionintheliftcapacityofthedockduetoanincreaseindockweight,butwillbuildinadditionalcorrosionallowance.SeeSection4.1ofHegerDryDock’s2016controlinspectionreport(Reference3)foratankbytanklistofnoteddeficiencies.Allrepairsrecommendedtobeaccomplishedassoonaspossibleinsection6ofthereportshouldbeconsideredPriority1andaddressedpriortoHEGERcertification.
Heger Dry Dock, Inc. BAE Systems Ship Repair Holliston, MA San Francisco, CA
Letter 16-87L Page 9
OncePriority1repairshavebeenaccomplished,HEGERwillfieldverifytheconditionofthedockandtakelightdockfreeboardsinordertocertifythedockinaccordancewithUSGCSFLCSTDSPEC8634iftheconditionsowarrants.Basedontheresultsofthisdesignreviewthedockisexpectedtohavethefollowingoperationallimitations:
LiftCapacity(18”Freeboard).................................................55,800LTLiftCapacity(12”Freeboard).................................................58,000LTMaxKeelLineLoad.....................................................................68LT/ft ExternalWaterDifferential.....................................................varies,max28feet InternalWaterDifferential......................................................20ftMaxSubmergenceDraft(on6’tide)....................................59’‐6”LongitudinalDeflection.............................................................+/‐3inchesMaxTrim.........................................................................................2ftper100ftMaxList............................................................................................2degreesAllowedWindSpeed..................................................................variesbyship,65knotsmin.required
Duetotheextentoftheexternalshellplatecorrosion,thedockwillhavemaximumexternalheadpressurerestrictiononatankbytankbasis.Themaximumheadpressurethatcanbeappliedtoatankwillbegovernedbytheleastmaterialthicknessmeasurementofthattank.Theexternalheadpressurelimitationswilldirectlyaffecttheamountofvesselloadthatcanbeappliedtothetank.Anemptydockseesapproximately10‐ftofheadpressure.Asmorevesselloadisappliedtothetank,theheadpressureincreases.Eachdockingwillhavetobecarefullylookedattoensurethatatank’soperationalrestrictionisnotexceeded.Duetothevariousoperationalrestrictionspresentedinthisreview,thecertificationissuedbyHEGERwillincludeaclausethatdockingplansandcalculationsforanyvesselexceeding60%ofthedock’sratedliftcapacitywillneedtobereviewedandapprovedbyaHEGERengineerpriortoitsdocking(untilPriority2repairsarecomplete).Pleasecontactmeifyouhaveanyquestionsorcommentsregardingthisletter.
Sincerely,HEGERDRYDOCK,Inc.MichaelNaylorEngineer
ENCLOSURE1HEGERDrawingPackage
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DESIGN, INSPECTION AND CERTIFICATION
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(508) 429-1800
BAE
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BAE SYSTEMS SHIP REPAIR
SAN FRANCISCO, CA.
COMMERCIAL CERTIFICATION OF FLOATING DRY DOCK #2
DRYDOCK #2 OPERATIONAL LIMITSGENERAL DRAWING INDEX
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ENCLOSURE2TRITONMooringLimitations
PROJECT:
FOR:
CLIENT:
DRY DOCK NO. 2 WIND STUDY
BAE Systems, Inc. San Francisco Ship Repair
BAE SYSTEMS, INC.
Contact: Justin Gleaton, Dockmaster
6-30-16
May 27, 2016
Troy E. Gillum, P.E.