A Single Throat to Choke?

As we head into the heart of summer and many people take their vacations, the OSU shipyard staff are settling in at Gulf Island for the long road ahead.  The shipyard, meanwhile, has been busy finalizing a number of important subcontracts with their “Single Source Vendors” or SSVs.

There will be several SSVs that will work for the shipyard and will be the single point for responsibility for such things as Over the Side Handling equipment (all the winches, controls, frames, etc),  the propulsion system, the bridge and navigation control system, and the underwater acoustic systems.  The concept behind the SSV is that there is one company that will be solely responsible for the work that not only they are providing, but their sub contractors as well.

We’ve learned from other projects that simply using a “Single Source Integrator” doesn’t provide the teeth necessary to efficiently resolve conflicts that may arise between different vendors.  For example, think of your house. Imagine you’re installing new drywall and having it painted. But, unfortunately when the project is done the seams in the drywall look terrible.  The drywaller blames the painter for using cheap paint, and the painter blames the drywalled for poor workmanship.  However, if there was a general contractor  who was solely responsible for all the work, it would be his responsibility to find a way to fix the problem.  I heard someone (not from OSU or the shipyard, by the way) at the kickoff meeting use the term “single throat to choke.”  Though that’s a bit extreme, it gets the point across.  It’s just a very clear method to assign responsibility for the most important and risky aspects of our research ship construction.  In a future post, once the contracts are finalized, I’ll announce who the SSVs will be.

Also this week, we met with a subset of our Science Oversight Committee to address a niggling issue that is very important to them. Basically, the issue has to do with our removable second winch on our Winch Deck (also called the O-1 level).  The science community was adamant that the winch we have specified can not support science operations that they envision the RCRVs should be able to perform.  The winch can not go deep enough with 2000m of .322 EM cable. Their strong preference is that it contain 7000m of .322.  Only then, they maintain, can it act as a true backup winch for our CTD operations, and allow science packages to go to required depths along the continental rise and other areas.

Although we’d love to support this, it’s not so simple as just adding a bigger drum with more wire.  Everything, and I mean everything in ship design, is a trade off.  Adding the additional capability will add up to 5000lbs to an area above the vessel’s center of gravity.  This will affect the ship’s stability and the added weight itself will cause problems to the vessel’s trim calculations.  So… we’re going to look at it.  Fingers crossed we can find a viable solution.  Our friends at the Glosten associates will be looking into this in the weeks ahead.

Ok. That’ll do it for this week.  As always, please feel free to drop in a question or a comment (even if you read this post months from now…).  Thanks for reading.

Posted in Uncategorized | Leave a comment

Kick Off!

I’m writing this from Houma, Louisiana, one of the nation’s top areas for ship construction and off shore support.  With access to the Gulf of Mexico via the Inter-coastal Waterway about 25 nautical miles south and located about an hour southwest of New Orleans, the amount of vendors, suppliers, outfitters, tech-reps, and manufactures here is incredible. Before this project, I didn’t really appreciate just how much infrastructure and expertise is in this area. I had spent some time in Houma during the Deepwater Horizon oil spill, but that was spent 20 hours a day in the command center so I didn’t really get out much to see the area.

At the top of the pecking order are the shipyards of which there are several, including of course, our prime contractor–Gulf Island.  Yesterday, OSU, NSF, and Gulf Island reps came together for our first formal meeting to kick off the project.  And it was very evident that all sides are excited to get to the business of building these ships! We discussed schedules, logistics, safety, the contract and those types of things. But the main purpose of the meeting in my estimation was simply to get to know each other. We’re going to be working together for years to come and like most human endeavors both large and small, success or failure often comes down to relationships.  How well do we work together?  Time will tell, but I’m happy to report that from my perspective, we’re off to a good start.  From the Vice President through the Project Manager, engineers, and support staff I’m optimistic for a very good working relationship.

OSU will have a permanent staff at the shipyard whose primary job will be to ensure that ship is built according to the contract. I may be biased, but our shipyard staff is absolutely top notch.  Everyone on it is exactly who you’d want for such a job and their combined experience is mind blowing. I’ve heard it called “the dream team.”  Leading the dream team is our Owner’s Representative who will act as our principal lead for all matters related to the construction. He’ll be supported by a deputy, contract manager, up to four inspectors, and the marine science technical director whose job it is to ensure that these oceanographic research ships are actually capable of conducting oceanographic research. They’re also actually currently hiring an admin assistant, so feel free to throw your hat in the ring if you want to join the dream team!

This model of shipyard staff is somewhat of a hybrid between a large on site staff that the Navy might employ and a smaller footprint that commercial customers might use.  We think we have a good balance of insight/oversight and cost.  Needless to say that when we’ll have three ships under construction at the same time, it’s going to be hopping! If funded as we hope, by the way, that will be in 2020.

One last point and I’ll sign off.  It was pointed out to me that I had a mistake in my last post (I’m sure it won’t be my last).  I had mentioned that European research vessels don’t use a standard deck bolt pattern.  While this may be true for many European ships, the U.K. has employed such a concept as far back as the mid ’80s and today can be found on both R/Vs Discovery and Cook, though the bolts are on either 50cm or 1m centers and not 2 foot centers as they are in the U.S.  I should have remembered this having visited them a few years back.  Both ships have served as inspiration in many ways to the RCRVs.

As always, thanks for reading and feel free to subscribe (see right hand side of this page). Feel free to comment or drop a question and I’ll do my best to respond.

Posted in Uncategorized | Leave a comment

Hit the Deck Running

I was interested to learn that one of the first technical scheduling meetings that we’ve had with Gulf Island had to do with what we call the “UNOLS Standard Deck Bolts.”  Though I found that a somewhat odd place to start, this requirement could be a driver of the shipyard’s build strategy, and, because this feature has not ever been required by their commercial customers,  they needed to learn more about it up front.

The first example of the UNOLS standard bolt pattern can be traced back at least as far as the AGOR 3 Class of ships (Robert Conrad) that were built by the Navy in the early 1960s, a good 10 years before UNOLS was even chartered.  The first Thomas G. Thompson operated by University of Washington was one such vessel. The cold war of the 1960s marked huge growth in the Oceanographic ship community and researchers and operators recognized the need to standardize certain operational features so that researchers could easily work on different ships.  One such feature they devised was series of recessed threads in the back deck into which a 1″ bolt could mate–basically a grid on exactly 2′ centers of 1″ nuts welded in the deck.  This simple system vastly decreases the turn around times between cruises.  Mariners need only unbolt a winch and crane it off, bring on a new anchor system for the next cruise and bolt it down, sound one prolonged blast on the ship’s whistle, and they’re underway. No welding, no grinding.

The system caught on and was incorporated into RVs Knorr and Melville in the late 1960s, into the intermediate Oceanus Class in the early 1970s and the Cape class in the early 1980s, as well as subsequent AGORs.  This standard yet modest design feature has saved countless hours and makes our vessels very adaptable.  The RCRVs will have the 2′ x 2′ foot deck bolt pattern not only on the back deck, but also throughout the foc’sle area, on the O-1 level winch deck, and even up on the Flying Bridge (or Bridge top).  If a science party wants to attach something to an RCRV, we’ll be ready.

I mentioned bolting down winches.  Imagine if a winch was bolted down and the wire rope was very strong and it, say, caught on the ocean bottom.  Then imagine if the standard bolt pattern we’re so proud of was actually not welded in all that strongly. It’s not hard to see that those bolts holding the winch down could just rip the threads right out of the deck maybe taking a big chunk of it with it right overboard. That would indeed be bad.  To avoid such a catastrophe, Glosten and Gibbs and Cox very carefully calculate the shear and pull forces and how to construct our deck to meet those requirements.  In our case, our deck bolts will be rated at 6000 pounds force in both a vertical and 45˚ from vertical plane. If a winch/wire rope has a 20,000 safe working tension, then the winch will need to be bolted with a minimum of four deck bolts to accommodate the force.

Before we started designing the RCRVs, I and OSU’s Marine Superintendent Stewart Lamerdin visited a number of great research ships including several from our European colleagues.  I was a little surprised to learned that many European ships use wood decking material. In fact, the amazing German research vessel R/V Sonne uses Bongossi wood from Africa.  It’s so dense that it doesn’t float. They don’t, however, employ a standard deck bolt pattern as does the U.S. Academic research fleet.  I should add that neither, to my knowledge, does NOAA as they typically have less variety between cruises and don’t generally require the flexibility.  I should also add that this feature adds quite a bit of both cost and weight to our ships. Constructing them on exact 2′ centers with only 1/16″ of tolerance while still maintaining a 6000 pounds force rating has its trade offs.

Questions about decks? Comments? Please feel free to comment here. Also, remember to subscribe (on the left), if you’d like to receive these posts in your email.

Posted in Uncategorized | Tagged , | 3 Comments

We’re off to a good start!

I’ve had several requests from the community to find a way to get the word out as to what’s happening with the construction of the RCRV’s.  Good suggestion, I thought, so I’m hereby starting this blog series that I’ll use to pass along updates and issues as they arise. Feel free to post comments or questions and I’ll do my best to respond.  Needless to say, inappropriate comments will not see the light of day, but I won’t censor constructive criticism.  We’ll see how this goes…

So, after a thorough and lengthy selection process, we’re on contract with Gulf Island Shipyard in Houma, LA to construct the first of what will hopefully be three great ships for the NSF and U.S. ocean science community.   We’re currently in the process of establishing OSU’s shipyard office on site.  The staff have been itching to get started for a long time, so it feels great to be making progress towards getting the keel laid. If all goes as planned, we hope to see that occur next spring.

In the meantime, the shipyard staff and Gulf Island will be working together (with our engineers from The Glosten Associates hereafter referred to as “Glosten”) to take our bid-ready ship design and turn it into a production ready package.  This process, called “Design Verification and Transfer” or DVT,  is where we verify Glosten’s design, make any tweaks as necessary to make it work for the shipyard construction processes, and then transfer it from Glosten to the shipyard (and its engineering team from Gibbs and Cox Marine Solutions, hereafter called “Gibbs and Cox”).  They’ll be going through every aspect of the ship from stem to stern, looking at every pipe and deck fitting; it’s a very detailed and lengthy process. And although it will take months to go through everything, it will save time in the end by minimizing re-work.  Think of the adage: Proper Prior Preparation Prevents Poor Performance.  We’re doing our prior preparation here…

One science-related issue that’s recently been discussed has to do with how the vessel will support sediment coring activities at sea. The RCRV program is currently working with OSU’s Marine Sediment Sampling Group (MARSSAM) to ensure that our new ships will be able to fully support obtaining cores from the ocean bottom of up to 50′ long. We’re working on an innovative solution that will be able to take advantage of the ship’s double articulated stern A-frame to bring them safely on board. Stay tuned for more on that as it develops.

Ok.  That’s good for the opening salvo into the blog-o-sphere.  I’ll try to get one of these posted every week or as interesting issues arise. Stay tuned!  /d

Posted in Uncategorized | 5 Comments